Dometic 620525.326, 620515.421, 620525.421, 620526.326, 620526.321 Installation Instructions Manual

...
Page 1
USA
C
S
SERVICE OFFICE Dometic Corporation 509 South Poplar Street LaGrange, IN 46761 260-463-4858
RECORD THIS UNIT INFORMATION FOR FUTURE REFERENCE: Model Number Serial Number Date Purchased
MODELS
620515, 620525, 620526, 630515 &
630516
Roof Top Air Conditioner & Heat Pump
Used With
3105007 Return Air Kit
3105935 Quick Cool Return Air Kit
3308120 Genesis Air Filtration System Return Air Kit
3109228.001 Duo-Therm Comfort Control Center™
CANADA
For Service Center Assistance Call:
800-544-4881
U
INSTALLATION
INSTRUCTIONS
REVISION
Form No. 3109530.067 2/04 (Replaces 3109530.059) (French 3109884.068) ©2004 Dometic Corporation LaGrange, IN 46761
This Unit Is Designed For OEM Installation. All Initial
Installations Must Be Approved By Dometic Corporation
This manual must be read and un­derstood before installation, ad­justment, service, or maintenance is performed. This unit must be in­stalled by a qualified service tech­nician. Modification of this product can be extremely hazardous and could result in personal injury or property damage.
Important: These Instructions
must stay with unit. Owner read carefully.
1
Lire et comprendre ce manuel avant de procéder à l'installation, à des réglages, de l'entretien ou des réparations. L'installation de cet appareil doit être effectuée par un réparateur qualifié. Toute modification de cet appareil peut être extrêmement dangereuse et entraîner des blessures ou dommages matériels.
MODELS
620515.321
620515.326
620515.421
620525.321
620525.326
620525.421
620526.321
620526.326
630515.321
630515.326
630515.421
630516.321
630516.326
Page 2
620515, 620525, 620526, 630515 & 630516 Installation Instructions
SAFETY INSTRUCTIONS
This manual has safety information and instruc­tions to help users eliminate or reduce the risk of accidents and injuries.
RECOGNIZE SAFETY INFORMATION
!
This is the safety-alert symbol. When you see this symbol in this manual, be alert to the potential for personal injury .
Follow recommended precautions and safe op­erating instructions.
UNDERSTAND SIGNAL WORDS
GENERAL INFORMATION
A. Product features or specifications as described or illus-
trated are subject to change without notice.
B. This air conditioner is designed for:
1. Installation on a recreational vehicle during the time the vehicle is manufactured.
2. Mounting on the roof of a recreational vehicle.
3. Connection to an air distribution system located in the ceiling/roof cavity of the recreational vehicle.
4. Roof construction with rafters/joists on minimum of 16 inch centers.
5. Minimum of 2.00" and maximum of 5.50" distance between roof to ceiling of recreational vehicle. Alter­nate installation methods will allow for roofs more than 5.50" thick.
C. The ability of the air conditioner to maintain the desired
inside temperature depends on the heat gain of the RV. Some preventative measures taken by the occupants of the RV can reduce the heat gain and improve the performance of the air conditioner. During extremely high outdoor temperatures, the heat gain of the vehicle may be reduced by:
1. Parking the RV in a shaded area
2. Using window shades (blinds and/or curtains)
3. Keeping windows and doors shut or minimizing usage
4. Avoiding the use of heat producing appliances.
A signal word , WARNING OR CAUTION is used with the safety-alert symbol. They give the level of risk for potential injury .
WARNING
!
indicates a potentially hazard­ous situation which, if not avoided, could result in death or serious injury .
CAUTION
!
indicates a potentially hazard­ous situation which, if not avoided may result in minor or moderate injury .
CAUTION
used without the safety alert symbol indicates, a potentially hazardous situa­tion which, if not avoided may result in property damage.
Read and follow all safety information and instruc­tions.
Operation on High Fan/Cooling mode will give optimum or maximum efficiency in high humidity or high outside tem­peratures.
Starting the air conditioner early in the morning and giving it a "head start" on the expected high outdoor ambient will greatly improve its ability to maintain the desired indoor temperature.
For a more permanent solution to high heat gain, accesso­ries like A&E outdoor patio and window awnings will reduce heat gain by removing the direct sun. They also add a nice area to enjoy company during the cool of the evening.
D. Condensation
Note: The manufacturer of this air conditioner will not be
responsible for damage caused by condensed moisture on ceilings or other surfaces. Air contains moisture and this moisture tends to condense on cold surfaces. When air enters the RV, condensed moisture may appear on the ceiling, windows, metal parts, etc. The air conditioner re­moves this moisture from the air during normal operation. Keeping doors and windows closed when this air conditioner is in operation will minimize condensed moisture on cold surfaces.
2
Page 3
620515, 620525, 620526, 630515 & 630516 Installation Instructions
SPECIFICATIONS
Cooling Amps Amps W.C. Supplied 1Unit/2Units
(BTU/HR) Amps Rotor Amps Rotor Max/Min Max/Min ***User (Pounds) Size**
Model Nominal Electrical Compressor Compressor Fan Motor Fan Motor SCFM-High Total Refrigerant Minimum AC Circuit Installed Minimum
No. Capacity Rating Rated Load Locked Rated Load Locked Speed Static R-22 (Oz.) Wire Size* Protection Weight Generator
620515.321 13,500 115 VAC, 12.4 60.0 3.1 8.8 335 /250 0.12/0.65 15.5 12AWG 20 Amp 102 3.5 KW/5.0 KW
620515.326 13,500 60 Hz., 1 PH 12.4 60.0 3.1 8.8 335/250 0.12/0.65 15.5 Copper 20 Amp 10 2 3.5 KW/5.0 KW
620515.421 13,500 11.5 50.0 3.1 8.8 335/250 0.12 / 0.65 17.0 Up To 24' 20 Amp 102 3.5 KW/5.0 KW
620525.321 13,500 12.4 60.0 3.1 8.8 335 / 250 0.12/0.65 15.5 20 Amp 102 3.5 KW/5.0 KW
620525.326 13,500 12.4 60.0 3.1 8.8 335/250 0.12/0.65 15.5 20 Amp 102 3.5 KW/5.0 KW
620525.421 13,500 11.5 50.0 3.1 8.8 335/250 0.12/0.65 17.0 20 Amp 102 3.5 KW/5.0 KW
620526.321 15,000 12.0 64.0 3.3 8.5 380/250 0.12/0.65 21.5 20 Amp 104 3.5 KW/5.0 KW
620526.326 15,000 12.0 64.0 3.3 8.5 380/250 0.12/0.65 21.5 20 Amp 104 3.5 KW/5.0 KW
630515.321 13,500 12.4 60.0 3.1 8.8 335/250 0.12/0.65 24.5 20 Amp 102 3.5 KW/5.0 KW
630515.326 13,500 12.4 60.0 3.1 8.8 335/250 0.12/0.65 24.5 20 Amp 102 3.5 KW/5.0 KW
630515.421 13,500 12.0 50.0 3.1 8.8 335/250 0.12/0.65 19.5 20 Amp 102 3.5 KW/5.0 KW
630516.321 15,000 12.0 64.0 3.3 8.5 380/250 0.12/0.65 21.5 20 Amp 104 3.5 KW/ 5.0 KW
630516.326 15,000 12.0 64.0 3.3 8.5 380/250 0.12/0.65 21.5 20 Amp 104 3.5 KW/5.0 KW
When sizing the generator, the total power usage of your recreational vehicle must be considered. Keep in mind generators lose power at high altitudes
an dfrom lack of maintenance.
