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Owner`s Manual
TABLE OF CONTENTS Manufacturer Warranty……………………………………………………………………………………..1 Utility Trailer Owner’s Manual……………………………………………………………………….…..6 Tire Safety Information…………………………………………………………………………………….57 Wiring………………………………………………………………………………………………………………68 Propane Safety…………………………………………………………………………………………………70 ProWatt SW Sine Wave Inverter………………………………………………………………………71 Atwood Water Heater…………………………………………………………………………………….105 Atwood Cooktops…………………………………………………………………………………………..120 Water Pump…………………………………………………………………………………………………..133 Max Coupler…………………………………………………………………………………………………..137 Solar Charge Controller……………………………………………………….…………………………140 Page 2 of 145 Turtleback Trailers LLC 855-732-2383 1424 E. Broadway Rd Phoenix AZ 85040 [email protected] — www.turtlebacktrailers.com Manufacturer Warranty THE WARRANTY BEGINS The warranty period begins on the date the vehicle is delivered to the first retail buyer or put into use, whichever is earlier. FOR HOW LONG AND WHAT IS COVERED BASIC COVERAGE The basic coverage period is 12 months. This warranty covers any repairs needed to correct defects in materials or workmanship of all parts and components of each new Turtleback Trailers LLC (Turtleback Trailers) vehicle supplied by Turtleback Trailers subject to the exclusions listed under the heading “WHAT IS NOT COVERED” WHAT IS COVERED - NO CHARGE Warranty repairs will be made at no charge for parts and/or labor except for tires. Any needed parts replacement will be made using Genuine Turtleback Trailers or Turtleback Trailers approved new or remanufactured parts. Turtleback Trailers reserves the right to make changes at any time, without notice, to production and service parts in their specifications, colors, and materials, including those used in connection with warranty repairs. For this reason, when approved by Turtleback Trailers and at Turtleback Trailers ’s discretion, functionally equivalent replacement parts may be used that do not exactly match the original production part. OBTAINING WARRANTY SERVICE You must take the vehicle to the authorized Turtleback Trailers dealer in Phoenix Arizona during regular business hours at your expense in order to obtain warranty service. If you require warranty service in another location other than Turtleback Trailers Phoenix location contact Turtleback Trailers for authorization prior to repairs. Page 3 of 145 MAINTENANCE, DATA ACCESS, AND RECORDS As a condition of this warranty, you are responsible for properly using, maintaining and caring for your vehicle as outlined in your OWNER’S MANUAL and your Turtleback Trailers SERVICE & MAINTENANCE GUIDE, and maintaining copies of all maintenance records & receipts for review by Turtleback Trailers . Evidence of the performance of the required maintenance should be kept and presented as proof of such maintenance in connection with related warranty repairs. To assist you in maintaining appropriate records, the maintenance log located in your Turtleback Trailers SERVICE & MAINTENANCE GUIDE can be used along with supporting repair invoices, receipts and other such records. WHAT IS NOT COVERED - GENERAL EXCLUSIONS This warranty does not cover damage, failures or corrosion resulting from or caused by: Failure to operate the vehicle in accordance with the OWNER’S MANUAL. Misuse Failure of a component not covered by warranty Racing and competitive driving Theft, vandalism, fire, or flooding (including engine water ingestion) Accident, collision, abuse Repairs performed by anyone other than an authorized Turtleback Trailers Commercial Vehicle certified dealer Normal wear and tear, including dings, dents, chips, or scratches Damage caused by any automated or manually operated car wash or by using a pressure washer DAMAGE OR FAILURES DUE TO ALTERATION OR MODIFICATION This warranty does not cover damage, failures or corrosion resulting from or caused by: Alteration, tampering, or improper repair. Installation of non-Turtleback Trailers approved accessories or components. Improper installation of any Turtleback Trailers approved aftermarket accessory or component. Page 4 of 145 SALVAGE TITLE This limited warranty does not apply to any vehicle, and is rendered VOID if the vehicle is (or ever has been) issued a “salvage” or similar title including, but not limited to junk, scrap, rebuilt, or flood titles under any state’s law; or has ever been determined to be a “total loss” or equivalent by any insurance company, such as by payment of a cash payment of claim in lieu of repairs because of a determination that the cost of repairs exceeded the actual cash value of the vehicle. DAMAGE, FAILURES OR CORROSION FROM ENVIRONMENTAL CONDITIONS This warranty does not cover damage, failures or corrosion resulting from or caused by: Stone chipping, chemical fallout (acid rain), tree sap, salt,hail,windstorm,lightning, flood or other environmental conditions. MAINTENANCE SERVICE EXPENSE This warranty does not cover normal maintenance services as specified in your Turtleback Trailers SERVICE & MAINTENANCE GUIDE such as cleaning and polishing; wheel alignment; lubricants, worn brake shoes, drums. Page 5 of 145 Utility Trailer Owner’s Manual ^ WARNING This Owner’s Manual contains safety information and instructions for your trailer. You must read this manual before loading or towing your trailer. You must follow all safety precautions and instructions. Turtleback Trailers, LLC 1424 E Broadway Road Phoenix, AZ 85040 Bumper Pull Trailers November 2013 1 Page 6 of 145 Contents 1. INTRODUCTION ............................................................................................ 5 2. SAFETY .................................................................................................... 6 2.1 Safety Alert Symbols And Signal Words .......................................................6 2.2 Major Hazards ...................................................................................................6 2.2.1 IMPROPER SIZING OF TRAILER TO TOW VEHICLE..................................................................... 6 2.2.2 DRIVING TOO FAST ............................................................................................................. 6 2.2.3 ADJUST DRIVING WHEN TOWING TRAILER .............................................................................. 7 2.2.4 TRAILER NOT PROPERLY COUPLED TO HITCH ......................................................................... 7 2.2.5 PROPER USE OF SAFETY CHAINS ......................................................................................... 8 2.2.6 PROPER CONNECTION OF BREAKAWAY BRAKE ........................................................................ 8 2.2.7 MATCHING TRAILER AND HITCH ............................................................................................ 8 2.2.8 WORN TIRES, LOOSE WHEELS AND LUG NUTS ....................................................................... 8 2.2.9 IMPROPER LOADING ............................................................................................................ 9 2.2.10 UNSAFE LOAD DISTRIBUTION ............................................................................................ 10 2.2.11 SHIFTING CARGO ............................................................................................................ 10 2.2.12 INAPPROPRIATE CARGO ................................................................................................... 10 2.2.13 INOPERABLE BRAKES OR LIGHTS .......................................................................................11 2.2.14 TRAILER MODIFICATIONS ...................................................................................................11 2.2.15 TRAILER TOWING GUIDE ...................................................................................................11 2.2.16 SAFE TRAILER TOWING GUIDELINES .................................................................................. 12 2.2.17 SAFETY WARNING LABELS ON YOUR TRAILER .................................................................... 13 2.2.18 REPORTING SAFETY DEFECTS ........................................................................................... 16 3. TIRE SAFETY INFORMATION......................................................................... 17 3.1 Trailer Tire Information ..................................................................................17 3.2 Steps For Determining Correct Load Limit - Trailer ...................................18 3.2.1 TRAILERS 10,000 POUNDS GVWR OR LESS ...................................................................... 18 3.2.2 TRAILERS OVER 10,000 POUNDS GVWR .......................................................................... 18 3.3 Steps For Determining Correct Load Limit - Tow Vehicle ..........................19 3.4 Glossary Of Tire Terminology.......................................................................19 3.5 Tire Safety - Everything Rides On It .............................................................21 3.5.1 SAFETY FIRST- BASIC TIRE MAINTENANCE ........................................................................... 22 3.5.2 FINDING YOUR VEHICLE’S RECOMMENDED TIRE PRESSURE AND LOAD LIMITS............................ 22 3.5.3 UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS .............................................................. 22 3.5.4 SAFETY FIRST- BASIC TIRE MAINTENANCE ........................................................................... 22 3.5.5 STEPS FOR MAINTAINING PROPER TIRE PRESSURE ................................................................ 22 3.5.6 TIRE SIZE ........................................................................................................................ 23 3.5.7 TIRE TREAD ..................................................................................................................... 23 3.5.8 TIRE BALANCE AND WHEEL ALIGNMENT .............................................................................. 23 3.5.9 TIRE REPAIR .................................................................................................................... 23 3.5.10 TIRE FUNDAMENTALS ....................................................................................................... 23 3.5.10.1 INFORMATION ON PASSENGER VEHICLE TIRES ............................................................. 23 3.5.10.2 UTQGS Information ...................................................................................................... 24 3.5.10.3 Additional Information On Light Truck Tires ............................................................. 24 3.5.10.4 Tire Safety Tips ............................................................................................................. 25 Page 7 of 145 Contents 4. COUPLING TO TOW VEHICLE ...................................................................... 26 4.1 Tow Vehicle And Hitch ...................................................................................26 4.1.1 TRAILER INFORMATION ....................................................................................................... 26 4.1.2 TOW VEHICLE................................................................................................................... 26 4.2 Coupling And Uncoupling The Trailer .........................................................26 4.3 Couple Trailer To Tow Vehicle ......................................................................27 4.3.1 BALL HITCH COUPLER ....................................................................................................... 27 4.3.1.1 BEFORE COUPLING TRAILER TO TOW VEHICLE ............................................................. 28 4.3.1.2 PREPARE COUPLER AND HITCH .................................................................................. 28 4.3.1.3 COUPLE TRAILER TO TOW VEHICLE ............................................................................ 28 4.3.2 TRAILER WITH RING AND PINTLE COUPLER ......................................................................... 29 4.3.2.1 BEFORE COUPLING TRAILER TO TOW VEHICLE ............................................................. 29 4.3.2.2 PREPARE RING AND PINTLE ....................................................................................... 29 4.3.2.3 COUPLE TRAILER TO TOW VEHICLE ............................................................................ 30 4.3.3 CONNECT SAFETY CHAINS ................................................................................................. 30 4.3.4 CONNECT ELECTRICAL CABLE ............................................................................................ 31 4.3.5 ATTACH BREAKAWAY BRAKE LANYARD................................................................................. 31 4.3.5.1 TEST ELECTRIC BRAKES ........................................................................................... 31 4.3.5.2 TEST ELECTRIC BREAKAWAY BRAKES.......................................................................... 31 4.3.5.3 TEST SURGE BRAKES (IF EQUIPPED) .......................................................................... 32 4.3.5.4 TEST SURGE BREAKAWAY SYSTEM.............................................................................. 33 4.4 Uncouple Trailer .............................................................................................33 4.5 Tongue Weight ...............................................................................................33 4.5.1 CHECKING TONGUE WEIGHT ............................................................................................... 34 4.6 Adjust Hitch Height (If Equipped) .................................................................34 5. LOADING AND UNLOADING ......................................................................... 36 5.1 Loading Trailer ...............................................................................................36 5.1.1 PREPARING TRAILER FOR LOADING ...................................................................................... 36 5.1.2 LOADING A RIGID DECK TRAILER ........................................................................................ 36 5.1.3 LOADING A TILT DECK TRAILER .......................................................................................... 37 5.1.3.1 MANUAL TILT TRAILER .............................................................................................. 37 5.1.3.2 HYDRAULIC TILT TRAILER .......................................................................................... 38 5.2 Unload Trailer .................................................................................................38 5.2.1 UNLOAD MANUAL TILT TRAILER .......................................................................................... 38 5.2.2 UNLOAD HYDRAULIC TILT TRAILER ...................................................................................... 38 5.3 Hydraulic Components .................................................................................39 5.4 Securing Cargo ..............................................................................................39 6. PRE-TOW CHECKLIST ................................................................................ 40 6.1 Pre-Tow Checklist ..........................................................................................40 6.2 Make Regular Stops ......................................................................................40 Page 8 of 145 7. BREAKING IN A NEW TRAILER .................................................................... 41 7.1 Retighten Lugs At First 10, 25 & 50 Miles....................................................41 7.2 Adjust Brake At First 200 Miles ....................................................................41 7.3 Synchronizing Brake Systems .....................................................................41 8. ACCESSORIES........................................................................................... 42 8.1 Accessory Battery .........................................................................................42 9. INSPECTION, SERVICE AND MAINTENANCE .................................................... 43 9.1 Inspection, Service & Maintenance Summary Charts ................................43 9.2 Inspection And Service Instructions............................................................46 9.2.1 TRAILER STRUCTURE ......................................................................................................... 46 9.2.1.1 FASTENERS AND FRAME MEMBERS ............................................................................. 46 9.2.1.2 WELDS ................................................................................................................... 46 9.2.2 TRAILER BRAKES - ELECTRIC ............................................................................................. 46 9.2.2.1 BRAKE DISCS, SHOES AND DRUMS ............................................................................ 46 9.2.2.2 MANUALLY ADJUSTING BRAKE SHOES ......................................................................... 47 9.2.2.3 ELECTRIC BRAKES.................................................................................................... 47 9.2.2.4 TOW VEHICLE OPERATED ELECTRIC BRAKES ................................................................ 