CABIN MATE

SELF CONTAINED MARINE AIR CONDITIONER

INSTALLATION, OPERATION & MAINTENANCE

TABLE OF CONTENTS

Preface

INSTALLATION

Unpacking and Inspection 1

Safety Considerations 1

Placement of System (Tools Required) 2

Spacing Allowances 3

Cabin Mate Dimensions 3

How It Works 3

Mounting Brackets 4

Condensate Drains 4

Supply and Return Air Grilles 5

Ducting 5

Sea Water Pump and Plumbing 6

Electrical 7

Notice and ABYC Standards 7

Wiring Diagrams 8

Passport II Display Panel Installation 9

Installation Checklist (review prior to installation) 9

Manual Control Panels (MCP) Installation 10

OPERATION

MCP Operation - 2 Knob (2KB) & 3 Knob (3KB) 10

Passport II Control 11

Display Panel Features 11, 12

Modes of Operation 12, 13

Programming the Passport II 13

Programmable Parameters 14, 15, 16

Troubleshooting Guidelines 17, 18, 19

MAINTENANCE

Seawater System, Return Air Filters, Winterization 19

Manufacturers Limited Warranty Agreement 20

 

PREFACE

Congratulations on the purchase of your Marine Air Systems' CABIN MATE. No matter which of the following features was the reason for your purchase of this air conditioner, we are sure it will meet your needs and will give you many years of efficient and trouble free use. The CABIN MATE units are self-contained direct expansion air conditioners designed for marine applications incorporating the following features:

High efficiency rotary compressor

Cupro-nickel condenser coil

Raised lance fin designed evaporator coil

Polyurathane coated 2" deep V-shaped drain pan with two condensate drain locations

Insulated anti-vibration base pan

Blower can be ordered with either top or side discharge

Pre-charged and pre-wired systems for easy connection

Charge Guard protection to insure integrity during handling and installation

This manual is intended to provide the information necessary to ensure proper installation, operation, and maintenance of the unit. Improper installation or misunderstood operating procedures can result in unsatisfactory performance and/or premature failure of this unit, so before proceeding please read this manual completely.

The CABIN MATE units are covered under the existing Marine Air Systems warranty policy contained in this manual. In the interest of product improvement, Marine Air Systems' specifications and design are subject to change without prior notice.

CLEAN AIR ACT AMENDMENTS OF 1990 [TITLE VI - SECTION 608(C-1)]

"Effective July 1, 1992, it shall be unlawful for any person, in the course of maintaining, servicing, repairing, or disposing of an appliance or industrial process refrigeration, to knowingly vent or otherwise knowingly release or dispose of any Class I* or Class II** substance used as a refrigerant in such appliance (or industrial process refrigeration) in a manner which permits such substance to enter the environment. De minimis releases associated with good faith attempts to recapture and recycle or safely dispose of any such substances shall not be subject to the prohibition set forth in the proceeding sentence." *Class I substances include CFC-12

**Class II substances include HCFC-22

MARINE AIR SYSTEMS, INC.

Marine Air Systems, Inc. (MAS) is a manufacturer of air conditioning and refrigeration equipment for the marine industry. MAS is committed to innovative technology, competitively priced products and market leadership. The MAS team has many years of experience in the design, manufacture, application and support of marine air conditioning and refrigeration. Our practical experience and design capability allows our application engineers and sales representatives to offer optimum solutions for your environmental control requirements. Marine Air Systems, Inc. is A Member of the Taylor Made GroupTM.

INSTALLATION

UNPACKING AND INSPECTION

When the equipment is received, all items should be carefully checked against the packing list to ensure all cartons have been received. Move units in the normal "up" orientation as indicated by the arrows on each carton. Examine cartons for shipping damage, removing the units from the cartons if necessary. If the unit is damaged, the carrier should make the proper notation on the delivery receipt acknowledging the damage.

CAUTION: When unpacking and installing the mechanical control, care must be taken not to kink or break the copper cap tube when uncoiling the sensing bulb. The cap tube is hollow and kinking or sharp bends will inhibit system operation.

SAFETY CONSIDERATIONS

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 codes. 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:

! DANGER

ELECTRICAL SHOCK HAZARD. DISCONNECT VOLTAGE AT MAIN PANEL OR POWER SOURCE BEFORE OPENING ANY COVER. FAILURE TO COMPLY MAY RESULT IN INJURY OR DEATH.

! WARNING

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

THIS COMPONENT IS CHARGED WITH HYDROCHLOROFLUOROCARBON (HCFC) REFRIGERANT R22. 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 (HCFC) 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.

! WARNING

TO MINIMIZE THE HAZARD OF ELECTRICAL SHOCK AND PERSONAL INJURY, THIS COMPONENT MUST BE EFFECTIVELY GROUNDED. REFER TO THE INSTALLATION GUIDELINES FOR FURTHER INFORMATION.

PLACEMENT OF SYSTEM

Selecting a good location for your air conditioner is the most important part of your preparations. 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. See diagram below.


 

The CABIN MATE unit should be installed as low as possible, BUT NEVER IN THE BILGE OR ENGINE ROOM AREAS. INSURE 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 air flow 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 prior to starting installation, including ducting, condensate drain, cooling water in and out, electrical power connections, location of control, and sea water pump placement, to assure easy access for routing and servicing.

