BR342 Ducted Installation Instructions Australian Version Electronic Wall Control

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1 Australian Version Electronic Wall Control 1

2 Introduction The BR342 reverse cycle rooftop air-conditioner is designed for installation onto Recreational Vehicles (RV s) at the time of manufacture or as a replacement for an existing ducted rooftop unit. Explanation of Symbols DANGER! Safety instruction: Failure to observe this instruction will cause fatal or serious injury. WARNING! Safety instruction: Failure to observe this instruction can cause fatal or serious injury. CAUTION! Safety instruction: Failure to observe this instruction can lead to injury. NOTICE! Failure to observe this instruction can material damage and impair the function of the product. NOTE Supplementary information for operating the product. 2

3 Safety Instructions Please observe the prescribed safety instructions and stipulations from the vehicle manufacturer and service workshops. The manufacturer accepts no liability for damage in the following cases: Faulty assembly or connection Damage to the product resulting from mechanical influences and excess voltage Alterations to the product without express permission from the manufacturer Use for purposes other than those described in the operating manual Note the following basic safety information when using electrical devices to protect against: Electric shock Fire hazards Injury 3

4 Safety Instructions Handling the Device WARNING! Installation and repair of the roof air conditioner may only be carried out by qualified personnel who are familiar with the risks involved and the relevant regulations. Inadequate repairs may cause serious hazards. For repair service, please contact the service centre in your country (addresses on the back page). Electrical devices are not toys. Keep electrical devices out of reach of children or infirm persons. Do not allow them to use electrical devices without supervision. Persons whose physical, sensory or mental capabilities or whose lack of experience and knowledge prevent them from using the device safely should not use it without supervision or instruction by a responsible person. Do not undo the upper cover of the roof air conditioner in the event of a fire. Use approved extinguishing agents instead. Do not use water to extinguish fires. CAUTION! The roof air conditioner must be installed securely so that it cannot fall down. Only operate the roof air conditioner if you are certain that the housing and the cables are not damaged. Do not use the roof air conditioner near flammable fluids or in closed rooms. Make sure no combustible objects are stored or installed near the air outlet. A distance of at least 50 cm must be kept. Do not reach into air outlets or insert any foreign objects in the device. 4

5 Safety Instructions Handling the Device 5 NOTICE! Only use the device as intended. The roof air conditioner is not suitable for use in agricultural or construction vehicles. Do not make any alterations or conversions to the device. Never drive through automatic car washes when the roof air conditioner is mounted. If faults occur in the refrigerant circuit, the system must be checked by a specialist company and repaired properly. The refrigerant must never be released into the air. Safety Instructions Handling Electrical Cables WARNING! The electrical power supply may only be connected by a qualified electrician CAUTION! Fit a fuse of at least 10 A to the connection with the vehicle s power supply. Attach and lay the cables so that they cannot be tripped over or damaged. NOTICE! Use cable ducts to lay cables through walls with sharp edges. Do not lay loose or bent cables next to electrically conductive materials (metal). Do not pull on the cables

6 Unit Data Roof Requirements A 350mm 350mm (±3.17mm) square opening (hereinafter referred to as "roof opening") is required for installing this unit Roof construction with rafters/joists support frames on a minimum of 405mm centres. Minimum of 38mm and maximum of 152mm distance between roof to ceiling of RV. Roof Cavity Depth Duct Cross-Sectional Area Duct Size Register Requirements Total System Static Pressure (Hi Fan, Grilles fitted) 50.8 to 139.7mm 13550mm² min Depth: mm Width: mm Total Length: m Short Run Length: 1/3 of Total No. per Run: 4 min Free Air Area: 9032mm² Duct End Distance: mm Elbow Distance: 381mm 1.8 to 3.0kPa Table A Air Distribution Duct Sizing & Design 6

7 Choosing a Fitment Location This unit is specifically designed for installation on the roof of an RV. When determining your cooling requirements, the following should be considered: Size of RV; Window area (increases heat gain); Amount of insulation in walls and roof; Geographical location where the RV will be used; Personal comfort level required. For one unit installation: The unit should be mounted slightly forward of centre (front to back) and centred from side to side. For two unit installations: Install one unit 1/3 and one unit 2/3 s from front of RV and centred from side to side. It is preferred that the unit be installed on a relatively flat and level roof section measured with the RV parked on a level surface. See table on right for maximum acceptable tilt. After Location Has Been Selected: Check for obstructions in the area where unit will be installed. See (FIG. 1). 7

