Webasto CC4E Installation And Service Instructions Manual
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Webasto CC4E Installation And Service Instructions Manual

Webasto CC4E Installation And Service Instructions Manual

Roof-top air-conditioning system
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Air-conditioning system
Installation and service
instructions
CC4E
(prefilled)

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Summary of Contents for Webasto CC4E

  • Page 1 Air-conditioning system Installation and service instructions CC4E (prefilled)

  • Page 2: Table Of Contents

    Roof-top air-conditioning system CC4E Webasto Thermosysteme CONTENTS 1. INTRODUCTION 1.1. Scope and purpose 1.2. Meanings of warnings, cautions and notes 1.3. Additional documentation required 1.4. Safety information and regulations 1.5. Certification 1.6. Corrections and improvements 2. GENERAL DESCRIPTION 2.1. Roof-top air-conditioner unit 2.2.
  • Page 3 Webasto Thermosysteme Roof-top air-conditioning system CC4E 6. MAINTENANCE 6.1. Safety precautions 6.2. General 6.3. Maintenance and care 6.4. Maintenance and service checklist 6.5. Inspections before repair 6.6. Troubleshooting 6.7. Repairs 6.8. Post-repair procedures and testing 6.9. Visual inspection 7. WARRANTY CLAIMS...

  • Page 4: Introduction

    Operating manual, roof-top air-conditioning system CC4E 1.4. Safety information and regulations The roof-top air-conditioning system CC4E has been designed and built in accordance with EC Directives. The system can be operated safely when installed and used correctly, in accordance with the installation and service instructions.

  • Page 5: Certification

    Webasto Thermosysteme Roof-top air-conditioning system CC4E Safety instructions for maintenance If faults develop in the refrigerant circuit, the system must be tested and repaired by an authorized specialist repairshop. Under no circumstances may refrigerant be discharged into the atmosphere (refer to Section 8 of the regulation dated 6 May 1991 banning CFCs and halones).

  • Page 6: General Description

    (2). The system is designed for operation with 24 V. The roof-top air-conditioning system CC4E is designed to cool / air-condition the driver’s cabs of heavy- goods vehicles, agricultural machines, earth-moving machines, airport service vehicles, municipal service vehicles and the driver’s area in buses.
  • Page 7 Webasto Thermosysteme Roof-top air-conditioning system CC4E Direction of travel Compact Cooler Fig. 2.2 Page 7 / 32...
  • Page 8 Roof-top air-conditioning system CC4E Webasto Thermosysteme The roof-top air-conditioning system is supplied with air distribution panel (Fig. 2.3) in addition to the roof- top unit. The following operating elements: ON / OFF rocker switch (1) and fan rocker switch (2) can be integrated into the air distribution panel.

  • Page 9: Electrical Components

    Electrical connections for the equipment are made as shown in the circuit diagrams Figs. 3.1 and 3.2. The CC4E is equipped with a protective circuit to prevent total exhaustion of the battery. The system is switched off automatically if the power supply drops below 20 V for more than 10 seconds. It is restarted by repeatedly switching on.
  • Page 10 Roof-top air-conditioning system CC4E Webasto Thermosysteme Fig. 2.4 Page 10 / 32...

  • Page 11: Design, Purpose And Principle Of Operation Of The Assemblies

    Webasto Thermosysteme Roof-top air-conditioning system CC4E Fig. 2.5 2.4. Design, purpose and principle of operation of the assemblies Condenser The condenser (3, Fig. 2.2) consists of a continuous pipe coil and fins interconnected to form a large heat exchanger surface.
  • Page 12 Roof-top air-conditioning system CC4E Webasto Thermosysteme Pressure switch The pressure switch (15, Fig. 2.2) includes a high-pressure and a low-pressure switch. It monitors the pressure in the high-pressure part of the refrigerant circuit and switches off both the electric motor and the compressor if the pressure is too low (e.g.

  • Page 13: Technical Data

    Webasto Thermosysteme Roof-top air-conditioning system CC4E TECHNICAL DATA 3.1. Air-conditioning system Designation Typ CC4E Dimensions, roof-top unit Length x width x height 1.110 mm X 774 mm X 215 mm Weight approx. 55 kg Operating voltages (depending on vehicle’s electr.

  • Page 14: Compressor

    Roof-top air-conditioning system CC4E Webasto Thermosysteme 3.3. Compressor Designation Type Sanden 5D5 H09 Dimensions (length x width x height) 183 mm X 124 mm X 124 mm Sense of rotation clockwise Stroke volume per revolution 131 cm Lubricating oil for refrigerating compressors...

  • Page 15: Circuit Diagram For Basic Version

    Webasto Thermosysteme Roof-top air-conditioning system CC4E 3.4. Circuit diagram for basic version Coupling Mot. ON mot. mot. Plus pin B+ Plus pin B- both sides both sides M8 dia. M10 dia. Nomenclature 24 V Cable size (vehicle side) Fuse F1,F2...

  • Page 16: Circuit Diagram For Deluxe Version

    Roof-top air-conditioning system CC4E Webasto Thermosysteme 3.5. Circuit diagram for deluxe version Coupling Mot. ON mot. mot. Plus pin B+ Plus pin B- both sides both sides M10 dia. M8 dia. Cable size (vehicle side) Nomenclature 24 V Ground Compressor Temp.

