DuraSea Condenser Unit Installation, Start
Contents
1. CARDBOARD OR PLASTIC SHEET BLOCKED IN COIL SIDES Outdoor Temp Less Than 65 F 18 C 1 When outdoor ambient temperature is below 65 F 18 C it may be necessary to restrict the condenser air flow to achieve normal operating pressures in the 325 to 375 psig 2240 to 2585 kPa range These pressures are necessary for checking the charge Block equal sections of the outdoor coil on all coil sides until the liquid pressure is in the 325 to 375 psig 2240 to 2585 kPa range see Figure 7 2 Charge the unit following the steps listed for Outdoor Temp 65 F 18 C or Higher on page 17 NOTE Accurate pressure gauge and temperature sensing devices are required System overcharge with refrigerant can lead to catastrophic failure Symptoms are high head high running current low superheat and high subcooling SYSTEM OPERATION The outdoor unit and indoor blower cycle are on demand from the room thermostat When the thermostat blower switch is in the ON position the indoor blower operates continuously Ensure that all safety controls are operating control panel covers are on and the service panels are in place2. 2 R 410A QUICK REFERENCE GUIDE MODEL NUMBER NOMENCLATURE INSTALLATION GUIDELINES IMPORTANT SAFETY CONSIDERATIONS Avoid Harmful Vapors Electrical Shock Hazard Other Hazards TooLs REQUIRED CODES AND REGULATIONS CHECK UNIT ELECTRICAL CHARACTERISTICS PLACEMENT OF THE SYSTEM INSTALLATION CLEARANCES RIGGING AND MOUNTING THE UNIT Rigging Mounting REFRIGERANT PIPING CONNECTIONS Copper Tubing Provide Safety Relief Determine Refrigerant Line Sizes Liquid Lift Suction Riser Multiple Evaporators On Single Condenser Install Filter Drier Install Liquid Line Solenoid Valve Selecting an Accumulator Make Piping Connections Insulate Suction Lines Routing of Liquid Line SERVICE VALVE OPERATION REPLACEMENT RETROFIT Existing evaporator coil Acid Test ua siw yaa s sau sites Installation 5 sZ L i pe kh ek rage PRESSURE TEST AND LEAK CHECKING EVACUATION ELECTRICAL CONNECTIONS Field Power Supply Field Control Wiring Thermostat 24VAC Controls DuraSea Condenser Installation Start Up amp Service Manual Read This Manual Before Proceeding INTRODUCTION The Dometic DuraSea Split System is a direct expansion air cooled air conditioning system d
3. 18 L 3153 DuraSea Condenser Installation Start Up amp Service Manual Quarterly Inspection and 30 days after initial start MAINTENANCE These items should be part of a routine maintenance program to be checked every month or two until a specific schedule for each can be identified for this installation QUARTERLY INSPECTION AND 30 DAYS AFTER INITIAL START Return air filter replaced or cleaned as appropriate Check condensate drain for blockage Clean if necessary SEASONAL MAINTENANCE These items should be checked at the beginning of each season or more often if local conditions and usage patterns dictate Clean and inspect the condenser coil Can be flushed with low pressure water hose if necessary Visually inspect connecting lines and coils for evidence of oil leaks e Check tightness of condenser fan motor mounting bolts Check tightness of compressor mounting bolts e Check wiring for loose connections Check indoor coil Clean if necessary Check evaporator blower motor amp draw compressor amperage and condenser fan amps Clean and wipe down cabinet with stainless steel protectant NOTE If the owner complains of insufficient cooling gauge the unit and check the refrigerant charge Refer to Refrigerant Charging Guidelines on page 15 ROUTINE CLEANING OF CONDENSER COILS Pe
4. DuraSea Condenser Installation Start Up amp Service Manual Preliminary Information START UP CHECKLIST PRELIMINARY INFORMATION OUTDOOR MODEL NO SERIAL NO INDOOR AIRHANDLER MANUFACTURER MODEL NO SERIAL NO PRE START UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE Y N IF SO WHERE WILL THIS DAMAGE PREVENT UNIT START UP Y N CHECK POWER SUPPLY DOES IT AGREE WITH UNIT Y N HAS THE GROUND WIRE BEEN CONNECTED Y N HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY Y N ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY Y N CONTROLS ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED Y N ARE ALL WIRING TERMINALS including main power supply TIGHT Y N IF APPLICABLE HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS Y N INDOOR UNIT HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE Y N ARE PROPER AIR FILTERS IN PLACE Y N HAS CORRECT FAN ROTATION BEEN CONFIRMED Y N PIPING ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR COILS AS REQUIRED Y N HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR OUTDOOR AND INDOOR COILS TXVs Thermostatic Expansion Valves SOLENOID VALVES FILTER DRIERS AND FUSIBLE PLUGS WITH A LEAK DETECTOR Y N LOCATE REPAIR AND REPORT ANY LEAKS HAVE LIQUID LINE SERVICE VALVES BEEN OPENED Y N HAVE SUCTION LINE SERVICE VALVES BEEN OPENED Y N CHECK VOLTAGE IMBALANCE LINE TO LINE VOLTS AB V AC V BC V
5. Dometic DuraSea Condenser Unit Installation Start Up amp Service Manual DuraSea Condenser Unit Dometic Rev 20141217 PN 337982 RETAIN THESE INSTRUCTIONS FOR L 3153 FUTURE REFERENCE COPYRIGHT 2013 2014 Dometic 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 Every precaution has been taken in the preparation of this manual to ensure its accuracy However Dometic Marine assumes no responsibility for errors and omission Neither is any liability assumed for damages resulting from the use of this product and information contained herein Dometic SYSTEM START UP 15 REFRIGERANT CHARGING GUIDELINES 15 PRELIMINARY REFRIGERANT CHARGE 15 SYSTEM CHECK 16 START UNIT suis nues vdi ee a 16 Compressor amp Fan Rotation 16 Compressor Overload 17 Final Charge Adjustment 17 System Operation 18 MAINTENANCE 19 QUARTERLY INSPECTION AND 30 DAYS AFTER INITIAL START 19 SEASONAL MAINTENANCE 19 ROUTINE CLEANING OF CONDENSER COILS 19 ROUTINE CLEANING amp PROTECTION OF CABINET 19 SER
6. E 8 L z t 56 0009 06 LOT 000 87 02010 511011931112305 0180 HUN Sulsuapuo 235100 OTE v8 909 7 06 ST A 09 09v 08 Sz v E 8 E 8 L z t 06 0009 09 9 9 000 87 asvvod Kilograms Unit Weight Pounds Ibs S9E v8 ESZ L6T 07 0 V 09 0 7 807 OzT SE 8 L 8 E 8 z t FE 0009 EZT 8 VI 000 09 227530 S9E v8 905 7 SZ oz A 09 09v OzT SE 8 L 8 E 8 L z t 06 0009 OL Yi 000 09 109v2q Meters SLE v8 ESZ L6T SS ov V 09 0 2 802 OT SE 8 L at 8 L at 5 0009 O9T 6 T 000 ZL 2230 SLE 78 909 57 0 oz A 09 09v OT SE 8 L at 8 L at 06 0009 L8 68 0022222 050 2 Fractional inches Refrigeration System SLY v8 ESZ L6T OL 05 V 09 0 7 807 09T Sv 8 T T et 8 T T 8 L FE 0009 SET 558 000 06 ao06v2a SLY 18 909 7 0 SZ A 09 09v 09T St 8 T T at 8 T T 8 L 06 0009 OTT VEL 000 06 306v3a Condenser Fan Flow SeS L8 ESZ L6T SL SS OST St 8 E T 8 s 8 T T 8 L 58 0000T L9T ETE 000021 0020120 METRIC CONVERSION CHARTS 55 L3 905 7 ov 0 A 09 097 VE 09 0ez 80z OST Sv 8 E T 8 s 8 T T 8 L 67 0000T TT E ST 000 0zT 107Tv2q ions icat t Line Specif igeran DuraSea Unit Refr Table 1 DuraSea Condenser Installation Sta
7. filter drier expansion valve etc Outdoor Fan Off 1 Motor not running Check power Check capacitor for single phase fan 2 Motor overload open Check overload rating Check for fan blade obstruction 3 Motor burned out Replace fan assembly L 3153 21 Troubleshooting DuraSea Condenser Installation Start Up amp Service Manual Table 3 General Troubleshooting continued PROBLEM POSSIBLE REASON SOLUTION Compressor cycles on low Indoor Air Fan Running pressure switch 1 Liquid line solenoid valve s fails to open Check liquid line solenoid valve s for proper operation Replace if necessary 2 Filter drier plugged Replace filter drier 3 Expansion valve power head defective Replace power head Low refrigerant charge Add charge Check low pressure switch setting Airflow Restricted 1 Coil is iced Check refrigerant charge 2 Coil dirty Clean coil fins 3 Air filters dirty Clean or replace filters 4 Dampers closed Check damper operation and position Indoor Air Fan Stopped Electrical connections loose Tighten all connections Fan relay defective Replace relay Motor overload open Power supply Motor defective Replace motor Fan belt broken or slipping Replace or tighten belt O Pe ONS Compressor running but Suction Pressure Low cooling insufficient 1 Refrigerant charge low Add refrigerant 2 Head pressure low Check refrigerant charge Check outdoor fan cycli
8. for Dometic any liability in connection with such warranty or any liability or expense incurred in the replacement or repair of its products other than those expressly authorized herein Dometic shall not be responsible for any liability or expense except as is specifically authorized and provided in this section Dometic reserves the right to improve its products through changes in design or material without being obligated to incorporate such changes in products of prior manufacture Dometic can make changes at any time in design materials or part of units of any one model year without obligation or liability to owners of units of the same year s model of prior manufacture This warranty gives you the purchaser specific legal rights and you may also have other rights which vary from state to state You also have implied warranty rights including an implied warranty of merchantability which means that your product must be fit for the ordinary purposes for which such goods are used The duration of any implied warranty rights is limited to the duration of the express warranty as found in Section Ill Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you 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 Failures resulting from abuse
