thermowell INSTALLATION, OPERATION AND MAINTENANCE MANUAL UC - UCP | DATA Di PRODUZIONE he [ MODELLO NUMERODISERIE i www.thermowellmarine.com41. Preface Dear ship-owner, congratulations on your purchase of this marine air conditioning system, which will assure high comfort levels in your boat. Thermowell marine air conditioners are efficient, powerful, compact and affordable units. You'll be satisfied by its advanced performances and latest technology. Before starting installation it is strongly recommended to read this manual, which is also basic and integrant part of the air conditioner, carefully and completely, because it provides important information to ensure proper installation, operation and maintenance of the unit and to get the best performance from the unit. Improper installation or operating procedures may cause unsatisfactory performances and / or premature failure in the unit and / or the boat. This A/C unit is to be used only for the purposes for which it has been designed and manufactured. If used in other ways, bad functioning or damages caused to people and/or things are not responsibility of the Manufacturer. Before starting with the installation you should assure that the unit has been purchased from an authorized Thermowell dealer/distributor, the cartons contain all the items checked into the packing list, the warranty certificate supplied with the unit is filled out correctly. In case of any bad functioning during operation, please refer to the “Troubleshooting” section in this manual. If the problem persists, please contact your authorized dealer/distributor. According to the most recent rules for environmental protection, all Thermowell units are equipped with ecological refrigerant. Since Thermowell follows a policy of continuous innovation of its own products, it is reserved the right to make changes on the technical specification and/or design of each product without any prior notice. Specifications showed in this manual are referred both to UC and UCP chillers as well as “customized” chillers. 2. Safety consideration Installation, start-up and maintenance have to be carried out only by a qualified staff having all the necessary technical qualifications for the maintenance of refrigerant and electric systems; the staff will work in conformity with the warnings on the unit, with the instructions contained in this manual and with 3Ne afety measures. ek einai power source off when not Using th 7 le unit long time, before maintenance or in case of failure uy 3. Unpacking the unit and inspection When the unit is received, all items should be Carefully checked against the packing list or shipment documents to ensure all cartons have been received and there are no damages. Chillers must be kept upright at all times and mainly while handled. If chiller is not upright when Teceiveg it is strongly recommended to keep it in horizontal Position at least for 24 hoursbefore installation and Start-up. Mainly check that refrigerant copper pipes are Perfectly dry: evidence of some lubricating oil indicates a broken in the refrigerant circuit. If there is some shipping damage, the carrier should make the Proper notation on the delivery receipt acknowledging the damage. It is necessary to send to Thermowell a photographic documentation of the damages within 10 days from the receiving of the unit, otherwise the claim will not be accepted. 4. Testing Thermowell tests all the Units in its factory, according to accurate internal standards, It is possible to check the units In their destination place Only if the same conditions of the factory are reproduced and kept for the necessary time. 5. Glossary of the main terms used in this manual 4 UCIUCP (chiller unit / preassembled chiller unit) - device mainly composed by compressor(s), tube in tube copper-nickel corrosion resistant heat exchanger for = water circuit, stainless steel brazed plates heat exces for fresh water Circuit, thermostatic expansion vel Copper pipes for refrigerant gas, reversing valves fon f PUMP operation, Safety devices, sea and fresh ts circuits connections, electric and electronic componen heat Fan Coil — also named air handler, is a waterat coonenSe! Placed inside the ambient to be hea net Cooled. It consists mainly in the following come pan @PPropriately assembled: finned coil, blower(s), 42" —_ —_manual bleeder valve, digital or mechanical thermostat Sea water circuit — open circuit consisting in piping, ball valve(s), strainer, pump, sea water intake and discharge through which the sea water flows reaching the copper- nickel heat exchanger installed into the chiller unit. Chilled water circuit — closed circuit mainly consisting in pump, insulated piping, manifolds and ball valves through vee the chilled water flows reaching the fan coils and go ack. Condensate drain circuit — open circuit used for drain discharge outside of the boat. Condensate is collected and drained from the aluminium or stainless steel pan installed under the air handler’s coil and under the UC / UCP chiller unit. Sea Water pump - centrifugal pump idoneous for continuous operation and for use in marine applications. It is used for the sea water circulation inside the tube in tube heat exchanger. If not differently specified it MUST be installed below the sea level. In air conditioning systems equipped with UC or UCP chillers, the sea water pump is mounted by the installer outside chillers themselves. In some customized units. Sea water circulation pump can be installed in the case of the chiller. Self