Dometic CARAVAN B3200 Manual

22
INSTALLATION & OPERATING
INSTRUCTIONS
Important:TheseInstructions
must stay with unit.
Ownerreadcarefully.
This manual must be read and understood before installation, adjustment,
service, or maintenance is performed.This unit must be installed by a quali-
fied service technician. Modification of this product can be extremely haz-
ardous and could result in personal injury or property damage.
Roof-Top Air Conditioner
CARAVAN MODEL B3200
TYPE 3253.331
Model
B3200
SERVICE OFFICE
DometicCorporation
ForInformation
Contact:
www.dometic.com
FormNo.3310147.000
Danish, Dutch, English,
Finnish,French,German,
Greek,Italian,Norwegian,
Portuguese,Spanish& Swedish
©20055/05 Dometic GmbH
D-57074Siegen
RECORDTHISUNITINFORMATION
FORFUTUREREFERENCE:
Model Number
Serial Number
Date Purchased

23
SAFETY INSTRUCTIONS
This manual has safety information and instruc-
tionstohelpuserseliminate or reducethe risk of
accidents and injuries.
RECOGNIZE SAFETY INFORMATION
Thisisthe safety-alert symbol.Whenyouseethis
symbol in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe op-
erating instructions.
UNDERSTAND SIGNAL WORDS
Asignal word, WARNING ORCAUTION isused
with the safety-alert symbol.They give the level
of risk for potential injury.
indicates apotentially hazard-
ous situation which, if not avoided, could result
in death or serious injury.
indicates a potentially hazard-
ous situation which, if not avoided may result in
minor or moderate injury.
used without the safety alert
symbol indicates, a potentially hazardous situa-
tion which, if not avoided may result in property
damage.
Read and follow all safety information and in-
structions.
!
WARNING
!
CAUTION
CAUTION
!
GENERAL INFORMATION
A. Product features or specifications as described or
illustrated are subject to change without notice.
B. This Air Conditioner Is Designed For:
1. Installation on a Caravan during the timetheCara-
vanis manufactured.
2. Mounting on the roof of a Caravan.
3. Roofconstructionwithrafters/joistsonminimumof
406mmcenters.
4. Minimum of 25mm and maximum of 100mm dis-
tancebetweenrooftoceilingof Caravan.Alternate
installation methods will allow for roofs more than
100mm thick.
C. Theabilityoftheairconditionertomaintainthedesired
inside temperature depends on the heat gain of the
Caravan.
Somepreventativemeasurestakenbytheoccupantsof
theCaravancanreducetheheat gainandimprovethe
performance of the air conditioner. During extremely
highoutdoortemperatures,theheatgainoftheCaravan
may be reduced by:
1. ParkingtheCaravaninashadedarea
2. Usingwindowshades(blindsand/orcurtains)
3. Keeping windows and doors shut or minimizing
usage
4. Avoidingthe use ofheat producingappliances
OperationonHighFan/Coolingmodewillgiveoptimum
ormaximumefficiency in highhumidityorhigh outside
temperatures.
Starting the air conditioner early in the morning and
giving it a "head start" on the expected high outdoor
ambient will greatly improve its ability to maintain the
desiredindoortemperature.
For a more permanent solution to high heat gain,
accessorieslikeanoutdoorpatioandwindowawningwill
reduceheatgainbyremovingthedirectsun.Theyalso
addaniceareatoenjoycompanyduringthecoolofthe
evening.
D. Condensation
Note: The manufacturer of this air conditioner will not be
responsiblefordamagecausedbycondensedmoistureon
ceilings or other surfaces. Air contains moisture and this
moisture tends to condense on cold surfaces. When air
enterstheCaravan,condensedmoisturemayappearonthe
ceiling, windows, metal parts, etc. The air conditioner
removesthismoisturefromtheairduringnormaloperation.
Keepingdoorsandwindowsclosedwhenthisairconditioner
is in operation will minimize condensed moisture on cold
surfaces.

