Carver Fanmaster User manual

CARVER
FANMASTER
WARM AIRFANHEATER
INSTALLATIONINSTRUCTIONS
PLEASE LEAVETHESEINSTRUCTIONSWITHTHE APPLIANCE
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1-GENERAL DESCRIPTION
TheFanmasterisanautomaticallycontrolledfandesignedtodistributewarmair
throughducts,tooutletspositionedaroundthecaravan.
TheFanmasterisdesignedtofitontothebackoftheinstallationboxofanyCarver
1800, 2000or3000heaterandtheairmaybeheatedeitherbytheCarverheater
orbytheFanmaster'sownintegralelectricelements.butnotby both simultaneously.
TheintegralelementsareautomaticallyormanuallyswitchablebetweenOkW,
1 <Wand2kW.Theyrequirea 230vACmainssupplyand will drawapproximately
8ampsat2kW.
Tr.efanandtheelectroniccontrolrequirea 12vDCsupplyand will draw
aooi-oximately1.5Aat full speed.
All functionsoftheFanmasterarecontrolledbya remote,wallmounted,controller.
This controllerdoesnotcontaina thermostatsensorsoitcanbemountedinany
convenientposition.
2- Specification
2.1HeatingElementSupply:
2.2FanandControlSupply:
2.3AirDelivery:
230vAC,8.1amp,1863W
Fused at10- 13amp.
12vDC,1.5amp,18W
Fused at5 amp.
100m3/hmaximum.
2.4Weight3.05Kg
2.5SafetyFeatures:A thermistorinthefan,sensingairtemperatureand
controllingtheelementpowerandfan speed.
An overtemperature,manuallyresetable trip sensing
elementtemperature.
2.6TheFanmasterisapprovedtoBS3456pt201(1990),EN60335pt1 (1988)
andmanufacturedtoBS5750pt2 (1987).Itissuitableforinstallationin
caravans complying with BS4626(1970).
2.7TheratinganddataplateisontopoftheFanmasterbody.
1.
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3. Warnings
3.1Itisrecommended that theFanmasterbeinstalledbya competentelectricianworkingto
IEE Regulations16theditionandthese fitting instructions.Beforeconnectiontothemains
supplythe work mustbecertifiedbyan NICEICapprovedelectricalcontractor.
3.2Any work involvinggas fittings ontheCarverheatersmustbeperformedbya competent
gas fitter workingtothecurrentGasandSafety(InstallationsandUse)Regulations1984.
3.3TheFanmasteruses230Vmainssupply.Thiscanbedangerous.Exerciseextreme
cautionduringinstallation.
3.4Beforestarting work, disconnectthecaravan from themainselectricalsupplyandisolate
anyon-board12vbattery.
4. Fanmaster KitandTools required.
4.1Fanmaster
1offFanmaster
1offRemoteController
1offTwinwireloom
1offThreewireloom
3 offNo.6x16mmSelftappingscrews
1offConnectionlid
2 offConnectionlidscrewsNo.4x9.5mm
4offCableclampscrewsNo.4x16mm
2 offScrewcoversforcontroller
2 offm/cscrewsforuse with optionalcontrollerbox
1setof literature
1Fanmaster front case badge
4.2ToolsRequired
No. 1 Posidrivdriver
No. 2 Posidrivdriver with 200mmbladelength
No. 2 SlottedScrewdriver
Two7mmA/Fspanners
Electrical Screwdriver
10mm drill
Pad saw
4.3MaterialRequired
3 corewire, PVC sheathed,Brown,Blue,Green/Yellow CSA 1.5mm2600vgradetoBS6004
forconnectingFanmastertomainssupply.
Doublepoleswitched outlet with contactseparationofatleast3mmoneachpolefusedat10A
or13Aplug(SeeSection11).
4.4 NOTE if fitting thenew FANMASTER toa NEWCarverspaceheater with norearmounted
accessory fan unit previouslyattached,proceedimmediately with section7("FittingFanmaster
totheinstallationbox").
4.5 Ifa CentralHeatingaccessoryfan
unit ofthe TBM ("Junior"), TEB, TENorTNtypehasbeen
fitted, anditisdesiredtoreplace with the FANMASTER, section5 orsection6,asappropriate,
mustbefollowedbefore fitting thenewheater.
4.6If fitting a newFanmastertoan SB, SDorSBTtypeofheater,thiscanonlybedone with the
later"UB"typeofinstallationboxwhichhasthreadedfanretaining insertsinplace.Inthis
case, fitting kit,Part No.101584shouldbeobtained,andtheproceduredetailedinsection
7shouldbefollowed.
2.
No. 2 Flatbladescrewdriver
Two7mmA/Fspanners.
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5.