* For wire length over 24 ft., consult the National Electric Code for proper sizing.
** Dometic Corporation gives GENERAL guidelines for generator requirements. These guidelines come from experiences people have had in actual applications.
*** CIRCUIT PROTECTION: Time Delay Fuse or HACR Circuit Breakers Required.
3
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CAUTION
M
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r
o
-
T
h
e
r
m
F
i
l
t
e
r
S
y
s
t
e
m
Micro-Therm
Filter
System
F I
L T
E
R R E
S
E
T
FILTER RESET
C L E
A
N F I
L
T
E
R
CLEAN FILTER
620515, 620525, 620526, 630515 & 630516 Installation Instructions
INSTALLATION INSTRUCTIONS
A. Precautions
WARNING
!
Improper installation may damage equipment, could endanger life, cause serious injury and/ or property damage.
1. Read Installation and Operating instructions care­fully before attempting to start your air conditioner installation.
2. Dometic Corporation will not be liable for any dam­ages or injury incurred due to failure in following these instructions.
3. Installation must comply with the National Electri­cal Code ANSI/NFPA-70 and CSA Standard C22.1 (latest edition) and any State or Local Codes or regulations.
4. DO NOT add any devices or accessories to this air conditioner except those specifically authorized by Dometic.
5. This equipment must be serviced by qualified per­sonnel and some states require these people to be licensed.
B. Choosing Proper Location For The Air
Conditioner
This air conditioner is specifically designed for installation on the roof of a recreational vehicle (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.
1. Normal Location-The air conditioner is designed to fit over an existing roof vent opening. When the vent is removed, it normally creates a 14-1/4" X 14-1/4" (±1/8") opening.
FIG. 2
1/2 L
L
2/3 L
L
1/3 L
It is preferred that the air conditioner be installed in a relatively flat and level roof section measured with the RV parked on a level surface. Note: A 8° slant to either side, or front to back, is acceptable for 620515, 620525, 620526, 630515 and 630516 series.
3. After Location Has Been Selected: a. Check for obstructions in the area where air
conditioner will be installed. See FIG. 3 & 4.
b. The roof must be designed to support 130
poundswhen the RV is in motion. Normally a 200 lb. static load design will meet this require­ment.
It is the responsibility of the installer of this air conditioner system to ensure structural in­tegrity of the RV roof. Never create a low spot on the roof where water will collect. Water standing around the air conditioner may leak into the interior causing damage to the prod­uct and the RV.
c. Check inside the RV for return air cover obstruc-
tions (i.e. door openings, room dividers, cur­tains, ceiling fixtures, etc.) See FIG. 3 & 4.
FIG. 3
FIG. 1
Roof Vent Opening
2. Other Locations-When no roof vent is available or another location is desired, the following is recom­mended: a. For one unit installation: The air conditioner
should be mounted slightly forward of center (front to back) and centered from side to side.
b. For two unit installations: Install one Air Condi-
tioner 1/3 and one Air Conditioner 2/3’s from front of RV and centered from side to side.
9-1/2"
28-3/4"
39"
3/4"
2"
17"
17"
20-7/8"
18-1/2"
4
Page 5
FIG. 4
AIR CONDITIONER DIMENSIONS (On Top of Vehicle)
Air Grill Perimeter
620515, 620525, 620526, 630515 & 630516 Installation Instructions
2. Roof Vent Removal a. Unscrew and remove the roof vent. b. Remove all caulking compound around open-
ing.
FIG. 5
1-1/2"
17"
1-1/4"
1-1/2"
17"
1-3/4"
14-1/4 x 14-1/4 (±1/8")
3"
2"
3"
2"
20-7/8"
Genesis
Opening
C. Roof Preparation
1. Opening Requirments - Before preparing the ceiling opening, the type of system options must be de­cided upon. If a remote sensor is to be used, provision must be made for it. If the load shed option is to be used, wires must be run from the load shed control to the Dometic A/C. If a furnace is to be connected, wires must be run from the furnace to the Dometic A/C. Read all of the following instructions before beginning the installation. If a roof vent opening will not be used a 14-1/4" x 14­1/4" (±1/8") opening must be cut through the roof and ceiling of the RV. This opening must be located between the roof reinforcing members.
18-1/2"
c. Seal all screw holes and seams where the roof
gasket is located. Use a good grade of all weather sealant.
d. If the opening exceeds 14-3/8" x 14-3/8", it will
be necessary to install spacers.
e. If the opening is less than 14-1/8" x 14-1/8", it
must be enlarged.
3. New Opening-(Installation Other Than Vent Open­ing) a. Mark a 14-1/4" x 14-1/4" (±1/8") square on the
roof and carefully cut the opening.
b. Using the roof opening as a guide, cut the
matching hole in the ceiling.
d. The opening created must be framed to provide
adequate support and prevent air from being drawn from the roof cavity. Lumber 3/4" or more in thickness must be used. Remember to pro­vide an entrance hole for power supplies, fur­nace wiring, 4-conductor control cable, remote sensor and load shed (Energy Management System) options as desired.
