Webasto FCF12000, FCF16000, FCF5000, FCF24000, FCF9000 Installation & Operation Manual

8/2018

FEEL COOL FAST

MARINE AIR CONDITIONER

Installation & Operation Manual

Table of Contents

INTRODUCTION ................................................................................................................................................. 5

PACKAGED COMPONENTS .............................................................................................................................. 6

OVERVIEW ......................................................................................................................................................... 6

INSTALLATION ................................................................................................................................................... 7

Unpacking and Inspection ....................................................................................................................................... 7

Safety Considerations ............................................................................................................................................. 7

Placement of System ............................................................................................................................................... 8

Blower Assembly ................................................................................................................................................... 10

Mounting Brackets ................................................................................................................................................. 10

Supply & Return Air Grilles and Transition Boxes.................................................................................................. 10

Ducting ................................................................................................................................................................... 11

Seawater Pump and Plumbing (Refer to page 31 for recommended flow rates and pump sizes) ......................... 11

Electrical Connections, Grounding and Bonding ................................................................................................... 13

Digital Display Installation ...................................................................................................................................... 14

Electric Box Installation.......................................................................................................................................... 14

Installation Checklist (Review Prior To Installation) ............................................................................................... 15

Wiring Diagrams .................................................................................................................................................... 16

OPERATION ...................................................................................................................................................... 21

Digital Display Operation ....................................................................................................................................... 21

Power ON/OFF.......................................................................................................................................................... 22

Sleep Mode of the digital display ............................................................................................................................... 22

FAN Control ............................................................................................................................................................... 22

Temperature Setting ................................................................................................................................................... 22

Mode Setting .............................................................................................................................................................. 22

Remote Control Operation – V1 ................................................................................................................................ 24

Remote Control Operation – V1 (continued) ............................................................................................................. 25

Remote Control Operation – V2 ................................................................................................................................ 27

ERROR CODES ................................................................................................................................................ 28

TROUBLESHOOTING ...................................................................................................................................... 28

MAINTENANCE ................................................................................................................................................ 30

Reversing Valves ................................................................................................................................................... 30

Seawater Strainer .................................................................................................................................................. 30

Condenser Coil Cleaning (Seawater Acid Flush) .................................................................................................. 30

Return Air Filters .................................................................................................................................................... 31

Winterization .......................................................................................................................................................... 31

UNIT DIMENSIONS & TECHNICAL SPECIFICATIONS ................................................................................... 31

LIMITED WARRANTY ....................................................................................................................................... 33

TECHNICAL ASSISTANCE ............................................................................................................................... 33

Introduction

Thank you for your purchase. No matter which of the following features was the reason for your purchase, we are sure it will meet your needs and give many years of efficient and trouble free use. These air conditioners are designed for marine applications incorporating the following features:

• Compact design

• High efficiency rotary compressors (5-24K)

• Cupronickel condenser coil

• Raised lance fin designed evaporator coil

• Polyester coated 2” (50mm) deep drain pan with four condensate drain locations

• Anti-vibration base pan

• Pre-charged and pre-wired systems for easy connections

• 3-speed fan motor. This eliminates all harmonic sounds and rumbles.

• Rotatable blower assembly

The controller offers the most technologically advanced design specifically made for the unique requirements of marine air conditioning. The controller has been designed with the following "user friendly" features:

• Non-volatile memory

• Low voltage display panel

• LED cabin temperature displayed in Fahrenheit or Celsius

• Multiple fan speed selections

• Compressor pressure fail safe protection

• Dehumidification Mode for humidity control

This manual is intended to provide the information necessary to ensure proper installati on, operation, and maintenance of a FCF air conditioner. Improper installation can result in unsatisfactory performance and/or premature failure. Before proceeding, please read this manual in its entirety. In the interest of product improvement, specifications and design are subject to cha ng e without prior notice.