REMOVALOFTBM "JUNIOR" FAN, PRIOR TOFANMASTER INSTALLATION
5.1Removethescrewssecuringthe
"UR" ductingtotheinletandoutlets
ottheTBMfan.
5.2Followingtheadviceinsection3.4,
removetheoldfan, with its
associated wiringandwallswitch,
leavingtheexistingmaincaravan
wiringloomsafe.
5.3Onthedownstreamsideoftheold
fan, removethe first existingplastic
"Tee" piece.Thiscanberetained
foranydesiredducting
modifications further downstream.
5.4Removetheinstallationboxplastic
adaptorandits shortlengthof
ducting.Theadaptorshouldbe
discarded.
5.5Foreachofthetwoductendsnow
remainingattherearofthegas
heatera straightadaptor- type
"UM" shouldbe fitted toextend
theseductstomeetthenew
Fanmaster. Securethenew
adaptorstotheducting with self
tappingscrews.
5.6NowproceedfromSection7 "Fitting
Fanmaster totheInstallationBox".
5.7Whenthishasbeencompleted,
extendthetwowarmairducts with
shortnewlengths,tomeetup with
theFanmasteroutlets.Followthe
detailsinSection10.
5.8 IMPORTANT: Fanmasterhasbeendesignedandapprovedtooperate with BOT-
warmairoutletsfullyutilised,thereforemodificationsmayberequiredtoupdateft
ductingwhenconvertingfromtheTBMtypefan.Particularattentionmustbepaic T
thenotesinSection9.FailuretodosowillcausetheFanmaster'sthermalM
protectiontooperateprematurely.
3.
To remove -
Fanmaster conversion
Fanmaster
•2)
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6.REMOVALOFTEB,TENORTNTYPEFANS,PRIOR TO FANMASTER
INSTALLATION
6.1 Releasethetwolengths of warm air
ductingfrom thefan unit by
removal of thesecuringselftapping
screws.
6.2All wiringassociatedwith the12v
"TBM" and"TEB"typesoffansMUST
beisolated by removing the fuses,
thendisconnected.Remove the
existingwallswitchandsupplycable
to the motor.
If the Line and Neutralcables to
theexistingwallswitch areof
1mmsquaresection andin good
condition, andare protected bya suitablefuse (i.e.5 Amps),they canbe used asa
12vsupply for Fanmaster.
Should the existing fanbea Mainselectric "TEN"or"TN" type,thenthiswiring
shouldfirst be isolatedfrom any 220/240vsupply. The existingwiring is then
removed, back toa suitableterminationpoint. The wiringMUST beof sufficiently
highrating(minimum of1.5mm squareconductors) to take the2 kW rating ofthe
240vFanmasterheater.
6.3 Unscrew the heater atits three
locationpoints and removefrom the
Installation Box.
6.4 IMPORTANT:All wiringassociated
withthesetypes offan must be
disconnected and removed
completely,asthenewreplacement
Fanmasterrequirescable ofa
superiorspecification.Failure todo
sowillcause a hazard.
6.5 Nowproceedfromsection 7: "Fitting
Fanmaster tothe Installation Box".
6.6 Whenthis has beencompleted,connect the existing two ends of ducting tothe
appropriateFanmasteroutletconnections as detailed in section 10.
6.7IMPORTANT: Fanmaster has beendesigned and approved to operatewith
BOTHwarm air outletsfullyutilised.Particularattentionmust be paid tothe notes in
Section 9.
4.
(Fig. 3)
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7.FittingFanmastertothe
installationbox.
7.1Removethecircularknock-outfrom
therearoftheinstallationbox.
(Fig. 5).
7.2Droponeofthe3 offNo.6x16mm
selftappingscrewsprovideddown
thetubelocatedtotheleftofthe
terminalblockbracketattheback
oftheFanmasterinsidethe
terminalenclosure.(Fig.6b)
Usingthe200mmlongNo.2
Posidriverpositionthescrewso
thatitprojectsthroughitshole.
Withthedriverstillinposition
locatetheFanmasterasshownin
Fig. 6bwiththeintakealignedwith
theknock-outandlooselyfixthe
screwintothelowerleft-handnut
(asseenfromthefront)(Fig.6b).
Fittheother2 screwsasshown
andtightenallthree.
7.3Ensurethatnopartofthe
Fanmastertouchestheheater
flue.
7.4ForSBtypeheaters.
ThestandardFanmasterfitting
screwsmustbediscarded,and
thesingleM4studandtwoM4
screwsmustbeusedfromkit,
PartNo.101584.
Followstage7.1,thenselectthe
100mmlongstudandscrewon
o
C)
(Fig. 5)
5mm
(Fig. 6a)
(Fig. 6b)
bothM4nutsandlocktogetherwithin5mmfromoneend(Fig.6a).
