USA SERVICE OFFICE Dometic Corporation 2320 Industrial Parkway Elkhart, IN 46516 574-294-2511 CANADA Dometic Corporation 46 Zatonski, Unit 3 Brantford, ON N3T 5L8 CANADA 519-720-9578 For Service Center Assistance Call: 800-544-4881 3310009.000 FORT CONTROL CENTER UPGRADE KIT REPLACEMENT INSTRUCTIONS CONVERSION OF 3106463.007 FORT CONTROL CENTER TO 3109228.001 FIVE BUTTON FORT CONTROL CENTER 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. SERVICE INSTRUCTIONS 3310009.000 UPGRADE KIT REVISION: Form No. 3310010.016 4/07 (Replaces 3310010.008) (French 3310011.014) 2007 Dometic Corporation LaGrange, IN 46761 1
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. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.! CAUTION Indicates a potentially hazardous situation which, if not avoided may result in minor or moderate injury. CAUTION! When used without the safety alert symbol indicates, a potentially hazardous situation which, if not avoided may result in property damage. Read and follow all safety information and instructions. 3310009.000 UPGRADE KIT INSTRUCTIONS GENERAL INSTRUCTIONS The 3310009.000 Upgrade Kit is designed specifically for all Duo Therm and Dometic Air Conditioner Models using the 4 button Comfort Control Center TM with the circuit board built into the electrical system. All field wiring modification should be made in compliance with the latest edition of ANSI/NFPA 70 NEC and ANSI A119.2 for recreational vehicles. These instructions must be read and understood before installation of this kit. This kit must be installed by a Dometic Service Center or a qualified service technician. Modification of this product can be extremely hazardous and could result in personal injury or property damage. Note: The Power Module Board is equipped with dip switches. Switches are in the OFF position when shipped. DO T turn switches ON unless instructed. Important: If more than one air conditioner/heat pump is installed on the coach; the systems in each unit must be upgraded with a 3109229.001 circuit board to match the 5 button CCC control supplied in this kit. Important: Keep Upgrade Instructions with air conditioner Owner s Manual for future reference. THE 3310009.000 UPGRADE KIT CONSISTS OF: Qty. Part Number Description (1) 3109229.009 CCC Power Module Board (1) 3109228.001 Comfort Control Center (1) 3108664.032 Operating Instructions, CCC (1) 3310010.008 Instructions, CCC Upgrade Kit (1) 3109409.001, Freeze Control PROCEDURE (A), A1-A5, pages 3-4, 620315 & 620325 Models (B), B1- B5 pages 5-6, 39224.602, 39424.602, 39524.601 & 39524.602 Models (C), C1-C6, pages 6, 42044.501, 42055.501, 42044.502 & 42055.502 2
(A) MODELS 620315 & 620325 A1. REMOVAL OF POWER MODULE BOARD Disconnect all power supplies and the positive (+) terminal from the supply battery. Failure to follow this instructions may create a shock hazard. 1. Turn OFF all 120 V AC and 12 V DC power. 2. Remove shroud, electric box and evaporator coil covers. 3. Unplug the RJ11-6C4P communication cable, red, white and blue sensor plugs and the 6 pin plug from the circuit board. 4. Disconnect the compressor, motor, heat strip and 120 VAC wire terminals off the circuit board.. 5. Remove dumdum putty sealing the opening for freeze control and save for resealing. 6. Release the circuit board from the mounting post and remove A2. INSTALLATION OF 5 BUTTON POWER MODULE BOARD 1. Place the new 5 button power module board on the 4 white post that held the original power module. 2. Connect the blue plug for the 3109409.001 freeze control sensor (supplied) onto the blue 2 pin plug of the new power module board. See FIG. 1. FIG. 1 Compressor or Blue T3, Motor T2, Motor Yellow T3 RED YELLOW T2 VIOLET T4 T1 BLACK K6 T5 NC Blue Furnace Thermostat K1 T1, Motor Gray Heater Yellow Load Shed s a. Remove the original freeze control. If the freeze control is in the 120 VAC wire to the compressor it must remain in the system. b. Route the loose sensor end of the freeze control through the bulk head and seal with the putty. SW1 P6 P5 P4 P3 120 VAC White F1 P2 P1 Blue RJ11-6C4P Cable Connections FIG. 2 3310009.000 UPGRADE KIT INSTRUCTIONS c. Insert the sensor portion of the freeze control into the evaporator coil 1 inch above the bottom right corner ( when facing rear of unit). d. Bend fins around new sensor to secure in position. Remove Hang Tag Do kdkd mfmf Freeze Control with wires. Bend fins over sensor to hold in place Freeze control sensor Insert Freeze Control at a slight angle between bottom coil approximately 1 3. the 6 connector wire harness plug onto the 6 pin connector on the board. 