Marine Marvair CHA24 Installation And Operation Manual

Reverse cycle chiller & air handlers

Hide thumbs

Table of Contents

Quick Links

Download this manual

Installation and Operation Manual

Model CHA24 Reverse Cycle Chiller

Chapter 1

Introduction and Safety Information ................................................................ 2

Chapter 2

Chiller Installation .......................................................................................... 3

Chapter 3

Air Handler Installation ................................................................................. 13

Chapter 4

Chiller Control .............................................................................................. 21

Chapter 5

Air Handler Control ....................................................................................... 29

Chapter 6

System Start-Up ........................................................................................... 54

Chapter 7

Warranty ...................................................................................................... 55

Appendix A Electrical Schematics .................................................................................... A-1

Appendix B Dimensional Drawings...................................................................................B-1

Appendix C Parts List ....................................................................................................C-1

Marvair

Division of AIRXCEL

PO Box 400 • Cordele, GA 31010

156 Seedling Dr. • Cordele, GA 31015

(229) 273-3636 • Fax (229) 273-5154

Email: marvair@airxcel.com

www.marvair.com/marine

Reverse Cycle Chiller & Air Handlers

Chiller Models CHA24-36-48-60 and

Air Handler Models CWAH04-06-09-12-18-24

Manufactured by:

, Inc

Model CWAH12 Air Handler

Marvair

Marine UK

Unit 6 Benridge Park • Holyrood Close

Poole, Dorset BH17 7BD.

+44 1202 650-700

www.marvair.co.uk

Part Number 01672

3/2011-4

Table of Contents

Need help?

Do you have a question about the CHA24 and is the answer not in the manual?