SPACING ALLOWANCES

The following space allowances should be considered when mounting the unit.

1) Allow a minimum of 6" around the perimeter of the unit in the area of the sea water and condensate drain piping for connecting and servicing hoses..

2) Allow a minimum of 3" of air space in front of the evaporator coil for the return air intake if it is adjacent to a bulkhead.

3) Allow a minimum of 3" of air space for the electric blower motor ventilation.

4) For flexible ducting connection, allow 2" for the duct ring, 1" for the duct bend, and add the diameter of the ducting to get the total distance as measured from the blower outlet and the supply air grille transition box.

The above dimensions are suggested minimums. Enough space should be allocated for installation and serviceability.

CABIN MATE DIMENSIONS (in/cm)


A (width)

B (depth)

C (height)

CM*7K

13.25/33.66

20.25/51.44

11.75/29.84

CM*9K

15.25/38.76

21.00/53.34

13.50/34.29

CM*12K

15.25/38.76

21.00/53.34

14.00/35.56

CM*16K

15.25/38.76

23.25/59.06

14.25/36.20

* P=Passport Control M=Mechanical Control

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 sea water pump circulates sea water 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 sea water and discharged overboard. The liquid refrigerant is then passed through the EVAPORATOR COIL and the cycle repeats. Removing heat from the cabin air lowers its temperature. The cooled air is blown through the ducting and out the supply air grille(s). If your a/c unit has reverse cycle heat, the refrigerant flows in the opposite direction through the reversing valve while in the heat mode. Heat is transferred from the sea water in the condenser coil to the refrigerant and then to the air blowing through the evaporator into the cabin.

MOUNTING BRACKETS


The CABIN MATE unit is supplied with a base pan which also serves as a condensate pan. Mounting clip brackets (4) are provided to secure the base pan onto a flat, horizontal surface.

CONDENSATE DRAINS


The CABIN MATE condensate drain pan is 2" high with two drain locations. During conditions of high humidity, condensate may be produced at a rate of approximately gallon per hour. With this in mind, 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 a quart of water into the pan and checking for good flow.

For installation of the condensate drain:

1. Remove the aft facing watertight plug from the base pan of the a/c unit.2. Slip the solid washer and the liquid-seal washer onto the PVC fitting in that order. 3. Connect the fitting through the exposed hole in the base pan with the locking nut. 4. Securely tighten with two (2) wrenches to provide a proper seal.

5. Attach a " I.D. reinforced hose to the hose barb and secure with stainless steel hose clamp.

6. Install the condensate drain hose downhill from the unit and aft to a sump.

7. Two drain fittings may be used and the hoses teed together provided there is a minimum 2" drop form the bottom of the base pan to the tee connection.

Note: Do not terminate condensate drain line within four (4) feet of any outlet of engine exhaust systems, nor in a compartment housing an engine, unless the drain is connected properly to a sealed condensate or shower sump pump.

SUPPLY & RETURN AIR GRILLES

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 upward. The return air grille should be installed as low and close to the a/c unit as possible to insure direct uninterrupted airflow to the evaporator. The return air grille should have a minimum four inches of clearance in front of it, free of any furniture or other obstructions. In no instance should a supply air discharge be directed toward a return air grille as this will cause the system to short cycle. Allow for adequate clearance behind the supply air grille for the transition box and ducting connection. The following table shows minimum grille sizes. See MAINTENANCE section of this manual for return air filter cleaning instructions.

DUCTING

Good air flow 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 degree bends can reduce airflow by 25%). The following table shows minimum duct diameters and their corresponding return and supply air grille areas in square inches. If a transition box is used, the total area of supply air ducts going out of the box should equal the area of the supply duct feeding the box. To calculate the square inch area of a round duct: divide the diameter by two to get the radius (r), multiply the radius by itself (r), and multiply that number by 3.1416 ().
MODEL # *7K *9K *12K *16K
DUCT DIA 5" dia 5" dia 6" dia 7" dia
DUCT AREA 19.6 sq in 19.6 sq in 28.3 sq in 38.5 sq in
R/A GRILLE 88 sq in 98 sq in 140 sq in 168 sq in
S/A GRILLE 40 sq in 50 sq in 70 sq in 84 sq in

The following is a summary of proper ducting connections:

 

  1. Pull back the fiberglass insulation exposing the inner mylar duct hose.

 

  1. Slide the mylar duct hose around the mount ring until it bottoms out.

 

  1. 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. Do not use band clamps, the mount rings are tapered and the hose will slide off.

 

  1. Wrap duct tape around the ducting and ring joint to prevent any air leaks.

 

  1. Pull the insulation back up over the mylar to the ring and secure with tape.

All ducting should:

 

  • Be 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 during boat operation.

 

  • Have all excess ducting lengths trimmed off.

 

  • Not be flattened or kinked.

 

  • Insulated when located in high heat load areas (hull side, mechanical compartments, etc.).

