Carver 3600 STC Auto User guide

CARVER
INSTALLATIONANDSERVICING
INSTRUCTIONS
FOR THE
3600STC & 3600STCAUTOCARAVANHEATERS
LEAVETHESEINSTRUCTIONSWITHTHEAPPLIANCE
THISAPPLIANCEMUST BE INSTALLEDINACCORDANCEWITHTHEMANUFACTURERS
INSTRUCTIONSANDTHEREGULATIONS IN FORCEANDONLYUSEDIN A SUITABLYVENTILATED
LOCATION. READTHEINSTRUCTIONSFULLYBEFOREINSTALLING OR USINGTHISAPPLIANCE.
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1. WARNINGSANDINFORMATION
1.1Whentheapplianceisinuse,theflueductingbecomeshot.Noplastics,fabricsoraerosolsmustbeplaced
neartheducting.
1.2Thisheatermustbeinstalledbya competentgasfitterworkingtothegasSafety(InstallationandUse)
Regulations,theHealthandSafetyatWorkRegulations,theCouncilforRegisteredGasInstallers
requirementsandthesefittinginstructions
1.3TheheaterissuitableforinstallationintocaravanscomplyingwithB.S.4626.
1.4Alwaysensuretheunderfloorairintakeispositionedsothatitcannotblockedbymudorsnow..
1-5Wherechildren,theelderlyortheinfirmarepresentwerecommendthatwheninusea guardbefitted
aroundtheheater.
1.6ThereMUSTNOTbea mantlepieceorshelvingsitedabovetheheater.
1.7CurtainsMUSTNOThangwithin150mmofthesidesoftheheaterorwithin300mmabovethetopofthe
outletgrille.
1.8Adjacentfurnitureorupholsterymustbeclearoftheheatercasebyatleast5 millimetres.
1.9TheCarver3600STC& 3600STCAutoheatersareapprovedtotherelevantsectionsofB.S.5258part
131986undertheUnitedKingdomAccrediationService(UKAS)andismanufacturedtothequality
standardofB.S.5750part2./ISO9002.
M0Thedatabadgeislocatedontheheatercarcass,behindthefrontcase.
1.11AerosolsandhighlyflammablematerialsMUSTNOTbestoredincompartmentsbehindofadjacenttothe
heater.
1.12Thisheaterdoesnotcontainasbestosoranyasbestosrelatedproducts.
1.13Thegassupplytotheheatermustbefroma regulatorofadequatecapacitygivinga workingpressureof
28mbrButaneor37mbrPropane.UnderNOcircumstancesshouldanindustrialoradjustableregulatorbe
usedoncaravanapplications.
1.14TheheaterMUSTNOTbeoperatedwhilerefuellingorwhenthevehicleisina confinedspacesuch
asa garage,orwhenthevehicleisinmotionortransit.
'.'5The3600STCAutoignitorisdesignedforconnectiontoa 12vor9vsupply,andmustnotbeusedwith
anyothertypeofelectricalsupply.
1.16The12vgassupplymustbeisolatedwhenthecaravanormotorhomeisintransit.
1.17Whentheheaterisfirstused,itisrecommendedthatyouopena doororwindowandturnthetempera-
turesettingtomaximumfor1 hour.Thiswillallowanyodourstoescape
Note:- Ifanyodourspersistcontactyourlocaldealer.
IMPORTANT:CORRECTPOLARITYOFTHEELECTRICALCONNECTIONSMUSTBEOB-
SERVEDORDAMAGETOTHEELECTRONICCOMPONENTSWILLRESULT.
2. THEHEATERKIT- 3600STC
TheHeaterkitisoneBoxcontaining:-
1 HeatExchangerAssembly 1Gasconnection
1 Casewithblankingbezelfitted 1Clampstrip
1 Controlrod/Piezoignitorassembley 1Installationbox(2parts)
4 ScrewsNo.8 x 30mmlong(Bown) 1Setofliteratureinpolythenebag
4 WoodScrewsNo.8 x 20mmlong
6 WoodscrewsNo.6 x 12mmlong Theflueductkitisoneboxcontaining:-
1 Screw(M5) - Exhaustclamp 3Flueductclips
1 ORing(Red) 1Cowl
1 Clampring 1Flangeheadscrew
1 Lockingring 1URInsulatingduct
1 Gasconnectionolive 1LengthofStainlessSteelFlueduct
3600STCAUTO
AsabovebutwithAutoignitionunitwiredandpre-fittedtotheheatexchangerassembly.
