REMOTE AUXILIARY AIR CONDITIONING SYSTEM AND AIR DISTRIBUTION

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1 ENGLISH REMOTE AUXILIARY AIR CONDITIONING SYSTEM AND AIR DISTRIBUTION INSTALLATION GUIDELINES For International Prostar ISO 9001:2000 L 2647 Rev

2 WARNING: Only trained technicians should perform these checks and tests. These units contain voltage of 12VDC, 24VDC, 115VAC and/or 230VAC. Some of these voltages can be lethal. These units also contain refrigerant under high pressure. Refrigerant circuits should only be accessed by licensed technicians. COPYRIGHT 2009 Dometic Corporation, Environmental Division, All Rights Reserved. No part of this publication may be reproduced, translated, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without prior written consent by Dometic Corporation, Environmental Division. Every precaution has been taken in the preparation of this manual to insure its accuracy. However, Dometic Corporation, Environmental Division assumes no responsibility for errors and omission. Neither is any liability assumed for damages resulting from the use of this product and information contained herein. 2 ENGLISH

3 Contents INTRODUCTION 5 LOCATING THE COMPONENTS 6 INSTALLING THE CONTROL/DISPLAY PANEL 7 MOUNTING THE POWER LOGIC BOX 7 ROUTING CABLES 7 INSTALLING THE SUPPLY AIR DISTRIBUTION 8 PREPARING THE CHEB FOR INSTALLATION 10 INSTALLING THE CHEB 11 INSTALLING THE CONDENSER 13 ROUTING THE REFRIGERANT LINES AND CONDENSER POWER CABLE 14 MOUNTING THE ESPAR DIESEL-FIRED HEATER 15 ENGLISH 3

4 4 ENGLISH

5 INTRODUCTION This document contains supplemental guidelines for installing the Qt-series control and air distribution for the Dometic auxiliary air conditioning system on an International ProStar. It is intended to be used in conjunction with the standard installation manual, which covers all other aspects of installing, testing and operating this system. Please be creative in your installation, but keep functionality and safety in mind. Key issues are: evaporator discharge venting, evaporator return air, and condenser air flow. Other issues include: controls accessibility, condensate removal, and wire and hose chafe protection. Required Tools: Drill motor Hole saws: 1-5/8", 1-7/8", 2-1/2", 4" and 5-1/2" Drill bits: 1/8", 5/32", 9/32" Nut drivers: 1/4", 3/8", 15/16" Phillips head screwdriver Open-end wrenches: (2) 7/16", (1 each) 5/16", 13/16", 3/4" and 15/16" Torque wrench may also be required Do not attempt to install any components until you read and understand the instruction in both manuals. ENGLISH 5

6 LOCATING THE COMPONENTS The Dometic remote auxiliary air conditioning system consists of two basic components: an outside condensing unit, which contains the condenser and an exhaust fan, and an inside unit, which contains the compressor, heater, evaporator and blower (CHEB). The two units are connected by precharged refrigerant lines with quick-connect fittings. The CHEB should be installed only in the center portion of the bunk area, in front of the dividing wall (Fig. 1). The Dometic condenser may be installed either under or behind the sleeper (Figs. 2a-2b). If you plan to install on a truck that has full fairings, and the generator is installed under the fairings, it is recommended that the condenser be mounted on the rear of the truck. For rear cab mounting, order Part which contains the proper blind threaded fasteners. Figure 2a Condensing unit mounted under truck IMPORTANT! Refer to the Dometic installation manual for details on installing and connecting the CHEB and condensing unit. Figure 2b Condensing unit mounted on back of sleeper Figure 1 CHEB installed in center portion of luggage area 6 ENGLISH