ITEM

QUANTITY

Air Conditioning unit

Mounting Bracket

Packaged Components

Fuses (3.15 AL 250V) 2 Remote controller with batteries 1 Digital Display / Cable 1 Duct Ring / Hardware 1 Blower Insulation Foa m 1 Installation / Operat io n M anual 1

Overview

All units are manufactured without service ports

HOW IT WORKS

Your self-contained air conditioner consists of four main components and a refrigerant gas circulating through the system. The BLOWER draws warm cabin air across the fins on the EVAPORATOR where the heat from the air is transferred to the refrigerant in the evaporator coil. As the refrigerant evaporates from a liquid into a gas, it absorbs the heat from the cabin air. The COMPRESSOR then compresses the refrigerant gas and pumps it through the outer tube in the CONDENSER COIL. The seawater pump circulates cool seawater through the inner tube in the condenser coil; this cools the refrigerant and condenses it into a liquid. The heat from the refrigerant is exchanged to the seawater and discharged overboard. The liquid refrigerant is then passed through the EVAPORATOR COIL and the cycle repeats; removing heat from the cabin air lowering its temperature. The cooled air is blown through the ducting and out the supply air grille(s). For reverse cycle heating, the refrigerant flows in the opposite direction through the reversing valve. Heat is transferred from the seawater in the condenser coil to the refrigerant and then to the air blowing through the evaporator into the cabin. Seawater temperature will directly affect the air conditioners efficiency. This air conditioner can effectively cool your boat in water temperatures up to 90°F and heat in water temperatures as low as 40°F.

Installation

Unpacking and Inspection

When the equipment is received, all items should be carefully checked according to the packaged components list within this manual to ensure all components have been received. Examine components for shipping damage. If the unit is damaged, the carrier should make the proper notation on the delivery receipt acknowledging the damage.

Safety Considerations

VERY IMPORTANT: Never install your air conditioner in the bilge or engine room areas. Ensure that the selected location is sealed from direct access to bilge and/or engine room vapors. Do not terminate condensate drain line within 3’ (914mm) of any outlet of engine, generator exhaust system, compartment housing an engine or generator , or in a bilge, unless the drain is connected properly to a sealed condensate or shower sump pump. Seal all cabin penetrations around condensate hoses to eliminate harmful bilge fumes in the cabin living spaces.

Installation and servicing of this system can be hazardous due to system pressure and electrical components. When working on this equipment, always observe precautions described in the literature, tags and labels attached to the unit. Follow all safety precautions. Wear safety glasses and work gloves and place a fire extinguisher close to the work area. The following is a summary of the labels on the unit:

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Special note. Make sure to read before proceeding.

Electrical shock hazard. Disconnect voltage at main panel or power source before opening any cover. Failure to comply may result in injury or death.

This component does n ot meet feder al requirements for ignition protection. Do not install in spaces containing gasoline engines, tanks, LPG/CPG cylinders, regulators, valves or fuel line fittings. Failure to comply may result in injury or death.

Notice the 115V series and the 230V series are charged with Hydro fluorocarbon (HFC) refrigerant R410A. Effective July 1, 1992, it shall be unlawful for any person to knowingly vent or otherwise knowingly release any class 1 (CFC) or class 2 (H CFC) substance as a refrigerant in a manner which permits such substance to enter the atmosphere per the clean air act of 1990. Public law 101-549 title IV section 608-c. Failure to comply may result in severe penalties, including f ines and impr is onment.

To minimize the hazard of electrical shock and personal injury, this component must be effectively grounded. Refer to the installation guidelines for further information. Caution! High compressor temperature is normal. Do not touch!

Placement of System

Selecting a good location for your air conditioner is the most important part of your preparation. Be sure to consider the size of the area you are cooling, the air distribution needs, and the size of the unit you have chosen. Keeping in mind that cool air has a tendency to fall; it is highly recommended that you locate the supply air grille as high as possible in the cabin.

number of 90 degree bends

The ducting should be r un as straight, smooth and taut as possible minimizing the

. See diagram below.