Selecta singleM4washer,andpositiononthestudbelowthenuts(Fig6a).Drop
thestudassemblydownthetubetotheleftoftheterminalbracket,asdescribedin
section7.2,andensurethattheendprojectsthroughtheholeintheFanmasterbase.
OfferuptheFanmastertotheinstallationboxwiththisstudandtheremainingtwo
M4x 20screwsasshowninFig6bandtightenallthree.Checkthatcondition
7.3is satisfied. 5.
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8 Fitting the Remote Controller
8.1 Select theposition forthe controller.
This willideallybeinanaccessible
positiononthe front wallofan
overhead lockeroronthewardrobe
side. Ensure thethreecoreloomwill
reach fromthecontrollertothe
Fanmaster andallowforclippingto
thestructure.
Cable entryisfrom therearofthe
controllerthroughthecut-outinthe
panel.
8.2Thecontroller doesnotcontain a
temperature sensorso itspositionis
notthermallysensitive.
8.3Intheselectedpositionusethe
templatefrompage10tomakethe
cut-outanddrilltheholes.Ifthe
panel is thin itmayneed
reinforcementtotakethescrews.
The useof masking tape on thearea
tobecutwill preventsplintering of
wood.
8.4Leadthethree-coreloomfromthe
Fanmaster totheController
and plugit into thecontrolleratone
end & into theFanmasteratthe
other.Theplugswillonlygointhe
correctwayround.Donot use force.
Fig. 7 and Fig. 12.
8.5Leadthetwo-coreloomfrom the
controllertothe van's 12v DC supply.
The whiteleadgoestothenegative
and thegreen via a 5 amp fuse tothe
positive. Fig.7.
8.6Screwthecontrollerinpositionusing
self tappingscrewsorthemachine
screws if theoptionalrearprotection
boxis used. Insert thescrew covers.
8.7Cliptheloomstothecaravan
structureleavingslacktoremove
thecontroller.
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9. Ducting and Duct
Layouts
9.1 The Fanmaster isa major
componentoftheCarverBlown
Air CentralHeatingSystem.
9.2 Thelayoutandinstallationofthe
ductsandoutlets is identical to
that requiredforthe Carver TEB
12vFan.
9.3 Each of the twin outletson the
Fanmaster accept "UR" flexible
ductingtogive a warmairsupply
tobothends ofthe caravan.
Each ductruncansupply2 or3
outlets. Itis recommended that
atleast one outlet isofthe
permanentlyopentype to
preventovertemperaturesafety
trippingoftheelectricelements.
9.4 DetailedDuctinstallation
information is availablefrom
Carver butthe threelayouts
shownaretypical.Fig. 8.
SEAT
WASH
J» ROOM
V•••4
V ®
o
SEAT
1
t
®
o
r
2 berth, end kitchen, heater opposite door,2 outlets lo
main seating area. 1 outlet to washroom. 1 outlet to
doorway and kitchen area (duct passes under the floor
encasedinDR Duct)
5 berth, centre krichen, heater opposite door;2 outlets at
each endto seating areas, 1 outlet to washroom, 1 outlet to
doorway Duct passes under the washroom (it shower tray
fitted), encased In D.R. Dud
BODYLENGTH 16'6'(5.1m)-
4 berth, centre kitchen, heater ondoor aide; 2 outlets
•achandlo seating araas.l outet to washroom. 1 outlet to
doorway, ducts passing under doorway (and washroom, W
shower tray fitted) encasedinD.R Duct
LL
Blanl
Plug (VD)
Air Outtoi (j
(Fig. 9)
7.
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10. Connection of Ducting to
Fanmaster
10.1 Push theendsoftheduct firmly past
theretainingridges into the
Fanmasterportsuptothestops
andretain with selftapping
screws. Fig.10.
10.2Insomeinstallationscaremustbe
takenin routing theduct into the
portstoavoidkinks.Fig.11.Itmay
beeasiertofittheductsbefore
securingtheFanmaster.
11. Mains Electrical Connection.
11.1Wirethemainssupplycable(PVC
sheathed, 3 core,Brown,Blueand
Green/Yellow, 1.5mm2/core,600v
gradetoBS6004) into themain
terminalblockontheFanmaster.
Thisismarked:
"E" EarthGreen/Yellowwire
"N" NeutralBluewire
"L" LiveBrownwire
Secure the12v3 coreloomandthe
mainssupplycable with thecable
clamp.Fig.12.
11.2Tosupplymainscurrenttothe
Fanmasterbymeansoffixed wiring,
leadthemainscable from the
Fanmastertoanaccessibledouble
poleswitched outlet with contact
separationofatleast3mmoneach
polefusedat10Awhichissupplied
from the output oftheMCBwhich
serves the13Asockets.
