UB1 AIR CONDITIONING UNIT INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS: Carefully read these instructions before installing your new air-conditioner. AUSTRALIAN AUTOMOTIVE AIR AL00500054E
1 Table of Contents 1. Introduction...1 2. Definition of Terms...1 3. Inventory...2 4. Tools Required...2 5. Installation Location...3 6. Installation Procedure...6 7. Operation Check...10 1. INTRODUCTION The UB1 air-conditioner is designed for use in pop-top and fixed roof caravans. As a general guide, air-conditioning performance will be acceptable in fixed roof caravans up to 7.0m in length. It is assumed that all walls and roof are insulated with insulation thickness of at least 25mm. Larger caravans, pop-tops with large canvas areas and poorly insulated caravans will limit the ability of the air-conditioner to achieve comfortable interior temperatures in extreme weather. If in doubt, consult with Australian Automotive Air or your dealer. Any applications other than those above should be referred to Australian Automotive Air for review. The unit is not designed for industrial or commercial use. 2. Definition of Terms Describes precautions that should be observed in order to prevent injury to the user during unit operation. Describes precautions that should be observed in order to prevent damage to the unit or its components, which may occur during unit operation if sufficient care is not taken. NOTE: Provides additional information that facilitates unit operation or installation. 2011 DENSO Automotive Systems Australia Pty. Ltd All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher. DENSO reserves the right to make changes without prior notice.
2 3 3. INVENTORY ITEM QTY 1. Main air-conditioning unit 1 2. Air Distribution Unit (including) 1 - Duct Adaptor Plate 1 - Duct Sleeve 1 3. Air Distribution Unit Facia (Reversed) 1 4. Flexible Air Duct 1 5. Floor Cutting Template 1 6. Air Distribution Unit Template 1 7. Operating Manual 1 8. Remote Control & Bracket 1 9. AAA Batteries 2 UB1 UNIT AIR DISTRIBUTION UNIT & Air Duct REMOTE CONTROL, BRACKET & BATTERIES LABEL 5. INSTALLATION LOCATION General points to consider before installation a. The air-conditioning unit requires a space of at least 1000mm length x 510mm width x 275mm height. Some examples include, under the rear double or single bed, under a bench seat or in the bottom of a kitchen cupboard. b. A 10A power outlet is required within reach of the 1.6m power supply cord on the air-conditioner. If necessary have a licensed electrician install and outlet near the intended position. c. Clearance is required from the return air inlet filter of at least 40mm. d. Vents must be provided in furniture with a minimum open area of 200mm x 200mm to allow unrestricted flow of return air to the air-conditioner. This may be achieved with multiple smaller vents. e. The floor beneath the unit must be clear of chassis rails, water tanks, gas/water pipes that could be damaged when cutting the vent and drain holes, or obstruct airflow when operating. f. Air inlet and outlet vents and the condensate drain must not be located in areas of the floor likely to be affected by splash from the wheels. If wheel splash is a risk, spray guards will need to be fitted in front of the vents and drain. g. The air distribution unit can be suspended below a cupboard or above a cupboard by selecting the appropriate facia. 4. TOOLS REQUIRED Ø 127 Hole Saw Ø 60 Hole Saw Not Supplied ITEM QTY Ø 20 Hole Saw or Spade Bit Screws (Floor) 12 Drill Bits Screws Air Distribution Unit 13 #2 Screw Driver Jigsaw or Equivalent Sealant 1 NOTE: Screw type/length, should be selected to suit caravan furniture material and thickness. h. Plan an air distribution unit location that allows the flexible duct to be discreetly routed to the main unit. The maximum duct length when extended is 3.5m. i. The cover of the electrical enclosure may need to be removed for certain service operations. Choose a location that allows the cover to be removed while the unit is installed. j. Provision needs to be made to allow the air filter to be removed for periodic cleaning or replacement. The filter is removed by sliding upwards. Before cutting any holes, carefully read and understand these instructions. Plan the placement of all components before you begin. REMEMBER: Measure twice, cut once.