  • Page 17: Installation Instructions

    Webasto Thermosysteme Roof-top air-conditioning system CC4E INSTALLATION INSTRUCTIONS 4.1. Safety precautions The safety instructions set out in chapter 1.4 must be read and noted before starting work. The system must be installed or supervised by personnel familiar with vehicle air-conditioning systems.
  • Page 18 Roof-top air-conditioning system CC4E Webasto Thermosysteme IMPORTANT Ensure that load-bearing elements (e.g. roof hoops, reinforcements) and installed parts are not damaged. – Cut template out of packaging material. – Remove intermediate roof / insulating material around the air ducts. – Mark the air duct openings (shaded areas, Fig. 4.1) on the roof and cut them out.

  • Page 19: Installing The Roof-Top Air-Conditioning Unit With Air-Distribution Panel

    Webasto Thermosysteme Roof-top air-conditioning system CC4E 4.6. Installing the roof-top air-conditioning unit with air-distribution panel Air duct sealing On cambered roofs or roofs with beads and gutters, a sealing frame must be produced using the sealing profiles provided (see Fig. 4.3).
  • Page 20 Affix the sealing profile to the roof with the Sikaflex 221 included in the installation kit as shown in Fig. 4.3. Coat the top of the sealing profile with Sikaflex sealing compound. Installation proposal for CC4E with Armaflex (viewed from above, onto the vehicle roof) Direction of travel...
  • Page 21 Webasto Thermosysteme Roof-top air-conditioning system CC4E Mounting the baseplate Remove hood of roof-top unit. Place the baseplate on the roof (sealing frame) and align it. Place spacers under the eight fastening points and insert the nine M6 bolts (with washers) into the holes (Fig. 4.4).
  • Page 22 Roof-top air-conditioning system CC4E Webasto Thermosysteme Pre-assembly of air distribution panel The rocker switches and the setpoint potentiometer (if applicable) must be installed in the air distribution panel, depending on the version and scope of supply concerned. Installation of the operating...

  • Page 23: Make Electrical Connections

    Webasto Thermosysteme Roof-top air-conditioning system CC4E NOTE The air distribution panel must not be aligned with the centre of the air intake opening. The air distribution panel must cover the air intake opening in the vehicle roof. 4.7. Make electrical connections The system must be protected by a 100 A fuse on the vehicle side.

  • Page 24: Startup

    Roof-top air-conditioning system CC4E Webasto Thermosysteme STARTUP 5.1. Safety precautions The safety instructions in chapter 1.4 must be observed. IMPORTANT The system may only be started when the hood has been fitted. Risk of injury due to motor fans, belts and the compressor coupling.

  • Page 25: Operation

    The interior of the vehicle is cooled in recirculation mode, in keeping with the set fan speed 1, 2 or 3. The temperature of the air-conditioning system CC4E without electronic room thermostat is controlled via the anti-icing thermostat in the system, which switches off the electric motor when the temperature at which ice forms on the evaporator is reached.
  • Page 26 Roof-top air-conditioning system CC4E Webasto Thermosysteme MAINTENANCE 6.1. Safety precautions The safety instructions and regulations in chapter 1.4 must be observed. 6.2. General Work on the refrigerant circuit may only be carried out by qualified personnel from duly authorized specialist repairshops.
  • Page 27 Webasto Thermosysteme Roof-top air-conditioning system CC4E 6.4. Maintenance and service checklist System component Maintenance task Frequency Refrigerant circuit – Hoses Check for chafing and general condition – Connections Test for leaks with leak tester – Refrigerant quantity Check refrigerant level in viewglass –...
  • Page 28 Roof-top air-conditioning system CC4E Webasto Thermosysteme 6.6. Troubleshooting General A systematic approach is advisable for troubleshooting. Appropriate action must be undertaken as described below for faults of a general nature or when normal conditions are not obtained during the pressure test.
  • Page 29 Webasto Thermosysteme Roof-top air-conditioning system CC4E Low pressure gauge indication too low: – Intake or delivery line restricted, e.g. by kinks – Expansion valve defective – Not enough refrigerant (check viewglass) – Evaporator air flow restricted 6.7. Repairs IMPORTANT Refrigerant must never be discharged into the atmosphere (refer to Section 8 of the regulation dated 6 May 1991 banning the use of CFCs and halones).
  • Page 30 Roof-top air-conditioning system CC4E Webasto Thermosysteme 6.8. Post-repair procedures and testing Check refrigerant pressures and pressure switches function tests General Every air-conditioning system filled with refrigerant is in a state of overpressure, which is equal throughout the system circuit and which depends on ambient temperature.
  • Page 31 Webasto Thermosysteme Roof-top air-conditioning system CC4E A viewglass is integrated into the circuit at the receiver-drier to check the refrigerant level. When correctly filled, refrigerant will flow through the viewglass without air bubbles roughly 5 minutes after starting the air-conditioning system. Occasional bubbles are meaningless. Replenishment is only necessary when foam builds up.
  • Page 32 Roof-top air-conditioning system CC4E Webasto Thermosysteme WARRANTY CLAIMS Parts subject to natural wear or which have been handled incorrectly are excluded from the warranty. The warranty period is not extended by repairs or delivery of replacement parts. If a warranty case occurs, contact the national representative responsible for your country, together with the –...
  • Page 34 Die Telefonnummer des jeweiligen Landes entnehmen Sie bitte dem Webasto Servicestellenfaltblatt oder der Webseite Ihrer jeweiligen Webasto Landesvertretung. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Deutschland Besucheradresse: Friedrichshafener Str. 9 82205 Gilching Deutschland Technical Extranet: http://dealers.webasto.com Nur innerhalb von Deutschland Tel.:...

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