Duo-Therm 57912.321, 57908.321, 57908.331, 57908.521, 57912.531 Installation & Operating Instructions Manual

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

C

S

RECORD THIS UNIT INFORMATION FOR FUTURE REFERENCE:

Model Number
Serial Number
Date Purchased

600 Series PENGUIN

579 Series BRISK AIR

590 Series QUICK COOL
595 Series QUICK COOL

Roof Top Air Conditioner

USED WITH

Part No. 3104998 Relay Kit

USA

SERVICE OFFICE
Dometic Corp.
509 So. Poplar St.
LaGrange, IN 46761
260-463-4858

WITH REMOTE BI-METAL THERMOSTAT

ALL INITIAL INSTALLATIONS MUST BE APPROVED BY THE SALES DEPT.

CANADA

Dometic Dist.
866 Langs Dr.
Cambridge, Ontario
CANADA N3H 2N7
519-653-4390

For Service Center
Assistance Call:

800-544-4881

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.

INSTALLATION & OPERATING

INSTRUCTIONS

REVISION

Form No. 3104994.136 6/03
(Replaces 3104994.128)
(French 3108174.040)
©2003 Dometic Corporation
LaGrange, IN 46761

Important:
Instructions must stay with unit.
Owner read carefully.

DUCTED

THIS UNIT IS DESIGNED FOR OEM INSTALLATION

AVERTISSEMENT

WARNING

U

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.

57908.321

57908.331

57908.521

57912.321

57912.531

57912.621

57912.622

57912.631

57915.331

57915.336

57915.421

57915.422

57915.426

1

!

MODELS

57915.521

57915.522

57915.526

57915.531

57915.536

57915.621

57915.622

57915.626

57915.631

57915.731

59016.521

59016.526

59016.621

59016.626

59516.331

59516.501

59516.506

59516.531

59516.336

59516.536

59516.601

59516.603

59516.606

59516.631

59528.601

59529.531

59529.601

59529.631

59530.531

59530.532

59530.536

59530.601

59530.631

59530.632

600312.321

600312.421

600315.321

600315.326

600315.421

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

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

A signal word , WARNING OR CAUTION is used
with the safety-alert symbol. They give the level of
risk for potential injury .

WARNING

!

ous situation which, if not avoided, could result in
death or serious injury .

CAUTION

!

ous situation which, if not avoided may result in
minor or moderate injury .

CAUTION

symbol indicates, a potentially hazardous situa­tion which, if not avoided may result in property
damage.

Read and follow all safety information and instruc­tions.

indicates a potentially hazard-

indicates a potentially hazard-

used without the safety alert

1. GENERAL INFORMATION

A. This air conditioner is designed for:

1. Installation on a recreational vehicle at 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 inches and maximum of 5.50
inches distance between roof to ceiling of recre­ational vehicle. Alternate installation methods will
allow for roofs more than 5.50 inches thick.

B. 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/heat pump. 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

Operation on High Fan/Cooling mode will give optimum
or maximum efficiency in high humidity or high outside
temperature.

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 a high heat gain,
accessories like A&E outdoor patio and window awnings
will reduce heat gain by removing the direct exposure to
the sun. They also add a nice area to enjoy company
during the cool of the evening.

C. 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/
heat pump is in operation will minimize condensed moisture
on cold surfaces.

2

12 AWG

Copper

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

up to 24’

SPECIFICATIONS

(BTU/HR) AMPS ROTOR AMPS ROTOR MAX/MIN MAX/MIN *** USER (POUNDS) SIZE**

COOLING AMPS AMPS “ W. C. SUPPLIED 1 UNIT/ 2 UNITS

115V AC,

60 HZ., 1PH.

When sizing the generator, the tot al power usage of your recreational vehicle must be considered. Keep in mind generators lose power at high altitudes and

from lack of maintenance.

