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 AV
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:
1.
A.
1.
3.
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
2

B. SPECIFICATIONS (FIG. 1 .B)
1 CAL
ELECTRIC
MODEL NO.'S
136.302 1 HEATER
Nominal Capacity (KW) 3.2
1.6
Electrical Rating
220-240V,, 50 Hz., Ph. 1
FL Amps
(Comp/Motor) 5.1/1.6
1 6.3/1.6
FIG. 1.6
DISC CONDITIONER
A
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.
B.
C.
D.
E.
3.
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
3

B.
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)
4. 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
C.
Check location acceptability before beginning the in-
stallation.
1. 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.
2. Check on the roof to be sure no obstructions are
in the area where the air conditioner will be in-
stalled.
3. 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
_---__---
T
/
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
4

A.Roof Vent Locations (FIG. 4.A)
1. Remove all screws that secure the vent to the roof
and remove the vent from the opening.
There may be electrical wiring located be-
2. 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.
4
1) REMO\E SCREWS
f Seam)
3) SCRAPE PUTTY
B.
1.
2.
SEAL HOLES
& SEAMS
3. Carefully cut a matching hole through the ceiling of
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-
4. 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
1. If the opening exceeds 360 x 360 mm, make it
smaller by installing spacers or close-off plates.
2. If the opening is smaller than 350 x 350 mm, it will
be necessary to enlarge the opening; see FIG.
4.8.
3. Route a grounded power supply line from circuit
breaker or fuse box to the roof opening. (FIG.
4.C.3)
a.
b.
C.
d.
e.
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 mm
2
COPPER supply for distances of 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
4. 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
A. Remove the carton from the air conditioner and dis-
card. (FIG. 5.A.1)
FIG. 5.A.1
6

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)
C. 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
c ,
REAR i.+f-
A.
B.
FIG. 5.B.2
SLIDE
AG
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
7

7.
A.
B.
C.
CEILING TEMPLATE
D.
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)
E.
Reach up into the return air opening and pull the
conduit power cable down for later connection. (FIG.
7.B)
Measure the roof thickness:
1. 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.
2.
If the distance is 50 to 70 mm, remove the perfo-
rated tabs on the lower discharge air duct.
3.
F.
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. 7
GASKET
PULL CONDUIT
THROUGH
IF 25mm CT< 50mm
IF 50mm CT< 75mm
IF 75 mm cT c 110 mm. INSTALL AS PACKAGED
8

8. 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.
A. 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.
1. 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 8B below.
2. 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 8B below.
B. 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
I respectively).
C.
D.
9.
A.
B.
C.
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 YD ONLY
FIG. 8
CEILING TEMPLATE
ELECTRICAL
POWER SUPPLY
SWITCH
BOX
REMOVE
KNOCKOUT
I
J
BOTTOM VIEW JUNCTION BOX 9

10. AIR BOX INSTALLATION
A. Remove the two return air grills and filters which are
shipped loose in the air box. (FIG. 10.A)
F.
G.
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.
B. 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
1. 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.
C.
D.
E.
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
10
FIG. 11.A.1
I
2. The selector switch controls the unit fan speeds,
and the heating, cooling and fan modes of opera-
tion.
FIG. 11 .A.2

B. COOLING OPERATION
1. Set the thermostat to the position which will
give your desired comfort level.
2. The selector switch is to be set as follows:
a. HIGH COOL: (30 ): Selected when
maximum cooling and dehumidifying is
required.
b. MED. COOL: (2 0): Selected when
medium cooling is required.
c. LOW COOL: (10 ): Selected when
minimum cooling IS required. Normally
this position is selected for night-time
operation.
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 theairand maintain an even temperature
in the van. It does not come on and off with the
compressor.
C. FAN OPERATION
When you wish to circulate the air inside your van
without heating or cooling, select one of the three fan
speeds:
(1 @& 2 @&, or 3 @& ). The fan will run continu-
ously and circulate the air in the van.
I
“[go
“FAN”
1
FIG. 11 .B.1
I
I
FIG. 11 .B.2
- I
I
0;
= COOLING
I
. I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
“COOLING”
ROOM
TEMPERATURE
COOLING
FAN
ON ON
“CIRCULATION” -
ROOM
TEMPERATURE
25°C
B 69
=
L
mmmmmmme------------
FIG. ll.C
11