FIG. 6
There may be electrical wiring between the roof and the ceiling. Disconnect 115 volt AC power cord and the positive (+) 12 volt DC ter­minal at the supply battery. Failure to follow this instruction may create a shock hazard causing death or severe personal injury.
The 14-1/4" x 14-1/4" (±1/8") opening is part of the return air system of the Air Conditioner and must be finished in accordance with NFPA Standard 501C Section 2.7.2.
Do Not Cut Roof Strucure Or Rafters
Leave Access For Power Supply Wiring
5
Good-Rafters Supported By Cross Beams
3/4" Min.
Good Location­Between Roof Rafters
Frame Opening So It Won't Collapse When Bolting Down
15" min.
Page 6
CAUTION
CAUTION
CAUTION
It is the responsibility of the installer of this air conditioner system to ensure structural integrity of the RV roof. Never create a low spot on the roof where water will collect. Wa­ter standing around the air conditioner may leak into the interior causing damage to the product and the RV.
4. Air Distribution System Sizing & Design (See Chart On Page 7)
CAUTION
It is the responsibility of the installer to insure the ductwork will not collapse or bend during and after the installation. Dometic Corporation will not be liable for roof structural or ceiling damage due to improperly insulated, sealed or collapsed ductwork.
The Installer of this air conditioner system must design the air distribution system for this particular application. Several requirements for this system MUST be met for the air conditioner to operate properly. These require­ments are as follows:
FIG. 7
FRAME
INSULATION
DUCT
LOW VOLTAGE WIRES:
12VDC Furnace Load Shed Sensors
ROOF
(TOWARD BACK OF RV)
DUCT
a. The duct material must meet or exceed any
agency or RVIA Standard that may be in exist­ence at the time the RV is produced.
b. All discharge air ducts must be properly insu-
lated to prevent condensation from forming on their surfaces or adjacent surfaces during op­eration of the air conditioner. This insulation must be R-7 minimum.
c. Ducts and their joints must be sealed to prevent
condensation from forming on adjacent sur­faces during operation of the air conditioner.
d. Return air openings must have 40 square inches
minimum free area including the filter.
TOP VIEW
(BACK OF RV)
FRAME
14-1/4" (±1/8”)
OPENING
AC POWER SUPPLY WIRE
FRAME
CCC, CONTROL CABLE(S) or 7-Wire Analog Cable
SIDE VIEW
14-1/4" (±1/8”)
OPENING
CEILING
DUCT
DUCT
INSULATION
620515, 620525, 620526, 630515 & 630516 Installation Instructions
e. Return air to the air conditioner must be filtered
to prevent dirt accumulation on air conditioner cooling surface.
5. Air Distribution System Installation a. Dometic Corporation recommends the basic
configuration shown on page 8, for installing this air conditioner system. We have found by test­ing, that this configuration works best in most applications of this air conditioner system. It is the responsibility of the Installer of this system to review each RV floor plan and determine the following:
Duct size
Duct layout
Register size
Register location
Thermostat location
These items must be determined in conjunction with the Air Distribution System and Sizing and Design Require­ments listed in the chart on page7. Terminate the start of the duct at the back edge of the 14-1/4" x 14-1/4" (±1/ 8" opening)
Important: Alternate configurations and methods
may be used which still allow the air conditioner to operate properly; however, these alternate configura­tions and methods must be approved by the Dometic Corporation in writing. The following instructions are based upon the use of Dometic Return Air Kits
3105007.XXX, 3105935.XXX, or 3308120.XXX Genesis Air Filtration System. The 3107180.006 Bolt/Cover Kit has the mounting bolts and cover for the AC junction box for use with these kits.
D. Wiring Requirments
1. Route a copper 12 AWG, with ground, 115 VAC supply line from the fuse or circuit breaker box to the roof opening. a. This supply line must be located in the front
portion of the 14-1/4" x 14-1/4" (±1/8") opening.
b. The power MUST be on a separate 20 amp time
delay fuse or HACR circuit breaker.
c. Make sure that at least 15" of supply wire
extends into the roof opening. This ensures easy connection at the junction box.
d. Wiring must comply with all National, State and
Local Wiring Codes.
e. Use a steel sleeve and a grommet or equivalent
methods to protect the wire where it passes into the opening.
2. Route a dedicated 12 VDC supply line (18-22 AWG) from the RV's converter or battery to the roof open­ing. a. This supply line must be located in the front
portion of the 14-1/4" x 14-1/4" (±1/8") opening.
b. Make sure that at least 15" of supply wire
extends into the roof opening.
c. In a multiple zone installation, this wiring is
required in only one of the 14-1/4" x 14-1/4" (±1/8") openings.
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620515, 620525, 620526, 630515 & 630516 Installation Instructions
Air Distribution Duct Sizing & Design Chart For Ducted Applications
Return Air Cover Model 3105007.XXX 3308120.XXX
3105935.XXX Genesis Air Filtration System
Roof Cavity Depth 2.0 In. Min. - 5-1/2 In. Max. 2.0 In. Min. - 5-1/2 In. Max. Duct Cross Sectional Area 21.0 Sq. In. Min. 32.0 Sq. In. Min.
Duct Size
Depth 1-1/2 In. Min. - 2-1/2 In. Max. 2.0 In. Min. - 2-1/2 In. Max. Width 7.0 In. Min. - 10.0 In. Max. 8.0 In. Min. - 10.0 In. Max. T ot al Duct Length 15.0 Ft. Min. - 40.0 Ft. Max. 15.0 Ft. Min. - 40.0 Ft. Max. Duct Length (short run) 1/3 Total Duct Length 1/3 Total Duct Length
Center Duct System (Only)
Depth 2.0" In. Min. - 2.0" Max. Width 8.0 In. Min. - 8.0 In. Max. T ot al Duct Length 15.0 Ft. Min. - 40 Ft. Max. Duct Length (Short Run) 1/3 T otal Length
Register Requirements
Number Required Per Run 4 Min. 4 Min. Register Free Air Area 14.0 Sq. In. 14.0 Sq. In. Distance From Duct End 5.0 In. Min. - 8.0 In. Max. 5.0 In. Min. - 8.0 In. Max. Distance From Elbow 15.0 In. 15.0 In.