MODEL NOMINAL ELECTRICAL COMPRESSOR COMPRESSOR FAN MOTOR FAN MOTOR SCFM-HIGH TOTAL REFRIGERANT MINIMUM AC INSTALLED MINIMUM

NO. CAPACIT Y RATING RATED LOAD LOCKED RATED LOAD LOCKED SPEED STA TIC R-22 (OZ) WIRE SIZE* PROTECTION WEIGHT GENERATOR

57908.321 7,180 6.9 36.0 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 75 2.5 KW / 4.0 KW

57908.331 7,180 6.9 36.0 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 75 2.5 KW / 4.0 KW

57908.521 7,100 6.6 34.0 2.5 5.8 325 / 250 0.55 / 0.90 17.0 20 Amp 75 2.5 KW / 4.0 KW

57912.321 11,000 9.5 53.0 2.5 5.8 325 / 250 0.55 / 0.90 15.5 20 Amp 94 2.5 KW / 4.0 KW

57912.531 11,000 8.0 53.0 2.5 5.8 325 / 250 0.55 / 0.90 18.5 20 Amp 94 2.5 KW / 4.0 KW

57912.621 11,000 8.5 48.3 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 94 2.5 KW / 4.0 KW

57912.622 11,000 8.5 48.3 2.5 5.8 325 / 250 0.55 / 0.90 18.0 20 Amp 94 2.5 KW / 4.0 KW

57912.631 11,000 8.5 48.3 2.5 5.8 325 / 250 0.55 / 0.90 18.0 20 Amp 94 2.5 KW / 4.0 KW

57915.331 13,500 1 1 .4 58.0 2.5 5.8 325 / 250 0.55 / 0.90 15.5 20 Amp 100 3.5 KW / 5.0 KW

57915.336 13,500 12.1 59.0 2.5 5.8 325 / 250 0.55 / 0.90 16.5 20 Amp 100 3.5 KW / 5.0 KW

57915.421 13,500 1 1 .5 50.0 2.5 5.8 325 / 250 0.55 / 0.90 13.5 20 Amp 100 3.5 KW / 5.0 KW

57915.422 13,500 1 1 .5 50.0 2.5 5.8 325 / 250 0.55 / 0.90 14.5 20 Amp 100 3.5 KW / 5.0 KW

57915.426 13,500 1 1 .5 50.0 2.5 5.8 325 / 250 0.55 / 0.90 13.5 20 Amp 100 3.5 KW / 5.0 KW

57915.521 13,500 12.1 59.0 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 94 3.5 KW / 5.0 KW

57915.522 13,500 12.1 59.0 2.5 5.8 325 / 250 0.55 / 0.90 16.5 20 Amp 94 3.5 KW / 5.0 KW

57915.526 13,500 12.1 59.0 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 94 3.5 KW / 5.0 KW

57915.531 13,500 12.1 59.0 2.5 5.8 325 / 250 0.55 / 0.90 16.5 20 Amp 94 3.5 KW / 5.0 KW

57915.536 13,500 12.1 59.0 2.5 5.8 325 / 250 0.55 / 0.90 16.5 20 Amp 94 3.5 KW / 5.0 KW

57915.621 13,500 1 1 .0 54.4 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 94 3.5 KW / 5.0 KW

3

57915.622 13,500 1 1 .0 54.4 2.5 5.8 325 / 250 0.55 / 0.90 16.5 20 Amp 94 3.5 KW / 5.0 KW

57915.626 13,500 1 1 .0 54.4 2.5 5.8 325 / 250 0.55 / 0.90 16.0 20 Amp 94 3.5 KW / 5.0 KW

57915.631 13,500 1 1 .0 54.4 2.5 5.8 325 / 250 0.55 / 0.90 16.5 20 Amp 94 3.5 KW / 5.0 KW

57915.731 13,500 1 1 .3 56.0 2.5 5.8 325 / 250 0.55 / 0.90 15.0 20 Amp 94 3.5 KW / 5.0 KW

59016.521 15,000 12.9 71.0 2.5 6.0 350 / 250 0.40 /1.1 0 26.5 20 Amp 101 3.5 KW / 5.0 KW

59016.526 15,000 12.9 71.0 2.5 6.0 350 / 250 0.40 / 1.10 26.5 20 Amp 101 3.5 KW / 5.0 KW

59016.621 15,000 12.9 77.0 2.5 6.0 350 / 250 0.40 / 1.10 26.5 20 Amp 101 3.5 KW / 5.0 KW

59516.331 15,000 1 1 .5 50.0 2.5 5.8 325 / 250 0.40 / 1.10 29.0 20 Amp 94 3.5 KW / 5.0 KW

59516.336 15,000 12.7 60.0 2.0 5.6 325 / 250 0.40 / 1.10 29.0 20 Amp 94 3.5 KW / 5.0 KW

59516.501 15,000 1 1 .5 50.0 2.5 5.8 325 / 250 0.40 / 1.10 31.0 20 Amp 94 3.5 KW / 5.0 KW