SEA WATER PUMP AND PLUMBING

Sea water temperature will directly affect the a/c units efficiency. This a/c unit can effectively cool your boat in water temperatures up to 908 F and heat (if reverse cycle option is installed) in water as low as 408 F. Several guidelines should be followed during the installation of the sea water system. Since the circulation pump is centrifugal and not self-priming, it must be mounted so that it is always at least one foot below the water line regardless of which tack the vessel is on. The pump may be mounted horizontally or vertically, however the discharge must always be above the inlet. The pump head should be rotated toward the direction of water flow. Install the sea water speed scoop intake as far below the water line and as close to the keel as possible in any application, but especially on a sail boat, to keep the intake in the water so that air does not get into the system when the boat heels over. The speed scoop intake must face forward and not be shared with any other pump. A sea cock (shut off valve) must be installed directly on the speed scoop outlet. A sea water strainer is mandatory between the sea cock and pump. Failure to install a sea water strainer will void the pump warranty. The sea water system should be installed with an upward incline from the speed scoop & sea cock, through the strainer, to the inlet of the pump and then up to the inlet of the a/c units condenser coil. The discharge from the a/c unit should then run to the sea water outlet through hull fitting which should be located where it can be visually checked for water flow, and as close as practicable to the waterline to reduce noise. Use only reinforced marine grade hose. All hose connections shall use double/reversed stainless steel hose clamps.

The following is a summary of the sea water system installation:

  1. Install the speed scoop thru-hull inlet as close to the keel and as far below the water line as
  2. possible, facing forward. Bed the scoop with a marine sealant designed for underwater use.

  3. Install a bronze, full flow sea cock on the speed scoop thru-hull inlet.
  4. Install a sea water strainer below the level of the pump with access to filter.
  5. Mount the pump at least one foot below the waterline and above the strainer.
  6. Connect the sea cock, strainer and pump with an uphill run of e" reinforced marine grade hose.
  7. Connect the discharge from the pump uphill to the bottom inlet of the a/c units condenser coil.
  8. Avoid loops, vertical bends (high spots) or the use of 908 elbows with sea water hose.
  9. Double clamp all hose connections with stainless steel clamps, reversing the clamps.
  10. Use teflon tape on all threaded connections.
  11. Connect all metallic parts in contact with sea water to the vessels bonding system including

the speed scoop inlet, strainer, pump and the air conditioner.

Several guidelines should be followed during the installation of the sea water system. Since the circulation pump is centrifugal and not self-priming, it must be mounted so that it is always at least one foot below the water line regardless of which tack the vessel is on. See Marine Air Systems' sea water pumps literature sheet to determine the proper pump size. INSTALL THE SEA WATER SPEED SCOOP INTAKE AS FAR BELOW THE WATER LINE AND AS CLOSE TO THE KEEL AS POSSIBLE IN ANY APPLICATION, BUT ESPECIALLY ON A SAIL BOAT, 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 not be shared with any other pump. All hose connections, except condensate drains, shall be secured by means of double/reversed stainless steel hose clamps. A sea water strainer is mandatory between the shut off valve (sea cock) and the pump to protect the pump from foreign matter such as seaweed. Failure to install a sea water strainer will void the pump warranty. The seawater system should be installed with an upward incline from the sea cock, through the strainer, to the inlet of the pump and then to the inlet of the condenser. The discharge from the condenser should then run downhill to the through hull. Use teflon tape on all threaded connections.

The following is a summary of the sea water 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.

2. Bed the scoop with a marine type sealant designed for underwater applications. 3. Install a bronze, full flow sea cock on the speed scoop thru-hull inlet.

4. Install a sea water strainer below the level of the pump.

5. Connect the sea cock and strainer with an uphill run of " hose.

6. Mount the pump above the strainer and at least one foot below the waterline.

7. Double clamp all hose connections with stainless steel clamps, reversing the clamps. 8. Connect the discharge from the pump to the bottom inlet of the condenser tube with " hose. Connect the discharge from the condenser tube to the overboard discharge thru-hull fitting with " hose. Avoid loops, vertical bends and the use of 90 elbows. See diagram below.

9. Connect all metallic parts in contact with sea water to the vessel's bonding system including the speed scoop inlet, strainer, pump and the air conditioner.

ELECTRICAL

All CABIN MATE units with the MCP 2 and 3 knob controls and with the original PASSPORT circuit board have five position terminal strips mounted on top of the electrical boxes. CABIN MATE units with the PASSPORT II have the terminal strip on the circuit board and connections are made by accessing the electrical box. The terminal strips are labeled for proper connections of the electrical supply, ground wires and pump circuits. Wiring diagrams are provided in the electrical boxes and in this manual. The correct size circuit breaker should be used to protect the system as specified on the a/c unit's data plate label A minimum of 12 AWG boat cable should be used to supply power to the CABIN MATE and the pump. All connections shall be made with ring terminals. Turn off a/c power supply circuit breaker before opening electrical box or removing cover from terminal strip.

Each a/c unit installed requires its own dedicated circuit breaker. If there is only one a/c unit installed, the sea water pump does not require a circuit breaker, the wiring from the sea water pump is connected to the terminal strip on the unit. If two or more a/c units use the same sea water pump, the pump wires will be connected to a pump relay panel (PRP) which in turn has its own dedicated circuit breaker. Please see the wiring diagram furnished with the PRP. Connections in the bilge below the waterline should use heat shrink type butt splices.