priming sea water pump — for particular applications, for example in sailing boat, it is strongly recommended the installation of a self priming pump. Such kind of pump can be i9nstalled also above the sea water level. For maximum installation height, contact the manufacturer of the pump or Thermowell Technical Department. Fresh water pump -— centrifugal pump idoneous for continuous operation and for use in marine applications. It is used for fresh water circulation inside the chiller and throughout the chilled water circuit This pump is already installed inside UCP unit, thus obtaining great time savings for installation. If using UC systems fresh water pump must be installed externally. There is NO need to install a sh water circuit is a self priming fresh water pump since fre: closed loop6. Installation scheme The following is 2 typical installation drawing showing th e items necessary for the installation of a centrali hydronic air conditioning system ed 7. Installation general rules an Handling Once un for their final ay UC. and UCP chillers must be handled itioning by picking up on all four comersthe unit baseplate simultaneously. Chiller sh: lifted by any of the components installed Witte tacos (for example refrigerant copper pipes) to avoid damages. 7.2 Placement UC and UCP chillers are properly designed to work under a wide range of operating conditions, both for what concern air ambient temperature both sea water temperature. In case of particularly heavy working conditions or in case of doubt, please refer to Thermowell Technical Department. Chillers are usually installed into the engine room. Temperatures usually reached in this ambient are not dangerous for the correct operation of the unit; it is important that the unit is never reached by sea water, salted vapour or bilge water. Main consideration to follow during installation is to choose a place where each component can be easily reachable for maintenance reasons or repairing. In particular service accessibility must be guaranteed to electric box and compressors. In some models it is possible a remote installation of the main electric box, normally fixed into the case of the unit. Chiller must be installed on horizontal surfaces using the four supplied stainless steel brackets. Insert the brackets on the tim of the condensate pan and secure them by means of self-tapping screws. Brackets should be installed one for all four side of the baseplate or two in the longer sides, to prevent movement even in the most critical conditions. It is recommended to use antivibrating disposal to avoid the transmission of vibration to the structuire of the boat Check that the isolators chosen have enough capacity to support the weight of the chiller. In order to make installation simplest, it is suggested to definitely secure the unit only once fresh water, sea water and drain discharge Ou circuits has been completely installed. Alt gh the air conditioner is very quiet in operation it is suggested = select the location for installation considering ~ . emissions (engine room rather than a cabin or saloon) 7.3 Piping connections ene to sea water and fresh water piping se through the connection hoses properly lal aa Ta chiller unit. If piping is made by rigid nee eet ee copper) it is recommended to install an m4 crvibrating Eatiteation before the unit or equivalenicsDouble clamps each water connection Be toonactons from and to UC/UCP serieg chi! should be easily removeable for maintenance OF repair Drain discharge pipe must be connected to the Proper hose connections installed on the drain pan 8. Sea water circuit Ane The components of a sea water circuit are sea water intake (scoop type), full flow sea cock (ball valve), Strainer, seq water pump, overboard discharge. The sea water intake should not be shared with any other different pump. For the seawater circuit realize a Proper sea water intake choosing a water intake “scoop type” with filtering grooves oriented forward in order to aid the pressure in the Cooling circuit during the navigation as well, allowing the use of the unit while cruising (see picture). Or. PROW WaTER oar DIRECTION DIRECTION It is strongly recommended to never intake the cooling water from the Cooling circuit of the engine or of the generator. If the installation of a new sea water intake is necessary, it must be placed as close as possible to the keel and as far below the sea water level as possible thus reducing the Possibility of air entering the circuit (however it is not a Problem if a self priming Pump is installed). Self priming Pump installation is Strongly recommended in sail boat. 4 ball valve connected directly on the sea water intake is peceeeay to interrupt the Sea water flow in the circuit Fe. sasaenance operation or when the boat is kept The strainer Should be Cleaning and in a Visible = Check the sei ted to provide easy access for Position as it is necessary to in the circuit. It must have @ ‘awater flowremovable internal basket for always discharge air from the Tera ne Cleaning check the right filling of the circuit. Strain: cad ile and chiller from impurities. Missing to install protect pump strainer will void both pump and chiller aren, lead The seawater pump |S needed to circulate th 4 quantity through copper-nickel heat altars ea sized according to the effective cooling aaa "e ed Sea water pump must be installed at least 30 Sis te water line on an horizontal surface. More inform: vied os installation and maintenance of the sea water ae se e manufacturer's instructions. The