Webasto FCF Series User manual

FEEL COOL FAST
MARINE AIR CONDITIONER
Installation & Operation Manual
8/2018

Table of Contents
INTRODUCTION................................................................................................................................................. 5
PACKAGED COMPONENTS.............................................................................................................................. 6
OVERVIEW ......................................................................................................................................................... 6
INSTALLATION ................................................................................................................................................... 7
Unpacking and Inspection....................................................................................................................................... 7
Safety Considerations ............................................................................................................................................. 7
Placement of System............................................................................................................................................... 8
Blower Assembly................................................................................................................................................... 10
Mounting Brackets................................................................................................................................................. 10
Supply & Return Air Grilles and Transition Boxes.................................................................................................. 10
Ducting ...................................................................................................................................................................11
Seawater Pump and Plumbing (Refer to page 31 for recommended flow rates and pump sizes).........................11
Electrical Connections, Grounding and Bonding................................................................................................... 13
Digital Display Installation...................................................................................................................................... 14
Electric Box Installation.......................................................................................................................................... 14
Installation Checklist (Review Prior To Installation)............................................................................................... 15
Wiring Diagrams.................................................................................................................................................... 16
OPERATION...................................................................................................................................................... 21
Digital Display Operation....................................................................................................................................... 21
Power ON/OFF.......................................................................................................................................................... 22
Sleep Mode of the digital display............................................................................................................................... 22
FAN Control............................................................................................................................................................... 22
Temperature Setting................................................................................................................................................... 22
Mode Setting.............................................................................................................................................................. 22
Remote Control Operation – V1 ................................................................................................................................24
Remote Control Operation – V1 (continued).............................................................................................................25
Remote Control Operation – V2 ................................................................................................................................27
ERROR CODES................................................................................................................................................ 28
TROUBLESHOOTING ...................................................................................................................................... 28
MAINTENANCE ................................................................................................................................................ 30
Reversing Valves................................................................................................................................................... 30
Seawater Strainer.................................................................................................................................................. 30
Condenser Coil Cleaning (Seawater Acid Flush) .................................................................................................. 30
Return Air Filters.................................................................................................................................................... 31
Winterization.......................................................................................................................................................... 31
UNIT DIMENSIONS & TECHNICAL SPECIFICATIONS................................................................................... 31
LIMITED WARRANTY....................................................................................................................................... 33
TECHNICALASSISTANCE............................................................................................................................... 33

Introduction
Thank you for your purchase. No matter which of the following features was the reason for your purchase, we are
sure it will meet your needs and give many years of efficient and trouble free use. These air conditioners are
designed for marine applications incorporating the following features:
•Compact design
•High efficiency rotary compressors (5-24K)
•Cupronickel condenser coil
•Raised lance fin designed evaporator coil
•Polyester coated 2” (50mm) deep drain pan with four condensate drain locations
•Anti-vibration base pan
•Pre-charged and pre-wired systems for easy connections
•3-speed fan motor. This eliminates all harmonic sounds and rumbles.
•Rotatable blower assembly
The controller offers the most technologically advanced design specifically made for the unique requirements of
marine air conditioning. The controller has been designed with the following "user friendly" features:
•Non-volatile memory
•Low voltage display panel
•LED cabin temperature displayed in Fahrenheit or Celsius
•Multiple fan speed selections
•Compressor pressure fail safe protection
•Dehumidification Mode for humidity control
This manual is intended to provide the information necessary to ensure proper installation, operation, and
maintenance of a FCF air conditioner. Improper installation can result in unsatisfactory performance and/or
premature failure. Before proceeding, please read this manual in its entirety. In the interest of product improvement,
specifications and design are subject to change without prior notice.

Packaged Components
ITEM
QUANTITY
Air Conditioning unit
1
Mounting Bracket
4
Fuses (3.15 AL 250V) 2
Remote controller with batteries 1
Digital Display / Cable 1
Duct Ring / Hardware 1
Blower Insulation Foam 1
Installation / Operation Manual 1
Overview
All units are manufactured without service ports
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
transferred to the refrigerant in the evaporator coil. As the refrigerant 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 lowering its temperature. The cooled air is blown through
the ducting and out the supply air grille(s). For reverse cycle heating, the refrigerant flows in the opposite direction
through the reversing valve. Heat is transferred from the seawater in the condenser coil to the refrigerant and then
to the air blowing through the evaporator into the cabin. Seawater temperature will directly affect the air
conditioners efficiency. This air conditioner can effectively cool your boat in water temperatures up to 90°F and
heat in water temperatures as low as 40°F.

