Electrolux CAL61.206 Manual

81 Electrolux
INSTALLATION & OPERATING INSTRUCTIONS
FOR CARAVAN ROOF MOUNT AIR CONDITIONERS
EINBAU-UND BETRIEBSANWEISUNGEN
FiiR
KLlMAGERiiTE ZUR DACHMONTAGE AN WOHNWAGEN
INSTRUCTIONS D’INSTALLATION ET DE FONCTIONNEMENT
POUR
CLIMATISEURS POUR CARAVANE
MONTERINGS- OCH BRUKSANVISNING
TAKMONTERAD LUFTKONDITIONERING FijR HUSVAGNAR
ISTRUZIONI PER L’INSTALLAZIONE E L’USO
DEL CONDIZIONATORE D’ARIA DA TETTO DI CARAVAN
MOD. CAL61.206 MOD. CAL136.206
PRE-WIRED FOR OPTIONAL ELECTRIC HEAT PACKAGE
DIESES GEAliT IST FiiR DAS WAHLWEISE LIEFERBARE
ELEKTROHElZGERliT VORVERDRAHTET
PRk-CABLk POUR ENSEMBLE
D’kLkMENT CHAUFFANT EN OPTION
KLiiR F6R ANSLUTNING AV ELVARMEUTRUSTNING
CABLATO PER ILGRUPPO RISCALDATOREOPZIONALE
OPERATING INSTRUCTIONS ON PAGES D ................. 2-15 BETRIEBSANWEISUNGEN AUF DEN SEITEN ............ 16-29
INSTRUCTIONS DE FONCTIONNEMENT AUX PAGES .... 30-43 BRUKSANVISNING PA SID .............................. 44-57
ISTRUZIONI PER L’USO NELLE PAGINE ................. 58-71
WARNING
IMPORTANT INSTRUCTIONS MUST STAY WITH UNIT OWNER - READ CAREFULLY.
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
WICHTIGE HINWEISE, DIE SIGH IM BESITZ DES WOHNWAGENINHABERS BEFINDEN MiiSSEN - BITTE
SORGFliLTlG DURCHLESEN.
DER SERVICE AN DIESER EINHEIT MUSS VON EINEM HIERZU BEFUGTEN SERVICE-TECHNIKER AUSGEFijHRT
WERDEN. EINE ABliNDERUNG DES GERiiTS KANN AUSSERORDENTLICH GEFUHRLICH SEIN UND ZU
ERNSTHAFTEN VERLETZUNGEN ODER SOGAR ZUM TODE FijHREN.
ATTENTION
LE CONTENU DE CETTE NOTICE EST TRkS IMPORTANT, AUSSI L’UTILISATEUR DE L’APPAREIL DOIT-IL EN
POSSkDER UN EXEMPLAIRE ET LE LIRE ATTENTIVEMENT.
LES INTERVENTIONS SUR L’APPAREIL DOIVENT ETRE UNIQUEMENT EFFECT&ES PAR UN TECHNICIEN
AGREg. L’kQUIPEMENT DE DOIT FAIRE L’OBJET D’AUCUNE MODIFICATION, CE QUI POURRAIT EN EFFET SE
Rl%LER EXTREMEMENT DANGEREUX, SINON MEME PROVOQUER UN ACCIDENT GRAVE OU MORTEL.
VARNING
VIKTIGA ANVISNINGAR: SKALL ALLTID MEDFijLJA AGGREGATET OCH NOGGRANT LliSAS AV jiGAREN.
SERVICE PA DETTA AGGREGAT FAR ENDAST UTFORAS AV AUKTORISAD MONTGR. ANDR~NGAR AV
UTRUSTNINGEN KAN VARA YTTERST FARLIGA OCH LEDA TILL ALLVARLIGA OLYCKOR ELLER DCjDSFALL.
ATTENZIONE
QUESTE ISTRUZIONI IMPORTANT1 DEVON0 ESSERE CONSEGNATE AL PROPRIETARIO DELL’UNITk
QUESTA UNITA DEVE ESSERE RIPARATA DA UN TECNICO QUALIFICATO. LE MODIFICHE POSSONO ESSERE
ESTREMAMENTE PERICOLOSE E POSSONO CAUSARE LESIONI GRAVE 0 MORTE.
Form No. 3104776.013 2/93
1992 1993 The Dometic Corp.
LaGrange, IN 46761