47 9.2.2.5 ELECTRIC BRAKE MAGNETS ....................................................................................... 47 9.2.3 TRAILER BRAKES - SURGE (IF EQUIPPED) ............................................................................ 47 9.2.3.1 SURGE BRAKE MASTER CYLINDER .............................................................................. 47 9.2.3.2 HYDRAULIC SURGE BRAKE ........................................................................................ 48 9.2.3.3 MASTER CYLINDER BLEEDING .................................................................................... 48 9.2.4 TRAILER CONNECTION TO TOW VEHICLE .............................................................................. 48 9.2.4.1 COUPLER AND BALL................................................................................................. 48 9.2.4.2 RING AND PINTLE .................................................................................................... 49 9.2.5 LANDING LEG OR JACK ..................................................................................................... 49 9.2.6 LIGHTS AND SIGNALS ........................................................................................................ 49 9.2.7 WHEEL RIMS.................................................................................................................... 49 9.2.8 TIRES .............................................................................................................................. 49 9.2.9 WHEEL BEARINGS............................................................................................................. 50 9.2.10 LUBRICATION .................................................................................................................. 50 9.2.11 HYDRAULIC RESERVOIR .................................................................................................... 50 9.2.12 LUG NUTS OR BOLTS ..................................................................................................... 50 Page 9 of 145 Introduction 1. INTRODUCTION Congratulations on the purchase of your trailer. We believe you will be happy and completely satisfied with your purchase. Our goal is to provide a valued customer a quality trailer at a reasonable price. For your safety, read and understand this manual before operating your trailer. If there are any questions about information in this manual, please consult your dealer. When calling about your trailer, please have the VIN number available for the dealer. The VIN number is normally on the front left side of the trailer. For future reference, please write your VIN number in the space below: ___________________________________________ This manual covers the basic trailer. You must read, understand and follow the instructions given by the trailer manufacturer, tow vehicle and trailer hitch manufacturers. Keep all manuals provided with your trailer in a safe place at all times. Inserts providing information on axles and tire warranty are provided with this manual. Please keep these inserts for future reference. Page 10 of 145 Safety 2. SAFETY NOTICE 2.1 SAFETY ALERT SYMBOLS AND SIGNAL WORDS An Owner’s Manual that provides general trailer information cannot cover all of the specific details necessary for the proper combination of every trailer, tow vehicle and hitch. You must read, understand and follow the instructions given by the tow vehicle and trailer hitch manufacturers, as well as the instructions in this manual. Our trailers are built with components produced by various manufacturers. Some of these items have separate instruction manuals. Where this manual indicates that you should read another manual, and you do not have that manual, contact your dealer for assistance. The safety information in this manual is denoted by the safety alert symbol: ^ This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The level of risk is indicated by the following signal words: ^ DANGER DANGER - Indicates a hazardous situation, which, if not avoided, WILL result in death or serious injury. ^ WARNING WARNING - Indicates a hazardous situation, which, if not avoided, could result in death or serious injury. ^ CAUTION CAUTION - Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury. NOTICE - Indicates a situation that could result in damage to the equipment or other property. 2.2 MAJOR HAZARDS Loss of control of the trailer or trailer/tow vehicle combination can result in death or serious injury. The most common causes for loss of control of the trailer are: • Improper sizing the trailer for the tow vehicle, or vice versa. • Excessive Speed: Driving too fast for the conditions. • Improper braking and steering under sway conditions • Overloading and/or improper weight distribution. • Not keeping lug nuts tight. • Failure to adjust driving behavior when towing a trailer. • Not maintaining proper tire pressure • Improper or mis-coupling of the trailer to the hitch. 2.2.1 IMPROPER SIZING OF TRAILER TO TOW VEHICLE Trailers that weigh too much for the tow vehicle can cause stability problems, which can lead to death or serious injury. The additional strain put on the engine and drive-train may lead to serious tow vehicle maintenance problems. Do not exceed the maximum towing capacity of your tow vehicle. The towing capacity of your tow vehicle, in terms of maximum Gross Trailer Weight (GTW) and maximum Gross Combined Weight Rating (GCWR) can be found in the tow vehicle Owner’s Manual. ^ DANGER Use of an under-rated hitch, ball or tow vehicle can result in loss of control leading to death or serious injury. Make certain your hitch and tow vehicle are rated for your trailer. 2.2.2 DRIVING TOO FAST With ideal road conditions, the maximum recommended speed for safely towing a trailer is 55 mph. Driving too fast can cause the trailer to sway, thus increasing Page 11 of 145 Safety the possibility for loss of control. Also your tires may overheat, increasing the possibility of a blowout. ^ WARNING Driving too fast for conditions can result in loss of control and cause death or serious injury. Adjust speed down when towing trailer. 2.2.4 TRAILER NOT PROPERLY COUPLED TO HITCH It is critical that the trailer be securely coupled to the hitch, and that the safety chains and emergency breakaway brake lanyard are correctly attached. Uncoupling may result in death or serious injury to you and to others. ^ WARNING 2.2.3 ADJUST DRIVING WHEN TOWING TRAILER Proper selection and condition of the coupler and hitch are essential to safely towing a trailer. When towing a trailer, you will have decreased acceleration, increased stopping distance, and increased turning radius. A loss of coupling may result in death or serious injury. The trailer will change the handling characteristics of the tow vehicle, making it more sensitive to steering inputs and more likely to be pushed around in windy conditions or when being passed by large vehicles. In addition, you will need a longer distance to pass, due to slower acceleration and increased length. With this in mind: • When encountering trailer sway, take your foot off the accelerator, and steer as little as possible in order to stay on the road. Use small “trim-like” steering adjustments. Do not attempt to steer out of the sway; you’ll only make it worse. Also do not apply the tow vehicle brakes to correct trailer swaying. On the other hand, application of the trailer brakes alone will tend to straighten out the combination, especially when going downhill. • Check rearview mirrors frequently to observe trailer and traffic. • Be aware of trailer height, especially when approaching bridges, roofed areas and trees. • Be alert for slippery conditions. You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer, than driving a tow vehicle without a trailer. • Anticipate the trailer “swaying.” Swaying can be caused by excessive steering, wind gusts, roadway edges, or by the trailer reaction to the pressure wave created by passing trucks and busses. • Use lower gear when driving down steep or long grades. Use the engine and transmission as a brake. Do not ride the brakes, as they can overheat and become ineffective. Hitch size must match coupler size. Be sure hitch load rating is equal to or greater than load rating of the coupler. Be sure hitch components are tight before coupling trailer to tow vehicle. Observe hitch for wear, corrosion and cracks before coupling. Replace worn, corroded or cracked hitch components before coupling trailer to tow vehicle. ^ WARNING An improperly coupled trailer can result in death or serious injury. Do not move the trailer until: • • • • • • • • Coupler is secured and locked to hitch. Safety chains are secured to tow vehicle. Trailer jack(s) are fully retracted. Trailer brakes are checked. Tires and wheels are checked. Breakaway switch is connected to tow vehicle; The trailer lights are connected and checked. Load is secured to trailer. Page 12 of 145 Safety 2.2.5 PROPER USE OF SAFETY CHAINS Safety chains are provided so that control of the trailer can be maintained if your trailer comes loose from the hitch. ^ WARNING 2.2.7 MATCHING TRAILER AND HITCH ^ DANGER Be sure hitch and tow vehicle are rated for the Gross Vehicle Weight Rating (GVWR) of your trailer. Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle, leading to death or serious injury, if the trailer uncouples from the tow vehicle. Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to death or serious injury. Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up, if the trailer comes loose. Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control, and may lead to death or serious injury. Fasten chains to frame of tow vehicle. 2.2.8 WORN TIRES, LOOSE WHEELS AND LUG NUTS Do not fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose. Inspect all trailer tires before each tow. If a tire has a bald spot, bulge, cut, cracks, or is showing any cords, replace the tire before towing. 2.2.6 PROPER CONNECTION OF BREAKAWAY BRAKE If equipped with brakes, your trailer will be equipped with a breakaway brake system that can apply the brakes on your trailer if your trailer comes loose from the hitch. You may have a separate set of instructions for the breakaway brake if the trailer is so equipped. The breakaway brake system, including battery, must be in good condition and properly rigged to be effective. ^ WARNING An ineffective or inoperative breakaway brake system can result in a runaway trailer, leading to death or serious injury if the coupler or hitch fails. Breakaway lanyard must be connected to the tow vehicle, NOT to any part of the hitch. If a tire has uneven tread wear, take the trailer to a trailer service center for diagnosis. Uneven tread wear can be caused by tire imbalance, axle misalignment or incorrect inflation. Tires with too little tread will not provide adequate frictional forces on wet roadways and can result in loss of control, leading to death or serious injury. Improper tire pressure causes increased tire wear and may reduce trailer stability, which can result in a tire blowout or possible loss of control. Therefore, before each tow you must also check the tire pressure. The proper tire pressure is listed on the Certification / VIN label, normally mounted on the front left side of the trailer, and should be checked when tires are cold. Allow 3 hours cool-down after driving as much as 1 mile at 40 mph before checking tire pressure. Before towing trailer, test the function of the breakaway brake system. If the breakaway brake system is not working, do not tow the trailer. Have it serviced or repaired. Page 13 of 145 Safety ^ WARNING Inflate tires to pressure stated on the Certification / VIN label. Improper tire pressure may cause unstable trailer. Blowout and loss of control may occur. Death or serious injury can result. Make sure of proper tire pressure before towing trailer. The tightness of the wheel nuts or bolts is very important in keeping the wheels properly seated to the hub. Before each tow, check to make sure they are tight. ^ WARNING Metal creep between the wheel rim and wheel nuts or bolts may cause rim to loosen. Death or injury can occur if wheel comes off. Tighten lug nuts or bolts before each tow. The proper tightness (torque) for wheel nuts or bolts and tightening sequence is listed in the Inspection, Service and Maintenance section of this manual. Use a torque wrench to tighten the lug nuts and use the crisscross star pattern sequence. Improper tightening of the lug nuts voids the axle warranty. Wheel nuts or bolts are also prone to loosen after first being assembled. When driving a new trailer (or after wheels have been remounted), check to make sure they are tight after the first 10, 25 and 50 miles of driving and before each tow thereafter. Failure to perform this check can result in a wheel separating from the trailer and a crash, leading to death or serious injury. ^ WARNING Wheel nuts or bolts are prone to loosen after being first assembled. Death or serious injury can result. Check wheel nuts or bolts for tightness on a new trailer, and after re-mounting a wheel at 10, 25 and 50 miles. ^ WARNING Inadequate wheel nut or bolt torque can cause a wheel to separate from the trailer, leading to death or serious injury. Verify wheel nuts or bolts are tight before each tow. 2.2.9 IMPROPER LOADING The total weight of the load you put on the trailer, plus the empty weight of the trailer itself, must not exceed the trailer’s Gross Vehicle Weight Rating (GVWR). If you do not know the empty weight of the trailer plus the cargo weight, you must weigh the loaded trailer at a commercial scale. In addition, you must distribute the load in the trailer such that the load on any axle does not exceed the Gross Axle Weight Rating (GAWR). If your trailer is equipped with a Tire & Loading Information Placard, mounted next to the Certification / VIN label, the cargo capacity weight stated on that placard is only a close estimate. The GVWR and GAWR are listed on the Certification / VIN label normally located on the front left side of the trailer. ^ WARNING An overloaded trailer can result in failure or loss of control of the trailer, leading to death or serious injury. Never load a trailer so that the weight on any tire exceeds its rating. Never exceed the trailer Gross Vehicle Weight Rating (GVWR) or axle Gross Axle Weight Rating (GAWR). Page 14 of 145 Safety 2.2.10 UNSAFE LOAD DISTRIBUTION Improper front / rear load distribution can lead to an unstable trailer or poor tow vehicle handling. Poor trailer stability results from tongue weights that are too low, and poor tow vehicle stability results from tongue weights that are too high. Refer to the “Loading And Unloading” section for more information. In the following table, the second column shows the rule of thumb percentage of total weight of the trailer plus its cargo (Gross Trailer Weight, or “GTW”) that should appear on the tongue of the trailer. For example, a large trailer with a loaded weight of 6,000 pounds, should have 10-15% of 6,000 pounds (600-900 lbs.) on the hitch. Tongue Weight as a Percentage of Loaded Trailer Weight Type of Hitch Percentage Ball Hitch or 10-15% for large trailers Ring & Pintle 6-10% for small trailers The numbers quoted are for example purposes only and should be tailored to the specific trailer. For questions regarding the actual percent of tongue weight for the trailer, check with the manufacturer for specifics. After loading, be sure to check that none of the axles are overloaded. Uneven left / right load distribution can cause tire, wheel, axle or structural failure. Be sure your trailer is evenly loaded left / right. Towing stability also depends on keeping the center of gravity as low as possible. ^ WARNING Improper tongue weight (load distribution) can result in loss of control of the trailer, leading to death or serious injury. Make certain that tongue weight is within the allowable range. Be sure to: • Distribute the load evenly, right and left. • Keep the center of gravity low. • Distribute the load front-to-rear to provide proper tongue weight (see chart). 2.2.11 SHIFTING CARGO Since the trailer “ride” can be bumpy and rough, you must secure the cargo so that it does not shift while the trailer is being towed. ^ WARNING A shifting load can result in failure, or to loss of control of the trailer, and can lead to death or serious injury. You must tie down all loads with proper sized fasteners, chains, straps, etc. to prevent the load from shifting while towing. 2.2.12 INAPPROPRIATE CARGO The trailer may be designed for specific cargo. If your trailer is designed for specific cargo, only carry that cargo in the trailer. A trailer must not be used to carry certain items, such as people, containers of hazardous substances or containers of flammable substances. ^ WARNING Do not transport people on your trailer. Besides putting their lives at risk, the transport of people on a trailer is illegal. Page 15 of 145 Safety ^ WARNING 2.2.14 TRAILER MODIFICATIONS Do not transport flammable, explosive, poisonous or other dangerous materials on your trailer. Modification of the trailer structure or alteration of your trailer can make the trailer unsafe and will void all warranty options. Before making any alteration to the trailer, contact your dealer or the manufacturer and describe the alteration you are contemplating. The exception is fuel in the tank of a vehicle or equipment being hauled. 