Questions and answers

Summary of Contents for Marine Marvair CHA24

Page 1: Table Of Contents
Reverse Cycle Chiller & Air Handlers Chiller Models CHA24-36-48-60 and Air Handler Models CWAH04-06-09-12-18-24 Installation and Operation Manual Model CHA24 Reverse Cycle Chiller Model CWAH12 Air Handler Chapter 1 Introduction and Safety Information ..............2 Chapter 2 Chiller Installation ..................3 Chapter 3 Air Handler Installation .................
Page 2: Chapter 1 Introduction And Safety Information
Reverse Cycle Chillers and Air Handlers Chapter 1 This is the safety alert symbol . When you see this symbol on a Marvair unit and in the instruction manuals be ® alert to the potential for personal injury. Understand the signal word DANGER, WARNING and CAUTION. These words are used to identify levels of the seriousness of the hazard.
Page 3: Equipment Inspection
Reverse Cycle Chillers and Air Handlers 1.3 Air Handler Model Identification CWAH Electrical Rating Nominal Capacity Chilled Water 04 = 4,000 BTUH A = 208/230V,1ø,60Hz Air Handler 06 = 6,000 BTUH B = 115V,60Hz 09 = 9,000 BTUH F = 220V,1ø,50Hz 12 = 12,000 BTUH W = 220/240V,1ø,50Hz 18 = 18,000 BTUH...
Page 4 Reverse Cycle Chillers and Air Handlers WARNING If the information in these instructions is not followed exactly, a fire, carbon monoxide poisoning or explosion may result causing property damage, personal injury or loss of life. • Read all instructions carefully prior to beginning the installation.
Page 5: Water Piping & Connections
Reverse Cycle Chillers and Air Handlers 2.3.2 Water piping & connections Chilled Water Please see the chiller dimensional drawings for location and size of the sea water and chilled water connections. For ease of service, unions and service valves (full flow type) are highly recommended on all inlet and outlet water connections.
Page 6 Reverse Cycle Chillers and Air Handlers Chilled Water pump package. The chilled water loop requires the following components for proper operation and start-up of the system. • Water pump, • A strainer, • A Spirovent® air eliminator, • Spirotop® air release valve, • An expansion tank, • A water pressure gauge • A water pressure regulating valve, • A shutoff ball valve and • A ¾” hose bib connection.
Page 7 Reverse Cycle Chillers and Air Handlers Notes: 1. The minimum number of service valves to isolate the chiller equipment is shown. More valves may be installed to isolate the strainer or pump or chiller separately, but this complicates the system and can lead to operation confusion. 2.
Page 8 4, Recommended Seawater Pipe Sizes Figure 5, Seawater & Chilled Water Manifold Sizes, and Figure 6, Seawater Manifold Orientation. Recommended Seawater Pipe Size Marvair Model Pipe or Hose Size (ID) CHA24 3/4” (19.1mm) CHA36 & 48 1” (25.4mm) CHA60 1-1/4" (31.75mm) Figure 4 Seawater &...
Page 9 Reverse Cycle Chillers and Air Handlers Seawater Manifold Orientation Equal Flow More Flow Less Flow More More More More Flow Flow Flow Flow Less Less Less Less Flow Flow Flow Flow INCORRECT CORRECT Figure 6 The best material for seawater piping and fittings is cupronickel. Suitable materials for piping are hi-grade bronze cupro-nickel and schedule 80 PVC (polyvinyl chloride) pipe.
Page 10 Reverse Cycle Chillers and Air Handlers Marvair strongly recommends that only centrifugal pumps be used as the seawater pump. When using a centrifugal pump, the Marvair reverse cycle chiller must be higher than the thru-hull fitting, but lower than the heeled water line. The overboard fitting may be either higher or lower than the unit.
Page 11 Reverse Cycle Chillers and Air Handlers Minimum Seawater Flow Rates Model Nominal Cooling Capacity Gal/Hr Litres/Min CHA24 2 tons CHA36 3 tons CHA48 4 tons 1,000 CHA60 5 tons 1,250 Figure 7 PUMP HEAD ORIENTATION Pump Head Orientation CORRECT CORRECT...
Page 12: Electrical Power Connections
Reverse Cycle Chillers and Air Handlers 2.3.3 Electrical power connections WARNING ELECTRICAL SHOCK HAZARD Failure to follow safety warnings exactly could result in serious injury, death and or property damage. Turn off electrical power at service panel BEFORE making any electrical connections and ensure a proper ground connection is made before connecting line voltage.
Page 13: Chapter 3 Air Handler Installation
Reverse Cycle Chillers and Air Handlers Chapter 3 - Air Handler Installation, Ducting and Chilled Water System CARBON MONOXIDE POISONING HAZARD Never install air handlers in the bilge or a room with an internal combustion engine. The condensate line must not terminate within three (3) feet (one meter) of the exhaust of any engine or generator nor in any room that contains an engine or generator.