24
** TheManufacturergivesGENERALguidelinesforgen-
erator requirements. These guidelines come from experi-
ences people have had in actual applications.
When sizing the generator, the total power usage of your
Caravanmustbeconsidered.Keepinmindgeneratorslose
power at high altitudes and from lack of maintenance.
Specifications
A. Precautions
INSTALLATION INSTRUCTIONS
B. Choosing Proper Location For The Air
Conditioner
Thisairconditionerisspecificallydesignedforinstallationon
the roof of a Caravan. When determining your cooling
requirements,thefollowingshouldbeconsidered:
•Size of Caravan;
•Windowarea(increasesheatgain);
•Amount of insulation in walls and roof;
•GeographicallocationwheretheCaravanwillbeused;
•Personalcomfortlevelrequired.
1. NormalLocation-Theairconditionerisdesignedto
fit over an existing roof vent opening.
FIG. 1
1/2L LL
1/3L
2/3L
FIG. 2
It is preferred that the air conditioner be installed on a
relatively flat and level roof section measured with the
Caravanparked on alevel surface.
Note:A8°slanttoeithersideisacceptable,butaFrontto
Back slant is not acceptable.
FIG. 3
Font to Back Slope Is NOT ACCEPTABLE
Model No. B3200 Electric
Heater
Type 3253.331
NominalCompressor
Capacity(KW) 3.2 1.5
ElectricalRating 220-240 VAC 50Hz., 1 Ph
Full Load Amps
(Compressor/Motor) 5.2 / 0.8 6.0 / 0.8
LockedRotorAmps
(Comp / Motor) 24 / 5.0 6.0 / 5.0
CircuitProtection 10 Amp Time Delay Fuse,
orCircuitBreaker
InputPower(KW) 1.35 1.64
Minimum Wire Size Up to 8 meters
use1mm2,Copper
**GeneratorSize 1 Unit - 3.5KW
2 Units - 5.0KW
Improperinstallation may damage equipment,
could endanger life, cause serious injury and/
or property damage.
1. ReadInstallationandOperatingInstructionscare-
fully before attempting to start your air conditioner
installation.
2. TheManufacturerwillnotbeliableforanydamages
or injury incurred due to failure in following these
instructions.
3. Installation must comply with all applicable codes
and/orregulations.
4. DONOTaddanydevicesoraccessoriestothisair
conditionerexceptthosespecificallyauthorizedby
TheManufacturer.
5. This equipment must be serviced by qualified
personnel and some local codes and regulations
requirethesepeopleto be licensed.
2. Other Locations-When no roof vent is available or
anotherlocationisdesired,thefollowingisrecom-
mended:
a. For one unit installation: The air conditioner
should be mounted slightly forward of center
(front to back) and centered from side to side.
b. Fortwounitinstallations:InstalloneAirCondi-
tioner 1/3 and one Air Conditioner 2/3’s from
frontofCaravanandcenteredfromsidetoside.

25
CAUTION
C. Roof Preparation
1. OpeningRequirements-Beforepreparingtheceil-
ing opening, read all of the following instructions
beforebeginningtheinstallation.
If an existing roof vent opening will not be used a
362mm x 362mm (± 3.2mm) opening must be cut
through the roof and ceiling of the Caravan. This
openingmustbelocatedbetweentheroofreinforc-
ingmembers.
There may be electrical wiring between the
roof and the ceiling.Disconnect 220 - 240Volt
AC power cord and the positive (+) 12Volt DC
terminal at the supply battery. Failure to fol-
low this instruction may create a shock haz-
ard causing death or severe personal injury.
FIG. 5
The362mmx362mm (± 3.2mm) openingispartof
thereturnairsystemoftheAirConditionerandmust
be finished in accordance with all Nation and local
codesand/orregulations.
2. RoofVentRemoval
a. Unscrewand remove the roof vent.
b. Remove all caulking compound around open-
ing.
c. Sealallscrewholesandseamswheretheroof
gasket is located. Use a good grade of all
weather sealant. See FIG. 6.
