CARAVER 3000 S CARAVAN User guide

CARVER
INSTALLATION ANDSERVICING
INSTRUCTIONS
FOR THE
3000 S CARAVAN HEATER
LEAVE THESE INSTRUCTIONS WITH THE APPLIANCE
WARNING THIS HEATERMUST BE INSTALLED AND SERVICED BY A COMPETENTGASFITTER
WORKING TO THEGASSAFETY(INSTALLATION AND USE)REGULATIONS 1990,THE HEALTH AND
SAFETY AT WORKACTANDTHESE FITTING INSTRUCTIONS.
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1. WARNINGS AND INFORMATION.
1.1Theheaterissuitableforinstallation into caravanscomplying with B.S.4626.
1.2Alwaysensuretheunderfloorairintakeispositionedso that itcannotbeblockedby mudorsnow.
1.3Wherechildren,theelderlyorthe infirm arepresentwerecommend that a guardbe fitted around
theheaterwheninuse.
1.4There MUST NOTbea mantlepieceorshelvingsitedabovetheheater.
1.5Curtains MUST NOThang within 150mmofthesidesoftheheateror within 300mmabovethetop
ofthe outlet grille.
1.6Adjacent furniture orupholsterymustbeclearoftheheater case byatleast5 millimetres.
1.7TheCarver3000heaterisapprovedtotherelevantsectionsofB.S.5258 part 131986underthe
National MeasurementAccreditationService (NAMAS) andismanufacturedto B.S. 5750 part 2.1
ISO 90021987.
1.8TheDataBadgeislocatedontopofthefloorplate,attheoppositeendtothecontrolrod.
1.9 Aerosols andhighlyflammablematerials MUST NOTbestoredincompartmentsbehindoradjacent
totheheater.
1.10Thegassupplytotheheatermustbe from a regulatorofadequatecapacitygivinga working
pressure of28mbarButaneor37mbarPropane.InNOcircumstancesshouldanindustrialor
adjustableregulatorbeusedoncaravansapplications.
1.11Theheater MUST NOTbeoperatedwhilerefuellingorwhenthevehicleisina confined space such
as a garage.
1.12Thisheaterdoesnotcontainasbestosoranyasbestosrelatedproducts.
2.THEHEATERKIT
2.1Theheaterkitisoneboxcontaining:-
1HeatExchangerAssembly
1Front Case
1Clampstrip
1Blankingbezel 1Installationbox(2parts)
1Control Bezel c/wblankingplug 1Setof literature inpolythenebag
1Controlrod/Piezoignitorassembly 1Setof
literature inpolythenebag
1Flameviewmoulding
The flueductkitisoneboxcontaining:-
1Nameplate
3 Flueductclips
3 ScrewsNo.8 X 30mmLong(Brown) 1Cowl
5 WoodScrewsNo8 X 20mmLong 1Flangeheadscrew
6WoodScrewsNo6 X 12mmLong 1URInsulatingduct
1Screw(M5)- Exhaustclamp 1AE3StainlessSteelFlueduct.
1O Ring(Red)
1Clampring
1Lockingring
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jCHOOSINGTHE POSITION FORTHE
HEATER.
Theheaterisnormally fitted into thepanel
belowthewardrobedoor.Beforecommenc-
ingany fitting ensure that theappliancewill
fit into thedesiredposition(seefig.1.). The
installationboxwillbe recessed into thepanel
ofthewardrobeby 110mm.
»• FITTING THEHEATER.
1.1 TURN OFFthegassupplyatthecylinder.
1.2If possible lift awaythefloorcoveri ng fromthe
front ofthepanelorwall into whichtheheater
is tobefitted.Ifthisisnotpossiblethe
templatewillhavetobepositionedontopof
thefloorcovering.
1.3Foldthetemplateupwardsalongthearrows
marked'WallCutout'frontface RH' andplace
inpositionasshowninfig.2. with therectan-
gularcutouttothe right. Markanddrilltwo
small holesatthe front corners(A& A onthe
template).Dropa nailorsimilarthroughthe
twoholesandcheckbelowthecaravan that
theareabetweenthenailsisfreeofobstruc-
tion.
