Coleman 9330F4552, 8330-752, 9330C755, 8530-750, 9530A751 Installation Instructions Manual

RV Products Division

INSTALLATION INSTRUCTIONS

FOR

9330F4552 FREE DELIVERY PLENUM KITS

8330-752 CONTROL BOX KIT (12 VDC COOL ONLY)

9330C755 CONTROL BOX KIT (12 VDC HEAT READY)

8530-750 CONTROL BOX KIT (24 VAC COOL ONLY)

9530A751 CONTROL BOX KIT (12 VDC HEAT PUMP)

9430A751 ZONE CONTROL KIT (12 VDC COOL ONLY)

9430A755 ZONE CONTROL KIT (12 VDC HEAT READY)

9630A751 ZONE CONTROL KIT (12 VDC HEAT PUMP)

Coleman is a registered trademark of The Coleman Company, Inc. used under license. Mach is a registered trademark.

1976N350 (9-14) PP

Airxcel, Inc.

RV Products Division

P.O. Box 4020

Wichita, KS 67204

TABLE OF CONTENTS

1. Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. General Information and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4. System Match-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5. Ceiling Plenum Installation Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Control Box Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7. Control Box Kits (Zone) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8. Wall Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9. Routing Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

10. Routing Thermostat Wiring (Zone) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

11. Routing 115 VAC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

12. Securing the Upper Unit to the Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

13. Installing the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

14. Installing the Control Box (Zone) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

15. Installing the Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

16. Installing the Ceiling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1. WARNINGS

IMPORTANT NOTICE

These instructions are for the use of qualified individuals
specially trained and experienced in installation of this
type equipment and related system components.

Installation and service personnel are required by some
states to be licensed. PERSONS NOT QUALIFIED
SHALL NOT SERVICE THIS EQUIPMENT.

WARNING

Improper installation may damage equipment, can create
a hazard and will void the warranty.

The use of components not tested in combination with
these units will void the warranty, may make the
equipment in violation of state codes, may create a hazard
and may ruin the equipment.

To prevent the possibility of severe personal injury or
equipment damage due to electrical shock, always be sure
the electrical power to the appliance is disconnected
during installation.

CAREFULLY FOLLOW ALL INSTRUCTIONS
AND WARNINGS IN THIS BOOKLET TO AVOID
DAMAGE TO THE EQUIPMENT, PERSONAL
INJURY OR FIRE.

The words “Shall” or “Must” indicate a requirement
which is essential to satisfactory and safe product
performance.

The words “Should” or May” indicate a
recommendation which is not essential and not
required, but which may be useful or helpful.

WARNING – SHOCK HAZARD

NOTE

2. GENERAL INFORMATION AND
REQUIREMENTS

This mount kit is designed to provide free delivery (no
ducting) air distribution. It is applicable to 47000, 48000
and 49000 Series Roof Top Units Only. The control
box mounts inside the upper unit return air opening. The
minimum recommended roof thickness with this system is
1”. The upper unit and ceiling assembly mount on a
square roof opening 14” to 15” on a side. The roof must
be capable of supporting 110 pounds of static load. Keep
in mind that dynamic loads exist in recreation vehicles.

All manual controls have been removed from the ceiling
plenum. They have been replaced with control relays.

The relays are mounted in the electrical box of the ceiling
plenum. The relays contain 12 VDC coils (which may be
energized by a wall mounted thermostat), with contacts
that control the 115 VAC used to power the roof top unit.

A low voltage controller controls all air conditioning
functions. The low voltage controller controls a 12 VDC
electrical circuit, which is used to energize the relays in
the ceiling plenum. The low voltage controller that
Airxcel, Inc. provides for the system may be a
combination (Heat/Cool).

2

These low voltage controllers are capable of operating
both the roof top air conditioner and any furnace with a
12 VDC control circuit of 1 amp or less (continuous
current).

All air conditioning equipment is subject to freeze up
when evaporator air flow is sufficiently reduced. Ducting
of any length creates potential for reduced evaporator air
flow and system freeze up. To protect both the installer
and Airxcel, Inc. from conditions that promote reduced
air flow and system freeze up, Airxcel, Inc. has equipped
the ceiling plenum compressor control circuit with a low
temperature probe. The low temperature probe monitors

3. PACKAGE CONTENTS

The mounting kit package contains the following:

1) Steel mount frame

2) Ceiling shroud assembly

3) Small parts package consisting of:

4. SYSTEM MATCH-UP

the temperature of the air conditioner evaporator coil.
When the temperature of the evaporator coil drops below
28 degrees F, the switch will open, stopping compressor
operation. Compressor operation will resume once the
evaporator warms to 55 degrees F.

