WAECO CoolAir RT880 Volvo Globetrotter XL Installation Guide

WAECO CoolAir RT880 Volvo Globetrotter XL

Safety Instructions

You must read the entire manual thoroughly and carefully.
We can only guarantee the reliability of the air conditioning roof unit if the instructions are adhered to. The same applies to the prevention of injury and damage to property.
The manufacturer accepts no liability for damage in the following cases:

• Faulty assembly or connection
• Damage to the product resulting from mechanical influences and excess voltage
• Alterations to the product without express permission from the manufacturer
• Use for purposes other than those described in the operating manual

Using the Device

• The freedom of movement of semi-trailers (of the outer edges of the semi-trailer when turning or jackknifing) and other vehicle attachments must not be restricted.
• Only use the air conditioning roof unit for the purpose specified by the manufacturer and do not make any alterations or structural changes to the device.
• Do not use the air conditioning roof unit if it is visibly damaged.
• The air conditioning roof unit must be installed safely so that it cannot tip over or fall down.
• Installation, maintenance and repair work may only be carried out by qualified personnel from a specialist company who are familiar with the risks involved and the relevant regulations.
• Do not use the air conditioning roof unit near flammable fluids and gases.
• Do not operate the air conditioning roof unit if the ambient temperature is below 0°C.
• Do not undo the upper cover of the air conditioning roof unit in the event of a fire. Use approved extinguishing agents instead. Do not use water to extinguish fires.
• Please inquire from your vehicle manufacturer whether the height entered in your vehicle documentation needs to be altered due to the installation of the air conditioning roof unit (height RT880: 166 mm, height SP950T: 75 mm).
• Disconnect all power supply lines when working on the air conditioning roof unit (cleaning, maintenance, etc.).

Handling Electrical Cables

• Use cable ducts to lay cables through walls with sharp edges.
• Do not lay loose or bent cables next to electrically conductive materials (metal).
• Do not pull on the cables.
• Attach and lay the cables in such a manner that they cannot be tripped over or damaged.
• The electrical power supply may only be connected by a specialist workshop.
• Fit a fuse of 25 amps to the connection to the vehicle’s power supply.
• Never lay power supply lines (battery leads) in the vicinity of signal or control cables.

Conventions in This Manual

General Information on The Installation Manual

This installation manual contains the essential information and instructions for installing the air conditioning roof unit. The information contained is orientated towards the company installing the air conditioning roof unit.
The following instructions are intended to help you properly use the installation manual:

• The installation manual is part of the scope of delivery and should be stored carefully.
• The installation manual provides you with important information on the installation of the device and can also be used as a reference material in the event of repairs.
• The manufacturer assumes no liability for non-observance of this installation manual. Any claims are excluded in this case.

Target Group

The installation and configuration information in this manual is intended for qualified installation personnel who are familiar with the guidelines and safety precautions to be applied during the installation of lorry accessory parts.

Intended Use

The installation kit (item no. 9100300037) enables the installation of an air conditioning roof unit CoolAir RT880 (item no. 9105305551) or a CoolAir SP950T roof evaporator unit (item no. 9105305548) in a roof ventilation opening (hatch) provided at the plant in a Volvo Globetrotter XL (L2H3) driver cab.
The CoolAir SP950T roof evaporator unit can only be operated in combi-nation with a CoolAir SP950C condenser unit. Both components together form the CoolAir SP950 parking cooler.

Scope of Delivery

CoolAir RT880/SP950T installation kit for VOLVO Globetrotter XL (L2H3), item no. 9100300037

Accessories

Available as accessories (not included in the scope of delivery):

• Connection cable 8 mm² x 9.5 m – 9100300027

Installation

Notes on Installation

These installation instructions must be read completely prior to the installation of the air conditioning roof unit.
The following tips and instructions must be observed wile installing the air conditioning roof unit:

• Always check whether any vehicle components could be damaged or their operation impaired by the unit before installing the air conditioning roof unit. The dotted line indicates the middle of the sunroof opening.
• Before installation, find out (by consulting the manufacturer of the vehicle) whether the construction is designed for the static weight and the loads of the parking cooler when the vehicle is in motion. The manufacturer of the air conditioning roof unit assumes no liability whatsoever.
• The roof inclination of the mounting surface may not exceed 8° in the direction of travel.
• The supplied assembly parts must not be modified during installation.
• The ventilation slots (grill) may not be covered (minimum distance from other attachment parts: 10 cm).
• You can connect the unit to the battery via the lorry’s terminal block or directly. The terminal block is to be preferred for the connection. On some vehicles, larger consumers connected to the terminal block are switched off after a short while if the power requirement is too high. Ask your vehicle manufacturer for the specifications of the terminal block.
• When installing the system and making the electrical connections, observe the guidelines from the body manufacturer.
• Pay attention to the connection plan for the device:

RT880

1. Control pad
2. Connection cable
3. Room temperature sensor
4. Earth
5. Klickson (compressor)
6. Compressor
7. Condenser fan
8. Vaporiser fan
9. Earth
10. 25 A fuse
11. 2 A fuse
12. 4 A fuse

SP950T

1. Condensate pump
2. Evaporator fan
3. Operating circuit board
4. Temperature sensor
5. Level sensor
6. Control unit
7. 25 A fuse
8. 4 A fuse vaporizer fan
9. 4 A fuse condenser fan
10. Condenser fan
11. Compressor
12. Klickson (compressor)

Steps for Installation

Removing the Sunroof

• Remove all screws and fixtures of the existing sunroof.
• Take out the sunroof.
• Remove the sealant around the opening, so that the surface is clean and free of grease.

Preparing the Unit Fastening

• Enlarge the existing ∅ 6.5 mm drill holes for fastening the sunroof to a diameter of 8.5 mm.

Preparing the Unit (RT880 only)

• Place the air conditioning roof unit on a work surface with the housing facing down.
• Screw in the 8 self-threading M8 thread inserts in the blind holes marked with “1”
  Use the supplied 1/4″ bit for this.

Attaching the Seal for the Cab Roof

• Stick the 2.5 m insulating tape (10 x 20 mm) to the cab roof, following the outline of the sunroof opening.
• Provide the abutting edge and the top edge of the insulating tape with an unhardened plastic butyl sealing compound (e.g. SikaLastomer-710).

Installing the Unit in the Sunroof

• Set the unit down centrally aligned and in the direction of travel on the sunroof opening.
• Place the spacer sleeve L = 18 mm and (SP950T only) the washer 8.4 x 16 on the fastening drill holes.
• Screw one hex screw M8 x 40 mm with a washer and spring washer in the 8 thread inserts on the bottom of the unit.
• Tighten the screws with a torque of 8 Nm.

Installing the Electrical Supply Lines
You can connect the unit to the battery via the lorry’s terminal block or directly. The terminal block is to be preferred for the connection. Ask your vehicle manufacturer for the specifications of the terminal block.

• Lay the supply line and connect it to the vehicle (red line to plus, black line to minus).
• Plug in the supply line plug into the socket of the air conditioning roof unit supply line.
• To relieve strain on the supply line, secure it with a cable tie, e.g. to the cab roof.

Installing Supply Lines to The Condenser Unit (SP950T only)
Observe the following instructions when installing the supply lines:

• Also observe the installation instructions for the condenser unit.

• The maximum cable length between the evaporator and condenser unit is 4.20 m.

• When installing and bending supply lines, avoid narrow radii. Use a suitable round object as a bending aid. A radius which is too narrow will buckle the refrigerant line, and the parking cooler will be inoperable.

• Shorten any supply line which is not needed by bending a curve.

• Apply packing compound to prevent water entering between the rear wall of the truck and the clip.

• Fasten the supply lines to the rear wall of the truck using the clips provided.

• Insert the corrugated piping in the holder provided.

• Put the cover on.

Fastening the Cover Frame

• Fasten the cover frame (5) to the cab roof (original fastening points) with the six self-tapping screws (7) and washers (6).

Configuration of Unit Software

Before you first start up the unit, the controls can be adapted to suit the installation conditions. This must be done by the person installing the unit.
In configuration mode, the following unit software parameters must be set at the control panel.

(68°F)
2| Low voltage cut-off| The battery monitor shuts down the unit at the voltage defined here.|

Characteristic figure 4 = 22,8 V

3| Operating mode| The unit starts with the operating mode defined here.| 0 = Automatic mode
4| Default settings| Parameters 1-3 can be reset to the default settings.| –
5| Temperature unit display| The temperature can be displayed in °C or °F.| °C

Starting and Ending Configuration Mode
The adjustable parameters can be changed in configuration mode:

• When using the ON/OFF button to switch on the unit, hold both buttons + and – pressed until the compressor LED flashes.
  • You are now in configuration mode.
  • The display version (e. g. “3.1S”) appears in the digital display for 2 seconds.
  • The first digit of the digital display shows the menu level and the second and third digits show the parameters which can be set, e.g. 1.17 for menu level 1 and a set target value of 17°C.
• Press the ON/OFF button to quit configuration mode.

Menu Level 1: Set Temperature
The unit always starts with a defined value for the room temperature. This parameter can be configured between 17 and 30°C (62 and 86°F).