9. may occur at outside ambient air temperatures near 130 F 54 C SAFETY INSTRUCTIONS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards it is the owner s and installer s responsibility to read and comply with all safety information and instructions accompanying these symbols Failure to heed safety information increases the risk of personal injury property damage and or product damage WARNING A The word WARNING indicates hazards or unsafe practices which COULD result in severe personal injury or death CAUTION A The word CAUTION indicates hazards or unsafe practices which COULD result in minor or moderate personal injury product damage or property damage SAFETY GUIDELINES 1 Allow only qualified experienced technicians to install or service this system 2 Install the system in accordance with all local codes If no local codes exist follow National Codes NEC in the U S CEC in Canada Open the electrical disconnect switch es before electrically connecting the unit Before operating the unit be certain it is properly grounded On 9 The units contain refrigerant gas under pressure Avoid puncturing or breaking any tubing 6 Before operating the system complete the refrigerant connections WARNING A To avoid personal injury shock or death ensure the electrical disconnect switch es is a
10. remains constant close the valve on the nitrogen cylinder and disconnect it from the gauge manifold Proceed to Evacuation on page 13 WARNING When using high pressure nitrogen in the system wear safety glasses and gloves Secure the hose end to prevent injury to personnel or damage to property Do not point the hose toward personnel or property To prevent inhalation the nitrogen should NOT be expelled into a confined space where personnel are working the work area should be well ventilated If the nitrogen is mixed with refrigerant contact with an open flame or hot surface could create PHOSGENE GAS which can cause respiratory problems or death Leak Check IMPORTANT Do not use a vacuum as a leak detection technique as moisture could be drawn into the system Arapid drop in gauge pressure indicates a large leak or several small ones A slow drop in gauge pressure indicates small leak s Open both gauge valves and pressurize the system again to maintain a positive pressure on the lines and evaporator while checking for leaks Use the following techniques to locate leaks Large leaks can often be detected by listening for a hissing sound or felt by placing your hand around the leaking fitting NOTE If pipe insulation encases a leaking fitting the escaping nitrogen can be forced down the insulation to a remote location giving a false indication of the leak location e Apply a soap solution on all connections and joint
11. the outdoor coil condenser airflow is unrestricted on all sides and above Figure 2 General System Layout Diagram SUPPLY AIR GRILLE FLEXIBLE DUCT TRANSITION BOX THERMOSTAT RETURN AIR GRILLE WITH FILTER AIR HANDLER TRANSFORMER BOX DURASEA DX AIR HANDLER INSULATED COPPER LINE SET DO NOT INSULATE TOGETHER CONDENSATE DRAIN MAIN FUSE BREAKER BOX DISCONNECT SWITCH HIGH VOLTAGE POWER CONTROL POWER 77 CRETE NOTE REFER TO UNIT NAMEPLATE FOR MINIMUM CIRCUIT AMPACITY AMPERAGE MINIMUM AND MAXIMUM FUSE OR CIRCUIT BREAKER FUSIBLE HACR PER NEC INSTALL POWER WIRING AND PROPERLY SIZED DISCONNECT SWITCH UNITS ARE APPROVED FOR USE ONLY WITH COPPER CONDUCTORS GROUND UNIT AT DISCONNECT SWITCH OR TO AN EARTH GROUND INSTALLATION CLEARANCES Special considerations must be given to location of the condensing unit s in regard to structures obstructions other units and any other factors that may interfere with air circulation Where possible the top of the unit should be unobstructed however if vertical conditions require placement beneath an obstruction there should be a minimum of 30 inches 762 mm between the top of the unit and the obstruction s The specified dimensions meet requirements for air circulation only Consult all appropriate regulatory codes prior to determining final clearances Another important consideration in selecting location for th
12. AB AC BC 3 AVERAGE VOLTAGE V MAXIMUM DEVIATION FROM AVERAGE VOLTAGE V VOLTAGE IMBALANCE 100 X MAX DEVIATION AVERAGE VOLTAGE IF OVER 2 VOLTAGE IMBALANCE DO NOT ATTEMPT TO START SYSTEM CALL LOCAL POWER COMPANY FOR ASSISTANCE CHECK INDOOR UNIT FAN SPEED AND RECORD CHECK OUTDOOR UNIT FAN SPEED AND RECORD AFTER AT LEAST 15 MINUTES RUNNING TIME RECORD THE FOLLOWING MEASUREMENTS SUCTION PRESSURE 23 L 3153 DuraSea Condenser Installation Start Up amp Service Manual L 3153 Pre Start Up SUCTION LINE TEMP SUBCOOLING TEMP LIQUID PRESSURE LIQUID LINE TEMP SUPERHEAT TEMP ENTERING OUTDOOR UNIT AIR TEMP LEAVING OUTDOOR UNIT AIR TEMP INDOOR UNIT ENTERING AIR DB dry bulb TEMP INDOOR UNIT ENTERING AIR WB wet bulb TEMP INDOOR UNIT LEAVING AIR DB TEMP INDOOR UNIT LEAVING AIR WB TEMP COMPRESSOR 1 AMPS L1 L2 L3 NOTES 24 DuraSea Condenser Installation Start Up amp Service Manual Section I What s Covered OWNERS LIMITED WARRANTY As hereinafter described Dometic limits the duration of any implied warranty to the duration of the underlying express warranty and also disclaims any liability for consequential or incidental damages arising from any application installation use or malfunction of any warranted product SECTION I WHAT s COVERED What does the Limited Warranty cover Products manufactured by Dometic Corp
13. These sizes are suitable for line lengths of 50 feet 15 24 m or less If a run of more than 50 feet 15 24 m is required contact Dometic applications team for assistance L 3153 L 3153 quawanosdui 1onpo d Jo 35312710 AY u UON212SIp 5 2130100 Je 381012 07 2alqns 272 y sql 34818 HUN y Wap 18127 punos SOA XEN UIN U01 99 01d 1322318 XEN z MPedWY 1In34D UIN seyd ZH SHOA 1 MO0d 8120 03 38JeY Juesasiujay 6101323 4 YN uunuiixelW ao aun 13205 5 q ao eur bn 5 ai ajea 35288 uonons ai ane aseg pinbr Wa sAs 012138 113 Y14 10 0N W49 uey Jasuapuo vY YIN 10553100102 UH N18 Buijo03 jeulwon I PON I 066 v8 ESZ L6T SE 56 V 09 0 7 807 08 sz 2 8 E 8 z t TE 0009 56 601 000 9 agevoa 8u13209 YUM 109 JaSUaPUOD Ul uinuluiniV 104 4819M yun Buisuapuo3 wo4 Aeme 34 WO painsgaw 372 punos 066 18 90S 7 ST zt A 09 09t 08 SZ v E 8 E 8 z t 0 0009 Sv 000 9 39 v2a paou se azis ay JO 5130 2310 PNI 30 7 Y YH JO 5350 Aejap awi 35 ISNIN SaZIS 9JIM J3BJE AJINbAJ suni JIM AISUu 1x3 s po2 E21 799 3 EUOIJEN YUM 32uepio22e u 313 aq PINOYS 2ZIS M s 43u aul 1380 104 33 uuoq 1Insuo2 0S Uey ss u18u aul UO 03520 sazis aul papuawWUOIaY OTE 18 ESZ L6T ov 0 V 09 0 7 807 08 SZ v e 8
14. VICE ANNA DN NAN 20 REFRIGERATION SYSTEM 20 Servicing Units on Roofs Decks With Synthetic Materials 20 Liquid Line Filter Drier 20 Field Refrigerant Access Ports 20 COMPRESSOR PROTECTION 20 Compressor Over Temperature Protection IP 20 Low Pressure Switch 20 High Pressure Switch 20 Low Ambient Option 20 LUBRICATION 20 Fan Motors 20 Compressor 20 GENERAL TROUBLESHOOTING 21 TROUBLESHOOTING 21 START UP CHECKLIST 23 PRELIMINARY INFORMATION 23 PRE START UP 23 OWNERS LIMITED WARRANTY 25 SECTION WHAT S COVERED 25 SECTION II WHAT S NOT COVERED 25 SECTION IIl COVERAGE PERIOD 26 SECTION IV GETTING SERVICE 26 TABLE OF WARRANTY PERIODS 27 L 3153 Table of Contents INTRODUCTION READ THIS MANUAL BEFORE PROCEEDING How IT WORKS Basic Principles The Importance of Outside Air Temperature SAFETY INSTRUCTIONS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS SAFETY GUIDELINES UNPACKING AND INSPECTION
15. acement components used are designed to operate with R 410A R 410A refrigerant cylinders are light maroon pink in color R 410A refrigerant cylinders have a dip tube which allows liquid to flow out of the cylinder in an upright position NOTE Recovery cylinder service pressure rating must be 400 psig 2758 kPa DOT RBA400 or DOT BW400 R 410A systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose 2 R 410A requires a different set of gauges than those used for R 22 Manifold sets should be 800 psig 5516 kPa high side and 250 psig 1724 kPa low side with 550 psig 3792 kPa low side retard Use hoses with 800 psig 5516 kPa service pressure rating 2 R 410A requires matched evaporator and condenser systems Leak detectors should be designed to detect HFC refrigerant R 410A as with other HFCs is only compatible with POE or PVE oils POE oils absorb moisture rapidly Do not expose oil to atmosphere Vacuum pumps will not remove moisture from oil A liquid line filter dryer listed for R 410A is required on every unit Do not use liquid line filter dryers with rated working pressures less than 600 psig 4137 kPa Do not install a suction line filter dryer in a liquid line e Wrap all filter dryers and service valves with wet cloth when brazing e Do NOT use an R 22 thermal expansion valve TXV Never open system to atmo