Installation
Unpacking and Inspection
When the equipment is received, all items should be carefully checked according to the packaged components list
within this manual to ensure all components have been received. Examine components for shipping damage. If the
unit is damaged, the carrier should make the proper notation on the delivery receipt acknowledging the damage.
Safety Considerations
VERY IMPORTANT: Never install your air conditioner in the bilge or engine room areas. Ensure that the selected
location is sealed from direct access to bilge and/or engine room vapors. Do not terminate condensate drain line
within 3’ (914mm) of any outlet of engine, generator exhaust system, compartment housing an engine or generator,
or in a bilge, unless the drain is connected properly to a sealed condensate or shower sump pump. Seal all cabin
penetrations around condensate hoses to eliminate harmful bilge fumes in the cabin living spaces.
Installation and servicing of this system can be hazardous due to system pressure and electrical components.
When working on this equipment, always observe precautions described in the literature, tags and labels attached
to the unit. Follow all safety precautions. Wear safety glasses and work gloves and place a fire extinguisher close
to the work area. The following is a summary of the labels on the unit:
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Special note. Make sure to read before proceeding.
Electrical shock hazard. Disconnect voltage at main panel or power source before
opening any cover. Failure to comply may result in injury or death.
This component does not meet federal requirements for ignition protection. Do not install in
spaces containing gasoline engines, tanks, LPG/CPG cylinders, regulators, valves or fuel
line fittings. Failure to comply may result in injury or death.
Notice the 115V series and the 230V series are charged with Hydro fluorocarbon (HFC)
refrigerant R410A. Effective July 1, 1992, it shall be unlawful for any person to knowingly vent
or otherwise knowingly release any class 1 (CFC) or class 2 (H CFC) substance as a
refrigerant in a manner which permits such substance to enter the atmosphere per the clean
air act of 1990. Public law 101-549 title IV section 608-c. Failure to comply may result in
severe penalties, including fines and imprisonment.
To minimize the hazard of electrical shock and personal injury, this component must be
effectively grounded. Refer to the installation guidelines for further information. Caution! High
compressor temperature is normal. Do not touch!

Placement of System
Selecting a good location for your air conditioner is the most important part of your preparation. Be sure to consider
the size of the area you are cooling, the air distribution needs, and the size of the unit you have chosen. Keeping in
mind that cool air has a tendency to fall; it is highly recommended that you locate the supply air grille as high as
possible in the cabin. The ducting should be run as straight, smooth and taut as possible minimizing the
number of 90 degree bends. See diagram below.
Size of Sealed room
Ensure the area which the air conditioner is located is not too small otherwise it will affect proper operation.
See the diagram below.

The unit should be installed as low as possible, BUT NEVER IN THE BILGE
OR ENGINE ROOM AREAS, ENSURE THAT THE SELECTED LOCATION
IS SEALED FROM DIRECT ACCESS TO BILGE AND/OR ENGINE ROOM
VAPORS. Installing the unit as low as possible (such as under a V-berth,
dinette seat or bottom of a locker) and ducting the supply
air as high as possible, creates an ideal airflow condition. This type of
installation will prevent short or premature cycling.
The unit should be positioned on a firm, level, horizontal surface and the
condensate drain line should run downward from the unit to a suitable drain
location. Plan all Connections, which must be made including ducting,
condensate drain, and seawater in and out, electrical power connections,
location of control, and seawater pump placement, to assure easy access for
routing and servicing.
Tools required:
•Screws drivers
•Pliers
•Pipe wrench
•Wire cutters/crimpers
•Drill & bit set
•Jigsaw
•Duct tape
•Electrical tape
•Thread sealer
•Bedding compound to seal thru
hull fittings
•Hardware to secure unit, pump,
strainer, grilles & electrical box

