DuoTherm Dometic 59146 Roof-Top Heat Pump ... - Dutchmen RV

RRECORD THIS INFORMATION FOR FUTURE REFERENCEBEFORE INSTALLING THE UNIT:Model NumberSerial NumberDate PurchasedPlace of PurchaseUSASERVICE OFFICEThe Dometic Corp.509 So. Poplar St.LaGrange, IN 46761(219) 463-4858CANADADometic Dist.866 Langs Dr.Cambridge, OntarioCANADA N3H 2N7(519) 653-4390MODEL 59146Roof-Top Heat Pumpused withAir Distribution Box KitTHIS UNIT IS DESIGNED FOR OEM OR AFTER MARKET INSTALLATIONALL INITIAL INSTALLATIONS MUST BE APPROVED BY THE SALES DEPT.For Service CenterAssistance Call:800-544-4881 This unit must be serviced by anauthorized serviceman. Modificationof the appliance can beextremely hazardous and couldlead to serious injury or death.Cet appareil doit être réparé seulementpar un réparateur autorisé.Modification de l'appareil pourraitêtre extrèmement dangereuse, etpourrait causer mal ou mort.637G®CERTIFIEDLR 23565INSTALLATION & OPERATINGINSTRUCTIONSMODEL59146Form No. 3107882.007 8/97©1997 The Dometic Corp.LaGrange, IN 467611

1. GENERAL INFORMATIONA. The roof top heat pump was designed to operatein a MILD GEOGRAPHICAL AREA for heatingwhere the heat loss is minimum. The Heat Pumpwill operate down to an outside ambient temperatureof 40 degrees. At 40 degrees, the outdoorthermostat will turn off the heat pump circuit. Aslong as the temperature remains below 40 degrees,the main furnace will heat your home. As theoutside temperature increases to 45 degrees, theoutdoor thermostat switches back to the heatpump circuit.The advantages of the Heat Pump Air Conditionerare:1) User friendly- only one unit for both heating andcooling.2) When used in mild climates where the outdoortemperature range is 40 degrees or higher, anL.P. furnace is not needed.3) Heat pump heating uses the campsite electricalhookup; therefore, you save on trips to refillL.P. tanks.NOTE: Geographical location usage should bedetermined before omitting a central furnace.SPECIFICATIONSMODEL NO. 59146Nominal Capacity (BTU/HR) 15,000Electrical Rating115 VAC, 60 Hz., 1 PH.Compressor Rated Load Amps 12.9Fan Motor Rated Load Amps 2.5Compressor Locked Rotor Amps 71.0Fan Motor Locked Rotor Amps 12.8Power, Cooling (KW) 1.95SCFM-High Speed Max./Min. 450/300Refrigerant (R22) oz. 34.5Minimum Wire Size *12 AWG Copper Up to 24 ft.Circuit Protection20 Amp Time Delay Fuse orHACR Circuit BreakerInstalled Weight (Pounds) 110Minimum Generator 1 Unit 3.5 KWSize ** 2 Units 5.0 KW* For distances over 24 ft. consult the National Electrical Code.** The Dometic Corporation gives GENERAL guidelines for generator requirements.These guidelines come from experiences people have had in actual applications.When sizing the generator, the total power usage must be considered. Also keep inmind generators lose power at high altitudes and from lack of maintenance.B. This air conditioner is designed for:1) Installation on a recreational vehicle at the time thevehicle is manufactured or aftermarket installations.2) Mounting on the roof of a recreational vehicle.3) Connection to an air distribution box system.4) Roof construction with rafters/joists on minimum of16 inch centers.5) Minimum of 1.75 inches and maximum of 4.50 inchesdistance between roof to ceiling of recreational vehicle.Alternate installation methods will allow forroofs more than 4.50 inches thick.6) Read installation and operating instructions carefullybefore starting your air conditionerinstallation.7) The Dometic Corporation will not be liable for anydamages or injury incurred due to failure in followingthese instructions.8) Installation must comply with the National ElectricalCode and any State or Local Codes or regulations.9) DO NOT add any devices or accessories to this airconditioner except those specifically authorized byDometic.10) This equipment must be serviced by qualifiedpersonnel and some states require these peopleto be licensed.2. OPERATING INSTRUCTIONSA. CONTROLS:1) The Selector Switch controls fan speed, heatingmode, and cooling modes.2) The thermostat controls the compressor ON/OFFoperation in a temperature range of 65° to 90°F.B. COOLING OPERATION:1) Set the thermostat at the desired temperaturelevel.2) Select the fan speed that best satisfies your needs:a) HIGH COOL: Selected when maximum coolingand dehumidification required.b) LOW COOL: Selected when room at desiredcomfort level and needs to be maintained.Normally this speed used for night time operation.2