16. amage 17 Logic boards with blown MOV s Power Surge 18 Mis programmed displays 19 Display heads with water damage 20 Dirty Condensers and or Evaporators 21 Failures due to improper winterization 22 Unit damage as a result of improper return packaging 23 Replacement of freon with substitute without authorization from factory 24 Environmental and or Recovery Fees 25 Welding and Nitrogen Fees 26 Travel costs are included in the hourly labor allowances and should not be billed as a separate item without preapproval form the factory Installation and application of Dometic components is not warranted by Dometic because Dometic has no control or authority over the selection location application or installation of these components SECTION III COVERAGE PERIOD What is the period of coverage See Limited Warranty Periods at the end of this book All Dometic components bear a data plate on which there are model and serial numbers The serial number is date coded To determine whether or not any Dometic component is in warranty proceed as follows 1 Determine the manufacture date of the component from the serial number on the data plate If you are not familiar with the date code write or call the Dometic Customer Service Department to obtain the manufacture date The hours of the Customer Service Department are 8 00 a m 5 00 p m USA Eastern Standard Time Zone Monday through Friday excluding holidays 2 I
17. ant piping involves three issues quality strength of existing tubing cleanliness and tube size Inspect all tube segments and joints for signs of damage corrosion or poor brazing Flush the interconnecting piping system with dry nitrogen to eliminate as much trace of mineral oil as possible INSTALLATION 1 Remove the existing evaporator coil or fan coil and install the replacement coil when appropriate 2 Drain oil from low points and traps in suction line tubing and hot gas bypass tubing if appropriate and Evaporator if they were not replaced Removing oil from evaporator coil may require purging of the tubing with dry nitrogen 3 Unless indoor unit is equipped with a R 410A approved metering device change the metering device to a thermal expansion valve TXV designed for R 410A 4 Remove the existing outdoor unit Install the new outdoor unit according to these installation instructions Install a new field supplied liquid line filter drier at the indoor coil just upstream of the TXV or fix orifice metering device If a suction line filter drier is also to be installed install suction line drier downstream of suction line service valve at condensing unit Evacuate and charge the system according to the instructions in this installation manual Operate the system for 10 hr Monitor the pressure drop across the suction line filter drier If pressure drop exceeds 3 psig 21 kPa replace suction line and liquid line filter driers Be sure
18. anual Start Unit To verify the compressor is rotating in the proper direction 1 Connect service gauges to the suction and liquid pressure fittings 2 Energize the compressor 3 The suction pressure should drop and the liquid pressure should rise as is normal on any start up COMPRESSOR OVERLOAD This overload interrupts power to the compressor when either the current or internal motor winding temperature becomes excessive and automatically resets when the internal temperature drops to a safe level This overload may require 60 minutes or longer to reset If the internal overload is suspected of being open disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester CAUTION A Unit Damage Hazard Failure to follow this caution may result in equipment damage Never charge liquid into the low pressure side of system Do not overcharge During charging or removal of refrigerant be sure indoor fan system is operating Ensure outdoor fan motors are running FINAL CHARGE ADJUSTMENT DuraSea R 410A systems use TXVs Thermal Expansion Valves to optimize system operation and thus cannot be charged using the superheat method System must be charged by Subcooling method 1 Operate the unit for a minimum of 15 minutes Ensure that pressure and temperature readings have stabilized 2 Indoor airflow must be within the unit s normal operating range 3 Indoor ambient temperature must be
19. ator or reversing valve LIQUID LINE FILTER DRIER The factory provided filter drier is specifically designed to operate with R 410A Replace the filter drier with factory authorized components only with a filter drier with desiccant made from 100 molecular sieve grade XH 11 Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system FIELD REFRIGERANT ACCESS PORTS Field service access to refrigerant pressures is through the access ports located at the service valves These ports are 1 4 inch 6 4 mm SAE Flare couplings with Schrader check valves and service caps Use these ports to admit nitrogen to the field tubing during brazing to evacuate the tubing and evaporator coil to admit initial refrigerant charge into the low side of the system and when checking and adjusting the system refrigerant charge When service activities are completed ensure the service caps are in place and secure check for leaks If the Schrader check valve must be removed and re installed tighten to 3 in Ibs 34 N cm COMPRESSOR PROTECTION COMPRESSOR OVER TEMPERATURE PROTECTION IP A thermostat installed on the compressor motor winding reacts to excessively high winding temperatures and shuts off the compressor LOW PRESSURE SWITCH Th
20. coverage shall not exceed three 3 years from the date of production 5 These warranty periods are effective March 1 2010 Warranty Coverage 2 Year Warranty 1st Year parts and labor 2nd Year compressor only Not to exceed three 3 years from date of production 2 Year Warranty 1st Year parts and labor 2nd Year parts only Not to exceed three 3 years from date of production Pump warranty see Pump section Parts 1 year from date of purchase of unit Labor 6 months from date of purchase of unit Not to exceed three 3 years from the date of manufacture Pump warranty see Pump section 1 Year Warranty parts and labor Not to exceed three 3 years from date of manufacture Pump warranty see Pump section Warranty Coverage 1 Year warranty parts and labor Pump seals are not covered under warranty 1 Year warranty parts only Pump seals are not covered under warranty 1 Year warranty parts only 90 Day warranty parts only Direct Expansion Self Contained and Split Systems Sale Type OEM or Dealer Installed OEM or Dealer Installed with digital or mechanical controls Catalog Sales OEM or Dealer Installed Product DuraSea Condeser Emerald Series Stowaway Turbo Stowaway Vector Turbo Vector Compact Condensers and Evaporators Cabin Mate Cool Mate Pumps Compressors Replacement Parts Sale Type OEM or Dealer Installed with complete system Dealer Installed and Afte
21. d his equipment back to the factory to have the repair work done Dometic will make every effort to return the equipment to the customer within a three week time period If the claim represents a legitimate warranty problem Dometic will pay the freight both ways Dometic prefers option one first option two second and option three only if one and two are not available The customer may contact the Dometic Service Departments at 804 746 1313 Virginia plant or 954 973 2477 Florida plant Monday through Friday 8 00am 5 00pm After hours evenings and weekends technical support is offered through Dometic s 24 7 Hotline at 888 440 4494 26 L 3153 DuraSea Condenser Installation Start Up amp Service Manual Table of Warranty Periods TABLE OF 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 The warranty is transferable and will carry the remainder of the original owner s warranty based on the original date of purchase or date of installation 2 Proof of purchase or installation may be required to verify warranty coverage 3 Any unit or replacement part installed due to a warranty failure carries the remainder of the original warranty Warranty coverage does not start over from the repair replacement date 4 Warranty
22. e manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations CHECK UNIT ELECTRICAL CHARACTERISTICS Confirm before installation of unit that voltage amperage and circuit protection requirements listed on unit data plate agree with power supply provided PLACEMENT OF THE SYSTEM Selecting a good location for your air conditioner is the most important part of your preparations 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 falls it is highly recommended that you locate the supply air grille as high as possible in the cabin Plan all connections which must be made prior to starting installation including ducting grilles copper line set condensate drain electrical power connections and location of control panel See Figure 2 for general layout example Select a location for the condensing unit and its support system pad rails or other that provides for the minimum clearances required for safety This includes the clearance to combustible surfaces airflow clearance wiring refrigerant piping and service access below around and above unit as specified in unit drawings Check for possible overhead obstructions which may 4 L 3153 DuraSea Condenser Installation Start Up amp Service Manual Installation Clearances interfere with unit lifting or rigging Locate the unit so that
23. e at highter pressure than standard R 22 systems Do not use R 22 service equipment or components on R 410A refrigerant equipment REFRIGERANT CHARGING GUIDELINES This unit is designed for use with R 410A refrigerant Do not use any other refrigerant in this system R 410A refrigerant is provided in pink rose colored cylinders These cylinders are available with and without dip tubes cylinders with dip tubes will have a label indicating this feature For a cylinder with a dip tube place the cylinder in the upright position access valve at the top when removing liquid refrigerant for charging For a cylinder without a dip tube invert the cylinder access valve on the bottom when removing liquid refrigerant Because R 410A refrigerant is a blend it is strongly recommended that refrigerant always be removed from the cylinder as a liquid Admit liquid refrigerant into the system in the discharge line If adding refrigerant into the suction line use a commercial metering expansion device at the gauge manifold remove liquid from the cylinder pass it through the metering device at the gauge set and then pass it into the suction line as a vapor Do not remove R 410A refrigerant from the cylinder as a vapor WARNING A Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible death or difficulty breathing Never sniff a refrigerant Never purge refrigerant into an enclosed ro