\A Ifanyobstructionisfoundthenrefoldthe
templatealongthearrowsmarked' Wall
cutout front faceLH' andplaceinposition
with therectangularcutouttothe left. Mark
anddrilltwosmallholesatthe front corners
(A& A ontemplate).Dropa nailorsimilar
throughthetwoholesandcheckbelowthe
caravan that theareabetweenthenailsis
freeofobstruction.
NOTE: Iftheheateristobe fitted inthis
position(called"LeftHand")thethermostat
phialontheGasControlValvehastobe
repositioned.Seesection4.13forinstruc-
tions.
\.5 Ifanobstructionisstillevident,theheater
mustberepositionedinanotherareainthe
vehicle.
WARDROBE DOOR
t
r
OPENING—
110mm)
E
E
in
00
i
i
E
E
IT)
m
t
r
i480mmj
'1 (fig-i)
WARDROBEPANEL
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When satisfactory,marktheholetotakethe
installationbox.This will requirea holetobe
cutinthepanel485mmhigh (from thefloor,
belowfloorcovering)X 480mmwide.Itis
recommended that thepanelsurfaceispro-
tectedbymaskingtape. Score thelinetobe
cut with sharpknife,tostoptheveneer lifting
(see fig.3) .Ifthepanelisofthehollowtype,
thenthevoidmustbefilledlocallyalongthe
opening with wood.
4.7Trimthefloorcovering from insidetheward-
robeorpaneltoa depthof135mm from the
front (seefig.4.).Ifthefloorcoveringisnot
wantedbehindtheinstallationboxremove
as required. Also trim thefloorcoveringin
front ofthepanelorpaneltothelinesonthe
template.
4.8Openoutthetemplate makingsure that the
arrows remain intheirrelative positions. Mark
and cutthefloor holeatA,A,A,& A.onthe
template. Remove some oftheinsulationand
inserttimberlinersforaddedsecurityofthe
fixingscrews,andto seal offthecaravans
floor insulation. Thelinersmust be secured to
thefloorusingsuitableadhesiveorscrews
and their size mustbesuch that allholes
marked on thetemplatefall within theinserts.
Do not use screws wherethey will contactthe
floorplatecorkgasketoftheheater.
4.9Drillfive2mm dia. holes, aslabelled'B'.atthe
rearofthetemplate,(seefig.5.).
4.10Lineupthefloorplateclampstrip with thefive
pre-drilled holes, ensuring that theoverhung
edge isfacingforward.Secure with 20mm
screws provided. Tightendownthetwoouter
screws firmly (see fig. 6) leave thethreeinner
screws looselydriven atthisstage.
(fig.3)
INSIDE WARDROBE
REMOVE FLOOR COVERING IN
.THIS AREA
TRIM FLOOR COVERING TOTHIS
LINE ON TEMPLATE
(fig-4)
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4.11Assemblyoftheinstallation Box.
Locate theinnerboxonthereartabs(see
fig. 7.)Fitthetopbracketsoftheinnerbox
throughtheslots in theouterboxtopflange
(see fig.8.).
Innocircumstancesmusttheheaterbe
installed withoutbothinnerandouterin-
stallationboxesbeing fitted correctlyas
this can cause damage totheheater and its
surroundingcabinetsandmayinvalidate
thewarranty.
Remove theboldcentralovalknock-out
(see fig.7.).
4.12Positiontheinstallationboxintotheopen-
ingensuring that thebottomedgeof.the
boxisontothefloor. Secure theboxtothe
panel with thesixwoodscrewsprovided,
(see fig.9.)
4.13a Moving Phial Bracket
Carefully slidethebracket,carrying the
thermostatsensor,fromthesteelheat
exchanger shield, retainingthespringclip
forfurtheruse.(Seefig10).
4.13b Fitting SpringClip
Fit thespringclipinthepressedslotinthe
topofthefloorplateasshowninfig.10.
Ensure that theclipis fitted with thebarbs
uppermost and onthe side ofthefloorplate
intendedtofaceintothecaravanliving
space.