59516.506 15,000 12.9 71.0 2.5 6.0 325 / 250 0.40 / 1.10 31.0 20 Amp 102 3.5 KW / 5.0 KW

59516.531 15,000 1 1 .5 50.0 2.5 5.8 325 / 250 0.40 / 1.10 26.5 20 Amp 94 3.5 KW / 5.0 KW

59516.536 15,000 1 1 .5 50.0 2.5 5.8 325 / 250 0.40 / 1.10 29 20 Amp 94 3.5 KW / 5.0 KW

59516.601 15,000 12.9 77.0 2.5 6.0 350 / 250 0.40 / 1.10 31.0 20 Amp 102 3.5 KW / 5.0 KW

59516.603 15,000 12.3 77.0 2.0 5.6 325 / 250 0.40 / 1.10 29.5 20 Amp 102 3.5 KW / 5.0 KW

59516.606 15,000 12.9 71.0 2.0 6.0 325 / 250 0.40 / 1.10 31.0 20 Amp 102 3.5 KW / 5.0 KW

* For wire lengths 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.

12 AWG

Copper

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

up to 24’

SPECIFICATIONS

COOLING AMPS AMPS “ W. C. SUPPLIED 1 UNIT/ 2 UNITS

(BTU/HR) AMPS ROTOR AMPS ROTOR MAX/MIN MAX/MIN *** USER (POUNDS) SIZE**

115V AC,

60 HZ., 1PH.

When sizing the generator, the tot al power usage of your recreational vehicle must be considered. Keep in mind generators lose power at high altitudes and

from lack of maintenance.

NO. CAPACITY RATING RATED LOAD LOCKED RATED LOAD LOCKED SPEED STATIC R-22 (OZ) WIRE SIZE* PROTECTION WEIGHT GENERATOR

MODEL NOMINAL ELECTRICAL COMPRESSOR COMPRESSOR FAN MOTOR FAN MOTOR SCFM-HIGH TOTAL REFRIGERANT MINIMUM AC INSTALLED MINIMUM

59516.631 15,00 12.3 77.0 2.0 5.6 325 / 250 0.40 / 1.10 29.5 20 Amp 102 3.5KW / 5.0KW

59528.601 N/A 6.0 45.6 2.0 5.6 325 / 250 0.41 / 1.10 16.5 15 Amp 92 3.5 KW / 5.0 KW

59529.531 N/A 6.9 49.0 2.0 5.6 325 / 250 0.40 / 1.10 18.5 15 Amp 94 3.5 KW / 5.0 KW

59530.601 N/A 8.0 48.3 2.0 5.6 325 / 250 0.40 / 1.10 19.0 15 Amp 94 3.5 KW / 5.0 KW

59530.631 N/A 8.0 48.3 2.0 5.6 325 / 250 0.40 / 1.10 19.0 15 Amp 94 3.5 KW / 5.0 KW

59530.531 N/A 7.8 53.0 2.0 5.6 325 / 250 0.40 / 1.10 19.0 15 Amp 94 3.5 KW / 5.0 KW

59530.532 N/A 8.0 53.0 2.5 5.8 325 / 250 0.40 / 1.10 18.5 15 Amp 94 3.5 KW / 5.0 KW

59530.536 N/A 7.8 53.0 2.0 5.6 325 / 250 0.40 / 1.10 19.0 15 Amp 94 3.5 KW / 5.0 KW

59530.601 N/A 8.0 48.3 2.0 5.6 335/ 250 0.40 / 1.10 19.0 15 Amp 93 3.5 KW / 5.0 KW

59530.631 N/A 8.0 48.3 2.0 5.6 335 / 250 0.40 / 1.10 19.0 15 Amp 94 3.5 KW / 5.0 KW

4

59530.632 N/A 8.5 48.3 2.5 5.8 325 / 250 0.40 / 1.10 18.0 15 Amp 94 2.5 KW / 4.0 KW

600312.321 11,000 9.5 53.0 3.1 8.8 335 / 250 0.12 / 0.65 16.5 20 Amp 95 2.5 KW / 4.0 KW

600312.421 11,000 10.7 50.0 3.1 8.8 335 / 250 0.12 / 0.65 16.0 20 Amp 101 2.5 KW / 4.0 KW

600315.321 13,500 12.4 60.0 3.1 8.8 335 / 250 0.12 / 0.65 15.5 20 Amp 96 3.5 KW / 5.0 KW

600315.326 13,500 12.4 60.0 3.1 8.8 335 / 250 0.12 / 0.65 17.0 20 Amp 102 3.5 KW / 5.0 KW

600305.421 13,500 1 1 .5 50.0 3.1 8.8 335 / 250 0.12 / 0.65 15.5 20 Amp 96 3.5 KW / 5.0 KW

* For wire lengths 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.