24. e low pressure switch is 1 4 inch 6 4 mm SAE Flare mounted on the suction line Switch is fixed non adjustable automatic reset type The switch protects compressor from loss of charge situation HIGH PRESSURE SWITCH The high pressure switch is 1 4 inch 6 4 mm SAE Flare mounted on the discharge line The switch is a fixed non adjustable automatic reset type The switch shuts off the compressor when discharge pressure rises above the factory setting LOW AMBIENT OPTION Units with the factory installed low ambient option will disengage the condenser fan when head pressure drops below a specified value and re engage fan when head pressure climbs above reset value LUBRICATION FAN MOTORS The fan motors have sealed bearings No provisions are required for lubrication COMPRESSOR The compressor has its own oil supply Loss of oil due to a leak in the system should be the only reason for adding oil after the system has been in operation L 3153 20 DuraSea Condenser Installation Start Up amp Service Manual Troubleshooting GENERAL TROUBLESHOOTING TROUBLESHOOTING If you have a digital control refer also to the troubleshooting section of the manual packaged with it Table 3 General Troubleshooting PROBLEM POSSIBLE REASON SOLUTION Compressor does not run Contactor Open 1 Power off Restore power 2 Fuses blown in field power circuit After finding cause and correcting replace with correct size fuse 3 No con
25. e unit s is the angle to obstructions Either coil side can be placed toward the structure with appropriate clearance It is not recommended for fan side to be placed towards structure Service access side of unit should be placed to provide adequate service clearance Corner installations are strongly discouraged Refer to Figure 3 on page 6 and Figure 4 page 6 for mandatory minimum installation clearance requirements DO NOT locate the unit Where fresh air supply to the outdoor coil may be restricted or when recirculation from the condenser fan discharge is possible Inawell or next to high walls Where the noise would prove to be a nuisance to the owner i e salons decks sleeping cabins etc L 3153 Installation Clearances DuraSea Condenser Installation Start Up amp Service Manual AVOID Locations that permit water from higher level runoff and overhangs to fall onto the unit Direct tubing contact with water pipes ductwork floor joists floors and walls e Suspending refrigerant tubing from structure with rigid wire or straps that would come in contact with tubing DO locate the unit To minimize the length of refrigerant piping required To provide adequate service clearances On a level surface or other sturdy platform Isolated from the structure to avoid transmission of vibrations DO Leave slack between structure and unit to absorb vibration When passing refrigerant tubes thro
26. esigned for use in marine and other harsh environments Its two primary components consist of a condensing unit and an evaporator unit A complete system also requires installation of control s ducting and a refrigerant line set READ THIS MANUAL BEFORE PROCEEDING This manual contains essential information to ensure proper installation operation and maintenance of your DuraSea Split System Improper installation or misunderstood operating procedures can result in unsatisfactory performance and or premature failure of these units so please read this manual completely before proceeding It is very important that you read and understand the contents of this manual before using the equipment and it should be kept for future reference If you have questions or require assistance with your DuraSea Condenser call your Dometic Marine Service Department at 1 954 973 2477 How IT WORKS BASIC PRINCIPLES The basic principle behind an air conditioner is the transfer of heat from one place to another In an air cooled air conditioner heat is removed from the inside cabin air and transferred to the outside air The efficiency of the system operation depends on both outside air and cabin temperatures THE IMPORTANCE OF OUTSIDE AIR TEMPERATURE When cooling the air conditioner will operate most efficiently in outside air temperatures below 100 F 38 C At higher air temperatures the unit will operate but at a reduced capacity A high pressure shutdown
27. g in unit s end panel to the connections 24VAC terminal block in the unit s control box Remainder of the system controls connection will vary according to the specific construction details of the indoor section air handler or packaged fan coil Plan for field connections carefully and install control wiring correctly per the project plan 13 A A L 3153 Electrical Connections DuraSea Condenser Installation Start Up amp Service Manual Figure 6 24VAC Wiring Diagram CAVAC THERMOSTAT 24VAC HOT AIR HANDLER Re 24VAC HOT W HEAT SINGLE TRANSFORMER SYSTEM JUMPER MUST BE INSTALLED IN A DURASEA A C G FAN RELAY G 8 NDE NS W HEAT RELAY ZO C 24VAC COMMON C 24VAC COMMON Y COMPRESSOR CONTACTOR NOTE DOMETIC MARINE AIR HANDLER UNITS DO NOT INCLUDE A 24VAC TRANSFORMER THEREFORE A SEPARATE 24VAC TRANSFORMER ELECTRIC BOX MUST BE USED THERMOSTAT Install an approved accessory thermostat according to installation instructions included with the accessory Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the thermostat installation instructions DuraSea unit is a single stage cooling unit Use a single stage cooling thermostat Select a thermostat cable or equivalent single leads of different colors Check the thermostat installation instructions for additional features which migh
28. ill require oil traps at equal intervals along the suction line Install one oil trap for a height difference of 15 to 25 feet 4 5 to 7 6 m between indoor and outdoor units Install two oil traps for a difference of 26 to 50 feet 7 9 to 15 2 m three for 51 to 100 feet 15 5 to 30 4 m and four for 101 to 150 feet 30 7 to 45 7 m Consider suction speed riser reduced tube size for vertical segment only or double suction riser arrangement if the proposed suction tube size does not provide necessary minimum flowrates for this riser Figure 5 Liquid and Suction Riser Diagram OOP TO PREVENT DRAINAGE DURING OFF CYCLE a EVAPORATOR ITCH DOWN DURASEA TO OUTDOOR OIL TRAP CONDENSING UNIT SEE DETAIL OF OIL TRAP UNIT SUCTION LINE LIQUID LINE 45 DEG STREET ELL LIQUID RISER ONG RADIUS STREET ELL DURASEA CONDENSING STREET ELL UNIT OIL TRAP CONSTRUCTION DETAIL SUCTION RISER a EVAPORATOR OIL TRAP SEE DETAIL OF OIL TRAP MULTIPLE EVAPORATORS ON SINGLE CONDENSER The DuraSea units are designated to be controlled by a single thermostat When two evaporator coil units are connected to a single condenser unit the evaporators plumbed in parallel Piping to each evaporator must be of same size and piping configuration must be similar in design and of same equivalent length L 3153 Service Valve Operation DuraSea Condenser Installation Start Up amp Service Manual INSTALL FILTER DRIER Every unit MUST have a f
29. ilter drier in the liquid line Locate the filter drier s at the indoor unit close to the evaporator coil s thermal expansion valve TXV inlets A R 410A rated filter drier is shipped in cartons near the base valves Remove drier from packaging and install in the liquid line s at the evaporator coil Do not remove connection fitting plugs until ready to connect and braze the filter drier into the liquid line position Ensure the filter drier paint finish is intact after brazing If the paint of the steel filter drier has been burned or chipped repaint or treat with rust preventative INSTALL LIQUID LINE SOLENOID VALVE It is recommended that a solenoid valve be placed in the main liquid line between the condensing unit and the evaporator coil Locate the solenoid valve at the outlet end of the liquid line near the evaporator coil connections with flow direction arrow pointed at the evaporator coil A liquid line solenoid valve is required when the liquid line length exceeds 75 ft 23 m This valve prevents refrigerant migration which causes oil dilution to the compressor during the off cycle at low outdoor ambient temperatures SELECTING AN ACCUMULATOR Because all DuraSea models use scroll compressors an accumulator is not required Long refrigerant line applications may require use of accumulator to protect compressor from excess charge If an accumulator is to be added check the accumulator manufacturer s literature carefully for indicat
