Cruisair Tempered Water System Installation, Operation & Maintenance Manual Dometic Group Marine Division Rev. 20140627 L-2810 English PN: 0880269 www.cruisair.com COPYRIGHT © 2007-2014 Dometic Group Marine Division. All Rights Reserved. No part of this publication may be reproduced, translated, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written consent by Dometic Group Marine Division.
Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS . . . . . . . 1 OPERATIONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HOW IT WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 APPLICATION & INSTALLATION STANDARDS . . . . . . . . . . . 2 INSTALLATION . . .
Cruisair Tempered Water System Installation, Operation & Maintenance Manual INTRODUCTION INTRODUCTION Congratulations on the purchase of your Cruisair tempered water system! This manual will provide necessary information for the proper installation, operation, and maintenance of your system. Cruisair units are well-engineered, well-built, and thoroughly tested at the factory. They will provide many years of trouble-free comfort if properly installed, operated, and maintained.
APPLICATION & INSTALLATION STANDARDS Cruisair Tempered Water System Installation, Operation & Maintenance Manual evaporator where the heat is transferred to the refrigerant in the evaporator coil, thus cooling the "chilled" water. The "heated" refrigerant gas is returned to the compressor, compressed, and then circulated through the outer tube in the chiller's condenser coil. Seawater is circulating through the condenser via the seawater system.
PLUMBING Cruisair Tempered Water System Installation, Operation & Maintenance Manual Variable Frequency Drives (VFD) Mount the VFDs close to the compressors on a vertical surface (+/- 10°) mounted in an accessible location. The drives need at least 2 inches (50 mm) clearance on the top, bottom, and both sides. Remove the protective cover (the sticker) on the top of the drive. Removing the protective cover and providing clearance allows the drives to dissipate heat. The drives are IP20.
PLUMBING Cruisair Tempered Water System Installation, Operation & Maintenance Manual REVERSE RETURN Figure 2: Reverse Return Schematic Reverse return helps evenly distribute the water (see Figure 2). Reverse return is always good practice for seawater (or with keel coolers). For chilled water, reverse return is always a good idea on the chiller manifolds. For the airhandlers, reverse return is only needed if the airhandlers do NOT have flow controls.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual PLUMBING Engine Room Autobleeder - Spirovent® The Spirovent® is an inline autobleeder. Install the Spirovent® in the main return line upstream of the circulating water pump but downstream of all airhandlers, the fill assembly, expansion tank, strainer, etc. In applications where the system water flow would exceed the maximum recommended flow rating of the Spirovent®, the Spirovent® may be installed in a sidestream (i.e.
PLUMBING Cruisair Tempered Water System Installation, Operation & Maintenance Manual • There is a large vertical rise. • Possibility of adding more capacity. Note that grossly over-sizing pipes can be harmful too. The drastic changes in water velocity can cause extra losses and noise in the system. Add up the total BTUs of the airhandlers served by a given pipe to determine the size of that pipe. Note that chillers are typically sized to be approximately 80% of the total airhandler load.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual PLUMBING DRAIN The system drain is placed at the lowest point in the loop to allow for easy servicing. Other drains may be necessary elsewhere if water traps are unavoidable. (Refer to “Avoiding Air & Water Traps” on page 4.) CIRCULATION PUMP • The circulating pump should be located near the chiller, pumping water into the chiller first, and then through the loop.
PLUMBING Cruisair Tempered Water System Installation, Operation & Maintenance Manual PRESSURE GAUGES & PRESSURE PORTS The Y-strainer should have pressure gauges to measure the pressure differential across the strainer. This will indicate when it is time to clean the strainer. A pressure gauge at the pump inlet is MANDATORY. The pump inlet pressure gauge should be located to allow good visibility when operating the fill valve. A pressure gauge at the discharge of the pump is recommended.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual PLUMBING Figure 4: Sample Piping Schematic Diagram L-2810 ENGLISH 9
PLUMBING Cruisair Tempered Water System Installation, Operation & Maintenance Manual FILL VALVE WARNING If the fill valve might be connected to a potable water supply, then a Reduced Pressure Zone (RPZ) backflow preventer is required to prevent possible contamination of the potable water supply. ADJUSTING FILL ASSEMBLY’S PRESSURE-REGULATING VALVE Refer to Figure 5 below and follow these steps to change the pressure setting: 1.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual PLUMBING SEAWATER/CONDENSER WATER SYSTEM GENERAL DEFINITION - SEAWATER PIPING The seawater cooling system consists of a through-hull fitting, water shut-off valve or seacock, strainer, seawater pump, water pipe or marine grade hose, and overboard discharge fitting. WATER IN/OUT Note the arrows on the unit indicating direction of water flow.
