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,

<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.

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.

overtemperature,manuallyresetable

trip

sensing

elementtemperature.

2.6TheFanmasterisapprovedtoBS3456pt201(1990),EN60335pt1 (1988)

andmanufacturedtoBS5750pt2 (1987).Itissuitableforinstallationin

caravans

complying

with

BS4626(1970).

2.7TheratinganddataplateisontopoftheFanmasterbody.

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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.

Fanmaster

KitandTools

required.

4.1Fanmaster

1offFanmaster

1offRemoteController

1offTwinwireloom

1offThreewireloom

offNo.6x16mmSelftappingscrews

1offConnectionlid

offConnectionlidscrewsNo.4x9.5mm

4offCableclampscrewsNo.4x16mm

offScrewcoversforcontroller

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

corewire,

PVC

sheathed,Brown,Blue,Green/Yellow

CSA

1.5mm2600vgradetoBS6004

forconnectingFanmastertomainssupply.

Doublepoleswitched

outlet

with

contactseparationofatleast3mmoneachpolefusedat10A

or13Aplug(SeeSection11).

4.4

NOTE

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.

No.

2 Flatbladescrewdriver

Two7mmA/Fspanners.

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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

thenotesinSection9.FailuretodosowillcausetheFanmaster'sthermalM

protectiontooperateprematurely.

remove -

Fanmaster

conversion

Fanmaster

•2)

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6.REMOVALOFTEB,TENORTNTYPEFANS,PRIOR

FANMASTER

INSTALLATION

6.1

Releasethetwolengths

warm

air

ductingfrom

thefan

unit

removal

thesecuringselftapping

screws.

6.2All

wiringassociatedwith

the12v

"TBM"

and"TEB"typesoffansMUST

beisolated

removing

the

fuses,

thendisconnected.Remove

the

existingwallswitchandsupplycable

the

motor.

the

Line

and

Neutralcables

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

isolatedfrom

any

220/240vsupply.

The

existingwiring

then

removed,

back

toa

suitableterminationpoint.

The

wiringMUST

beof

sufficiently

highrating(minimum

of1.5mm

squareconductors)

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

disconnected

and

removed

completely,asthenewreplacement

Fanmasterrequirescable

ofa

superiorspecification.Failure

todo

sowillcause

hazard.

6.5

Nowproceedfromsection

"Fitting

Fanmaster

tothe

Installation

Box".

6.6

Whenthis

has

beencompleted,connect

the

existing

two

ends

ducting

tothe

appropriateFanmasteroutletconnections

detailed

section

10.

6.7IMPORTANT:

Fanmaster

has

beendesigned

and

approved

operatewith

BOTHwarm

air

outletsfullyutilised.Particularattentionmust

paid

tothe

notes

Section

(Fig.

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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

(Fig.

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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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

thin

itmayneed

reinforcementtotakethescrews.

The

useof

masking

tape

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

supply.

The

whiteleadgoestothenegative

and

thegreen

via

amp

fuse

tothe

positive.

Fig.7.

8.6Screwthecontrollerinpositionusing

self

tappingscrewsorthemachine

screws

theoptionalrearprotection

boxis

used.

Insert

thescrew

covers.

8.7Cliptheloomstothecaravan

structureleavingslacktoremove

thecontroller.

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Ducting

and

Duct

Layouts

9.1

The

Fanmaster

isa

major

componentoftheCarverBlown

Air

CentralHeatingSystem.

9.2

Thelayoutandinstallationofthe

ductsandoutlets

identical

that

requiredforthe

Carver

TEB

12vFan.

9.3

Each

the

twin

outletson

the

Fanmaster

"UR"

flexible

ductingtogive

warmairsupply

tobothends

ofthe

caravan.

Each

ductruncansupply2 or3

outlets.

Itis

recommended

that

atleast

one

outlet

isofthe

permanentlyopentype

preventovertemperaturesafety

trippingoftheelectricelements.

9.4

DetailedDuctinstallation

information

availablefrom

Carver

butthe

threelayouts

shownaretypical.Fig.

SEAT

WASH

J»

ROOM

V•••4

V ®

SEAT

berth,

end

kitchen,

heater

opposite

door,2

outlets

main

seating

area.

outlet

washroom.

outlet

doorway

and

kitchen

area

(duct

passes

under

the

floor

encasedinDR

Duct)

berth,

centre

krichen,

heater

opposite

door;2

outlets

each

endto

seating

areas,

outlet

washroom,

outlet

doorway

Duct

passes

under

the

washroom

(it

shower

tray

fitted),

encased

D.R.

Dud

BODYLENGTH

16'6'(5.1m)-

berth,

centre

kitchen,

heater

ondoor

aide;

outlets

•achandlo

seating

araas.l

outet

washroom.

outlet

doorway,

ducts

passing

under

doorway

(and

washroom,

shower

tray

fitted)

encasedinD.R

Duct

Blanl

Plug

(VD)

Air

Outtoi

(Fig.

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10.

Connection

Ducting

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

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

Fanmaster

Functions

12.1Reconnectthebattery,gasandmainselectricalsuppliestothecaravan.

12.2TestthefunctionsmodebymodereferingtoSection3 oftheFanmasterUser's

Instructions.

Servicing

13.1Noregular servicingoftheFanmasterisrequired butitisrecommended

that

the

earthcontinuityandinsulationresistanceoftheentirecaravanmainsinstallationis

checked

annually.

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