T ot al System St atic Air Pressure
Blower at High Speed, Filter & Grill In Place 0.12 - 0.65 In. W.C. 0.12 - 0.65 In. W.C.
Note: Duct sizes listed are inside dimensions.
3. If a Remote Temperature Sensor is used, the con­nector end must be routed to the roof opening of the system which it will control. Make sure that at least 15" of the sensor cable extends into the roof open­ing. Refer to the Remote Sensor Instructions for details of the installation. See Section E-1.
4. If a furnace is to be controlled by the system, the two furnace thermostat leads must be routed to the roof opening of the air conditioner that will control it. Make sure that at least 15" of the furnace thermostat wires extend into the roof opening.
5. If an Energy Management System (load shed fea­ture) is to be used with the control, two wires must be routed to the roof opening of the zone to be managed. The signal required for this function is normally open relay contact. When the EMS calls for the compressor to shut off, the relay contacts should close. Make sure at least 15" of the EMS wires extend into the roof opening.
6. Route a 4-conductor control cable from the Comfort Control Center™ mounting position into the 14-1/4" x 14-1/4" (±1/8") roof opening. Make sure that at least 15" of the wire extends into the roof opening and 6" extend from the wall at the mounting position of the Comfort Control Center™. See Section E-2.
7. In the event that other Air Conditioners are installed (additional zones) an additional 4-conductor control cable must be routed to the other Air Conditioners. Make sure that at least 15" of the wire extends into the roof opening. See FIG. 31.
8. If an automatic generator start kit (AGS) will be installed, a 4-conducter control cable must be routed from the last air conditioner to location of AGS kit. Follow AGS kit instructions for installation.
E. Dometic Comfort Control Center™ & Cable
Installation
1. Location a. If the system is to be used WITHOUT a Re-
mote Temperature Sensor, the proper loca­tion of the Comfort Control Center™ is very important to ensure that it will provide a comfort­able RV temperature. Observe the following rules when selecting a location:
Locate the Comfort Control Center™ 54"
above the floor.
Install the Comfort Control Center™ on a
partition, not on an outside wall.
NEVER expose it to direct heat from lamps,
sun or other heat producing items.
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Page 8
620515, 620525, 620526, 630515 & 630516 Installation Instructions
FIG. 8
Duct Size And Requirements For 3105007.XXX And 3105935.XXX Return Air Cover
Register Required Short Duct Run Minimum
1/3 T ot al Duct Length
Total Outlet Air Area Minimum 21.0 Sq. In.
Ducts Min. Max. Depth 1-1/2” 2-1/2” Width 7.0” 10.0” Total Length 15.0’ 40.0’
Register Required
Note: Duct Size is Inside Dimensions
Duct Size And Requirements For 33308120.XXX Genesis Air Filtration System Return Air Kit
FIG. 8 Register Required
Short Duct Run Minimum 1/3 Tot al Duct Length
Total Outlet Air Area Minimum 32.0 Sq. In.
Ducts Min. Max. Depth 2.0” 2-1/2” Width 8.0” 10.0” Total Length 15.0’ 40.0’
Roof Rafters
Register Required
Registers
8 Min.-- 12 Max. (Per Unit) 14 Sq. In Free Area Per Register
Register Required
14-1/4"x14-1/4" (±1/8")
Roof Opening
Register Required
Registers
8 Min.-- 12 Max. (Per Unit) 14 Sq. In Free Area Per Register
Register Required
Note: Duct Size is Inside Dimensions
Avoid locations close to doors that lead
outside, windows or adjoining outside walls.
Avoid locations close to supply registers
and the air from them.
b. If the system is to be used WITH a Remote
Temperature Sensor in ALL zones, the Com­fort Control CenterTM may be mounted any-
where that is convenient in the coach. Try to avoid hard to reach and hard to see areas.
Refer to the instructions provided with the
Remote Temperature Sensor for details of installation.
c. A 3/8" diameter hole will be needed to route the
cable through the wall. See Section D-3.
2. Control Cable Installation A 4-conductor control cable must be routed from the roof opening to the Comfort Control Center
a. Choose the shortest, most direct route from the
14-1/4" x 14-1/4" (±1/8") opening to the Com-
fort Control Center
TM
location selected. Leave 6" of cable extending through the wall. See Section D-6.
TM.
Roof Rafters
8
Register Required
14-1/4"x14-1/4" (±1/8")
Roof Opening
b. The control cable that should be used is a flat,
4-conductor telephone cable.
c. The control cable must be terminated with two
(2) RJ-11 telephone connectors. Refer to the crimp tool manufacture for crimping instruc-
tions.
Important: RJ-11 connectors must be installed as
shown in FIG. 9A & 9C.
FIG. 9A
FIG. 9B
Page 9
620515, 620525, 620526, 630515 & 630516 Installation Instructions
Insert Screwdriver under
Tab
OFF
ON
TEMP
CAUTION
FIG. 9C
Black
Red
Green
Yellow
Pin 1
RJ-11 Connector
Flat Four Conductor Cable
3. Comfort Control CenterTM Installation a. Carefully remove the base plate from the Com-
fort Control CenterTM. This may be accom-
plished by inserting a small screwdriver under the tab on thebottom edge of the front cover and gently prying. See FIG. 10.
FIG. 10
MODE
FAN
P
M
TE
UP
Black
Red
Green
Yellow
This unit weighs approximately 100 pounds. To prevent back injury, use a mechanical hoist to place Air Conditioner on roof.
3. Lift and place the unit over the prepared opening using the gasket on the unit as a guide.
Do not slide the unit. This may damage the neoprene gasket attached to the bottom and may create a leaky installation.
FIG. 12
FRONT
DOWN
ZONE
ON
OFF
Insert Screwdriver under Tab
b. Insert the control cable through the hole in the
base plate and mount the plate to the wall with two (2) screws provided. Check the alignment to ensure level installation.
c. Install the control cable RJ-11 connector into
the back of the Comfort Control Center™ and gently press onto the base plate.
