Dometic Kohler 7APU Operation And Installation
Operation and
Installation
Heavy Duty Truck
Auxiliary Self-Contained
Heating & Air Conditioning System
Models:
7APU
by:
TP-6512 2/07a
Table of Contents
Self-Contained HVAC System for Truck
Sleepers • Introduction 4
Notice ................................................................................. 4
Drawings and Diagrams ..................................................... 4
Air Conditioning Basics ....................................................... 4
The Effect of Outside Air Temperature ................................ 4
Self-Contained System Components ................................. 4
Subsystems ........................................................................ 5
System Controls ................................................................. 5
Condensate Drain .............................................................. 5
Self-Contained HVAC System for Truck
Sleepers • Installation 6
Before You Start 6
Required Additional Parts ................................................... 6
Required Tools .................................................................... 6
Choosing The Correct Place
For Your Unit 6
Mounting The Unit .............................................................. 6
Wiring The Unit ................................................................... 7
Ducting The Supply Air ....................................................... 7
Attaching The Drain Hose .................................................. 8
Installing the Return Air Grill ............................................... 8
Self-Contained HVAC System for Truck
Sleepers • Operation 9
Humidity Control Program 14
Programming The Time Period ......................................... 15
Programming The Dehumidification Time ......................... 15
Recommended Humidity Control Settings ........................ 15
Fault Shutdowns and Error Messages 15
Fault Codes ...................................................................... 15
Low Voltage Shutdown ..................................................... 15
Software Error .................................................................. 15
Determining Your Software Version Number ..................... 15
Quick SMXir Troubleshooting Guide ................................. 16
Troubleshooting 16
System Maintenance 17
Owner’s Limited Warranty 18
Description of Figures 20
Starting Up Your New System 9
The SMXir Keypad/Display ................................................. 9
The SMXir Remote Control .............................................. 10
SMXir Basic Operation 11
Power On .......................................................................... 11
System Off ........................................................................ 11
Selecting Setpoint ............................................................ 11
Displaying Temperature .................................................... 11
Cool Mode ........................................................................ 11
Heat Mode ........................................................................ 11
Automatic Changeover ..................................................... 11
Manual Fan Speed Control............................................... 11
Automatic Fan Speed Control........................................... 11
Adjusting Brightness ......................................................... 11
Using The Humidity Control Routine ................................ 11
Anti-Ice Routine ................................................................ 12
Programming the SMXir System 12
Factory Memory Reset ..................................................... 12
Fahrenheit/Celsius Display ............................................... 12
Compressor Differential .................................................... 12
Fan Response Differential ................................................ 13
Low Fan Speed Adjustment ............................................. 13
High Fan Speed Adjustment............................................. 13
Fan Mode ......................................................................... 14
AC Line Voltage Calibration .............................................. 14
Temperature Calibration ................................................... 14
L-2347K
Revised: 6-22-06
3
YY
Y
YY
English
Self-Contained HVAC System for Truck Sleepers • Introduction
Warning
This manual contains essential information concerning
the safe and proper installation and operation of your air
conditioning system. Read and follow all safety instructions in the manual and on the unit to help reduce the
risk of accident or injury or death. If there are any
statements or procedures that you do not understand,
contact your dealer.
Notice
US federal law prohibits the intentional release of refrigerant
gases into the environment, including the R-22, R134a, and
R417a refrigerant used in some air conditioning systems.
Special care must be taken when installing, charging, and
servicing this equipment to prevent any loss of refrigerant.
Only EPA certified technicians with the proper equipment
should perform service on the refrigerant circuit.
Drawings and Diagrams
The figures that are referenced throughout can be found at
the back of this manual. In addition, this equipment may be
shipped with specific installation sheets or wiring diagrams
that may supercede the information located herein.
Air Conditioning Basics
The basic principle of an air conditioner is the movement of
heat. In a direct expansion (DX) air-cooled air conditioner,
heat is transferred from the inside air to the refrigerant gas in
the evaporator coil. The refrigerant then is pumped by the
compressor to the condenser coil where the heat is released
to the outside air.
Heat is provided by an electric heat element and heat output
is not affected by outside temperature.