11.3Alternativelyto retro-fit the
Fanmastertoanexistingmains
installationtheFanmastermaybe
suppliedthrougha 13Aplug from an
existing 13Asocket.
III "(Pig.11)
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11.4BeforeconnectionchecktheFanmasteranditscableforEarthContinuityand
Insulation Resistance. AfterconnectioncheckforEarthImpedance.
11.5 Clip the cables tothe caravan structureso that theycannotbedisturbedorstrained
byitemsdropping behindtheheater andfitthelidtotheFanmasterconnectionbox.
11.6RemoveFanmasterbadgebackingandstickon bottom right handsideofheater.
Thebadgemustbe firmly pressedontoallowtheselfadhesivebackingtostickto
the case.
12. Testing of Fanmaster Functions
12.1Reconnectthebattery,gasandmainselectricalsuppliestothecaravan.
12.2TestthefunctionsmodebymodereferingtoSection3 oftheFanmasterUser's
Instructions.
13 Servicing
13.1Noregular servicingoftheFanmasterisrequired butitisrecommended that the
earthcontinuityandinsulationresistanceoftheentirecaravanmainsinstallationis
checked annually.
9.
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TRIMTEMPLATETOTHISLINE
CARVER
CARVER& CO(ENGINEERS)LTD
COPPICESIDEINDUSTRIALESTATE
BROWNHILLS,WALSALL
ENGLANDWS87ES
A
DRILL2 HOLES80AT
POINTSA & B.
CUTALONGLINE
WITHPADSAW.
B
2HOLES0 2
PARTNo.605796
10.
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14.FaultDiagnosisFlowdiagram
PRESS SELECTBUTTON
LIGHTS
NO LIGHT
FLASHINGCONTINUESAFTER
SELECTION
CHECK LOOMCONNECTOR
TOFANMASTERP.C.B.FOROPEN
CIRCUIT.
SELECTS
OK
L
USE VOLTMETERTOMEASURE
12V.SUPPLYTOFANMASTERP.C.B.
O.K.LOW
I
CHARGEBATTERY CHANGEP.C. B.
NOFAN
REMOVE MAIN COVERONFANMASTER
CHECK 2 WAYCONNECTOR
ISFIRMLYPUSHEDHOME
ONREMOTECONTROLLER
I
OK
I
WITH VOLTMETERCHECK
FOR12V.SUPPLYTO
CONTROLLERP.C.B.(FIG. 3)
| OK—
REPLACE
CONTROLLER
NONE
CHECK CARAVAN
SUPPLY, FUSESETC.
- FANRUNS,NOHEAT
CHECK 240V SUPPLY
USING VOLTMETER.
CHECK SOLDEREDCONNECTIONS IF FAULTY
RESOLDERTOMOTOR OK
OK
CHECK THERMALCUT-OUTBY
PRESSINGRESETFLAPONCOVER
CHECK FOR10-11VOLTSONMOTOR
OKREPLACEMOTOR
NOVOLTS
' REPLACEP.C.B.
OK
REMOVECOVER& CHECK
CONNECTIONSAND CONTINUITY OF
ELEMENTS WITH MULTI-METER
12.
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GUARANTEE
CARVERPRODUCTSAREFULLYGUARANTEEDFORA PERIOD
OF2 YEARSFROMDATEOFFIRSTPURCHASEAGAINST
FAULTYWORKMANSHIPORMATERIALS.WEWILLREPAIROR
REPLACEANYSUCHFAULTYITEMS
"FREEOFCHARGE"
PROVIDEDTHEYHAVEBEENINSTALLEDANDUSEDIN
ACCORDANCEWITHOURINSTRUCTIONS.
"ACCEPTANCEOFTHISGUARANTEEDOESNOT
INANYWAYDIMINISHYOURSTATUTORYRIGHTS".
NOTE: THECUSTOMERMUSTWHEREVERPOSSIBLE,
LEAVETHEHEATERINSTALLEDINTHEVEHICLE,
ANDWHEREVERPRACTICAL,RETURNTHEHEATER
TOTHECARVERMAINDEALERFROMWHOMITWASPURCHASED
ORINSTALLED.INSPECIALCIRCUMSTANCES,HOWEVER,IT
MAYBETAKENTOANOTHERCARVERMAINDEALER.
CUSTOMERSERVICEDEPARTMENT
CARVER& CO.(ENGINEERS)LIMITED
COPPICESIDEINDUSTRIALESTATE
BROWNHILLS,WALSALL
ENGLAND,WS87ES.
TEL: [phone]FAX:[phone]
PartNo.605682Issue1.PrintedbyLITHOPRINT(Coleshill)LimitedTel:(01675)46259"
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