7 INSTALLING THE CONTROL/DISPLAY PANEL Mount the control in such a location as to give the driver good access. The suggested location would be near the current HVAC controls; however, that may be very tough on this model. In this particular installation, we mounted the control on the driver s side cabinet, just below the slide-out drawer. Route the CXP cable through the cabinet, behind the wall and down into the bunk area. Route the CXP cable to the rear of the bunk for later connection. MOUNTING THE POWER LOGIC BOX The Power Logic Box (PLB) should be mounted under the rear, center portion of the bunk, toward the driver's side of center. Use four #8 x ½ self-tapping screws to mount the bracket to the bunk wall (Fig. 3). ROUTING CABLES The PLB box comes with several different types of cables: Wires enclosed in split loom Flexible power cables Phone type cables The wires in orange split loom will go toward the CHEB unit. The flexible power cord(s) will go toward the power distribution panel. The phone cable mounted on the CHEB unit plugs into the hole marked TSEP. The phone cable from the Control/Display plugs into the hole marked Display. We suggest placing the cables in the direction you wish them to go before mounting the box. It just makes things a little easier. All cables should be neatly routed and clipped to prevent chafing. IMPORTANT! Refer to the Dometic installation manual for details on routing and connecting cables from the Control/Display panel to the PLB and CHEB. Figure 3 PLB mounting location ENGLISH 7

8 INSTALLING THE SUPPLY AIR DISTRIBUTION For this installation, we will send most of the air through the factory ductwork. To make this work properly, we will install a flapper valve into the rear main duct (Figs. 4-5). To remove this duct, remove the screw at the rear wall and the one close to the trucks HVAC unit. In order to install the flapper valve, mark where the valve will fit once installed. Remove the rear main duct, and cut a hole in the duct large enough for the flapper to operate, while small enough for all the fasteners to catch (Fig. 6). Prepare the flapper valve by installing foam around the very edge of the flapper valve (Fig. 7). Install the flapper valve into the duct, while paying special attention to the direction of the flapper (Fig. 8). Mount using the #8 x ½ screws that are included with the kit (Figs. 9-10). Figure 5 Rear main duct marked where flapper valve will be installed Figure 4 Rear main duct (view from passenger's side luggage door) Figure 6 Rear main duct cut for installation of flapper valve 8 ENGLISH

9 Figure 7 Installing foam on flapper valve Figure 9 Flapper valve installed into rear main duct Figure 8 Ready to install the flapper valve into the rear main duct Figure 10 Rear main duct reinstalled into truck ENGLISH 9

10 PREPARING THE CHEB FOR INSTALLATION Before you install the CHEB into the truck, you need to make a couple of modifications. First remove the oval duct connector from the side of the unit (Fig. 11). Use a ¼" nut driver for this. Next, find the metal plenum provided in the kit which has an oval duct attachment. The plenum will be mounted on the side of the unit where you removed the plastic adapter. Use the provided self-tapping screws to mount the plenum (Fig. 12). Figure 11 Remove the oval adapter Figure 12 Install the new plenum on the side air discharge 10 ENGLISH

11 INSTALLING THE CHEB Install the CHEB in the center part of the truck, under the bunk. To make this work, you will have to remove the small, metal storage bins. Use a small grinder to cut off the Huck rivets. the holes (Fig. 14). You also need to drill a 5-1/2" hole in the rear wall for the duct to go from the CHEB to the flapper valve (Fig. 15). Locate the CHEB template. Place the template with the evaporator coil facing the front of the truck (Fig. 13). Place the template so that the measurement from the centerline of the drain connection to the rear wall of the space is 9". Then measure from the edge of the unit nearest the refrigerant connections to the driver s side bunk wall. Place the template so that the measurement is 5-¼". Mark for the two quick-connect holes 3-½" off the edge of the unit using the construction lines. Drill through the rubber mat with a 2-½" hole saw (DO NOT DRILL THROUGH THE METAL). Then drill through the metal with a 1-7/8" hole saw. Drill the drain hole with a 1-5/8" hole saw. Install the watertight grommets (grey) into the two 1-7/8" holes. Push in until they lock in the hole. Figure 14 Cut hole into rear wall for duct to access the flapper valve Use the edge of the unit line to situate one of the mounting brackets for hole marking. Be sure your bracket is located in an area noted by XXXXX, which gives locations available for mounting. Figure 15 Installing the power cables into the grommets Figure 13 Laying out the CHEB template Prior to installing the refrigerant lines though the grommets or installing the CHEB, you may want to run both the power cord and condenser power cable through Insert the CHEB unit into the truck. Make sure that the drain fitting is lined up with the hole. Install the brackets by using one ¼"-20 X 2-½" bolt (provided) and one small washer from the top. Secure underneath the truck with one large washer, and one nylok nut. Snug all bolts, to the point where the bracket just starts to bend, then stop. ENGLISH 11