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

REAR
OF
UNIT

14-1/4" x 14-1/4”
(±1/8)

OPENING

CAUTION

!

2. PRECAUTIONS

WARNING

!

Improper installation may damage equip­ment, could endanger life, cause serious
injury and/or property damage.

A. Read Installation and Operating instructions carefully

before attempting to start your air conditioner/heat
pump installation.

B. The Dometic Corporation will not be liable for any

damages or injury incurred due to failure in following
these instructions.

C. Installation must comply with the National Electrical

Code and any State or Local Codes or regulations.

D. DO NOT add any devices or accessories to this air

conditioner except those specifically authorized by
Dometic.

E. This equipment must be serviced by qualified person-

nel and some states require these people to be
licensed.

3. CHOOSING LOCATION FOR THE
AIR CONDITIONER

This air conditioner is specifically designed for installation
on the roof of a recreational vehicle (RV).

A. For One Unit Installation:

The air conditioner/heat pump should be mounted slightly
forward of center (front to back) and centered from side
to side.

B. For Two Unit Installations:

Install one air conditioner/heat pump one-third and one
air conditioner two-thirds from front of RV and centered
from side to side.

It is preferred that the air conditioner/heat pump be installed
on a relatively flat and level roof section measured with the
RV parked on a level surface; however,

1. Up to an 8° slant to either side or front-to-back is
acceptable on 600 Series Air Conditioners.

2. Up to a 15° slant to either side or front-to-back is
acceptable on 579, 590, 591 or 595 Series Air
conditioners.

AFTER LOCATION HAS BEEN SELECTED:

a.Check for obstructions in the area where air

conditioner/heat pump will be installed. See
FIG. 1.

b. The roof must be designed to support 130

pounds when the RV is in motion. Normally 200
pound 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.

FIG. 1 AIR CONDITIONER DIMENSIONS (On Top of Vehicle)

579, 590, 591 & 595 SERIES

KEEP THIS AREA FREE OF OBSTRUCTIONS

7-5/8”

5-1/4”

14-1/4" x 14-1/4”
(±1/8) OPENING

7-5/8”

14-7/8”

18"

REAR
OF
UNIT

600 SERIES

5

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

4. AIR DISTRIBUTION SYSTEM
SIZING & DESIGN

The Installer of this air conditioner system must design the air distribution system for their particular application. Several
requirements for this system MUST be met for the air conditioner to operate properly. These requirements are as follows:
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 insulated 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.
E. Return air to the air conditioner must be filtered to prevent dirt accumulation on air conditioner cooling surface.

CAUTION

It is the responsibility of the installer of 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.

AIR DISTRIBUTION

DUCT SIZING & DESIGN CHART

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 T ot al Duct Length 1/3 T otal Duct 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.

Duct Static 0.55 - 0.90 In. W.C. 579 Series 0.55 - 0.90 In. W.C. 579 Series

Blower at High Speed, 0.40 - 1.10 In. W.C. 590, 591, 595 Series 0.40 - 1.10 In. W.C. 590, 591, 595 Series
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.
** 12VDC Power supply is required.

6

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

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. It is the responsibility of the
Installer of this system to review each RV floor plan and determine the following:

1. Duct size

2. Duct layout
3 Register size

4. Register location

5. Thermostat location
These items must be determined in conjunction with the Air Distribution System and Sizing and Design Requirements listed
in the chart on page 6.

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 3105007.XXX Return Air Kits , 3105935.XXX
Quick Cool Kits, or 3308120.XXX Genesis Air Filtration System (3308120.XXX Genesis Air Filtration System
indicator light requires 12VDC power from the vehicle). The 3104998.XXX control kit has the mounting bolts
supplied for use with these kits.

B. ROOF AND CEILING OPENING PREPARATION

WARNING

!

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.

1. A 14-1/4" x 14-1/4" (±1/8") opening must be cut through the roof and ceiling of the RV. This opening must be located
between the roof reinforcing members.

2. Mark a 14-1/4" x 14-1/4" (±1/8") square on the roof and carefully cut the opening.

3. Using the roof opening as a guide, cut the matching hole in the ceiling.

4. 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 supply wiring and
thermostat cable.

5. 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.

