Dometic CAL136.302 User manual

CARAVAN

ROOF MOUNT AIR CONDITIONER

MODEL CAL136.302

INCLUDES ELECTRIC HEAT KIT

-IMPORTANT INSTRUCTIONS

MUST STAY WITH

UNIT

OWNER-READCAREFULLY.

WICHTIGE HINWEISE, DIE SICH IM BESITZ

DES WOHNWAGENINHABERS BEFINDEN

MUSSEN

BITTE

SORGFALTIG DURCHLE-

SEN.

LE CONTENU DE CETTE NOTICE EST TRES

IMPORTANT, AUSSI L’UTILISATEUR DE

L’APPAREIL DOIT-IL EN POSSEDER

UN EXEMPLAIRE ET LE LIRE

ATTENTIVEMENT.

VIKTIGA ANVISNINGAR.

SKALL ALLTID MEDFOLJA AGGREGATET

OCH NOGGRANT LASAS AV AGAREN.

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.

ACHTUNG

DER SERVICE AN DIESER EINHEIT MU6 VON EINEM HIERZU

BEFUGTEN SERVICE-TECHNIKER AUSGEFURT WERDEN.

EINE

ABANDERUNG

DES

GERiiTS

KANN

AUBERORDENTILICH

GEFAHRLICH SEIN UND ZU ERNSTHAFTEN VERLETZUNGEN

ODER SOGAR ZUM TODE FUHREN.

ATTENTION

LES INTERVENTIONS SUR L'APPAREIL DOIVENT ETRE.

UNIQUEMENT EFFECTUEES PAR UN TECHNICIEN AGREE.

L’EQUIPEMENT NE DOIT FAIRE L’OBJET D’AUCUNE

MODIFICATION, CE QUI POURRAIT EN

EFFET

SE REVELER

EXTREMEMENT DANCEREUX, SINON MEME PROVOQUER

UN ACCIDENT GRAVE OU MORTEL.

VARNING

SERVICE PA

DETTA

AGGREGAT FAR ENDAST

UTFORAS

EN AUKTORISERAD

MONTOR.

ANDRINGAR AV

UTRUSTNINCEN KAN VARA YTTERST FARLIGA OCH

LEDA

TILL ALLVARLIGA OLYCKOR ELLER DODSFALL.

Form No. 3104963.024

6/93

1992,

1993 The

Dometic

Corp.

LaGrange,

IN 46761

GENERAL INFORMATION

THREE SPECIFIC NEEDS:

Installation opening.

2. Additional wiring.

Cut through roof and ceiling.

220-240V,

50 Hz, 10 Amp.

SPECIAL WIRING

Power with the air conditioner on must be above 209 V and frequency must be 50 Hz at all times.

204

WRONG

DUETOWIRING

LOSSES.

APPEARS OK

CHECK AT UNIT

WIRING VOLT LOSSES WRONG FREQUENCY

LOW GENERATOR

OUTPUT ALTITUDE

B. SPECIFICATIONS (FIG. 1 .B)

CAL

ELECTRIC

MODEL

NO.'S

136.302

HEATER

Nominal Capacity (KW) 3.2

1.6

Electrical Rating

220-240V,,

Hz., Ph. 1

FL Amps

(Comp/Motor) 5.1/1.6

6.3/1.6

FIG. 1.6

DISC CONDITIONER

RATING PLATE

ERIAL

NUMBER

NEOPRENE RUBBER

** Normal Min.

Generator Size

** The Manufacturer gives only general guidelines for

Generator

requirements.

These Generator require-

ments come from experiences consumers have with

our equipment in field applications. When sizing

Generators, the total electrical power consumption of

the Caravan must be considered. Keep in mind that

Generators lose power because of altitude increases

above sea level, high outside temperatures, and lack

of maintenance.

NOTE: Some authorities require that this

appliance be Installed only by an authorized

electrlclan.