4.13c Fitting Phial Carrier
Taking carenottotrap,damageorkinkthe
thermostatcapillary,relocate thesensor
and bracketassemblyonthetopofthe
floorplateonthesamesideasthespring
clip. Fittheforkedendofthebracket on the
heat exchanger support leg, then push fully
homewhileensurinthespringclipflange
gripsthebracketbottomflangethroughits
square hole.(Seefig.11).
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4.14Lowertheheater into thefloor holeand
positiontheheatercentrallyintheinstalla-
tion box,ensure that therearedgeofthe
floorplateispushedunderthefloorplate
clampstrip.(seefig.12point1.)
Check that thethermostatphialandits
carrierfaceout into theliving space.
4.15 Once theheaterisinposition use thethree
brownscrewsprovidedtosecureitviathe
holes in the front edgeofthefloorplate(see
fig.13).Drill2 millimetrepilotholeswhen
screwing into solidwood.
4.16Workinginsidethewardrobetightenthe
remainingthree20mmscrewstothe
floorplateclampstrip.
4.17Itisimportant that allthescrewsare tight-
ened evenlytoavoiddistortionoftheheat
exchanger floorplate,andtoensureanair
tight seal tothefloor.
U8; IMPORTANT : Thefloorplate MUST NOT
bepositionedontopofanyfloorcovering,
as thiswouldpreventasatisfactory airtight
room seal.
5. FITTING THEFLUEANDCOWL.
NOTE:-The cowl must be fitted tothe
roof ofthe caravan only andthe whole
installation must conform to BS5440
Parti.
5.1Thecentreofthecowlshouldbeatleast
80mmfromtheedgeofthecaravan.Ifthe
caravan hasa slopingroofensure that no
partofthecowloverhangstheedgeofthe
caravan. Thefluedirectionshouldbeas
straightaspossibleandshouldrisecon-
tinuallyfromtheheatertothe cowl. Itshould
runagainstthepaneltowhichitwillbe
screwed
5.2Cuta60mmdiameterholeintheroofatthe
requiredposition.Toavoiddistortionin
insulatedordoubleroofsinserta band(1)
ofaluminiumofthesame width asthegap.
Fitthecowlfromtheoutsideensuring the
rubber seal (2)isinplaceandthen,from
inside, fitand firmly tightentheplastic nut
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5.3Be very careful when handling the flue
duct astheedgesare extremely sharp.
Bend oneendoftheinnerflueductsharply
to90°asshowninfig.15.
NOTE:-
To helpyoufitthefluethefollowingtools
areavailablefromCarver Spares
Department-
CuttingJigPartNumber R701067
(Jig toassistincuttingthefluesquare.)
Mandrel PartNumber R701063
(Toassistinthebendingoftheflue.)
5.4Frominsidethewardrobefeedthebend
end oftheinnerflueductthroughtheknock-
outintheinstallationbox. Slide thelocking
ring(1),theclampring(2)andthe O ring(3)
over theendoftheduct end. (seefig.16.)
5.5Firmly push theductintotheheatexchanger
upto the stop. SlidetheOring, clamp ringand
lockingring up totheheatexchangermaking
sure thetappedholeinthelockingringis
towardsthetop.Engagetheearsofthe
lockingringbehindtheprojectionsonthe
heatexchangerandrotateit so that theears
arenear horizontal. Insert and tightentheM5
screw. Thiswillcompressthe0 ringandfix
theexhaustduettothe heater. This joint is
critical forthe safe operation ofthe
heater (see fig. 17.)
5.6Laytheinnerflueductalongitsrequired
routetotheoutsidecowltakingintoac-
counttheattachmenttothefluesupport,
(para. 5.8.)Allow110mmforinsertioninto
thecowlandcuttolength, erringonthe
long side. Slide theinsulatingductoverthe
flueuntilthelowerendisinsidetheinstal-
lationboxandcutso that itsupperendis
flush with theinnerduct.
