Dometic CAL61.003 Manual

INSTALLATION &
OPERATING INSTRUCTIONS
CARAVAN ROOF MOUNT AIR CONDITIONER
MODEL CAL61.003 PRODUCT NO. 9916403-01
MODEL CAL136.003 PRODUCT NO. 9916503-01
INCLUDES ELECTRIC HEAT KIT
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.
Form No.3100377.013 10/86

1. GENERAL INFORMATION
A. THREE SPECIFIC NEEDS:
1.
Installation opening
Cut through roof and ceiling
,@&
2.
Additional Wiring
115V-60 Hz -
20 Amo
, 5PECIAL
SHORE LINE
COMPARTMENT
FUSE PANEL
3. Power must be above 105V- and frequency
must be 60 Hz at all times.
04V - WRONG
WIRING VOLT LOSSES
WRONG FREQUENCY
LOW GENERATOR
OUTPUT
ALTITUDE
- 2-

B.
SPECIFICATIONS (FIG. 1 .B)
WARNING
IMPROPER INSTALLATION MAY DAMAGE
EQUIPMENT, COULD ENDANGER LIFE, CAUSE
SERIOUS
INJURY AND/OR PROPERTY
DAMAGE.
MODEL NO.‘s
1 CAL 136 1 CAL 61
ELECTRIC 1
Nominal Capacity (KW) 3.9 2.1 I 1.6
Electrical Rating 115V- 60 He. 1 Ph.
FL Amps (Camp/Motor) 12.413.1 8.112.9 12.7
LR Amps (Camp/Motor) 63.5185 34.216.9 NA
Power (KW) 1.7 1.1 1.53
Min. Wire Size Up to 8 meters, use 2.5
mm2 Copper
Circuit Protection 20 Amp Time Delay Fuse or
20 Amp Circuit Breaker, Time Delay
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.
DISCHARGE AIR
NEOPRENERUBBER
Front\
GASKET
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.
**Normal Min.
1 Unit 3SKW
Generator Size 2 Units
S.OKW
**
The Manufacturer gives only general guidelines
for Generator reauirements. These Generator
requirements come from experience 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.
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 installations: Install one Air
Conditioner l/3 and one Air conditioner
2/3’s back from front of van and centered
from side to side. (FIG. 3.A.2)
L = Length
NOTE:
Some authorities require that this appliance be
installed only by an authorized electrician.
PRECAUTIONS FOR
SAFE INSTALLATION
Read
these
installation and
instructions thoroughly and
before attempting installation
Conditioner.
2.
A.
operating
carefully
of Air

B.
Many air conditioners can be installed at
existing
roof vent
openings. These
openings may be larger or smaller than 355
X 355 mm and will need modification.
(FIG. 3.B)
4.
Be sure your roof structure is capable
of supporting 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)
FORCE WHILE
MOVING
WEIGHT OF A/C
PLUS SERVICE
C. Check location acceptability before
beginning the installation.
4. ROOF PREPARATIONS
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 up to 20” can be
tolerated but a backward pitch can
never be accepted.
WARNING
Disconnect all power supplies to the van, insure
the generator is shut off if present and
disconnect the positive battery terminal from
the battery before performing any cutting on
the van. FAILURE TO FOLLOW THIS
INSTRUCTION MAY CREATE A SHOCK
HAZARD. (FIG. 4)
20 * WITH A/C
FACING FORWARD
FIG. 3.C.l
Turn Off
Generator Setr
2.
Check on the roof to be sure no
obstructions are in the area where
the air conditioner will be installed.
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)
FIG. 4.
t
Disconnect
d Battery
ROOF/AIR BOX CROSS-SECTION FIG. 3.C.3
T
PROHIBITS INSTALLATION
P
*CABINET - PROHIBITS USE
-4-

A.
Roof Vent Locations (FIG. 4.A.)
CAUTION:
1. Remove all screws that secure the
vent to the roof and remove the vent There may he electrical wiring located between
roof and
from the opening.
ceiling.
Disconnect all electricity.
2.
Remove all sealing compound from (FIG. 4.)
around the vent opening.
3. Seal all screw holes and all roof
seams with a quality all weather
sealant.
3. Carefully cut a matching hole through
4the ceiling of the van. (FIG. 4.B.3)
1. Remove Screwr
FIG. 4.A
+- t
355 X 355mm
.--- ___
-------7 Opening
75mm
I
f
A
-I-
cantu Lin
Iot
opming
4 + + AG--ICEmm
/
$1
75mmI
1
_______y _______[
C 283mm
c 283mm-e
FIG.4.B.3
B. Other: Cutting new or modifying existing
openings. This opening should be located
between roof structural members.
1.
Mark the 355 X 355 mm opening on
the roof with a marker. (FIG. 4.B.l)
2.
Carefully cut the
(FIG. 4.B.2)
CUT HOLE
opening in the roof.
FIG. 4.B.2
4.
Seal holes and seams. (FIG. 4.A)
y-s&sL ”
NO BLOCKAGES
DON’T REMOVE
STRUCTURE
GOOD
DEPENDS ON
STRUCTURE