Condensate Drains
The condensate drain pan is 2” (50mm) deep with four drain locations. During conditions of high humidity,
condensate may be produced at a rate of approximately 1/2 gallon per hour (1.9 liters per hour). 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 water into the pan and checking
for good flow.
For installation of the condensate drain:
●Attach a 3/4” I.D. or 5/8” I.D. reinforced hose to the hose barb and secure with stainless steel hose
clamps.
●Install the condensate drain hose downhill from the unit and aft to a sump.
●Four drain fittings may be used and the hoses joined together with a tee fitting provided there is a
minimum 2" drop from the bottom of the base pan to the tee connection.
Do not terminate condensate drain line within three 3’ (914mm) of any outlet of engine, generator
exhaust systems, compartment housing an engine or generator, nor in a bilge, unless the drain is
connected properly to a sealed condensate or shower sump pump. Seal all condensate hose
penetrations.
Blower Assembly
You can achieve multi-directional supply air discharge from a single unit by rotating the blower to the desired
position in 45° increments. It is ideal for tight installations as 360° of rotation is available with which to position the
blower. Its advanced design allows the blower to be easily removed for rotating or servicing by removing 4 screws.
Rotate the blower to allow the most direct flow of air to the supply air grille.
After the blower has been properly positioned, make sure to install the supplied
strip of insulation foam around the collar to prevent condensation build up.
Mounting Brackets
The air conditioning unit is supplied with a base pan that also serves as a
condensate pan. Mounting clip brackets (4) are provided to secure the base pan to
a flat, horizontal surface. Hardware for the mounting clips must be provided by the
installer as needed.
Supply & Return Air Grilles and Transition Boxes
Install the supply air grille as high as possible in a location that will provide uniform air distribution throughout the
cabin. Grille louvers should be directed properly for best air flow. The return air grille should be installed as low and
close to the air conditioner as possible to insure direct uninterrupted airflow to the evaporator. The return air grille
should have a minimum four inches (4') of clearance in front of it, free from any furniture or other obstructions. In no
instance should a supply air discharge be directed towards a return air grille, as this will cause the system to short
cycle. Allow for adequate clearance behind the supply air grille(s) for the transition box and ducting connection.
See the Maintenance section of this manual for return air 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 (two tight 90° bends can reduce airflow by 25%). If a transition box is used, the total area of supply
air ducts going out of the box should at least equal the area of the supply duct feeding the box. To calculate the
square inch area of a round duct, multiply the radius by itself (r2) and multiply that number by 3.1416(π). 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. Use finish washers with the screws
if necessary. 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 grille.
All ducting should:
●Be insulated and appropriately sized for each application.
●Run as smoothly and taut as possible.
●Have as few bends or loops as possible.
●Be securely fastened to prevent sagging or chafing during vessel operation.
●Have all excess ducting lengths trimmed off.
●Not be flattened or kinked.
●Be properly protected against potential damage when routed through open areas or bulkheads.
Seawater Pump and Plumbing (Refer to page 31 for recommended flow rates and pump sizes)
Several guidelines should be followed during the installation of the seawater system. If the circulation pump is
centrifugal and not self-priming, it must be mounted so that it is always at least 1’ (305mm) below the water line
regardless of which tack the vessel is on. Pump must always be mounted per manufacturers recommendations,
however, the discharge must always be above the inlet. Pump head should be rotated toward the direction of water
flow. Install the seawater speed scoop intake as far below the water line and as close to the keel as
possible in any application, but especially on a sailboat, to keep the intake in the water when the boat
heels over so that air does not get into the system. The speed scoop intake must face forward and not be
shared with any other pump. A seawater strainer is mandatory between the shut off valve (seacock) and the pump
to protect the pump from any foreign matter. Failure to install a seawater strainer will void the pump warranty. The
seawater system should be installed with an upward incline from the speed scoop & seacock, through the strainer,
to the inlet of the pump, next to the inlet of the air conditioning unit's condenser coil. The discharge from the air
conditioning unit should run to the seawater outlet thru-hull fitting that should be located where it can be visually
inspected for water flow as close to the waterline to reduce noise. All hose connections should be secured using
double/reversed stainless steel hose clamps. Use thread sealer on all threaded connections.