4 5 Slide Up to Remove Some examples of typical installation locations are illustrated below. Double bed installation Filter Condensate Drain Condenser Air Vents Single bed installation 1000 min 100 min Filter Removal ø127 510 min 40 min Return Air 275 min
6 7 6. INSTALLATION PROCEDURE 6.1 Cut the Floor Holes Tape the template to the floor in the desired installation position. On the template mark the position of nearby items such as chassis members, gas/water lines, wiring & cables. Ensure that the floor holes do not interfere with any components. If necessary consider changing the orientation and location to avoid these items. - Use the template provided to mark out the location of holes for condenser air inlet, condenser air outlet and the condensate drain. Carefully check below the floor for gas pipes, water pipes, electrical wiring, brake cables and chassis components before cutting or drilling. NOTE: Drill Ø2 pilot holes and confirm position and clearance before cutting any larger holes. a. Using a Ø20 hole saw, drill the 4 corners of the rectangular condenser air inlet then use a jigsaw to cut out the rectangular opening. b. Using a Ø20 hole saw, drill the 4 corners of the rectangular condenser air outlet then use a jigsaw to cut out the rectangular opening. c. Use a 60mm hole saw to cut the condensate drain opening. d. Seal the exposed edges of the floor panel with sealant to prevent water damage. 6.2 Fit the Air-Conditioner The air conditioning unit weighs over 40kg. Always use 2 persons to lift or move the unit. Lifting flanges are located at each end of the unit. To avoid damaging the unit or floor, avoid dragging the airconditioner. a. Locate the air-conditioner over the vents and drain hole. b. Check from beneath the floor that the unit is centrally located in each cut-out and that the metal case of the unit is not touching the floor. Direct contact between the metal air-conditioner case and the floor or furniture will provide a path for noise and vibration to be transmitted. Always ensure that the airconditioner is clear of any touch conditions. c. Align the feet as shown. - Install 3 screws in each foot to secure the unit to the vehicle. ø127 ø20 The installer must ensure that the feet are adequately secured to the floor of the vehicle. Thin or weak floors may require reinforcing pads to be used under the floor and through bolts to attach the feet. ø60
8 9 6.3 Route the Air Duct and Cable NOTE: The duct has a minimum outer bend radius of approx. 150mm. Carefully check the intended path before drilling or cutting to avoid wiring, pipes & hoses. NOTE: Drill Ø2 pilot holes and confirm position and clearance before cutting any larger holes. a. Drill 127mm holes using the hole saw along the planned route of the air duct. b. Drill a second series of 20mm holes beside the air duct route for the electrical cable. c. Fit the sleeve to the duct. d. Route the duct. e. Extend the duct fully at the airconditioner end then fit over the air outlet. NOTE: To prevent accidental removal of duct a screw maybe inserted into the indicated position. 6.4 Fit the Air Distribution Unit NOTE: Drill Ø2 pilot holes and confirm position and clearance before cutting any larger holes. a. Use the Air Distribution Unit Template to mark the location of the air duct hole and cable hole. Use a 127mm hole saw to cut the air duct hole. Drill the 20mm hole for the electrical cable. Generally it is better to mount the adaptor as far back as possible in the air distribution unit. There is approximately 40mm of adjustment, determine the best arrangement before marking and drilling holes. Refer to note d b. Fit the Air Duct Adaptor Plate though the hole and fix to the cabinetry using 5 self tapping wood screws. Make sure that the adaptor plate is square with the front of the cabinet before screwing in place. c. Route the electrical cable from the Air Distribution Unit back to the airconditioner. d. Plug the cable into the connector location on the electrical box of the airconditioner. Loop the wire harness cable through the strain relief hook on the electrical box. e. Fit the Air Distribution Unit over the Duct Adaptor Plate making sure that the unit sits flush on the surface of the cabinetry. f. Use 8 self tapping screws to secure the Air Distribution Unit. Take care not to over-tighten the screws securing the air distribution unit. The unit is plastic and over-tightening the screws may cause the housing to split. Do not use counter type sunk screws. Make sure that the surface of the Air Distribution Unit has not been contaminated with grease or dust and avoid touching the self-adhesive surface of the fascia. Poor adhesion could cause the Fascia to peel away from the Air Distribution Unit. If necessary, clean the surface with an alcohol wipe before fitting the new label. g. The air distribution unit is supplied with two fascia labels. For under cupboard mounting, use the label already a fixed to the unit. If the unit is to be mounted above a cupboard, remove the existing fascia label and fit the replacement fascia (supplied loose). Under Cupboard Above Cupboard Remove the backing paper and attach to the air distribution unit front face.
10 h. Extend the duct at the Air Distribution Unit end and fit over the Duct Adaptor Plate. Ensure that the duct is firmly fitted. NOTE: To prevent accidental removal of duct a screw maybe inserted into the indicated position. Refer to note 7. Operation Check a. Install the batteries in the rear of the remote control. b. Plug the power supply cord into a 10A power outlet and switch on. The power indicator (blue) should flash to indicate power supply. c. Press the power button on the remote and select an operating mode and temperature that will cause the compressor to run. d. After an appropriate wait time (within 3 minutes) the compressor, exterior fan and interior fan should all start. Note that in heating mode, the interior fan may not start until the system has warmed up sufficiently. e. Leave the air-conditioner running for 15 minutes to verify the following: There are no strange noises from the system. No excessive vibration can be felt in the vehicle. Cool / warm air is flowing from the air distribution unit grille. There are no large air leaks from the duct or air distribution unit. Airflow direction can be freely adjusted using the grilles on the air distribution unit. The unit beeps when remote control command are selected. The blue power indicator is lit while the unit is operating. That the unit is able to draw air easily back to the return air inlet filter. When viewed from below the vehicle, the condenser air inlet, outlet holes and drain are all unobstructed and air is flowing freely. If all these are met installation is complete.