Size of Sealed room

Ensure the area which the ai r conditioner is located is not t oo sm all otherwise it will affect proper operation. See the diagram below.

strainer, grilles & electrical box

The unit should be ins talled as low as pos s i ble, BUT NEVER IN T HE BILG E

OR ENGINE ROOM AREAS, ENSURE T HAT THE SELECTED LOCAT ION IS SEALED FROM DIRECT ACCESS TO BILGE AND/OR ENGINE ROOM VAPORS. Installing the unit as low as possible (such as under a V-berth,

dinette seat or bottom of a locker) and ducting the supply air as high as possible, creates an ideal airflow condition. This type of installation will prevent short or premature cycling.

The unit should be positioned on a firm, level, horizontal surface and the condensate drain line should ru n downward f rom the unit to a suitabl e drain location. Plan all Connections, which must be made including ducting, condensate drain, and seawater in and out, electrical power connections, location of control, and seawater pump placement, to assure easy access for routing and servicing.

Tools required:

• Screws drivers

• Pliers

• Pipe wrench

• Wire cutters/crimpers

• Drill & bit set

• Jigsaw

• Duct tape

• Electrical tape

• Thread sealer

• Bedding compound t o seal thru

hull fittings

• Hardware to secure u nit, p um p,

Condensate Drains

The condensate drain pan is 2” (50mm) deep with four drain locations. During conditions of high humidity, condensate may be produced at a rate of approximately 1/2 gallon per hour (1.9 liters per hour). It is important to route condensate drains downward to a sump pump. It is not recommended to route condensate drains to the bilge. After the condensate drain installation is complete, test the installation by pouring water into the pan and checking for good flow.

For installation of the condensate drain:

● Attach a 3/4” I.D. or 5/8” I.D. reinforced hose to the hose barb and secure with stainless steel hose clamps.

● Install the condensate drain hose downhill from the unit and aft to a sump.

● Four drain fittings may be used and the hoses joined together with a tee fitting provided there is a

minimum 2" drop from the bottom of the base pan to the tee connection.

Do not terminate cond ensate drain line wit hin three 3’ (914mm) of any out let of engine, generator exhaust systems , compartment housing an engin e or generator, nor in a bilge, unless the dr ain is connected properly to a sealed condensate or shower sump pump. Seal all condensate hose penetrations.

Blower Assembly

You can achieve multi-directional supply air discharge from a single unit by rotating the blower to the desired position in 45° increments. It is ideal for tight installations as 360° of rotation is available with which to position the blower. Its advanced design allows the blower to be easily removed for rotating or servicing by removing 4 screws. Rotate the blower to allow the most direct flow of air to the supply air grille.

After the blower has been properly positioned, make sure to install the supplied strip of insulation foam around the collar to prevent condensation build up.

Mounting Brackets

The air conditioning unit is supplied with a base pan that also serves as a condensate pan. Mounting clip brackets (4) are provided to secure the base pan to a flat, horizontal surface. Hardware for the mounting clips must be provided by the installer as needed.

Supply & Return Air Grilles and Transition Boxes

Install the supply air grille as high as possible in a location that will provide uniform air distribution throughout the cabin. Grille louvers should be directed properly for best air flow. The return air grille should be installed as low and close to the air conditioner as possible to insure direct uninterrupted airflow to the evaporator. The return air grille should have a minimum four inches (4') of clearance in front of it, free from any furniture or other obstructions. In no instance should a supply air discharge be directed towards a return air grille, as this will cause the system to short cycle. Allow for adequate clearance behind the supply air grille(s) for the transition box and ducting connection. See the Maintenance section of this manual for return air filter cleaning instructions.

