INSTALLATION & OPERATING INSTRUCTIONS

INSTALLATION & OPERATING INSTRUCTIONS
INSTALLATION &
OPERATING INSTRUCTIONS
ROOF MOUNT AIR CONDITIONER
MODELS 600215-001, 600315-001,
600212-001, 600312-001, -002
Pre-Wired For Optional Heat Package
WARNING
THIS UNIT MUST BE SERVICED BY
AN AUTHORIZED SERVICEMAN.
MODIFICATION OF THE APPLIANCE
CAN BE EXTREMELY HAZARDOUS
AND COULD LEAD TO SERIOUS
INJURY OR DEATH.
R
0
CERTIFIED
I
-IMPORTANT INSTRUCTIONSMUST STAY WITH UNIT
OWNER-READ CAREFULLY
Form No. 191414 2/85
I
AVIS:
CET appareil doit etre repare seulement
par un reparateur aurorise. Modification
de I’appareil pourrait etre extremement
dangereuse, et pourrait causer mal ou
mort.
THE DUO-THERM CORPORATION
LaGrange, Indiana 46761-2399
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GENERAL SPECIFICATIONS & NOTICES
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This equipment must be serviced only by qualified
service personnel. Some states require installation and
service personnel to be licensed.
E.
SPECIFICATIONS
MODEL NO.‘S
Nominal BTUH Capacity
600215
600212
Optional
600315
600312
Heater
13,500
11,000
5600
115V,, 60 Hz. 1 Ph
Electrical Rating
FL Amps (Comp/Motor)
12.4/3.1
10.1/3.1
12.7
LR Amps (Comp/Motor)
63.5/8.3
56.6/8.3
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Kilowatts
1.7
1.5
1.53
Min. Wire Size
Up to 24’. use 12 AWG, Copper
Circuit Protection
20 Amp Time Delay Fuse or
20 Amp Circuit Breaker, HACR Type
**Normal Min. 1 Unit
3.5KW
2.5KW
3.5KW
5.0 KW
4.0KW
5.0KW
Generator Size
2 Unit
LOCATION OF AIR CONDITIONER ON
RECREATIONAL VEHICLE
This Air Conditioner is designed to be installed on the roof of a
Recreational Vehicle. One or more units may be installed on
the vehicle, dependent upon the size and strength of the roof
and the expected cooling requirements of the RV.
Normal Location of Air Conditioner(s)
(Refer to FIG. 1)
A.
Normally the Air Conditioner(s) is installed in an existing
roof vent. When the roof vent is removed it normally
creates a 14” x 14” opening through the roof required
for the installation of the Air Conditioner(s).
Other Locations for Air Conditioner(s):
When no roof vent location is available or a roof vent
location is not to be used, it is recommended that the
Air Conditioner(s) be installed as follows:
For one unit installation: Air Conditioner should
1.
be mounted slightly forward of center (front to
back) and centered from side to side on the RV.
For two unit installations: Install one Air Condi2.
tioner 1/3 and one Air Conditioner 2/3 back from
front of RV and centered from side to side.
B.
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* The Duo-Therm Corporation gives only general guidelines
for Generator requirements. These Generator requirements
come from experience consumers have with our equipment
in field applications. When sizing the Generator, the total
electrical power consumption of the Recreational Vehicle
must be taken into consideration. Keep in mind that
Generators lose power because of altitude increases above
sea level and lack of maintenance.
In ALL CASES the Air Conditioner(s) MUST be mounted
in a relatively FLAT AND LEVEL section of the roof
when the RV is parked on a level surface.
This Air Conditioner is Listed by Underwriters Laboratories,
Inc. as complying with UL Standard 484.
After Location Selection
(Refer to FIGS. 2 & 3)
C.
Reference is made through out these instructions to Optional
Electric Heater. This heater is an accessory to the Air Conditioner and can be purchased by requesting Electric Heater Kit
No. 3-18706. This heater is installed in the air box of the Air
Conditioner and the installation instructions are packed with
the heater.
Check on RV roof to be sure no obstructions are in
the area where the Air Conditioner will be installed.
Check inside RV where Air Conditioner Air Box will
be located to insure there will be no interference
with door openings, curtains, room dividers, etc.
Be sure your RV roof structure is capable of supporting a weight of 130 Ibs. when the RV is in motion.
(Normally if roof can support a static load of approx.
200 Ibs. it meets this requirement.)
1
2.
3.