12 INSTALLING THE CHEB Figure 16 Connecting the refrigerant lines Figure 17a Install the ductwork to the flapper valve Insert the refrigerant lines into their respective grommets (Fig. 16). Lightly lubricate one side of each coupling with light oil or refrigerant oil. Be sure to get the face and the threads. Hand tighten the quick-connects making sure they thread up correctly. Tighten with the correct wrenches (13/16", ¾", and 15/16"). Tighten to ft/lbs. If any hissing is heard during the tightening process, DO NOT STOP TIGHTENING. It is because the fittings are not quite aligned correctly. Keep tightening and the hissing will stop. Connect the TSEP (temperature sensor cord located on CHEB) to the PLB. Connect the electrical connectors between the CHEB and PLB (one in the orange split loom). Route and clip to prevent chafing. Figure 17b Ductwork to flapper valve Connect the ductwork to the CHEB, use the hose clamps to secure; use only as much duct as you have to, as extra duct will impede air flow. Avoid sharp bends where possible (Fig. 17a-17b). Use wide sweeps and long radii. Install the drain fitting into the bottom of the CHEB from the under side of the truck, finger tighten. Place the hose clamp over the end of the P-trap. Push the end of the P-trap over the drain fitting and tighten the clamp (Fig. 18). Figure 18 Installing the P-trap 12 ENGLISH

13 INSTALLING THE CONDENSER The Dometic condenser may be installed either under or behind the sleeper. These installations (and the parts in the kit) are for an installation underneath the sleeper. If you plan on mounting the generator and/or generator radiator underneath the sleeper fairings, we recommend mounting the HVAC condenser on the rear of the sleeper. You will need kit for a rear mount installation. The condenser mounts midline of the truck, just behind the transmission. The condenser adaptor is provided for ease of mounting the condenser. First, mount the condenser to the adaptor (Fig. 19a). Make sure that the refrigerant connections are facing toward the end with four holes in it, which in turn will face toward the rear of the truck. Find the hardware you will need to mount the adaptor: two #10 x 1" self-tappers and four ¼"-20, 1" bolts with washers and nuts. Figure 19b Hooking the adapter plate over the Z-channel Use the hooks provided on the adaptor to hook over the cab support Z-channel (Fig. 19b). At the other end of the adaptor, there are two small holes. Use the self-tappers to drill through these holes for the initial mounting of the adaptor. Once they are secure, use a ¼" drill bit to drill for the four ¼" bolts (Fig. 19c). Figure 19c Condenser adapter fastener detail Figure 19a Mounting the condenser adapter ENGLISH 13

14 ROUTING THE REFRIGERANT LINES AND CONDENSER POWER CABLE The refrigerant lines will pass over the Z-channels and then back around to the quick-connects. Connect the quick-connects in the manner described previously. Secure the refrigerant lines as shown, with the cushion clamps secured directly to the Z-channel (Fig. 20). Use cable ties to secure the refrigerant lines to each other and to the condenser power cable. After connecting the condenser power cable, secure the power cord in such a manner that the connections are pulled in a linear fashion, not to the side. Figure 20 Quick-connects and refrigerant lines secured 14 ENGLISH

15 MOUNTING THE ESPAR DIESEL-FIRED HEATER It is best to mount the Espar diesel-fired heater in a location that is protected so that items can not easily block the air flow or pile on top of the heater. A recommended location is the protected area in the front of the driver s side luggage box (Fig. 21). Figure 21 Espar diesel-fired heater mounted in front of driver's side luggage box ENGLISH 15

16 Dometic Corporation, Environmental Division P.O. Box I Richmond, VA USA I Fax I UNITED STATES & CANADA SERVICE ONLY Weekdays 8:00 am to 5:00 pm (Eastern Time) All other times ISO 9001:2000 L 2647 Rev For all other areas visit our website to find your nearest distributor.

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