6. Route a copper 12 AWG, with ground, 115VAC 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 supply MUST be on a separate Time Delay Fuse or HACR Circuit Breaker (20 amp for 579, 590, 591,59516

and 600 series and 15 amp for 59528, 59529 and 59530).

c. Make sure at least 15" of supply wire extends into the roof opening. This ensures easy connection at the junction

box.

Note: if using the 3308120.XXX return air cover. Route a 18 - 22 AWG. fused 12VDC power supply lead from the

converter or battery to the roof opening. Make sure 15" of wire extends into the opening.
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.

7. See Section 6. Thermostat & Cable Installation

7

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

C. AIR DISTRIBUTION DUCT INSTALLATION

1. Install the Air Distribution Ducts in the RV Roof Cavity. The Distribution System must meet:
a. RV’s requirements
b. System requirements listed in Section 4 on page 6 of this Manual. Terminate the start of the Duct at the back edge

of the 14-1/4" x 14-1/4" (±1/8") opening previously cut. See FIG. 2, 3, & 4.

FIG. 3

Duct Size And Requirements For 3105007.XXX And 3105935.XXX Return Air Cover

Register Required
Short Duct Run Minimum

1/3 T otal 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’

FIG. 2

INSULATION

FRAME

ROOF

DUCT

SIDE VIEW

(TOWARD BACK OF RV)

DUCT

TOP VIEW

(BACK OF RV)

FRAME

14-1/4" (±1/8”)

OPENING

AC POWER
SUPPLY WIRE

FRAME

4 CONDUCTOR
THERMOSTAT CABLE

14-1/4" (±1/8”)

OPENING

CEILING

DUCT

DUCT

INSULATION

Register Required

Registers

8 Min.-- 12 Max.
(Per Unit)
14 Sq. In. Free Area
Per Register

Register Required

Note: Duct Size is Inside Dimensions

FIG. 4

Duct Size And Requirements For 33308120.XXX Genesis Air Filtration System

Register Required
Short Duct Run Minimum

1/3 T ot 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’

Register Required

Note: Duct Size is Inside Dimensions

Roof
Rafters

Roof
Rafters

8

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

14-1/4" x 14-1/4" (±1/8")

Roof Opening

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

CAUTION

6. THERMOSTAT & CABLE INSTALLATION

A. LOCATION

The proper location of the thermostat is very important to ensure that is will provide a comfortable RV temperature. Observe
the following general rules when selecting a location.

1. Locate the thermostat 54" above the floor.

2. Install thermostat on a partition, NEVER on an outside wall.

3. NEVER expose it to direct heat from lamps, sun or other heat producing items.

4. Avoid locations close to doors that lead outside, windows or adjoining outside walls or directly under cabinets or overhangs
which limit air movement.

5. Avoid locations close to supply registers and the air from them.

6. NEVER locate thermostat in a room that is warmer or cooler than the rest of the coach - such as the kitchen.

7. The major living area is normally a good location.

B. CABLE INSTALLATION

1. A four-conductor cable, 18 to 22 AWG is to be used for low voltage connections.

2. Choose the shortest, direct route from the 14-1/4" x 14-1/4" (±1/8") opening to the thermostat location selected.

3. Consider where screws, nails or staples might contact the cable.

4. Leave approximately 6" of cable extending through the wall for connection to the thermostat.

5. Leave approximately 15" of cable extending into the 14-1/4" x 14-1/4" (±1/8") opening for connection at unit.

6. If system is to control a gas furnace: Route a 18 gauge wires from the furnace to wall thermostat.

7. PLACING THE AIR CONDITIONER ON THE ROOF

A. Remove the air conditioner from the carton and discard carton. The unit mounting bolts and literature are in separate plastic

bag. Be sure to place this information in the RV.

B. Place the air conditioner on the roof.

FIG. 5

CAUTION

Please Recycle
All Cardboard

This unit weighs approximately 100 pounds.
To prevent back injury, use a mechanical
hoist to place air Conditioner/heat pump on
roof.

C. Lift and place the unit over the prepared opening using the gasket on unit as a guide. The roof gasket on the bottom of the

base pan goes toward the front of the RV. Sliding the unit on the roof will damage the roof gasket. See FIG. 6.

FIG. 6

Do not slide the unit. This may damage the
neoprene gasket attached to the bottom and
create a leaky installation.

!

D. Place 3104998 Relay Kit and Return Air Cover Kit, inside the RV. These cartons contain mounting hardware for the air

conditioner and will be used inside the RV. This completes the outside work. Minor adjustments can be done from the inside
of the RV if required.