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n PRECAUTIONS FOR SAFE INSTALLATION
A.
Read installation and operating instructions thoroughly
and carefully before attempting installation of Air
Conditioner.
WARNING: IMPROPER INSTALLATION MAY DAMAGE
EQUIPMENT, COULD ENDANGER LIFE, CAUSE SERIOUS
INJURY AND/OR PROPERTY DAMAGE.
B.
C.
D.
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The Duo-Therm Corporation will not be liable for any
damages or injury due to failure to follow these installation and operating instructions.
A.
ROOF PREPARATIONS
Roof Vent Locations
1.
2.
Installation must comply with the National Electric
Code and all applicable State and Local Codes and/or
Regulations.
3.
DO NOT add any devices or accessories to this equipment except those specifically authorized by The
Duo-Therm Corporation.
-2-
Remove all screws that secure roof vent to roof
and remove vent from opening.
Remove all caulking compound from around vent
opening.
Seal all screw holes where vent was attached to
roof and all roof seams in the area with a good
grade of all weather sealant.
B.
Other Than Roof Vent Locations
(Refer to F IG.4)
If other than a roof vent location for the Air Conditioner(s) was selected, a 14” x 14” opening must be cut into
the roof and ceiling of the RV. It is recommended that
this opening be located between roof reinforcing members.
CAUTION:
1.
2 .
CAUTION:
3.
C.
Disconnect all power supplies to RV and disconnect positive battery terminal from the RV
battery before performing any cutting on the
RV surface. FAILURE TO FOLLOW THIS
INSTRUCTION MAY CREATE A SHOCK
HAZARD.
Mark 14” x 14” opening on roof of RV with
marker.
Carefully cut opening in roof of RV.
There may be electrical wiring located between
roof and ceiling.
Carefully cut a matching hole through the ceiling
of the RV.
Opening Preparations
(Refer to FIG. 4)
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PLACING OF AIR CONDITIONER(S)
ON ROOF
A.
Remove the carton from the Air Conditioner and discard.
B.
Lift unit up and place over the prepared 14” x 14”
opening. The blunt end of Air Conditioner goes toward
the rear of the RV. (Refer to FIG. 2).
CAUTION:
C.
DO NOT slide the air conditioner across the
roof. There is a neoprene rubber gasket attached to the bottom of the air conditioner which
may be damaged by sliding. A torn or damaged
gasket may not seal the air conditioner to the
roof of the RV.
Locate the rubber gasket as near as possible to centered
over the 14” x 14” opening.
This completes the outside work. Minor adjustments to Air
Conditioner location may be done from the inside of the RV.
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UPPER DISCHARGE AIR DUCT
INSTALLATION (Refer to FIG. 4)
The Upper Discharge Air Duct is shipped inside the Lower
If the opening exceeds 14%” x 14%“. it will be
Discharge Air Duct attached to Ceiling Template. Use two of
necessary to make the opening smaller by instalthe six sheet metal screws to attach the Upper Discharge Air
ling spacers or close off plates.
Duct to the bottom of the Air Conditioner. They are in the
If the opening is smaller than 14” x 14”. it will
2.
bag of installation hardware.
be necessary to enlarge the opening.
Route a grounded power supply line from circuit
3.
Remove the upper duct from the ceiling template duct
A.
breaker or fuse box to the roof opening.
and install it over the blower discharge opening.
a.
The power supply must be a separate circuit,
The edge without the flange goes toward the
Note:
fused with a 20 Amp Time Delay Fuse or 20
rear of the RV.
Amp Circuit Breaker, HACR Type.
b.
The power supply must be grounded 12AWG
B.
Secure the duct in place with the two screws provided.
COPPER supply for distances of 24’ or less.
There are prepunched holes in the basepan for ease of
C.
The power supply wiring m u s t comply with
installation.
National, State and Local wiring codes.
Depending on entrance location, up to 20” of
d.
CEILING TEMPLATE INSTALLATION
wire must extend into 14” X 14” opening to
insure ease of attachment to the air conditioner.
@I (Refer to FIG. 4)
e.
If vent fan was removed, the existing wire may be
A.
Reach through the 14” x 14” opening and adjust the Air
utilized, provided it is of proper size and properly
conditioner until the gasket is centered on the opening.
fused.
Framing is required around the 14” x 14” opening to
4.
B.
Measure the distance from the bottom of Air Condiinsure adequate support, provide a smooth surface for
tioner to the ceiling surface:
sealing and prevent hot or cold air from being drawn
into opening.