IMPORTANT

The low temperature sensor is part of the ceiling
plenum electrical circuit. The probe must be inserted
into the evaporator coil of the roof top unit by the
installer when bolting the ceiling plenum to the roof
top unit.

a) Mounting bolt (x4)
b) Mount screws (x3)
c) Supply duct assembly
d) Shoulder screw/spring (x4)

Ceiling Assembly Control Box Wall
Desired Function Kit Thermostat

12 VDC Control 8330-752 7330G335
Cooling Only or 8330-336

12 VDC Control 9330C755 7330G335
Cool/Heat Ready or 8330-336

24 VAC Control 8530-750 7330B344
Cooling Only or 8330B324

12 VDC Control 9530A751 8530A345
Heat Pump

Ceiling Assembly Control Box Wall
Desired Function Kit Thermostat

12 VDC Zone
Control Cooling 9430A751 9330A335
Only

12 VDC Zone
Control 9430A755 9330A335
Cool/Heat Ready

12 VDC Zone
Control Heat 9630A751 9330A335
Pump

3

5. CEILING PLENUM INSTALLATION REQUIREMENT

1. The ceiling plenum must be installed under the roof
opening.

The ceiling plenum bolts below the roof top unit.

Compression of the framed ceiling cavity between the
roof top unit and the ceiling plenum is what holds both
components in place.

2. Ceiling cavity depth (the measurement from the ceiling to
the roof – maximum 6”).

3. The 115 VAC service for the roof top unit must be routed
into the ceiling plenum. To prevent wire pinching and to
promote ease of installation, allowances must be made for
routing the 115 VAC supply wiring into the front of the
roof opening.

4. The wirebox has a 9 pin receptacle extending from the
front. This mates with the roof unit 115 volt electrical
conduit. When making this connection, verify that the
plugs are properly aligned and have snapped together
securely.

Standard Control Box

Cool Only

Boxes

Yes B BLUE Completes -12 VDC circuit for all relays Yes
Yes Y YELLOW Energizes coil on Compressor Relay Yes
Yes GH GREEN Energizes coil on High Fan Relay Yes
Yes GL GRAY Energizes coil on Low Fan Relay Yes
Yes FREEZE WHITE Evaporator Freeze Sensor Connections Yes
Yes FREEZE

No W WHITE Energizes coil on Heat Relay Yes

Plenum Terminal

Designation

Thermostat Wire

Connection

Zone Control Box

Plenum Terminal

Designation

R+ Red Provides +12 VDC to upper unit control box

Cool Shed

(2 Terminals)

Heat Shed

(2 Terminals)

Room (2 Terminals) Any The remote room temperature sensor attaches here*

Freeze (2 Terminals) White Freeze sensor attaches here

Gen Any Allows system to connect to an automatic start generator system

B- Blue Provides -12 VDC to upper unit control box
Sig 1 Purple Communication line between upper unit control box and thermostat
Sig 2 Black Communication line between upper unit control box and thermostat

* Zone 1 has option of using thermostat as room sensor

Thermostat Wire

Connection

White

Jumper Wire

White

Jumper Wire

5. The wirebox for the heat/cool units will have a two pin
receptacle which mates with the umbilical plug from the
heater assembly.

6. LOW VOLTAGE CONTROL WIRING (WALL
THERMOSTAT)

A. A low voltage terminal strip on the front of the box

connects to the low voltage control wires. The wires
attach by 1/4" quick connects.

B. The low voltage control wiring must be run from the

wall thermostat mounting location to the wirebox low
voltage terminals. To prevent wire pinching and to
promote ease of installation, allowances must be
made for routing the low voltage wiring into the front
of the opening.

Function of Low Voltage Terminal

Extending From Ceiling Plenum

Function of Low Voltage Terminal Extending From Ceiling

Plenum

Removing jumper wire will allow system to be connected to N.C.

contacts of a load shed system

Removing jumper wire will allow system to be connected to N.C.

contacts of a load shed system

Heat Ready

Boxes

4

6. CONTROL BOX KITS

1. 8330-752 – 12 VDC Controlled, Cool Only

This kit consists of a control box assembly. The evaporator
freeze sensor is shipped in an envelope for installation by
quick connects to terminal strip “Freeze”.