F. Placing the Air Conditioner On The Roof
1. Remove the air conditioner from the carton and discard carton.
2. Place the air conditioner on the roof.
FIG. 11
4. Place the return air kit inside the RV. This box contains mounting hardware for the air conditioner and will be used inside the RV.
This completes the outside work, Minor adjustments can be done from inside of the RV if required.
G . Inst alling Air Conditioner
Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover. For unit with Genesis Air Filtra­tion System see page 1 1.
1. Installation Of Ceiling T emplate
FIG. 13
Ceiling Template
Return Air Grill
Divider Plate
Return Air Cover
a. Check gasket alignment of the air conditioner
over the roof opening and adjust if necessary . Unit may be moved from below by slightly lift­ing. See FIG. 14.
9
Page 10
FIG. 14
CAUTION
FIG. 15
b. Remove return air cover and ceiling template
from the 3105007.XXX or 3105935.XXX kit car­ton.
c. Locate the four 8" x 1/4" x 20 unit mounting
bolts, junction box cover and Romex connec­tor in the 3107180.006 bolt kit.
Center Unit From Below
Roof Gasket
d. Reach up into the return air opening and pull
the unit electrical cord down. Mount the junc­tion box with screws to the framing in front of the 14-1/4" x 14-1/4" (±1/8") opening . See FIG .
15.
620515, 620525, 620526, 630515 & 630516 Installation Instructions
FIG. 16
Screws
2. Installation Of Divider Plate a Measure the ceiling to roof thickness:
Front of Vehicle
Roof Gasket
Tighten to compress gasket to 1/2"
Finger Tight
If distance is 2.0" - 3-3/4", remove perfo-
rated tab from divider plate.
If distance is 3-3/4" - 5-1/2", remove no tabs.
b. Remove the backing paper from double sided
tape located on ceiling template. See FIG. 17.
FIG. 17
Fasten Junction Box To Front Of Opening
e. Install the Romex connector in the junction box. f. Hold the ceiling template up to the 14-1/4" x
14-1/4" (±1/8") opening. Be sure the large plate faces the rear of the RV .
S tart each mounting bolt through the ceil-
ing template and up into the unit base pan by hand. Install wood screw in each end of the ceiling template. This insures a tight fit of the return air cover to ceiling. See FIG.
16.
EVENLY tighten the bolts to a torque of
40 to 50 inch pounds. This will compress the roof gasket to approximately 1/2". The bolts are self locking so over tight­ening is not necessary. See FIG. 16.
CAUTION
If bolts are left loose there may not be ad­equate roof seal or if over tightened, damage may occur to the air conditioner base or ceil­ing template. Tighten to specifications listed in this manual.
c. Place divider plate up to bottom of air condi-
tioner base pan firmly. The foam tape on the divider plate must seal to bottom of base pan. See FIG . 17.
Improper installation and sealing of divider plate will cause the compressor to quick cycle on the cold control. This may result in fuse or circuit breaker opening and/or lack of cool­ing.
FIG. 18
10
Page 11
Note: The adhesive on the insulation is extremely sticky.
Micro-Therm
Filter
System
FILTER RESET
CLEAN FILTER
Be sure the part is located where desired before pressing into place.
d. With slight pressure then push the divider plate
against the double sided tape on the ceiling template.
e. Locate the 1/8" x 7" x 18" self -adhesive insula-
tion supplied with the return air kit. Remove the backing paper from the insulation and carefully stick onto the ceiling template divider panel. See FIG. 19.
FIG. 19
Excess width is intended to seal the di-
vider plate to the sides of the 14-1/4" x 14­1/4" (±1/8") opening. This is to help pre­vent cold air discharge from circulating into the air conditioner return air opening.
If the insulation is too high, stick excess
height of insulation to the air conditioner base pan. Do not cover up unit rating plate.
Installing unit with 3308120.XXX Genesis Air Fil-
tration System Return Air Kit. For unit with
3105007.XXX or 3105935.XXX Return Air Kit, see page 9.
FIG. 20
Foam Divider
Slider
Return Air Cover
Ceiling Template
Filter
Grill
620515, 620525, 620526, 630515 & 630516 Installation Instructions
1. All Non-Center Duct Installations
Note: The Genesis Air Filtration System can be installed on the units that use a center discharge duct through the 14-1/ 4" x 14-1/4" (±1/8") opening. Installing units with the center discharge duct go to page 12 "Section 2" Center Duct In­stallation.
a. Check gasket alignment of the air conditioner
over the roof opening and adjust if necessary . Unit may be moved from below by slightly lift­ing. See FIG. 14.
Remove return air cover, ceiling template,
foam divider and air filter from the 3308120 carton.
Locate the four 8" x 1/4" x 20 unit mount-
ing bolts, junction box cover and Romex connector in the 3107180.006 bolt kit.
Install the Romex connector in the junc-
tion box.
Pull down the unit's electrical cord and fas-
ten the junction box with screws to the fram­ing in the front of the 14-1/4" x 14-1/4" (±1/ 8") opening. See FIG. 15.
b. Installing Foam Divider
Locate the foam divider and insert it corner
to corner in the 14-1/4" x 14-1/4" (±1/8") opening with the adhesive tape up. (Do not remove paper to expose adhesive). The foam divider should be level with the ceiling (±1/4"). T ear off the excess at the pre-cut perforations in divider . See FIG . 21.
FIG. 21
Base Pan
Upside Down Foam Divider
Place Foam Divider In (14-1/4" x 14-1/4" (±1/8") Ceiling Opening Against Base Pan Bottom
Do Not Peel Tape Off Adhesive
Ceiling
Foam Divider Ceiling Level
(±1/4") T ear Off
Excess
c. Install Ceiling T emplate
Peel the paper off of the foam divider and
stick it in place on the center of the rear flange of the return air opening on the ceil­ing template. See FIG . 22.
FIG. 22
Foam Divider
r
e t l
i
F m r
e h
T
-
o r c i
Handle
M
m e t
s y S
N A E
L C
R E
R
E
T
T
L
L
I
I
F
F
T E S E
R
Adhesive
Peel Off Paper - Center Divider - Stick To Rear Flange On Ceiling Template
11
Page 12
CAUTION
620515, 620525, 620526, 630515 & 630516 Installation Instructions
Start each mounting bolt through the ceil-
ing template and up into the unit base pan by hand.