30. in 70 F to 80 F 21 C to 27 C range 4 Mount the temperature sensing device on the liquid small line close to the liquid line service valve and insulate it so that outdoor ambient temperature does not affect the reading 5 Use a thermometer to measure the outdoor ambient temperature The outdoor temperature will determine the next step Outdoor Temp 65 F 18 C or Higher 1 Check subcooling and superheat Subcooling Saturated Liquid Temp Liquid Line Temp Subcooling should be 6 2 3 3 1 C Superheat Suction Line Temp Saturated Suction Temp Superheat should be 12 4 F 6 6 2 C a If subcooling and superheat are low adjust TXV to 10 F to 12 F 5 5 C to 6 6 C of superheat then check subcooling b If subcooling is low and superheat is high add charge to raise subcooling to 6 2 F 3 3 1 C then check superheat c If subcooling and superheat are high adjust TXV valve to 10 F to 12 F 5 5 C to 6 6 C of superheat then check subcooling d If subcooling is high and superheat is low adjust TVX valve to 10 F to 12 F 5 5 C to 6 6 C of superheat and remove charge to lower the subcooling to 6 2 F 3 3 1 C 5 Disconnect manifold set installation is complete NOTE Do not adjust charge based on suction pressure unless there is a gross undercharge L 3153 17 Start Unit DuraSea Condenser Installation Start Up amp Service Manual Figure 7 Blocking Outdoor Coil
31. ion of its suitability for use with R 410A look for minimum working pressure of 200 psig 1380 kPa Select the accumulator first on the basis of its minimum capacity in tons to ensure oil return from the accumulator then on tube size or holding capacity CAUTION A Do not leave system open to atmosphere any longer than necessary for installation The compressor PVE or POE oil is extremely susceptible to moisture absorption and could cause compressor failure Ensure ends of tubing are sealed before and during installation MAKE PIPING CONNECTIONS Piping connections at the DuraSea unit are base valves with stub tube extensions Do not open the unit service valves until all interconnecting tube brazing has been completed The stub tube connections include 1 4 in SAE service fittings with Schrader valve cores Before making any brazed connections to the unit service valves remove both Schrader valve caps and cores and save for re installation Connect a source for nitrogen to one of these service fittings during tube brazing to prevent the formation of copper oxides inside the tubes at brazed joints When brazing the field tubing to base valves TXV valve or filter drier wrap the valves in wet rags to prevent overheating Use a brazing alloy of 5 minimum silver content Do not use flux Purge the refrigerant line with nitrogen during brazing to prevent the formation of copper oxide inside the refrigerant lines After brazing quench the joints with wa
32. iven to installing a trap in the condensate drain line s so that normal discharge of condensate can fill the trap and prevent the ingress of carbon monoxide CO or other potentially harmful vapors WARNING A 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 feet 1 meter of any outlet of engine or generator exhaust systems nor in a compartment housing an engine or generator nor in a bilge unless the drain is connected properly to a sealed condensate or shower sump pump Failure to comply may allow bilge or engine room vapors to mix with the air conditioner s return air and contaminate living areas which may result in injury or death ELECTRICAL SHOCK HAZARD WARNING A Electrical shock hazard Disconnect voltage at main panel or power source before opening any cover Failure to comply may result in injury or death To minimize the hazard of electrical shock and personal injury this component must be effectively grounded Refer to the installation guidelines for further information L 3153 3 Tools Required DuraSea Condenser Installation Start Up amp Service Manual OTHER HAZARDS Installation and servicing of this system can be hazardous due to system pressure and electrical components When working on this equipment always observe precautions desc
33. lly If it is necessary to move the unit into position mount the unit on longitudinal rails using a minimum of 3 rollers Apply force to the rails not the unit If the unit is to be skidded into position place it on a large pad and drag it by the pad Do not apply any force to the unit Raise from above to lift the unit from the rails or pad when unit is in its final position MOUNTING After the unit is in position remove all protective coverings The condensing unit should be secured using mounting hardware provided to level surface that is designed for the weight of the unit and torsion loads from the vessel s movement Unit should be mounted above the deck so it is unaffected by vessel washdown activity If mounted in area has debris and clippings the mounting surface should extend a minimum of 6 inches 150 mm beyond unit cabinet Install a gravel or other apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow If vibration isolators are required for a particular installation use the data in Table 2 on page 16 to make the proper selection REFRIGERANT PIPING CONNECTIONS COPPER TUBING Refrigeration grade tubing is required to connect the refrigerant circuit from the evaporator to the condensing unit You must use tubing with the proper diameter and wall thickness specified for R 410A pressures Refrigerant tubing is normally soft drawn and nitrogen purged All refrigerant lines should be ca
34. misuse accident fire or submergence Any part manufactured by Dometic which shall have been altered so as to impair its original characteristics Any parts which fail as a result of misuse improper application or improper installation a fF oN Items not manufactured by Dometic i e items which are purchased from another manufacturer and supplied as received by Dometic without alteration or modification except as any part of a Dometic manufactured unit or component 6 Components or parts used by or applied by the purchaser as an integral part of products not manufactured by Dometic 7 Labor resulting from difficult access to a Dometic product The original installer or OEM is responsible for accessibility of unit 8 Leaks due to improper installation of split systems and refrigeration systems for example packing glands flare nuts quick disconnects The adjustment of the refrigerant charge on a split system should be charged to the original installer or OEM 9 Freight Damage see page 10 for instructions for handling freight damage 10 Pumps that have been run dry are water damaged or have blown freeze plugs 11 Pumps with cracked heads 12 Pump seals are not covered L 3153 25 Section III Coverage Period DuraSea Condenser Installation Start Up amp Service Manual 13 UV light bulbs are not covered 14 Liquid line filter dryers are not covered 15 Blowers with water damage 16 Logic boards with water d
35. n range of 10 to 25 degrees System must be charged by Subcooling method Charge in cool mode steady state to acheive 4 to 8 degrees F of subcooling at condenser base valve System overcharged with refrigerant can lead to catastrophic failure Symptoms are high head pressure high running current and high subcooing Compressor Tube Diameter Lineset Maximum Factory Charge in ounces to be added by installer for Lineset in feet of length noted Unit Liquid Suction Charge ft Charge oz Charge oz 15 20 30 35 40 45 50 24k 3 8 5 8 0 56 128 80 8 11 14 17 20 30k 3 8 3 4 0 59 128 80 9 12 15 18 21 36k 3 8 3 4 0 59 128 80 9 12 15 18 21 48k 3 8 3 4 0 59 192 80 9 12 15 18 21 60k 1 2 7 8 1 05 192 120 16 21 26 32 37 72k 1 2 7 8 1 05 192 120 16 21 26 32 37 90k 1 2 11 8 1 14 256 160 17 23 29 34 40 120k 5 8 1 3 8 1 82 272 160 27 36 46 55 64 3 3 3 3 5 5 6 9 NOTE Suction accumulator and crankcase heater must be used if system charge exceeds Compressor Maximum Charge Consult Dometic Applications team Example DCA60 with 40 feet 12 1 m of refrigerant line From Table 2 add 26 ounces 737 g of R 410A refrigerant SYSTEM CHECK 1 The electrical power source must agree with the unit s nameplate rating 2 Check all air handler s and other equipment auxiliary components Consult the manufacturer s instructions regarding any other equipment connected to the condensing unit If the unit has field installed accessories be sure all are
36. ng control operation Air filters dirty Clean or replace filters Expansion valve power head defective Replace power head Indoor coil partially iced Check low pressure setting Indoor airflow restricted Remove obstruction Suction Pressure High oa Pp 1 Heat load excessive Check for open doors or windows in vicinity of fan coil Unit operates too long or 1 Low refrigerant charge Add refrigerant continuously 2 Control contacts fused Replace control 3 Air in system Purge and evacuate system 4 Partially plugged expansion valve or filter drier Clean or replace System is noisy 1 Piping vibration Support piping as required 2 Compressor noisy Check mounts Check tubing for rubbing Replace compressor if bearings are worn Compressor loses oil 1 Leak in system Repair leak 2 Crankcase heaters not energized during shutdown Check wiring and relays Check heater and replace if defective 3 Improper interconnecting piping design Check piping for oil return Replace if necessary Frosted suction line 1 Expansion valve admitting excess refrigerant Adjust expansion valve Shortage of refrigerant due to leak Repair leak and recharge Expansion valve opens too wide Adjust expansion valve Hot liquid line D Restricted filter drier Remove restriction or replace 2 Liquid line solenoid valve partially closed Replace valve Frosted liquid line 22 L 3153
