2-25-05 Briskair 579, 590 and 595 Series Air Distribution ...1].060.pdf · 2 579, 590 & 595 Air Distribution Box With Analog Relay Kit Installation Instructions A. THIS AIR CONDITIONER

1

579, 590 & 595 Air Distribution Box With Analog Relay Kit Installation Instructions

INSTALLATIONINSTRUCTIONS

USASERVICE OFFICEThe Dometic Corporation2320 Industrial ParkwayElkhart, IN 46515(574) 294-2511

CANADADometic Distribution866 Langs Dr.Cambridge, OntarioCANADA N3H 2N7(519) 653-4390

For Service CenterAssistance Call:800-544-4881

BRISK AIR®

579 Series590 Series595 Series

ROOF TOP AIR CONDITIONERUSED WITH

3107210 AIR DISTRIBUTION BOX KIT and3107541 ANALOG RELAY KIT

REVISIONForm No. 3108464.060 2/05(Replaces 3108464.053)(French 3108982.061)©2005 Dometic CorporationLaGrange, IN 46761

C US

57908.52157912.62257912.63157915.32257915.33157915.42257915.52257915.531

57915.53657915.54157915.54657915.62257915.63157915.73159016.52159016.62159516.303

59516.33159516.33659516.50159516.53159516.53659516.60159516.60359516.631

Lire et comprendre ce manuel avant deprocéder à l'installation, à des réglages,de l'entretien ou des réparations.L'installation de cet appareil doit êtreeffectuée par un réparateur qualifié.Toute modification de cet appareil peutêtre extrêmement dangereuse etentraîner des blessures ou dommagesmatériels.

WARNING! AVERTISSEMENTAVERTISSEMENT!

RECORD THIS UNIT INFORMATION FORFUTURE REFERENCE:Model NumberSerial NumberDate Purchased

Important: These instructions must stay withunit. Owner read carefully.

This manual must be read and un-derstood before installation, adjust-ment, service, or maintenance isperformed. This unit must be in-stalled by a qualified service techni-cian. Modification of this productcan be extremely hazardous andcould result in personal injury orproperty damage.

2


A. THIS AIR CONDITIONER IS DESIGNED FOR:

1. Installation on a recreational vehicle during the timethe vehicle is manufactured.

2. Mounting on the roof of a recreational vehicle.3. Roof construction with rafters/joists on minimum of

16 inch centers.4. Minimum of 2.00 inches and maximum of 4.00

inches distance between roof to ceiling of recre-ational vehicle. Alternate installation methods willallow for roofs more than 4.00 inches thick.

B. The ability of the air conditioner to maintain the desiredinside temperature depends on the heat gain of the RV.Some preventative measures taken by the occupants ofthe RV can reduce the heat gain and improve theperformance of the air conditioner. During extremelyhigh outdoor temperatures, the heat gain of the vehiclemay be reduced by:1. Parking the RV in a shaded area2. 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 optimumor maximum efficiency in high humidity or high outsidetemperature.

Starting 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.

For a more permanent solution to a high heat gain,accessories like A&E outdoor patio and window awningswill reduce heat gain by removing the direct exposure tothe sun. They also add a nice area to enjoy companyduring the cool of the evening.

C. CondensationNote: The manufacturer of this air conditioner will not beresponsible for damage caused by condensed moisture onceilings or other surfaces. Air contains moisture and thismoisture tends to condense on cold surfaces. When airenters the RV, condensed moisture may appear on theceiling, windows, metal parts, etc. The air conditionerremoves this moisture from the air during normal operation.Keeping doors and windows closed when this air conditioneris in operation will minimize condensed moisture on coldsurfaces.

1. GENERAL INFORMATIONSAFETY INSTRUCTIONS

This manual has safety information and instruc-tions to help users eliminate or reduce the risk ofaccidents and injuries.

RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see thissymbol in this manual, be alert to the potential forpersonal injury.

Follow recommended precautions and safe op-erating instructions.