2. PRECAUTIONS FOR SAFE

INSTALLATION

A. Read these installation and operating instructions

thoroughly

and carefully before attempting installation

of Air Conditioner.

The Manufacturer will not be liable for any damages or

injury due to failure to follow these installation and

operating instructions.

Installation must comply with all applicable codes and/

or regulations.

DO NOT add any devices or accessories to this

equipment.

This equipment must be serviced only by qualified

service personnel. Some areas require installation

and service personnel to be licensed.

LOCATION

This air conditioner is designed for installation and use on

the roof of a Caravan. One or more units may be used on

the vehicle. Consider the van’s size, roof structure, and

cooling requirements when determining your needs.

A. DESIGN RECOMMENDATIONS

For one unit installation: The air conditioner should be

mounted slightly forward of center (front-to-back) and

centered from side-to-side on the van. (FIG.

3.A.1)

For two unit installation: Install one air conditioner

1/3

and one air conditioner 2/3’s back from front of van

and centered from side-to-side. (FIG. 3.A.2)

FIG. 3.A.1

IMPROPER INSTALLATION MAY DAMAGE EQUIP-

MENT, COULD ENDANGER LIFE, CAUSE SERIOUS

INJURY AND/OR PROPERTY DAMAGE.

FIG. 3.A.2

LENGTH

Many air conditioners can be installed at existing roof

vent openings. These openings may be larger or

smaller than 355 x355 mm and will need modification.

(FIG. 3.8)

Be sure your roof structure is capable of

support-

ing a weight of 65 Kg when the van is in motion.

(Normally if the roof can support a static load of

approximately 100 Kg it meets this requirement).

(FIG. 3.C.4)

AIR CONDITIONER ROOF VENT-REMOVE WEIGHT OF AK

FIG.

3.C.4

Check location acceptability before beginning the in-

stallation.

If possible, mount the air conditioner in a section of

the roof which is both flat and level when the van

is parked on a level surface; otherwise, a sideways

pitch or forward pitch up to 20 degrees can be

tolerated but a backward pitch can NEVER be

accepted.

Check on the roof to be sure no obstructions are

in the area where the air conditioner will be in-

stalled.

Check inside where the air conditioner air box will

be located to insure there will be no interference

with door openings, curtains, room dividers, etc.

(FIG. 3.C.3)

ROOF/AIR BOX CROSS-SECTION

-I---

------

355 mm

_---__---

PROHIBITS INSTALLATION

4. ROOF PREPARATIONS

Disconnect all Dower supplies to the van, insure the

generator (if

present

is shut off and disconnect the

positive battery terminal from the battery before per-

forming any cutting on

the van.

FAILURE TO FOLLOW

THIS INSTRUCTION MAY CREATE A SHOCK HAZARD.

(FIG. 4)

UNPLUG ALL

OWER TO COACH

TURN OFF

GENERATOR SETS

FIG. 4

FIG. 3.C.3

*CABINET

PROHIBITS USE

A.Roof Vent Locations (FIG. 4.A)

Remove all screws that secure the vent to the roof

and remove the vent from the opening.

There may be electrical wiring located

be-

Remove all sealing compound from around the

vent opening.

tween roof and ceiling. Disconnect all elec-

3. Seal all screw holes and all roof seams with a tricky. (FIG. 4)

quality all weather sealant.

REMO\E

SCREWS

f Seam)

3) SCRAPE PUTTY

SEAL HOLES

SEAMS

Carefully

cut

a matching hole through

the

ceiling

the van. (FIG.

4.B.3)

FIG. 4.B.3 AIR BOX PERIMETER

355 x 355 mm

Other:

Cutting new or modifying existing openings.

This opening should be located between roof

struc-

Seal holes and seams. (FIG. 4.A)

tural members.

Mark the 355 x 355 mm opening on the roof with a

marker. (FIG.

4.B.1)

Carefully cut the opening in the roof.

(FIG.