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 4.B.
3. Route a grounded power supply line
from circuit breaker or fuse box to
the roof opening. (FIG. 4.C.3)
a. The power supply must be a
separate circuit, fused with a 20
amp Time Delay Fuse or 20 amp
Circuit Breaker.
b.
The power
supply
must be
grounded 2.5 mm2 COPPER sup-
ply for distances of 7.5m or
less.
C. The power supply wiring MUST
comply with all applicable
regulations and wiring codes.
d. Depending on entrance location,
up to l/2 meter of supply wire
must extend into the roof
opening to insure ease of
attachment to the air
conditioner.
e. If vent fan was removed, the
existing wire may be utilized,
provided it is of proDer size and
properlv fused.
BOX
FIG. 4.C.3 600 mm
EXCESS WIRE
FOR HOOK-UP
4.
Framing is required around the roof
opening to insure adequate support,
provide a smooth surface for sealing
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.
FIG. 4.C.4
FRAME OPENING SO IT
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 accumulate
when the air conditioner is installed.
This may create a water leak into
the interior of the Caravan.
5.
A.
&W&lO3FOF AIR CONDITIONERS
Remove the carton from the
conditioner and discard. (FIG. 5.A.l)
air
- 6-

B. LIFT AND PLACE the unit over the
prepared roof opening. The blunt end of
the air conditioner goes toward the m
of the van. (FIG. 5.B.l)
CAUTION:
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.2
DON’T SLIDE
OR DRAG
6. UPPER DISCHARGE AIR DUCT
INSTALLATION (FIG. 6)
The upper discharge air duct is shipped inside
the lower discharge air duct attached to the
ceiling template.
A. Remove the upper duct from the ceiling
template duct and install it over the
blower discharge opening.
NOTE: The edge without the flange goes
toward the rear of the van.
B.
Secure the duct in place with two of the
pointed
screws
provided.
There are
prepunched holes in the base pan for ease
of installation.
i+
TSIDE WITHOUT
gbJ
TAB TO REAR
1;
OF APPLIANCE
7 \OWER
-7-

7.
A.
B.
C.
CEILING TEMPLATE
INSTALLATION
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:
1.
If the distance is 25 to 50 mm,
remove the perforated tabs on the
upper discharge air duct and tabs on
the lower discharge air duct.
2.
If the distance is 50 to 75 mm,
remove the perforated tabs on the
lower discharge air duct.
3. If the distance is 75 to 110 mm, do
not remove any of the perforated
tabs. (FIG. 7.C)
FIG. 7.A., B., C.
Caakat,
FROM BELOW
THICKNESS
PULL CONDUIT
THROUGH
IF 26 mm < T c 50 mm
IF 50 mm < T < 75 mm
D.
E.
F.
DO
Take the ceiling template and slide the
lower discharge air duct over the outside
of the upper discharge air duct.
Holding the ceiling template in place with
one hand, install the three 150 mm long
mounting bolts up through the ceiling
template and into the air conditioner 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 l/2 of its original 25
mm thickness. (FIG. 7.E)
CAUTION:
NOT overtighten the mounting bolts as this
may damage the air conditioner base.
FIG. 7.D., E.
4.5 - 5.5 NM
-
IF 75 mm < T c 110 mm - INSTALL AS PACKAGED
-8-

8. CONNECTION OF POWER SUPPLY
TO AIR CONDITIONER (Fig. 8)
WARNING
Be sure power supply is OFF before connecting
power supply leads to the air conditioner.
A.
B.
C.
D.
E.
Route the power supply line, previously
installed to the roof opening, into the
junction box on the ceiling template.
Connect -the power supply line to the air
conditioner at the terminal block provided
in the junction box. Connect red to red,
black to black and earth to earth, (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 covers onto
the boxes with three blunt tipped screws
provided.
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.
FIG. 8
CEILING TEMPLATE & HEATING ASSEMBLY
9.
A.
B.
C.
HEATER INSTALLATION (FIG. 8)
Install the heat package to the ceiling
template using
the four (4) pointed,
serrated 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 return air
opening.
Insure the insulation covering the conduit
knockout in the air box is still in place as
shown.
FIG. 9 LEAVE
INSULATION REMOVE
IN PLACE KNOCKOUT
GRILL - THIS END ONLY ELECTRICAL.
/
LUG
ii9
. .
L-
J
BOTTOM VIEW
JUNCTION BOX
-Q-