9-1/2"
39"
28-3/4"
20"
2-1/2"
22"
FIG. 4
24cm
102cm
74cm
51cm
6.4cm
56cm
510mm
283
mm
105
mm 105
mm
283
mm
75mm
75mm
Center Line
Of Opening
Air Box
Perimeter
Keep This Area
Free From
Obstructions
105mm
181mm
181mm
362mmx
362mm
(± 3.2mm)
Opening
543mm
Center Line Of Unit
305mm
102mm
102mm
Rear
Of
Unit
362mm x
362mm
(± 3.2mm)
Opening
3. After Location Has Been Selected:
a. Check for obstructions in the area where air
conditioner will be installed. See FIG. 4.
b. The roof must be designed to support 65 Kg.
when the Caravan is in motion. Normally
a 100Kg. static load design will meet this
requirement.
It is the responsibility of the installer of this
air conditioner system to ensure structural in-
tegrity of the Caravan roof. Never create a low
spot on the roof where water will collect.Wa-
ter standing around the air conditioner may
leak into the interior causing damage to the
product and the Caravan.
c. Check inside the Caravan for return air kit
obstructions(i.e.dooropenings,roomdividers,
curtains,ceiling fixtures,etc.). See FIG.4 &5.

26
FIG. 6
FIG. 7
DoNotCut
RoofStructure
OrRafters
Good-Rafters
SupportedBy
CrossBeams
GoodLocation-
BetweenRoof
Rafters
Frame Opening So It
Won'tCollapseWhen
BoltingDownUnit
LeaveAccessForPower
Supply Wiring 375mm Min. At
Front of opening
25mm Min.
d. If the opening exceeds 362mm x 362mm
(± 3.2mm), it will be necessary to re-size the
opening to 362mm x 362mm (± 3.2mm).
e. If the opening is less than 362mm x 362mm
(± 3.2mm), it must be enlarged.
3. NewOpening-(InstallationOtherThanVentOpen-
ing)
a. Marka362mmx362mm(±3.2mm)squareon
the roof and carefully cut the opening.
b. Using the roof opening as a guide, cut the
matching hole in the ceiling.
c. Theopeningcreatedmustbeframedtoprovide
adequate support and prevent air from being
drawn from the roof cavity. Lumber 25mm or
moreinthicknessmustbeused.Rememberto
provideanentranceholeforpowersuppliesat
the front of the opening. See FIG. 7.
It is the responsibility of the installer of this
air conditioner system to ensure structural
integrity of the Caravan roof. Never create a
low spot on the roof where water will collect.
Water standing around the airconditionermay
leak into the interior causing damage to the
product and the Caravan.
CAUTION
D. Wiring Requirements
1. 220 - 240 VAC Supply Line
Routeacopper1mm2,withground,220-240VAC
supply line from the time delay fuse or circuit
breakerboxto the roofopening.
a. This supply line must be located in the front
portion of the 362mm x 362mm (± 3.2mm)
opening.
b. ThepowerMUSTbeonaseparate10Amptime
delay fuse or HACR circuit breaker.
c. Make sure that at least 375mm of supply wire
extendsintotheroofopening.Thisensuresan
easy connection at the junction box.
d. WiringmustcomplywithallNationalandLocal
WiringCodesand/orregulations.
e. Useasteelsleeveandagrommetorequivalent
methodstoprotectthewirewhereitpassesinto
theopening.
E. Placing Air Conditioner OnThe Roof
Thisunitweighsapproximately45Kilograms.
Topreventbackinjury,useamechanicalhoist
to place Air Conditioner on roof.
FIG. 8
Do not slide the unit. This may damage the
roof gasket attached to the bottom and may
create a leaky installation.
CAUTION
FIG. 9 FRONT
1. Removetheairconditionerfromthecartonanddis-
card carton.See FIG.8.
2. Place the air conditioner on the roof.
3. Lift and place the unit over the prepared opening
usingthegasketontheunitasaguide.SeeFIG.9.