UNDERSTAND SIGNAL WORDS

A signal word , WARNING OR CAUTION is usedwith the safety-alert symbol. They give the level ofrisk for potential injury.

indicates a potentially hazard-ous situation which, if not avoided, could result indeath or serious injury.

indicates a potentially hazard-ous situation which, if not avoided, may result inminor or moderate injury.

used without the safety alertsymbol indicates, a potentially hazardous situa-tion which, if not avoided, may result in propertydamage.

Read and follow all safety information and instruc-tions.

!

WARNING!

CAUTIONCAUTION

CAUTION!

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1. PRECAUTIONS

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

A. Read Installation and Operating Instructions carefullybefore attempting to start your air conditioner installa-tion.

B. The Dometic Corporation will not be liable for anydamages or injury incurred due to failure in followingthese instructions.

C. Installation must comply with the National ElectricalCode and any State or Local Codes or regulations.

D. DO NOT add any devices or accessories to this airconditioner except those specifically authorized byDometic.

E. This equipment must be serviced by qualified personneland some states require these people to be licensed.

2. CHOOSING PROPER LOCATIONFOR THE AIR CONDITIONER

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

A. NORMAL LOCATIONThe air conditioner is designed to fit over an existing roofvent opening. When the vent is removed, it normallycreates a 14-1/4" X 14-1/4" (±1/8") opening.

B. OTHER LOCATIONS

INSTALLATION INSTRUCTIONSWhen no roof vent is available or another location isdesired, the following is recommended:

1. For one unit installation: The air conditioner should bemounted slightly forward of center (front to back) andcentered from side to side.

2. For two unit installations: Install one Air Conditioner1/3 and one Air Conditioner 2/3’s from front of RV andcentered from side to side.

It is preferred that the air conditioner be installed in a relativelyflat and level roof section measured with the RV parked ona level surface.Note: A 15° slant to either side, or front to back, isacceptable.

FIG. 1

34.4"

12.7" *

29.5"

*10.7" FORMODEL57908

WARNING!

5


C. AFTER LOCATION HAS BEEN SELECTED:1. Check for obstructions in the area where air condi-

tioner will be installed.2. The roof must be designed to support 130 pounds

when the RV is in motion. Normally a 200 lb. staticload design will meet this requirement.

It is the responsibility of the installer of thisair conditioner system to ensure structuralintegrity of the RV roof. Never create a lowspot on the roof where water will collect. Wa-ter standing around the air conditioner mayleak into the interior causing damage to theproduct and the RV.

3. Check inside the RV for air box obstructions (i.e. dooropenings, room dividers, curtains, ceiling fixtures,etc.)

3. ROOF PREPARATIONBefore preparing the ceiling opening, the type of systemoptions must be decided upon. If a furnace is to be con-nected, wires must be run from the furnace to the DometicA/C. Read all of the following instructions before beginningthe installation.

There may be electrical wiring between theroof and the ceiling. Disconnect 120 volt ACpower cord and the positive (+) 12 volt DCterminal at the supply battery. Failure to fol-low this instruction may create a shock haz-ard causing death or severe personal injury.

A. CEILING OPENING REQUIREMENTS1. A 14-1/4" x 14-1/4" (±1/8") opening must be cut

through the roof and ceiling of the RV. This openingmust be located between the roof reinforcing mem-bers.

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

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

B. OPENING PREPARATION1. If the opening exceeds 14-3/8" x 14-3/8", it will be

necessary to install spacers.2. If the opening is less than 14-1/8" x 14-1/8", it must be

enlarged.3. Route a copper 12 AWG, with ground, 120 VAC

supply line from the fuse or circuit breaker box to theroof opening.a. This supply line must be located in the front portion

of the 14-1/4" (±1/8") opening.b. The power MUST be on a separate 20 amp time

delay fuse or HACR circuit breaker.c. Make sure that at least 15" of supply wire extends

into the roof opening. This ensures easy connec-tion at the junction box.

d. Wiring must comply with all National, State andLocal Wiring Codes.

e. Use a steel sleeve and a grommet or equivalentmethods to protect the wire where it passes intothe opening.