10.
A.
AIR BOX INSTALLATION
Remove the two return air grills and
filters which are shipped loose in the air
box. (FIG. 10.A)
I
B.
Slide the front end of the air box over
the shafts of the thermostats and selector
switch. (FIG. I0.B)
FIG. 10.B.
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. 1O.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. lOC., D., E.
i
I
- 10 -
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 attempting to
run the unit.
11. OPERATING INSTRUCTIONS
(Refer to FIG. 7)
A.
CONTROLS
1.
The Thermostat has a temperature
range of 185°C in Cool ( @ ) position
to 32.5”C 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.
FIG. ll.A.1
2.
The Selector Switch controls the unit
fan speeds, and the heating, cooling
and fan modes of operation.
.-
*;:+2; o
FIG. 11 .A.2

.
B. COOLING OPERATION
.
.
1. Set the thermostat to the position
.
which will give your desired comfort
FIG. 11.B.l
level.
2. The selector switch is to be set as
follows:
a.
HIGH COOL (30): Selected when
)/i
maximum cooling and dehumidifying
.
.
is required.
b.
MED COOL (20): Selected when
FIG. 11 .B.2
.
.
medium cooling is required.
.
C. LOW COOL (I@): Selected when
minimum
:I;
.
cooling is required.
.
.
Normally this position is selected
.
.
for night time operation.
.
.
.
.
The air conditioner compressor will come
. . . . . . . * . . . . . . . . . . . .
=
25°C.
= COOLING
.
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 van. It does
not come on and off with the compressor.
.
,,---- “COOLING”
I
ROOM
TEMPERATURE
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 continuously and
circulate the air in the van.
FIG. ll.C.
.
.
,
I
“CIRCULATION”
ROOM
TEMPERATURE
CO$bLNG
FAN
ON
FIG. ll.B.
..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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
only.
1.
2.
from the air on cool days or mornings
Set the thermostat to the 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 (1 a;,) position for best results.
The electric heater will turn on and off as
heating is required to maintain your desire
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.
OFF POSITION
To shut the air conditioner Off, place the
selector switch in the OFF position, (0).
“OFF”
HaEFAFT
CO$;;NG
FOAFF
FIG. ll.E
F.
When the 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.
FIG. ll.D.1
.
.
.
.
’ n
=
.
I 25°C.
.
: ,.:.
. . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
FIG. ll.D
“HEATING”
ROOM
TEMPERATURE
ROOM
TEMPERATURE
ST
ill]
_:
:, >:’
. . . . . . . . . . . . . . . . . . . . . . . . . .. .
FIG. ll.F COOLING ON
e-3 Q
e-2
O-1
1
f
COOLING
COOLING
ON - OFF,
\
COOLING ON @ 9
MINiTES
12 -

12. MAINTENANCE
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.
(FIG.
1O.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.
13. SERVICE - Unit Does Not Operate
If your unit fails to operate or operates
D.
In the air conditioner air box, check to be
improperly,
check the following before calling sure the air conditioner conduit is plugged
your service center. into the selector switch box. (FIG.
8.E)
A.
B.
C.
If the van is connected to a motor
generator, check to be sure the motor
generator is running and producing power.
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.
Check your fuse or circuit breaker.
E.
After the above checks call your local
service center for further help. This unit
must be service by qualified service
personnel only.
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 opening in the ceiling (FIG.
2 and FIG. 10.A)
- 13-

ASSEMBLY DRAWING
Discharge Air
Rating Plate and Serial Number
Neoprene Rubber Gasket
Upper Discharge Air Duct
Roof Line
Roof Reinforcement Member
Power Supply Line
Prepared Installation Opening
25 X 380 mm Thick Framing
Lower Discharge Air Duct
Ceiling Template
Junction BOX
Unit Mounting Bolts (150 mm)
Heat Package
Mounting Legs
Air Box

I
K
r
I I
! FAN
1;
RUN CAP. COMPRESSOR
I
I
RED
I
.
JUNCTION
BOX
i
-HEAT PACKAGE
--
_-l
FACTORY WlAlNG -
FELD WIRING ----
LINESPLICE l
115vrv ,60 Hz., 10
-- USE COPPER CONDUCTORS ONLY
YEL I _ _
I
.
I
/
TERMINAL 4 I @ 1 IS USED FOR WIRE
CONNECTION ONLY AND NOT A
;;N$yiONAL PART OF THE START
.
THERMOSrAT
- 16-