These systems are designed to cool or heat most common
sleepers, but may have limitations due to sleeper size, insulation, the amount of glass, and the climate where the unit is
operated. Some tips to help maintain desired temperature are:
• Park in a shaded area when trying to cool.
• Cover windows with shades or towels to block direct
sunlight and limit heat transfer through the glass.
• Keep windows and doors closed.
• Close curtain between sleeper and cab.
• Reduce use of heat-producing appliances.
• When heating, park in a location that blocks prevailing
wind.
• When using shore power, make sure that the power cord
is the correct gauge for the amperage requirements of the
unit. If the power cord is too long and/or too small of a wire
(gauge), there can be a voltage drop at the unit, which will
affect performance, could cause damage, and may also
be a fire hazard. Power cord should be minumum 12
gauge wire.
Note - Moisture:
Dometic will not be held responsible for damage caused by
condensation of moisture on surfaces within the compartment. Humid outside air contains water vapor, which, when
the outside air enters a cooled space, can condense on cool
surfaces such as windows, walls, or metal objects. Normal
operation of the air conditioner removes moisture from the
air, and keeping openings to the outside closed should
reduce secondary condensation.
The heat exchange process relies on the movement of both
inside air through the evaporator coil and outside air through
the condenser coil. If airflow in either coil is compromised,
the efficiency of the system will drop. Continued usage with a
partially blocked air system will eventually damage the unit.
Severe airflow blockage will cause the unit to over-heat,
activate the unit’s safety devices, and shut the unit off.
Part of the cooling process, in addition to lowering temperature, is the removal of moisture from the air. This lowers the
humidity, which makes the area feel more comfortable and
helps keep the compartment dry.
The Effect of Outside Air Temperature
The performance of the air conditioner is dependent on both
outside and inside air temperatures. The unit is designed for
full capacity at 95°F (35°C) outside temperature. If the
temperature rises above this, the performance of the unit will
drop. However, the unit should still provide some cooling
even in temperatures as high as 125°F (52°C).
L-2347K Introduction
Self-Contained System Components
Self-contained units
nents of an air conditioning system mounted on one chassis,
including the compressor, air-cooled condenser, evaporator
coil, blower, electrical box and related parts.
The self-contained unit is normally mounted in the compartment. Inside air is pulled into the unit, where it is cooled or
heated, then discharged through ducting to a grill usually
located on a wall high in the compartment.
The refrigerant circuit in a self-contained unit is pre-charged
and sealed at the factory, and no additional charging is
needed at installation.
4
have all major mechanical compo-
YY
Y
YY
English
Subsystems
Self-contained units require subsystems that are purchased
separately because of the many variations and options
available. These subsystems include the air distribution
system and the system control.
Air Distribution System
Compartment air is drawn into the self-contained unit
through a return air grill, it is cooled or warmed and blown
back into the compartment through a ducting system. The air
should be discharged high in the compartment and away
from the return air grill to ensure good circulation. Good air
distribution throughout the space is the key to comfort. An air
filter is located on the cooling unit or on the return air grill,
and must be cleaned regularly.
System Controls
SMX controls are advanced microprocessor systems that
provide a more comfortable environment and better system
protection than mechanical controls. In addition, over 20
programmable functions allow the user to customize the
system to suit the specific needs of their environment.
The SMXir System consists of the following components:
• Power/Logic (P/L) board - Monitors and controls all
functions of the air conditioning unit.
• Keypad/Display - A 10-button user interface with a digital
readout and LED indicators.
• Temperature-Sensing Element - Air temperature is
monitored by a temperature-sensing element (TSEP) that
plugs into the power/logic board.
• Connecting Cable - The keypad/display connects to the
P/L board with a CXP connecting cable.
Condensate Drain
When the air conditioner is running, moisture is removed
from the air by the evaporator coil. This condensation is then
caught in a drain pan and must be drained off. In humid
climates the system can produce a large amount of condensate water that could cause significant damage if the drain
system doesn’t work properly.
Warning
The drain should have a hose attached, and should
have a trap to create a water seal to prevent hazardous
or deadly gasses from entering!