1.
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3. CHOOSING THE POSITION FORTHE
HEATER.
Theheater is normallyfittedinto the panel
belowthewardrobedoor.Beforecommenc-
inganyfittingensurethattheappliancewill
fitintothedesiredposition(seefig. 1.). The
installationboxwillberecessedintothepanel
ofthewardrobe by 110mm.
4. FITTING THEHEATER.
4.1TURNOFFthegassupply at thecylinder.
4.2Ifpossibleliftawaythefloorcoveringfromthe
frontofthepanelorwallintowhichtheheater
is tobe fitted. If this isnot possible the
templatewillhave to bepositionedontop of
thefloorcovering.
4.3Foldthetemplateupwardsalongthearrows
marked'WallCutout'frontface RH' andplace
inpositionasshowninfig.2.withtherectan-
gularcutout tothe right.Mark anddrill two
smallholesatthefrontcorners(A& C onthe
template).Drop a nail or similarthrough the
twoholesandcheckbelowthecaravanthat
theareabetweenthenails is free of obstruc-
tion.
WARDROBEDOOR
OPENING— 110 mm
I II I M
E
E
IT)
CO
St
E
E
in
ID
480mm («g-1)
4.4 Ifany obstruction is foundthenrefold the
templatealong the arrowsmarked ' Wall
cutoutfrontface LH' andplace in position
withtherectangular cut out to theleft.Mark
anddrilltwosmallholes at thefrontcorners
(B & D ontemplate).Drop a nail or similar
throughthetwoholesandcheckbelow the
caravanthat the areabetween the nails is
free of obstruction.
NOTE: tfthe heater istobe fitted in this
position(called"LeftHand") the thermostat
phial ontheGas ControlValve hastobe
repositioned. See section 4.13for instruc-
tions.
4.5 Ifan obstruction is stillevident, the heater
must be repositioned in anotherarea inthe
vehicle.
2.
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4.6Whensatisfactory,mark theholetotakethe
installationbox.Thiswillrequirea holetobe
cutinthepanel485mmhigh(fromthefloor,
belowfloorcovering)X 480mmwide.Itis
recommendedthatthepanelsurfaceispro-
tectedbymaskingtape.Scorethelinetobe
cutwithsharpknife,tostoptheveneerlifting
(seefig.3).Ifthepanelisofthehollowtype,
thenthevoidmustbefilledlocallyalongthe
openingwithwood.
4.7Trimthefloorcoveringfrominsidetheward-
robeorpaneltoa depthof135mmfromthe
front(seefig.4.).Ifthefloorcoveringisnot
wantedbehindtheinstallationboxremove
asrequired.Alsotrimthefloorcoveringin
frontofthepanelorpaneltothelinesonthe
template.
4.8Openout thetemplatemakingsurethatthe
arrowsremainintheirrelativepositions.Mark
andcutthefloorholeatA,B,C,& D.onthe
template.Removesomeoftheinsulationand
inserttimberlinersforaddedsecurityofthe
fixingscrews,andtosealoffthecaravans
floorinsulation.Thelinersmustbesecuredto
thefloorusingsuitableadhesiveorscrews
andtheirsizemustbesuchthatallholes
markedonthetemplatefallwithintheinserts.
Donotusescrewswheretheywillcontactthe
floorplatecorkgasketoftheheater.
4.9Drillfour2mrndia.holes,aslabelledatthe
rearofthetemplate,(seefig.5.).
4.10Line upthefloorplateclampstripwiththe
fourpre-drilledholes,ensuringthatthe
overhungedgeisfacingforward.Secure
with20mmscrewsprovided.Tightendown
thetwoouterscrewsfirmly(see fig. 6)leave
thetwoinnerscrewslooselydrivenatthis
stage.
Insidewardrobe
Removefloorcoveringin
thisarea, \ 51
9-
Trimfloorcoveringtothis
lineontemplate
(fig. 4)
3.
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4.11AssemblyoftheinstallationBox.
Locatetheinnerboxonthereartabs(see
fig. 7.)Fitthetopbracketsoftheinnerbox
throughtheslotsintheouterboxtopflange
(seefig.8.).
Innocircumstancesmusttheheaterbe
installedwithoutbothinnerandouterin-
stallationboxesbeingfittedcorrectlyas
thiscancausedamagetotheheaterandits
surroundingcabinetsandmayinvalidate
thewarranty.
(fig- 7)
Removetheboldcentralovalknock-out
(seefig.7.).