27
FIG. 11
Step a
RemoveAt
Perforation Step b
RemoveAt
Perforation
Step c
UseAs
Packaged
UpperDischarge
AirDuct
LowerDischarge
AirDuct
RearOfAir
Conditioner
UpperDischarge
AirDuct EdgeWithout
Flange To
RearOfUnit
FIG. 10
If bolts are left loose there may not be an ad-
equate roof seal or if over tightened, damage
may occur to the air conditioner base or ceil-
ing template.Tighten to torque specifications
listed in this manual.
CAUTION
FIG. 12 Slide Lower Air
DischargeDuct
OverUpperDuct
Roof
Gasket
Hold Ceiling Template With
One Hand And Install 3
Mounting Bolts Finger Tight
AirConditioner
ReturnAir
Opening
Disconnect 220 - 240 Volt AC. Failure to follow
theseinstructions could create a shockhazard
causing death or severe personal injury.
WARNING
!
4. PlacetheMechanicalAirDistributionBoxKitinside
theCaravan.Thisboxcontainsmountinghardware
for the air conditioner and will be used inside the
Caravan.
Thiscompletestheoutsidework.Minoradjustmentscanbe
done from the inside of the Caravan if required.
F. Installing The Air Conditioner
1. Removeair box and mounting hardware from car-
ton. Theupperductisshippedinsidethelowerduct
which is part of the ceiling template.
2. Check for correct alignment and adjust the unit as
necessary (Roof Gasket centers over 362mm x
362mm(±3.2mm).
3. Removeupperductfromceilingtemplateandlocate
it over blower discharge. See FIG. 10.
Note:EdgewithoutflangeinstallstowardREARofopening.
4. Usetwo(2)sharppointed#10sheetmetal screws
toholdducttobasepan. Screwholesareprovided
in bottom of base pan for these screws.
5. Reachupintoreturnairopeningoftheairconditioner
and pull the unit's electrical cord down for later
connection.
6. Measure the ceiling to roof thickness:
a. Ifdistanceis25mm-50mm,removeperforated
tabs from both upper and lower ducts. See
FIG. 11.
b. Ifdistanceis50mm- 75mm,removeperforated
tabs from bottom duct only. See FIG. 11.
c. If distance is 75mm - 100mm, install ducts as
received. See FIG. 11.
7. Install ceiling template by sliding lower duct over
upper duct. See FIG. 12.
8. Holdtheceilingtemplatewithonehandandwiththe
other,installthethree150mmlongmountingbolts
through the template and into the base pan.
a. Finger-tighten the bolts and check alignment.
Thereshouldbeanequalopeningoneachside
andtherearflangemustbetightagainsttheroof
opening.
b. EVENLYtightenthethreeboltstoatorqueof
4.5 to 5.5 NM (Newton Meters). This will
compresstheroofgaskettoapproximately
13mm. The bolts are self locking so over
tighteningisnotnecessary.
G. Connection Of Power Supply To Air
Conditioner
Important: The electrical installation must be done
by an authorized electrician. In some areas they must
be licensed.

28
1. You may either wire direct into the junction box for
apermanentconnectionorwireamoldedpluginto
the junction box for a plug-in connection.
a. If a Permanent Connection: Route the power
supply line, previously installed to the roof
opening, into the junction box on the ceiling
template.Connectasdescribedinparagraph2.
b. IfaPlug-inConnection:Usetheelectricsupply
line,of"D.WiringRequirements",topowerand
electrical outlet installed, according to appli-
cablelaw,attheendoftheroofopeningfurthest
from the junction box.
Important: Do not plug the molded cord in until you
have completely installed the air conditioner and are
readyforanoperationalcheck.(OperatingInstructions)
•Routethemoldedplugsetfromtheelectric
outletintothejunctionsboxinsuringnotto
coil excess wire so it will block air flow.
Connect the plug set to the terminal block
asdescribedinparagraph2.
2. Connectthepowersupplylinetotheairconditioner
at the terminal block provided in the junction box.
Connectwhitetowhite,blacktoblackandgreento
greenorbarecopperwire(L.N.and respectively).