2.2.15 TRAILER TOWING GUIDE If your trailer has electric brakes, your tow vehicle will have an electric brake controller that sends power to the trailer brakes. Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow. Acceleration, maneuverability and braking are all diminished with a trailer in tow. It takes longer to get up to speed; you need more room to turn and pass, and more distance to stop when towing a trailer. Before towing the trailer, you must operate the brake controller while trying to pull the trailer in order to confirm that the electric brakes operate. While towing the trailer at less than 5 mph, manually operate the electric brake controller in the tow vehicle cab. You should feel the operation of the trailer brakes. You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer. Because of the significant differences in all aspects of maneuverability when towing a trailer, the hazards and risks of injury are also much greater than when driving without a trailer. If your trailer has hydraulic “surge” brakes, pull the emergency breakaway brake lanyard to check the operation of the surge mechanism. You are responsible for keeping your vehicle and trailer in control, and for all the damage that is caused if you lose control of your vehicle and trailer. Be sure that the electric brakes and all of the lights on your trailer are functioning properly before towing the trailer. Electric brakes and lights on a trailer are controlled via a connection to the tow vehicle, generally a multi-pin electrical connector. Find an open area with little or no traffic for your first practice. Before you start towing the trailer, you must follow all of the instructions for inspection, testing, loading and coupling. Also, before you start towing, adjust the mirrors so you can see the trailer as well as the area to the rear of it. 2.2.13 INOPERABLE BRAKES OR LIGHTS ^ WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes, and can lead to collision. Before each tow: • Check that the electric brakes work by operating the brake controller inside the tow vehicle. • Check that all lights and turn signals work. You must provide mirrors that allow you to safely observe approaching traffic. Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear a towed trailer. Drive slowly at first, 5 mph or so, and turn the wheel to get the feel of how the tow vehicle and trailer combination responds. Next, make some right and left hand turns. Watch in your side mirrors to see how the trailer follows the tow vehicle. Turning with a trailer attached requires more room. Stop the rig a few times from speeds no greater than 10 mph. If your trailer is equipped with brakes, try using different combinations of trailer/electric brake and tow vehicle brake. Note the effect that the trailer brakes have when they are the only brakes used. When properly adjusted, the trailer brakes will come on just before the tow vehicle brakes. It will take practice to learn how to back up a tow vehicle with a trailer attached. Take it slow. Before backing up, get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles. Page 16 of 145 Safety Some drivers place their hands at the bottom of the steering wheel, and while the tow vehicle is in reverse, “think” of the hands as being on the top of the wheel. When the hands move to the right (counter-clockwise, as you would do to turn the tow vehicle to the left when moving forward), the rear of the trailer moves to the right. Conversely, rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left, while backing up. Be careful not to allow the trailer to turn too much, because it will hit the rear of the tow vehicle. To straighten the rig, either pull forward, or turn the steering wheel in the opposite direction. • • The tires are not visibly low on pressure. The cargo is secure and in good condition. Slow down for bumps in the road. Do not brake while in a curve unless absolutely necessary. Instead, slow down before you enter the curve. Do not drive so fast that the trailer begins to sway due to speed. Generally never drive faster than 55 m.p.h. Allow plenty of room for passing. A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without a trailer. 2.2.16 SAFE TRAILER TOWING GUIDELINES Before towing, check coupling, safety chain, brakes, tires, wheels and lights. Check the lug nuts or bolts for tightness. Recheck the load tie downs to make sure the load will not shift during towing. Check coupler tightness after towing 50 miles. Adjust the brake controller to engage the trailer brakes before the tow vehicle brakes. Follow the brake controller manufacturer’s literature. Use your mirrors to verify that you have room to change lanes or pull into traffic. Use your turn signals well in advance. Allow plenty of stopping space for your trailer and tow vehicle. Use lower gears for climbing and descending grades. Do not ride the brakes while descending grades; they may get so hot that they stop working. Then you will potentially have a runaway tow vehicle and trailer. Do not apply the tow vehicle brakes to correct extreme trailer swaying. Instead, lightly apply the trailer brakes with the hand controller. Make regular stops, about once each hour. Confirm that: • The coupler is secure to the hitch and is locked. • Electrical connectors are made. • There is appropriate slack in safety chains. • There is appropriate slack in breakaway lanyard. Page 17 of 145 Safety 2.2.17 SAFETY WARNING LABELS ON YOUR TRAILER Depending on trailer configuration, your trailer may not be equipped with all safety labels shown. Page 18 of 145 Safety Page 19 of 145 Safety ^ WARNING To protect you and others against death or serious injury, all applicable labels shown must be on the trailer and must be legible. If any of these labels are missing or cannot be read, contact your dealer for replacement labels. Page 20 of 145 Safety 2.2.18 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Turtleback Trailers, LLC 1424 E Broadway Road Phoenix, AZ 85040 If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Turtleback Trailers, LLC 1424 E Broadway Road Phoenix, AZ 85040 To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-4249153); or go to http://www.safercar.gov; or write to: Administrator, NHTSA, 1200 New Jersey SE, Washington, DC 20590. You can also obtain other information about motor vehicle safety from http://www.safercar.gov. Page 21 of 145 Tire Safety 3. TIRE SAFETY INFORMATION 3.1 TRAILER TIRE INFORMATION This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6. Trailer tires may be worn out even though they still have plenty of tread left. This is because trailer tires have to carry a lot of weight all the time, even when not in use. Section 3.1 contains “Trailer Tire Information”. Section 3.2 contains “Steps for Determining Correct Load Limit - Trailer”. Section 3.3 contains “Steps for Determining Correct Load Limit – Tow Vehicle”. Section 3.4 contains a Glossary of Tire Terminology, including “cold inflation pressure”, “maximum inflation pressure”, “recommended inflation pressure”, and other non-technical terms. Section 3.5 contains information from the NHTSA brochure entitled “Tire Safety – Everything Rides On It”. This brochure, as well as preceding subsections, describes the following items; • Tire labeling, including a description and explanation of each marking on the tires, and information about the DOT Tire Identification Number (TIN). • Recommended tire inflation pressure, including a description and explanation of: A. Cold inflation pressure. B. Vehicle Placard and location on the vehicle. C. Adverse safety consequences of under inflation (including tire failure). D. Measuring and adjusting air pressure for proper inflation. • Tire Care, including maintenance and safety practices. • Vehicle load limits, including a description and explanation of the following items: A. Locating and understanding the load limit information, total load capacity, and cargo capacity. B. Calculating total and cargo capacities with varying seating configurations including quantitative examples showing / illustrating how the vehicles cargo and luggage capacity decreases as combined number and size of occupants’ increases. This item is also discussed in Section 3. C. Determining compatibility of tire and vehicle load capabilities. D. Adverse safety consequences of overloading on handling and stopping on tires. It is actually better for the tire to be rolling down the road than to be idle. During use, the tire releases lubricants that are beneficial to tire life. Using the trailer tires often also helps prevent flat spots from developing. The main cause of tire failure is improper inflation. Check the cold tire inflation pressures at least once a week for proper inflation levels. “Cold” means that the tires are at the same temperature as the surrounding air, such as when the vehicle has been parked overnight. Wheel and tire manufacturers recommend adjusting the air pressure to the trailer manufacturer’s recommended cold inflation pressure, in pounds per square inch (PSI) stated on the vehicle’s Federal Certification Label or Tire Placard when the trailer is loaded to its gross vehicle weight rating (GVWR). If the tires are inflated to less than the recommended inflation level or the GVWR of the trailer is exceeded, the load carrying capacity of the tire could be dramatically affected. If the tires are inflated more than the recommended inflation level, handling characteristics of the tow vehicle/trailer combination could be affected. Refer to the owner’s manual or talk to your dealer or vehicle manufacturer if you have any questions regarding proper inflation practices. Tires can lose air over a period of time. In fact, tires can lose 1 to 3 PSI per month. This is because molecules of air, under pressure, weave their way from the inside of the tire, through the rubber, to the outside. A drop in tire pressure could cause the tire to become overloaded, leading to excessive heat build up. If a trailer tire is under-inflated, even for a short period of time, the tire could suffer internal damage. High speed towing in hot conditions degrades trailer tires significantly. As heat builds up during driving, the tire’s internal structure starts to breakdown, compromising the strength of the tire. It is recommended to drive at moderate speeds. Statistics indicate the average life of a trailer tire is about five years under normal use and maintenance conditions. After three years, replacing the trailer tires with new ones should be considered, even if the tires have adequate tread depth. Some experts claim that Page 22 of 145 Tire Safety after five years, trailer tires are considered worn out and should be replaced, even if they have had minimal or no use. This is such a general statement that it may not apply in all cases. It is best to have your tires inspected by a tire supplier to determine if your tires need to be replaced. If you are storing your trailer for an extended period, make sure the tires are fully inflated to the maximum rated pressure and that you store them in a cool, dry place, such as a garage. Use tire covers to protect the trailer tires from the harsh effects of the sun. overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the Certification / VIN label and/or on the Tire Placard. This value should never exceed the maximum cold inflation pressure stamped on the tire. 3.2.1 TRAILERS 10,000 POUNDS GVWR OR LESS 3.2 STEPS FOR DETERMINING CORRECT LOAD LIMIT - TRAILER Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a Federal Certification / VIN label that is located on the forward half of the left (road) side of the unit. This certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most weight the fully loaded trailer can weigh. It will also provide the Gross Axle Weight Rating (GAWR). This is the most a particular axle can weigh. If there are multiple axles, the GAWR of each axle will be provided. If your trailer has a GVWR of 10,000 pounds or less, there is a vehicle placard located in the same location as the certification label described above. This placard provides tire and loading information. In addition, this placard will show a statement regarding maximum cargo capacity. Cargo can be added to the trailer, up to the maximum weight specified on the placard. The combined weight of the cargo is provided as a single number. In any case, remember: the total weight of a fully loaded trailer can not exceed the stated GVWR. When loading your cargo, be sure it is distributed evenly to prevent overloading front to back and side to side. Heavy items should be placed low and as close to the axle positions as reasonable. Too many items on one side may overload a tire. The best way to know the actual weight of the vehicle is to weigh it at a public scale. Talk to your dealer to discuss the weighing methods needed to capture the various weights related to the trailer. This would include the weight empty or unloaded, weights per axle, wheel, hitch or king-pin, and total weight. 1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s placard. 2. This figure equals the available amount of cargo and luggage load capacity. 3. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity. 4. The trailer’s placard refers to the Tire Information Placard attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer. 3.2.2 TRAILERS OVER 10,000 POUNDS GVWR (Note: These trailers are not required to have a tire information placard on the trailer and may not have one installed) 1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means. 2. Locate the GVWR (Gross Vehicle Weight Rating) of the trailer on your trailer’s VIN (Certification) label. 3. Subtract the empty weight of your trailer from the GVWR stated on the VIN label. That weight is the maximum available cargo capacity of the trailer and may not be safely exceeded. National Highway Transportation Safety Administration (NHTSA) in addition to notifying us. Excessive loads and/or under inflation cause tire Page 23 of 145 Tire Safety 3.3 STEPS FOR DETERMINING CORRECT LOAD LIMIT - TOW VEHICLE Cold inflation pressure: The pressure in the tire before you drive. Cord: The strands forming the plies in the tire. 1. Locate the statement, “The combined weight of 2. 3. 4. 5. 6. occupants and cargo should never exceed XXX lbs.,” on your vehicle’s placard. Determine the combined weight of the driver and passengers who will be riding in your vehicle. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds. The resulting figure equals the available amount of cargo and luggage capacity. For example, if the “XXX” amount equals 1400 lbs. and there will be five 150 lb. passengers in your vehicle, the amount of available cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.). Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage capacity calculated in previous step. If your vehicle will be towing a trailer, load from your trailer will be transferred to your vehicle. Consult the tow vehicle’s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle. Cord separation: The parting of cords from adjacent rubber compounds. Cracking Any parting within the tread, sidewall, or inner liner of the tire extending to cord material. CT: A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire. Curb weight: The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine. Extra load tire: A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Groove: The space between two adjacent tread ribs. 3.4 GLOSSARY OF TIRE TERMINOLOGY Accessory weight: The combined weight (in excess of those standard items which may be replaced) of automatic transmission, power steering, power brakes, power windows, power seats, radio and heater, to the extent that these items are available as factoryinstalled equipment (whether installed or not). Gross Axle Weight Rating: The maximum weight that any axle can support, as published on the Certification / VIN label on the front left side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached to the towing vehicle. Bead: The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the rim. Gross Vehicle Weight Rating: The maximum weight of the fully loaded trailer, as published on the Certification / VIN label. Actual weight determined by weighing trailer on a public scale, without being attached to the towing vehicle. Bead separation: This is the breakdown of the bond between components in the bead. Hitch Weight: The downward force exerted on the hitch ball by the trailer coupler. Bias ply tire: A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less than 90 degrees to the centerline of the tread. Innerliner: The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire. Carcass: The tire structure, except tread and sidewall rubber which, when inflated, bears the load. Chunking: The breaking away of pieces of the tread or sidewall. Innerliner separation: The parting of the innerliner from cord material in the carcass. Intended outboard sidewall: The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that Page 24 of 145 Tire Safety is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle. Light truck (LT) tire: A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. May be used on trailers. Load rating: The maximum load that a tire is rated to carry for a given inflation pressure. Occupant distribution: The distribution of occupants in a vehicle as specified in the third column