8 Choosing a Fitment Location NOTICE! Maintain structural integrity. Otherwise damage to product and/or RV could occur. The roof must be designed to support 59 kg when the RV is in motion. Normally a 90.7kg. static load design will meet this requirement. Check inside the RV for return air grille (RAG) obstructions (i.e. door openings, room dividers, curtains, ceiling fixtures, etc.). See (FIG. 2). FIG. 2 19mm 431.8mm 431.8mm Roof Preparation 38mm WARNING! Fire or Electrical Shock Hazard: Make sure there are no obstacles (wires, pipes, etc.) inside RV s [roof / floor / walls]. Shut OFF gas supply, disconnect 240VAC power from RV, and disconnect positive(+) 12VDC terminal from supply battery BEFORE drilling or cutting into RV. Failure to obey these warnings could result in death or serious injury mm 31.75mm 44.45mm 38mm 431.8mm 8

9 Roof Preparation NOTE Opening Requirements: Before preparing the ceiling opening, the type of system options MUST be decided upon. Read all of the following instructions before beginning the installation. Carefully mark and cut the required roof opening. See Roof Requirements" section on pg 6. Using the roof opening as a guide, cut the matching hole in the ceiling. NOTICE! Maintain structural integrity. Otherwise damage to product and/or RV could occur. NEVER create a low spot on RV roof. Otherwise, water will pool and could cause a leak. The opening created must be framed to provide adequate support and prevent air from being drawn from the roof cavity. Framing stock 3/4 or more in thickness must be used. Remember to provide an entrance hole for power supplies, indoor temperature sensor (if applicable), thermostat communication cable, and furnace wires (if applicable) at the front of the opening. See (FIG. 3). 9

10 Air Distribution Duct Sizing & Design The installer of this system must design the air distribution system for their particular application. Several requirements must be met for the unit to operate properly. NOTICE! Make sure ductwork will NOT bend or collapse during and after installation, and that it is correctly insulated and sealed. Otherwise, damage to roof structure and ceiling could occur. All discharge air ducts must be properly insulated to prevent condensation from forming on their surfaces or adjacent surfaces during operation of unit. This insulation must be R-7 minimum. See (FIG. 4). FIG. 4 Ducts and their joints must be sealed to prevent condensation from forming on adjacent surfaces during operation of the unit. Return air openings must have 40 square inches minimum free area including the filter. Return air to the unit must be filtered to prevent dirt accumulation on unit cooling surface. 10

11 Air Distribution Duct Sizing & Design Dometic recommends the basic configuration shown in (FIG 6), for installing this system. We have found by testing, that this configuration works best in most applications. It is the responsibility of the installer to review each RV floor plan to determine the following: Duct size Duct layout Register size Register location Thermostat location Indoor Temperature Sensor Location FIG. 5 These items must be determined in conjunction with the Air Distribution Duct System Sizing & Design requirements. See "Table - Air Distribution Duct Sizing & Design" on page (4). 7742mm² free area per register 11

12 Air Distribution Duct Sizing & Design These items must be determined in conjunction with the Air Distribution Duct System Sizing & Design requirements. See "Table A - Air Distribution Duct Sizing & Design" on page 6. Wiring Requirements Route a copper, with ground, 240VAC supply wire from the time delay fuse or circuit breaker box to the roof opening. The proper size wire can be determined from chart on page 6. NOTE If vent fan was removed, the existing wire may be used provided it is of proper size, location, and correctly fused. This supply wire must be located in the front portion of the roof opening. The power MUST be on an appropriately sized separate time delay fuse or circuit breaker. The proper size protection can be determined from data table on page 6. Make sure that at least 381mm of supply wire extends into the roof opening. This insures an easy connection at the junction box. Protect the wire where it passed into the opening with approved method. 12

13 Placing Unit on Rooftop Remove the unit from the carton and discard carton. CAUTION! Lifting Hazard: Use proper lifting technique and control when lifting product. The rooftop unit weighs approximately 35 kg. Follow occupational health of safety guide when lifting or moving the unit. Failure to obey this caution could result in injury. Place unit on the roof. NOTICE! Do NOT slide unit. Otherwise, damage to gasket (on bottom of unit) may occur, and could cause a leak. Lift and place the unit over the prepared opening using the gasket on the unit as a guide. See (FIG. 4). Place the electronic wall control kit and the RAG kit inside the RV. These boxes contain mounting hardware for the unit and will be used inside the RV. FIG. 6 NOTE This completes the outside work. Minor adjustments can be done from inside the RV if required. 13

14 Installing the Unit Check gasket alignment of the unit over the roof opening and adjust if necessary. Unit may be moved from below by slightly lifting. See FIG. 7. Remove return air cover and ceiling template from carton. See FIG. 8. The unit is fixed using a four (4) bolt pattern for installing the RAG kit. These bolts and the electronic wall control are supplied separately. Reach up into the return air opening and pull the unit electric cord and control cables down for later connection. See FIG. 9. FIG. 7 FIG. 8 FIG. 9 14

