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FCF9000

Webasto FCF 5000, FCF 9000, FCF 12000, FCF 16000 Installation & Operation Manual

MARINE AIR CONDITIONER
Installation & Operation Manual
Table of Contents
UNPACKING AND INSPECTION ............................................................................................................................6
SAFETY CONSIDERATIONS .................................................................................................................................6
PLACEMENT OF SYSTEM.....................................................................................................................................7
CONDENSATE DRAINS .........................................................................................................................................8
BLOWER ASSEMBLY.............................................................................................................................................8
MOUNTING BRACKETS ........................................................................................................................................8
SUPPLY & RETURN AIR GRILLES AND TRANSITION BOXES ............................................................................8
DUCTING ................................................................................................................................................................9
SEAWATER PUMP AND PLUMBING .....................................................................................................................9
ELECTRICAL CONNECTIONS, GROUNDING AND BONDING .......................................................................... 11
WIRED REMOTE CONTROLLER INSTALLATION ............................................................................................. 12
CONTROL BOX INSTALLATION ......................................................................................................................... 12
INSTALLATION CHECKLIST (REVIEW PRIOR TO INSTALLATION) ........................................................................... 13
WIRING DIAGRAMS............................................................................................................................................ 14
WIRED DISPLAY CONTROL OPERATION ......................................................................................................... 16
Power ON/OFF ................................................................................................................................................ 17
FAN Control ...................................................................................................................................................... 17
Temperature Setting ......................................................................................................................................... 17
MODE Setting .................................................................................................................................................. 17
Display Fahrenheit or Centigrade .................................................................................................................... 18
Error Codes ...................................................................................................................................................... 18
Key lock ............................................................................................................................................................ 18
Starting Interval Setting .................................................................................................................................... 18
Auto –off function of the manual controller ...................................................................................................... 19
Accessories ...................................................................................................................................................... 19
REMOTE CONTROL OPERATION ..................................................................................................................... 20
Button / Function and Description (Cover Closed) .......................................................................................... 20
Button / Function and Description (Cover Open) ............................................................................................. 21
Mode Operations .............................................................................................................................................. 21
Battery Replacement in Wireless Remote Control .......................................................................................... 22
REVERSING VALVES ......................................................................................................................................... 25
SEAWATER STRAINER ...................................................................................................................................... 25
BLOWERS ........................................................................................................................................................... 25
CONDENSER COIL CLEANING.......................................................................................................................... 25
RETURN AIR FILTERS ........................................................................................................................................ 25
WINTERIZATION ................................................................................................................................................. 26
Operation / Installation Manual – FCF 5,000, 9,000, 12,000, 16,000
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 provide many years of efficient and trouble free use. The FCF Series air conditioners are designed for marine applications incorporating the following features:
Compact design High efficiency rotary compressors (5-16K) Cupronickel condenser coil Raised lance fin designed evaporator coil Polyester coated 2” (50mm) deep drain pan with two condensate drain locations Anti-vibration base pan Pre-charged and pre-wired systems for easy connections 3 speed blower 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 Moisture mode cycle for humidity control
This manual is intended to provide the information necessary to ensure proper installation, operation, and maintenance of the unit. Improper installation can result in unsatisfactory performance and/or premature failure of the unit. Before proceeding, please read this manual completely. In the interest of product improvement, specifications and design are subject to change without prior notice.
Page 4
OVERVIEW
HOW IT WORKS
Operation / Installation Manual – FCF 5,000, 9,000, 12,000, 16,000
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 a/c unit's efficiency. This a/c unit can effectively cool your boat in water temperatures up to 90°F and heat in water temperatures as low as 40°F.
Page 5
Operation / Installation Manual – FCF 5,000, 9,000, 12,000, 16,000
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 unit cannot and should not be mounted in spaces containing gasoline engines, tanks, LPG/CPG cylinders, regulators, valves or fuel line fittings. Failure to follow this warning could result in injury or death and violation of federal requirements for ignition protection.
To minimize the hazard of electrical shock, this component must be effectively grounded. High compressor temperature is normal. Do not touch.
INSTALLATION
UNPACKING AND INSPECTION
When the equipment is received, all items should be carefully checked against the packing list to ensure all cartons have been received. Move units in the normal "up" orientation as indicated by the arrows on each carton. Examine cartons for shipping damage, removing the units from the cartons if necessary. 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 three 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 sole 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:
Notice this component is charged with Hydro chlorofluorocarbon (H CFC) refrigerant R22. 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 fines and imprisonment.
Page 6
PLACEMENT OF SYSTEM
Tools required:
Screws drivers Pliers Pipe wrench Wire cutters / crimpers Drill & 7/8" bit Jigsaw Duct tape Electrical tape Teflon tape Bedding compound to seal thru hull
fittings
Hardware to secure unit, pump,
strainer, grilles & control panel
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. See diagram below.
The unit should be installed as low as possible, BUT NEVER IN THE
BILGE OR ENGINE ROOM AREAS, ENSURE THAT THE SELECTED LOCATION 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 run downward from the unit to a suitable 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.
Page 7
Operation / Installation Manual – FCF 5,000, 9,000, 12,000, 16,000
Operation / Installation Manual – FCF 5,000, 9,000, 12,000, 16,000
CONDENSATE DRAINS
The condensate drain pan is 2” (50mm) high with two drain locations. During conditions of high humidity, condensate may be produced at a rate of approximately a 1/2 gallon per hour (1.9 liters per hour). With this in mind, 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 proper flow.
For installation of the condensate drain:
● Attach a 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.
● Two drain fittings may be used and the hoses (teed) together using a tee fitting provided there is a
minimum 2" drop from the bottom of the base pan to the tee connection.
Do not terminate condensate drain line within three 3’ (914mm) of any outlet of engine, generator exhaust systems, compartment housing an engine or generator, nor in a bilge, unless the drain 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. It is ideal for tight installations as 180° 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.
MOUNTING BRACKETS
The a/c 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.
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 upward. The return air grille should be installed as low and close to the a/c unit as possible to ensure 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.
Page 8
Operation / Installation Manual – FCF 5,000, 9,000, 12,000, 16,000
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° 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
2
) 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 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.
● Insulated when located in high heat load areas (hull side, mechanical compartments, etc.).
● Be properly protected against potential damage when routed through open areas or bulkheads.
SEAWATER PUMP AND PLUMBING
Several guidelines are required during the installation of the seawater system. Since the circulation pump is centrifugal, 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 may be mounted horizontally or vertically, 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 especially 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 a/c unit's condenser coil. The discharge from the a/c 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. Hose connections must be secured using double/reversed stainless steel hose clamps. Use Teflon
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