Page 14 Reverse Cycle Chillers and Air Handlers board in the unit's electrical box must be accessible. Mount the air handler on a horizontal surface and secure the condensate pan to the surface using the four clips that were provided with the air handler.
Page 15: Return Air Grille
Reverse Cycle Chillers and Air Handlers For optimum air circulation, it is good practice to install the supply air grilles near the top of the cabin and the return air grille near the floor. This normally provides good circulation of the conditioned air throughout the cabin.
Page 16 Reverse Cycle Chillers and Air Handlers return air grille must have sufficient open air to permit adequate air to the air handler. The air handler has cardboard placed over the coil to protect the coil during installation. The cardboard must be removed and the filter installed prior to operating the air handler. The Marvair air handler has a factory provided filter located in front of the air coil.
Page 17 • Take care during the installation of the system to prevent any debris from entering the loop. It is good practice to flush the system before filling the system. Miminum Chilled Water Flow Rates Model Gals/Min. Litres/Min CHA24 CHA36 CHA48 CHA60 Figure 11 Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page 17 of 57...
Page 18 Reverse Cycle Chillers and Air Handlers Figure 12 Air Vents Marvair recommends the use of air/water separators manufactured by Spirotherm, Inc. such as Spirovent®. The Spirovent will remove air from the chilled water loop. It should be installed in the main return line from the air handlers and before the chilled water circulating pump but after the chilled water strainer and service valve.
Page 19 Reverse Cycle Chillers and Air Handlers line will prevent the flow switch to operate properly. Testing the System It is recommended to check the piping of the chilled water circulation system for leaks while it is being installed. Testing the system after the system is complete may be difficult if fittings and valves are behind walls or hard to access areas.
Page 20 Reverse Cycle Chillers and Air Handlers Determine the proper quantity of anti-freeze or glycol to add to the system according to the anti-freeze or glycol manufacturer’s instructions. Typically, the minimum is a 20% anti- freeze solution, but a higher percentage is required in cold climates. Remove the pressure from the system at the drain point (in the engine room).
Page 21: General Description
Reverse Cycle Chillers and Air Handlers Chaper 4 - Chiller Control 4.1 General Description The MARVAIR® CHILLER digital control operates Marvair chillers to provide closed loop water temperature control. The MARVAIR® CHILLER digital control is designed to operate with a reverse cycle, chilled water marine air-conditioning system.
Page 22: Mode Select Button
Reverse Cycle Chillers and Air Handlers Applying power: When power is first applied, the display will show the software revision, and then return to the last state the unit was in when power was removed. Up Button On/Off Button Mode Select Service Button Button (Unmarked)
Page 23: Mode Selection
Reverse Cycle Chillers and Air Handlers Operating Screen Water Inlet Temperature Water Outlet Temperature Heating Temperature Set Point Operating Status Graphic Cooling 4.3 Mode Selection To change from heating to cooling or cooling to heating, tap the mode select icon. Set the desired loop water temperature by tapping the up or down icon.
Page 24 Reverse Cycle Chillers and Air Handlers System Status Screen High Refrigerant Pressure AC Line Voltage Switch (CLosed or OPen) Low Refrigerant Pressure System Current Switch (CLosed or OPen) Flow Switch (CLosed or OPen) System Frequency Viewing System Status In the ON state, press and hold the Mode select icon for three seconds. The display will indicate AC line voltage, System current, AC Line frequency, and High and Low pressure switch status and Flow switch status.
Page 25: Configurable Parameters
Reverse Cycle Chillers and Air Handlers LOW AC VOLTAGE: The AC line voltage was below the voltage set in the programmable parameters for more than 10 minutes. OVER CURRENT: The total system run current exceeded the limit set in the programmable parameters.
Page 26 Reverse Cycle Chillers and Air Handlers Description Default Value Display brightness 4=Minimum 15=Maximum Screen Saver Brightness 0=Minimum 8=Maximum Staging Delay 15 or 45* 5-135 Seconds Current Limit 0-35 Amps (0 is disabled) Low AC Line Detection 75-100 or 175-200 VAC High Limit Threshold 130°F (54.4°C) 100-135°F (38°C - 57°C)
Page 27: Specifications