Ducting

Good airflow is critical for the performance of the entire system. It is highly dependent on the quality of the ducting installation. The ducting should be run as straight, smooth and taut as possible minimizing the number of 90 degree bends (two tight 90° bends can reduce airflow by 25%). If a transition box is used, the total area of supply air ducts going out of the box should at least equal the area of the supply duct feeding the box. To calculate the square inch area of a round duct, multiply the radius by itself (r

) and multiply that number by 3.1416(π). The

following is a summary of proper ducting connections:

1. Pull back the fiberglass insulation exposing the inner Mylar duct hose.

2. Slide the Mylar duct hose around the mount ring until it bottoms out.

3. Screw 3 or 4 stainless steel sheet metal screws through the duct hose into the transition ring. Make sure to catch the wire in the duct hose with the heads of the screws. Use finish washers with the screws if necessary. Do not use band clamps, as the hose will slide off.

4. Wrap duct tape around the ducting and ring joint to prevent any air leaks.

5. Pull the insulation back up over the Mylar to the ring and tape this joint.

6. Remove excess ducting and use the same connection method at the supply air grille.

All ducting should:

● Be insulated and appropriately sized for each application.

● Run as smoothly and taut as possible.

● Have as few bends or loops as possible.

● Be securely fastened to prevent sagging or chafing during vessel operation.

● Have all excess ducting lengths trimmed off.

● Not be flattened or kinked.

● Be properly protected against potential damage when routed through open areas or bulkheads.

Seawater Pump and Plumbing (Refer to page 31 for recommended flow rates and pump sizes)

Several guidelines should be followed during the installation of the seawater system. If the circulation pump is centrifugal and not self-priming, it must be mounted so that it is always at least 1’ (305mm) below the water line regardless of which tack the vessel is on. Pump must always be mounted per manufacturers recommendations, however, the discharge must always be above the inlet. Pump head should be rotated toward the direction of water flow. Install the seawater speed scoop intake as far below the water line and as close to the keel as

possible in any application, but espe cially on a sailboat, to keep the intake in the water when the boat heels over so that air does not get into the system. The speed scoop intake must face forward and not be

shared with any other pump. A seawater strainer is mandatory between the shut off valve (seacock) and the pump to protect the pump from any foreign matter. Failure to install a seawater strainer will void the pump warranty. The seawater system should be installed with an upward incline from the speed scoop & seacock, through the strainer, to the inlet of the pump, next to the inlet of the air conditioning unit's condenser coil. The discharge from the air conditioning unit should run to the seawater outlet thru-hull fitting that should be located where it can be visually inspected for water flow as close to the waterline to reduce noise. All hose connections should be secured using double/reversed stainless steel hose clamps. Use thread sealer on all threaded connections.

Summary of the seawater system installation:

1. Install the speed scoop thru-hull inlet as close to the keel and as far below the water line as possible, facing forward. Bed the scoop with a marine sealant designed for underwater use.

2. Install a bronze, full flow seacock on the speed scoop thru-hull inlet.

3. Install a seawater strainer below the level of the pump with access to filter.

4. Mount the pump above the strainer and at least 1’ (305mm) below the waterline.

5. Connect the seacock and strainer with an uphill run of 3/4" reinforced marine grade hose.

6. Connect the discharge from the pump uphill to the bottom inlet of the air conditioning unit's condenser coil with 3/4" or 5/8” hose as required. Connect the discharge from the condenser coil to the overboard discharge thru-hull fitting with 3/4" or 5/8” hose as required.

7. Avoid loops, high spots or the use of 90° elbows with seawater hose (each 90° elbow is equivalent to 2.5' (762mm) of hose and a 90° elbow on the pump outlet is equivalent to 20' (6.1m) of hose).

8. Double clamp all hose connections with stainless steel clamps, reversing the clamps.

9. Use thread sealer on all threaded connections.

10. Connect all metallic parts in c on tact with seawater to the vessel's bonding system including the speed scoop inlet, strainer, pump and the air conditioner. Failure to do so will void warranty.

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