A Division of AIRXCEL, Inc. Installation Instructions for International 8000 Series Rooftop Air Conditioners . TABLE OF CONTENTS (clickable) I. General Information II. Air Conditioning Sizing III. Selecting An Installation Location IV. Installing The Rooftop Unit V. Securing The Air Conditioner To The Roof VI. Electrical Wiring VII. Installing The Ceiling Assembly (8000 Series) VIII. Completing The Installation (8000 Series) IX. Installing The Ceiling Assembly (9000 Series) X. Completing The Installation (9000 Series) These instructions are a general guide for installing the International Series RV Products rooftop air condtioners. For specific air conditioner details, it will be necessary to refer to the printed Customer Envelope Package supplied with each air conditioner. IMPORTANT NOTICE These instructions are for the use of qualified individuals specialy trained and experienced in installation of this type of equipment and related system components. Installation and service personnel are required by some states to be licensed. PERSONS NOT QUALIFIED SHALL NOT INSTALL NOR SERVICE THIS EQUIPMENT. NOTE The words "Shall" or "Must" indicate a requirement which is essential to satifactory and safe product performance. The words "Should" or "May" indicate a recommendation or advice which is not essential and not required but which may be useful or helpful. WARNING - SHOCK HAZARD To prevent the possibility of severe personal injury or equipment damage due to electrical shock, always be sure the electrical power source to the appliance is disconnected. CAREFULLY FOLLOW ALL INSTRUCTIONS AND WARNINGS OF THIS DOCUMENT TO AVOID DAMAGE TO THE EQUIPMENT, PERSONAL INJURY OR FIRE. WARNING Improper installation may damage equipment, can create a hazard and will void the warranty. The use of components not tested in accordance with these units will void the warranty, may make the equipment in violation of state codes, may create a hazard and may ruin the equipment. Table of Contents I. GENERAL INFORMATION OEM - Please make sure the Customer Envelope Package accompanies the air conditioner. INSTALLER AND/OR DEALER - Please make sure the Customer Envelope Package is presented to the product consumer. INQUIRIES ABOUT THE A/C UNIT - Inquiries to your RV Products representative or to RV Products pertaining to product installation should contain both the model and serial numbers of the rooftop air conditioners. All rooftop air conditioning units have model and serial number identification in two locations; 1) rating plate sticker made be viewed by looking through the shroud louvers on the compressor side of the rooftop air conditioning unit. The rating plate sticker can be seen without removing the outer plastic shroud, 2) model/serial number sticker (silver color) is located on the bottom or inside the return air opening of the base pan of the rooftop air conditioner. If the air conditioner is installed, the sticker may be viewed by lowering the ceiling assembly shroud. NOTE All 8000 series rooftop air conditioners should be installed with a 8000 or 9000 series ceiling assembly. All 6700 series rooftop air conditioners should be installed with a 6700 series ceiling assembly. Table of Contents II. AIR CONDITIONING SIZING The ability of an air conditioner to cool a vehicle or maintain a consumer desired temperature is dependent on the heat gain of the vehicle. The physical size, the window area, the quality and amount of insulation, the exposure to sunlight, the number of people using the vehicle and the outside temperature, may increase the heat gain such that the capacity of the air conditioner is exceeded. As a general rule, air supplied (discharged air) from the air conditioner will be 15 to 20 degrees cooler than the air entering (return air) the ceiling assembly bottom air grills. For example, if the air entering the air conditioner is 80 degrees F (return air), the supply air (discharge air) into the vehicle will be 60 to 65 degrees F. As long as this temperature difference (15 to 20 degrees) is being maintained, the air conditioner is operatiing properly. Again, give careful consideration to the vehicle heat gain variables. During extreme outdoor temperatures, the heat gain of the vehicle may be reduced by: parking the vehicle in a shaded area keeping windows and doors closed avoiding the use of heat producing appliances using window shades (blinds and/or curtains) For a more permanent solution to high heat gain situations, additional vehicle insulation, window awnings and/or window glass tinting should be considered. Table of Contents III. SELECTING AN INSTALLATION LOCATION Your RV Products air conditioner has been designed for use primarily in recreational vehicles. Is the roof of the vehicle capable of supporting both the roof unit and ceiling assembly without additional support structures? Inspect the interior ceiling mounting area to avoid interference with existing structural members such as: bunks, curtains, tracks or room dividers. The depth of the ceiling assembly shroud is 3". Be sure to check clearance to doors which must be swung open (refrigerators - closets - cabinets). Most of the time, roof mount air conditioners are installed at existing roof vent locations. If there are no roof vents (existing mounting hole), the following placement locations are recommended. Motorhomes - a single unit or the forward of two units should be mounted within 9 feet of the drivers compartment. Travel Trailers or Mini-Homes - a location should be selected that is near the door slightly forward of the vehicle center length. Vans - location should be in the center of the roof (side to side - front to back). Truck with Camper - location should be between 4 and 5 feet from the rear of the camper to achieve maximum cooling effect. Table of Contents IV. INSTALLING THE ROOFTOP UNIT DANGER - SHOCK HAZARD DISCONNECT ALL POWER TO THE VEHICLE BEFORE PERFORMING ANY CUTTING TO THE VEHICLE. CONTACT WITH HIGH VOLTAGE CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH. IMPORTANT TO PREVENT DAMAGE TO THE WIRING AND BATTERY, DISCONNET THE BATTERY CABLE FROM THE POSITIVE BATTERY TERMINAL BEFORE PERFORMING ANY CUTTING TO THE VEHICLE. Once the location of your air conditioner has been determined (See Section III), a reinforced and framed roof hole opening must be provided (may use existing vent hole). Before cutting into the vehicle roof, verify that the cutting action will clear all structural members and crossbeams. Additionally, the location of any inner roof plumbing and electrical supplies must be considered. A. If a roof vent is already present in the desired mounting location for the air conditioner, the following steps must be taken: Remove all screws which secure the roof vent to the vehicle. Remove the vent and any additional trim materials. Carefully remove all caulking from around the roof opening to obtain clean exterior roof surface. It may be necessary to seal some of the old roof vent mounting screw holes which may fall outside of the air conditioner basepan gasket. Examine the roof opening. If the opening is smaller than 14" x 14", the opening must be enlarged. B. If a roof vent opening is not used, a new opening (See Figure 1.) will have to be cut into the vehicle roof. A matching opening will also have to be cut into the interior vehicle ceiling. If the ceiling opening is carpeted, snagging could occur. After the opening in the roof and interior ceiling are the correct size, a framed support structure must be provided between the exterior rooftop and interior ceiling. The reinfored frame structure must provide the following guidelines: Capable of supporting both the weight of the rooftop air condtioner and the interior ceiling assembly. Capable of holding or supporting the roof outer surface and interior ceiling apart, so that when the rooftop air conditioner and ceiling assembly are bolted together, no collapsing occurs. RV Products recommends that the spacing from the vehicle rooftop to the interior ceiling top be no less than 1". A typical support frame is shown in figure 1. The frame must provide an opening through the frame to allow passage for the power supply wiring. Route supply wiring through the frame at the same time the support frame is being installed. IMPORTANT - Allow 24" of supply wiring through the support frame (working length). After the support frame is installed, seal all gaps between the frame in both the roof exterior and the interior ceiling of the vehicle (cavity walls). Additionally, seal the gap around the electrical supply wiring. C. The air conditioner must be mounted as near level from front to rear and side to side as is possible when the vehicle is parked on level plane. Figures 2 and 3 show maximum allowable degree deviations (mounting