Reverse Cycle Chillers and Air Handlers this function, press the On/Off button. Flow faults are disabled while Purge Air is active. Flow switch status may be viewed in the system status screen. See Viewing System Status for details. • Reset parameters: To reset all parameters to factory defaults, select YES and then exit the program mode by pressing the joystick center button.
Page 28 Reverse Cycle Chillers and Air Handlers Circulating Pump output MAX: ..........¼ HP at 115 VAC ½ HP at 230 VAC Compressor output MAX: ............1HP at 115 VAC 2HP at 230 VAC Minimum operating temperature: ........... 0°F -18°C Maximum operating temperature: .......... 180°F 82°C Maximum RH conditions: ............
Page 29: General Information
Reverse Cycle Chillers and Air Handlers Chapter 5 - Chilled Water Air Handler Control and Display General Information There are two control kits for the Marvair chilled water air handlers – one with the MachAir I display and the other with the o-LED display. The control boxes for the two kits are identical except for the position of the jumpers on the board.
Page 30 Reverse Cycle Chillers and Air Handlers The ends of the cables are color coded to ensure that the cables are correctly connected to the board. Sections 5.1- 5.4 describe the configuration and operation of the o-LED display. Sections 5.5– 5.14 describe the configuration and operation of the MachAir I controller 5.1 General Description The Marvair®...
Page 31 Reverse Cycle Chillers and Air Handlers Up Button On/Off Button Mode Select Fan Operation Button Button Down Button Joystick operation: The four position joystick may be tapped up, down, right, left or in the center to make changes to the operation of the control. Gently tap this switch to operate it. Excessive force will damage the switch.
Page 32 Reverse Cycle Chillers and Air Handlers Room Air Cool Mode Temperature Temperature Cool Mode Set Point Symbol Valve Status Automatic Fan Fan Operating Mode Cool mode To select cooling only, tap the mode select icon to scroll through the symbols in the top left of the display until the cool symbol appears.
Page 33 Reverse Cycle Chillers and Air Handlers Room Air Temperature Automatic Mode Temperature Automatic Mode Set Point Symbol Valve Status Fan Operating Fan Speed Indicator Automatic Mode To select automatic mode, tap the mode select icon to scroll through the symbols in the top left of the display until the automatic mode symbol appears.
Page 34 Reverse Cycle Chillers and Air Handlers Outside Air Temperature If the optional outside air temperature sensor is installed, the temperature set point in the upper right of the display will alternate with OAT showing outside air temperature. System Status AC Line Voltage System Current AC Line Loop Water...
Page 35 Reverse Cycle Chillers and Air Handlers To enter the configuration mode, first put the unit in the OFF state. Next press the following sequence of icons: Mode, Up, Down, Mode (or by pressing and holding the center of the button in for 10 seconds).
Page 36 Reverse Cycle Chillers and Air Handlers o Alt Air Enabled: When set for alt air enabled, the alternate air jack can be used with an optional air sensor to replace the display mounted air sensor. When set for outside air enabled, an optional sensor may be installed to monitor out side air temperature.
Page 37 Reverse Cycle Chillers and Air Handlers Minimum operating temperature ..........0°F -18°C Maximum operating temperature ..........180°F 82°C Maximum RH conditions ............99% Non condensing Maximum length of the display cable ........75 Feet (23m) Maximum length of the Outside air sensor cable ....50 Feet (15m) 5.5 MachAir I Display/Controller General Description The MachAir I controller/display is designed for use with Marvair Chilled Water Air Handlers.
Page 38: Basic Operation
Reverse Cycle Chillers and Air Handlers • 3-digit, 7-segment display indicates °Fahrenheit or °Celsius. • Automatic fan speed reduction as set point is approached. • Six [6] manual fan speeds. • 18 programmable parameters for custom installations. • Water In sensor allowing individual cabin heating. • Moisture Mode for controlling relative humidity. • Universal 115/230 VAC power supply. • Non-volatile memory retains settings without batteries. • Programmable display brightness control for night use. Optional Features The following optional items can be added by plugging the device into the appropriate jack and making the necessary programming changes.
Page 39 Reverse Cycle Chillers and Air Handlers Power Button: Press the power button once to toggle the unit to the on mode. Press the power button again to toggle the unit to the off mode. Fan Button: Press and release the fan button to advance from auto to manual fan. Press and release to increase the manual fan speeds, 1 through 6.