NOTICE:

Field wiring must comply with ABYC (American Boat and Yacht Council) electrical standards. Power to the unit must be within the operating voltage range indicated on the data plate. Properly sized fuses and circuit breakers must be installed for branch circuit protection. See equipment rating plate for maximum size. All CABIN MATE a/c units must be effectively grounded to minimize the hazard of electric shock and personal injury. The following standards apply:

1. AC (alternating current) grounding (green) wire must be provided with the AC power conductors and connected to the ground terminal (marked "GRND") at the AC power input terminal block of the unit(s), per ABYC standard E-8.

2. 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.

3 When servicing or replacing existing equipment containing a chassis-mounted "ground" stud, the service person or installer must check the vessel's wiring for the existence of the connection required in item 2 above.

ABYC standards are available from:

American Boat and Yacht Council

3069 Solomon's Island Road

Edgewater, MD 21036

Telephone: (410) 956-1050

CABIN MATE WIRING DIAGRAMS

PASSPORT II DISPLAY PANEL INSTALLATION

Before mounting the Passport II digital display panel touch pad, consider the location. The air sensor built into the display panel will provide excellent room air temperature sensing given a proper installation. The display panel should be mounted on an inside wall, slightly higher than mid-height of the cabin, in a location with freely circulating air where it can best sense average temperature. The cut out size for the display panel is 3" wide by 2" high. Do not mount the display in direct sunlight, near any heat producing appliances or in a bulkhead where temperatures radiating from behind the panel may affect performance. Do not mount the display in the supply air stream. Do not mount the display above or below a supply or return air grille. Do not mount the display behind a door, in a corner, under a stairwell or any place where there is no freely circulating air. Mount the display within display cable length (custom lengths available) of the air conditioner. Plug the cable into the circuit board in the electrical box and into the back of the display panel. Secure the display panel to a bulkhead with the adhesive strips provided. Clean the mounting surface with isopropyl alcohol only prior to placement (test alcohol on hidden portion of surface first). If the adhesive strips cannot be used, use #6 truss head screws to mount the display. The panel has predrilled holes in each corner that can be accessed by peeling back the adhesive strips. Carefully & slowly drill 5/32" holes through the front of the lexan cover lining up with the predrilled holes in back. Do not use a screw gun and do not over-tighten screws when mounting panel. Over-tightening screws will damage the lexan cover. If a proper location for room temperature sensing cannot be found for the display, an optional remote air sensor may be used. Mount the remote air sensor in the return air stream behind the return air grille/opening and plug its cable into the appropriately marked socket on the circuit board. NOTE: Read programmable parameter "U 8" before mounting panel or sensor.

INSTALLATION CHECKLIST (review prior to installation)

Sea Water cooling system:

Speed scoop located near keel and as far below the water line as possible

Shut off valve and speed scoop properly sealed and tight

Sea water pump at least one foot below water line and securely mounted

Strainer mounted below pump with access to filter

Double/reversed stainless steel hose clamps on all hose connections

Hose runs uphill from speed scoop and sea cock to strainer, pump and a/c unit, then downhill from a/c unit to overboard discharge

Water flowing freely from overboard discharge while pump is running

Mounting

Proper spacing allowed around unit

Attached to solid level platform with four hold down clips provided

Condensate drain routed aft and down hill

Blower rotated toward supply air grille

Electrical

All butt connections on pump wire tightly crimped and heat shrunk

AC power source installed and grounded/bonded in accordance with ABYC standards

Control wires connected to terminal strip with ring terminals

Circuit breakers sized according to specifications on the data plate label

Passport display cable is connected at both ends.

Grilles and Ducting

Supply air grille mounted as high as possible

Return air grille mounted as low and as close to the a/c unit as possible

Return air grille mounted away from bilge vapors

Ducting is pulled taut, straight and properly connected

MANUAL CONTROL PANELS (MCP) INSTALLATION

The MCP should be located within cap tube length of the CABIN MATE unit. The cut out size for the 2 knob MCP is 2.5" wide by 4.5" tall. The 3 knob MCP is configured either vertically (shown) or horizontally. The cut out size is 2.5" by 7.0", see MCP for orientation. Once the cut out is made, carefully uncoil the copper cap tube with return air sensor (copper bulb) and route the control wires and cap tube through the hole and back to the unit using caution not to kink the cap tube. Mount the return air sensor into the clips provided on the evaporator coil. If the return air sensor cannot be mounted on the evaporator coil, mount it behind the return air grille. The sensor must be mounted in the return air stream. Make electrical connections according to the wiring diagrams.

OPERATION

MCP OPERATION 2 KNOB (2KB) & 3 KNOB (3KB)

1) Ensure sea water intake ball valve (sea cock) is open.

2) Turn SYSTEM SWITCH control knob to OFF.

3) Turn on AC circuit breaker. If the sea water pump has its own circuit breaker, turn that on too.

4) Turn the SYSTEM SWITCH control knob to FAN (2KB) or START (3KB), this energizes the fan and sea water pump (3KB, see note). Turn THERMOSTAT control knob to the coolest position by rotating it fully clockwise. If system has reverse cycle, turn knob counter-clockwise for heat.