This framing should be wood strips
1.
If the distance is 1” to 2”. remove perforated tabs
on the Upper Discharge Air Duct and tabs on the
15’ x 1” x thickness of roof to ceiling distance. A hole
Lower Discharge Air Duct.
for the power supply must be provided.
If the distance is 2” to 3”, remove perforated tabs
2.
on the Lower Discharge Air Duct.
NOTE: Under no circumstancesshould the roof be constructed
If the distance is 3” to 4 1/4", do not remove any of
to create a low spot where water will accumulate when the
3.
the perforated tabs.
Air Conditioner is installed. This may create a water leak into
the interior of the RV.
If the distance is greater than 4 1/4", an optional duct,
4.
Part No. 3-18556, and bolt kit, Part No. 3-18557, are
You will find a return air duct in the carton with the
5.
available.
Air Conditioner. This air duct is a piece of sheet metal
4
Take the ceiling template and slide the lower discharge
folded flat.
C.
air duct over the outside of the upper discharge air duct.
a.
Unfold and form this into a 14” x 14” square.
b.
Insert into the opening in the roof and align the
Holding the ceiling template in place with one hand,
hole in duct with the hole for the electrical power
D.
install the three 1/4" x 6” mounting bolts up through
supply wire.
the ceiling template and into the air conditioner with
C.
Trim off excess sheet metal above and below the
other hand, until mounting bolts are finger tight. (See
roof and ceiling of the RV.
FIG. 5 for location of bolts).
1.
-3-
FIG. 4
Discharge Air
Rating Plate and Serial Number
Neoprene Rubber Gasket
Upper Discharge Air Duct
Return Air Duct
Roof Line
Roof Reinforcement Member
Power Supply Line
14” x 14” Opening
1” x 15” x Thick. Framing
Lower Discharge Air Duct
Ceiling Template
Junction Box
Unit Mounting Bolts
NOTE:
Remove the return air grilles by placing a flat bladed screw driver or
simular tool into the latches. By using a prying motion, the grilles
are easily removed. NOTE: Two latches, on either side, must be
unhooked.
E.
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Evenly tighten the three mounting bolts to secure the
air conditioner to the roof. The mounting bolts should
be tightened to a torque of 40 to 50 in. Ibs. to insure
adequate air conditioner to roof seal.
CAUTION:
X
A.
Controls
1.
Thermostat (Dial on right side when facing air box)
has a temperature range of 65OF in COOL position to 9OoF in WARM position. The thermostat
controls the unit compressor ON and OFF cycle in
the cooling mode and the electric heater ON and
OFF cycle in the heating mode.
2.
Selector Switch (Dial on left side when facing air
box) controls the unit fan speeds, heating mode,
cooling mode and fan mode of operation.
B.
Cooling Operation
Set the thermostat to the position which will
1.
give your desired comfort level.
2.
The selector switch is to be set as follows:
Selected when maximum
a.
HIGH COOL:
cooling and dehumidifying is required.
b.
MED COOL: Selected when medium cooling
is required.
LOW COOL: Selected when minimum coolC.
ing is required. Normally this position is
selected for night time operation.
DO NOT overtighten the mounting bolts as
this may damage the air conditioner base.
@ CONNECTION OF: POWER SUPPLY TO
AIR CONDITIONER (Refer to FIG. 5)
CAUTION:
Be sure power supply is OFF before connecting
power supply leads to the air conditioner.
A.
Route the power supply line, previously installed to the
14” x 14” opening, into the junction box on the ceiling
template.
B.
Connect power supply line to air conditioner leads with
three twist connectors provided.
Connect white to
white, black to black and green to green or bare copper
wire.
C.
Using electricians tape, tape twist connectors firmly to
wires.
D.
Tighten the strain relief onto the power supply line, to
hold it firmly in place.
E.
Carefully push excess wire back into junction box and
install cover onto box with screw provided. (The one
blunt point screw in the mounting hardware).
F.
Plug the electrical conduit hanging from the bottom of
the air conditioner into the mating connector on the
switch box located on the ceiling template.
The air conditioner compressor will come on and
off as cooling is required to maintain your desired
temperature level as set at the thermostat.
NOTE: The air conditioner blower runs continuously
to circulate the air and maintain an even temperature
in the RV. It does not come on and off with the compressor.
C.