NOTE: The blower runs continuously to circulate air andmaintain an even temperature. The compressor willcome on as cooling is required to maintain the selectedtemperature level.AFTER SHUTTING THE AIR CONDITIONER DOWNWITH EITHER SELECTOR SWITCH OR THERMO-STAT, WAIT AT LEAST TWO (2) MINUTES BE-FORE RESTARTING. THIS ALLOWS THE RE-FRIGERANT PRESSURE TO EQUALIZE AND COM-PRESSOR TO RESTART EASILY. FAILURE TOFOLLOW THIS INSTRUCTION MAY CAUSE CIR-CUIT BREAKER OR FUSE TO OPEN.C. FAN OPERATION:This will circulate the air in your RV without cooling orheating. There are two positions: HIGH FAN or LOWFAN to select from, depending upon personal choiceand model.D. HEATING OPERATION:NOTE: The heat pump will not replace a furnace forheating your RV in cold weather. The intent is towarm the coach during mild winter weather.1) Turn the selector switch to:a) High heatb) Low heat2) Set the thermostat to your comfort level.3) The fan and compressor will come on and beginheating.4) When the desired temperature level is reached,the compressor will cycle as required to maintainselected temperature. The blower will runcontinuously to circulate air and maintain aneven temperature.E. "OFF" POSITION: This is to turn Unit off.3. MAINTENANCEA. AIR FILTER:Periodically remove the return air filter located abovethe removable panel in the air box. Wash the filter withsoap and warm water, let dry and the reinstall.NOTE: Never run the air conditioner without return airfilter in place. This may plug the unit evaporator coilwith dirt and may substantially affect the performanceof the unit.B. AIR BOX HOUSING:Clean air box housing and control panel with a softcloth dampened with a mild detergent. Never usefurniture polish or scouring powders.C. FAN MOTOR:Factory lubricated and requires no service undernormal use.D. FROST FORMATION ON COOLING COIL:Under certain conditions, frost may form on the evaporatorcoil. If this should occur, inspect the filter andclean if dirty. Make sure air louvers are not obstructed.3Air conditioners have a greater tendency to frost whenthe outside temperature is relatively low. This may beprevented by adjusting the thermostat control knob toa warmer setting (counter clockwise). Should frostingcontinue, operate on HIGH FAN setting until thecooling coil is free of frost.4. REDUCING HEAT GAINThe ability of the air conditioner to maintain the desiredinside temperature depends on the heat gain ofthe RV. Some preventative measures taken by theoccupants of the RV can reduce the heat gain andimprove the performance of the air conditioner. Duringextremely high outdoor temperatures, the heatgain of the vehicle may be reduced by:A. Parking the RV in a shaded areaB. Using window shades (blinds and/or curtains)C. Keeping windows and doors shut or minimizingusageD. Avoiding the use of heat producing appliancesStarting the air conditioner early in the morning andgiving it a "head start" on the expected high outdoorambient will greatly improve its ability to maintain thedesired indoor temperature.NOTEThe manufacturer of this air conditioner will not beresponsible for damage caused by condensed moistureon ceilings or other surfaces. Air contains moistureand this moisture tends to condense on coldsurfaces. When air enters the RV, condensed moisturemay appear on the ceiling, windows, metal parts,etc. The air conditioner removes this moisture fromthe air during normal operation. Keeping doors andwindows closed when this air conditioner is in operationwill minimize condensed moisture on cold surfaces.5. SERVICE - Unit Does Not OperateIf your unit fails to operate or operated improperly,check the following before calling your service center.A. If RV connected to motor generator, check to be suremotor generator is running and producing power.B. If RV connected to power supply by a land line, checkto be sure line is sized properly to run air conditionerload and it is plugged into power supply.C. Check your fuse or circuit breaker to see if it is open.D. After the above checks, call your local service centerfor further help. This unit must serviced by qualifiedservice personnel only.When calling for service, always give the following:1. Air Conditioner Model and Serial Number foundon rating plate located on base pan of air conditionerbottom.2. Air Distribution Box Kit Part and Serial Numberfound on rating plate located on ceiling template.Observe this rating plate through the air dischargelouver of Air Distribution Box.