D.
HEATING OPERATION
NOTE: This electric heater will not replace a furnace
for heating your van in cold weather. It is intended to
remove the chill from the air on cool days or mornings
only.
1. Set the thermostat to the position which will give
your desired comfort level.
2. The selector switch can be set in any of the three
heating positions, but normally it will be placed in
the Low Heat (la ) 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.
NOTE: The air conditioner fan runs continuously to
circulate the air in the van. It does not come on and off
with the heater.
E. POSITION
To shut the air conditioner OFF, place the selector
switch in the OFF position, (0).
I- “OFF” -I
I \
I I
0
II
HEAT COOLING FAN
OFF OFF
OFF
FIG. 11 .E
F. When the air conditioner is turned on and the thermo-
stat 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 thermo-
stat, 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.
FIG. 11 .D.1
I
I
II
=
I
II
I
I
FIG. 11 .D.2
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
FIG. ll.D
25” c.
HEATING
- “HEATING”
ROOM
TEMPERATURE HEAT
ON
FAN
ON
ROOM
TEMPERATURE
HEAT
OFF
*
FAN
ON
L
________-_---_----
FIG. ll.F COOLING ON
MINUTES
12

12. MAINTENANCE
AIR FILTERS: Periodically remove the return air filters
located above the removable panels in the air box. Wash
filters with soap and warm water, let dry and then reinstall
(FIG. 10.C)
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.
FROST FORMATION on Cooling Unit: Under certain
conditions, frost may form on the evaporator coil. If this
should occur, inspect the filter and clean if dirty. Make sure
air louvers are not obstructed. Air conditioners have a
greater tendency to frost when the outside temperature is
relatively low. This may be prevented by adjusting the
thermostat control knob to a warmer setting (counterclock-
wise). Should frosting continue, operate on low, med., or
high FAN setting until the cooling coil is free of frost.
13. SERVICE - Unit Does Not Operate
If your unit fails to operate or operates improperly, check
the following before calling your service center.
D.
A.
B.
C.
If the van is connected to a motor generator, check to
be sure the motor generator is running and producing
power.
E.
In the air conditioner air box, check to be sure the air
conditioner conduit is plugged into the selector switch
box. (FIG. 8.E)
After the above checks, call your local service center
for further help. This unit must be serviced by qualified
service personnel only.
If the van is connected to a power supply by a land line,
check to be sure the line is sized properly to run your
air conditioner load and that it is plugged into the power
supply.
When calling for service, always give the air conditioner
Model Number, Product Number, and Serial Number. This
information can be found on the unit rating plate located on
the air conditioner base pan. To locate these, remove the
return air grill from the air box and look up through the roof
Check your fuse or circuit breaker. opening in the ceiling. (FIG. 2 and 10.A)
13

R CONDITIONE
. . . . . . . . . .
... . . . ....
.
. . .._.....__.................. . . .
.,.._._,_.._..._................ . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . . . . . . . . .
. . . . .
. . .
. . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. .
.._,,........
..,,........ . . . . .
_...,............
PREPARED ..‘..‘:;:.‘::::.‘;.‘.‘::.‘:::
:. . . . .
INSTALLATION
.._...,.......... . . .
‘,‘,.,
UNIT MOUNTING
BOLTS (150mm)
MOUNTING LEGS
DISCHARGE AIR
RATING PLATE & SERIAL NO.
NEOPRENE RUBBER GASKET
UPPER DISCHARGE AIR DUCT
ROOF LINE
ROOF REINFORCEMENT
MEMBER
POWER SUPPLY LINE
25 X 380mm THICK FRAMING
LOWER DISCHARGE AIR DUCT
(Attached to ceiling template)
UNlT MOUNTlNG BOLTS(15Omm)
CEILING TEMPLATE
JUNCTION BOX
HEAT PACKAGE
MOUNTING LEGS
AIR BOX
14

WIRING DIAGRAM
LIMIT SWITCH
HEAT PACKAGE
; L___
--- 220/240V 50 Hz 10
__ USE COPF’ER CONDUCTORS ONLY
I
ELECTRICAL
BOX
COMPRESSOR
FACTORY WIRING
___
FIELD WlRlNG ----
UNE SPLICE l
I
PTCR
THERMOSTAT
3 104972.009
15