4.B.2)

FIG. 4.B.2

CUT HOLE

DEPENDS ON

STRUCTURE

DON’T REMOVE

STRUCTURE

GOOD

LINES

C. Roof Opening Preparations

If the opening exceeds

360 x 360

mm, make it

smaller by installing spacers or close-off plates.

If the opening is smaller than 350 x 350 mm, it will

be necessary to enlarge the opening; see FIG.

4.8.

Route a grounded power supply line from circuit

breaker or fuse box to the roof opening. (FIG.

4.C.3)

FIG. 4.C.3

The power supply must be a separate circuit,

fuse with a 10 amp Time Delay Fuse or 10 amp

Circuit Breaker.

The power supply must be grounded

1.5

COPPER supply for distances

7.5m

or less.

Thepowersupplywiring

MUST comply with all

applicable regulations and wiring codes.

Depending on entrance location, up to

1/2

meter of supply wire must extend into the roof

opening to insure ease of attachment to the air

conditioner.

If vent fan was removed, the existing wire may

be utilized, provided it is of

proper

size and

properly fused.

JUNC

BOX

EXCESS WIRE

Framing is required around the roof opening to insure

adequate support, provide a smooth surface for seal-

ing and prevent hot or cold air from being drawn into

the opening. This framing should be wood strips 380 x

25 mm X thickness of roof to ceiling distance. A hole for

the power supply must be provided. (FIG. 4.C.4.)

FRAME OPENING SO IT

FIG.

4.C.4

WON’T COLLAPSE WHEN

BOLTING DOWN APPLIANCE

LEAVE ACCESS FOR

POWER SUPPLY WIRING

NOTE:

Under no circumstances should the roof be

constructed to create a low spot where water will accumu-

late when the air conditioner is installed. This may create

a water leak into the interior of the Caravan.

5. PLACING AIR CONDITIONERS ON

ROOF

Remove the carton from the air conditioner and dis-

card. (FIG. 5.A.1)

FIG. 5.A.1

B. LIFT AND PLACE the unit over the prepared roof

opening. The

blunt

end of the air conditioner goes

toward the rear of

the

van. (FIG.

5.B.1)

Center the rubber gasket as near as possible over the

opening.

This completes the outside work. Minor adjustments to the

air conditioner position may be done from inside the van.

DO NOT slide the air conditioner across the roof. The

rubber gasket attached to the bottom of the air conditioner

will not seal properly if damaged or torn by sliding. (FIG.

5.B.2.)

FIG. 5.B.1.

LIFT AND

PLACE

CENTER ON OPENING

REAR

i.+f-

FIG.

5.B.2

SLIDE

6. UPPERDISCHARGE AIR DUCT

INSTALLATION (FIG. 6)

The upper discharge air duct is shipped inside the lower

discharge air duct attached to the ceiling template.

Remove the upper duct from the ceiling template duct

and install it over the blower discharge opening.

FIG. 6

NOTE: The edge without the flange goes toward the

rear of the van.

Secure the duct in place with two of the pointed screws

provided. There are prepunched holes in the base pan

for ease of installation.

SIDE WITHOUT

TAB TO REAR

OF APPLIANCE

CEILING TEMPLATE

INSTALLATION

Take the ceiling template and slide the lower discharge

air duct over the outside of the upper discharge air

duct.

Reach through the roof opening and adjust the air

conditioner until the gasket is centered on the opening.

(FIG. 7.A)

Reach up into the return air opening and pull the

conduit power cable down for later connection. (FIG.

7.B)

Measure the roof thickness:

If the distance is 25 to 50 mm, remove the perfo-

rated tabs on the upper discharge air duct and tabs

on the lower discharge air duct.

If the distance is 50 to 70 mm, remove the perfo-

rated tabs on the lower discharge air duct.

Holding the ceiling template in place with one hand,

install the three 150 mm long mounting bolts up

through theceilingtemplateand intotheairconditioner

with other hand, until mounting bolts are finger-tight.