37. ng units provide a disconnect switch per NEC or CEC of adequate size Disconnect sizing data is provided on the unit informative plate Locate on unit cabinet or within sight of the unit per national or local codes Do not cover unit data plate if mounting the disconnect on the unit cabinet All field wiring must comply with NEC and all local codes Size wire based on MCA Minimum Circuit Amps on the unit data plate Connect wiring as per diagram located on unit Provide a ground fault and short circuit over current protection device fuse or breaker per NEC Article 440 or local codes Refer to unit informative data plate for MCB Maximum Circuit Breaker device size Use HACR type circuit breakers or time delay fuses to assure sufficient time delay to permit the compressor to start Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate On 3 phase units voltages between phases must be balanced within 2 and the current within 10 Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components Such operation would invalidate any applicable Dometic warranty FIELD CONTROL WIRING DuraSea condenser uses a 24 VAC control voltage provided by air handler See Figure 6 page 14 for typical field control connections and the unit s label diagram for field supplied wiring details Route control wires to the DuraSea unit through the openin
38. nless steel If found remove the rust using WD 40 and a Scotch Brite pad When clean apply a stainless steel protective coating that will prevent surface rust Reapply it regularly WD 40 is a trademark of the WD 40 Company Scotch Brite is a trademark of 3M L 3153 19 Refrigeration System DuraSea Condenser Installation Start Up amp Service Manual SERVICE CAUTION Equipment Damage Hazard Failure to follow this caution may result in damage to equipment The compressor in a R 410A system uses a POE oil and PVE These oils are extremely hygroscopic meaning they absorb water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere REFRIGERATION SYSTEM SERVICING UNITS ON ROOFS DECKS WITH SYNTHETIC MATERIALS POE polyolester compressor lubricants are known to cause long term damage to some some synthetic materials including roofing Exposure even if immediately cleaned up may cause embrittlement leading to cracking and possible failure When performing any service which may risk exposure of compressor oil to the synthetic surfaces take appropriate precautions to protect Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch metering device coil accumul
39. om or space All refrigerants must BY LAW be reclaimed If an indoor leak is suspected thoroughly ventilate the area before beginning work e Liquid refrigerant can be very cold To avoid possible frostbite or blindness avoid contact and wear gloves and goggles If liquid refrigerant does contact your skin or eyes get medical help immediately Never burn refrigerant as poisonous gas will be produced Always follow EPA guidelines PRELIMINARY REFRIGERANT CHARGE DuraSea condensing units are pre charged with refrigerant as per unit data plate Pre charge amount is sufficient for condensing unit plus 15 foot of lineset Additional charge must be added for the evaporator and linesets longer than 15 feet 4 5 m The amount of refrigerant to be added can be estimated from Table 2 See example below 1 Purge gauge lines Connect service gauge to base valve service ports 2 Add R 410A liquid refrigerant into the lineset through the liquid service valve 3 After charge is added open the liquid line and suction line service valves to the top seated position L 3153 15 System Check DuraSea Condenser Installation Start Up amp Service Manual Table 2 R 410A Refrigerant Start Up Charge Use this table to determine start up charge of system DuraSea R410A systems use Thermal Expansion Valves to optimize system operation and thus cannot be charged using superheat method A properly operating TXV will maintain Superheat i
40. oration Dometic are under limited warranty to be free from defects in workmanship or materials This being under normal use and service with the obligation of Dometic under this limited warranty being limited to replacing or repairing any component s which shall disclose defects within the limits defined in Section III Which upon examination by Dometic shall appear to the satisfaction of Dometic to be defective or not up to specifications This Limited Warranty is made in lieu of all other express warranties obligations or liabilities on the part of Dometic In addition Dometic shall not be responsible for any incidental or consequential damages In those instances in which a cash refund is made such refund shall effect the cancellation of the contract of sale without reservation of rights on the part of the purchaser Such refund shall constitute full and final satisfaction of all claims which the purchaser has or may have against Dometic due to any actual or alleged breach of warranty either express or implied including without limitation any implied warranty or merchantability or fitness for a particular purpose Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you The Dealer is not an agent for Dometic except for the purpose of administering the above warranty to the extent herein provided Dometic does not authorize the dealer or any other person to assume
41. pped to protect against moisture and dust infiltration Tubing should always be cut square keeping ends round and free from burrs Clean the tubing to prevent contamination Extreme care must be taken not to crush or kink any portion of either line set Use proper tools for line bending avoiding sharp bends or kinks Any kinked or crushed section must be replaced There should be no vertical loops oil traps in the copper lines When using multiple evaporators ensure that the fittings are sized correctly to allow correctly sized tubing to be connected to air handler fittings and provide proper refrigerant flow to and from each air handler PROVIDE SAFETY RELIEF If local codes dictate an additional safety relief device purchase locally and install locally Installation will require the recovery of the factory shipping charge before the factory tubing can be cut and the supplemental relief device is installed DETERMINE REFRIGERANT LINE SIZES Determine the linear length of interconnecting piping required between the outdoor unit and indoor unit evaporator Consider and identify the arrangement of the tubing path quantity and type of elbows in both lines liquid line solenoid size filter drier and any other refrigeration specialties located in the liquid line Refer to the indoor unit installation instructions for additional details on refrigeration specialties devices Select the recommended line sizes for DuraSea unit from Table 1 on page 8
42. properly installed and correctly wired 3 Check tightness of all electrical connections 4 Be sure liquid line and low side of the system are properly leak checked and dehydrated 5 Be sure the unit is properly evacuated leak checked and charged 6 Ensure the liquid line and suction line service valves are set to the top seated position 7 All barriers and covers must be in place NOTE The units are factory charged with the required amount of oil If oil recharging is required call Dometic for proper amount START UNIT Set the space thermostat to a set point above ambient temperature so that there is no demand for cooling Close the power disconnect switch Reset the space thermostat below ambient temperature so that a call for cooling is ensured COMPRESSOR amp FAN ROTATION On 3 phase units with scroll compressors it is important to be certain that the compressor is rotating in the proper direction When a three phase scroll compressor is operating in reverse it is noisier and its current draw is substantially reduced compared to rated values A phase monitor is recommended to indicate reverse power phasing The condenser fan should be blowing air toward fan grille To correct phase order 1 Tum off power to the unit tag disconnect 2 Reverse any two of the unit power leads 3 Reapply power verify correct compressor pressures and condenser air flow 16 L 3153 DuraSea Condenser Installation Start Up amp Service M
43. raSea service valves Close the valve to the vacuum pump Wait five minutes then check the pressure on the thermocouple vacuum gauge Ifthe pressure is not more than 1000 microns the system is leak free and properly evacuated Proceed to Preliminary Refrigerant Charge on page 15 Ifthe pressure rises but holds at about 2000 microns moisture and noncondensibles are still present Open the valve to the vacuum pump and continue evacuation until moisture is removed Ifthe pressure rises above 5000 microns a leak is present Go back to Pressure Test and Leak Checking on page 11 Close the valve to the thermocouple vacuum gauge Close the valve to the vacuum pump Shut off the pump ELECTRICAL CONNECTIONS WARNING Failure to follow this warning could result in personal injury or death Disconnect ALL power before servicing Do not use gas piping as an electrical ground Unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur Wiring must conform with NEC or CEC and all local electrical codes Undersized wires could cause poor equipment performance equipment damage or fire WARNING To avoid risk of fire or equipment damage use copper conductors NOTE Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 35 C rise FIELD POWER SUPPLY When installi