4. Connect the white sensor plug onto its color matching connector on the board. 5. Connect the 120 VAC black power wire to the terminal of the K6 relay. 6. Connect the or Blue Compressor wire to the terminal of the K6 relay. 7. Connect the motor wire to the T3 terminal of the power module board. 8. Connect the Yellow motor lead on the T2 terminal of the power module board. On heat pump models the reversing valve is connected to T2. 9. Connect the motor wire to the T1 terminal of the power module board. 10. Connect the gray heat strip wire to the terminal of the K1 relay. 11. Connect the RJ11-6C4P plugs on the communications cable into the either of the power module P1 or P2 sockets. Note: If more than one unit is controlled by the Comfort Control Center TM they must be converted to match to use the 3109229.009 circuit board. A3. CONFIGURATION OF THE POWER MODULE BOARD. Depending on the equipment options installed by the recreational vehicle manufacturer, the appropriate dip switches will need to be switched to the "ON" position. Placing the switch in the "ON" position selects that option. 3
FIG. 3 12 345 6 7 8 ON HEAT STRIP ZONE 2 ZONE 3 ZONE 4 FURNACE DIFFERENTIAL STAGE GEN START DIP SWITCHES Note: Dip switches are in the "OFF" position when shipped from the factory. 1. Zone selection - when two or more units are installed and controlled by one Comfort Control Center TM, the appropriate zone dip switch must be set in each electronic control box for the Zone 2, 3 and 4. See FIG. 3 2. Heat Strip selection - For units with a heat strip installed at the factory, the #1 dip switch will be in the "ON" position. All other models will have the dip switches in the "OFF" position. See FIG. 3. 3. Heat pump models must have the red plug of the outdoor ambient sensor plugged into the RED (P3) plug. See FIG. 3. 4. Furnace selection - when a furnace has been connected to a zone, place the furnace dip switch "ON" for that zone. See FIG. 3. 5. Differential - differential is the temperature difference between the "ON/OFF" cycle of the thermostat. The normal differential is preset in the circuit board with the dip switch set to the "OFF" position. In some situations, it may be necessary to decrease the Differential. The location of the thermostat may create a condition where the normal Differential will not maintain your comfort zone. If this occurs, the Differential can be shortened by placing the Differential dip switch in the "ON" position. Note: Setting the Differential dip switch should only be required when the installation conditions are less than desirable and is not covered under the limited warranty. 6. STAGE is not used on these units. Leave in the "OFF" position. 7. Gen start selection - leave in the "OFF" position. 8. Replace the unit electrical box cover. 9. Replace the shroud. 10. Repeat this procedure for each additional zone. A4. FORT CONTROL CENTER TM IN- STALLATION 1. Remove the old comfort control and its mounting plate from the wall. 2. Carefully remove the base plate from the Comfort Control Center TM. This may be accomplished by inserting a small screwdriver under the tab on the bottom edge of the front cover and gently prying. See FIG. 4. 4 FIG. 4 2. Insert the control cable through the hole in the base plate and mount the plate to the wall with two (2) screws provided. Check the alignment to ensure level installation. 3. Install the control cable RJ11-6C4P connector into the back of the Comfort Control Center and gently press onto the base plate. A5. SYSTEM RESET After setting the dip switches in the electric box, a system reset must be preformed. See FIG. 5. FIG. 5 MODE MODE FAN UP FAN UP DOWN ZONE DOWN ZONE TEMP OFF ON TEMP OFF ON Insert Screwdriver under Tab Mode Push-Button Fan Push-Button Up Push-Button Down Push-Button Zone Push-Button ON/OFF Switch 1. Turn on the AC and DC power supplies to the air conditioner. Turn the ON/OFF switch to the "OFF" position. 2. Simultaneously Depress and hold the MODE and ZONE push-buttons while turning the ON/OFF switch to "ON". FF should appear in the LCD display until the MODE and ZONE push-buttons are released. 3. When a dip switch is turned ON or OFF after initial configuration, a system reset will need to be done before the Comfort Control Center TM will recognize the updated selection.