(FIG. 7.E)

Evenly torque the three mounting bolts to 4.5 to 5 NM

to secure the air conditioner to the roof and insure a

good water seal. The rubber gasket (FIG.

7.A,

B, C)

should compress to roughly

1/2

of its original 25 mm

thickness.

If the distance is 75 to 110 mm, do not remove any

of the perforated tabs. (FIG. 7.C)

DO NOT over-tighten the mounting bolts as this may

damage the air conditioner base.

FIG.

GASKET

PULL CONDUIT

THROUGH

IF 25mm

CT<

50mm

IF 50mm

CT<

75mm

IF 75 mm

cT c 110 mm. INSTALL AS PACKAGED

CONNECTION OF POWER SUPPLY

Besure power supply is OFF before connecting

power supply leads to the air conditioner.

NOTICE

The electrical installation must be done by an author-

ity electrician.

You may either wire direct into the junction box for a

permanent connection or wire a molded plug into the

junction box for a plug-in connection.

If a Permanent Connection:

Route the power

supply line, previously installed to the roof open-

ing, into the junction box on the ceiling template.

Connect as described in part

below.

If a Plug-In Connection:

Use the electric supply

line, of part

4C3,

to power an electrical outlet

installed, according to applicable laws, at the end

of the roof opening furthest from the junction box.

CAUTION: DO NOT

plug the molded cord in

until you have completely installed the air

conditioner and are ready for an operational

check (Section 11).

Route the molded plug set from the electric outlet into the

junction box insuring not to coil excess wire so it will block

air flow. Connect the plug set to the terminal block as

described in Section

below.

Connect the power supply line to the air conditioner at

the terminal block provided in the junction box. Con-

nect red to red, black to black, and green to green or

bare copper wire (P, P, and

respectively).

Tighten the strain relief onto the power supply line, to

hold it firmly in place.

Carefully push all excess wire back into the junction

box and install cover onto the box with two blunt tipped

screws provided.

HEATER INSTALLATION

Install the heat package to the ceiling template using

the four (4) pointed screws provided. The heater

element will align below the discharge air opening and

the mounting holes will align with the prepunched

holes in the ceiling template.

Push the electrical plug onto the receptacle at the back

of the switch box. Push excess conduit up into the

return air opening.

Insure the insulation covering the conduit knockout in

the air box is still in place as shown.

LEAVE INSULATION IN PLACE

FIG.

/GRILL

-THIS

ONLY

FIG. 8

CEILING TEMPLATE

ELECTRICAL

POWER SUPPLY

SWITCH

BOX

REMOVE

KNOCKOUT

BOTTOM VIEW JUNCTION BOX 9

10. AIR BOX INSTALLATION

Remove the two return air grills and filters which are

shipped loose in the air box. (FIG. 10.A)

The power supply to the air conditioner may now be

turned ON.

Your air conditioner is now installed and ready for

operation. Please read the following instructions be-

fore attempting to run the unit.

FIG. 10.A.

Slide the front end of the air box over the shafts of the

thermostats and selector switch. (FIG. 10.B)

11. OPERATING INSTRUCTIONS

A. CONTROLS

The thermostat has a temperature range of 18.5%

in Cool

(0)

position to 32.5% in Warm

(0)

position.

The thermostat controls the unit

compressor ON and OFF cycle in the cooling

mode and the electric heater ON and OFF cycle in

FIG. 10.B

the heating mode.

Install the four screws through legs in air box into the

prepunched holes in the ceiling template. NOTE:

There are three optional mounting holes for which no

screws are provided. (FIG. 10.C)

Install the return air grills and filters by simply pushing

them into place. (FIG. 10.D)

Install the two knobs provided on the ends of the

thermostat and selector switch shafts.

FIG.

10.C.,

D., E

FIG.

11.A.1

The selector switch controls the unit fan speeds,

and the heating, cooling and fan modes of opera-

tion.

FIG. 11 .A.2

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