degrees from total surface flat plane). Figure 1. Figure 2. Figure 3. If the roof of the vehicle is sloped (not level) such that the air conditioner cannot be mounted within the maximum allowable degree deviations, an exterior leveling shim will need to be added to make the air conditioner level. A typical front the back leveling shim is shown in Figure 4. Figure 4. Once the air conditioner has been leveled, some additional shimming may be required above the interior ceiling assembly. The air conditioner and the interior ceiling assembly must have a squared installation relationship before they are secured together. D. After the mounting hole is properly prepared, remove the carton and shipping pads from around the air conditioner. Carefully lift the unit to the top of the vehicle. Do not use the outer plastic shroud for lifting. Place the air conditioner over the prepared mounting hole. The pointed end (nose) of the shroud must face towards the front of the vehicle. Pull the electrical conduit down from the air conditioner though the mounting opening and let hang. Table of Contents V. SECURING THE AIR CONDITIONER TO THE ROOF A mounting frame is supplied with the ceiling assembly. Follow the steps below to secure the air conditioner to the roof. Refer to Figure 5. A. Locate the air conditioner mount gasket over the 14" to 15" square opening in the roof. B. Install the ceiling assembly mount frame using the four bolts found with ceiling assembly. Proper tension has been achieved for each bolt when any portion of eash gasket indicating tab has been pulled down even with the roof. See Figure 5. The upper unit has now been properly installed with optimum gasket compression. Figure 5. The Following Two Sections Pertain Only To 8000 Series Ceiling Assemblies Table of Contents VI. ELECTRICAL WIRING ROUTING 115 VAC WIRING Following RV Products' high voltage wiring specifications and all local and national electrical codes, route the rooftop unit 115 VAC supply wiring from its power source to the wirebox. High Voltage Wiring Specifications U.L. require copper conductors only with minimum #12 AWG. To prevent voltage drops greater than 10% during starting loads, adhere to the following guideline: For length greater than 50' use #10 AWG. Circuit Protection - Refer to upper unit nameplate. DANGER - SHOCK HAZARD MAKE SURE THAT ALL POWER SUPPLY TO THE UNIT IS DISCONNECTED BEFORE PERFORMING ANY WORK ON THE UNIT TO AVOID THE POSSIBILITY OF SHOCK INJURY OR DAMAGE TO THE EQUIPMENT. DANGER WHEN USING NONE-METALLIC SHEATH CABLES (ROMEX, ETC.), STRIP SHEATH BACK TO EXPOSE 4-6" OF THE SUPPLY LEADS. STRIP THE INDIVIDUAL WIRE LEAD ENDS FOR WIRE CONNECTION (ABOUT 3/4" BARE WIRE). INSERT THE SUPPLY WIRES INTO THE ELECTRICAL CONNECTOR CLAMP. SHEATH MUST PROTRUDE PAST THE CLAMP BUSHING INSIDE THE BOX AS ILLUSTRATED. MAKE SURE SHEATH CABLE IS CENTERED IN CLAMP BEFORE TIGHTENING UP ON IT. DO NOT OVER TIGHTEN!! THIS COULD RESULT IN PINCHING THROUGH THE PLASTIC WIRE INSULATION AND CAUSE SHORTING OR "HOT" WIRES TO GROUND (SHOCK HAZARD). THE CLAMP IS INTENDED FOR STRAIN RELEIF OF THE WIRES. SLIGHT PRESSURE IS USUALLY SUFFICIENT TO ACCOMPLISH THIS. IF OTHER THAN NON-METALLIC CABLES ARE USED FOR SUPPLY CONDUCTORS, APPROPRIATE STRAIN RELIEF CONNECTORS OR CLAMPS SHOULD BE USED. IN NO CASE SHOULD CLAMPING OR PINCHING ACTION BE APPLIED TO THE INDIVIDUAL SUPPLY LEADS (NEUTRAL AND "HOT" WIRES). DANGER - SHOCK HAZARD TO PREVENT THE POSSIBILITY OF SHOCK HAZARD, THE WHITE WIRE MUST BE CONNECTED TO NEUTRAL IN THE SERVICE BOX ENTRANCE AND THE MECHANICAL GROUND MUST BE CONNECTED TO A GROUNDING LUG EIGHER IN THE SERVICE BOX OR THE MOTOR GENERATOR COMPARTMENT. Table of Contents VII. INSTALLING THE CEILING ASSEMBLY (8000 SERIES) NOTE The optional Elect-A-Heat is intended to take the chill out of the indoor air when the air is a few degrees too cool for comfort. The Elect-A-Heat is an effective "chill chaser". It is not a substitute for a furnace. Make sure that you have properly matched the rooftop air conditioner and interior ceiling assembly. The following step by step instructions must be performed in the following sequence to insure proper installation. A. Carefully uncarton the ceiling assembly. Controls are factory installed in the ceiling assembly (except ceiling assemblies for applications with remote control box/thermostat). B. Remove the shroud from the ceiling assembly