2. 9330C755 – 12 VDC Controlled, Heat Ready

This kit consists of a control box assembly. The evaporator
freeze sensor is shipped in an envelope for installation by
quick connects to terminal strip “Freeze”. The heater
assembly for the 47000 series is 47233*4551. The heater
assembly for the 48000 and 49000 series is 9233*4551. Heat
kits are purchased separately.

7. CONTROL BOX KITS (ZONE)

1. 9430A751 – 12 VDC Zone Controlled, Cool Only

This kit consists of a control box assembly. The evaporator
freeze sensor is shipped in an envelope for installation by
quick connects to terminal strip marked “FREEZE”.

2. 9430A755 – 12 VDC Controlled, Heat/Cool

This kit consists of a control box assembly. The evaporator
freeze sensor is shipped in an envelope for installation by
quick connects to terminal strip marked “FREEZE”. The
heater assembly for the 47000 series is 47233*4551. The
heater assembly for the 48000 and 49000 series is 9233*4551.
Heat kits are purchased separately.

8. WALL THERMOSTATS

1. Locate and install the thermostat per instructions
found with the thermostat.

2. For 12 VDC thermostats, it is required that the
thermostat 12 volt negative connection be routed

9. ROUTING THERMOSTAT WIRING

1. Following the instructions packed with the
thermostat, determine a location for thermostat
mounting.

2. Following Airxcel, Inc. low voltage wiring
specifications and all local and national electrical
codes:

A. Route the thermostat 12 VDC supply wiring

from the power source to the thermostat
mounting location.

5

3. 8530-750 – 24 VAC Controlled, Cool Only

This kit is similar to the 8330-752 with the exception of a
transformer that is attached to the box assembly.

4. 9530A751 – 12 VDC Controlled, Heat Pump

This kit is similar to the 9330C755 but is wired for the heat
pump function. Backup electric heat is available. The heater
assembly for the 47000 series is 47233*4551. The heater
assembly for the 48000 and 49000 series is 9233*4551. Heat
kits are purchased separately.

3. 9630A751 – 12 VDC Zone Controlled, Heat Pump

This kit consists of a control box assembly. The evaporator
freeze sensor is shipped in an envelope for installation by
quick connects to terminal strip marked “FREEZE”. Backup
electric heat is available. The heater assembly for the 47000
series is 47233*4551. The heater assembly for the 48000 and
49000 series is 9233*4551. Heat kits are purchased
separately.

directly from the converter or battery. It is highly desirable
provide 12 volt control power from the battery side of the
converter. These precautions should prevent control
problems.

Two wires are required:

One supply lead must be +12 VDC and red

in color.

The second supply lead must be -12 VDC

and blue in color.

B. To protect the wall mount thermostat from

over-current damage, a 2 amp fuse has been
provided with the thermostat.

C. Route the thermostat control wiring from the

thermostat mounting location into the front
of the ceiling plenum opening.

Four (4) wires are required (5 wires for

heat/cool boxes). These wires are as
follows:

(1) Blue wire for -12 VDC circuit

(1) Yellow wire for compressor circuit
(1) Green wire for high fan circuit
(1) Gray wire for low fan circuit

10. ROUTING THERMOSTAT WIRING (ZONE)

1. Following the instructions packed with the
thermostat, determine a location for thermostat
mounting.

2. Following Airxcel, Inc. low voltage wiring

specifications and all local and national electrical
codes:

A. Route the thermostat control wiring from the
thermostat mounting location into the front
of the ceiling plenum opening.

These wires are as follows:

(1) Red wire to +12 VDC circuit (R+)
(1) Blue wire to -12 VDC circuit (B-)
(1) Purple wire to communication

signal (Sig 1)
(1) Black wire to communication
signal (Sig 2)

(1) Any color for auto generator start

(optional) (Gen)

(2) Any color for room temperature

sensor (zone 1 optional, required

for other zones)

(1) For each heating appliance

(Up to 4)

(2) Any color for cool load shed

(optional)
(2) Any color for heat load shed
(optional)

11. ROUTING 115 VAC WIRING

Following Airxcel, Inc. high voltage wiring specifications and
all local and national electrical codes, route the roof top unit
115 VAC supply wiring from its power source to the wirebox.

High Voltage Wiring Specifications based on Minimum
Overcurrent Protection Device Amperage – (see upper
unit nameplate)

1. U.L. requires copper conductors only with minimum

#12 AWG when using the minimum recommended
overcurrent protection device. Higher rated devices
or longer wiring runs will require #10 AWG or
greater copper conductors.