Summary of the seawater system installation:
1. Install the speed scoop thru-hull inlet as close to the keel and as far below the water line as possible,
facing forward. Bed the scoop with a marine sealant designed for underwater use.
2. Install a bronze, full flow seacock on the speed scoop thru-hull inlet.
3. Install a seawater strainer below the level of the pump with access to filter.
4. Mount the pump above the strainer and at least 1’ (305mm) below the waterline.
5. Connect the seacock and strainer with an uphill run of 3/4" reinforced marine grade hose.
6. Connect the discharge from the pump uphill to the bottom inlet of the air conditioning unit's condenser coil
with 3/4" or 5/8” hose as required. Connect the discharge from the condenser coil to the overboard
discharge thru-hull fitting with 3/4" or 5/8” hose as required.
7. Avoid loops, high spots or the use of 90° elbows with seawater hose (each 90° elbow is equivalent to 2.5'
(762mm) of hose and a 90° elbow on the pump outlet is equivalent to 20' (6.1m) of hose).
8. Double clamp all hose connections with stainless steel clamps, reversing the clamps.
9. Use thread sealer on all threaded connections.
10. Connect all metallic parts in contact with seawater to the vessel's bonding system including the
speed scoop inlet, strainer, pump and the air conditioner. Failure to do so will void warranty.

Electrical Connections, Grounding and Bonding
Turn off air conditioner power supply circuit breaker before opening electric box.
All air conditioner units have a terminal strip mounted inside the electric box. The terminal strip is labeled for proper
connections of the electrical supply, ground wires and pump circuits. A wiring diagram is provided in the electrical
box and later in this manual. The wiring diagram in the electrical box supersedes any found in this manual and
ABYC standards. The correct size circuit breaker should be used to protect the system as specified within the
technical specifications section. Aminimum of 12 AWG boat cable should be used to supply power to the air
conditioning unit and the seawater pump. All connections should be made with ring or captive fork terminals.
Each air conditioner installed requires its own dedicated circuit breaker. If there is only one air conditioner installed,
the seawater pump does not require a circuit breaker; the wiring from the seawater pump is connected to the
terminal strip in the electric box. If two or more air conditioners use the same seawater pump, the pump wires will
be connected to a pump relay, Please refer to the wiring diagram. Electrical connections in the bilge and/or below
the waterline should use heat shrink type butt splices. Field wiring must comply with ABYC electrical codes. Power
to the unit must be within the operating voltage range indicated on the data plate. Properly sized marine grade
circuit breakers must be installed for circuit protection. All units must be effectively grounded to minimize the
hazard of electrical shock and personal injury. Make sure to connect the green grounding wire to the GRND stud
within the electrical box per ABYC standard E-8, or equivalent.
1. 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, or equivalent.
•When servicing or replacing existing equipment that contains a chassis-mounted ground stud, the
installer must check the vessel's wiring for the existence of the connection required in item 1
above.
The air conditioner unit must be connected to the ship's bonding system to prevent
corrosion due to stray electrical current or voltage. 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 vessels bonding system. This will help eliminate
any possibility of corrosion due to stray current or voltage.

Digital Display Installation
DO NOT turn the unit off and immediately turn it back on. Wait at least 30 seconds for
refrigerant pressures to stabilize.
Before mounting the digital display, consider the location. The digital display
should never be mounted in direct sunlight or exposed to excessive
moisture.
NOTE: The display cable must be grounded at the electrical box.
Electric Box Installation
Mount the electric box using four M5 screws.
Mount the electric box in a cool dry location leaving plenty of room for access.