3. Tightenthestrainreliefontothepowersupplylineto
holdfirmlyinplace.Becarefulnottopinchandshort
wires.
Note:Ifoptionalelectricheaterispartofthisinstallation,now
is the time to install it. Installation instructions are provided
with the electric heater kit.
4. Carefullypushallexcesswirebackintothejunction
box and install cover onto the box with two blunt
screwsprovided.
5. Plug the electrical conduit from the upper unit into
the mating switch box connector. See FIG. 13.
6. Wrap wire tie around plug connector(s) to prevent
removal in field service.
FIG. 13
Route Power Supply
Through Romex
Connector
Plug Conduit Into
Switch Box And
SecureWithWire
TieTo Prevent
Removal
Install
Cover
H. Air Distribution Box Installation
1. Remove the two return air grills and filters.
2. Slide the front end of the air box over the shafts of
the thermostat and selector switch. See FIG. 14.
FIG. 14
Slide Air Box over Controls
3. Install four screws through legs in air box into the
pre-punchedholes in theceiling template.
4. Installthereturnairgrills and filters by simplypush-
ing them into place.
5. Install the two knobs provided on the ends of the
thermostat and selector switch shafts.
6. The power supply to the air conditioner may now
beturned"ON".
7. Your air conditioner is now installed and ready for
operation.Pleasereadthefollowing instructionsbe-
fore attempting to run the unit.
OPERATING INSTRUCTIONS
A. Controls
1. The Selector Switch has eight positions including
"OFF".Thiscontrolsfanspeed,heatingmode,and
cooling modes. See FIG. 15.
FIG. 15
SelectorSwitch
3
2
1
1
2
3
FIG. 16
2. The thermostat controls the compressor ON/OFF
operationincoolingtemperaturerangeof18.5°Cto
32.5° C. See FIG. 16.
Note: The thermostat does not control the unit optional
electric heater if installed.
Thermostat

29
B. Cooling Operation
1. Setthethermostatatthedesiredtemperaturelevel.
2. Selectthefanspeedthatbestsatisfiesyourneeds:
a. HIGHCOOL: Selectedwhenmaximumcooling
anddehumidificationrequired.(3 )
b. MEDCOOL:Selectedwhennormaloraverage
coolingrequired.(2 )
c. LOW COOL: Selected when room at desired
comfort level and needs to be maintained.
Normallythisspeedusedfornighttimeopera-
tion. (1 )
Important:Whentheairconditioneristurned onand
thethermostatcallsforcooling,thefanandcompressor
startatthesametime.Aftershuttingtheairconditioner
down manually by either the selector switch or the
thermostat, always wait 2-3 minutes before turning on
theairconditioner.Thisallowstherefrigerantpressures
intheairconditionersystemtoequalizesothecompres-
sormayrestart.
Note: The blower runs continuously to circulate air and
maintainaneventemperature. Thecompressorwillcomeon
ascoolingisrequiredtomaintaintheselectedtemperature
level.
C. Fan Operation
1. This will circulate the air in your Caravan without
coolingorheating.Therearethreepositions:HIGH
FAN (3 ), MED FAN (2 )or LOW FAN (1 )to
selectfrom,dependinguponpersonalchoice.See
FIG.15.
D. Heating Operation (If soequipped)
Note: This electric heater will not replace a furnace for
heatingyourCaravanincoldweather.Theintentistoremove
the chill on cool days or mornings.
1. Turntheselectorswitchto"OPTHEAT"( ).
See FIG. 15.
2. TheHeaterwillcome on andbeginheating.
3. When desired temperature level in Caravan is
reached, move the selector switch to "OFF" or
"FAN"position.
Note:ThermostatdoesnotcontrolheaterON/OFFcycle.If
theoptionalheaterisnotinstalledandselected,thefanwill
runas"LOWFAN" operation.
E. "OFF" Position
1. This is to turn Unit off.
F. Customer Maintenance
1. Periodically remove the return air filters located
abovetheremovablepanelsintheairbox.Washthe
filters with soap and warm water, let dry and then
reinstall.