L-2347K Introduction
5
YY
Y
YY
English
Self-Contained HVAC System for Truck Sleepers • Installation
Before You Start
1. Read installation and operating instructions carefully
before attempting to install and operate your air conditioning unit.
2. The manufacturer will not be liable for any damages,
injury, or death incurred due to failure to follow the
instructions.
3. Installations must always comply with the National
Electrical Code, and any state/local codes or regulations.
4. Only a qualified service technician must service this unit.
Any attempt to service the unit otherwise may void the
warranty.
5. Make sure that you have the required parts and tools to
complete the job, as this will help keep the installation
time to a minimum.
Warning
• Improper installation could damage equipment,
endanger life, cause serious injury, or property
damage.
• If you have any doubts that you cannot complete this
installation safely and as the directions state, find a
qualified technician to do it for you.
• Make sure that power is turned off at the source
before making any connections. Failure to do so could
cause injury or death.
Required Additional Parts
If you have received only the unit, and not the complete kit,
you will need to supply some additional parts for installation,
such as ductwork, grill(s), drain fitting, ½" X ½" wire mesh,
½" thick weather stripping, two 5½" hose clamps, one 1-1/8"
hose clamp, wiring, ¼" nuts and bolts, and 5/8" dia. drain
hose. The duct should be 5" diameter minimum. The two
large hose clamps can be used to secure the duct to the unit
and the grill to the duct. The drain fitting should be 3/8" MPT
to a 5/8" hose barb. The wire mesh will be used to put over
the holes that will be cut through the sleeper floor to assure
that small animals and other uninvited guests do not get into
the sleeper. Use the weather stripping to seal the area
between the AC unit and the floor of the sleeper. The wiring
sizes are noted in the SPECIFICATIONS section.
Warning
The seal between the unit and the floor is extremely
important. This seal is intended to prevent deadly
gasses from entering the living space!
Required Tools
Tools that will aid in installation: drill and bits, 1-5/8" hole saw,
reciprocating saw with metal blades, Phillips and straight
blade screwdrivers, measuring tape, and Teflon tape or
equivalent.
Choosing The Correct Place
For Your Unit
The self-contained unit is easier to install than the remote
system, but it will take up more room under the bunk. A
remote system consists of two major components, the
condenser and the evaporator, while the self-containted unit
stands alone. The remote condenser is installed outside the
cab; the remote evaporator is installed inside the sleeper.
Generally speaking, the self-contained unit is installed with
the long dimension lengthways of the sleeper. This would put
the evaporator intake close to the bunk bulkhead. The
evaporator intake must be have a minimum open area equal
to the size of the coil face. For example, a coil that is 10" x
9½" would require 95 in
evaporator discharge can then be ducted to wherever best
suits the truck arrangement.
Mounting The Unit
Installing the Self-Contained Unit
Decide where you are going to install the unit. Using the
template provided, mark off the required holes (condenser
inlet and outlet, mounting holes, and drain hole), and check
for interference between the holes and the structural
members that are under the sleeper floor. After you have
checked, cut the holes in the floor of the sleeper. Use the
wire mesh to cover each hole so that small animals cannot
get in. Take the weather stripping, and make a frame around
the holes on the unit. Install the MPT drain fitting into the
drain hole using the Teflon tape. Line the unit up over the
holes, and set squarely onto the floor.
NOTE: Take care not to crush or break the drain fitting while
moving the unit around. Use the four bolts, washer and nuts
to secure the unit to the floor.
NOTE: The manufacturer is not responsible for mounting, nor
is responsible for failure of such mounting and subsequent
unit damage. The unit will need to be positioned so that
electrical and refrigerant connections can be accessed, and
so that cleaning of the condenser coil may be performed.
The unit should be securely fastened to the mounting frame
with ¼" bolts and lock nuts.
2
of open return to the unit. The
L-2347K Installation
6
YY
Y
YY
English
Controls
Two types of controls are used with these self-contained
units. Model ASCF7 has a built-in mechanical control. All
other models use the SMXir digital keypad/display which is
sold separately.