6

(1) White wire for heat circuit

3. Airxcel, Inc. low voltage wiring specifications:

A. All low voltage wiring should be 18 gauge

minimum.

B. Low voltage wiring must be routed into the front

side of the ceiling plenum opening.

B. See Figure 5 for wiring requirements for
multiple zones.

3. Airxcel, Inc. low voltage wiring specifications:

A. All low voltage wiring should be no
smaller than 18 gauge.

B. Low voltage wiring must be routed into
the front side of the ceiling plenum opening.

C. Low voltage wiring should not be routed
with high voltage wiring.

D. If low voltage and high voltage wires must
cross, they should do so at right angles from
one another.

2. To prevent voltage drops greater than 10% during
starting loads, adhere to the following guideline:

For lengths greater than 50’, use #10 AWG or larger
copper conductors. Match to the overcurrent
protection device provided.

Circuit Protection – Refer to upper unit nameplate

High Voltage Wiring Specifications based on Overcurrent
Protection Device rated higher than the minimum
required (see upper unit nameplate)

Follow all local and NEC (National Electrical Code) for
proper sizing of wire AWG based on Overcurrent
Protection Device selected and the length of the wiring run
to the air conditioner.

12. SECURING THE UPPER UNIT TO THE ROOF

The supplied mounting frame is used to secure the upper unit
to the roof per the following steps (See Figure 1).

A. Locate the upper unit mount gasket over the 14” to
15” square opening in the roof.

B. Install the ceiling assembly mount frame using the
four bolts found with the ceiling assembly.

C. Proper tension has been achieved for each bolt when
any portion of each gasket indicating tab has been
pulled down even with the roof (See Figure 1). The
upper unit has now been properly installed with
optimum gasket compression.

Representative of 47000, 48000 and 49000 Series Units

7

FIGURE 1

13. INSTALLING THE CONTROL BOX

1. Remove the control box assembly cover which is
held by two sheet metal screws. Feed the field lead
wires and ground through the strain relief found with
the control box.

2. Attach black supply conductor to black “pigtail” lead,
white to white and ground to green with wire nuts
provided in control box kit.

3. Insure that no bare wires can come into contact with
live electrical parts and that wires cannot be pinched
between the control box sides and lid. Insert the
strain relief into the control box entry hole to secure
the field wiring. Reinstall the control box lid.

4. Attach the thermostat wires to the control box per
illustrations below:

A. Control Box 8330-752

B. Control Box 9330C755, 9530A751

C. Control Box 8530-750

5. Connect the roof unit 115 volt electrical conduit to
the wirebox 9 pin receptacle and verify that the plugs
are properly aligned and have snapped together
securely.

6. Locate the two machine screws inside the evaporator
cover of the upper unit. Align the control box over
the screws and use the wing nuts supplied with the

control box to secure it to the upper unit enclosure.
See Figure 2 for control box orientation in 48000 and
49000 series units. See Figure 9 for 47000 series
units.

7. Insert the evaporator freeze sensor between
evaporator fins near the bottom center of the
evaporator and between the bottom two tubes (See
Figure 2). Insert straight in until contacting the
staggered tube directly in back of the insertion point.
When contact has been made, elevate the exposed
end of the sensor approximately 45 degrees, then
continue insertion at a 45 degree angle until the
sensor is completely embedded into the evaporator.

8

FIGURE 2

14. INSTALLING THE CONTROL BOX (ZONE)

1. Remove the control box assembly’s cover which is
held by two sheet metal screws.

2. Set the “zone” jumper to the proper zone position for
the particular position the air conditioner or heat
pump will be in the coach (Refer to Figure 3 – Zone
1 is shown). Zones should be numbered from the
front of the back of the coach with Zone 1 in front.

3. Set the “HP”/”NON HP” jumper to “HP” if the unit
is a heat pump or to “NON HP” if the unit is not a
heat pump (Refer to Figure 3 – Non HP is shown).

4. Feed the field lead wires and ground through the
strain relief found with the control box then through
the 7/8” hole in the side of the box.

5. Wire nut the black field power conductor to the
stripped black 12-gauge wire in the control box.

6. Wire nut the white field power conductor to the
stripped white 12-gauge wire in the control box.

7. Wire nut the ground field power conductor to the
stripped green ground wire in the control box.

8. Insure that no bare wires can come into contact with
live electrical parts and that wire cannot be pinched
between the control box sides and lid. Insert the
strain relief into the control box entry hole to secure
the field wiring. Reinstall the control box lid.