EVENLY tighten the bolt s to a torque of
40 to 50 inch pounds. This will compress the roof gasket to approximately 1/2". The bolts are self locking so over tight­ening is not necessary. See FIG. 16.
CAUTION
If bolts are left loose there may not be ad­equate roof seal or if over tightened, damage may ocur to the air conditioner base or ceiling template. Tighten to specifications listed in this manual.
d. Use Aluminum foil tape (not supplied) to seal
the ends of the foam divider to the sides of the opening. Make sure the area behind the flange on the ceiling template is sealed. See FIG . 23.
FIG. 23
Route wires through Slot
Use Aluminum Foil Tape To Seal the Foam Divider To The Sides of 14-1/4" x 14-1/4" (±1/8") Ceiling Opening
Catch Flange In Groove Of Return Air Cover
Make Sure To Seal Behind Flange
Pull down the unit's electrical cord and fas-
ten the junction box with screws to the framing in the front of the 14-1/4" x 14-1/4" (±1/8") opening. See FIG . 19.
Install the Romex connector in the junc-
tion box.
b. Installing Foam Divider
Cut notch in the center section of the foam
divider to fit (approximately 2 x 8 inches) snugly around duct. See FIG. 24.
FIG. 24
Foam Divider
Place the foam divider in the return air open-
ing above the center duct before ceiling tem­plate.
c. Install Ceiling T emplate
Apply a piece of foam weather stripping (not
supplied) to the upper side of ceiling tem­plate to make a seal between it and the duct. Use a soft piece of foam weather strip 1 x 3/4 x 10 inches. See FIG. 25.
FIG. 25
Tape Covered Adhesive
Mark And Cut 2" x 8" Opening For Center Duct
Stick Weather Strip To Top Of Ceiling Template
CAUTION
Improper installation and sealing of foam di­vider will cause the compressor to quick cycle on the cold control. This may result in fuse or circuit breaker opening and/or lack of cool­ing.
2. Center Discharge Duct Application Installation Note: If using non-center duct installation, refer to all Non­Center Duct Installations Section 1on page 1 1. Important: A duct adapter (not supplied) must be installed between the unit discharge and the customer installed cen­ter duct. This duct adapter must be approved by Dometic.
a. Check gasket alignment of the air conditioner
over the roof opening and adjust if necessary . Unit may be moved from below by slightly lift­ing and sliding. See FIG. 14.
Remove return air cover, ceiling template,
foam divider and air filter from the 3308120 carton.
Locate the four 8" x 1/4 x 20 unit mounting
bolts, junction box cover and Romex con­nector in the 3107180.006 bolt kit.
Ceiling Template
Weather Strip
Start each mounting bolt through the ceil-
ing template and up into the unit base pan by hand.
EVENLY tighten the bolt s to a torque of
40 to 50 inch pounds. This will compress the roof gasket to approximately 1/2". The bolts are self locking so over tight­ening is not necessary. See FIG. 16.
If bolts are left loose there may not be ad­equate roof seal or if over tightened, damage may ocur to the air conditioner base or ceiling template. Tighten to specifications listed in this manual.
12
Page 13
d. Use Aluminum foil t ape (not supplied) to seal
the ends of the foam divider to the sides of the opening. Make sure the area behind the flange on the ceiling template is sealed. See FIG . 23.
CAUTION
Improper installation and sealing of foam di­vider will cause the compressor to quick cycle on the cold control. This may result in fuse or circuit breaker opening and/or lack of cool­ing.
e. Cut the opening in the center duct using the
discharge opening in the ceiling template for a pattern. Seal the center duct to the ceiling tem­plate using foil tape, foam insulation or silicon sealant.
H. Wiring Of System
Reach up into the return air opening and pull the remaining wires down.
1. Connection Of Low Voltage Wires
620515, 620525, 620526, 630515 & 630516 Installation Instructions
Installation (Installing unit with 3308120.XXX Genesis Filtration System Return Air Kit)
c. Connect the previously run furnace thermostat
wires (if applicable) to the blue wires protruding from the return air opening. The polarity of these connections does not matter.
d. Connect the previously run Energy Manage-
ment System wires (if applicable) to the yellow wires protruding from the return air opening. The polarity of these connections does not matter.
e. Terminate the 4-conductor control cable(s) pro-
truding into the 14-1/4" x 14-1/4" (±1/8") roof opening. The cable(s) must be terminated with a telephone RJ-11 connector. Refer to the crimp tool manufacturer for crimping instructions.
Important: RJ-11 connectors must be installed as
shown in FIG. 6A & 6C.
f. Plug the control cable(s) into the telephone
jack(s) protruding from the return air opening. (It does not matter which one.)
2. Connection Of 115 Volt Power Supply
CAUTION
Disconnect the positive (+) 12 volt DC termi­nal at the supply battery. Damage to equip­ment could occur if the 12 volt DC is not shut off.
a. Route Remote Temperature Sensor cable, if
applicable, and attach it to the connector that matches its color protruding from the return air opening.
FIG. 26
DC Power Supply
Furnace
b. Connect the previously run 12 VDC to the red
Center Unit From Below
AC Power Supply
Roof Gasket
CCC Leads
Remote Sensor
an dblack wires protruding from the unit return air opening. (In multiple zone installations, this needs to be doneat only one zone.) Connect +12 VDC to the red wire; –12 VDC to the black wire. (Do not connect wires if using the
3308120.XXX Genesis Air Filtration System Return Air Kit.) See Section I Decorative Cover
Pull Electrical Cord Down
Disconnect 115 volt AC. Failure to follow these instructions could create a shock hazard causing death or severe personal injury.
a. Route power supply line through Romex con-
nector into junction box on side away from the ceiling template. Tighten connector.
This product is equipped with a 3-wire (grounded) system for protection against shock hazard. Make sure that the product is wired into a properly grounded 115 volt AC circuit and the polarity is correct. Failure to do so could result in death, personal injury or damage to the equipment.
b. Connect white to white; black to black; and
green to green or bare copper wire using appro­priate sized twist connectors.
c. Tape the twist wire connectors to the supply
wire to assure they don't vibrate off. d. Push the wires into the box. e. Install the cover onto the junction box.