5.7 Push backtheendoftheouterductand
firmlyinserttheinnerductintothecowl
right upitsstop(about110mm).Allowthe
outerducttospringovertheoutsideofthe
cowluptothenut.Justbelowthenutdrilla
3mmholethroughbothductsandthecowl
and fittheflangeheadscrewthroughall3
items,(seefig.18.)
75mm STRAIGHT
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5.8Insidethewardrobefitthemainflue sup-
port bracketina positionwhichprevents
thefluesagging.Securethefluetoit with
thestrapprovided. Secure thefluealongits
lengthagainstthecaravanstructureusing
allofthe3ductclipsprovided, (see fig. 19.)
Itisimportant that theflue risescontinually
fromtheheatertothecowland that there
areasfewbendsaspossiblealongits
length.
Itis extremely important that the flue
system issoundand that ithas been
correctly fitted at both ends.The safety
oftheoccupants depend onthe integ-
rity ofthe flue system.
6.CONNECTIONTOTHEGASSUP-
PLY
Ensure that thegassupply is turned OFF at
thecylinder.
Connect the8mmdiameter caravan heater
feedpipetothegasvalveunderthe cara-
van, using thenut and oliveprovided.When
tighteningthevalveconnection,two span-
nersMUSTbe used: one totightenthenut
andtheother,forsteadyingpurposes,on
the flat surfacesofthevalveitself.
Thegaspipesorvalve MUST NOTbe
placed underanystrainwhile fitting tothe
heater.
NOTE: The size ofthesupplypipe MUST
NOT belessthan6mm(1/4")O.D.For
heaterservicingpurposesan approved
isolatingvalve,mountedinanaccessible
positionisrecommended.Afterconnect-
ing, turn onthegasatthecylinderand
check thesystemuptotheappliancegas
valveforleaksusingsoapywaterorother
approvedleaktestingmethods.
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7. FINAL ASSEMBLY
7.1Firstfittogetherthecontrolrod/ piezo
assembly. Pass theendofthecontrolrod
upwardsthroughtheholeinthetopofthe
installationbox.Addthedisc,rubberside
down,andsecurelypressontheknob,
aligningits"<?"shapedhole with the flat on
therod. Locate theigniter ball joint overthe
shaped gas controlrodextensionandpush
securely together,(seefig.20)
7.2Firmlypushthesmallinsulatedfemale
connectorontheigniterleadthroughthe
guideholeandontothemaleterminalon
theigniter unit. Connect thefreeendofthe
earth lead tothetab on thesideofthepiezo
igniterhousing(seefig.20).
7.3For right handheaterssnapthecontrol
knobbezel into the right handaperturein
thetopofthe front case andtheblanking
plate into the left. Reversefor left hand
heaters,(seefig.21.)
7.4For right handheaterssnaptheviewing
plate into the right handapertureinthe
front ofthe case and thenameplate into the
left. Reverse forthe left handheaters,(see
fig.22).
7.5 Locate theheater case overthetopedgeof
theinstallationboxandthecontrolknob.
Press inthebottomofthe case ontothe
springclipslocatedatthebottomofthe
installationbox.(seefig23).Itwillbe use-
ful,atthisstage,tocheckthepiezoopera-
tion,bypressingthecontrolknob firmly
downwardsseveraltimesandobserving
thesparkattheburner,oneachoperation.
Ifa sparkisnotpresent,checkassembly
procedureinsection7.2.
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B.TESTINGTHEHEATER
3.1 Purge anyair from the system by pressingdownandturning the controlknob tothe ignition
position ("^u^") andfirmlyholding it down, for approximately 20 seconds.
3.2Turn the controlknobclockwise totheoff("O") position and release.
3.3 WAIT3 MINUTES TO CLEAR ANY RESIDUAL GAS.
3.4 Press down and turn the controlknob tothe "^v^"positionandthenpressigniterfirmlydown-
wards. A clickwill be heard asthe igniteroperates to light the pilotburner.
3.5Continueholding the gascontrolknobdownwhilstchecking that pilot the burner is alight by
observation through the viewingwindow. Ifthe pilotburnerdoes not lightimmediately,push the
igniterdownrepeatedlyuntil it doeslight.