of Table I of 49 CFR 571.110. Open splice: Any parting at any junction of tread, sidewall, or innerliner that extends to cord material. Outer diameter: The overall diameter of an inflated new tire. Maximum load rating: The load rating for a tire at the maximum permissible inflation pressure for that tire. Overall width: The linear distance between the exteriors of the sidewalls of an inflated tire, including elevations due to labeling, decorations, or protective bands or ribs. Maximum permissible inflation pressure: The maximum cold inflation pressure to which a tire may be inflated. Pin Weight: The downward force applied to the 5th wheel or gooseneck ball, by the trailer kingpin or gooseneck coupler. Maximum loaded vehicle weight: The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight. Ply: A layer of rubber-coated parallel cords. Measuring rim: The rim on which a tire is fitted for physical dimension requirements. Non-pneumatic rim: A mechanical device which, when a non-pneumatic tire assembly incorporates a wheel, supports the tire, and attaches, either integrally or separably, to the wheel center member and upon which the tire is attached. Non-pneumatic spare tire assembly: A nonpneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of this standard. Non-pneumatic tire: A mechanical device which transmits, either directly or through a wheel or wheel center member, the vertical load and tractive forces from the roadway to the vehicle, generates the tractive forces that provide the directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those functions. Non-pneumatic tire assembly: A non-pneumatic tire, alone or in combination with a wheel or wheel center member, which can be mounted on a vehicle. Normal occupant weight: This means 68 kilograms (150 lbs.) times the number of occupants specified in the second column of Table I of 49 CFR 571.110. Ply separation: A parting of rubber compound between adjacent plies. Pneumatic tire: A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load. Production options weight: The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in curb weight or accessory weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and special trim. Radial ply tire: A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90 degrees to the centerline of the tread. Recommended inflation pressure: This is the inflation pressure provided by the vehicle manufacturer on the Tire Information label and on the Certification / VIN tag. Reinforced tire: A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Rim: A metal support for a tire or a tire and tube assembly upon which the tire beads are seated. Page 25 of 145 Tire Safety Rim diameter: This means the nominal diameter of the bead seat. Rim size designation: This means the rim diameter and width. Rim type designation: This means the industry of manufacturer’s designation for a rim by style or code. Rim width: This means the nominal distance between rim flanges. Section width: The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to labeling, decoration, or protective bands. Sidewall: That portion of a tire between the tread and bead. Sidewall separation: The parting of the rubber compound from the cord material in the sidewall. Special Trailer (ST) tire: The “ST” is an indication the tire is for trailer use only. individual tire that is determined by distributing to each axle its share of the curb weight, accessory weight, and normal occupant weight (distributed in accordance with Table I of CRF 49 571.110) and dividing by 2. Weather side: The surface area of the rim not covered by the inflated tire. Wheel center member: In the case of a non-pneumatic tire assembly incorporating a wheel, a mechanical device which attaches, either integrally or separably, to the non-pneumatic rim and provides the connection between the nonpneumatic rim and the vehicle; or, in the case of a non-pneumatic tire assembly not incorporating a wheel, a mechanical device which attaches, either integrally or separably, to the nonpneumatic tire and provides the connection between tire and the vehicle. Wheel-holding fixture: The fixture used to hold the wheel and tire assembly securely during testing. 3.5 TIRE SAFETY - EVERYTHING RIDES ON IT Test rim: The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with that tire. The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It can be obtained and downloaded from NHTSA, free of charge, from the following web site: Tread: That portion of a tire that comes into contact with the road. http://www.nhtsa.dot.gov/cars/rules/TireSafety/ ridesonit/tires_index.html Tread rib: A tread section running circumferentially around a tire. Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards, and inspecting tires for cuts, slashes, and other irregularities are the most important things you can do to avoid tire failure, such as tread separation or blowout and flat tires. These actions, along with other care and maintenance activities, can also: Tread separation: Pulling away of the tread from the tire carcass. Treadwear indicators (TWI): The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread. Vehicle capacity weight: The rated cargo and luggage load plus 68 kilograms (150 lbs.) times the vehicle’s designated seating capacity. Vehicle maximum load on the tire: The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded vehicle weight and dividing by two. Vehicle normal load on the tire: The load on an • • • • Improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve fuel economy Increase the life of your tires. This booklet presents a comprehensive overview of tire safety, including information on the following topics: • Basic tire maintenance Page 26 of 145 Tire Safety • • • Uniform Tire Quality Grading System Fundamental characteristics of tires Tire safety tips. Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure. 3.5.1 SAFETY FIRST- BASIC TIRE MAINTENANCE Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle. Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above, to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and vehicle load limits, avoid road hazards, and regularly inspect your tires. 3.5.2 FINDING YOUR VEHICLE’S RECOMMENDED TIRE PRESSURE AND LOAD LIMITS Tire information placards and vehicle certification labels contain information on tires and load limits. These labels indicate the vehicle manufacturer’s information including: • • • • • Recommended tire size Recommended tire inflation pressure Vehicle capacity weight (VCW–the maximum occupant and cargo weight a vehicle is designed to carry) Front and rear gross axle weight ratings (GAWR– the maximum weight the axle systems are designed to carry). Both placards and certification labels are permanently attached to the trailer near the left front. determine this number based on the vehicle’s design load limit, that is, the greatest amount of weight a vehicle can safely carry and the vehicle’s tire size. The proper tire pressure for your vehicle is referred to as the “recommended cold inflation pressure.” (As you will read below, it is difficult to obtain the recommended tire pressure if your tires are not cold.) Because tires are designed to be used on more than one type of vehicle, tire manufacturers list the “maximum permissible inflation pressure” on the tire sidewall. This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions. 3.5.4 SAFETY FIRST- BASIC TIRE MAINTENANCE It is important to check your vehicle’s tire pressure at least once a month for the following reasons: • • • Most tires may naturally lose air over time. Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when parking. With radial tires, it is usually not possible to determine under inflation by visual inspection. For convenience, purchase a tire pressure gauge to keep in your vehicle. Gauges can be purchased at tire dealerships, auto supply stores, and other retail outlets. The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper psi when a tire is cold. The term cold does not relate to the outside temperature. Rather, a cold tire is one that has not been driven on for at least three hours. When you drive, your tires get warmer, causing the air pressure within them to increase. Therefore, to get an accurate tire pressure reading, you must measure tire pressure when the tires are cold or compensate for the extra pressure in warm tires. 3.5.3 UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS 3.5.5 STEPS FOR MAINTAINING PROPER TIRE PRESSURE Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air pressure– measured in pounds per square inch (psi)–a tire requires to be properly inflated. (You will also find this number on the vehicle information placard expressed in kilopascals (kPa), which is the metric measure used internationally.) 1. Locate the recommended tire pressure on the Manufacturers of passenger vehicles and light trucks vehicle’s tire information placard, certification label, or in the owner’s manual. 2. Record the tire pressure of all tires. 3. If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pressure. 4. If the tire pressure is too low, note the difference between the measured tire pressure and the correct tire pressure. These “missing” pounds of pressure Page 27 of 145 Tire Safety are what you will need to add. 5. At a service station, add the missing pounds of air pressure to each tire that is under inflated. 6. Check all the tires to make sure they have the same air pressure except in cases in which the front and rear tires are supposed to have different amounts of pressure). If you have been driving your vehicle and think that a tire is under inflated, fill it to the recommended cold inflation pressure indicated on your vehicle’s tire information placard or certification label. While your tire may still be slightly under inflated due to the extra pounds of pressure in the warm tire, it is safer to drive with air pressure that is slightly lower than the vehicle manufacturer’s recommended cold inflation pressure than to drive with a significantly under inflated tire. Since this is a temporary fix, don’t forget to recheck and adjust the tire’s pressure when you can obtain a cold reading. 3.5.6 TIRE SIZE To maintain tire safety, purchase new tires that are the same size as the vehicle’s original tires or another size recommended by the manufacturer. Look at the tire information placard, the owner’s manual, or the sidewall of the tire you are replacing to find this information. If you have any doubt about the correct size to choose, consult with the tire dealer. wheels so that they are positioned correctly relative to the vehicle’s frame. This adjustment maximizes the life of your tires. These adjustments require special equipment and should be performed by a qualified technician. 3.5.9 TIRE REPAIR The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected before being plugged and patched. 3.5.10 TIRE FUNDAMENTALS Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall. 3.5.10.1 INFORMATION ON PASSENGER VEHICLE TIRES 3.5.7 TIRE TREAD The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding, especially when the road is wet or icy. In general, tires are not safe and should be replaced when the tread is worn down to 2/32 of an inch. Tires have built-in tread wear indicators that let you know when it is time to replace your tires. These indicators are raised sections spaced intermittently in the bottom of the tread grooves. When they appear “even” with the outside of the tread, it is time to replace your tires. Another method for checking tread depth is to place a penny in the tread with Lincoln’s head upside down and facing you. If you can see the top of Lincoln’s head, you are ready for new tires. 3.5.8 TIRE BALANCE AND WHEEL ALIGNMENT To avoid vibration or shaking of the vehicle when a tire rotates, the tire must be properly balanced. This balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel-and-tire assembly. A wheel alignment adjusts the angles of the P: The “P” indicates the tire is for passenger vehicles. Next number: This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire. Next number: This two-digit number, known as the aspect ratio, gives the tire’s ratio of height to width. Page 28 of 145 Tire Safety Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement. R: The “R” stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years. Maximum Permissible Inflation Pressure: This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions. 3.5.10.2 UTQGS Information Next number: This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter. Treadwear Number: This number indicates the tire’s wear rate. The higher the treadwear number is, the longer it should take for the tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200. Next number: This two- or three-digit number is the tire’s load index. It is a measurement of how much weight each tire can support. You may find this information in your owner’s manual. If not, contact a local tire dealer. Note: You may not find this information on all tires because it is not required by law. Traction Letter: This letter indicates a tire’s ability to stop on wet pavement. A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest as “AA”,”A”, “B”, and “C”. M+S: The “M+S” or “M/S” indicates that the tire has some mud and snow capability. Most radial tires have these markings; hence, they have some mud and snow capability. Speed Rating: The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time. Note: You may not find this information on all tires because it is not required by law. Temperature Letter: This letter indicates a tire’s resistance to heat. The temperature grade is for a tire that is inflated properly and not overloaded. Excessive speed, under inflation or excessive loading, either separately or in combination, can cause heat build-up and possible tire failure. From highest to lowest, a tire’s resistance to heat is graded as “A”, “B”, or “C”. 3.5.10.3 Additional Information On Light Truck Tires U.S. DOT Tire Identification Number: This begins with the letters “DOT” and indicates that the tire meets all federal standards. The next two numbers or letters are the plant code where it was manufactured, and the last four numbers represent the week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other numbers are marketing codes used at the manufacturer’s discretion. This information is used to contact consumers if a tire defect requires a recall. Tire Ply Composition and Materials Used: The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in the tire, which include steel, nylon, polyester, and others. Maximum Load Rating: This number indicates the maximum load in kilograms and pounds that can be carried by the tire. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT: The “LT” indicates the tire is for light trucks or Page 29 of 145 Tire Safety trailers. ST: An “ST” is an indication the tire is for trailer use only. Max. Load Dual kg (lbs) at kPa (psi) Cold: This information indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each rear axle (a total of six or more tires on the vehicle). Max. Load Single kg (lbs) at kPa (psi) Cold: This information indicates the maximum load and tire pressure when the tire is used as a single. Load Range: This information identifies the tire’s loadcarrying capabilities and its inflation limits. 3.5.10.4 Tire Safety Tips Preventing Tire Damage Slow down if you have to go over a pothole or other object in the road. • Do not run over curbs or other foreign objects in the roadway, and try not to strike the curb when parking. • Tire Safety Checklist Check tire pressure regularly (at least once a month), including the spare. • Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or trauma. • Remove bits of glass and foreign objects wedged in the tread. • Make sure your tire valves have valve caps. • Check tire pressure before going on a long trip. • Do not overload your vehicle. Check the Tire Information Placard or Owner’s Manual for the maximum recommended load for the vehicle. • Page 30 of 145 Coupling To Tow Vehicle 4. COUPLING TO TOW VEHICLE Follow all of the safety precautions and instructions in this manual to ensure safety of persons, cargo, and satisfactory life of the trailer. 4.1 TOW VEHICLE AND HITCH If the vehicle and hitch are not properly selected and matched to the Gross Vehicle Weight Rating (GVWR) of your trailer, you can cause an accident that could lead to death or serious injury. If you already have a tow vehicle, know your vehicle tow rating and make certain the trailer’s rated capacity is less than or equal to the tow vehicle’s rated towing capacity. ^ DANGER Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control, and may lead to death or serious injury. Use of a hitch with a load rating less than the load rating of the trailer can result in loss of control and may lead to death or serious injury. Verify hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer. 4.1.1 TRAILER INFORMATION The Certification / Vehicle Identification Number (VIN) tag is located on the front left side of the trailer. The trailer Certification / VIN tag contains the following critical safety information for the use of your trailer: MANUFACTURER: Name of trailer manufacturer. DATE OF MANUFACTURE: Month and year the trailer was manufactured. GVWR: The Gross Vehicle Weight Rating is the maximum allowable gross weight of the trailer and its contents. The gross weight of the trailer includes the weight of the trailer and all of the items within it (such as cargo and other supplies). GAWR: The Gross Axle Weight Rating is the maximum gross weight that an axle can support. It is the lowest of axle, wheel, or tire rating. Sometimes the tire or wheel rating is lower than the axle manufacturers rating, and will then determine GAWR. The sum total of the GAWR for all trailer axles may be less than the GVWR for the trailer, because some of the trailer load is carried by the tow vehicle, rather than by the trailer axle(s). The total weight of the cargo and trailer must not exceed the GVWR, and the load on an axle must not exceed its GAWR. TIRE SIZE: The tire size and load range for your trailer. RIM SIZE: The rim size and load range for your trailer. PSI: The tire air pressure (kPa / PSI) measured with tires cold. VIN: The Vehicle Identification Number. VEHICLE TYPE: Model or style of trailer. CERTIFICATION STATEMENT: “This trailer meets all the Federal Motor Vehicle Safety Standards in effect on the date of manufacture shown above”. 