I . Decorative Cover Installation
Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover . For Genesis Air Filtration system Return Air Kit See Page 14.
Note: On models equipped with a solar panel, see wiring
instructions for the solar panel before proceeding.
1. Remove the return air grill from the return air cover.
2. Place the return air cover up to the ceiling tem­plate.
13
Page 14
Micro-Therm
Filter
System
FILTER RESET
CLEAN FILTER
DIP SWITCHES
3. Install cover to template with # 8 x 3/8" blunt point Phillips head screws provided (6 required).
4. Reinstall filter return air grill into return air cover. Align tabs with mating notches and snap into place
5. Install two hole plugs into screw holes in back of return air cover. See FIG. 27.
FIG. 27
Return Air Cover
Hole Plugs
Return Air Grill
620515, 620525, 620526, 630515 & 630516 Installation Instructions
b. Connect the black wire from the air conditioner
and the black wire from the filter indicator light with the black negative 12VDC supply wire.
See FIG. 23. Note: Number 10 cabinet screw can be used to replace the two front screws to hold the plastic cover flush to the ceil­ing, if required.
5. Tighten the screws holding the return air cover . Slide the filter from the right side (looking toward the RV front) over the wires. Make sure the wires are se­cured above the filter and are out of its way .
6. Place grill on return air cover and snap in place.
Decal is on end over circuit board.
7. Place slide handle through slots in grill into the
slide posts. Handle will fit in either direction.
Installing unit with 3308120.XXX Genesis Air Filtra-
tion System Return Air Kit. For 3105007.XXX or
3105935.XXX Return Air Kit See Page 13.
Note: On models equipped with a solar panel, see wiring
instructions for the solar panel before proceeding.
FIG. 28
Foam Divider
Slider
Return Air Cover
r c i
Handle
M
1. Install the slider in the return air cover and raise it
to the ceiling template. See FIG. 28.
2. Route the wires from the return air cover through the template slot leaving about 3" between, and position wire here so they can be reached after plastic cover is installed. See FIG. 23.
3. Place the front of the return air cover against the ceiling and slide towards the rear. The flange on the ceiling template will catch in the groove on the return cover. Adjust the position (right to left) and install the front two screws. Start and tighten the remaining screws to hold it in place.
4. Connect together the wires from the thermostat, control box and filter indicator. a. Connect the red wire from the air conditioner
and the red wire from the filter indicator light with the red positive 12VDC supply wire. See FIG. 23.
S r e
t
l i F
m
r e h
T
­o
m e t
s y
L C
R E T
L I
I
F
F
T
E S E
R
Ceiling Template
Filter
Grill
N A E
R E T L
J. System Configuration, Reset & Checkout
1. Electronic Control Configuration Depending on the equipment options installed by the recreational vehicle manufacturer, the appropriate dip switches will need to be switched to the "ON" position. See Fig. 29. Placing the switch in the "ON" position
selects that option. Note: Dip switches are in the "OFF" position when shipped from the factory except for models supplied with the heat strip factory installed, (620515). For this model , the #1 dip switch will be in the "ON" position. To gain access to the dip switches, the shroud must be removed from the unit. Remove the four mounting screws around the perimeter of the unit. Next remove the electrical box cover. (The electrical box will be on the curb side of the RV after installation.)
ON
12 345
HEAT STRIP
ZONE 2 ZONE 3
ZONE 4 FURNACE
678
DIFFERENTIAL STAGE GEN START
a. Zone selection - when two or more units are
installed and controlled by one Comfort Con-
trol CenterTM, the second unit becomes Zone
2, the third unit Zone 3, and the fourth unit Zone
4. The appropriate zone dip switch must be set in each electronic control box for the Zone 2, 3
14
and 4.
FIG. 29
DIP SWITCHES
Page 15
MODE
FAN
UP
DOWN
OFF
ON
ZONE
TEMP
b. Heat Strip selection - For units with a heat strip
installed at the factory (Model 620515), the #1 dip switch will be in the "ON" position. All other models will have the dip switches in the "OFF" position.
c. Heat pump models (630515 or 630516) must
have the red plug of the outdoor ambient sensor plugged into the RED (P3) plug.
d. Furnace selection - when a furnace has been
connected to a zone, place the furnace dip switch "ON" for that zone.
e. Differential - differential is the temperature differ-
ence between the "ON/OFF" cycle of the ther­mostat. The normal differential is preset in the circuit board with the dip switch set to the "OFF" position. In some situations, it may be neces­sary to decrease the Differential. The location of the thermostat may create a condition where the normal Differential will not maintain your comfort zone. If this occurs, the Differential can be shortened by placing the Differential dip
switch in the "ON" position. Note: Setting the Differential dip switch should only be required when the installation conditions are less than desirable and is not covered under the limited warranty.
f. STAGE is not used on these units. Leave in the
"OFF" position.
g. Gen start selection - leave in the "OFF" position. h. Replace the unit electrical box cover. i. Replace the shroud. j. Repeat this procedure for each additional zone.
2. System Reset After setting the dip switches in the electric box, do a system reset. See FIG. 30.
a. Turn the ON/OFF switch to the "OFF" position. b. Simultaneously Depress and hold the MODE
and ZONE push-buttons while turning the ON/ OFF switch to "ON". FF should appear in the LCD display until the MODE and ZONE push­buttons are released.
620515, 620525, 620526, 630515 & 630516 Installation Instructions
FIG. 30
Mode Push-Button
E
D
O
M
N
FA
P
M
E
T
P
U
N
W
O
D
E
N
ZO
N
O
FF
O
Fan Push-Button Up Push-Button Down Push-Button
Zone Push-Button
ON/OFF Switch
c. When a dip switch is turned on or off after initial
configuration, a system reset will need to be done before the Comfort Control Center
TM
will
recognize the updated selection.
3. System Checkout We recommend that power be supplied to the air conditioner and check for proper operation. Verify that all features of the installed system work. See Comfort Control Center™ Operating Instructions. Check fan speeds, cooling mode, heat pump mode, furnace (if connected) and heat strip. If the features do not work, check all wiring and confirm that the correct options have been selected on the Electronic Control Board.