4.12Positiontheinstallationboxintotheopen-
ingensuringthatthebottomedgeofthe
boxis ontothefloor.Securetheboxtothe
panelwiththesixwoodscrewsprovided,
(seefig.9.)
4.13aMovingPhialBracket
Carefullyslidethebracket,carryingthe
thermostatsensor,fromthesteeiheat
exchangershieid,retainingthespringclip
forfurtheruse.(Seefig10).
4.13bFittingSpringClip
Fitthespringclipinthepressedslotinthe
topofthefloorplateasshowninfig.10.
Ensurethattheclipisfittedwiththebarbs
uppermostandonthesideofthefloorplate
intendedtofaceintothecaravanliving
space.
(fig. 9)
4.13cFittingPhialCarrier
Takingcarenot totrap,damageorkinkthe
thermostatcapillary,relocatethesensor
andbracketassemblyonthetopofthe
floorplateonthesamesideasthespring
clip. Fittheforkedendofthebracketonthe
heatexchangersupport leg, thenpushfully
homewhileensuringthespringclipflange
gripsthebracketbottomflangethroughits
squarehole.(Seefig.11).
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4.14Lowertheheater into thefloorholeand
positiontheheatercentrallyintheinstalla-
tion box,ensure that therearedgeofthe
floorpiateispushedunderthefioorplate
clampstrip.(see fig. 12point1.)
Check that thethermostatphialandits
carrierfaceout into theliving space.
On 3000S Automodels,takecarenotto
damagetheflyingleadsorterminalblock,
andensure that theyremainabovefloor
level with theheaterfitted.
4.15Oncetheheaterisinpositionusethefour
brownscrewsprovidedtosecureitviathe
holes inthe front edgeofthefloorpiate(see
fig.13).Drill2 millimetrepilotholeswhen
screwing into solidwood.
4.16Workinginsidethewardrobetighten the
remainingtwo20mmscrews on thefioorplate
clampstrip.
4.17itisimportant that allthescrewsare tight-
ened evenlytoavoiddistortionoftheheat
exchanger floorplate,andtoensureanair
tight seal tothefloor.
4.18 IMPORTANT : Thefloorpiate MUST NOT
bepositionedontopofanyfloorcovering,
as thiswouldpreventa satisfactory airtight
room seal.
FITTING THEFLUEANDCOWL.
5,
5.1
5.2
NOTE:-The cowl must be fitted tothe
roof ofthe caravan only andthe whole
installation must conform to BS5440
Part 1.
Thecentreofthecowlshouldbeatleast
80mmfromtheedgeofthecaravan.Ifthe
caravan hasa slopingroof ensure that no
partofthecowloverhangstheedgeofthe
caravan. Thefluedirectionshouldbeas
straightaspossibleandshouldrise con-
tinuallyfromtheheatertothecowl.ltshould
runagainstthepaneltowhichitwillbe
screwed
Cut a 60mmdiameterholeintheroofatthe
requiredposition.Toavoiddistortionin
insulatedordoubleroofsinserta band(1)
ofaluminiumofthesame width asthegap.
Fitthecowlfromtheoutsideensuringthe
rubber seal (2)isinplaceandthen,from
inside, fitand firmly tightentheplasticnut
(3) with thescrewontheside(seefig.14).
Spring clip fitted (fi9-11)
(fig.15
fa-13)
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5.3Beverycarefulwhenhandlingtheflue
ductastheedgesareextremelysharp.
Bendoneendoftheinnerflueductsharply
to90°asshowninfig.15.
NOTE:-
Tohelpyoufitthefluethefollowingtools
areavailablefromCarverSpares
Department:-
CuttingJigPartNumberR701067
(Jigtoassistincuttingthefluesquare.)
MandrelPartNumberR701063
(Toassistinthebendingoftheflue.)
5.4Frominsidethewardrobefeedthebend
endoftheinnerflueductthroughtheknock-
outintheinstallationbox.Slidethelocking
ring (1), theclampring(2)andtheO ring(3)
overtheendoftheductend.(seefig.16.)
5.5Firmlypushthe ductintothe heatexchanger
uptothe stop. SlidetheOring,clampringand
lockingringuptotheheatexchanger making
surethe tappedholeinthe lockingringis
towardsthetop.Engagetheearsofthe
lockingringbehindthe projections onthe
heatexchanger androtate itso thatthe ears
arenearhorizontal.Insertandtightenthe M5
screw.Thiswill compressthe 0 ringandfix
the exhaustducttothe heater.Thisjointis
criticalforthesafeoperationofthe
heater (see fig. 17.)
