Installation manual

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English
behind the supply air grill). Note that the blower and duct
ring can be positioned either vertically or horizontally. See
Figure 2 at the back of this manual.
The dimensions shown in the table of Figure 2 are suggested
minimums. Enough space should be allocated for installation
and serviceability.
How It Works
Your self-contained air conditioner consists of four main
components and a refrigerant gas circulating through the
system. The BLOWER draws warm cabin air across the fins
on the EVAPORATOR where the heat from the air is trans-
ferred to the refrigerant in the evaporator coil. As the refriger-
ant evaporates from a liquid into a gas it absorbs the heat
from the cabin air. The COMPRESSOR then compresses the
refrigerant gas and pumps it through the outer tube in the
CONDENSER COIL. The seawater pump circulates cool
seawater through the inner tube in the condenser coil, this
cools the refrigerant and condenses it into a liquid. The heat
from the refrigerant is exchanged to the seawater and
discharged overboard. The liquid refrigerant is then passed
through the EVAPORATOR COIL and the cycle repeats.
Removing heat from the cabin air lowers its temperature. The
cooled air is blown through the ducting and out the supply air
grill(s). See Figure 3 at the back of this manual for component
identification.
Mounting Brackets
The air conditioning unit is supplied with a base pan that also
serves as a condensate pan. Mounting clip brackets and
screws (4) are provided to secure the base pan onto a flat,
horizontal surface. See Figure 4 at the back of this manual.
Condensate Drains
The condensate drain pan is 1¾" high with two drain loca-
tions. During conditions of high humidity, condensate may be
produced at a rate of approximately ½ gallon per hour. With
this in mind, it is important to route condensate drains
downward to a sump pump. It is not recommended to route
condensate drains to the bilge. After the condensate drain
installation is complete, test the installation by pouring a quart
of water into the pan and checking for good flow.
For installation of the condensate drain (refer to Figure 5 at
the back of this manual):
1. Remove the aft facing watertight plug from the base pan
of the air conditioning unit.
2. Slip the solid washer and the liquid-seal washer onto the
PVC fitting in that order.
3. Connect the fitting through the exposed hole in the base
pan with the locking nut.
4. Securely tighten with two (2) wrenches to provide a
proper seal.
5. Attach a 5/8" I.D. reinforced hose to the hose barb and
secure with stainless steel hose clamps.
6. Install the condensate drain hose downhill from the unit
and aft to a sump.
7. Two drain fittings may be used and the hoses teed
together provided there is a minimum 2" drop from the
bottom of the base pan to the tee connection.
Note:
Do not terminate condensate drain line within three (3) feet 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 conden-
sate or shower sump pump.
Blower Assembly
With the Zephyr, you can achieve horizontal or vertical supply
air discharge by rotating the blower as desired. Its design
allows the blower to be rotated by removing the screws
holding the blower plate to the evaporator coil shroud. Rotate
the blower to allow the most direct flow of air to the supply air
grill. To rotate the 10-16K blowers, remove the two plastic
plugs for access to the mounting screws.
Supply & Return Air Grills
and Transition Boxes
As previously indicated, install the supply air grill(s) as high as
possible and the return air grill as low and close to the Zephyr
as possible to insure direct uninterrupted airflow to the
evaporator. The cut out for the 4" supply air grill for the 5K unit
is 4" in diameter and the flange is 5½" in diameter. The cut out
for the rectangular transition box used with the 10 & 12K units
is 11
5
/ 8 " by 5
5
/ 8 " and 13
5
/ 8 " by 5
5
/ 8 " for the 16K unit. Connect
the 6" or 7" oblong duct ring to the transition box by first
placing the ring on the box and tracing the hole. Cut the
oblong hole out of the box. Secure the ring to the box with
rivets (trim ¼" from ring flanges if necessary). Completely seal
the joint between ring and box with silicone. A minimum
clearance of 3" plus the duct diameter size is required behind
the grill for attaching the ducting (see earlier section,
“Spacing
Allowance and Unit Dimensions”)
. The return air filter,
mounted to the front of the evaporator, removes debris from
the air prior to the air being drawn across the evaporator coil
and fins. Dust and lint can clog and reduce airflow across the
evaporator coil resulting in poor performance. See the
Maintenance section for filter cleaning instructions.
Ducting
Good airflow is critical for the performance of the entire
system. It is highly dependent on the quality of the ducting
installation. The ducting should be run as straight, smooth and
taut as possible minimizing the number of 90 degree bends