6. INSTALLATION INSTRUCTIONSA. PRECAUTIONS! DANGERIMPROPER INSTALLATION MAY DAMAGEEQUIPMENT, COULD ENDANGER LIFE,CAUSE SERIOUS INJURY AND/ORPROPERTY DAMAGE.12.7"3105975 AIR34.4"DISTRIBUTIONBOX19-3/4" 22-1/4"3107209 AIRDISTRIBUTIONBOX19-3/4"4-1/8"7-3/4"5-3/8 15"14-1/4" X 14-1/4"OPENINGKEEP THIS AREA FREE OF OBSTRUCTIONS3105975AIR DISTRIBUTION BOXFRONT3-1/8"14-1/4" X 14-1/4"OPENING2-5/8"4-1/8"7-3/4"2-1/2"18"29.5"REAROFUNIT3107209AIR DISTRIBUTION BOX14" x 14"OPENING1) Read Installation and operating instructions carefullybefore starting your air conditioner installation.2) The Dometic Corporation will not be liable for anydamages or injury incurred due to failure in followingthese instructions.3) Installation must comply with the National ElectricalCode and any State or Local Codes or regulations.4) DO NOT add any devices or accessories to this airconditioner except those specifically authorizedby Dometic.5) This equipment must be serviced by qualifiedpersonnel and some states require these peopleto be licensed.B. CHOOSING LOCATION FORTHE AIR CONDITIONERThis air conditioner is specifically designed for installationon the roof of a recreational vehicle (RV).1) NORMAL LOCATIONS:The air conditioner is designed to fit over anexisting roof vent opening. When the vent isremoved, it normally creates a 14" x 14" opening.2) OTHER LOCATIONS:When no roof vent is available or anotherlocation is desired, the following is recommended:For one unit installation: The air conditionershould be mounted slightly forward of center(front to back) and centered from side to side.For two unit installations: Install one airconditioners 1/3 and one air conditioner 2/3'sfrom front of RV and centered from side to side.It is preferred that this air conditioner be installed in arelatively flat and level roof section measured with the RVparked on a level surface; however,a) Up to a 15° slant to either side or front-tobackis acceptable on 591 Series HeatPumps.3) AFTER LOCATION SELECTION:a) Check for obstructions in the area where airconditioner will be installed.b) The roof must be designed to support 130pounds when the RV is in motion. Normally a200 lb. static load design will meet this requirement.c) Check inside the RV for air box obstructions.(i.e. door openings, room dividers, curtains,ceiling fixtures, etc.)11-1/8"11-1/8"4