1. GENERAL INFORMATION
A. THREE SPECIFIC NEEDS:
1. Installation opening.
Cut through roof and ceiling.
2. Additional wiring.
220-240V, 50 Hz, 10 Amp.
3. Power must be above 209 V and frequency must be 50 Hz at all times.
204 V-WRONG
WIRING VOLT LOSSES
/
WRONG FREQUENCY
\
LOW GENERATOR
OUTPUT ALTITUDE
2

B. SPECIFICATIONS (FIG. l.B)
MODEL NO."s
Nominal Capacity (KW)
Electrical Rating
FL Amps (Comp/Motor)
LR Amps (Comp/Motor)
Power (KW)
Min. Wire Size
Circuit Protection
CAL
CAL
ELECTRIC
136.206 61.206
HEATER
3.7 2.1
1.6
220-240V, 50 Hz.,
Ph. 1
7.0/1.6
4.0/1.6
6.3/1 .6
31.0/4.4 20.0/4.4
14.4
1.7 1.1
1.9
Up to 6 meters, use 1.5 mm2Copper
10 Amp Time Delay Fuse or
10 Amp Circuit Breaker
FIG. l.B
DISC CONDITIONER
A
RATING PLATE %
SERIAL NUMBER
NEOPRENE RUBBER
l * 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.
This air conditioner is prewired for Optional Elec-
tric Heater Package.
NOTE: Some authorities require that this
appliance be Installed only by an authorized
electrician.
2. PRECAUTIONS FOR SAFE
INSTALLATION
A. Read these installation and operating instructions
thoroughly and carefully before attempting installation
of Air Conditioner.
IMPROPER INSTALLATION MAY DAMAGE EQUIP-
MENT, COULD ENDANGER LIFE, CAUSE SERIOUS
INJURY AND/OR PROPERTY DAMAGE.
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
un
it 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
LENGTH
FIG. 3.A.2
3

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.
AIR CONDITIONER ROOF VENT-REMOVE
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)
WEIGHT OF A/C
PLUS SERVICE
““‘O_
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 4. ROOF PREPARATIONS
is parked on a level surface; otherwise, a sideways
pitch or forward/backward pitch up to 10 degrees
can be tolerated but a backward pitch can NEVER
be accepted.
FIG.
3.C.1
!
Disconnect all power 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)
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.
t
(FIG. 3.C.3) DISCONNECT
d
BATTERY
FIG. 3.C.3
ROOF/AIR BOX CROSS-SECTION
PROHIBITS INSTALLATION
*CABINET
- PROHIBITS USE

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 tricity (FIG. 4)
quality all weather sealant.
4
1) REMOVE SCREWS
3. Carefully cut a matching hole through the ceiling of
the van. (FIG. 4.B.3)
f Seam)
3) SCRAPE PUTTY
AIR BOX PERIMETER
FIG. 4.B.3
\
tr-
I
I
I
I
510mm ,- -..
B.
1.
2.
SEAL HOLES
& SEAMS
L: - - - - j’“t”” _ _ _!
It J
283mm&283mm
Other: Cutting new or modifying existing openings.
This opening should be located between roof struc-
tural members.
4. Seal holes and seams. (FIG. 4.A)
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
NO BLOCKAGES
DEPENDS ON
STRUCTURE
DON’T REMOVE
STRUCTURE GOOD
LINES

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
mm2
COPPERsupply for distances of 7.5m or less.
The power supply wiring 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
JUNCTI
BOX
EXCESS WIRE
FOR HOOK-UP
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
FIG. 5.B.2
DON’T SLIDE
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.
B.
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.
TAB TO REAR
OF APPLIANCE
7

7.
A.
B.
C.
CEILING TEMPLATE
D.
INSTALLATION
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:
F.
1.
2.
3.
Take the ceiling template and slide the lowerdischarge
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 theceiling template and into the airconditioner
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 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 75 mm, remove the perfo-
rated tabs on the lower discharge air duct.
If the distance is 75 to 110 mm, do not remove any
DO NOT over-tighten the mounting bolts as this may
of the perforated tabs. (FIG. 7.C)
damage the air conditioner base.
FIG.
7
GASKET
FROM BELOW
PULL CONDUIT
THROUGH
IF25mm <T< 50mm
IF50mm <T< 75mm
IF 75 mm < T < 110 mm, INSTALL AS PACKAGED
8