Front

9

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

8. INSTALLATION OF COLD CONTROL

A. Remove parts package, control box, and thermostat from the 3104998.XXX Kit Carton.
B. Freeze Control Inst allation 579, 590, 591, & 595 Series Brisk Air Models (See Fig. 7.)

1. Snap freeze control into place on return bend located at left side of evaporator coil as follows:
a. Locate “D” shaped notch in flange of evaporator coil.
b. Place the horseshoe end of the freeze control through this notch and snap onto the coil return bend. When positioned

correctly , control wires will be 900 to direction of coil fin surface.

c. Remove installation notice hang tag from freeze control.

FIG. 7

Coil
Return
Bend

Freeze Control
With Wires To Left Side

C. Freeze Control installation on 600 Series Penguin Models (See Fig. 8.)

1. Snap freeze control into place on return bend located at right side of evaporator coil as follows:
a. Locate “D” shaped notch in flange of evaporator coil.
b. Place the horseshoe end of the freeze control through this notch and snap onto the coil return bend. When positioned

correctly , control wires will be 900 to direction of coil fin surface.

c. Remove installation notice hang tag from freeze control.

FIG. 8

Brisk Air Model Series
579, 590, 591, & 595

Remove
Hang Tag

Penguin Model Series 600

Coil
Return
Bend

Remove
Hang Tag

Freeze Control
With Wires To Right Side

10

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

9. WIRING OF CONTROL SYSTEM

A. Position the control box (standing up) with the 6 pin connector to the curb side of the vehicle and the service access facing

the rear of the vehicle.

B. CONNECTION OF 115 VOL T AC SUPPL Y

WARNING

!

Disconnect 115 volt AC. Failure to follow
these instructions could create a shock haz­ard causing death or severe personal injury.

WARNING

!

This product is equipped with a 3-wire
(grounded) system for protection against
shock hazard. Make sure that the appliance
is wired into a properly grounded 1 15 volt AC
circuit and the polarity is correct. Failure to
do so could result in death, personal injury
or damage to the equipment.

1. Route the previously run AC power supply line through the Romex Connector and into relay control junction box.

2. Reach up into the return air opening of the air conditioner and pull the unit electrical cord down for later installation.

3. Connect the white to white; black to black; and green to green or bare copper wire using appropriate sized twist wire
connectors. Tape the twist wire connectors to the supply wiring to assure they do not vibrate off.

4. Tighten screws on Romex connector being careful not to pinch and cut into the insulation on power supply leads.

5. Push excess wires into junction box. Install junction box cover , with model number/serial number facing out onto the
relay control box with #8 x 3/8” blunt point Phillips head screw provided.

Note: Model Number /Serial Number label must face out.

C CONNECT LOW VOLT AGE WIRES

Note: If 3308120.XXX return air cover is being installed. Position the 12VDC supply wires out of the way to be connected

after the decorative cover is installed.

1. Connect red wire from control box to the thermostat "RC" terminal.

2. Connect the control box orange wire to the thermostat "G" terminal.

3. Connect the control box yellow wire to the thermostat “Y” Terminal.

4. Connect the control box blue wire to the thermostat “H” terminal.
Note: The provided thermostat is a "heat/cool thermostat". These instructions cover only the cooling connections
required. If connection of furnace is required, follow the instructions provided with the furnace. Normally the furnace will
connect to the "RH" and "W" terminals on the thermostat.

Note: See FIG . 9 for thermost at connection points.

FIG. 9

D. Plug unit electrical cord into the mating connector on the relay control box. These connectors are polarized and will easily

snap together. Do not force.

RH

Thermostat Connections

Red Wire (Control Box) - "RC" (Thermostat)
Orange Wire (Control Box) - "G" (Thermostat)

H

11

RC

G

W

Y

Yellow Wire (Control Box) - "Y" (Thermostat)
Blue Wire (Control Box) - "H" (Thermostat)
Red (Furnace if Present) - "RH" (Thermostat)
White (Furnace if Present) - "W" (Thermostat)

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

10. INSTALLATION OF AIR CONDITIONER

Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover.
A. INSTALLA TION OF CEILING TEMPLA TE

1. 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. 11A.

2. Remove return air cover and ceiling template from
the 3105007.XXX or 3105935.XXX kit carton.

FIG.
10A

Divider Plate

Ceiling Template

Return Air

Return Air

Cover

Grill

3. Locate 1/4 “ unit mounting bolts in the parts pack-

age.