plate. C. THIS ENTIRE STEP "C." IS NOT REQUIRED ON "COOLING ONLY" CEILING ASSEMBLIES. On ceiling asseblies equipped with the Elect-A-Heat heater package (heat/cool ceiling assemblies), detach the bottom heating element support plate by removing the screws located around the outer edge. The electrical connection plug will need to be disconnected before the heat element support plate can be removed. D. Before the ceiling assembly can be mounted to the mount frame, the duct collar must be fastened to the basepan of the air conditioner with three (3) screws (See Figure 6.). E. Secure the ceiling assembly plate to the mounting frame with the screws provided. F. Pull fabric duct material through ceiling assembly discharge duct opening. Slit the four corners of fabric duct which extends below duct opening (See Figure 6.). DANGER - FIRE HAZARD DO NOT USE FABRIC DUCT TAPE ON OR AROUND FABRIC DISCHARGE AIR DUCT COLLAR. ALUMINUM TAPE MAY BE USED IF NEEDED. G. Place metal flange in discharge duct opening, trapping fabric between it and the ceiling assembly (See Figure 6.). H. Pull fabric tight. This will minimize material bunching inside the discharge duct collar. I. Fasten the metal flange to the ceiling assembly with four (4) screws. To avoid air noise and restrictions, trim any excess fabric that may extend beyond edge of metal flange. J. Route the power supply wire to the back of the selector switch control box. Do not attach at this time. K. Take the rooftop air conditioner electical conduit and plug it into the back of the thermostat control box. Make sure that the "ridged" side of the plug is aligned and matched with the "ridged" side of the thermostat control box connection. DO NOT USE EXCESSIVE FORCE and make sure the lock-in tabs are snapped in place (See Figure 7.). L. Remove the selector switch control box cover (one screw). Take the supply wire and slide it into the back of the selector switch control box through the strain relief that is provided. M. Connect the power line to the black and white pigtail wires found in the control box using two wire nuts. IMPORTANT - Connect black wire to black wire and white wire to white wire. Install the brown wire (green to bare copper) to the green headed screw in the selector switch control box. Using a U.L. approved electricians tape, secure the wire nuts to the wires in workmanlike manner (See Figure 8.). N. Tighten the strain relief clamp to secure the supply wire. DO NOT OVERTIGHTEN (See Figure 9.). Reinstall the selector switch box cover. Some ceiling assemblies may be equipped with a plastic strain relief. Figure 6. Figure 7. Figure 8. Figure 9. Table of Contents VIII. COMPLETING THE INSTALLATION (8000 SERIES) To complete the installation and system checkout requirements, the following steps must be performed. A. Check the thermostat probe position. Make sure the thermostat probe is routed through the holding guide and is not touching any metal surface. B. THIS ENTIRE STEP "B." IS NOT REQUIRED ON COOLING ONLY CEILING ASSEMBLIES. Reinstall the Elect-A-Heat assembly by first; connecting the heat plug from the selector switch control box to the heater receptacal in the Elect-A-Heat heater package, and secondly; secure the Elect-A-Heat package to the ceiling assembly with the screws previously removed. C. Make sure the non-allergenic filters are properly positioned in the ceiling shroud. D. Reinstall the ceiling shroud (secure with two screws provided by RV Products). Put the control knobs (found in single parts package) on the selector switch and thermostat controls. E. Turn selector switch to OFF position. F. Turn ON the power supply to the rooftop air conditioner. G. System Checkout - RV Products manufactures a wide range of rooftop air conditioners which incorporate different product operation features. To properly evaluate the performance of a newly installed air conditioner it is necessary to review the specific unit operation characteristics (features) described in product operation and maintenance instructions (Customer Envelope Package). The Following Two Sections Pertain Only To 9000 Series Ceiling Assemblies Table of Contents IX. INSTALLING THE CEILING ASSEMBLY (9000 SERIES) NOTE The optional Elect-A-Heat is intended to take the chill out of the indoor air when the air is a few degrees too cool for comfort. The Elect-A-Heat is an effective "chill chaser". It is not a substitute for