(B) MODELS 39224.602, 39424.602, 39524.601 & 39524.602 B1 4. Verify that all features of the installed system work. See Comfort Control Center Operating Instructions. Check fan speeds, cooling mode, heat pump mode, furnace (if connected) and heat strip. If the features do not work, check all wiring and confirm that the correct options have been selected on the Electronic Control Board. REMOVAL OF CIRCUIT #1 POWER MODULE BOARD Disconnect all power supplies and the positive (+) terminal from the supply battery. Failure to follow this instructions may create a shock hazard. Important: The unit was designed with two circuit boards. Installation of this kit will require the removal of the second circuit board. 1. Turn OFF all 120 VAC and power. 2. Remove cover from the electric box to gain access to the circuit boards. Note: Depending on the location of the unit it may require removal of the unit from the coach. Models 39224 and 39424 used remotely located control boxes. Note: The dual basement air conditioner/heat pump uses two electrical circuits. The kit will convert the wire to the use of only one board. 3. Start with circuit board #1 and disconnect the 6 pin plug, ambient sensor (red plug), RJ11-6C4P communication cable plug and white remote sensor plug (if used). 4. Disconnect the 120 VAC power from the Terminal on the K6 relay, Mark wire to prevent mixup with compressor wire. 5 Disconnect the black compressor wire from the terminal on the K6 relay. 6. Disconnect the and motor wire. 7. Disconnect the violet wire from the reversing valve. 8. Remove circuit board off the stand off post. B2. REMOVAL OF CIRCUIT #2 POWER MODULE BOARD 1. Disconnect the 6 pin plug, and discard. 2. Remove and discard the RJ11-6C4P communication cable between circuit board #1 and circuit board #2. 3. Remove and discard the ambient sensor (39424 and 39524 models only). 5 4. Disconnect the Orange 120 VAC power from the Terminal on the K6 relay. Mark the wire to prevent mix-up with compressor wire. 5. Disconnect the Orange compressor wire from the terminal on the K6 relay. 6. Remove circuit board from the stand off post and discard. B3. INSTALLATION OF 3109229.009 POWER MODULE BOARD 1. Remove the jumper wire between the terminal on the K1 relay and T5 on the printed circuit board and discard. 2. Place the new power module board on the stand off posts from which the circuit board #1 was removed. 3. Connect the 6 pin plug onto the new circuit board. 4. Connect the plug on the ambient sensor (39424 and 39524 only) onto the color matching plug of the new circuit board. 5. Connect the RJ11-6C4P communication cable plug from the CCC Control into the new board. Note: The ambient sensor for circuit #2 in not used. 6. Place the 120 VAC power wire on the terminal of the K6 relay on the new 5 button power module board. See FIG. 6. FIG. 6 Compressor or Orange Motor Reversing Valve Violet Motor Remove Jumper T3 RED YELLOW T2 VIOLET T4 T5 T1 BLACK K6 NC K1 Compressor Orange Blue Furnace Thermostat SW1 Yellow Load Shed s P6 P5 P4 P3 120 VAC Or Orange F1 P2 P1 Blue White RJ11-6C4P Cable Connections 7. Connect the compressor wire on the terminal of the K6 relay on the new circuit board. Note: Make sure the 120 VAC wire and compressor wire are not reversed. 8. Connect the Orange 120 VAC power wire to the terminal of the K1 relay on the new circuit board. 9. Connect the Orange wire to the compressor onto the terminal of the K1 relay. 10. Connect the motor wire to T1 on the new circuit board.