C. ROOF PREPARATION1) ROOF VENT REMOVAL:a) Unscrew and remove the roof vent.b) Remove all caulking compound aroundopening.c) Seal all screw holes and seams where the roofgasket will be located. Use a good grade of allweather sealer.2) NEW OPENING:(Installations Other Then Vent Openings)3/4" MIN.LEAVE ACCESSFOR POWERSUPPLY WIRINGFRAME OPENING SO ITWON'T COLLAPSE WHENBOLTING DOWN AIRCONDITIONERDISCONNECT ALL POWER SUPPLIES AND THE POSI-TIVE (+) TERMINAL FOR THE SUPPLY BATTERY. FAIL-URE TO FOLLOW THIS INSTRUCTION MAY CREATE ASHOCK HAZARD.a) A 14-1/4" x 14-1/4" opening must be cut throughthe roof and ceiling of the RV. It is recommendedthis opening be located between roofreinforcing members.b) Mark a 14-1/4" x 14-1/4" square on the roof andcarefully cut the opening.c) Using the roof opening as a guide, cut thematching hole in the ceiling.There may be electrical wiring between the roof andceiling.3) OPENING PREPARATION:a) If the opening exceeds 14-1/2" x 14-1/2",it will be necessary to install spacers.b) If the opening is less than 14-1/4" x 14-1/4", itmust be enlarged.c) Route a copper 12 AWG, with ground, supplyline from the fuse or circuit breaker box to theroof opening.1. The power supply must be on a separate 20amp Time Delay Fuse or HACR CircuitBreaker.2. Wiring must comply with all National, Stateand Local wiring codes.3. Make sure at least 20" of wire extend into theroof opening. This insures easy air conditionerattachment.4. If vent fan was removed, the existing wiremay be used provided it is of proper size andcorrectly fused.d) The opening must be framed to provide adequatesupport and prevent air from beingdrawn from the roof cavity. Lumber 3/4" thick ormore and long enough to bridge the openingmust be used. Remember to provide andentrance hole for the power supply wire.NEVER create a LOW SPOT on the roof where water willcollect. Water standing around the air conditioner mayleak into the RV interior.e) The 14-1/4" x 14-1/4" roof opening is part of thereturn air duct and must be finished in accordancewith NFPA standard 501C, Standard forRecreational Vehicles, Section 2-7.D. PLACING THE AIR CONDITIONER ON THEROOF1) Remove the Air Conditioner from the carton anddiscard the carton.2) Place the air conditioner on the roof.Use care in lifting.This unit weighs approximately 100 pounds.3) Lift and place the unit over the prepared openingusing the gasket as a guide. The condenser coilgoes toward the rear of the RV.5

a) Remove upper duct from ceiling template andlocate it over blower discharge.NOTE: Edges without flanges install toward REAR andSIDE of opening.b) Use two (2) sharp pointed #10 x 1/2" sheet metalscrews (A) to hold duct to base pan. Holesprovided in bottom of basepan for these screwsto go into.2) Check for correct alignment and adjust the unit asnecessary (Roof Gasket centers over 14" opening).3) Reach up into return air opening of the air conditionerand pull the unit electrical cord down for laterconnection.4) Measure the ceiling to roof thickness:CENTER A /CFROM BEL OWGASKET! CAUTIONDO NOT slide the unit. This may damage the neoprenegasket attached to the bottom and create a leakyinstallation.MEASURECEILINGTHICKNESSPULL DOW NELECTRICAL CORD4) Place the Air Box Kit inside the RV. This boxcontains mounting hardware for the air conditionerand will be used inside the RV.This completes the outside work. Minor adjustments canbe done from the inside if required.E. DISCHARGE DUCT AND CEILINGTEMPLATE1) Remove air box and mounting hardware fromcarton. The upper duct is shipped inside the lowerduct which is part of the ceiling template.FRONT O FCOACHUPPERLOWERAASIDE W ITHOUTTAB T O R EAR A NDSIDE OF A IRCONDITIONERa) If distance is 1"-2", remove perforated tabs fromboth upper and lower ducts.b) If distance is 2"-3", remove perforated tabs frombottom duct only.c) If distance is 3"-4", install ducts as received.d) If distance is 4"-6", use optional duct adaptor,Part No. 313606.000 and Bolt Kit, Part No.3100895.006.5) Install ceiling template by sliding lower duct overupper duct.6) Start each mounting bolt by hand before tighteningany of them. The four (4) threaded inserts in thebase pan can be seen to aid in starting the bolts.EVENLY TIGHTEN MOUNTING BOLTS TO ATORQUE OF 40 TO 50 INCH POUNDS.This will compress the roof gasket to approximately1/2". The bolts are self locking so overtightening is not necessary.7) Install wood screws (C) in each end of ceilingtemplate and into junction box. This insures a tightfit of air box to ceiling.F. CONNECTION OF POWER SUPPLYNOTE: All wiring must comply with the NationalElectrical Code and any State or Local Codesor regulations.1) Route supply line into junction box thru providedRomex Connector. Six (6) inch leads are sufficientfor connection to unit wires and ground screws.6