4. 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.

FIG . 1 1A

Center Unit From Below

Installing unit with 3308120.XXX Genesis Air Filtra­tion System.
Note: A 12VDC power source is required for this installa-

tion. See Section 5. B. Paragraph 6

A. INSTALLATION OF FOAM DIVIDER

1. 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"). Tear off the excess at the

FIG . 10B

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 T ape Off
Adhesive

Ceiling

Foam Divider Ceiling
Level

(±1/4") Tear Off

Excess

pre-cut perforations in divider. See FIG. 10B.

2. Peel the paper off of the foam divider and stick it in
place on the center of the rear edge of the return air

FIG . 1 1B

Foam Divider

Gasket

AC Power

4 Wire Thermostat
Cable

Pull Conduit Down

Supply

Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover, continued on page 12, column A.

Adhesive

Peel Off Paper - Center Divider - Stick To
Rear Flange On Ceiling Template

opening on the ceiling template See FIG . 11B.

B. INST ALL CEILING TEMPLA TE

1. Position the electrical control box towards the front
of the opening with

all of the system control wires

connected to the control box. Place the ceiling tem­plate up to the return air opening in the ceiling. See
FIG . 12B.

Wires Connected T o
Control Box

FIG . 12B

Control
Box

Vehicle
Front

Base
Pan

Installing unit with 3308120.XXX Genesis Air Filtration
System, continued on page 13, column B.

12

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover, continued from page 12, column
A.

5. Start each mounting bolt through the ceiling tem­plate and up into the unit base pan by hand. Evenly

tighten mounting bolts to compress gasket to
1/2" this will be a torque of 40 - 50 inch pounds.
See FIG. 12A.

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.

FIG . 12A

Screw

6. Install wood screw in each end of the ceiling tem­plate. This insures a tight fit of the return air cover
to ceiling. See FIG. 12A

B. INSTALLA TION OF DIVIDER PLA TE

1. Measure the ceiling to roof thickness:
a. If distance is 2.0” - 3-3/4”, remove perforated tab

from divider plate.

b. If distance is 3-3/4” - 5-1/2”, remove no tabs.

2. Remove the backing paper from double sided tape
located on ceiling template. See FIG. 13A.

FIG . 13A

T o Front of RV

Finger
Tight

Tighten To
40 - 50 In. Lbs.

Peel Off
Backing Paper

Installing unit with 3308120.XXX Genesis Air Filtration
System, continued from page 12, column B.

2. Install relay box on ceiling template depending on
the model use FIG. 13B for Brisk Air unit and Fig.
14B for Penguin units.

FIG . 13B

Control
Box

FIG . 14B

Control Box

3. Start each mounting bolt through the ceiling

template and up into the unit base pan by hand.

Evenly tighten mounting bolts to compress
gasket to 1/2" this will be a torque of 40 ­50 inch pounds.

Brisk Air Models Mount
Control Box On Front
Flange

Ceiling
Template

Penguin Models Mount
Control Box On T op of
Ceiling Template

Ceiling Template

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.

4. 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 . 15B.

Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover, continued on page 14, column A.

FIG. 15B

Route wires
through Slot

Catch Flange In Groove Of
Return Air Cover

13

Use Aluminum Foil Tape To Seal the
Foam Divider To The Sides of 14-1/4"
x 14-1/4" (±1/8") Ceiling Opening

Make Sure To Seal
Behind Flange

Installing unit with 3105007.XXX or 3105935.XXX

CAUTION

Return Air Cover, continued from page 13, column A.

3. Place divider plate up to bottom of air conditioner
base pan firmly . The foam tape on the divider plate
must seal to bottom of base pan. See FIG. 14A.
Note: The adhesive on the insulation is extremely
sticky. Be sure the part is located where desired
before pressing into place.

4. With slight pressure then push the divider plate

CAUTION

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 . 14A

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

Push Divider Firmly T o Base
Pan And Divider

against the double sided tape on the ceiling tem­plate.

5. Locate the 1/8” x 7” x 18” self -adhesive insulation

supplied with the return air kit. Remove the backing
paper from the insulation and carefully stick onto
the ceiling template divider panel. See FIG . 15A.

a. Excess width is intended to seal the divider plate

to the sides of the 14-1/4" x 14-1/4" (±1/8")
opening. This is to help prevent cold air discharge
from circulating into the air conditioner return
air opening.

b. If the insulation is to high, stick excess height

of insulation to the air conditioner base pan. Do
not cover up unit rating plate.