5) Turn FAN SPEED control knob to highest setting (3KB).

6) Verify that the fan is running and that there is steady airflow out of the supply air grille.

7) Turn the SYSTEM SWITCH to COOL (2KB) or RUN (3KB), this will start the compressor and sea water pump (2KB, see note). The indicator light on the 3KB control will illuminate.

8) Check for a steady solid stream of sea water from the overboard discharge.

9) To set the thermostat, allow sufficient time for the unit to cool/heat the area to the desired temperature. When the area is sufficiently cooled/heated, turn the thermostat knob slowly toward the center position until it clicks once (the indicator light on the 3KB will turn off). The thermostat is now set to maintain a constant temperature. While heating, if the ambient temperature is less than 50F, set the FAN SPEED control knob to low (3KB) for five to ten minutes until the unit begins to heat well, then increase the fan speed for more heat output.

Note: The sea water pump comes on with the fan on the 3KB and with the compressor on the 2KB. (continued)

The thermostat on the MCP control panel serves to cycle the compressor on and off and provide an automatic changeover from cooling to heating (reverse cycle only) with a 3F differential. Rotating the thermostat to the left after it has been set for cooling will cause the unit to heat. If you rotate the thermostat to the right, the unit will cool. If the thermostat is left stationary after being set, the unit will cycle from cooling to neutral, or heating to neutral depending on the requirement.

Note: Do not turn the unit off and immediately turn it back on. Wait at least 30 seconds.

PASSPORT II CONTROL

 

DISPLAY PANEL FEATURES

POWER BUTTON: Press and release to turn unit on and off.

NOTE: To "press and release" a button, press and hold for one second and then release.

FAN BUTTON: Press and hold until the letter "A" appears for automatic fan speed or the numbers "1" (slow) through "6" (fast) appear for manual fan speed. Fan may be used while a/c is off.

UP & DOWN BUTTONS: Press and hold either button until desired temperature (set point) is displayed. Press either button momentarily to show current set point. Range = 60-85F.

COOL LED: Lights when the compressor is running in cool mode or in automatic mode while cooling.

FAN LED: Lights when fan is on in manual mode.

HEAT LED: Lights when the compressor is running in heat mode, in automatic mode while heating or if optional electric heat is installed and operating.

DISPLAY WINDOW: Shows current cabin temperature. Can show outside air temperature if the optional O.A.T. sensor is installed. Also used in viewing and setting program parameters.

AIR SENSOR: Cabin temperature is detected by the face plate air sensor unless the optional remote air sensor is installed.

BLANK DISPLAY FOR NIGHT TIME OPERATION: Press the FAN and DOWN buttons simultaneously to blank the display for night time operation. The appropriate LEDs will remain lit during cooling and heating. When the desired temperature has been achieved, the middle segment of the display window will remain lit to indicate that the system is on. Press any button to return to normal display mode.

OUTSIDE AIR TEMPERATURE: When the optional outside air sensor is installed, press the UP and DOWN buttons simultaneously to display the outside air temperature. The outside air sensor should not be mounted in direct sunlight.

MODES OF OPERATION

COOL ONLY MODE: When the Passport II is configured for cool only mode, only cooling systems will be operated as required. When the temperature drops below the set point the system will not automatically switch into the heating mode.

HEAT ONLY MODE: When the controller is programmed for heating mode, only the heating system will be selected for operation as required. Should the temperature rise above the set point the system will not switch to the cooling mode automatically.

AUTOMATIC MODE: When the controller is configured for the automatic mode, both heating and cooling will be supplied as required. The heat and cool LED indicators will light according to which mode is operating. Temperature differential in a given mode will be maintained at 2F, however, a 4F difference is required to allow the control to change modes.

HUMIDITY MODE: While the system is on, press the POWER and the DOWN buttons simultaneously to enter the humidity or moisture control mode. The characters "II1" will appear in the temperature display. Every four hours, the fan is started and air circulated for thirty minutes. During this time the air temperature is sampled and entered into memory. The cooling cycle is started and continues until the temperature is lowered 2F. The compressor is allowed a maximum of one hour running time to reach the desired temperature. Four hours after the temperature is satisfied or the compressor times out, the cycle is repeated. During the cycle, the cool LED will be lit when the compressor is running. Humidity mode is provided to maintain a specific temperature and humidity range when the yacht is unoccupied for extended periods of time.

AUTOMATIC FAN MODE: Press and hold the FAN button until the letter "A" appears in the display window. Automatic fan mode allows the control to determine fan speeds based on the room temperature. The closer the room temperature is to the set point, the slower the fan will run. This permits a balance between the most efficient temperature control and the slowest (quietest) fan speed. The fan LED will not be lit during automatic fan mode.

MANUAL FAN MODE: Press and hold the FAN button during normal operation to select one of the six manual fan speeds available. Six (6) is the highest and one (1) represents the lowest speed available. When a manual fan speed has been selected the fan LED will be lit.

NOTE: High and low fan speeds can be further tailored to suit the user by adjusting the fan limits. See programming modes "U 2" and "U 3".