sea water pump must be mounted as near as possible to the connection of th seawater circuit on the intake line e fixed with intake a delivery sides ina vertical position so that trapped air can go out above the pump. Sea water pumps must be designed for continuous operation and idoneous for marine ambient application. When the circuit is filled for the first time, it will be necessary to discharge the air in the pump. This operation will be repeated at each launching of the boat. Never install the pump on the bottom of the boat because water in the bilge could cause a short circuit In each case (typical of the sailing boats) where the sea water pump cannot be installed below the water line, it is necessary to install a self-priming sea water pump The seawater circuit must be as short as possible, without kinks or loops which could prevent the pump priming or increase pressure drops of water in the circuit with consequent loss of performance of the a/c unit. The line between the water intake valve and the pump should be as short as possible. It is suggested to install a throttle valve on it to make the maintenance easier. The seawater strainer must be installed at the beginning of the intake line, as shown in the installation diagram. The seawater circuit should always rise, from rain intake to the pump and from the pump to the condensing pea After the unit heat exchanger, i in or drop the discharge part, which must always be line so that the circuit will be self bleeding: ea water Connections between eae Sail : tthe circuit and sea water pipe MUS e hat The discharge side i the circuit should be made S°the water dischar i ge will not cause exce t oY me and your neighbours. a ee the picture below for a th | summary of the se: ter circuit installation (correct and incorrect examples) an CORRECT STeAOY vrvano Low rnc met TO.UnIT Twen oonnernno To OUTLET. HOSES DOUBLE CLAMi ne zs WATER WET AND OUTLET WELL TANCED x INCORRECT 9. Fresh water circuit Fresh water circuit is a closed circuit through which fan coils are connected to the chiller unirt. Piping sections are always according to the capacity of the chiller unit and their length. Pipes sections cannot be too small to avoid erosion of the pipes, too high water velocities and more noise. Also it will increase pressure drop along the pipes which results in reduced water flow through the air handlers and reduced performance of the entire system. Connections between each component of the fresh water circuit and fresh water pipe must be hoses double clamped. , Manifolds must be equipped with ball valves installed > each water outlet, ble Fresh water circuit must not be connected to the potal water system of the boat. Pressure inside the fresh water circuit must be 0.8-1 Coen The fresh water pump is needed to circulate the oyed water quantity through the air handler circuit and it! a is according to the effective cooling power of the chillel. always suggested to install a strainer prior to the catch eventual impurities in the fresh water circuit.Fan coil - following aiso named air handler, consists mainly in the ponents: finned coil (water/air heat exchanger), blower(s), drain x ji pan, bleeder vaive, fresh water inlet and outlet connection. Water inlet is from bottom of the coil and water outlet from the top end Fan coils must be installed i ee cabin, in a Spgeeee ee poston: mao ie z Place easily accessible for maintenance feasons and using the supplied inox stee! brackets. Insert the brackets on the rim of the condensate pan and secure onto a flat, horizontal surface by means of self-tapping screws. Fan coils cannot be installed for any reason in the bilge or engine room. Return air flow to the fan coil must be sealed from any direct access to bilge or engine room, thus avoiding that bilge or engine room vapors could mix with the treated air contaminating living ambients. Fan coils produce condensate water which is kept in the chassis and which must be drained and discharged overboard. The condensate draining tubing must be connected to the drain nipples of the condensate pan. Itis necessary to install the unit at a certain level to give a minimum slope to the discharge hose. 3 When installing the unit, it should be vertically blocked to prevent movements caused by the impact of the boat with the waves (for example when the unit is installed forward on powerful motorboats). ee The inlet air grille must be installed as close as possbee.(° the fan coil to allow an uninterrupted airflow to the unit. ne connection between the air blower and the air eh ar is made using insulated flexible duct and coupe pas clamps. Take care of may tightening ing the absence of air losses. , a ren he Fearcuit is filled for the first time, it will =necessary to discharge the air in the fan Coils throy h manual bleeder valve. 9h the Fan coil controls must be installed at 1.5m height (aroy cabin’s mid-height) from the floor on a dry place, without air current, away from heating or Cooling Sources (windows, air return or delivery grilles mines a : and so on) in a significant position for Controlling the room comfort. 