4.1.2 TOW VEHICLE When equipping a new vehicle or an older vehicle to tow a trailer, ask the vehicle dealer for advice on how to outfit the tow vehicle. Vehicle manufacturers will provide you with the maximum towing capacities of their various models, as well as the GCWR. No amount of reinforcement will give a 100 horsepower, 2,500 pound truck the towing capacity that a 300 horsepower, 5,000 pound truck has. 4.2 COUPLING AND UNCOUPLING THE TRAILER A secure coupling (or fastening) of the trailer to the tow vehicle is essential. A loss of coupling may result in death or serious injury. Therefore, you must understand and follow all of the instructions for coupling. The following parts are involved in making a secure coupling between the trailer and tow vehicle: Coupling: The trailer connecting mechanism by which the connection is actually made to the trailer hitch. This does not include any structural member, extension of the trailer frame, or brake controller. Page 31 of 145 Coupling To Tow Vehicle Hitch: The connecting mechanism including the ball support platform and ball and those components that extend and are attached to the towing vehicle, including bumpers intended to serve as hitches. Safety chains: Chains permanently attached to the trailer such that if the coupler connection comes loose, the safety chains can keep the trailer attached to the tow vehicle. With properly rigged safety chains, it is possible to keep the tongue of the trailer from digging into the road pavement, even if the coupler-to-hitch connection comes apart. Trailer lighting (and braking) connector: A device that connects electrical power from the tow vehicle to the trailer. In addition, if your trailer has a separate braking system, the electrical connector will also supply power to the trailer brakes from the tow vehicle. Breakaway switch: If the trailer becomes uncoupled from the tow vehicle, the breakaway switch lanyard, attached independently to the tow vehicle hitch, will pull a pin in the emergency electrical breakaway switch on the trailer. The breakaway switch is activated by a battery on the trailer to energize the trailer brakes independently of the towing vehicle. ^ WARNING An improperly coupled trailer can result in death or serious injury. Do not move the trailer until: • • • • • • • • Coupler is secured and locked to hitch. Safety chains are secured to tow vehicle. Trailer jack(s) are fully retracted. Trailer brakes are checked. Tires and wheels are checked. Breakaway switch is connected to tow vehicle; The trailer lights are connected and checked. Load is secured to trailer. 4.3 COUPLE TRAILER TO TOW VEHICLE The trailer may be equipped with a ball hitch coupler or a ring & pintle coupler. See the appropriate section for the coupler on your trailer. 4.3.1 BALL HITCH COUPLER It is important to check the state of charge of the emergency breakaway battery before each trip. Simply pull the pin out of the switch by hand and then try to pull the trailer. If you feel a significant drag force the brakes are activated. Be sure to re-insert the pin in the breakaway switch. Also be sure to allow enough slack in the breakaway brake lanyard such that the switch will only activate (pin pulls out) if the coupler connection comes loose. Jack: A device on the trailer that is used to raise and lower the trailer tongue. A ball hitch coupler connects to a ball that is located on or under the rear bumper of tow vehicle. We have utilized a ball hitch coupler that is suitable for the size and weight of the trailer. The load rating of the coupler and the necessary ball size are listed on the trailer tongue. You must provide a hitch and ball for your tow vehicle, that meets or exceeds the GVWR of the trailer. The ball size must be the same as the coupler size. If the hitch ball is too small, too large, is underrated, is loose or is worn, the trailer can come loose from the tow vehicle, and may cause death or serious injury. The tow vehicle, hitch and ball must have a rated towing capacity equal to or greater than the trailer gross vehicle weight rating (GVWR). It is essential that the hitch ball be the same size as the coupler. The ball size and load rating (capacity) are marked on the ball; hitch capacity is marked on the hitch. Page 32 of 145 Coupling To Tow Vehicle 4.3.1.1 BEFORE COUPLING TRAILER TO TOW VEHICLE 1. Be sure the size and rating of hitch ball match the size and rating of the coupler. Hitch balls and couplers are marked with their size and rating. 6. Raise the bottom surface of the coupler to be above the top of the hitch ball. 4.3.1.2 PREPARE COUPLER AND HITCH 1. Lubricate hitch ball and inside of coupler with a thin ^ WARNING Coupler-to-hitch mismatch can result in uncoupling, leading to death or serious injury. Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler. layer of automotive bearing grease. 2. Remove safety latch pin and open coupler locking mechanism. In the open position, coupler is able to drop fully onto hitch ball. See the coupler instructions for details of placing the coupler in the “open” position. 3. Slowly back up tow vehicle so that hitch ball is near or aligned under coupler. Be sure the SIZE of the hitch ball matches the size of the coupler. 2. Wipe the hitch ball clean and inspect it visually and by feel for flat spots, cracks and pits. ^ WARNING A worn, cracked or corroded hitch ball can fail while towing, and may result in death or serious injury. Your trailer may be equipped with a different style coupler. If so, see the coupler manufacturers operating instructions. 4.3.1.3 COUPLE TRAILER TO TOW VEHICLE 1. Lower the trailer tongue until the coupler fully and visually check that the hitch ball nut is solid against the lock washer and hitch frame. 4. Wipe the inside and outside of the coupler clean and inspect it visually for cracks and deformations; feel the inside of the coupler for worn spots and pits. 5. Be sure the coupler is tight to the tongue of the trailer. All coupler fasteners must be visibly solid against the trailer frame. engages the hitch ball. If the coupler does not line up with the hitch ball, adjust the position of the tow vehicle. 2. Close latch and engage the coupler locking mechanism. In the engaged position, the locking mechanism securely holds the coupler to the hitch ball. 3. Insert the safety lock pin through the hole in the locking mechanism. 4. Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged. A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle. Using the trailer jack, test to see that you can raise the rear of the tow vehicle by 1 inch, after the coupler is locked to the hitch. ^ WARNING NOTICE Before coupling trailer, inspect the hitch ball for wear, corrosion and cracks. Replace worn or damaged hitch ball. 3. Rock the ball to make sure it is tight to the hitch, A loose hitch ball nut can result in uncoupling, leading to death or serious injury. Make sure the hitch ball is tight to the hitch before coupling the trailer. The tongue jack can be damaged by overloading. Do not use the tongue jack to raise the tow vehicle more than 1 inch. 5. If the coupler cannot be secured to the hitch ball, do not tow the trailer. Contact your dealer for assistance. Page 33 of 145 Coupling To Tow Vehicle 6. Lower the trailer so that its entire tongue weight is held by the hitch, and continue retracting the jack to its fully retraced position. ^ CAUTION ^ WARNING Ring-to-pintle mismatch can result in uncoupling, leading to death or serious injury. Drop leg jacks may be spring loaded and may rapidly return to the raise position when released. Be sure the LOAD RATING of the pintle is equal or greater than the load rating of the ring. Keep clear when releasing drop legs. Be sure the SIZE of the pintle matches the size of the ring. 7. Fully retract jack drop leg if equipped. 2. Wipe the pintle clean and inspect it visually and by Go to Section 4.3.3 “Connect Safety Chains” to continue connecting trailer to tow vehicle. 4.3.2 TRAILER WITH RING AND PINTLE COUPLER A ring on the trailer connects to the pintle that is located on or under the rear bumper of tow vehicle. We have utilized a ring that is suitable for the size and weight of the trailer. The load rating of the ring and the necessary pintle size are listed on the trailer tongue. You must provide a pintle for your tow vehicle, where the load rating of the hitch and pintle is equal to or greater than that of your trailer. The pintle size must be the same as the ring size. If the pintle is too small, too large, is underrated, is loose or is worn, the trailer can come loose from the tow vehicle, and may cause death or serious injury. The tow vehicle, hitch and pintle must have a rated towing capacity equal to or greater than the trailer gross vehicle weight rating (GVWR). It is essential that the pintle be the same size as the coupler. The pintle size and load rating (capacity) are marked on the pintle; ring capacity is marked on the ring. feel for flat spots, cracks and pits. ^ WARNING A worn, cracked or corroded pintle can fail while towing, and may result in death or serious injury. Before coupling trailer, inspect the pintle for wear, corrosion and cracks. Replace worn or damaged pintle. 3. Rock the pintle to make sure it is tight to the hitch, and visually check that the pintle fasteners are solid against the hitch frame. 4. Wipe the inside and outside of the ring clean and inspect it visually for cracks and deformations; feel the inside of the ring for worn spots and pits. 5. Be sure the ring is tight to the tongue of the trailer. All ring fasteners must be visibly solid against the trailer frame. ^ WARNING A loose pintle can result in uncoupling, leading to death or serious injury. Make sure the pintle is tight to the hitch before coupling the trailer. 4.3.2.1 BEFORE COUPLING TRAILER TO TOW VEHICLE 1. Be sure the size and rating of pintle match the size and rating of the ring. Hitch ring and pintles are marked with their size and rating. 6. Raise the bottom surface of the ring to be above the top of the open pintle. 4.3.2.2 PREPARE RING AND PINTLE 1. Lubricate the inside of the pintle with a thin layer of automotive bearing grease. 2. Remove the safety latch pin and open the pintle locking mechanism. Page 34 of 145 Coupling To Tow Vehicle 3. In the open position, the ring is able to drop fully 7. Fully retract jack drop leg if equipped. onto the pintle. Go to Section 4.3.3 “Connect Safety Chains” to continue connecting trailer to tow vehicle. 4.3.3 CONNECT SAFETY CHAINS 1. Visually inspect the safety chains and hooks for 4. See the coupler instructions for details of placing the pintle in the “open” position. 5. Slowly back up the tow vehicle so that the pintle is aligned under the ring. 4.3.2.3 COUPLE TRAILER TO TOW VEHICLE 1. Lower the trailer tongue until the ring fully engages wear or damage. Replace worn or damaged safety chains and hooks before towing. 2. Safety chains must crisscross under the coupler so if the trailer uncouples, the safety chains can hold the tongue up above the road. Loop around a frame member of the tow vehicle or to holes provided in the hitch system, but do not attach them to an interchangeable part of the hitch assembly. 3. Attach hooks up from underneath the hole. Do not just drop into hole. 4. Provide enough slack in chains to permit tight turns, but not be close to the road surface to drag. the pintle. If the ring does not line up with the pintle, adjust the position of the tow vehicle. 2. Close pintle and engage the pintle locking mechanism. In the engaged position, the locking mechanism securely holds the ring to the pintle. 3. Insert the safety lock pin through the hole in the locking mechanism. 4. Be sure the ring is all the way on the pintle and the locking mechanism is engaged. A properly engaged locking mechanism will allow the pintle to raise the rear of the tow vehicle. Using the trailer jack, test to see that you can raise the rear of the tow vehicle by 1 inch, after the pintle is closed and locked. NOTICE The tongue jack can be damaged by overloading. Do not use the tongue jack to raise the tow vehicle more than 1 inch. 5. If the ring cannot be secured to the pintle, do not tow the trailer. Contact your dealer for assistance. 6. Lower the trailer so that its entire tongue weight is held by the hitch, and continue retracting the jack to its fully retraced position. ^ CAUTION Drop leg jacks may be spring loaded and may rapidly return to the raise position when released. Keep clear when releasing drop legs. Page 35 of 145 Coupling To Tow Vehicle ^ WARNING Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle, leading to death or serious injury, if the trailer uncouples from the tow vehicle. hydraulic actuator will engage or the electric brake pullpin will be pulled out before all of the slack in the safety chains is taken up. Do not connect the lanyard to a safety chain, hitch ball or hitch ball assembly. This would keep the breakaway brake system from operating when it is needed. Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up, if the trailer comes loose. Fasten chains to frame of tow vehicle. Do not fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose. 4.3.4 CONNECT ELECTRICAL CABLE 1. Connect the trailer lights to the tow vehicle’s electrical system using trailer electrical cable. 2. Check all lights for proper operation. Repair or replace non-working lights before towing trailer. 3. Check electric brakes for proper operation using brake controller mounted in the cab. ^ WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes, and can lead to collision. Before each tow: • Check that the electric brakes work by operating the brake controller inside the tow vehicle. • Check that all lights and turn signals work. 4.3.5 ATTACH BREAKAWAY BRAKE LANYARD If the coupler or hitch fails, a properly connected and working breakaway brake system will apply the trailer brakes. The safety chains will keep the tow vehicle attached and as the trailer brakes are applied, the trailer/tow vehicle combination will come to a controlled stop. Connect the lanyard to the tow vehicle so that the 4.3.5.1 TEST ELECTRIC BRAKES If your trailer has electric brakes, your tow vehicle will have an electric brake controller that sends power to the trailer brakes. Before towing the trailer on the road, you must operate the brake controller while trying to pull the trailer in order to confirm that the electric brakes operate. While towing the trailer at less than 5 mph, manually operate the electric brake controller in the tow vehicle. You should feel the operation of the trailer brakes. If the trailer brakes are not functioning, the brake system MUST be evaluated to determine the cause of the problem and corrective action MUST be taken before the trailer is used. Take the unit to your dealer or a qualified brake specialist. Use this procedure each time you tow the trailer to check brake system operation. 4.3.5.2 TEST ELECTRIC BREAKAWAY BRAKES The breakaway brake system includes a battery, a switch with a pullpin and lanyard, and a breakaway brake controller. Read and follow the instructions here as well as the instructions that have been prepared by the breakaway brake manufacturer. If you do not have these instructions, contact your dealer for assistance. Hydraulic tilt trailers may use the hoist battery to provide power to the breakaway brakes. If your trailer is not setup this way, there will be a small breakaway battery mounted near the breakaway switch. Most trailers are setup to charge the battery from Page 36 of 145 Coupling To Tow Vehicle the tow vehicle. If the electrical system on your tow vehicle does not provide power to the battery, you must periodically charge the battery with a commercial battery charger to keep the battery charged. ^ CAUTION Extreme cold weather can degrade battery performance and cause brakes to not operate properly. Check battery charge level before towing. Do not tow trailer if the battery requires recharging. A discharged brake battery will not activate the brakes if the trailer uncouples from the tow vehicle. The battery must be fully charged before towing trailer. To test the breakaway brake battery, remove the pullpin from the switch and attempt to pull the trailer forward. You should feel the trailer resisting being towed, but the wheels will not necessarily be locked. If the brakes do not function, do not tow the trailer until brakes, or battery, are repaired. Immediately replace the pullpin. The breakaway brake battery discharges rapidly when the pullpin is removed. ^ WARNING An ineffective breakaway brake system can result in a runaway trailer, leading to death or serious injury if the coupler fails. Test the function of the breakaway brake system before towing trailer. Do not tow trailer if breakaway brake system is not working; have it serviced or repaired. Connect breakaway lanyard to the tow vehicle, NOT to the safety chain, ball, pintle, hitch, or support. Do not tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure. ^ WARNING Failure to replace the pullpin can result in ineffective brakes, leading to loss of control, serious injury or death. If you do not use your trailer for three or more months, or during winter months: • Store the battery indoors; and • Charge the battery every three months. Replace the breakaway brake battery according to the intervals specified by battery manufacturer. 