44. re in the OFF position before installing modifying or servicing the unit Lock out and tag the switch with a suitable warning label Wiring must conform with NEC or CEC and all local codes L 3153 1 1 4104 Quick Reference Guide DuraSea Condenser Installation Start Up amp Service Manual UNPACKING AND INSPECTION Units are securely packed in shipping crates Upon arrival carefully check all items against the packing list to ensure all cartons were received and correct equipment was received Always keep the unit in the up orientation as indicated by the arrows on each carton Check the cartons for external damage removing the units from the packaging if necessary If damage is found file a request in writing for inspection by the carrier agent immediately The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage If no damage is found carefully remove all shipping material and properly dispose of it After unpacking keep the units as upright as possible Laying a unit on its side or top could cause equipment damage R 410A QUICK REFERENCE GUIDE This system uses R 410A refrigerant R 410Ais an environmentally safe hydrofluorocarbon HFC refrigerant R 410A refrigerant operates at 50 70 higher pressures than R 22 Ensure that the servicing equipment and repl
45. require change out of outdoor unit metering device and filter driers Change out of indoor coil evaporator and interconnecting tubing is highly recommended 10 L 3153 DuraSea Condenser Installation Start Up amp Service Manual Pressure Test and Leak Checking EXISTING EVAPORATOR COIL If the existing evaporator coil is to be re used check with the coil manufacturer to verify the coil construction is suitable for operation with the higher pressures of R 410A Also determine if the existing TXV valve is compatible with R 410A replace if necessary The minimum factory test pressure rating of evaporator must be 250 psig 1725 kPa Existing coil will need to be purged with Nitrogen to remove as much mineral oil as possible to eliminate cross contamination of oils ACID TEST If the existing system is being replaced because of a compressor electrical failure assume acid is in system If system is being replaced for any other reason use an approved acid test kit to determine acid level If even low levels of acid are detected install a 100 percent activated alumina suction line filter drier in addition to the replacement liquid line filter drier Remove the suction line filter drier after evaluation period of operation with a maximum of 72 hours of operation Recommendation Install a ball valve in the line at the filter location when installing a suction filter in the suction line Existing refrigeration piping Reuse of existing refriger
46. ribed in the literature tags and labels attached to the unit Follow all safety codes Wear safety glasses and work gloves and place a fire extinguisher close to the work area CAUTION A United States federal law prohibits the intentional release of refrigerant gases into the environment including the R 410A refrigerant used in this air conditioning system Special care must be taken when installing charging and servicing Dometic equipment to prevent any loss of refrigerant Dometic does not recommend the practice of using refrigerant to purge air and moisture from the system at installation This formerly used practice of purging is in violation of United States federal law TOOLS REQUIRED Before starting make sure you have all of the following tools Standard tool box Service wrench 2 Flaring tool Refrigerant gauge manifold rated for R 410A only Refrigerant tank rated for R 410A only Nitrogen tank Vacuum pump Scale Micron gauge Electronic leak detector rated for R 410A Drill hole saw Jig saw Insulated tape Duct tape Electrical tape Teflon tape Hardware to secure unit pump grilles and control panel CODES AND REGULATIONS This product is designed and manufactured to comply with national codes Installation in accordance with such codes prevailing local codes regulations and National Electrical Code NEC U S A is the responsibility of the installer Th
47. riodic cleaning with an environmentally sound coil cleaner is essential to extend the life of the coils Coil cleaning should be part of the unit s regularly scheduled maintenance procedures to ensure long life of the coil Failure to clean the coils may result in reduced durability in the environment Avoid the use of Coil brighteners High pressure washers Poor quality water for cleaning Use of non recommended coil cleaners is strongly discouraged since coil and unit durability could be affected CAUTION A Unit Damage Hazard Failure to follow this caution may result in corrosion and damage to the unit Harsh chemicals household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of any kind These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin tube interface where dissimilar materials are in contact If there is dirt below the surface of the coil use an environmentally sound coil cleaner as described above CAUTION A Unit Reliability Hazard Failure to follow this caution may result in reduced unit performance High velocity water from a pressure washer garden hose or compressed air should never be used to clean a coil The force of the water or air jet will bend the fin edges and increase airside pressure drop ROUTINE CLEANING amp PROTECTION OF CABINET Check the exterior cabinet of the unit periodically for any formation of rust on the stai
48. rmarket sales Aftermarket sales Aftermarket sales AIR CONDITIONING ACCESSORIES Warranty Coverage 1 Year warranty parts only UV bulb is not covered under warranty 1 Year warranty parts only 27 Sale Type Aftermarket sales Aftermarket sales Product Pumps Compressors Replacement parts and components Product In Duct Breathe Easy Air Purifiers SmartStart Control L 3153 NOTES NOTES Dometic
49. rt Up amp Service Manual Refrigerant Piping Connections DuraSea Condenser Installation Start Up amp Service Manual Refrigerant Piping Connections LIQUID LIFT A liquid lift condition exists when the outdoor unit is located below the indoor evaporator unit and liquid flows vertically up in a portion of the liquid line The vertical column of liquid reduces the available state point subcooling at the evaporator coil s thermal expansion valve This effect reduces the length of liquid lift height of elevation that a liquid line size can accommodate Longer linear tube lengths will also reduce the amount of liquid lift possible Mounting the evaporator coil above the condensing unit will require an inverted loop in the suction line adjacent or near the connection to the evaporator The top of the loop must be slightly higher than the top of the coil See Table 1 for maximum liquid lift capabilities If cannot provide the required lift distance on this installation relocate the outdoor unit to reduce the equivalent line length or the lift requirement SUCTION RISER A suction riser condition exists when the outdoor unit is located above the indoor evaporator unit and suction vapor must flow vertically up to return to the compressor Oil return is a concern when the suction tube size is too large to produce the minimum refrigerant velocity to ensure oil return at minimum load conditions Mounting the condensing unit above the evaporator coil w
50. s Bubbles indicate leaks so mark these locations Clean off the soap solution when leak checking is complete CAUTION Care must be taken to ensure soap solution does not ingress into a leaking fitting s and contaminate the system Ifthe leaks cannot be located with the previous methods an electronic leak detector should be used For this procedure add a trace of R 410A refrigerant to the nitrogen in the system if permitted by current EPA regulations NOTE Ensure the electronic leak detector you use is capable of sensing HFC type refrigerants Repeat the procedures above until all leaks are found and repaired After repair repeat the steps in Pressure Test on page 11 When pressure testing is completed remove the nitrogen source at the outdoor unit service valves and re install the two Schrader valve cores Torque the cores to 3 in Ibs 23 34 N cm L 3153 A 12 DuraSea Condenser Installation Start Up amp Service Manual Evacuation EVACUATION If you have confirmed that the system maintains pressure the line set and evaporator s are now ready for evacuation of the nitrogen or nitrogen refrigerant mixture if an electronic leak detector was needed from the system Release nitrogen from system Evacuation Dehydration Evacuate and dehydrate the connected refrigeration system excluding the condensing unit to 200 microns using a two stage vacuum pump attached to the service ports on the Du
51. sphere while it is under a vacuum When system must be opened for service evacuate then break vacuum with dry nitrogen and replace filter dryers Do not vent R 410A into the atmosphere MODEL NUMBER NOMENCLATURE For an explanation of the model numbers see Figure 1 page 3 2 L 3153 Important Safety Considerations Options A None B Nema 4x electric Box amp heatshrunk electric connections C Low ambient Fan Cycling Control D Phase Monitor E Valve Fan Side VFS standard on 7 5 10 ton models F Variable Frequency Drive G Crankcase Heater H Suction Accumulator Reserved for future use J Reserved for future use K Combination of options B C D G and H Design Revision A Initial Rev Not Used 0 Not Used Coil Options A AlFin Copper Tube B E Coat Al Fin Copper Tube C Copper Fin Tube DuraSea Condenser Installation Start Up amp Service Manual Figure 1 Model Number Nomenclature DuraSea Condensing Unit Refrigerant Type A R410A B R417A Nominal Tonnage 030 2 5 Tons 036 3 Tons 048 4 Tons 060 5 Tons 072 6 Tons 090 7 5 Tons 120 10 Tons Control Type A None use with 24VAC Thermostat Q Q Control Voltage 2361 230V 60 1 2251 220V 50 1 2363 208 230V 60 3 4663 460V 60 3 3853 380V 50 3 INSTALLATION GUIDELINES IMPORTANT SAFETY CONSIDERATIONS AVOID HARMFUL VAPORS Consideration should be g