CIRCULATION MODE (FAN ONLY): With the system off, press and hold the FAN button until the desired fan speed is indicated by the numbers "1" (slow) through "6" (fast). To turn the fan off press and hold the FAN button until the number "0" appears in the display window.

PROGRAMMING THE PASSPORT II

The program mode is used to adjust operating parameters to tailor the system for efficient operation and to allow for user flexibility. Installation variables such as ducting, sensor location and system layout effect the operation of the overall system. Custom programing allows the system to operate as efficiently as possible in any given installation.

TO ENTER PROGRAM MODE: With the system off, press and hold the POWER button for five seconds until the letter "U" appears in the display window. Release the button and the first parameter's setting appears followed by "U 1".

TO UNLOCK PROGRAM MODE: After entering the program mode, simultaneously press and release the POWER and DOWN buttons.

TO SELECT PROGRAM PARAMETER: Press and hold the FAN button to scroll through the parameters indicated by the program number. Programs are described in the following table.

TO CHANGE THE PROGRAM PARAMETER: Use the UP and DOWN buttons to select data or set the desired limits. The range of parameter settings is listed in the following table.

TO RESET DEFAULT SETTINGS: With the system off, press and hold the POWER button for ten seconds until the software version number, such as "A13" appears in the display window.

TO LOCK NEW DEFAULT SETTINGS: Once the desired program changes have been made and before exiting the program mode, simultaneously press and release the UP and DOWN buttons. Locking new defaults will render the factory defaults obsolete. Make note of the new defaults in the following chart for future reference.

TO EXIT PROGRAM MODE: Press the POWER button or press no button for sixty seconds. The software version number is displayed for one second prior to exiting the program mode.

PROGRAMMABLE PARAMETERS:

TABLE HERE

U 1 OPERATING MODE: The operating mode is used to select heating, cooling, or automatic modes. Zero (0) selects automatic mode, one (1) selects cooling mode and two (2) selects heating mode. Systems that do not have heating capabilities should be programmed for cooling mode (1). The factory default is zero (0) for automatic mode (one (1) if cool only).

U 2 HIGH FAN SPEED LIMIT: The high fan speed limit can be tailored to suit various motors and operating conditions. The range of values is 56 through 85 in arbitrary units. The factory default is 85.

U 3 LOW FAN SPEED LIMIT: The low fan speed limit determines the lowest output allowed for the low fan speed. The range of values is 30 through 55 in arbitrary units. The factory default is 50.

Both the high and low fan limits may be adjusted as follows: While the system is off, start the fan by pressing and holding the FAN button until the number "1" appears in the display. Enter the program mode while the fan is running and select "U2" or "U3". Raising and lowering the fan limits while the fan is running allows the programmer to experience fan speed changes as they are made. Once the high and low fan speed limits are set, the system will automatically reprogram itself to produce six equally spaced fan speeds between them.

U 4 COMPRESSOR STAGING TIME DELAY: The compressor staging time delay is provided for use where more than one a/c system is being operated from the same power source. Setting the staging delays at different intervals allows for only one compressor to start at a time to lessen the amperage load on the power source. The minimum delay is five (5) seconds and the maximum is one-hundred thirty five (135) seconds. The factory default setting is fifteen (15) seconds (one-hundred thirty five (135) seconds if cool only).

U 5 TEMPERATURE CALIBRATION: Use this feature to calibrate the air sensor within a range of 10F. The factory default is 0F.

U 6 COMPRESSOR FAIL-SAFE PROTECTION: This feature is provided to monitor the refrigerant circuit. When a high head pressure condition occurs the display will flash "HHH", when the refrigerant system is low on pressure "PPP" will flash only if the optional low pressure switch is installed. This display indicates that the system requires maintenance. See the TROUBLESHOOTING GUIDELINES in this manual. The four parameter settings are:

Zero (0): Turns off all protection, no action is taken and no message displayed.

One (1): No message displayed with 90 seconds between continuous restarts.

Two (2): Message displayed with 90 seconds between continuous restarts.

Three (3): Message displayed with three 90 second restarts, manual reset is required.

The factory default is three (3).

U 7 FAHRENHEIT OR CELSIUS TEMPERATURE DISPLAY: The PASSPORT II can display temperature in either degrees Fahrenheit (F) or degrees Celsius (C). Setting to zero (0) displays F and setting to one (1) displays C. The factory default is zero (0).

U 8 ALTERNATE AIR SENSOR OPERATION: Installing an alternate remote air sensor will override the face plate (digital display panel touch pad) air sensor unless this program parameter is set to one (1). This program is utilized only if the a/c unit is used to supply air to two different locations, i.e., salon and aft cabin, and if it is desired to control the temperature from these locations at different times of the day, i.e., day and night. The remote air sensor should be installed in the return air stream behind the return air grille. In this case, the display panel would be in a different room than the a/c unit. If the a/c unit and display panel are in the same room, mount the remote air sensor in the other room using the same guide lines for locating the display panel as stated in "Passport II Display Panel Installation" in this manual. To activate program set parameter to one (1). To toggle from sensor to sensor, simultaneously press the fan and up buttons while a/c unit is on. When the alternate air sensor is operating, the letter "A" will appear in the display window while viewing the set point. To view set point press either up or down button. The factory default is zero (0).