4. If a furnace is to be connected, wires must be run fromthe furnace to the Dometic Air Conditioner.

5. The opening created must be framed to provideadequate support and prevent air from being drawnfrom the roof cavity. Lumber 3/4" or more in thicknessmust be used. Remember to provide an entrance holefor power supplies, furnace wiring (if applicable) andthermostat wires.

FIG. 2

7-5/8"

5-1/4" 14-7/8"

7-5/8"

REAROF

UNIT

KEEP THIS AREA FREE OF OBSTRUCTIONS

FRONT 18"

14-1/4"x14-1/4"

OPENING

CAUTION

WARNING!

6


It is the responsibility of the installer of thisair conditioner system to ensure structuralintegrity of the RV roof. Never create a lowspot on the roof where water will collect. Wa-ter standing around the air conditioner mayleak into the interior causing damage to theproduct and the RV.

6. The 14-1/4" x 14-1/4" (±1/8") opening is part of thereturn air system of the Air Conditioner and must befinished in accordance with NFPA Standard 501CSection 2.7.

7. Route a dedicated 12V DC supply line (18-22 AWG)from the RV's converter or battery to the roof opening.a. Wire must be fused at 3 Amps.b. This supply line must be located in the front portion

of the 14-1/4" (±1/8") opening.c. Make sure that at least 15" of supply wire extends

into the roof opening.8. If a furnace is to be controlled by the system, the two

furnace thermostat leads must be routed to the roofopening of the air conditioner that will control it. Makesure that at least 15" of the furnace thermostat wiresextend into the roof opening.

15"min.

3/4" MIN.

FRAME OPENING SO IT WON'TCOLLAPSE WHEN BOLTING DOWNAIR CONDITIONER

LEAVE ACCESS FORPOWER SUPPLY WIRING

FIG. 3

4. THERMOSTAT AND CABLEINSTALLATION

A. LOCATIONThe proper location of the thermostat is very importantto insure that it will provide a comfortable RV tempera-ture. Observe the following general rules when select-ing a location.

1. Locate the thermostat about 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;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 thekitchen.

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

B. CABLE INSTALLATION 1. A seven-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" (±

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 10" of cable extending into the

14-1/4" ± (1/8") opening for connection at unit6. If system is to control a gas furnace: Route two 18

gauge wires from the furnace to 14 inch opening atthis time.

5. PLACING THE AIR CONDITIONERON THE ROOF

A. Remove the Air Conditioner from the cartonand discard.

B. Place the Air Conditioner on the roof.

This unit weighs approximately 100 pounds.To prevent back injury, use a mechanical hoistto place Air Conditioner on roof.

FIG. 4

CAUTION

WARNING!

7


FIG. 6C. Lift and place the unit over the prepared opening using

the gasket on unit as a guide. The exposed coil goestoward the rear of the RV. See FIG. 5

Do not slide the unit. This may damage theneoprene gasket attached to the bottom andcreate a leaky installation.

D. Place the 3107210 Air Box Kit and Analog Control Kitinside the RV. Both boxes contain mounting hardwarefor the air conditioner and will be used inside the RV.

This completes the outside work. Minor adjustments can bedone from the inside of the RV if required.

6. DISCHARGE DUCT & CEILINGTEMPLATE INSTALLATION

A. Remove the air box and mounting hardware from theircarton. The upper duct is shipped inside the lower ductwhich is part of the ceiling template.

B. Remove the upper duct from the ceiling template andlocate it over the blower discharge.

Note: The edge without the flange installs toward the rearand side of the opening. See FIG. 6C. Use two of the sharp pointed sheet metal screws to hold

the duct to the base pan. The holes are pre-punched inthe pan for each location.

D. Check gasket alignment over roof opening and adjust ifnecessary (roof gasket centers over opening). Unit maybe moved from below by lifting and sliding.