Installation Checklist (Review Prior To Installation)
Seawater cooling system:
Speed scoop located as far below the water line and as close to the keel as possible
Shut off valve (sea cock) and speed scoop properly sealed and tightened
Seawater pump is at least 1’ (305mm) below water line and securely mounted
Strainer mounted below pump with access to filter
Double/reversed stainless steel hose clamps on all hose connections
Thread sealer on all threaded connections
Hose runs uphill from speed scoop and sea cock to strainer, pump and air conditioning unit, then downhill
(if possible) from air conditioner unit to overboard discharge
Water flowing freely from overboard discharge while pump is running
Pump relay panel, if used, must have its own circuit breaker sized for the pump (20 amp max)
All metal fittings should be bonded
Mounting
Not in engine room or bilge area, must be sealed away from exhaust or fumes
Proper spacing allowed around unit
Attached to solid level platform with hold down brackets provided
Condensate drain routed aft and down hill to a sealed sump (not bilge)
All penetrations to bilge area sealed
Blower rotated toward supply air grille
Electrical
All butt connections on pumps are tightly crimped and covered with heat shrink
AC power source installed and grounded/bonded in accordance with ABYC standards
Control wires connected to terminal strip with captive fork or ring terminals
Circuit breakers sized according to technical specifications section.
Pump Relay Panel (if used) has a dedicated circuit breaker sized for the pump but not to exceed 20 amps
maximum.
Grilles and Ducting
Supply air grille mounted as high as possible
Return air grille mounted as low and as close to the air conditioner as possible
Return air grille mounted away from bilge vapors or exhaust fumes
Ducting is pulled taut, straight, smooth and properly connected with no excess
Quick Start Operations Checklist
Ensure seawater intake ball valve (sea cock) is open.
Turn on the air conditioners circuit breaker. If the seawater pump has its own circuit breaker, make sure to
turn it on.
Turn the system on. Set the desired cabin temperature (set point).
Check for a steady solid stream of water from the overboard discharge.
Verify that there is steady airflow out of the supply air grille
If the unit does not appear to be operating properly, refer to troubleshooting guidelines. Note: Do not turn
the unit off and immediately back on. Allow at least 30 seconds for refrigerant pressure equalization.

Wiring Diagrams
Power 115V ~ 60Hz
115V ~ 60Hz Line In
L
115V ~ 60Hz Neutral
N
Cooling Pump Line In
1
Cooling Pump Neutral
2
Power 208V / 230V ~ 60Hz
208V / 230V ~
60Hz Line In
L
208V / 230V ~ 60Hz Neutral
N
Cooling Pump Line In
1
Cooling Pump Neutral
2

Fuse = 3.15 AL 250V

Fuse = 3.15 AL 250V
WIRING SCHEMATIC FCF 12,000 (115V & 230V) FCF 16,000 (115V & 230V)

Fuse = 3.15 AL 250V

Fuse = 3.15 AL 250V

Operation
Digital Display Operation
•Don't install the digital display in a location where it can get wet.
•Don’t knock, throw or open the digital display.
1. Remote receiver 6. Fan control button
2. Display 7. Temp. Setting button (Increasing)
3. Fan speed display (HIGH-MID-LOW and AUTO speed) 8. Temp. Setting button (Decreasing)
4. Display of mode operation (COOL-DEHUMIDIFY-HEAT and AUTO) 9. ON/OFF button
5. Mode button
The digital display has a built in memory function that’s will retain the last modes settings. Settings include
operation mode, set temperature, operation fan speed, and the temperature display format.
In cooling / heating / dehumidify mode, the pump starts before the compressor starts, stops
after a 5 second delay of the compressor.

Power ON/OFF
•Press ON/OFF button to turn the unit display on. Press the ON/OFF button a second time to select
mode and start operation.
•While the display is active press the ON/OFF button once to turn the unit OFF. Press the ON/OFF
button a second time if the display has already entered sleep mode to turn the unit OFF.
Sleep Mode of the digital display
The ambient temperature display will automatically enter a sleep status within 5 minutes of inactivity. Press any
button on the display or the remote controller to wake the display.
Note: Normal unit operation will continue while in sleep mode, it’s only the digital display that turns off.
FAN Control
•Press the FAN button, the fan speed will change in the following order:
→ HIGH →MID → LOW → AUTO →
•In “DEHUMIDIFY” mode, the fan will work at low speed automatically
Temperature Setting
•Press temperature setting key
▲To increase in 1o increments
▼To decrease in 1o increments
•The setting range of temperature in each mode:
COOL 61°F 86°F or 16°C 30°C
DEHUMIDIFY 61°F 86°F or 16°C 30°C
HEAT 61°F 86°F or 16°C 30°C
FAN In this mode, temperature cannot be changed.
AUTO In this mode, temperature cannot be changed.
Mode Setting
•Press this key to change the operation mode in order of
→ COOL → DEHUMIDIFY → FAN → HEAT → AUTO →
COOL Mode Operation
•In “COOL” mode, the LED next to the icon will illuminate when mode is selected on the digital
display.
●If room temperature is higher than set temperature, the unit runs in COOL mode.
●If set temperature is higher than room temperature then only the fan will run.