4.3.5.3 TEST SURGE BRAKES (IF EQUIPPED) Hydraulic surge actuator systems provide automatic and smooth trailer braking without special application by the tow vehicle driver. While this is extremely convenient it can sometimes be difficult to determine if the surge setup is functioning properly. The following steps provide a quick field-test to confirm that the trailer brake system is operational. ^ WARNING The field-test procedure indicates only if the trailer brake system is functional, but DOES NOT provide information on how efficiently it will operate. Regular inspection, maintenance, and adjustment of all brake system components (including the surge actuator, tubing, hoses, brake clusters, drums, and associated hardware/support structure) are still required to ensure maximum brake performance and smooth, even brake operation. Move the trailer to flat, level ground, pulling FORWARD several feet before parking. This forward motion will ensure trailers equipped with free-backing brakes are in their normal operating mode. Disconnect the trailer from the tow vehicle and jack up the trailer’s tongue until it is horizontal. Hook the trailer’s safety chains (NOT the actuator’s breakaway cable) together to form a loop, which is centered below the actuator’s coupler. Place wheel chock blocks two feet behind the trailer to prevent a runaway trailer. Place a sturdy board, such as a 2 inch by 4 inch piece of lumber, into the chain loop below the coupler. The Page 37 of 145 Coupling To Tow Vehicle board should be 4 feet or longer so it will extend several feet above the actuator. Keep the end of the board a few inches off the ground, and position it to press against the front end of the actuator’s coupler. Press the board towards the rear of the trailer. Keep pressing the top of the board to stroke the actuator and its internal master cylinder. If the trailer brake system is operational, the brakes will apply and keep the trailer from rolling away from you. Properly adjusted uni-servo or duo-servo type brakes will prevent you from moving the trailer back more than a few inches. Free-backing type brakes will initially provide rolling resistance, but continued force on the board will switch them into free-backing mode, and you’ll be able to move the trailer backwards. If you have uni-servo or duo-servo brakes, and stroking the actuator (as described above) causes the trailer to roll away from you freely or with only minimal resistance, the brakes are NOT applying properly. If you have freebacking brakes and stroking the actuator (as described above) causes the trailer to roll away without initial resistance, then the brakes are NOT applying properly. The brake system MUST be evaluated to determine the cause of the problem and corrective action MUST be taken before the trailer is used. Use this procedure each time you tow your trailer to check your surge brake system operation. 4.3.5.4 TEST SURGE BREAKAWAY SYSTEM 1. Park the trailer on a firm level surface and block trailer tires. Disconnect electrical connector. Disconnect breakaway brake switch lanyard. Disconnect safety chains from tow vehicle. Unlock the coupler and open it. Before extending jack, make certain the ground surface below the jack pad will support the tongue load. 7. Rotate jack handle to extend the jack and transfer the weight of the trailer tongue to the jack. 8. Raise the trailer coupler above the tow vehicle hitch. 9. Drive tow vehicle forward. 2. 3. 4. 5. 6. 4.5 TONGUE WEIGHT It is critical to have a portion of the trailer load carried by the tow vehicle. That is, the trailer tongue must exert a downward force on the hitch. This is necessary for two reasons. First, the proper amount of tongue weight is necessary for the tow vehicle to be able to maintain control of the tow vehicle/trailer system. If, for example, the tongue exerts an upward pull on the hitch, instead of pushing down on it (because the trailer is overloaded behind its axle(s)), the rear wheel of the tow vehicle can lose traction or grip and cause loss of control. Also, even if there is some weight on the tongue, but not enough weight on the tongue, the trailer can become unstable at high speeds. Remember, the faster you go the more likely the trailer is to sway. Before towing, check that the breakaway lever and lanyard are properly positioned. If the breakaway lever and lanyard are not located correctly due to either the lanyard being pulled during use or by accident, it MUST be reset prior to the trailer being moved. If there is too much tongue weight, the tow vehicle is prone to jack-knife. The front wheels of the tow vehicle can be too lightly loaded and cause loss of steering control and traction, if the front wheels are driving. See the Surge Brake Actuator manual for the correct resetting and testing procedure. In addition to tow vehicle control, tongue weight is necessary to insure that the trailer axle(s) do not exceed their Gross Axle Weight Rating (GAWR). ^ WARNING The breakaway system is designed to operate if the trailer separates from the tow vehicle. DO NOT use the breakaway system as a parking brake. 4.4 UNCOUPLE TRAILER Follow these steps to uncouple trailer from the tow vehicle: In the following table, the second column shows the rule of thumb percentage of total weight of the trailer plus its cargo (Gross Trailer Weight, or “GTW”) that should appear on the tongue of the trailer. For example, a large trailer with a loaded weight of 6,000 pounds, should have 10-15% of 6,000 pounds (600-900 lbs.) on the hitch. Tongue Weight as a Percentage of Loaded Trailer Weight Type of Hitch Percentage Ball Hitch or 10-15% for large trailers Ring & Pintle 6-10% for small trailers Page 38 of 145 Coupling To Tow Vehicle The numbers quoted are for example purposes only and should be tailored to the specific trailer. For questions regarding the actual percent of tongue weight for the trailer, check with the manufacturer for specifics. ^ WARNING Improper tongue weight (load distribution) can result in loss of control of the trailer, leading to death or serious injury. 4.6 ADJUST HITCH HEIGHT (IF EQUIPPED) The height of the hitch on the trailer must be adjusted so that the trailer, when loaded to rated capacity, is level while connected to the tow vehicle. A level trailer allows equal weight distribution on the axles. Your dealer or a trailer service center can perform this adjustment or you can use the following steps to adjust the hitch height yourself. If the trailer is not equipped with an adjustable hitch, an offset ball mount may be available from your hitch manufacturer. Make certain that tongue weight is within the allowable range. ^ WARNING Be sure to: • Distribute the load evenly, right and left. • Keep the center of gravity low. • Distribute the load front-to-rear to provide proper tongue weight (see chart). Improper hitch height adjustment can result in overloaded tires, blowout and loss of control, leading to death or serious injury. Adjust the hitch height so that the loaded trailer is level. 4.5.1 CHECKING TONGUE WEIGHT To check the tongue weight, the tow vehicle and trailer must be on level ground, as they will be when the trailer is being towed. Take the trailer to a truck stop or grain elevator where there is a “certified” scale. Place the tow vehicle only onto the scale and get the weight. This weight must be less than your tow vehicle’s GVWR. Pull the trailer onto the scale and uncouple it from the tow vehicle, leaving just the trailer on the scale. Get a ticket which lists the total trailer weight. Re-connect the trailer to your tow vehicle and the drive the tow vehicle wheels off the scale, just leaving the trailer axles on the scale. Get a “ticket”, which lists the trailer’s axle weight. Simply subtract the axle weight from the total weight to determine the hitch weight. 1. Connect trailer to tow vehicle and load the trailer to 2. 3. 4. 5. rated capacity. See Loading And Unloading. Park the tow vehicle and trailer on a firm level surface. Stand away from the trailer and visually verify if the trailer is level front-to-rear. If the front of the trailer is higher than the rear, the hitch must be raised. If the front of the trailer is lower than the rear, the hitch must be lowered. Uncouple trailer from tow vehicle. See Coupling And Uncoupling. Remove the lock nuts and bolts (1) on hitch. Discard lock nuts. Inspect bolts for damage and replace if necessary. Contact your dealer for the correct size and grade of bolts. While you are at the scale, you should weigh the entire combination vehicle. This result should be less than the Gross Combined Weight Rating (GCWR) for your towing vehicle. Some scales allow you to get individual axle weights also. If this is possible, get the tow vehicles front and rear axle weights to make sure they are in the same proportion as the tow vehicle alone, and that the rear axle is not overloaded. Page 39 of 145 Coupling To Tow Vehicle ^ WARNING Used lock nuts are prone to loosen, resulting in the hitch separating from the trailer, which can lead to death or serious injury. NEVER re-use a lock nut. Use new lock nuts each time the hitch height is adjusted. Contact your dealer for the proper grade and size of lock nut. 6. Raise or lower the hitch as necessary. 7. Install bolts and new lock nuts. 8. Tighten lock nuts to torque specified by your dealer. 9. Couple the trailer to the tow vehicle and verify that the trailer is level front to rear. Adjust if necessary. 10. Unload trailer. See Loading And Unloading. Page 40 of 145 Loading And Unloading 5. LOADING AND UNLOADING Improper trailer loading causes many accidents and deaths. To safely load a trailer, you must consider: • Overall load weight. • Load weight distribution. • Proper tongue weight. • Securing the load properly. To determine that you have loaded the trailer within its rating, you must consider the distribution of weight, as well as the total weight of the trailer and its contents. The trailer axles carry most of the total weight of the trailer and its contents (Gross Vehicle Weight, or “GVW”). The remainder of the total weight is carried by the tow vehicle hitch. ^ WARNING Do not transport people on your trailer. Besides putting their lives at risk, the transport of people on a trailer is illegal. 5.1 LOADING TRAILER 5.1.1 PREPARING TRAILER FOR LOADING 1. Inspect the floor of the trailer. 2. Inspect the tie down rings and track system for damage, looseness or signs of bending before loading the trailer. ^ WARNING It is essential for safe towing that the trailer tongue and tow vehicle hitch carry the proper amount of the loaded trailer weight, otherwise the trailer can develop an undesirable sway at towing speeds, or the rear of the towing vehicle can be overloaded. Read the “Tongue Weight” information in Section 4. Damaged or loose tie down rings or track can break, allowing cargo to become loose. The load distribution must be such that no component part of the trailer is loaded beyond its rating. You must consider the rating of the tires, wheels and axles. For tandem and triple axle trailers, you must make sure that the front-to-rear load distribution does not result in overloading any axle. Inspect and test tie downs and track before loading cargo. Towing stability also depends on keeping the center of gravity as low as possible. Load heavy items on the floor and over the axles. When loading additional items, be sure to maintain even side-to-side weight distribution and proper tongue weight. The total weight of the trailer and its contents must never exceed the total weight rating of the trailer (Gross Vehicle Weight Rating, or “GVWR”). Do not transport people, containers of hazardous substances, or flammable liquids. The exception is fuel in the tank of vehicles or equipment being hauled. ^ WARNING Do not transport flammable, explosive, poisonous or other dangerous materials on your trailer. Loose cargo can shift the center of gravity, and result in loss of control of the trailer. Do not use a damaged or loose tie downs or track to secure cargo. 3. Park the tow vehicle and trailer on a firm and level surface. 4. Clear the area around the trailer. 5.1.2 LOADING A RIGID DECK TRAILER 1. Couple the trailer to the tow vehicle. ^ WARNING Trailer must be coupled to tow vehicle before loading trailer. 2. Lower rear stabilizers (if equipped) or place blocking under rear of trailer so the weight of the cargo does not raise the front of the trailer during loading. The exception is fuel in the tank of a vehicle or equipment being hauled. Page 41 of 145 Loading And Unloading ^ CAUTION ^ WARNING Use a safe lifting procedure to avoid injury when handling ramps. Loading a pivoting-deck trailer before retracting the deck catch pin can crack the catch pin, which can cause loss of cargo or loss of control of the trailer. Death or serious injury may result. 3. Remove ramps from storage position and secure to rear of trailer. Adjust ramp position to align with equipment tires or tracks. ^ WARNING Load can suddenly move or topple, which can result in death or serious injury. Do not load or unload trailer unless coupled to tow vehicle and is on a firm and level surface. NOTICE Ramps are not rated for load bearing capacity. They will NOT support the load bearing capacity of the trailer. Do not overload ramps. 4. Load the cargo on trailer with approximately 60% 5. 6. 7. 8. of the cargo in the front half of the trailer. Secure the load to the trailer using appropriate straps, chains and tensioning devices. Refer to www.fmcsa.dot.gov for regulations regarding cargo securement rules. Remove ramps and place in storage position. Secure ramps to trailer. Raise rear stabilizers (if equipped) or remove blocking under rear of trailer. 5.1.3 LOADING A TILT DECK TRAILER A tilt deck trailer may be equipped with a manual or a hydraulic tilt deck. 5.1.3.1 MANUAL TILT TRAILER 1. Couple the trailer to the tow vehicle. ^ WARNING Trailer must be coupled to tow vehicle before loading trailer. Before loading the trailer, retract the deck catch pin. If the deck catch pin becomes bent, do not straighten it. Replace the deck catch pin before towing the load. 3. Load the cargo on trailer with approximately 60% of the cargo in the front half of the trailer. Deck will pivot down into the driving position as the cargo is moved forward on the deck. 4. Extend the deck catch pin into the deck to lock the deck into the driving position. Verify the catch engages the hole in the pivoting deck. ^ WARNING An unlocked pivoting deck can result in loss of cargo or loss of control of the trailer, which can result in death or serious injury. Before towing the trailer: • Lock the pivoting deck in the driving position. • Verify that the catch engages the hole in the pivoting deck. 5. Secure the load to the trailer using appropriate straps, chains and tensioning devices. Refer to www.fmcsa.dot.gov for regulations regarding cargo securement rules. ^ WARNING Shifting cargo can result in loss of control of the trailer, and can lead to death or serious injury. Tie down all loads with proper sized fasteners, chains, straps, etc. 2. Release deck latch pin to pivot trailer deck for loading. Page 42 of 145 Loading And Unloading 5.1.3.2 HYDRAULIC TILT TRAILER 1. Couple the trailer to the tow vehicle. ^ WARNING Trailer must be coupled to tow vehicle before loading trailer. 2. Read and understand the hoist operating procedure before operating the tilt deck. 3. Locate the tilt deck controller. Position yourself in a 4. 5. 6. 7. 8. 9. safe location clear of the tilt deck. Press and hold button to raise the tilt deck. Release the button when the rear of the tilt deck touches the ground. Load the cargo on trailer with approximately 60% of the cargo in the front half of the trailer. Secure cargo to prevent movement. Press and hold button to lower the tilt deck. Release the button when the tilt deck is in the driving position. Secure the load to the trailer using appropriate straps, chains and tensioning devices. Refer to www.fmcsa.dot.gov for regulations regarding cargo securement rules. Stow controller. ^ WARNING Shifting cargo can result in loss of control of the trailer, and can lead to death or serious injury. Tie down all loads with proper sized fasteners, chains, straps, etc. 5.2 UNLOAD TRAILER 5. Release deck latch pin to pivot trailer deck for unloading. ^ WARNING Unloading a pivoting-deck trailer before retracting the deck catch pin can crack the catch pin, which can cause loss of cargo or loss of control of the trailer. Death or serious injury may result. Before unloading the trailer, retract the deck catch pin. If the deck catch pin becomes bent, do not straighten it. Replace the deck catch pin before towing the load. 6. Carefully move cargo toward rear of trailer. Deck will pivot down into the unload position as the cargo is moved rearward on the deck. 7. Pivot deck back to the driving position and extend the deck catch pin to lock the deck. Verify the catch engages the hole in the pivoting deck. ^ WARNING An unlocked pivoting deck can result in loss of cargo or loss of control of the trailer, which can result in death or serious injury. Before towing the trailer: • Lock the pivoting deck in the driving position. • Verify that the catch engages the hole in the pivoting deck. 5.2.1 UNLOAD MANUAL TILT TRAILER 1. Couple the trailer to the tow vehicle. 