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Direct Expansion Split Marine Air Conditioning System Installation, Operation & Maintenance Direct Expansion Split
Marine Air Conditioning System
Installation, Operation & Maintenance
Table of Contents
I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
II
General Description of Basic Components
A.
Fan Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B.
Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C.
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D.
Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E.
Pump Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F.
Ducting, Grilles & Transition Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G.
Seawater Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
H.
Refrigerant Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
I.
Basic Theory of System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
III
Installation of Basic Components
A.
Fan Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B.
Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
C.
Refrigerant Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
D.
Flaring Copper Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
E.
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F.
Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
IV
Before Starting the System for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
V
System Leak Checking and Refrigerant Charging
A.
Leak Checking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
B.
Charging the System with Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C.
Recovering Refrigerant from the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VI
System Operation
A.
Systems with AQS3 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
B.
Systems with Tempwise 2001 Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
C.
Reverse Cycle System Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
VII
Maintenance
A.
Fan Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B.
Seawater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
VIII
Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
IX
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
X
Thermostat Cut-out Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
XI
Refrigerant Charging Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
XII
Refrigerant Line Set Sizing and Refrigerant Tee Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . 35
XIII
System Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 4
I.
Introduction
Thank you for purchasing an Aqua-Air
®
Direct Expansion Split Marine Air
Conditioning System.
The purpose of this manual is to inform you of the different components that you
will need to install a fully operational direct expansion split air conditioning system on
your boat and to give you the basic information necessary to correctly install all of the
components that comprise the direct expansion split air conditioning system.
The Aqua-Air
®
direct expansion split air conditioning system have been
specifically designed for use in the marine environment. Systems are available in a
range of capacities from 5-48,000 BTU/H in either 115/1/60 or 230/1/60 voltage inputs
(the 24-48,000 BTU/H units are also available in 208-230/3/50-60 and 460/3/50-60 ). All
systems are rated for full capacity on 60 Hz power, however, they can be operated on
50 Hz power sources with a corresponding 17% decrease in capacity. The 50 Hz power
sources would normally be 100/1/50, 200-220/1/50, or 380/3/50. All of the systems are
available as reverse cycle units.
II.
General Description of Basic Components
There are six basic components that make up a typical Aqua-Air
®
marine self
contained system:
A.
Fan Coil
B.
Condensing Unit
C.
Thermostat
D.
Seawater Pump
E.
Pump Relay
F.
Ducting, Grilles and Transition Boxes
G.
Seawater Kit
H.
Refrigerant Line Sets
Following is a description of each major component.
A.
Fan Coil
The Fan Coil ( also referred to as an evaporator or air handler ) is a refrigerant to
air heat exchanger located in the area that is to be either cooled or heated. The basic
unit is made up of the following major components:
1.
Evaporator coil
2.
Capillary tube refrigerant metering device
3.
Squirrel cage blower and motor or propeller fan blade and motor
4.
Metal chassis with integral drain pan 5
Fig. 1
There are two different fan coil configurations, defined only by the direction that
the air passes through the fan coil.
1.
Blow-thru Fan Coil - air is blown across the evaporator coil
Examples:
AQB, AQBH, AQE, AQL
2.
Draw-thru Fan Coil - air is drawn across the evaporator coil
Examples:
AQO, AQOC, AQOH, AQC
B.
Condensing Unit
The Condensing Unit is made up of the following major components:
1.
Refrigerant compressor
2.
Suction accumulator
3.
Reversing valve ( if it is a heat pump model )
4.
Base valves with service ports
5.
Condenser
6.
Electrical starting components for the compressor
7.
Drain pan & mounting base
C.
Thermostat
The thermostat / controller used to operate the unit can be provided in one of four
different configurations:
1.
Three knob manual thermostat ( AQS3 series thermostat ). The
thermostats main components are:
Off-Fan-Run mode switch
Fan speed control
Thermostat
Terminal block
This thermostat is mounted in the area to be cooled/heated within 10' of
the fan coil so that the air sensing bulb will be in the return air flow. 6
Fig. 2
Fig. 3
2.
Tempwise 2001 digital thermostat ( TW2D series ). The thermostats main
components are:
Display Panel
Control Module
Display Cable
This thermostat is mounted in the area to be cooled/heated. The control
module should be mounted close to the fan coil for ease of connecting the
fan motor.
The thermostat is available with either a black ( TW2DB ) or white
( TW2DW ) display head. The display head has an internal air sensor.
3.
Tempwise 2001 digital thermostat display head ( TW2-01B or W ) when
used with the T series condensing units. The thermostats main
components are:
Display Panel
Control Module ( factory mounted &
pre-wired to the condensing unit )
Display Cable
The display panel and display cable are the only items that need to be
installed as the control module is already mounted on the condensing unit.
The display head has an internal air sensor.
The display panel is available in either black ( TW2-01B ) or white
( TW2-01W ). The display head has an internal air sensor. 7
Fig. 4
CP-05
Seawater
Pump
D.
Seawater Pump
The seawater pump is used to circulate seawater through the condenser on the
condensing unit(s). These are all centrifugal pumps and are NOT self priming. This
makes it necessary for the pump to be mounted below the ships running water line
(under all conditions).
A condensing unit requires approximately 250 GPH ( 946 LPH ) for every 12,000
BTU/H in capacity. Table 1 summarizes the amount of water necessary for a given
capacity.
Condensing Unit Required Seawater Flow Rates
Unit Capacity, BTU/H
Seawater Flow in GPH / LPH
Seawater Pump
5,000 to 12,000
250 / 946
CP-02
12,001 to 24,000
500 / 1,892
CP-05
24,001 to 48,000
1,000 / 3,784
CP-10
48,001 to 72,000
1,500 / 5,677
CD100B-36-03C
72,001 to 144,000
3,000 / 11,353
CD100B-40-05C
Table 1 8
Figure 5 Duct Kit Components
E.
Pump Relays
A pump relay is necessary when two or more condensing units are supplied
water from a single seawater pump. Aqua-Air
®
offers three different pump relays:
AQP2R
Designed for use with two condensing units and one seawater
pump. Both condensing units must be on the same shore line. No
external power source is needed. This relay is not ignition protected
and therefore must not be used on