3.6Continue to hold the controlknobdown for20 secondswhile the flamefailureprotectiondevice
operates, thenrelease the controlknoband the pilotburnerwillremainalight. To operate the
mainburner, turn the knobanti-clockwiseand setatthe desiredpositionbetweenhighand low.
3.7 Ifthe burnerdoes not remainalight,repeatoperationfromstage8.3. but alwayswait 3 min-
utesbeforeattempting to relight the heater.
3.8 To turn off, return the controlknob to'•' position.
3.9 TO ADJUSTTHEROOM TEMPERATURE
Turn the GasControlKnob tothe setting that gives the requiredcomfort level. The mainburner
wiU'cycle' on and off automatically as required by the thermostat to maintain totheset tempera-
ture butthe pilotflamewillalwaysremainalight.
9. TECHNICALSPECIFICATION.
HEAT INPUT
MAX
MIN
3.75 kW
0.40 kW
HEAT OUTPUT
MAX
3.2 kW
GAS CONSUMPTION
BUTANE MAX
MIN
274 grams/hr
29.3 grams/hr -
PROPANE MAX
MIN
270 grams/fir
29.3 grams/hr
EFFICIENCY MAX.
GROSS
86.0 %
GAS SUPPLY PRESSURE
BUTANE
PROPANE
28 mbar
37 mbar
GAS FEED PIPE TO HEATER
8mm O/D
MINIMUM SUPPLY PIPE SIZE
6mm O/D
IGNITION
PIEZO
WEIGHT
12.6kg
CARAVAN SIZE RECOMMENDATIONS (UK).
7.9metres (26ft) March to October
6.4metres (21ft)All Year
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SERVICINGINSTRUCTIONS
TheGasSafetyandUseRegulations1990andvariousBritishStandardslaydownstrictrequire-
mentsfortheinstallationandservicingofLPGappliancesinstalledindomesticpremisesandmobile
homes,suchascaravansormotorvans.CarversoperatespecialtrainingschemesforDealersand
theirstafftoensurethattheyunderstandtheselegalandtechnicalrequirementswhenworkingon
CarverLPGappliances.Thisfacilityisbackedupbya 24houron-callsystemoperatingfromCarver's
HQat0543452127.
TheinstalleroftheLPGappliance,beitattheCaravanManufacturer'sfactoryorattheDealer'ssite
orontheCaravansiteitself,carriesthefirstresponsibilityforthecorrectinstallationaccordingtoRegula-
tionsandtheseCarverInstructionsbutthisresponsibilityiscarriedforwardtoanyserviceengineer
whoisrequiredtoserviceorrepairtheappliance.
Iftherefore,youarecalledtoa sitetoserviceorrepairtheLPGheateryoumustensurethatthere
havebeennoadversechangesofinstallationorusesincethetimeofinstallationorlastservicing
andcomplyingwithRegulationsappliesjustasimportantlyeveniftheserviceengineer'soperationis
onlydisconnectingandre-connectingtheapplianceforattentionoffthesite.
TheserequirementsunderstandablyaredirectedattheSAFEandEFFICIENTuseoftheheater.
Therearenoshortcutstosafetyandyouareremindedthatyoumustbeproperlytrainedbeforeyou
workonLPGappliances.
TheCarver3000 S isa reliablewelltriedapplianceandshouldgiveyearsofsatisfactoryandtrouble
freeusebutlikeallgasappliances,itneedsservicingona routineschedule.Thefollowingschedule
coversworkontheappliance,bothinthecaravanandwhenremovedfromthecaravanforattention
intheworkshop.Thesearethemainheadingsoftheschedulebutotherworkmayberequiredde-
pendingonthecircumstancesatthetimeofdealingwiththeheater.
(i)Whenservicedinthecaravanitselfandnormallyworking
(1)Checkthat theapplianceisbeingusedcorrectly,i.e.therarenofirerisksthroughproxim
itytoshelvesandclothing.
(2)Checkthattheairinletandflueoutletarenotblockedinanywayandareinthecorrectposi
tiononthevan;(refertoBS5440Part2 forguidance)
(3)Checkthesystemsforgastightness;
(4)Checkthefluesystemforsoundnessduringoperation.
