Installation manual

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English
(two tight 90 degree bends can reduce airflow by 25 percent).
The following is a summary of proper ducting connections:
1. Pull back the fiberglass insulation exposing the inner
mylar duct hose.
2. Slide the mylar duct hose around the mount ring until it
bottoms out.
3. Screw 3 or 4 stainless steel sheet metal screws through
the duct hose into the transition ring. Make sure to catch
the wire in the duct hose with the heads of the screws. Do
not use band clamps, as the hose will slide off.
4. Wrap duct tape around the ducting and ring joint to
prevent any air leaks.
5. Pull the insulation back up over the mylar to the ring and
tape this joint.
6. Remove excess ducting and use the same connection
method at the supply air grill.
Manual Control Panel Installation
The manual control panel should be located within cap tube
length of the Zephyr unit. The dimensions for the 2-knob
panel is 3¼" x 5½". The cut out size for the 2-knob panel is
2½" wide by 4¾" tall. The 3-knob panel is configured either
vertically or horizontally. Dimensions for the 3-knob is 2
15
/ 16 " x
7
15
/ 16 ". The cut out size for the 3-knob panel is 2" by 6¾".
(Refer to Figures 6 and 7 at the back of this manual.) Once
the cut out is made, carefully uncoil the copper cap tube with
return air sensor (copper bulb) and route the control wires and
cap tube through the hole and back to the unit
using caution
not to kink the cap tube
. Mount the return air sensor into the
clips provided on the evaporator coil. If the return air sensor
cannot be mounted on the evaporator coil, mount it behind
the return air grill. The sensor must be mounted in the return
air stream. Make electrical connections according to the
wiring diagrams provided. (See wiring diagrams, Figures 8 and
9 at the back of this manual.)
Electrical Connections, Grounding
& Bonding
All Zephyr units have a five position terminal strip mounted
inside the electric box. The terminal strip is labeled for proper
connections of the electrical supply, ground wires and pump
circuits. Wiring diagrams are provided in the electrical box and
in this manual. The correct size circuit breaker should be used
to protect the system as specified on the air conditioning unit’s
data plate label. A minimum of 12 AWG boat cable should be
used to supply power to the air conditioning unit and to the
seawater pump (see next paragraph). All connections to the
terminal strip shall be made with ring terminals supplied with
the Zephyr kit. Turn off AC (alternating current) power
supply circuit breaker before opening electrical box and
accessing the terminal strip.
Each air conditioning unit installed requires its own dedicated
circuit breaker. If there is only one air conditioning unit
installed, the seawater pump does not require a circuit
breaker; the wiring from the seawater pump is connected to
the terminal strip on the unit. A minimum of 12 AWG boat
cable should be used to extend the wires on the pump, if
necessary, using the butt slices included with the kit. If two or
more air conditioning units use the same seawater pump, the
pump wires will be connected to a pump relay panel (PRP)
which in turn has its own dedicated circuit breaker (see the
wiring diagram furnished with the PRP). Any electrical
connections in the bilge below the waterline should use heat
shrink type butt splices.
The air conditioning unit must be connected to the boat’s
bonding system to prevent corrosion due to stray electrical
current. All pumps, metallic valves and fittings in the seawater
circuit that are isolated from the air conditioning unit by PVC
or rubber hoses must be individually bonded to the boat’s
bonding system also. This will help eliminate any possibility of
corrosion due to stray current.
Note
Failure to properly ground and bond the system will void
the warranty!
Notice and ABYC Standards:
Field wiring must comply with ABYC (American Boat and
Yacht Council) electrical standards. Power to the unit must be
within the operating voltage range indicated on the data plate.
Properly sized fuses and circuit breakers must be installed for
branch circuit protection. See equipment rating plate for
maximum size. All air conditioning units must be effectively
grounded to minimize the hazard of electric shock and
personal injury. The following standards apply:
1. AC (alternating current) grounding (green) wire must be
provided with the AC power conductors and connected to
the ground terminal (marked “GRND”) at the AC power
input terminal block of the unit(s), per ABYC standard E-8.
2. Connections between the vessel’s AC system grounding
conductor (green wire) and the vessel’s DC (Direct
Current) negative or bonding system should be made as
part of the vessel’s wiring, per ABYC standard E-9.
3. When servicing or replacing existing equipment contain-
ing a chassis-mounted “ground” stud, the service person
or installer must check the vessel’s wiring for the exist-
ence of the connection required in item 2 above.
ABYC standards are available from:
American Boat and Yacht Council
3069 Solomon’s Island Road
Edgewater, MD 21036
Telephone: [phone]