Attach the thermostat wires to Zone 1 control box per the
illustration below (Refer to Figure 4):

FIGURE 3

FIGURE 4

9

FIGURE 5

10

Zone 2 is wired in by jumpering from Sig 1, Sig 2, B- and R+
on Zone 1 box to Zone 2 box. Zone 3 is wired in by
jumpering from Sig 1, Sig 2, B- and R+ on Zone 2 box to
Zone 3 box. Zone 4 is wired in by jumpering from Sig 1, Sig
2, B- and R+ on Zone 3 box to Zone 4 box (See Figure 5).

Connect the roof unit 115 volt electrical conduit to the
wirebox 9 pin receptacle and verify that the plugs are properly
aligned and have snapped together securely.

Position the control box over the screws and use the wing nuts
to fasten the control box to the upper unit enclosure. For
47000 series units, refer to Figure 9 on page 13. Note that the
box is installed with the wiring exiting upwards.

Insert the evaporator freeze sensor between evaporator fins
near the bottom center of the evaporator and between the
bottom two tubes (See Figure 2). Insert straight in until
contacting the staggered tube directly in back of the insertion
point. When contact has been made, elevate the exposed end
of the sensor approximately 45 degrees, then continue
insertion at a 45 degree angle until the sensor is completely
embedded into the evaporator.

15. INSTALLING THE HEATER ASSEMBLY

NOTE

The optional Electric Heating Element is intended to take the
chill out of the indoor air when the air is a few degrees too
cool for comfort. The Electric Heating Element is an effective
“chill chaser”. It is not a substitute for a furnace.

A. If adding the electric heater to 48000 and 49000

series units, position the assembly in the upper unit
return air opening as shown in Figure 6. The heater
bracket must be installed over the metal basepan
extrusion and positioned between the basepan and the
plastic drain pan (See Figure 7). Tighten set screw to
secure the assembly so as to prevent movement.
47000 series units will mount as shown in Figure 10
(see page 13) using wing nuts.

FIGURE 6

Complying with the warnings listed below, connect the 115
VAC supply wiring to its power source. Be sure all power
remains off until beginning checkout procedure.

DANGER

TO PREVENT THE POSSIBILITY OF
SHOCK INJURY FROM APPLIANCE
OPERATION:

THE WHITE WIRE MUST BE
CONNECTED TO NEUTRAL IN THE
SERVICE BOX ENTRANCE AND THE
MECHANICAL GROUND MUST BE
CONNECTED TO A GROUNDING
LUG IN THE SERVICE BOX OR THE
MOTOR GENERATOR
COMPARTMENT.

B. Insert the two-pin connector of the heater umbilical
into the receptacle on the control box. Insure that the
connector snap-locks into position.

TIE ALL WIRING TO INSURE NO CONTACT WITH
THE HEATER OR ANY SHARP EDGES. KEEP IN
MIND THAT HIGH VELOCITY AIR WILL BE
ENCOUNTERED IN THIS AREA.

FIGURE 7

11

16. INSTALLING THE CEILING ASSEMBLY

A. Fasten the duct collar to the basepan of the air
conditioner with three (3) screws (See Figure 8).

B. Raise the ceiling assembly and secure to the
mounting frame with four (4) provided shoulder
screw/spring assemblies (See Figure 8).

C. The ceiling assembly shroud is curved to contour to
a crowned ceiling. If installation is to a flat ceiling
and gaps are present on the sides of the shroud,
insert the four optional 3/4 inch screws (provided)
through the mounting posts and secure them to the
mounting frame above. See Figure 8 for screw
locations.

D. Pull fabric duct material through ceiling assembly
discharge opening. Peel the release liner from the
adhesive strip around the discharge opening. Press
the fabric duct material firmly in place around

opening. Cut off excess fabric on inside of ceiling
assembly chute with a box knife taking care not to
tear the fabric beyond the adhesive strip.

E. Make sure the non-allergenic filters are properly
positioned in the ceiling grille. Install the ceiling
grille by positioning on the bottom of the shroud
and engaging the two 1/4 turn fasteners.

F. Turn the selector switch to OFF position.

G. Turn ON the power supply to the roof top air
conditioner.

H. Follow the “System Operation and Checkout” guide
in the thermostat installation instructions to insure
proper operation.

FIGURE 8

12

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FIGURE 9

FIGURE 10

13