11. Connect motor wire to T3 on the new circuit board. 12. Connect the Violet wire from the reversing valve to T4 (YELLOW) on the new circuit board. 13. Connect the ambient sensor into the matching 2 pin connector (red) on the new circuit board. 14. Turn the Stage (#7) dip switch ON. If furnace is controlled by the system turn the furnace dip (#5) switch ON. See FIG. 7. FIG. 7 Furnace Stage 12 345 6 7 8 B4. FORT CONTROL CENTER TM IN- STALLATION See A4. on page 4. B5. SYSTEM RESET See A5. on page 4. Disconnect all power supplies and the positive (+) terminal from the supply battery. Failure to follow this instructions may create a shock hazard. ON HEAT STRIP ZONE 2 ZONE 3 ZONE 4 FURNACE DIFFERENTIAL STAGE GEN START DIP SWITCHES (C) MODELS 42044.501, 42055.501, 42044.502 & 42055.502 C1. REMOVAL OF POWER MODULE BOARD 1. Turn OFF all 120 V AC and 12 V DC power. 2. Remove cover from the electric box to gain access to the circuit board. Note: Depending on the location of the unit it may require removal of the unit from the coach. 3. Disconnect the 6 pin plug, ambient sensor (red plug), RJ11-6C4P communication cable plug and white remote sensor plug (if used). 4. Disconnect the 120 VAC power and transformer wire from the Terminal on the K6 relay, Mark wire to prevent mix-up with compressor and condenser motor wire. 5 Disconnect the compressor and condenser motor wire from the terminal on the K6 relay. 6. Disconnect the wire from T3 and evaporator motor wires from T1 of the circuit board.. 6 7. Disconnect the wire from the reversing valve off the T2 terminal of the board. 8. Remove circuit board off the stand off post. C2. INSTALLATION OF POWER MODULE BOARD 1. Place the new power module board on the stand off posts from which the old board was removed. 2. Connect the 6 pin plug, ambient sensor (red plug), RJ11-6C4P communication cable plug and white remote sensor plug (if used). 3. Place the 120 VAC power and transformer wire on the terminal of the K6 relay on the new 5 button power module board. See FIG. 8. FIG. 8 Comp & Cndsr Mtr Evap Motor Reversing Valve Evap Motor T3 RED YELLOW T2 VIOLET T4 Blue Furnace Thermostat BLACK T1 T5 K6 NC K1 Yellow Load Shed s 120 VAC Line & Transformer 4. Connect the compressor wire on the terminal of the K6 relay on the new circuit board. Note: Make sure the 120 VAC wire and compressor wire are not reversed. 5. Connect the evaporator motor wire to T1 on the new circuit board. 6. Connect evaporator motor wire to T3 on the new circuit board. 7. Connect the black wire from the reversing valve to T2 on the new circuit board. 8. Connect the ambient sensor into the color matching 2 pin connector (red) on the new circuit board. Note: Make sure the transformer and 120 VAC wire are not reversed with the condenser motor and compressor wires. C5. FORT CONTROL CENTER TM IN- STALLATION See A4. on page 4. C6. SYSTEM RESET See A5. on page 4. SW1 P6 P5 P4 P3 F1 P2 P1 RJ11-6C4P Cable Connections White