5.6Laytheinnerflueductalongitsrequired
routetotheoutsidecowltakingintoac-
counttheattachmenttothefluesupport,
(para. 5.8.)Allow110mmforinsertioninto
thecowlandcuttolength,erringonthe
longside.Slidetheinsulatingductoverthe
flueuntilthelowerendisinsidetheinstal-
lationboxandcutsothatitsupperendis
flushwiththeinnerduct.
5.7Pushbacktheendoftheouterductand
firmlyinserttheinnerductintothecowl
rightupits stop(about110mm).Allowthe
outerducttospringovertheoutsideofthe
cow!uptothenut.Justbelowthenutdrilla
3mmholethroughbothductsandthecowl
andfittheflangeheadscrewthroughall3
items, (seefig.18.)
75mm. STRAIGHT
6.
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5.8Insidethewardrobefitthemainfluesup-
port bracketina positionwhichprevents
thefluesagging.Securethefluetoit with
thestrapprovided. Secure thefluealongits
lengthagainstthecaravanstructureusing
allofthe3 ductclipsprovided,(see fig. 19.)
Itisimportant that thefluerisescontinually
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 thegassupplyisturned OFF at
thecylinder.
Connect the8mmdiametercaravanheater
feedpipetothegasvalveunderthe cara-
van, using thenutandoliveprovided.When
tighteningthevalveconnection,two span-
nersMUST be used: onetotightenthenut
andtheother,forsteadyingpurposes,on
the fiat surfacesofthevalveitself.
Thegaspipesorvalve MUST NOTbe
placed underanystraimwhile fitting tothe
heater.
NOTE: The size ofthesupplypipe MUST
NOT belessthan6mm(1/4")O.D.For
heaterservicingpurposesanapproved
isolatingvalve,mountedinanaccessible
positionisrecommended.Afterconnect-
ing, turn onthegasatthecylinderand
check thesystemuptotheappliancegas
valveforleaksusingsoapywaterorother
approvedleaktestingmethods.
©
GREEN
POSITIVE •
SUPPLY
AUTO IGNITER
FLYING LEADS
(fig.21)
WHITE
NEGATIVE
SUPPLY
o
At
FIBREGLASS
SLEEVE
7
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7. CONNECTION TOTHE12vor 9vD.C.
SUPPLY 3600 STCAUTO
7.1 Disconnectandisolatethecaravanbattery
andensure that thecaravancircuitry isnot
connected to any240vmainssupply.
7.2 Pass the sleevedflyingleadsthrough the
lowerholeinthebackoftheinstalltionbox
behind the controlshaftsupportbracket.
(See fig.20).
7.3Thewiresarecoloured in accordance with
thefollowingcode:
GREEN - POSITIVE (+).
WHITE - NEGATIVE (-V
WARNING: CORRECTPOLARITYMUST
BE'OBSERVED WHEN CONNECTING TO
THECARAVANSUPPLY OR THEAUTO
IGNITION UNIT WILL BEDAMAGED. (See
fig. 21)
IMPORTANT: THECARAVANSUPPLYTO
THEAUTO IGNITIONUNIT MUST BE
PROTECTED BYA FUSE OF MAXIMUM
RATING OF5A.
7.4Whensatisfactory,reconnect the caravan
battery,againobservingthecorrectpolarity.
8. FINAL ASSEMBLY
8.1 Firstfitthecontrolrod assembly. Separatethe
rod from theplasticigniterhousing and pass the
rod downthroughthe hole in theinstallationbox
front, ensuring that thefoam backed aluminium
disc remainssitting ontopof theinstallation
box, foamsidedown.
Reconnect the rod tothe piezo housing. Locate
thebottomball joint overtneshaped gas control
rod, and push securely together, (see fig.22B)
3600 STCONLY:
8.2Firmlypushthesmaliinsulatedfemaleconnector
onthe raniter lead throughtheguidehole and on
tothemaleterminalon!heigniter unit. Connect
thefreeendoftheearthleadtothetabonthe
side ofthepiezoigniterhousing(seefig.22)
8.3Theheater case has been factory built tosuit a
RightHandinstallation. Fora left hand
installation,push the blankingbezel outof
position on thetop panel and push into place on
the right handside(see fig. 23)
8.4 Locate theheater case overthetop edge ofthe
installationboxandthecontrolknob. Press in
thebottom of the case on to thespringclips
located atthe bottom of theinstallationbox.