FIG. 5

GASKETCENTER A /CFROM BEL OW

MEASURECEILINGTHICKNESS

PULL DOW NELECTRICAL CORD

FIG. 7

E. Reach up into the return air opening and pull the conduitpower cable down for later connection. See FIG. 7

Note: In some applications it may be necessary to extendthe 6 pin cable. Order cable number 3105584.001 if needed.

CAUTION

F. Measure the ceiling thickness:1) If the distance is 2" to 3", remove perforated tabs

from bottom duct only.2) If the distance is 3" to 4", install ducts as received.3) If the distance is 4" to 6" (maximum thickness),

optional Duct Kit and Bolt Kit are available:Duct Kit (Part No. 3106775.004)Bolt Kit (Part No. 3100895.006)

G. Remove the junction box cover from the Analog ControlBox.

H. Plug the electrical conduit (6 pin connector) from theupper unit into the mating connector in Analog ControlBox.

8


I. Freeze Control Installation (Two Types)1. Type using a snap on spring clip

a. Fits on all 579, 590, 591 and 595 Series BriskAir units by placing the cold control switch upthrough the base pan and on the second refrig-erant tube from the bottom in the center of theevaporator coil. Make sure the spring clip isfastened securely to the tubing and the coldcontrol surface is making contact with alumi-num fins on evaporator coil. See FIGS. 8 & 8A.

c. Place the horseshoe end of the freeze controlthrough this notch and snap onto the coil re-turn bend. When positioned correctly, controlwires will be toward the evaporator housing awayfrom the evaporator coil header. See FIG. 8B.

d. Remove installation notice hang tag from freezecontrol. See FIG. 8B

7. WIRING OF SYSTEMA. CONNECTION OF 120 VOLT POWER SUPPLY

Disconnect 120 volt AC. Failure to follow theseinstructions could create a shock hazardcausing death or severe personal injury.

This product is equipped with a 3-wire(grounded) system for protection againstshock hazard. Make sure that the applianceis wired into a properly grounded 120 volt ACcircuit and the polarity is correct. Failure todo so could result in death, personal injury ordamage to the equipment.

1. Route the 120 VAC supply line through the strainrelief in Analog Control box. Tighten strain relief,making sure enough wire is inside electronic box toconnect with unit 120 VAC wire. Tighten screws onstrain relief connector being careful not to pinch andcut into the insulation on power supply leads.

2. Connect the white to white; black to black; andgreen to green or bare copper wire using appropri-ately sized twist wire connectors. Tape the twistwire connectors to the supply wiring to assure theydo not vibrate off.

3. Push the wires into the box and tighten the strainrelief.

4. Install the cover (part of the mounting hardware) withthe one blunt point screw provided.

B. CONNECTION OF LOW VOLTAGE WIRES - See FIG. 9

FIG. 8B

FIG. 8A

RemoveHang Tag Up

Through

Place ColdControl InCenter Of CoilOn 2nd TubeFrom Bottom

FIG. 8

Wrap Closed Cell FoamInsulation Around ColdControl Switch

Snap The OpenLoop Of Spring ClipOn Second Tube InCenter OF Evapora-tor Coil

b. Keep wires away from heat strip (if applicable)and sharp edges to prevent damaging the wires.Use wire ties if necessary. See FIGS. 8 & 8A.

c. Remove installation notice hang tag from freezecontrol. See FIGS. 8 & 8A.

2. Type using a horseshoe welded snap clip.a. Install on return bend located at left (curb side)

side of evaporator coil as follows:b. Locate “D” shaped notch in flange of evapora-

tor coil. See FIG. 8B.

WARNING!

WARNING!

Disconnect the positive (+) 12 volt DC termi-nal at the supply battery. Damage to equip-ment could occur if the 12 volt DC is not shutoff.

CAUTION

1. Current model color codinga. Connect the previously run +12V DC to the red wire

labeled +12V protruding from the relay kit.b. Connect the previously run -12V DC to the black wire

labeled -12V protruding from the relay kit.c. Connect the red/white wire to the thermostat +7.5.d. Connect the unit green wire to the thermostat GND

terminal.