Note:Neverruntheairconditionerwithoutreturnairfilterin
place. This may plug the unit evaporator coil with dirt and
may substantially affect the performance of the unit.
2. Cleanairboxhousing andcontrolpanelwithasoft
cloth dampened with a mild detergent. Never use
furniturepolishorscouringpowders.
3. Theblowermotorisfactorylubricatedandrequires
noservice under normaluse.
4. Under certain conditions, frost may form on the
evaporator coil. If this should occur, inspect the
filterandcleanifdirty.Makesureairlouversarenot
obstructed. Air conditioners have a greater ten-
dency to frost when the outside temperature is
relatively low. This may be prevented by adjusting
the thermostat control knob to a warmer setting
(counterclockwise).Shouldfrostingcontinue,oper-
ateonLOW,MED,orHIGH FAN onlysetting until
the cooling coil is free of frost.
5. Ifyour unit fails to operate or operated improperly,
check the following before calling your service
center.
a. IfCaravanconnectedtomotorgenerator,check
to be sure motor generator is running and
producingpower.
b. IfCaravanconnectedtopowersupplybyaland
line, check to be sure line is sized properly to
run air conditioner load and it is plugged into
powersupply.
c. Check your fuseor circuit breakerto see ifit is
open.
d. After the above checks, call your local service
center for further help. This unit must be ser-
viced by qualified service personnel only.
6. If any wiring or supply cord is damaged and
needs to be replaced, it must be replaced by the
manufacturer or its service agent or a similarly
qualifiedperson.
7. Whencallingforservice,alwaysgivethefollowing:
a. AirConditionerModelandSerialNumberfound
on rating plate located on base pan of air
conditionerbottom.
b. AirDistributionBoxKitPartandSerialNumber
found on rating plate located on ceiling tem-
plate.Observe this ratingplate throughthe air
box filter grill opening.

30
RoofMountAssembly
Rear
AirConditioner
UpperDischarge
Duct
CeilingTemplate
MountingBolts
AirBox
RoofOpening
FIG. 17

31
AIR CONDITIONER WIRING DIAGRAM
AIR BOX WIRING DIAGRAM
3105595.015
PASSED
DIELECTRIC
GR/YL
FAN CAP
FAN CAP
BLU
5
6
7
GR/YL
WHT
WHT
1
2
3
4
RED
YEL
BLK
ID
BRN
BRN
RED
RUN CAP
RUN CAP
WHT
MOTOR
ID
RED
RED
R
WHT
C
S
O.L.
COMPRESSOR
COMP STARTER
COMP STARTER
PTCR
*
START
CAP
COMPRESSOR
COMPRESSOR
O.L.
RS
C
RUN CAP
RUN CAP
7
6
5
4
3
2
1
SWITCH
ROTARY
H
C
L1
4
2
1
MOTOR
2
HEAT ACCESSORY
HEAT ACCESSORY
BLK
BLK
BLK
ELEMENT
LIMIT SWITCH
3
1
WHT
LIMIT SWITCH
BOX
JUNCTION
JUNCTION
LINE SPLICE
LINE SPLICE
FIELD WIRING
FIELD WIRING
FACTORY WIRING
TSTAT
TSTAT
USE COPPER CONDUCTORS ONLY
USE COPPER CONDUCTORS ONLY
220/240 VAC 50 HZ, 10
220/240 VAC 50 HZ, 10
3105580.025
FAN CAP
FAN CAP
ID
ID
BLK
YEL
RED
BLU
WHT
WHT
GR/YL
BLK
YEL
RED
BLU
WHT
WHT
GR/YL
BRN
BRN
WHT
RED
RED
WHT
GRY
WHT
WHT
BLK
GR/YL GR/YL
GR/YL
BLU
43
ACTIVE (L)
ACTIVE (L)
NEUTRAL (N)
NEUTRAL (N)
EARTH ( )
EARTH ()
GR/YL
GR/YL
PTCR
COMP STARTER
START
*
CAP