Page 40: Overview Of The Operation
Reverse Cycle Chillers and Air Handlers 5.7 Overview of the operation The MachAir I controller/display is a user friendly, easy to operate, programmable temperature control. Press the ON/OFF button once to engage the system. The display indicates room temperature when the system is on and the display is blank when the system is off. Press and release the Mode Button until the desired Mode LED is illuminated.
Page 41 Reverse Cycle Chillers and Air Handlers Memory The MachAir I Air Handler Control has nonvolatile memory which requires no batteries or any form of backup power. When power is lost the operating parameters are retained indefinitely. When power is restored, the control resumes operating as last programmed. All operating and program¬ming parameters are entered into nonvolatile memory instantly and are retained indefinitely.
Page 42 Reverse Cycle Chillers and Air Handlers 3. UP BUTTON Momentarily press the up button and the set point will appear in the temperature display. Press and release the up button to increase the set point one degree. The set point is increased by one degree each time the up button is pressed and released. The highest set point allowed is 85°F.
Page 43: Modes Of Operation
Reverse Cycle Chillers and Air Handlers has been selected. This mode is used to control humidity during periods when the vessel is unoccupied. 12. MANUAL FAN LED The manual fan LED will be lit when one of six manual fan speeds has been selected.
Page 44: Fan Modes
Reverse Cycle Chillers and Air Handlers Cool Only Mode When Cool LED is on, only the cooling systems are selected and operated as required. When the temperature drops below the set point, the system will not automatically switch to the heating mode.
Page 45: Configuration Mode
Reverse Cycle Chillers and Air Handlers Manual Fan Speeds Six (6) is the fastest and one (1) represents the slowest fan speed. Manual fan mode allows the user to select and maintain the desired fan speed manually. When a manual fan speed has been selected, the fan speed bar graph will indicate the speed selected by the number of LEDs lit.
Page 46 Reverse Cycle Chillers and Air Handlers NOTE: The control will exit the program mode and return to the Off Mode if no programming is attempted for one (1) minute. Restoring Memorized Default Settings IMPORTANT! The memorized default settings can be restored by entering the program mode and setting P-16 to rSt.
Page 47: Programmable Parameters
Reverse Cycle Chillers and Air Handlers 5.12 Programmable Parameters There are eighteen programmable parameter locations with their Factory Default Settings listed in this section. The table below indicates what these parameters are, along with the permitted values and the original Factory Default Settings. Program Description Default...
Page 48 Reverse Cycle Chillers and Air Handlers Software Identification The software version of the control is identified for one (1) second prior to the exit from the program mode. The software identification number, i.e. ("A10") will appear in the display for one second, then the control will return to the off mode.
Page 49 Reverse Cycle Chillers and Air Handlers brightest. Typically a dark cabin will require a setting of four or five. A very bright cabin will require a setting of twelve or thirteen. The factory default setting is thirteen (13). P-10 Fahrenheit or Celsius Selection The unit can be programmed to display either Fahrenheit or Celsius.
Page 50 Reverse Cycle Chillers and Air Handlers P-15 Fan Motor Selection There are two basic fan motor types, shaded pole [SP] and split capacitor [SC]. Each motor reacts differently to speed control and each motor requires different timing for optimum fan speed variation. The default setting is "SP" which selects the shaded pole motor type, however, "SC"...
Page 51 Reverse Cycle Chillers and Air Handlers temperature exceeds the ambient by 22°F or until the room temperature is satisfied. The electric heat is allowed to overlap the loop water heat to supplement the main heating system during very cold conditions. 5.13 Special Hardware Instructions Outside Air Sensor Option Install this option by plugging the Outside Air Sensor into the Alternate Air Sensor Jack (J1).
Page 52 Reverse Cycle Chillers and Air Handlers 5.14 Specifications SET POINT OPERATING RANGE ................55°F TO 85°F AMBIENT TEMPERATURE OPERATING RANGE DISPLAYED ......55°F TO 85°F SENSOR ACCURACY ....................± 2°F AT 77°F LOW VOLTAGE LIMIT 115 VOLT UNITS .................75 VAC LOW VOLTAGE LIMIT 220 VOLT UNITS ...............175 VAC LOW VOLTAGE PROCESSOR RESET ................65 VAC LINE VOLTAGE ..................