PLUMBING Cruisair Tempered Water System Installation, Operation & Maintenance Manual SIZE See Table 2 for recommended pipe sizing. If the hose or pipe is a long run or with many fittings, use the next larger size.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual REFRIGERANT CIRCUIT PUMP The seawater pump must be placed in a location that is below the water line and near the tempering unit. The centrifugal pump is not self-priming and water must flow freely to it. The pump may become air locked if air is drawn into the seawater system. Sailboats may require special considerations to prevent air locking when heeling.
WIRING Cruisair Tempered Water System Installation, Operation & Maintenance Manual PLUGS Connect power and accessories per the diagram in the electric box. MTC and MTD models have polarized plugs which mate with plugs on the wire leads from the control panel. The standard TWC model has no plug, because it comes with an electric box that includes the control circuit board pre-wired to the chiller.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual START-UP SINGLE-PHASE NOTICE Single phase chillers usually have a position-sensitive start relay inside the electric box. When mounting the electric box, be sure the start relay is oriented in an acceptable orientation. Read the text on the start relay itself to determine acceptable orientation.
START-UP Cruisair Tempered Water System Installation, Operation & Maintenance Manual FLUSH As a condition of warranty, the installer is required to provide clean circulating water. Otherwise, dirt can collect in the evaporators causing them to freeze and rupture. Airhandler valves and other components can also become clogged or otherwise harmed by the dirt and debris.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual START-UP The water should be clean, such as potable water, and warm, if possible, so as to lessen the amount of air dissolved in the water. Check the system thoroughly for leaks after the initial fill. 1. Locate the main system vent (or the highest airhandler vent if a main system vent is not provided) and open the valve (or vent tube) at this location.
START-UP Cruisair Tempered Water System Installation, Operation & Maintenance Manual water may be colder, but there is less flow, so the net capacity is reduced. Flow rates sufficiently low will cause flow-switch faults and can severely damage chillers by causing them to freeze. For the seawater, the flow rate should be 3 gpm per ton of chiller. (Some chillers may require a higher flow rate - consult the factory if you are not sure.) Rates lower that 2.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual OPERATION • Are all wiring harnesses properly secured? • Are wiring connections made, color to color, correctly at terminal strips? • Are plugs and pins properly aligned and securely connected? • Are all components properly grounded? • Are proper sized circuit breakers used? • Are terminal strips located in a dry, safe place and properly covered? • Check high voltage wiring. • Check low voltage wiring.
MAINTENANCE Cruisair Tempered Water System Installation, Operation & Maintenance Manual CONTROLS Cruisair supplies a variety of controls for airhandlers and chillers. Refer to the appropriate control manual for more information. MAINTENANCE MAINTENANCE LOG BOOK Create a maintenance log book for the chiller system, or add a section to the maintenance log book of the vessel. Begin by recording the data taken at start-up.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual 4. MAINTENANCE Voltage to the equipment should be measured periodically to insure a proper power supply. Pumps, fans, etc. typically allow voltage +/-10% of their nominal voltage rating. Compressors typically allow +/-5%. SHELL-AND-TUBE CONDENSERS Shell-and-tube condensers can last a long time, but only if properly cared for and maintained. Remove the end plate and check for fouling and especially for marine growth.