8. CONNECTION OF POWER SUPPLY
C. Tighten the strain relief onto the power supply line, to
TO AIR CONDITIONER (FIG. 8)
hold it firmly in place.
NOTE:
If optional Electric Heater is part of this installa-
WARNING
tion, now is the time to install it. Installation
Instructions are provided with the Electric Heater
Kit.
Be sure 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.
D.
A. You may either wire direct into the junction box for a
E.
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 Plua-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 10).
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
4 respectively).
Carefully push all excess wire back into the junction
box and install cover onto the box with two blunt tipped
screws provided.
Plug the electrical conduit from the upper unit into the
mating switch box connector.
FIG. 8
CEILING TEMPLATE
POWER SUPPLY
SWITCH
ELECTRICAL
CONDUIT
BOTTOM VIEW
BOX
JUNCTION BOX
9

9. AIR BOX INSTALLATION
A. Remove the two return air grills and filters which are
shipped loose in the air box. (FIG. 9.A)
G.
Your air conditioner is now installed and ready for
operation. Please read the following instructions be-
fore attempting to run the unit.
I
1
REMOVE GRILLS
\
FIG. 9.A.
B. Slide the front end of the air box over the shafts of the
thermostats and selector switch. (FIG. 9.B)
FIG. 9.B
10. OPERATING INSTRUCTIONS
A. CONTROLS
1. The thermostat has a temperature range of 18.5”C
in Cool (0) position to 325°C in Warm (a)
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.
C.
D.
E.
F.
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. 9.C)
Install the return air grills and filters by simply pushing
them into place. (FIG. 9.D)
Install the two knobs provided on the ends of the
thermostat and selector switch shafts.
The power supply to the air conditioner may now be
turned ON.
CEILING TEMPLATE
I(
AIR BOX
I
10
FIG.. 1 0.A.1
The selector switch controls the unit fan speeds,
and the heating, cooling and fan modes of opera-
tion.
FIG. 10.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: (20): 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 the air and 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 orcooling, select one of the three fan
speeds:
(1 @& 2 *, or 3 * ). The fan will run continu-
ously and circulate the air in the van.
FIG. 1 O.B.l
I
I
i
FIG. 10.B.2
I
- I
! = COOLING
@ I
I
I
I
I
I
r-----------l
I
I
I
I
I
I
I
I
I
I
I
I
I
II
I
I
I
I
II
I
“COOLING”
ROOM
TEMPERATURE 1
ON ON
“CIRCULATION” -
ROOM
TEMPERATURE
25°C
I @
=
COOLING
FAN
OFF
ON
I
J
FIG. ll.B
L____________________
FIG. ll.C
11

D. HEATING OPERATION (If so equipped)
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.
2.
. 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
(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).
F.
“OFF”
HEAT
Co:kkNG
FAN
OFF OFF
FIG. 10.E
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. 1 O.D.l
I
I
FI( = 25OC.
II
I
I
FIG. 10.D.2
I
-11 = HEATING
5
r
___-----
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
FIG. 10.D “HEATING”
-
ROOM
TEMPERATURE
HEAT
ON
FAN
ON
ROOM
TEMPERATURE
25°C
it -
=
HEAT
OFF
FAN
ON
L
___-__-------m---m
FIG. 10.F COOLING ON
0-3 0
*2
O-1
1
f
COOLING
“;iNG + OFF,
12

11. 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. 9.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.
12. 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 9.A)
13

AIR CONDITIONER ASSEMBLY
PREPARED
INSTALLATION
OPENING
UNIT MOUNTING
BOLTS (150mm)
CONDITIONER
DISCHARGE AIR
RATING PLATE &SERIAL NO.
NEOPRENE RUBBER GASKET
UPPER DISCHARGE AIR DUCT
ROOF LINE
ROOF REINFORCEMENT
MEMBER
POWER SUPPLY LINE
25 X 380mm FRAMING
LOWER DISCHARGE AIR DUCT
(Attached to ceiling template)
UNIT MOUNTING BOLTS (150MM)
CEILING TEMPLATE
JUNCTION BOX
MOUNTING LEGS
MOUNTING LEGS
AIR BOX
14

WIRING DIAGRAM
RUN CAP. COMPRESSOR
I I :!-A0 I
1 - T'STAT I
1
;HEs PACKAGE
1
FACTORY WIRING -
FIELD WIRING ----
LINE SPLICE l
TERMINAL4 ( @ 1 IS USED FOR WIRE
CONNECTION ONLY AND NOT A
rM;lONAL PART OF THE START
I
I
I
COMPRESSOR
START
relay
- 220/240 V-
50 Hz
---I