9


e. Connect the unit yellow wire to the thermostat COOLterminal.

f. Connect the unit tan wire to the thermostat FANterminal.g. Connect the unit blue wire to the thermostat HI FAN.h. Connect the unit orange wire to the thermostat HSterminal (if applicable).i. Connect the unit white wire to the thermostat FURterminal (if applicable).j. Connect the unit blue/white wires to the two furnace

control wires (if applicable).

2. Early model color codinga. Connect the previously run +12V DC to the red wirelabeled +12V protruding from the relay kit. Connectthe previously run -12V DC to the black wire protrudingfrom the relay kit.b. Connect the other red wire labeled +12V to Tstat +12

Screw.c. Connect the other relay kit black wire (unmarked) to

the thermostat GND terminal.d. Connect the relay kit yellow wire to the thermostatCOOL terminal.e. Connect the relay kit orange wire to the thermostatFAN terminal.f. Connect the relay kit blue wire to the thermostat HIFAN.g. Connect the relay kit violet wire to the thermostat

HS/HP terminal (if applicable).h. Connect the relay kit white wire to the thermostatfurnace terminal (if applicable).i. Connect the relay kit blue wires with white strip to the

two furnace control wires (if applicable).C. Locate the Analog Control Kit 3107541 on the ceiling

template as shown in FIG. 10. Drive two #10 x 3/8 bluntpoint Phillips head screws (provided) through ceilingtemplate into holes in electronic kit to hold into place.

D. If your installation includes the optional electric heat kit,install it at this time. Follow the instructions with the heatpackage for its installation procedure.

E. Take the ceiling template and slide the lower unit over theupper duct.

F. Hold the ceiling template with one hand and with theother, install the four 1/4" mounting bolts through thetemplate and into the base pan.1. Finger-tighten the (4) bolts and check alignment.

There should be an equal opening on each side and

uld occur if

THERMOSTAT WITH COVER REMOVED

FIG. 9

FIG. 10

CAUTION

the rear flange must be tight against the roof opening.2. EVENLY tighten the bolts to a torque of 40 to 50 inch

pounds. This will compress the roof gasket to approxi-mately 1/2".

If bolts are left loose there may not be anadequate roof seal or if over tightened, dam-age may occur to the air conditioner base orceiling template. Tighten to torque specifica-tions listed in this manual.

8. AIR BOX INSTALLATIONA. Remove return air grille from air box by pulling in on half-

round finger catches. See FIG. 11B. Hold air box up to ceiling template and install three (3) #10

x 3/8" (C) screws at air box mounting point.C. Snap hole plug (D) into place at rear of air box.D. Install four (4) wood screws (B) which hold the air box tight

to ceiling, if desired.E. Reinstall return air grille and filter into air box.F. The air conditioner installation is now complete. Turn on

power to the unit for operational check. Please read UnitOperating Instructions before proceeding.

Note: There are four optional mounting holes on the outeredge of the return air opening for which screws are provided.These are only required where an uneven ceiling does notallow proper fitting of the air box.

10


AIR CONDITIONING UNIT

FIG. 11

A. (4) 1/4" — #20 x 7" bolts

B. (4) #8 x 5/8" long sharp point wood screws

C. (7) #10 x 3/8" blunt point tapping screws

D. (1) Hole Plug

MOUNTING PARTS

(D)

FIG. 12

11


PART No. 3107541.017PART No. 3107541.017

FOR USE WITH AIR CONDITIONER:FOR USE WITH AIR CONDITIONER:

509 S. POPLAR ST.509 S. POPLAR ST.

LAGRANGE, IN 46761LAGRANGE, IN 46761

115VAC, 60Hz, 1 O115VAC, 60Hz, 1 O

3107759.023R

PASSED

DIELECTRIC

FACTORY WIRINGFACTORY WIRING

LINE SPLICELINE SPLICE

FIELD WIRINGFIELD WIRING

LOW-FAN

HI-FAN

T2

T1

BLK2

1 BLU

3

4

N/C

RED

COM

NO

2

4

1

3CON1

6 3

4

5

1

2

CON2

T3 T4

F1 CON3

1 2

BLK

BLK

GRN/YEL

5

6

WHT

GRN

RED/WT

BL/WT

BL/WT

BLU

WHT

TAN

YEL

BLK

RED3 AMP FUSE3 AMP FUSE

A/C

CONNECTION

IF USEDIF USED

INDICATOR

SOLAR/FILTER

12VDC -12VDC -

FURNACE

FURNACE

12VDC +12VDC +CONTROL

FREEZE

115 VAC,115 VAC,

USE COPPERUSE COPPER

60 HZ, 1 O60 HZ, 1 O

CONDUCTORS

ONLY

FOR A/C WITH OPTIONAL HEATSTRIPFOR A/C WITH OPTIONAL HEATSTRIP

579, 590, 595, 600579, 590, 595, 600

T-STAT

ORNNO

COM

2

3

1

N/A

GRY

WHT

RELAY BOARDRELAY BOARD

HEATSTRIP

CONNECTION

SERIAL No.SERIAL No.

RELAY KIT FIELD WIRING DIAGRAMCOOLING/FURNACE

COOLING/FURNACE/HEAT STRIP

UPPER UNIT WIRING DIAGRAM

GRN/YELRUN CAPRUN CAP

*CAP

STARTPTCR

3105052.0333105052.033

* SOME MODELSSOME MODELS

NOT USED ONNOT USED ON

COMPRESSOR

CMOTOR

HERM

C

FAN

GRN/YEL

COMP STARTERCOMP STARTER

O.L.

R

*

S

4

6

5

3

2

6 PIN CONN6 PIN CONN

1

RED

WHT

RED

YEL

BLK

WHT

RED

WHT

BRN

WHT BLU

PASSED

DIELECTRICDIELECTRIC

PART No. 3107541.009PART No. 3107541.009

FOR USE WITH AIR CONDITIONER:FOR USE WITH AIR CONDITIONER:

509 S. POPLAR ST.509 S. POPLAR ST.

LAGRANGE, IN 46761LAGRANGE, IN 46761

115VAC, 60Hz, 1 O115VAC, 60Hz, 1 O

3107750.022R

PASSED

DIELECTRIC

FACTORY WIRINGFACTORY WIRING

LINE SPLICELINE SPLICE

FIELD WIRINGFIELD WIRING

LOW-FAN

HI-FAN

T2

T1

BLK2

1 BLU

3

4

N/A

RED

COM

NO

2

4

1

3CON1

6 3

4

5

1

2

CON2

T3 T4

F1 CON3

1 2

BLK

BLK

GRN/YEL

5

6

WHT

GRN

RED/WT

BL/WT

BL/WT

BLU

WHT

TAN

YEL

BLK

RED3 AMP FUSE3 AMP FUSE

A/C

CONNECTIONCONNECTION

IF USEDIF USED

INDICATOR

SOLAR/FILTER

12VDC -12VDC -

FURNACE

FURNACE

12VDC +12VDC +CONTROL

FREEZE

115 VAC,115 VAC,

USE COPPERUSE COPPER

60 HZ, 1 O60 HZ, 1 O

CONDUCTORS

ONLY

FOR A/C WITHOUT HEATSTRIP OPTIONFOR A/C WITHOUT HEATSTRIP OPTION

579, 590, 595, 600579, 590, 595, 600

T-STAT

SERIAL No.SERIAL No.

RELAY KIT FIELD WIRING DIAGRAM

Documents

2-25-05 Briskair 579, 590 and 595 Series Air Distribution ...1].060.pdf · 2 579, 590 & 595 Air Distribution Box With Analog Relay Kit Installation Instructions A. THIS AIR CONDITIONER