MAINTENANCE Cruisair Tempered Water System Installation, Operation & Maintenance Manual PUMPS Remove oil, dust, dirt, water and chemicals from exterior of motor and pump. Keep motor air inlet and outlet open. Blow out interior of open motors with clean compressed air at low pressure. Regularly drain moisture from TEFC motors. Check the pump housing and impeller shroud for excessive wear. Worn or pitted impellers will reduce the water flow and should be replaced.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual MAINTENANCE EXCESSIVE CLEANING WILL VOID THE WARRANTY. Therefore, a factory-approved dealer should carefully document the amps, pressures, temperatures, and water flow rates that justify the coil cleaning BEFORE cleaning the coil.
SHELL-AND-TUBE SPECIAL CONSIDERATIONS Cruisair Tempered Water System Installation, Operation & Maintenance Manual SHELL-AND-TUBE SPECIAL CONSIDERATIONS Figure 6: Shell-and-Tube Components GASKETS: IMPORTANT! The gasket should be replaced every time the cover is removed. If the gasket is in poor condition or improperly installed, the tube sheet can be seriously damaged.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual 9. TROUBLESHOOTING Reattach the end cover to the condenser. See “Bolt Torque” on page 25. EXTERNAL ANODES Sacrificial anodes offer protection against galvanic corrosion. If the condenser itself does not have an anode, the installer must provide one separately. Maintain a sacrificial anode in the seawater pipe upstream of the seawater pump.
TROUBLESHOOTING Cruisair Tempered Water System Installation, Operation & Maintenance Manual FLOWSWITCHES CIRCULATING PUMP The circulating pump should come on as soon as the system is put in either cooling or heating mode. If not, check: • AC power panel breakers • Pump relay circuit AIR IN LOOP Air in the system can block water flow through tempering units. Refer to “Filling And Bleeding” on page 16.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual OWNERS LIMITED WARRANTY 1. Measure the circulated water temperature differential between the plate coil inlet and outlet. In the cooling mode, a temperature drop greater than 10°F (5.6°C) indicates restricted water flow through the unit. THIS MUST BE CORRECTED. THE EVAPORATOR WILL BE DESTROYED IF WATER IS ALLOWED TO FREEZE!! Note that the flow switch should have caught this, so there may be a flow switch problem also. 2.
OWNERS LIMITED WARRANTY Cruisair Tempered Water System Installation, Operation & Maintenance Manual SECTION II - WHAT’S NOT COVERED What does this Limited Warranty not cover? This Warranty Shall Not Apply to: 1. Failures resulting from improper installation or use contrary to instructions. 2. Failures resulting from abuse, misuse, accident, fire, or submergence. 3. Any part manufactured by Dometic, which shall have been altered so as to impair its original characteristics. 4.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual OWNERS LIMITED WARRANTY the Customer Service Department are 8:00 a.m. - 5:00 p.m. (USA, Eastern Standard Time Zone) Monday through Friday excluding holidays. 2. It is possible that there might exist a considerable time lag between the date a component is manufactured and the date it is put in service. In such instances, the date of manufacture could indicate that the item is out of warranty.
OWNERS LIMITED WARRANTY TABLE OF Cruisair Tempered Water System Installation, Operation & Maintenance Manual WARRANTY PERIODS AIR CONDITIONING Important Notes: 1. Warranty periods begin from the date of possession of the boat by the first owner if OEM installed or date of installation if dealer installed, but not to exceed three (3) years from date of production.
Cruisair Tempered Water System Installation, Operation & Maintenance Manual GLOSSARY GLOSSARY AIRHANDLER: The fan coil unit that circulates air into a specific area for heating or cooling. ANTIFREEZE: An additive (typically propylene glycol) for the circulating water used to lower the freezing point and inhibit corrosion.
GLOSSARY Cruisair Tempered Water System Installation, Operation & Maintenance Manual HIGH LIMIT SWITCH: A high temperature thermostat used as a safety device to shut down the condensing unit when the water temperature in the circulation piping circuit reaches 120ºF. This prevents the possibility of damaging any PVC piping or any other components due to the water getting too hot. HIGH/LOW PRESSURE SWITCHES: Electrical control devices operated by high and low side system refrigerant pressures respectively.
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