U 9 REVERSED FAN SPEEDS DURING HEATING: During normal operation in the cooling mode with the fan speed set to "A" (automatic), the fan speed is reduced as the set point temperature is approached. During heating, this is not always the preferred method of operation. When this parameter is set to one (1), the fan speed will increase as the set point is approached during heating. This will reduce head pressure by increasing air flow across the coil as the set point is approached. As the ambient cabin temperature rises, the fan speed will slow which will increase head pressure making the air seem warmer. Setting the parameter to zero (0) will cause the fan speed to decrease as the set point is approached during heating, as it does in the cooling mode. The factory default is one (1).

U10 CONTINUOUS FAN OPERATION OR CYCLE FAN WITH COMPRESSOR: The fan can be programmed to run continuously while the system is on, or can be allowed to cycle with the compressor. When cycled with the compressor, the fan will only operate when cooling or reverse cycle heating is called for. To cycle the fan with the compressor select zero (0). To operate the fan continuously select one (1). The factory default is one (1).

U11 REVERSE CYCLE OR ELECTRIC HEAT: Units not equipped with reverse cycle heating, or reverse cycle units operating in sea water temperatures below 40F, may need to have electric heaters added. IMPORTANT: the Passport II circuit board reversing valve output is use to control the optional electric heater. The valve output relay can only carry 6 amps, therefore, a heavy duty contactor must be installed to carry the electric heater current. Select one (1) for the electric heat option, select zero (0) for reverse cycle heating. The factory default is zero (0).

U12 FAN MOTOR TYPE SELECTION: This feature allows the controller to be programmed for the type of motor on the unit's fan. Zero (0) selects a shaded pole motor which is used on most a/c units. Select one (1) for units having "HV" or "EBM" in their model number, these units have a split capacitor motor. The controller has been factory programmed for the appropriate motor type.

U15 DE-ICING CYCLE: Under certain extreme conditions ice may build up on the evaporator coil. Running the a/c at a low set point with the hatches and doors open on a hot humid day would be an example of this. If the a/c runs for an hour in cool mode and during that time the ambient temperature does not change by more than one degree, the de-icing cycle will activate turning the unit into reverse cycle heat for one to three minutes depending on the setting. The programmable parameter may be set at zero (0), one (1), two (2), or three (3) minutes. If the evaporator coil is still iced up after three minutes, see the trouble shooting section of this manual. The factory default is zero (0) which is off.

TROUBLESHOOTING GUIDELINES
FAULT POSSIBLE REASON CORRECTION
System will not start. Air conditioner circuit breaker is off. Turn circuit breaker on at ship's panel.
  Wiring at terminal strip is mis-wired. Check wiring diagram; correct if necessary.
  Input line voltage is insufficient. Check power source (shore/generator) for proper voltage. Check wiring and terminals for proper sizes and connections.
Passport II display panel is not lit. 8-pin display cable plugs are not making contact (unplugged, dirt, bent, or broken pins). With POWER OFF at the circuit breaker, remove connector and inspect. If damaged, replace connector or entire display cable.
No cooling or heating. Temperature set point is above (in cooling) or below (in heating) ambient temperature. Lower or raise set point.
  Manual control knob may not be in "COOL" (2KB) or "RUN" (3KB) position. Reset selector knob.
  Passport programmed for heat or cool only. Reprogram parameter U1 for appropriate mode: cooling, heating or auto.
  Low sea water temperature (in heating). Reverse cycle operation is affected by the temperature of the sea water, as the water temperature is reduced so is the capacity of the output of the warm air. If electric heat is installed, reprogram parameter U11.
  Obstructed sea water flow. Clean sea water strainer. Check for obstructions at speed scoop thru-hull inlet. Check for good steady flow from overboard discharge.
  Sea water pump may be air-locked. Remove hose from pump discharge to purge air from line.
  Electric heat option not operating properly. The Passport board has a 6 amp relay for reverse cycle, if electric heat is installed, a contactor must be used to carry the heater current. Check wiring and see programmable parameter U11.
  Fan is not running. See below
  Coil is iced (in cooling). See below
  "HHH" is displayed on panel. See below
  "PPP" is displayed on panel. See below
Fan is not running. Passport is programmed for fan cycling with compressor. Reprogram parameter U10.