a furnace. Make sure that you have properly matched the rooftop air conditioner and interior ceiling assembly. The following step by step instructions must be performed in the following sequence to insure proper installation. A. Carefully uncarton the ceiling assembly. Controls are factory installed in the ceiling assembly (except ceiling assemblies for applications with remote control box/thermostat). B. Remove the grille and filters from the ceiling assemblies. C. If equipped with Elect-A-Heat option, remove the heater assembly from the ceiling assembly chute. Position the heater assembly in the air conditioner return air opening as shown in Figure 10. The heater bracket must be installed over the metal basepan extrusion and positioned between the basepan and the plastic drain pan (See Figure 11.). Tighten set screw to secure the assembly so as to prevent movement. D. Fasten the duct collar to the basepan of the air conditioner with three (3) screws (See Figure 14.). E. Plug the rooftop air conditioner electrical conduit into the 9 position receptacle located in the thermostat side of the ceiling assembly. If installing an Elect-A-Heat ceiling assembly, plug the heater cord into the 2 position receptacle (See Figure 12.). F. Install the provided cable clamp in the 7/8" diam. hole on the back of the metal field wiring box. Insert the supply wiring through the cable clamp and into the field wiring box so that 4-6" of supply conductor is inside the box. Secure the cable clamp over the supply wire sheath so that no movement is possible (See Figure 13.). G. Connect the supply power conductors to the black and white pigtail wires and the supply ground wire to the green pigtail wire found in the field wiring box using the three (3) provided wire nuts. IMPORTANT - Connect the black supply to the black pigtail and the white supply to the white pigtail using a U.L. approved electrical tape, secure the wire nuts to wires in workmanlike manner. (See Figure 13.). H. Place the metal control box shield over the thermostat, switch and field wiring boxes. Make certain that all wires are pushed into the control boxes or laying in the wireway between the thermostat and switch boxes and will not be pinched by the control box shield. Control box shield is properly installed when the two holes in the shield are aligned with the two (2) screw holes in the ceiling assembly chute (See Figure 12.). I. Raise the ceiling assembly and secure to the mounting frame with four (4) provided shoulder screw/spring assemblies. The front two (2) screws should pass through the clearance holes in the metal control box shield (See Figure 15.). J. The ceiling assembly shroud is curved to contour to a crowned ceiling. If installation is to a flat ceiling and gaps are present on the sides of the shroud, two (2) metal clips and screws are provided to pull the sides of the shroud flush with ceiling. Position the clips through return air slots on the sides of the shroud and attach the clips to the mounting frame with provided screws (See Figure 14.). K. Pull the fabric duct material through ceiling assembly discharge opening. Peel the release liner from the adhesive strip around the discharge opening. Press the fabric duct material firmly in place around opening. Cut off excess fabric on inside of ceiling assembly chute with a box knife taking care not to tear the fabric beyond the adhesive strip. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Table of Contents X. COMPLETING THE INSTALLATION (9000 SERIES) A. Make sure the non-allergenic filters are properly positioned in the ceiling shroud. B. Install the ceiling grille by positioning on the bottom of the shroud and engaging the two (2) 1/4 turn fasteners. C. Turn the selector switch to OFF position. D. Turn ON the power supply to the rooftop air conditioner. E. System Checkout - RV Products manufactures a wide range of rooftop air conditioners which incorporate different product operation features. To properly evaluate the performance of a newly installed air conditioner it is necessary to review the specific unit operation characteristics (features) described in product operation and maintenance instructions (Customer Envelope Package). ROOFTOP UNIT DIMENSIONS Figure 16. Figure 17. QUICK REFERENCE CHART DIMENSIONS Exterior Shroud Height Width Length 13-1/4" 29" 43" Interior Shroud Height Width Length 2.1" 19.9" 20.1"