11. Air distribution circuit A good air distribution circuit is essential to obtain best performances from an air Conditioning system. Air duct should be flexible, insulated (for example with glass wool) and externally covered by anti condense film (for example aluminium film). As general rules, the return air grille must be installed as Close as possible to the fan coil to allow an uninterrupted airflow to the unit; the air supply grille should be installed as higher as possible to create the ideal air flow into the ambient avoiding short cycling; the duct should be positioned as straight as possible minimizing the number of the bend and the derivation tees. Different installations can produce the stratification of the air into the ambient and a non uniform temperature distribution. The max length of the duct should be 2.5-3 meter, to Prevent and reduce noise diffusion from the blower motor it is recommended to connect to the blower itself at least 1.5 meter length air duct The connection between the air blower and the air supply grille is made using insulated flexible duct and double PVC hose clamps. The same clamps could be used for the connection of the duct to eventual pipe derivation tees used for the air distribution inside contiguous ambient. Take care of Strictly tightening the clamps checking the absence of air losses. ne grilles should be Equipped with a filter to avoid Nosetin Rae of dust on the finned coil which can cause creme Pence However all fan coils produced by Coil itself. As quipped with an air filter positioned on the general rule, the surface of the return air grille Should be the Same as that of the air handler. 12 Waa12. Condensate drain line Fan coils produce condensate water whi bilge of the engine room. Once the condensate drain line has been installed, it is strongly recommended to test it filling the drain pan of each fan Coil in the circuit verifying the regular flow. 13. Power supply For the electrical connection of the unit please refer to the wiring diagram supplied with the unit. Before start-up assure that power available is the same as stated on the identification label placed on the unit. 14. Start up : i This is a procedure to follow when starting the chilled water air conditioning system. Before servicing the unit it is strongly suggested to check all the electrical and seawater circuit oon Open the ball valve on the sea water line, installed on the inlet and outlet side of the pump: those installed on the manifolds. Open each bleeder valve ra Fill the fresh water circuit with glycol-water mixing ressure of 0,8 bar. P Set desired temperature on each ambient Turn on the chiller unit i ——o hose eventually s andCheck water flows in both sea and fresh eng for air flow and temperature from carts nce the unit is Operating, it is necessary ia iy water flow through the exchan overboard seawater outlet. ited 15. Maintenance Troubleshooting and repai 1 } Pair should be al qualified maintenance personnel. i oa Py Do not attempt service using clean water. All electrical Parts must be kept clean and dry. Check periodically for electrical leaks, which, if detected, must be immediately eliminated. The seawater strainer installed on seawater pump intake requires to be checked and cleaned periodically. This Strainer is absolutely necessary as it prevents the seawater pump and circuit to be clogged by dirty particles. There is not a fixed rule to determine the periodicity of strainer maintenance, which depends on the number of running hours and on the level of water pollution. In cool mode a reduced water flow reduces the efficiency and eventually Causes a unit shutdown. If the unit is used in the harbours when there is backwash or strong wind there could be an intake of dirty particles with following obstruction of the strainer. When freezing temperature are expected, it is necessary to drain all the water from the condenser, the sea water pump, the strainers and the connection tubing. . particular, you have to: a) close the seawater intake; remove the condensing unit inlet water hose; c) clean ne strainer and drain completely the water inside it and insi the pump. ‘ ; Check Priodically that the condensate discharges into water are not clogged by dirtyness or other. If the unit or the boat is not used for a long necessary to unlock the working of the seav periodically following the instructions containe time, it will be eawater pump d in its 14operating manual. If the boat must be on land for water to drain from the circuit t stagnation and let fresh wat Remember to discharge the ci connection of the pump. Often check that the water pressure i circuit is around or equal to 0,8 bar. Do not use flammable materials, sprays or chemical substances in cleaning the unit and the controller. Avoid the unit working if the filters are not installed, in order to prevent dust and dirt to settle on it. Keep the copper-nickel heat exchanger circuit always clean washing it with proper products once every two years. This operation has to be carried out by a qualified refrigerator technician. Do not operate the unit while using any heating device inside the cabin. ss Avoid the unit working when the boat is veering or with rough sea: the excessive lateral or longitudinal inclination of the boat could cause the loss of water om Pe condensate pan and the blockage or Coe i ec compressors due to the non-circulation of lubricating oll. more than 30 days, allow all ‘© avoid corrosion due to the er flow for some Minutes. rcuit when launching for the inside the fresh water 15Technical information in this manual are not binding. Thermowell in his pursuit of a policy of constant development and upgrading of the manual may make any modifications without prior notice thermowell Thermowell Sede Legale Via Ugo Foscolo , 8 73010 Surbo (LE) - Italy Lecce - Italy Tel +39 0832 300214 Fax +39 0832 300214 info@thermowellmarine.com service@thermowellmarine.com www.thermowellmarine.com 16