Place Insulation In Position
(Do Not Cover Unit Rating Plate)

FIG . 15A

14

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

Micro-Therm

Filter

System

FILTER
RESET

CLEAN
FILTER

11. INSTALLATION OF INSIDE DECORATIVE COVER.

Installing unit with 3105007.XXX or 3105935.XXX
Return Air Cover.
A. Locate the relay control box on the ceiling template

with the white 6 connector plug on the right (curb side)
side of RV.

B. Drive two #10 x 3/8” blunt point Phillips head screws

through the ceiling template into holes in control box to
hold it in place.

C. Remove the return air grill from the return air cover.
D. Place the return air cover up to the ceiling template.
E. Install cover to template with #8 x 3/8” blunt point Phil-

lips head screws provided (6 required).

F. Reinstall filter return air grill into return air cover. Align

tabs with mating notches and snap into place

G. Install two hole plugs into screw holes in back of return

air cover. See FIG. 16A.

FIG . 16A

Return Air
Cover

Hole
Plugs

Return
Air Grill

This completes the installation of the air conditioner.
We recommend that power be supplied to the air condi­tioner/heat pump and check for proper operation. Refer
to Operating Manual or Users Guide for a description of
the air conditioner/heat pump operation.

Installing unit with 3308120.XXX Genesis Air Filtra­tion System.
A.

Install the slider in the return air cover and raise it to
the ceiling template. Route the wires from the return air
cover through the template slot leaving about 3” be­tween, and position wire here they can be reach after
plastic cover is installed. See FIG. 14B. 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. In­stall the remaining screws.

Note: Number 10 cabinet screw can be used to re­place the two front screws to hold the plastic cover
flush to the ceiling.

1. Connect together the wires from the 12VDC power
supply and filter indicator.

a. Connect the red wire from the (+12VDC) power

supply and the red wire from the filter indica­tor light with the red. See figure 13B.

b. Connect the black (-12VDC) power supply and

the black wire from the filter indicator light.
Note:

If solar panel is installed see instruc-

tions packaged with solar panel option.

B. Insert the filter from the right side (looking toward the

RV front) over the wires. Make sure the wires are se­cured above the filter and will stay out of its way.

C. Place grill on return air cover and snap in place. Decal

is on end over circuit board.

FIG . 16B

Foam
Divider

Ceiling
Template

Slider

Filter

Return Air
Cover

m
e
t

s
y

S

r
e
t

l
i

F

m
r
e

h

-T

o
r
c
i

M

N
A
E

L
C

R
E

R

E

T

T

L

L

I

I

F

F

T

E
S
E

Handle

R

D. Place slide handle through slots in grill into the slide

posts. Handle will fit in either direction.

This completes the installation of the air conditioner/
heat pump. We recommend that power be supplied to
the air conditioner/heat pump and check for proper op­eration. Refer to Operating Manual or Users Guide for a
description of the air conditioner operation.

15

Grill

INSTALLATION INSTRUCTIONS DUCTED BI-METAL

USE COPPER CONDUCTORS ONLY

115 VAC 60 HZ 10

LINE SPLICE

FIELD WIRING

ELEC CONN

6 PIN CONN

RUN CAP

NOT USED ON
SOME MODELS

RELAY KIT FIELD WIRING DIAGRAM

YEL

BLK

FREEZE
CONTROL

BLK

Y

TB8 TB7

RC

H

G

RED

BLU

ORN

RELAY BOARD

NO

COM

BLK

WHT

GRN/YEL

115 VAC 60 HZ 10
USE COPPER CONDUCTORS ONLY

AC

WHT

LOW

HI

BLU

BLK

RED

WHT

GRN/YEL

1

2

3

4

5

6

FIELD WIRING
FACTORY WIRING
LINE SPLICE

UNIT FIELD WIRING DIAGRAM

TO T 'STAT

ELEC CONN

FROM A/C

3104938.018

GRN/YEL

FAN

C

HERM

RUN CAP

BRN

WHT

RED

MOTOR

WHT

R

WHT

RED

COMP STARTER

START

PTCR

CAP

*

O.L.

BLK

YEL

WHT

RED

C

*

COMPRESSOR

S

BLU

GRN/YEL

PASSED

DIELECTRIC

6 PIN CONN

1

2

3

4

5

6

NOT USED ON

*

SOME MODELS

3105052.025

16