15
Page 16
REAR REMOTE SENSOR (Required
with Second
Air
Conditioner)
14-1/4" x 14-1/4" (±1/8”)
OPENING
14-1/4" x 14-1/4" (±1/8”)
OPENING
OPTIONAL FURNACE
FURNACE 2
WIRES
OPTIONAL FRONT REMOTE
SENSOR
12V DC INPUT 2
WIRES
4-CONDUCTOR CONTROL CABLE
BREAKER BOX
115V AC REAR A/C
4-CONDUCTOR CONTROL CABLE
115VAC FRONTA/C
FURNACE 2
WIRES
DOMETIC COMFORT CONTROL
CENTER
FIG. 31
4-CONDUCTOR CONTROL CABLE
620515, 620525, 620526, 630515 & 630516 Installation Instructions
REAR REMOTE SENSOR
115V AC REAR A/C
(Required with Second Air Conditioner)
14-1/4" x 14-1/4" (±1/8”) OPENING
4-CONDUCTOR CONTROL CABLE
DOMETIC COMFORT CONTROL CENTER
FURNACE 2 WIRES
14-1/4" x 14-1/4" (±1/8”) OPENING
BREAKER BOX
115VAC FRONTA/C
12V DC INPUT 2 WIRES
FURNACE
OPTIONAL FRONT REMOTE SENSOR
OPTIONAL FURNACE
FURNACE 2 WIRES
16
Page 17
12V -
SOLAR OR
IF USED
12V +
60 Hz,
115 VA C
USE COPPER
CONTROL
RJ-11CABLE TO COMFORT
LOAD SHED
LOAD SHED
AMBIENT SENSOR
CABLE
RUN CAP
REVERSING VALVE
FIELD WIRING
SPLICE CAP
FACTORYWIRING
STARTCAP
GRN/YEL
COMPRESSOR
620515, 620525, 620526, 630515 & 630516 Installation Instructions
TO COMFORT
RJ-11 CABLE
LOAD SHED
IF USED
SOLAR OR
12V +
12V -
FIELD
WIRING
SPLICE
CAP
LOAD SHED
HEATER ELEMENT
USE COPPER
60 Hz,
115 VA C
ON SOME
RUN CAP
WIRING DIAGRAM FOR MODELS
620515.321, 620515.326, 620515.421, 620525.321, 620525.326
620525.421, 620526.321 & 620526.326
PASSED
DIELECTRIC
REMOTE SENSOR
WHITE
P3
FIELD WIRING
FACTORY WIRING
F1
3 AMP
SPLICE CAP
FUSE
LOAD SHED
LOAD SHED
FURNACE FURNACE
YEL
BLU
YEL
BLU
12V -
BLK
RED
K6
COM
NO
12V +
SOLAR OR
DIRTY FILTER
INDICATORS
IF USED
3106682.036
WIRING DIAGRAM FOR MODELS
CABLE
P4
A/C
POWER
MODULE
BOARD
BLK
BLK
FREEZE
CONTROL
WHITE
P5
T5
P6
T3
RJ-11 CABLE TO COMFORT
CONTROL
BLK
BLK
P1
P2
BLK
K1
COM
NO
T1
T2
RED
YEL
BLK
BLK
MOTOR
WHT
GRN/YEL
WHT
BRN
WHT
BLK
WHT
RUN CAP
FAN
C
HERM
COMPRESSOR
O.L.
R
RED
START CAP
S
C
RED
PTCR
WHT
BLK
GRN/YEL
WHT
WHT
LIMIT SWITCH
BLK
GRN/YEL
HEATER ELEMENT
BLK
NOT USED
ON SOME
MODELS
115 VA C
60 Hz,
1O
USE COPPER
CONDUCTORS ONLY
WIRING DIAGRAM FOR MODELS
RED
EARLY VERSION
630515.321, 630515.326
630515.421
630516.321, 630516.326
RJ-11CABLE
FIELD WIRING
LOAD SHED LOAD SHED
FURNACE FURNACE
3106613.023
12V -
12V +
FACTORYWIRING
SPLICE CAP
A/C POWER MODULE BOARD
BLK
REMOTE SENSOR
CABLE
WHITE
P3
P4
F1
3 AMP FUSE
YEL
YEL
BLU
BLU
BLK
RED
COM
K6
NO
BLK
TO COMFORT
CONTROL
RED
BLK BLK
P1
P2
P5
AMBIENT SENSOR
T5
BLK
P6
K1
COM
NO
T1
T3
T2
YEL
BLK
MOTOR
BLK
GRN/YEL
WHT
BLK
WHT
GRN/YEL
BRN
WHT
WHT
RUN CAP
FAN
C
HERM
BLK
BLK
GRN/YEL
LATER VERSION
630515.321, 630515.326
630516.321, 630516.326
BLK
COMPRESSOR
O.L.
R
S
C
WHT
RED
PTCR
RED
RED
WHT
STARTCAP
REVERSING VALVE
115 VAC 60 Hz,
USE COPPER CONDUCTORS ONLY
1o
PASSED
DIELECTRIC
A/C POWER
P3 MODULE BOARD
F1
3 AMP FUSE
LOAD SHED LOAD SHED
SOLAR OR
DIRTY FILTER
INDICATORS
IF USED
FURNACE FURNACE
12V ­12V +
YEL
BLU
RED
K6
BLK
REMOTE SENSOR
CABLE
WHITE
P4
YEL
BLU
BLK
COM
NO
BLK
17
FREEZE
CONTROL
WHITE
T5
RJ-11CABLE TO COMFORT
CONTROL
RED
BLK
BLK
P1
P2
P5
AMBIENT SENSOR
BLK
P6
K1
COM
NO
T1
T3
T2
MOTOR
YEL
BLK
BLK
WHT
BLK
GRN/YEL
WHT
BLK
GRN/YEL
BRN
WHT
WHT
BLK
REVERSING VALVE
RUN CAP
FAN
HERM
GRN/YEL
BLK
C
STARTCAP
WHT
R
RED
COMPRESSOR
O.L.
S
C
RED
PTCR
RED
FIELD WIRING
FACTORYWIRING
SPLICE CAP
115 VA C 60 Hz,
USE COPPER CONDUCTORS ONLY
3106613.049
1o
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