If you have model ASCF7, then read the below section
“Mechanical Controls” and ignore all information on the
SMXir control. Review the sections “Troubleshooting” and
“System Maintenance” for future reference.
If your system uses the SMXir digital keypad/display, then
you may skip the “Mechanical Controls” section and start
with the section “SMXir Controls”, reading through to the end
of this manual.
Mechanical Controls
The mechanical control on model ASCF7 is built-in and
requires no additional installation. To operate the mechanical
control, follow these instructions:
1. Turn power on to the system.
2. Set the thermostat to the coldest setting by rotating it fully
clockwise.
cable that is plugged into the SMX circuit board/elec box is
the TSEP (temperature sensing element). That cable is
mounted on the unit in front of the evaporator coil in the
return air stream and is plugged into the socket marked
“TEMP”. CXP cables are available in a variety of lengths,
please contact your dealer if need be. Although the CXP
looks like a standard telephone cable, it is not; phone cables
will not work as a display cable. Access the elec box by
removing the panel on the end of the unit, above the cable
feed-thru holes.
Warning
Make sure all power is off before opening any
electrical box.
Warning
The SMX interconnect (CXP) and temperature sensor
cables (TSEP) transmit low voltage DC signals, and
outside interference can affect their operation. Do not
route these cables beside A/C power cables, high
voltage wiring, or antenna wires. Keep the cable runs as
short as possible to reduce the chance of interference.
3. Set the FAN/COOL selector switch to HI COOL.
4. Close all doors and windows to your sleeper compartment.
5. Once the temperature reaches a comfortable level, rotate
the thermostat slowly counterclockwise, stopping at the
point where the unit cycles off. That is now the setpoint.
The fan will run faster on HI COOL and slower on LO COOL
as the system cycles on and off in the cooling mode. Or, if
you just want the fan only, then choose the LO FAN or HI
FAN settings. Model ASCF7 with the mechanical control
does not supply heat.
SMXir Controls
The SMXir digital keypad/display may be mounted in any
convenient location, on a bulkhead or in a cabinet or closet,
for instance. Choose a location that is easy to reach, but not
in the way of daily routines. Make sure that the mounting
location is within the display cable (CXP) length of the A/C
unit. Route the CXP cable prior to mounting SMXir control.
Use the enclosed instructions for mounting the SMXir. Drill a
hole for the CXP cable to feed through. Mount the display
backing plate centered over that hole. Run the cable through
the hole and plug it into the display. Then snap the display
onto the backing plate, being careful not to crimp the cable.
Wiring The Unit
Warning
Care must always be exercised when dealing with
electricity. Wiring should be done only by a qualified
technician. Contact an electrician if you have any
questions.
Refer to the wiring diagrams in the back of this manual or the
diagram that is located inside the electrical panel of the unit.
The unit should be wired according to power requirements
given on the data plate and per NEC recommendations. The
unit must alwasy be grounded. Always refer to NEC or state/
local codes for further wiring recommendations.
Ducting The Supply Air
The supply air grill should be mounted in a place that will
allow for the best air distribution, preferably up high. Locate
the best place to mount the grill and verify that you have
enough duct to cover the length between the unit and the
grill. Cut out for the grill, and mount securely. Use the large
hose clamps to secure the duct to the unit and to the back of
the grill. Air discharged through low-mounted grills should be
directed upward by tuning the louvers 45° up.
The other end of the CXP should be plugged into the SMX
circuit board/elec box socket marked “DISPLAY”. The other
L-2347K Installation
7
YY
Y
YY
English
Attaching The Drain Hose
Climb under the sleeper with the length of 5/8" diameter
hose and the small hose clamp. Secure the hose to the hose
barb with the clamp. Secure the hose to something under the
sleeper that is fixed. Fashion the hose such that is forms a
trap, such as a plumber’s running trap. The trap will help
keep fumes and bugs out by providing a water seal.
Installing the Return Air Grill
Install the return air grill so that the path between the grill
and the coil face of the unit is open and unrestricted. The
path should not be any smaller in square inch area than the
size of the coil face. Place the grill so that it will not be
covered up by cargo, sheets, boxes, etc.
L-2347K Installation
8
YY
Y
YY
English
Loading...