• Start configuration mode.
  • The first digit of the display shows the menu level and the second and third show the parameter which can be set.
• Press the Operating Mode button to change the parameters.
• Use the + and – buttons to select the target value (in °C) at which the unit should start operation.
  • The digits in the display flash until the parameter you entered is confirmed.
• Press the Operating Mode button to confirm your entry.
  • The set value is saved and is then used when the unit is restarted.
  • You are now in menu level 1 again and can use the + and – buttons to switch between menu levels.

Menu Level 2: Low Voltage Cut-off
The battery monitor protects the battery from excessive discharging.

If only the set power supply is available here for the air conditioning roof unit, the unit is switched off.

• Start configuration mode.
  • The first digit of the display shows the menu level and the second and third show the parameter which can be set.
• Press the + button once to switch to menu level 2.
• Press the Operating Mode button to change the parameter.
  • The digits in the display flash until the parameter you entered is confirmed.
• Use the + and – buttons to set the value for low voltage shutdown. The characteristic figures at second and third place on the digital display represent the voltage (V) at which the unit is shut down:
  Characteristic F igure| Low Voltage Shutdown
  ---|---
  1| 22.2
  2| 22.4
  3| 22.6
  4| 22.8
  5| 22.9
  Characteristic Figure| Low Voltage Shutdown
  ---|---
  6| 23.0
  7| 23.1
  8| 23.2
  9| 23.4
  10| 23.6
• Press the Operating Mode button (fig. 0 4,page 8) to confirm your entry.
  • The set value is saved and is then used when the unit is restarted.
  • You are now in menu level 2 again and can use the + and – buttons to switch between menu levels.

Menu Level 3: Operating Mode
The unit always starts with a defined operating mode for room temperature. This parameter can be configured:

• Start configuration mode.
  • The first digit of the display shows the menu level and the second and third show the parameter which can be set.
• Press the + button twice to switch to menu level 3.
• Press the Operating Mode button to change the parameters.
  • The digits in the display flash until the parameter you entered is confirmed.
• Use the + and – buttons to set the mode with which the unit starts up:
  Characteristic Figure| Operating Mode
  ---|---
  0| Automatic mode
  1| Operating mode 1
  2| Operating mode 2
  3| Operating mode 3
• Press the Operating Mode button to confirm your entry.
  • The set value is saved and is then used when the unit is restarted.
  • You are now in menu level 3 again and can use the + and – buttons to switch between menu levels.

Menu Level 4: Default Setting
You can reset the parameters you set in configuration mode on menu levels 1 to 3 to the default settings:

• Start configuration mode.
  • The first digit of the display shows the menu level and the second and third show the parameter which can be set.
• Press the + button three times to switch to menu level 4.
  • The digital display shows –.
• Press the Operating Mode button, to reset the unit to the factory settings.
  • — flashes in the digital display.
• Press the + button.
  • The digital display shows 00.
• Press the Operating Mode button to confirm your entry.
  • The parameters set in configuration mode are reset to the default setting.
  • You are now in menu level 4 and can use the + and – buttons to switch between menu levels.

Menu Level 5: Temperature Unit Display
The system can display the room temperature in °C or °F. This parameter can be configured:

• Start configuration mode.
  • The first digit of the display shows the menu level and the second and third show the parameter which can be set.
• Press the + four times to switch to menu level 5.
• Press the Operating Mode button to change the parameters.
  • The digits in the display flash until the parameter you entered is confirmed.
• Use the + and – buttons to select the temperature unit that the system should display.
• Press the Operating Mode button to confirm your entry.
  • The set value is saved and is then used when the unit is restarted.
  • You are now in menu level 5 again and can use the + and – buttons to switch between menu levels.

Technical Data

| Air conditioning roof unit CoolAir RT880
---|---
Item number:| 9105305551
Cooling capacity:| 850 W
Rated input voltage:| 24 Vg
Input voltage range:| 20 Vg – 30 Vg
Current consumption:| 12 – 22 A
Low voltage shutdown:| Configurable
Dimensions (L x B x H in mm)
(height above vehicle roof):| 635 x 830 x 166
Weight:| approx. 21 kg

| CoolAir SP950 parking cooler with SP950T roof evaporator unit
---|---
Item number:| 9105305548
Cooling capacity:| 850 W
Rated input voltage:| 24 Vg
Input voltage range:| 20 Vg – 30 Vg
Current consumption:| 12 – 22 A
Low voltage shutdown:| Configurable
Dimensions (L x B x H in mm) Evaporator unit:
Condenser unit:| **** 577 x 779 x 75 mm
156 x 346 x 490 mm
Weight: Evaporator unit: Condenser unit:| approx. 15 kg
approx. 12 kg

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