5.2.2 UNLOAD HYDRAULIC TILT TRAILER 1. Couple the trailer to the tow vehicle. ^ WARNING Trailer must be coupled to tow vehicle before unloading trailer. ^ WARNING Trailer must be coupled to tow vehicle before unloading trailer. 2. Park the tow vehicle and trailer on a firm and level surface. 3. Clear the area around the trailer. 4. Remove chains, straps and tensioning devices. 2. Park the tow vehicle and trailer on a firm and level surface. 3. Clear the area around the trailer. 4. Remove chains, straps and tensioning devices. 5. Read and understand the hoist operating procedure Page 43 of 145 Loading And Unloading before operating the tilt deck. 6. Locate the tilt deck controller. Position yourself in a safe location clear of the tilt deck. 7. Press and hold button to raise the tilt deck. Release the button when the rear of the tilt deck touches the ground. 8. Unload the cargo from trailer. 9. Press and hold button to lower the tilt deck. Release the button when the tilt deck is in the driving position. 10. Stow controller. 5.3 HYDRAULIC COMPONENTS Do not alter or substitute and hydraulic components on the trailer. The hydraulic system is designed with each component being compatible with the safe and reliable operation of the hydraulic system. Under no circumstances should you alter the hydraulic pressure or flow rate in the hydraulic system. ^ DANGER Crushing hazard. An altered or component substituted hydraulic system may malfunction, resulting in the tilt deck falling without warning. NEVER alter or substitute any hydraulic system component. Always have the hydraulic system repaired or maintained by a qualified technician. 5.4 SECURING CARGO ^ WARNING Shifting cargo can result loss of control of the trailer, and can lead to death or serious injury. Tie down all loads with proper sized fasteners, chains, straps, etc. Refer to www.fmcsa.dot.gov for regulations regarding cargo securement rules. Page 44 of 145 Pre-Tow Checklist 6. PRE-TOW CHECKLIST 6.1 PRE-TOW CHECKLIST Before towing, double-check all of these items: • Tires, wheels and lug nuts. See “Breaking In A New Trailer” section of this manual. • Tire Pressure. Inflate tires on trailer and tow vehicle to the pressure stated on the Certification / VIN label. • Coupler secured and locked. See “Coupling To Tow Vehicle” section of this manual. • Safety chains properly rigged to tow vehicle, not to hitch or ball. See “Coupling To Tow Vehicle” section of this manual. • Test Tail, Stop, and Turn Lights. • Test trailer brakes. • Safety breakaway lanyard fastened to tow vehicle, not to safety chains. See “Coupling To Tow Vehicle” section of this manual. • Cargo properly loaded, balanced and tied down. See the appropriate “Loading And Unloading” section of this manual. • Tongue weight and weight distribution set-up. • Ramps secured for travel. • Fire extinguisher. • Flares and reflectors. 6.2 MAKE REGULAR STOPS After each 50 miles, or one hour of towing, stop and check the following items: • Coupler secured. • Safety chains are fastened and not dragging. • Cargo secured. Page 45 of 145 Breaking In A New Trailer 7. BREAKING IN A NEW TRAILER ^ WARNING 7.1 RETIGHTEN LUGS AT FIRST 10, 25 & 50 MILES Wheel lugs can shift and settle quickly after being first assembled, and must be checked after the first 10, 25 and 50 miles of driving. Failure to perform this check may result in a wheel coming loose from the trailer, causing a crash leading to death or serious injury. Improper tightening of the lug nuts or bolts voids the axle warranty. If trailer and tow vehicle brakes do not work properly together, death or serious injury can occur. Road test the brakes in a safe area at no more than 30 m.p.h. before each tow. To insure safe brake performance and synchronization, read and follow the axle/brake and the brake controller manufacturers’ instructions. If you do not have these instructions, contact your dealer for assistance. Refer to the Inspection, Service and Maintenance section of this manual. ^ WARNING Lug nuts or bolts are prone to loosen after being first assembled. Death or serious injury can result. Check lug nuts or bolts for tightness on a new trailer, and after re-mounting a wheel at 10, 25 and 50 miles. 7.2 ADJUST BRAKE AT FIRST 200 MILES Brake shoes and drums experience a rapid initial wear. The brakes must be adjusted after the first 200 miles of use, and each 3,000 miles thereafter. Some axles are fitted with a mechanism that will automatically adjust the brake shoes. Read your axle and brake manual to see if your brakes adjust automatically. If you do not have the axle and brake manual, contact your dealer for assistance. If your trailer is not fitted with automatically adjusting brakes, the brakes will need to be manually adjusted. See section 9 for instructions. 7.3 SYNCHRONIZING BRAKE SYSTEMS Trailer brakes are designed to work in synchronization with the brakes on the tow vehicle. When the tow vehicle and trailer braking systems are synchronized, both braking systems contribute to slowing, and the tongue of the trailer will neither dive nor rise sharply. Page 46 of 145 Accessories 8. ACCESSORIES This section provides some basic information for the safe operation of accessories. You must read and follow these instructions before using the accessory. If you are uncertain whether you have all of the instructions, contact your dealer before operating the accessory. 8.1 ACCESSORY BATTERY Your trailer may be equipped with an accessory battery that operates the tilt deck. The battery may be kept charged either by the tow vehicle, by an auxiliary charger or by using an onboard battery maintainer/charger (if equipped). If the trailer is used daily, it is recommended that the battery charger be plugged in after each days use. The battery may be located in a tongue mounted battery box or a side mounted box. The accessory battery must be kept in a charged condition during storage. The battery could freeze and break if it becomes discharged. If the battery is not fully charged, the hydraulic pump will lose pressure which may cause hydraulic fluid to flow back into the hydraulic reservoir, overfilling the reservoir and ejecting fluid into the battery box. ^ WARNING Risk of battery exploding. Battery box prop rod may contact battery terminals, which may result in the battery exploding. Place battery box lid prop rod in retaining clip. Page 47 of 145 Inspection, Service And Maintenance 9. INSPECTION, SERVICE AND MAINTENANCE 9.1 INSPECTION, SERVICE & MAINTENANCE SUMMARY CHARTS You must inspect, maintain and service your trailer regularly to insure safe and reliable operation. If you cannot or are unsure how to perform the items listed here, have your dealer do them. Note: In addition to this manual, also check the relevant component manufacturer’s manual. Item Breakaway Brakes • Electric • Hydraulic Breakaway Battery Brakes • Electric • Surge Inspection And Service Before Each Tow Inspection/Service Manual Section Reference Shoes And Drums Safety Chains And Hooks Coupler And Hitch Ball Check operation. Check operation. Fully charged, connections clean. Section 4. Section 4. Section 4 and 9. Check operation. Check operation. Check master cylinder level. Adjust Check for wear, damage. Check for cracks, pits, and flats. Replace w/ ball and coupler having trailer GVW Rating. Section 4 and 9. Grease. Ring And Pintle Wheels - Lug Nuts Or Bolts & Hub Section 4 and 9. Check locking device & replace Section 4 and 9. when worn. Check for cracks, pits, and flats. Section 4 and 9. Replace w/ ring and pintle having trailer GVW Rating. Grease. Tires Section 9. Section 4. Section 4 and 9. Section 4 and 9. Check locking device & replace Section 4 and 9. when worn. Check tire pressure when cold. Section 6 and 9 Inflate as needed. Section 6 and 9 Check for damage. Check for tightness. Section 6. Tighten. For new and remounted Section 7 and 9. wheels, check torque after first 10, 25 & 50 miles of driving and after any impact. Page 48 of 145 Inspection, Service And Maintenance Inspection And Service Every Month Inspection / Service Manual Section Reference Lubricate tilt deck pivot points (if Section 9. equipped). Item Lubrication Lubricate hydraulic cylinder ends (if Section 9. equipped). Item Brakes, electric • Magnet • Inspection and Service Every 6 Months or 6,000 Miles Inspection/Service Manual Section Reference Controller (in tow vehicle) Tires Check wear and current draw. Section 9. Check power output (amperage) Section 9. and modulation. See Controller Mfr’s Manual Inspect tread thoroughly. and sidewalls Section 9. Replace tire when treads are worn, Section 9. when sidewall has a bulge, or sidewall is worn. Brakes • Electric • Surge Brake Shoes And Drums Safety Chains & Hooks Coupler And Hitch Ball Rotate every 5,000 Miles. Section 9. Check Operation. Check Operation. Check Master Cylinder Level. Adjust Check for wear, damage. Check for cracks, pits, and flats. Replace w/ ball and coupler having trailer GVW Rating. Section 4. Grease. Ring And Pintle Section 7 and 9. Section 4. Section 4. Section 4 and 9. Check locking device and replace Section 4 and 9. when worn. Check for cracks, pits, and flats. Section 4. Replace w/ ring and pintle having trailer GVW Rating. Grease. Section 4 and 9. Check locking device & replace Section 4 and 9. when worn. Page 49 of 145 Inspection, Service And Maintenance Item Brakes, all types • Shoes and Drums Inspection And Service Every Year or 12,000 Miles Inspection/Service Manual Section Reference Check for scoring and wear. Replace Section 9. per manufacturer’s specifications. See Brake Mfr’s Manual Jack, Drop-leg (if equipped) Structure • Frame Members • Welds Wheels • Wheel Bearings • Grease gears at top. See Jack Mfr’s Manual Inspect all frame members, bolts & Section 9. rivets. Repair or replace damaged, worn or broken parts. Inspect all needed. welds. Repair as Section 9. Disassemble / inspect / assemble Section 9 & See Axle Mfr’s Manual and repack. Replace promptly if immersed in water. Rims Inspect for cracks & dents. Replace as needed. Structure • Axle Attachment Bolts Check BY DEALER Section 9. Page 50 of 145 Inspection, Service And Maintenance 9.2 INSPECTION AND SERVICE INSTRUCTIONS ^ WARNING Worn or broken suspension parts can cause loss of control and injury may result. Have trailer professionally inspected annually and after any impact. To perform many of the inspection and maintenance activities, you must jack up the trailer. When jacking and using jack stands, place them so as to clear wiring, brake lines, and suspension parts (springs, torsion bars, etc.). Place jacks and jack stands under the outer frame rail to which the axles are attached. ^ WARNING Never go under trailer unless it is on firm and level ground and resting on properly placed and secured jack stands. ^ WARNING ^ WARNING Broken or damaged fasteners can cause injury or damage to trailer and contents. Inspect for, and repair all damaged parts at least once a year. 9.2.1.2 WELDS All welds can crack or fail when subjected to heavy loads or movement of cargo that was not properly secured. Any time that you know or suspect that the trailer has been subjected to heavy loads or movement of cargo, immediately inspect the welds and fasteners for damage. To prevent severe damage to your trailer, inspect all of the welds for cracks or failure at least once a year. If a weld failure is detected, contact your dealer. ^ WARNING Do not attempt to repair a cracked or broken weld unless you have the skills and equipment to make the repair. Crushing hazard. Improper weld repair will lead to early failure of the trailer structure and serious injury or death. The tow vehicle and trailer could be inadvertently moved while a person is under the trailer. See your dealer for weld repairs. The tow vehicle engine must be off, ignition key removed and parking brakes set before entering the area under the trailer. 9.2.1 TRAILER STRUCTURE Wash the trailer as needed with a power washer and a detergent solution. ^ WARNING Broken or damaged welds can cause injury or damage to trailer and contents. Inspect for, and repair all damaged parts at least once a year. 9.2.2 TRAILER BRAKES - ELECTRIC 9.2.2.1 BRAKE DISCS, SHOES AND DRUMS 9.2.1.1 FASTENERS AND FRAME MEMBERS Inspect all fasteners and structural frame members for bending and other damage, cracks, or failure. Repair or replace any damaged fastener and repair the frame member. If you have any questions about the condition or method of repair of fasteners or frame members, get the recommendation of, or have the repair done by your dealer. Properly functioning brake shoes and drums are essential to ensure safety. You must have your dealer inspect these components at least once per year, or each 12,000 miles. Brake adjustment is not covered under the axle warranty. The brake shoes must be adjusted after the first 200 miles of use, and each 3,000 miles thereafter. Most axles are fitted with a brake mechanism that will automatically adjust the brake shoes when the trailer Page 51 of 145 Inspection, Service And Maintenance is “hard braked” from a rearward direction. Trailer disc brakes are self-adjusting and do not need to be periodically adjusted. Using pads or shoes without enough brake lining material can result in brake damage, create excessive heat and potentially cause the loss of braking capacity. Read your axle and brake manual to see how to adjust your brakes. If you do not have this manual, contact your dealer for assistance. 9.2.2.2 MANUALLY ADJUSTING BRAKE SHOES Some braking systems are not automatically adjusted. These brakes require manual adjustment. The following steps apply to adjust most manually adjustable brakes. Read your axle and brake manual to see how to adjust your brakes. If you do not have this manual, contact your dealer for assistance. 1. Jack up the trailer and secure it on adequate capacity jack stands. 2. Be sure the wheel and brake drum rotate freely. 3. Remove the adjusting-hole cover from the adjusting 4. 5. 6. 7. 8. slot on the bottom of the brake backing plate. With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn. Note: Your trailer maybe equipped with drop spindle axles. See axle manual for your axle type. You will need a modified adjusting tool for adjusting the brakes in these axles. Rotate the starwheel in the opposite direction until the wheel turns freely with a slight drag. Replace the adjusting-hole cover. Repeat the above procedure on all brakes. Lower the trailer to the ground. 9.2.2.3 ELECTRIC BRAKES Two different types of electric brakes may be present on the trailer: an emergency electric breakaway system, which acts only if the trailer comes loose from the hitch and the breakaway pin is pulled. The other brake is an electric braking system that acts whenever the brakes of the tow vehicle are applied. Breakaway Battery - This battery supplies the power to operate the trailer brakes if the trailer uncouples from the tow vehicle. Be sure to check, maintain and replace the battery according to the battery manufacturer’s instructions. Your trailer may use the hydraulic system battery to operate the breakaway brakes. ^ CAUTION Extreme cold weather can degrade battery performance and cause brakes to not operate properly. Check battery charge level before towing. Breakaway Switch - This switch engages the electric brakes if the trailer uncouples from the tow vehicle. To check for proper functioning of the switch, battery and brakes, you must pull the pin from the switch and confirm that the brakes apply to each wheel. You can do this by trying to pull the trailer with the tow vehicle, after pulling the pin. The trailer brakes may not lock, but you will notice that a greater force is needed to pull the trailer. ^ WARNING If electric breakaway brakes do not operate when trailer is uncoupled from the tow vehicle, death or serious injury can occur. Check emergency breakaway brake system before each tow. 9.2.2.4 TOW VEHICLE OPERATED ELECTRIC BRAKES The electric brakes that operate in conjunction with the tow vehicle brakes must be “synchronized” so that braking is properly distributed to the tow vehicle brakes and the trailer brakes. For proper operation and synchronization, read and follow the axle/brake and the brake controller manufacturers’ instructions. If you do not have these instructions, contact your dealer for assistance. 9.2.2.5 ELECTRIC BRAKE MAGNETS To make certain an electrically-operated braking system will function properly, you must have your dealer inspect the magnets at least once a year, or each 12,000 miles. See the brake manual for wear and current inspection instructions. 