Page 53 Reverse Cycle Chillers and Air Handlers Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page 53 of 57...
Page 54: Chapter 6 System Start-Up
Reverse Cycle Chillers and Air Handlers Chapter 6 - System Start-up 1. Turn the seacock valve in the seawater system to the open position. 2. Open all manifold valves and air handler valves. 3. Turn on the seawater pump. Verify that water is being discharged overboard. 4.
Page 55: Chapter 7 Warranty
Reverse Cycle Chillers and Air Handlers Chapter 7 - Warranty Marvair® Marine Chiller and Air Handler Warranty Parts If any part of your Marvair marine chiller or air handler fails because of a manufacturing defect within twenty-four months from the date of purchase of a new boat or within twenty-four months from the date of installation of the unit(s), but not to exceed thirty-six from the date of manufacture by Marvair, Marvair will furnish without charge, EXW Cordele, Georgia, the required replacement part.
Page 56 Reverse Cycle Chillers and Air Handlers An owner requesting performance under this Warranty shall provide reasonable access to the allegedly defective or malfunctioning product to Marvair and its authorized agents and employees. This warranty does not cover damage caused by improper installation including any refrigerant leaks in the tubing and fittings between the evaporator and condenser sections on split systems;...
Page 57: Appendix A - Chiller And Air Handler Electrical Schematics
Reverse Cycle Chillers and Air Handlers Appendix A - Chiller and Air Handler Electrical Schematics Jumper location and field wiring schematic CHA24-60RCA/W Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-1...
Page 58 Reverse Cycle Chillers and Air Handlers Electrical schematic CHA24-60RCA/W Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-2...
Page 59 Reverse Cycle Chillers and Air Handlers Jumper location and field wiring schematic CHA24-60RCC Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-3...
Page 60 Reverse Cycle Chillers and Air Handlers Electrical schematic CHA24-60RCC Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-4...
Page 61 Reverse Cycle Chillers and Air Handlers Jumper location and field wiring schematic CHA24-60RCE Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-5...
Page 62 Reverse Cycle Chillers and Air Handlers Electrical schematic CHA24-60RCE Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-6...
Page 63 Reverse Cycle Chillers and Air Handlers Field wiring and jumper positions for the CWAH with the o-LED display Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-7...
Page 64 Reverse Cycle Chillers and Air Handlers Field wiring and jumper positions for the CWAH with the MachAir I display Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-8...
Page 65 Reverse Cycle Chillers and Air Handlers CWAH electrical schematic Reverse Cycle Chiller and Air Handler Installation & Operation Manual 3/2011 Page A-9...
Page 66: Top View
Reverse Cycle Chillers and Air Handlers Appendix B - Dimensional Drawings Two and three ton chiller, models CHA24/CHA36 TOP VIEW "A" 3" FRONT VIEW LOOP WATER OUTLET 1" F.T.P 1 3/4" LOOP WATER INLET 1" F.T.P. LEFT SIDE "G" SW OUTLET "C"...
Page 67 Reverse Cycle Chillers and Air Handlers Four and five ton chiller, models CHA48/CHA60 TOP VIEW "A" "B" FRONT VIEW 2.000 LOOP WATER INLET 1" FPT NOM SW OUTLET 1" 25MM LOOP WATER OUTLET 1" FPT NOM LEFT SIDE "C" "G"* "E"...
Page 68 Reverse Cycle Chillers and Air Handlers Air Handlers, models CWAH04/06/09/12/18/24 TOP VIEW PLENUM MAY BE REPOSITIONED INSULATION PAD BACK VIEW LEFT SIDE VIEW Dimensions - CWAH-04 Inches 14-3/8 11-3/8 11-1/4 2-1/4 Dimensions - CWAH-06 Inches 15-3/8 11-1/4 2-1/4 Dimensions - CWAH-09 Inches 10-7/8 16-7/8...
Page 69: Appendix C - Parts Lists
Reverse Cycle Chillers and Air Handlers Appendix C - Parts Lists Chiller Parts List Part Number Description CHA24RCx CHA36RCx CHA48RCx CHA60RCx Compressor, 208/230v. 1ø, 60 Hz 10333 10349 13010 10313 Compressor, 208/230v. 3ø, 60 Hz 10327 10350 10311 10314 Compressor, 220/240v. 1ø, 50 Hz 10384 10385 10386...
Page 70 Reverse Cycle Chillers and Air Handlers Air Handler Parts List Part Number Description CWAH04 CWAH06 CWAH09 CWAH12 CWAH18 CWAH24 3-Way Motorized Valve 20399 208/230v. 60 Hz & 220v. 50 Hz Coil 60217 60128 60218 60129 60132 60214 Air Mover 208/230v. 60 Hz & 220v. 50 Hz 40094 30076 30076...

This manual is also suitable for:

Cha36 Cha48 Cha60 Cwah04 Cwah06 Cwah09 ... Show all