(see fig.24). It will be useful at thisstage, to
check The operationofthe piezo orautoigniter.
For thepiezo, press theknob firmly downwards
several times and observe a spark atthe
burner.
On the Auto,when the caravansupply is
restored,press the knobdown and turn
anticlockwisewhere a constant"ticking"willbe
heard. Observethespark at theburner, and
theknobilluminatedindicator.
If a sparkcannot be seen, checktheassembly
procedureinsections 7 and 8.
Beforeusingyourapplianceremove the
protectivecoveringonthebrassstrip, if fitted.
/- ""N Blanking
\^f~ Bezel
(fig. 23)
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9.TESTINGTHEHEATER• 3600 STC-
9.1Ensurethegasis turned onatthecylinder.
9.2Purgeanyair from thesystembypressing down andturningthecontrolknobto theignitionposition("—^")andfirmlyholding
itdown,for approximately 20seconds.
9.3Turnthecontrolknobclockwisetotheoff("•")positionandrelease,
9.4 WAIT 3 MINUTES TOCLEARANYRESIDUALGAS.
9.5Press down and turn thecontrolknobtothe" —*—" positionandthenpressigniterfirmlydownwards.A clickwillbeheardas
the igniter operates to light the pilot burner.
9.6Continueholdingthegascontrolknob down whilst checkingthatpilotburnerisalightbyobservationthroughtheviewingwindow.
Ifthe pilot burner doesnot light immediately, pushtheigniterdownrepeatedlyuntilitdoeslight
9.7Continueto holdthecontrolknob down for20secondswhiletheflamefailureprotectiondeviceoperates,thenreleasethecontrol
knobandthe pilot burner will remain alight. Tooperatethemainburner, turn theknobanti-clockwiseandsetatthedesiredposition
between highandlow.
9.8Ifthe burner doesnotremain alight, repeat operationfromstage8 3 but always wait 3 minutes before attempting to relight the
heater.
9.9To turn off, return thecontrolknobtoW position
9.10TOADJUSTTHEROOMTEMPERATURE
TurntheGasControlKnobto the setting that givestherequiredcomfort level. Themainburnerwill 'cycle' onandoffautomatically
as required bythe thermostat to maintain tothesetternperaturebutthepilotflamewillalwaysremainalight
10TESTINGTHEHEATER-3600STCAUTO. _
10.1Ensurethegasisturnedonatthecylinder,andthatthevehicle's12vsupplyor9v batteryiscorrectlyconnectedandswitchedon.
10.2 Turnthecontrolknobanti-clockwisetotheV»-^" position,wheretheigniterwillbeheardtooperatebyanaudible"ticking"noiseand
theindicatorwillilluminate.
10.3 Press theknobfirmlydownwardswhiletheignitercontiuestooperateforseveralsecondswhileairispurgedfrom thegassupply.
Observe thatthepilotisalightthroughtheviewingwindow,whentheaudibletickingstopsandtheindicatorstopsilluminating.
10.4Whenthepilotburnerlights,contiuetoholdtheknobfor20 seconds whifetheflamefailure protectiondeviceoperates,thenreleasethe
controlknobandthepilotburnerwillremainalight.
i10.5Testthe"Full Flame" fuction,bynowturningthecontrolknobfurtheranticlockwisetiothedesiredpositionbetweenhighandlow.
i10.6 Iftheburnerdoesnotremainalight,repeattheoperationfrom stage1. ALWAYS WAIT THREE MINUTES BEFORE ATTEMPTING TO
RELIGHT THE HEATER
To turn off, return thecontrolknobtothe"•"position.
11TECHNICALSPECIFICATION
HEAT INPUT
MAX
MIN
3.75kW
0.40kW
HEAT OUTPUT
MAX
3.2kW
GAS CONSUMPTION
BUTANE MAX
MIN
274grams/hr
29.3 grams/hr
PROPANE MAX
MIN
270 grams/hr
29.3 grams/hr
EFFICIENCY MAX.
GROSS
86.0%
GAS SUPPLY PRESSURE
BUTANE
PROPANE
28 mbar
37 mbar
GAS FEED PIPE TO HEATER
8mmO/D
MINIMUM SUPPLY PIPE SIZE
6mmO/D
IGNITION
PIEZO/AUTO
WEIGHT
12.3Kg
CARAVAN SIZE RECOMMENDATIONS (UK). 7.9metres(26ft)MarchtoOctober
6.4metres(21ft)All Year
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