TROUBLESHOOTING GUIDELINES CONTINUED
FAULT POSSIBLE REASON CORRECTION
No air flow. Air flow is blocked. Locate obstructions, clean return air filter and grill.
  Coil is iced (in cooling). See below
Unit switches to heat while in cool mode. De-icing feature enabled due to coil icing up. See below
Coil is iced. Thermostat set point is too low. Raise set point.*
  Improper air flow. Clean return air filter or remove obstructions from return air stream. Check for crushed or restricted ducting, ducting must be as straight and taut as possible. If problem persists program low fan speed parameter U3 for maximum value (55).*
  Supply air is short-cycling. Redirect supply air so that it is not blowing into the return air stream.*
  Humidity level too high. Close hatches and doors*.
    * Read programmable parameter U15 and reset. If de-icing cycle does not melt ice, switch a/c to heat until ice melts or use hair dryer to melt ice.
"HHH" is displayed on Passport panel. High pressure switch is open (in cooling) due to improper sea water flow. Strainer or intake may be plugged, sea cock may be closed, check sea water hose for kinks or collapses. Verify pump operation, check pump circuit breaker if applicable.
  High pressure switch open (in heating) due to improper air flow. Clean return air filter or remove obstructions from return air stream. Check for crushed or restricted ducting, ducting must be as straight and taut as possible. If problem persists program low fan speed parameter U3 for maximum value (55). Reprogram parameter U9 for "1" to reverse fan speeds.
"PPP" is displayed on Passport panel. Low pressure switch is open due to low sea water and/or low return air temperatures. Try restarting the a/c unit, the optional low pressure switch has a ten minute time delay that may be in effect.
  Low pressure switch is open due to loss of refrigerant. Check a/c unit for refrigerant oil leakage, call service technician (see back of manual).
System runs continuously. (continued) Improper Passport air sensor location. Verify display head location with criteria found in this manual. Install alternate air sensor if necessary.

TROUBLESHOOTING GUIDELINES CONTINUED
FAULT POSSIBLE REASON CORRECTION
System runs continuously. Set point temperatures are improperly programmed, too low for cooling or too high for heating. Raise or lower set point.
  Port hole or hatch open. Close all port holes and hatches.

MAINTENANCE

Seawater System

Insure that your pump receives adequate sea water flow by regularly cleaning the strainer basket. Periodically check the overboard discharge for a steady stream of water. Check sea water intake speed scoop for obstructions. Make sure hoses are not kinked or crushed.

Return Air Filters

Check the return air filter about once a month and clean as necessary. To clean the filter, rinse with water and air dry.

Winterization

There are several methods of winterization, some of which work better than others. The four various methods employed using a 50/50 non-polluting biodegradable anti-freeze/water solution are:

1. Pumping of anti-freeze solution into the overboard discharge thru-hull fitting, and discharging through the intake thru-hull fitting.

2. Use of the sea water pump to pump anti-freeze solution through the system and discharging through the overboard thru-hull fitting. Close sea cock, remove hose from strainer discharge, raise hose above pump (so pump does not lose its prime) and pour in anti-freeze solution. Pump solution through system. The strainer and hose to sea cock will also need to be drained of water.

3. Use of pressurized air injected at the overboard discharge fitting and the water being discharged through the sea water intake fitting.

4. Use of pressurized air to force water from the intake through the overboard discharge.

Note: Collect all discharged liquids and recycle or dispose of in a proper manner.

Any method which causes the anti-freeze solution to flow downward is the method of choice. By this means, the anti-freeze solution will displace any water trapped and eliminate the possibility of freezing in hidden areas.

In addition, since the sea water pump utilizes a magnetically driven impeller, the impeller should be removed from the wet end assembly, wiped with an alcohol solution, and stored in a warm, dry area until commissioning takes place.

MANUFACTURERS LIMITED WARRANTY AGREEMENT

The following warranty is extended to cover the CABIN MATE series of self contained air conditioners manufactured or supplied by Marine Air Systems Inc., and is subject to qualifications as indicated.

Marine Air Systems warrants for the periods set forth below that products manufactured or supplied by it will be free from defects in workmanship and material, provided such products are installed, operated and maintained in accordance with Marine Air Systems' written instructions.

ALL IMPLIED WARRANTIES INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE TERMS AND PERIODS OF WARRANTY SET FORTH BELOW AND, TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED.

Components comprising a complete system on a new installation are covered by a limited one (1) year warranty from the date of purchase, but not to exceed two (2) years from date of manufacture. Labor costs are covered for six (6) months from the date of purchase. Costs which exceed the limited schedule of allowances, i.e., parts, labor, travel, removal and reinstallation are the responsibility of the customer. OEM installed systems are warranted for a period of one (1) year from the date of sale of the vessel, not to exceed two (2) years from the date of manufacture.

Marine Air Systems Inc. will repair or replace at its option, components found to be defective due to faulty materials or workmanship, when such components, examined by an authorized service dealer or a factory service representative, are found to have a defect for which the company is responsible. In addition, Marine Air Systems will pay labor costs as outlined in its Schedule of Limited Warranty Allowances for removal and re-installation of such components. Refer to Manufacturer's Limited Warranty Policy for complete coverage and exclusions. Replacement components are warranted for the duration of the remaining warranty period in effect on the original component.

This limited warranty is extended in lieu of all other warranties, agreements or obligations, expressed or implied, concerning Marine Air Systems' components. This limited warranty is extended only to the original purchaser and is not transferable. This warranty shall be governed by the laws of the State of Florida and gives the original first end user definite legal rights.

This warranty does not cover damages incidental and or consequential to the failure of Marine Air Systems' equipment including but not limited to; normal wear, accident, misuse, abuse, negligence or improper installation, lack of reasonable and necessary maintenance, alteration, civil disturbance or act of God.

No person or dealer is authorized to extend any other warranties or to assume any other liabilities on Marine Air Systems' behalf, unless made or assumed in writing by an officer of Marine Air Systems.

Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Marine Air Systems assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of this product and information contained herein.