(5)Checkthattheheaterhasbeeninstalledcorrectly.RefertotheseInstallationInstructionsespecially
ontheneedforproperclearancesaroundtheheater;
(6)Checkthatthegassupplysystemiscorrectlyinstalledandworking;
(7)Checkthattherearenodangeroushotspotsontheheaterwheninoperation;indicatedbyburnt
areasofdecorativepaintwork;
(8)Checkthatthecontrolsoperatesmoothlyandcorrectlyandthattheflamefailuresystemworks
correctly;
(9)Checktheflamestructureontheburneritselfandseethattheignitionsystemworkssatisfactorily;
(10)Nowremovethecasefromtheheater,replaceanyfaultycomponents,cleanawayallextraneous
dust,checktheoperationofallcomponentsandsafetydevices;
(11)Checkthegastightnessoftheinstallationattheendoftheservicingschedule;
(12)Confirmthattheuserunderstandstheoperationoftheheater.
(ii)Whentheapplianceisservicedawayfromthecaravan
Servicingtheapplianceitselfina separateworkshopwillrequire,whereappropriate,attentiontoitems
2-10above.
(iii)Faultdiagnosis
Whencalledintodiagnoseandrepairanyworkingfault,evena simplecorrectionwillstillrequire
youtocarryoutthestandardservicingscheduleincaseonedetectablefaulthascloakedotherpoten
tialfaults.
Wehaveincluded here a faultdiaanosticchartto helD voutotracefaultsintheianitionsvstem.
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FAULT FINDING
Turnthecontrolknobto pilot / ignition,position,
and press firmly down
Heater Lights
I
YES
I
NO_
.Cana sparkbeseenthroughthewindowontothe
topoftheburner?
YES
I
Isgassupplyand
isolatingtapson?
NO Check ignitor..Istherea sparktothetopof
Itheburner?
YES
NO
Purge systemTurnongassupply
and/orisolatingtaps,
check cylinderisnotempty.
Continue toholdthecontrolknobdownfora
minimumof twenty seconds. Onreleaseofthe
knobdoestheflamecontinuetoburn?
NO
YES
Replace _
component
Isburnertoelectrode
positioncorrect?i.e.3 to4mmsparkgap
YES
NO.
Relocate
is leadsatisfactory?i.e.anydamagetothewire
Iinsulation
r~
YES
n
NO
Replace
•component
YES
NO
Wait3 minutesandrelight.Holdthecontrolknob
fully downfor30 seconds.
I
Does theflamecontinuetoburn?
YES
NO Isthethermocouplescrew tight into the bottom of
thecontrol?
THE IGNITION SYSTEM
SYSTEM IS OPERATING
SATISFACTORILY. TURN
CONTROL KNOB TO
REQUIRED SETTING.
I—
YES
Isthethermocoupletip
intheburnerflame?
NO Screwtofinger tight plus
1/4 turn ^
r i
NO.
YES
I
Isthethermocouplesatisfactory?
.Adjust.
YES NO Replace.
component
Replace gas
controlvalve
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WARRANTY
Carver Products arefullywarrantedfora periodof2 years
fromdateoffirstpurchaseagainstfaultyworkmanshipor
materials.
We will repairorreplaceany such faultyitems "FREE OF
CHARGE" providedtheyhavebeeninstalledandusedin
accordance with ourinstructions.
This warrantyappliesonlytotheUnitedKingdom.
Acceptance ofthiswarrantydoesnotinanywaydiminishyour
rightsenjoyedundertheSaleof Goods Act, 1979.
NOTE: Thecustomermustwhereverpracticalreturnthe
product totheCarverDealerfromwhomitwas purchased.
In special circumstances, however,itmaybetakentoanother
Carver MainDealer.
CUSTOMER SERVICE DEPARTMENT
CARVER & CO. (ENGINEERS)LIMITED
COPPICE SIDEINDUSTRIAL ESTATE,
BROWN HILLS, WALSALL, ENGLAND, WS87ES.
TEL: [phone] FAX: [phone]
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