15 Installing the Unit Hold the ceiling template up to the roof opening. Make sure the large plate faces the rear of the RV. See FIG. 10. Start each mounting bolt through the ceiling template and up into the unit base pan by hand. Install wood screw in each end of the ceiling template. This ensures a tight fit of the return air cover to ceiling. See FIG. 10. FIG. 10 NOTICE! Tighten mounting bolts to correct torque specifications. Overtightening could damage unit s base pan or ceiling template. Not enough torque will allow an inadequate roof seal, and could cause a leak. Tighten to 4.5 to 5.5Nm Tighten all four (4) mounting bolts EVENLY to 4.5 to 5.5 Nm. See FIG.10 FIG. 11 Measure the ceiling to roof thickness: If distance is mm, remove perforated tab from divider plate. See FIG. 11. If distance is mm, remove no tabs. Remove the backing paper from double-sided tape located on ceiling template. See FIG mm 15

16 Installing the Unit NOTICE! Incorrect installation of the divider could cause compressor to shortcycle, resulting in supply circuit overload and reduced product performance. FIG. 11 Place the divider plate up to bottom of the unit base pan firmly. The foam tape on the divider plate must seal to bottom of base pan. See FIG. 11. NOTE The adhesive on the double-sided tape is extremely sticky. Make sure the divider plate is properly positioned before pressing into place. FIG. 12 With slight pressure push the divider plate against the double-sided tape on the ceiling template. Locate the mm self-adhesive insulation supplied with the RAG kit. Remove the backing paper from the insulation and carefully stick onto the ceiling template divider plate. See FIG

17 Installing the Unit Excess width is intended to seal the divider plate to the sides of the roof opening. This is to help prevent cold air discharge from circulating into the unit return air opening. If the insulation is too high, stick excess height of the insulation to the unit base pan. Do not cover up unit rating plate. Wiring Connections Fix the return air sensor so it is position in the return air stream. Connect the communication wire to the wire from the electronic wall control (also refer to instructions provided with the wall control). Make connections for the 240VAC positive (+), negative (-) and earth from the supply to the rooftop unit and ensure they are well insulated. Tuck any excess wire up out of the way. WARNING! Electrical Shock Hazard: Verify 240VAC power is disconnected from the RV. Failure to obey this warning could result in death or serious injury. WARNING! Electrical Shock Hazard: Provide grounding in compliance with all applicable electrical codes. Failure to obey this warning could result in death or serious injury. 17

18 Installing the Return Air Cover Remove the return air grille from the return air cover. Place the return air cover up to the ceiling template. Install cover to template using six (6) supplied #8 x 3/8 blunt point Phillips head screws. Re-install filter return air grille into return air cover. Align tabs with mating notches and snap into place. Install two (2) hole plugs into screw holes in back of return air cover. See FIG. 13. FIG

19 Fitment of Optional Condensation Drain Extension The unit features condensation drain outlets which allow the fitment of a PVC tube in order to channel the condensation water to a specific area. For example it can be used to channel the condensation water to the rear of the caravan or RV and prevent runoff to the sides where doorways or windows are. FIG. 14 shows one example setup. Commonly available PVC tubing should be used of 12.7mm inner diameter and pushed onto the drain pipe fitting on the bottom of the rooftop unit around 15mm to help prevent detachment over time (refer to FIG. 14). The PVC tube should be routed around the foam support blocks on the underside of the rooftop unit to ensure the tube does not get compressed. The condition of the PVC tube should be regularly checked to ensure it is free of any defects that may prevent good drainage (such as being blocked, compressed or kinked). NOTICE! It is important to minimise sharp bends, kinks or high/low points in the tube as it may prevent proper draining of the condensation, and in severe cases this could result in water dripping inside the caravan. NOTE The PVC tube should NEVER raise higher than the level of the drain pipe fitting. FIG

20 Service Unit does not Operate If your unit fails to operate or operates improperly, check the following before calling your service centre. If RV connected to generator, check to be sure the generator is running and producing power. If RV connected to power supply by a land line, check to be sure line is sized properly to run unit load and it is plugged into power supply. Check your fuse or circuit breaker to see if it is open. Ensure fuse is not burnt, or circuit breaker is "ON" and not activated. After the above checks, call your local service centre for further help. This unit must be serviced by qualified service personnel only. When calling for service, always give the following: Unit model and serial number found on the identification label located on base pan of unit bottom. Return air grille must be removed from air distribution box to view. Air distribution box model and serial number found on rating plate located on ceiling template. Observe this rating plate through the filter opening. Contact Details 20

21 21 BR342 Ducted Installation Instructions Wiring Diagram Heat Pump BR36H70CR

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