52. t require additional conductors in the cable For wire runs up to 50 ft 15 m use no 18 AWG American Wire Gage insulated wire 35 C minimum For 50 to 75 ft 15 to 23 m use no 16 AWG insulated wire 35 C minimum For over 75 ft 23 m use no 14 AWG insulated wire 35 C minimum All wire sizes larger than no 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat 24VAC CONTROLS Most commercial evaporator units include a transformer to provide 24VAC to provide power for thermostat Dometic Marine evaporators do not include a 24VAC output In this instance the optional DuraSea 24VAC control box can be used to provide 24VAC power source to operate the DuraSea condenser fan compressor and indoor fan motor contactor or control relay Additional devices may also include a liquid line solenoid valve supplemental electric heater contactors or control relays and other devices selected by system designer Ensure the transformer is sized to handle additional power requirement of supplemental devices 14 L 3153 DuraSea Condenser Installation Start Up amp Service Manual Refrigerant Charging Guidelines SYSTEM START UP Use the START UP CHECKLIST on page 23 to make notes as you go through the start up procedures WARNING A Failure to follow this warning could result in personal injury death and or equipment damage R 410A refrigerant systems operat
53. ter or a wet cloth to prevent overheating of valves INSULATE SUCTION LINES Insulation is necessary to prevent condensation from forming and dropping from the suction line Apply Armaflex or satisfactory equivalent closed cell tubular insulation with 72 minimum wall thickness to all suction lines between evaporator coil connection and unit s suction service valve In severe hot and humid areas thicker wall insulation may be needed Insulation must be installed in a manner which protects tubing from damage and contamination ROUTING OF LIQUID LINE The liquid line must be outside the suction line insulation If part of the liquid line must run through an area that will be hotter than 120 F 49 C then that portion of the liquid line must be insulated Be careful not to kink or dent the refrigerant lines Kinked or dented lines will cause poor performance or compressor damage SERVICE VALVE OPERATION The DuraSea condensing unit is equipped with service valves to ensure safe handling of the high pressure R 410A refrigerant The unit is shipped with the valve frontseated downward position to contain the factory charge in the unit Gauge hoses can be connected and disconnected without the presence of system pressure The gauge port is isolated from the system if the stem is backseated The gauge ports have a standard core valve which can be removed and replaced while the stem is backseated REPLACEMENT RETROFIT Replacement retrofit installations
54. tis 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 However based on the date the equipment is first put in service the item may still be covered by the Dometic warranty as described in Section I For proof of date put in service Dometic will require a copy of the bill of sale of the Dometic equipment from the installer or new boat dealer to the original owner SECTION IV GETTING SERVICE How do you get service Please read the following Warranty Procedure If the failure of a Dometic component is determined to be covered under the Dometic warranty and the time in service is determined to be within the warranty time limit the owner has the following three options 1 Preferred option Have a Dometic authorized Servicing Dealer perform the work needed The customer needs to call Dometic Customer Service Department for a recommendation as to the closest dealer If the customer already knows an authorized servicing dealer the dealer should be contacted directly 2 Second option If the customer contacts Dometic Service Department for a Servicing Dealer and Dometic has no one in that particular area Dometic will authorize the use of a local service company and Dometic will work with the local company to assist in any way possible 3 Third option The customer may sen
55. to purge system with dry nitrogen and evacuate when replacing filter driers Continue to monitor the pressure drop across suction line filter drier Repeat filter changes as necessary Never leave suction line filter drier in system longer than 72 hr actual time CAUTION Unit Damage Hazard Failure to follow this caution may result in equipment damage or improper operation Never install a suction line filter drier in the liquid line of an R 410A system PRESSURE TEST AND LEAK CHECKING Once the refrigerant line set connections are made a pressure test and a leak check of the system must be performed NOTE The base valves on the unit are shipped in the frontseated position to retain the refrigerant in the condensing unit These valves must not be opened until the system is ready for operation Pressure Test NOTE It is sometimes assumed that any apparent leakage must originate in the equipment but in reality leaks can also occur in the gauge manifold and hoses Before use inspect the fittings on the manifold for tightness and replace any damaged hoses or worn gaskets 1 Before testing ensure both hand valves on the gauge manifold are closed relative to the center port i e turned IN all the way 2 Connect the high and low side hoses of your R 410A gauge manifold to the condenser base valves IMPORTANT Do not open the unit service valves 3 Connect a dry nitrogen cylinder to the center port on the gauge manifold and set the reg
56. trol power Check control transformer primary connections and circuit breaker 4 Thermostat circuit open Check thermostat setting 5 Safety device lockout circuit active Reset lockout circuit 6 Low pressure switch open Check for refrigerant undercharge obstruction of indoor airflow Make sure liquid line solenoid valve s is open 7 High pressure switch open Check for refrigerant overcharge obstruction of outdoor airflow air in system Be sure outdoor fans are operating correctly 8 Compressor overtemperature switch open Check for open condition Allow time for reset Replace compressor if necessary 9 Loose electrical connections Tighten all connections 10 Compressor stuck See compressor service literature Contactor Closed 1 Compressor leads loose Check connections 2 Motor windings open See compressor service literature 3 Single phasing Check for blown fuse Check for loose connection at compressor terminal Compressor stops on high Outdoor Fan On pressure switch High pressure switch faulty Replace switch Reversed fan rotation Confirm rotation correct if necessary Airflow restricted Remove obstruction Air recirculating Clear airflow area Noncondensables in system Recover refrigerant and recharge as required Refrigerant overcharge Recover refrigerant as required Line voltage incorrect Consult power company QD NE ON TS GD Refrigerant system restrictions Check or replace
57. ugh the bulkhead seal the opening with RTV or a pliable silicon based caulk Ensure that the suction and liquid line tube diameters are appropriate for unit capacity Avoid unnecessary turns and bends by running refrigerant tubing as directly as possible In general short runs of refrigerant piping are better than long runs If practical locate the unit accordingly Figure 3 Installation Clearance DCA 24 72 6 FOR 24 amp 48K ye 12 FOR 60 amp 72K METRIC CONVERSION CHART inches N SERVICE ACCESS PANEL Figure 4 Installation Clearance DCA 90 120 os INNES gg 7 ELEC IW SERVICE L LE 7 SERVICE AX PANEL 6 L 3153 DuraSea Condenser Installation Start Up amp Service Manual Rigging and Mounting the Unit RIGGING AND MOUNTING THE UNIT CAUTION Unit Damage Hazard Failure to follow this caution may result in equipment damage All panels and top must be in place when rigging or moving RIGGING These units are designed for overhead rigging Spreader bars or a field provided H style frame just above the top edge of unit are required All panels and top must be in place when rigging As further protection for coil faces plywood sheets may be placed against the sides of the unit behind cables Run cables to a central suspension point so that the angle from the horizontal is not less than 45 degrees Raise and set the unit down carefu
58. ulator to a maximum pressure of 500 psig 3447 kPa IMPORTANT Compressed air or CO should not be used as they can add moisture and ether contaminates to the system Refrigerant should never be used unless needed for electronic leak detection L 3153 11 Pressure Test and Leak Checking DuraSea Condenser Installation Start Up amp Service Manual WARNING To avoid possible explosion the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve CAUTION Never exceed 800 psi 5516 kPa due to the possibility of rupturing hoses or line set connections 4 Open the hand valve a minimal amount on the line coming from the nitrogen cylinder Once the regulator on the nitrogen tank is set open the high pressure valve on the gauge manifold Pressurize the refrigerant lines and the evaporator s to 500 psig 3447 kPa To reach 500 psig 3447 kPa you may need to further open the hand valve on the nitrogen cylinder 6 The needle s will rise as pressure enters the line set and evaporator s Once the point of the predetermined pressure has been reached close the gauge valve s Monitor the gauge reading s after the pressure has stabilized should be less than a minute The pressure should be left in the system for a minimum of 15 minutes If the gauge pressure drops there is a leak in the system Refer to Leak Check on page 12 to determine the location of the leak s Ifthe gauge pressure
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