3105975 AIR DISTRIBUTION BOX 3107209 AIR DISTRIBUTION BOXCORNERREINFORCEMENT(TYP.)MOUNTING BOLT (B)UNITJUNCTIONBOXWOOD SCREW (C)MOUNTING BOLT(B)UNITELECTRICALCORDMOUNTINGBOLT (B)WOOD SCREW(C)SCORNER NUTRETAINERMOUNTINGBOLT (B)DISCHARGE A IRDUCTFRONT OFCOACH2) Connect white wire in junction box to white orneutral wire from supply line.3) Connect black wire in junction box to black or hotwire from supply line.4) Connect supply ground wire to identified groundscrew in junction box.5) Install junction box cover with two (2) blunt pointscrews.6) Plug unit electrical cord into the mating connectoron control box.G. INSTALL AIR BOX3105975 AIR DISTRIBUTION BOX:1) Remove return air grille from air box by pulling outon push/pull fasteners.2) Install air box over two (2) weld studs on ceilingtemplate and secure with nuts (G).3) Install machine screw (F) in round air box hole.4) Install four (4) wood screws (C) that hold air boxtight to ceiling.5) Reinstall return air grille and snap cover plate (H)into air box.6) The air conditioner installation is now complete.Turn on power to the unit for operational check.Please read Unit Operating Instructions beforeproceeding.3107209 AIR DISTRIBUTION BOX:1) Remove return air grille from air box by pulling inon half-round finger catches.2) Hold air box up to ceiling template and install three(3) #10 x 3/8" screws at air box mounting point.3) Snap hole plug (E) into place at rear of air box.4) Install four (4) wood screws (B) that hold air boxtight to ceiling if so desired.5) Reinstall return air grille and filter into air box.6) The air conditioner installation is now complete.Turn on power to the unit for operational check.Please read Unit Operating Instructions beforeproceeding.7

3105975 AIR DISTRIBUTION BOX 3107209 AIR DISTRIBUTION BOXWOOD SCR EW (C)CEILING T EMPLATEWELD ST UDSWOOD SCR EW (C)MACHINESCREW (F )NUT (G)COVER P LATE (H)PUSH/PULLFASTENERSRETURN A IR GR ILLEWOOD SCR EW (C)WOODSCREW (C)MOUNTING PARTSMOUNTING PARTSA. (2) #10 x 1/2" long sharp point sheet metal screws.A. (4) 1/4" - 20 x 7" BoltsB. (4) 1/4" — #20 x 7" boltsB. (4) #8 x 5/8" long sharp point wood screwsC. (7) #8 x 5/8" long sharp point wood screwsC. (4) #10 x 3/8" blunt point tapping screwsD. (4) #10 x 3/8" blunt point tapping screwsD. (1) Romex connectorE. (1) Romex connectorF. (1) Machine screw, 3/8" longE. (1) Hole PlugG. (2) #10 — 24 Hex nutsH. Cover plate(Continued on Page 9)8

H. INSTALLATION ON TENT CAMPERROOF1) The permanent wiring leading to unit junctionbox may originate in a flanged surfaceinlet located in roof section near the sidewall.2) A unique outlet receptacle for air conditionershould be located in the side wall ofvehicle beneath the flanged surface inlet.3) A cord set fabricated from an oil, water, andozone resistant material, such as TypeAIR CONDITIONING UNITAIR CONDIT IONERAIR BOX PERMANENTWIRING INROOF ORRACEWAYCORD SET(Type SJOW -Aor Equivalent,Must be V isible)UNIQUE P LUGJUNCTIONBOXUNIQUERECEPTACLESO N O O THERPLUG M AY B EPUT I NTO T HISCIRCUITSJOW-A, shall be used to connect theflanged surface inlet and the air conditioningreceptacle. This cord set shall be visibleduring use and shall not be installed inraceways or placed behind walls or cabinetpanels.AIR BOX WIRING DIAGRAMELECTRICAL BOX WIRING DIAGRAM115 VAC60 HZ 1 PHUSE COPPERCONDUCTORSONLYFIELD WIRINGFACTORY WIRINGLINE SPLICEWHTBLK123BLKYELBLKROTARYSWITCHL1H4 REDC5ELEC CONNFROM A/C6GRYGRN/YELBLU 32 1THERMOSTATBLU3106006.0049