Fan Operation
When you wish to circulate the air inside your RV,
without heating or cooling, select one of the three fan
speeds (HIGH FAN, MED FAN or LOW FAN). The
fan will run continuously and circulate the air in the
RV.
D.
Heating Operation:
Installed).
NOTE: If optional heater is part of this installation, follow the
instructions provided with the electric heater kit.
Remove the two return air grills and filters which are
shipped loose in the air box.
B.
Slide the front end of the air box over the shafts of the
thermostat and selector switch.
C.
1.
2.
Install the return air grills and filters by simply pushing
them into place.
E.
Install the two knobs provided on the ends of the thermostat and selector switch shafts.
F.
The power supply to the air conditioner may now be
turned ON.
G.
Your air conditioner is now installed and ready for
operation. Please read the following instructions before
attemotins to run unit.
Set the thermostat to position which will give your
desired comfort level.
The selector switch can be set in any of the three
heating positions, but normally it will be placed in
the LOW HEAT position for best results.
The electric heater will turn on and off as heating is
required to maintain your desired temperature level as
set at thermostat.
Install the four screws through legs in air box into the
prepunched holes in the ceiling template.
NOTE:
There are four optional mounting holes for which no
screws are provided.
D.
(With Optional Electric Heater
NOTE: This electric heater will not replace a furnace
for heating your RV in cold weather. It is intended to
remove the chill from the air on cool days or mornings
only.
AIR BOX INSTALLATION
(Refer to FIG. 4)
A.
OPERATING INSTRUCTIONS
(Refer to FIG. 6)
NOTE: The air conditioner fan runs continuously to
circulate the air in the RV. It does not come on and
off with the heater.
E.
Operation of air conditioner WITHOUT Optional Electric
Heater installed.
When the optional electric heater is not installed in the
air conditioner and the selector switch is in one of the
heating positions (HIGH HEAT, MED HEAT or LOW
HEAT) the air conditioner works as if it were in Fan
Operation. No damage will be caused to the air conditioner when these positions are used.
-6-
F.
G.
H.
XT,
Off Position
To shut the air conditioner OFF place the selector
switch in the OFF position.
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XII
SERVICE-Unit Does Not Operate
If your unit fails to operate or operates improperly, check the
following before calling your service center.
Compressor Time Delay Models:
When the 6002XX Series Air Conditioners are turned on
the fan starts immediately. When the thermostat calls
for cooling, there is a 2 minute delay before the compressor starts. This is to reduce the load on the power
supply and prevents short cycling of the compressor.
Compressor Non-Time Delay Models:
When the 6003XX Series Air Conditioners are turned on
and the thermostat calls for cooling, the fan and compressor start at the same time. After shutting the air
conditioner down manually by either the selector switch
or the thermostat, always wait at least 2 to 3 minutes
before turning the air conditioner back on. This allows
the refrigerant pressures in the air conditioner to
equalize so the compressor may restart.
MAINTENANCE
A.
If RV is connected to motor generator, check to be
sure motor generator is running and producing power.
B.
If RV is connected to power supply by a land line.
check to be sure line is sized properly to run air conditioner load and it is plugged into power supply.
C.
Check your fuse or circuit breaker to see if it is open.
D.
In the air conditioner air box, check to be sure the air
conditioner conduit is plugged into the selector switch
box.
E.
After the above checks call your local service center for
further help. This unit must be serviced by qualified
service personnel only.
When calling for service always give the air conditioner
Model Number and Serial Number. This information can
be found on unit rating plate located on the air conditioner base pan. To locate, remove return air grill from
air box and look up through 14” x 14” opening in
ceiling. (See FIG. 4).
AIR FILTERS:
Periodically remove the return air filters
located above the removable panels in the air box. Wash the
filters with soap and warm water, let dry and then reinstall.
Note: Never run the air conditioner without return air filters
in place. This may plug the unit evaporator coil with dirt and
may substantially affect the performance of the unit.
-7-
WIRING DIAGRAM
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RUN CAP.
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TERMINAL 4 ( @ )IS USED FOR WIRE
CONNECTION ONLY AND NOT A
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RELAY.
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FACTORY WIRING SHUR S T A R T O N L Y - - - l
FIELD WIRING
LINE SPLICE
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115 V.A.C., 60 Hz, 1 0
USE COPPER CONDUCTORS ONLY
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WIRING SCHEMATIC
SWITCH
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THERMOSTAT
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OMITTED ON SHUR START MODELS)*
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