9.2.3 TRAILER BRAKES - SURGE (IF EQUIPPED) 9.2.3.1 SURGE BRAKE MASTER CYLINDER Page 52 of 145 Inspection, Service And Maintenance Check fluid level prior to using the trailer. The master cylinder is normally located on the tongue of the trailer. The fluid level must maintained at full mark on reservoir. Check with your dealer for the type of brake fluid used in the brake system. 9.2.3.2 HYDRAULIC SURGE BRAKE Before each tow, perform the following steps: 1. Check that the brake master cylinder level as instructed above. Check for leaks and repair as required. 2. Examine the actuator for wear, bent parts, corroded/ seized parts, or other damage. Have the affected components replaced with genuine service parts. 3. Check to determine that the actuator mounting bolts are tightened to the manufacturer’s specification. 4. Test the actuator and brake function as described in the Coupling To Tow Vehicle section of this manual. Actuator travel over one inch indicates that the brakes need adjustment (or that the actuator has been structurally damaged). Actuator travel is the distance the coupler case assembly moves to the outer case during braking. Adjust the brakes following the instructions given in the brake installation manual. Failure to adjust brakes will result in loss of braking. 5. Before storage or after extended use, apply motor oil to the coupler components and the internal rollers to keep them moving freely and to prevent corrosion. 6. See the surge brake manufacturer’s manual for other inspection and maintenance activities. If you do not have this manual, contact your dealer for assistance. 2. Fill the master cylinder with correct fluid. 3. Install a bleeder hose on the bleeder screw of the farthest wheel cylinder from the actuator. If the trailer has multiple axles, bleed the rear axle first. Submerse the other end of the hose in a glass container of brake fluid, so that air bubbles can be observed. 4. Open the bleeder screw and have an assistant stroke (but not release) the actuator. Brake fluid and/or air bubbles will flow into the jar. Close the bleeder screw. The helper can then allow the actuator to return to its rest position. 5. Repeat the process until no more bubbles are released with the stroke. Air trapped in the brake lines will greatly reduce your braking efficiency. Be sure to close the bleeder screw securely when the cylinder is fully bled. Repeat the bleeding operation at each wheel cylinder. During the bleeding process, replenish the master cylinder reservoir with fresh brake fluid so that the level does not fall below half full. This will ensure that no air is drawn into the system. 6. After all brakes have been bled, refill the master cylinder before operating. Be sure to install the master cylinder filler cap. ^ WARNING Use only fresh brake fluid from a sealed container. DO NOT reuse fluid. After filling and bleeding, refill the actuator. Failure to maintain an adequate fluid level may cause brake failure. 9.2.3.3 MASTER CYLINDER BLEEDING 9.2.4 TRAILER CONNECTION TO TOW VEHICLE Remove the master cylinder’s cap and fill the reservoir to three quarters full with DOT-3 or DOT 4 brake fluid. DO NOT allow brake fluid to contact painted surfaces since it will damage the finish. Wipe up any spills immediately and wash the area with water. 9.2.4.1 COUPLER AND BALL Bleed the brake system manually or with a pressure bleeder. Pressure bleeding equipment simplifies the process, and is available at most automotive supply stores. Use the instructions provided with the pressure bleeder. If you chose to manually bleed the system, an assistant is required. Use the following steps to manually bleed the brake system: 1. Disconnect the trailer from the tow vehicle and jack the trailer’s tongue until it is horizontal. Make sure that the wheels are blocked so that the trailer will not roll away. Before each tow, coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation; and check the locking device that secures the coupler to the ball for proper operation. See the coupler manufacturer’s manual for other inspection and maintenance procedures. If you do not have this manual, contact your dealer for assistance. If you see or feel evidence of wear, such as flat spots, deformations, pitting or corrosion, on the ball or coupler, immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and coupler system. All bent or broken coupler parts must be replaced before towing the trailer. Page 53 of 145 Inspection, Service And Maintenance The coupler latch lever must be able to rotate freely and automatically snap into the latched position. Oil the pivot points, sliding surfaces, and spring ends with SAE 30W motor oil. Keep the ball pocket and latch mechanism clean. Dirt or contamination can prevent proper operation of the latching mechanism. To avoid risk of collisions, all lights must work. 9.2.7 WHEEL RIMS When replacing a ball, the load rating must match or exceed the GVWR of the trailer. If the trailer has been struck, or impacted, on or near the wheels, or if the trailer has struck a curb, inspect the rims for damage. Replace any damaged wheel. Inspect the wheels for damage every year, even if no obvious impact has occurred. 9.2.4.2 RING AND PINTLE 9.2.8 TIRES Before each tow, coat the ring with a thin layer of automotive bearing grease to reduce wear and ensure proper operation; and check the locking device that secures the pintle to the ring for proper operation. Before each tow, check the tire pressure to make sure it is at the level indicated on the tire sidewall or VIN label. Tire pressure must be checked while the tire is cold. Do not check tire pressure immediately after towing the trailer. Allow at least three hours for the tires to cool, if the trailer has been towed for as much as one mile. Tires can lose air over a period of time. See the pintle manufacturer’s manual for other inspection and maintenance activities. If you do not have this manual, contact your dealer for assistance. If you see or feel evidence of wear, such as flat spots, deformations, pitting or corrosion, on the ring or pintle, immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ring and pintle system. All bent or broken coupler parts must be replaced before towing the trailer. The pintle handle lever must be able to rotate freely and automatically snap into the latched position. Oil the pivot points, sliding surfaces, and spring ends with SAE 30W motor oil. Keep the ring pocket and latch mechanism clean. Dirt or contamination can prevent proper operation of the latching mechanism. Replace the tire before towing the trailer if the tire treads have less than 2/32 inch depth or the telltale bands are visible. A bubble, cut or bulge in a side wall can result in a tire blowout. Inspect both side walls of each tire for any bubble, cut or bulge; and replace a damaged tire before towing the trailer. If you are storing your trailer for an extended period, make sure the tires are inflated to the maximum rated pressure indicated on the sidewall or VIN label and that you store them in a cool, dry place such as a garage. Use tire covers to protect the tires from the harsh effects of the sun. When replacing a ring, the load rating must match or exceed the GVWR of the trailer. 9.2.5 LANDING LEG OR JACK If a grease fitting is present, use a grease gun to lubricate the jack mechanism. Grease the gears in the top of hand-cranked jacks once a year, by removing the top of the jack and pumping or hand packing grease into the gears. 9.2.6 LIGHTS AND SIGNALS Before each tow, check all trailer lights for proper operation. ^ WARNING Page 54 of 145 Inspection, Service And Maintenance Never go under trailer unless it is on firm and level ground and resting on properly placed and secured jack stands. If your axle(s) are equipped with a grease zerk on the ends of the axle(s), the bearings must be greased every 6 months or 6,000 miles to ensure reliable and safe operation of your trailer. 1. Remove the rubber plug from the axle end. 2. Place grease gun on zerk. 3. Pump grease until new grease begins to appear. Use a different color grease each time so you will know when the new grease begins to appear. 4. Install rubber plug and cap. Repeat for remaining wheel bearings. If your trailer axle(s) are not equipped with grease zerks, refer to the axle manufacturer’s manual for service and maintenance information. 9.2.10 LUBRICATION Lubricate tilt deck pivots and hydraulic cylinder ends every month (if equipped). 9.2.11 HYDRAULIC RESERVOIR Check fluid level prior to towing the trailer. The reservoir is normally located inside the battery box. Tire Inspection Chart ^ WARNING Worn, damaged or under-inflated tires can cause loss of control, injury and damage. Check tires before each tow. 9.2.9 WHEEL BEARINGS A loose, worn or damaged wheel bearing is the most common cause of brakes that grab. To check your bearings, jack up the trailer and secure it on adequate capacity jack stands. Check wheels for side-to-side looseness. The tilt deck must be fully lowered before checking fluid level. The reservoir should be filled to the full mark on the side of the reservoir. Use a quality hydraulic fluid with anti-wear properties, rust and oxidation inhibitors. Fluid ejecting from the reservoir could indicate a low battery. 9.2.12 LUG NUTS OR BOLTS Lug nuts or bolts are prone to loosen right after a wheel is mounted to a hub. When driving on a remounted wheel, check to see if the lug nuts or bolts are tight after the first 10, 25 and 50 miles of driving, and before each tow thereafter. ^ WARNING If the wheels are loose, or spin with a wobble, the bearings must be serviced or replaced. ^ WARNING Page 55 of 145 Inspection, Service And Maintenance Lug nuts or bolts are prone to loosen after being first assembled. Death or serious injury can result. Check lug nuts or bolts for tightness on a new trailer, and after re-mounting a wheel at 10, 25 and 50 miles. ^ WARNING Metal creep between the wheel rim and lug nuts or bolts can cause rim to loosen. Death or injury can occur if wheel comes off. Tighten lug nuts or bolts before each tow. Tighten the lug nuts or bolts in three stages to the final torque for the axle size on your trailer, to prevent wheels from coming loose. Tighten each lug nut or bolt in the order shown in the following figure. Use a calibrated torque wrench to tighten the fasteners. Verify that wheel studs are free of contaminates such as paint or grease, which may result in inaccurate torque readings. Over-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels, and will void the axle warranty. See your axle manufacturers manual or your dealer for wheel nut or bolt torque specifications. Page 56 of 145 Tire Safety Information 1. TIRE SAFETY INFORMATION This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6. Section 2.1 contains “Steps for Determining Correct Load Limit - Trailer”. Section 2.2 contains “Steps for Determining Correct Load Limit – Tow Vehicle”. Section 2.3 contains a Glossary of Tire Terminology, including “cold inflation pressure”, “maximum inflation pressure”, “recommended inflation pressure”, and other non-technical terms. Section 2.4 contains information from the NHTSA brochure entitled “Tire Safety – Everything Rides On It”. This brochure This brochure, as well as the preceding subsections, describes the following items; Tire labeling, including a description and explanation of each marking on the tires, and information about the DOT Tire Identification Number (TIN). Recommended tire inflation pressure, including a description and explanation of: A. Cold inflation pressure. B. Vehicle Placard and location on the vehicle. C. Adverse safety consequences of under inflation (including tire failure). D. Measuring and adjusting air pressure for proper inflation. Tire Care, including maintenance and safety practices. Vehicle load limits, including a description and explanation of the following items: A. Locating and understanding the load limit information, total load capacity, and cargo capacity. B. Calculating total and cargo capacities with varying seating configurations including quantitative examples showing / illustrating how the vehicles cargo and luggage capacity decreases as combined number and size of occupants’ increases. This item is also discussed in Section 3. C. Determining compatibility of tire and vehicle load capabilities. D. Adverse safety consequences of overloading on handling and stopping on tires. 1.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a Federal certification/VIN label that is located on the forward half of the left (road) side of the unit. This certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most weight the fully loaded trailer can weigh. It will also provide the Gross Axle Weight Rating (GAWR). This is the most a particular axle can weigh. If there are multiple axles, the GAWR of each axle will be provided. If your trailer has a GVWR of 10,000 pounds or less, there is a vehicle placard located in the same location as the certification label described above. This placard provides tire and loading information. In addition, this placard will show a statement regarding maximum cargo capacity. Cargo can be added to the trailer, up to the maximum weight specified on the placard. The combined weight of the cargo is provided as a single number. In any case, remember: the total weight of a fully loaded trailer can not exceed the stated GVWR. For trailers with living quarters installed, the weight of water and propane also need to be considered. The weight of fully filled propane containers is considered part of the weight of the trailer before it is loaded with cargo, and is not considered part of the disposable cargo load. Water however, is a disposable cargo weight and is treated as such. If there is a fresh water storage tank of 100 gallons, this tank when filled would weigh about 800 pounds. If more cargo is being transported, water can be off-loaded to keep the total amount of cargo added to the vehicle within the limits of the GVWR so as not to overload the vehicle. Understanding this flexibility will allow you, the owner, to make choices that fit your travel needs. When loading your cargo, be sure it is distributed evenly to prevent overloading front to back and side to side. Heavy items should be placed low and as close to the axle positions as reasonable. Too many items on one side may overload a tire. The best way to know the actual weight of the vehicle is to weigh it at a public scale. Talk to your dealer to discuss the weighing methods needed to capture the various weights related to the trailer. This would include the weight empty or unloaded, weights per axle, wheel, hitch or king-pin, and total weight. Page 57 of 145 Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the certification/VIN label and/or on the Tire Placard. This value should never exceed the maximum cold inflation pressure stamped on the tire. 1.1.1. TRAILERS 10,000 POUNDS GVWR OR LESS Tire and Loading Information Placard – Figure 1-1 1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s placard. See figure 1-1. 2. This figure equals the available amount of cargo and luggage load capacity. 3. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity. The trailer’s placard refers to the Tire Information Placard attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer. 1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: THESE TRAILERS ARE NOT REQUIRED TO HAVE A TIRE INFORMATION PLACARD ON THE VEHICLE) 1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means. This step does not have to be repeated. 2. Locate the GVWR (Gross Vehicle Weight Rating) of the trailer on your trailer’s VIN (Certification) label. 3. Subtract the empty weight of your trailer from the GVWR stated on the VIN label. That weight is the maximum available cargo capacity of the trailer and may not be safely exceeded. 1.2. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TOW VEHICLE 1. Locate the statement, “The combined weight of occupants and cargo should never exceed XXX lbs.,” on your vehicle’s placard. 2. Determine the combined weight of the driver and passengers who will be riding in your vehicle. 3. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds. 4. The resulting figure equals the available amount of cargo and luggage capacity. For example, if the “XXX” amount equals 1400 lbs. and there will be five 150 lb. passengers in your vehicle, the amount of available cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.). 5. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage capacity calculated in Step # 4. 6. If your vehicle will be towing a trailer, load from your trailer will be transferred to your vehicle. Consult the tow vehicle’s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle. 1.3. GLOSSARY OF TIRE TERMINOLOGY Accessory weight The combined weight (in excess of those standard items which may be replaced) of automatic transmission, power steering, power brakes, power windows, power seats, radio and heater, to the extent that these items are available as factory-installed equipment (whether installed or not). Page 58 of 145 Bead The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the rim. Bead separation This is the breakdown of the bond between components in the bead. Bias ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less than 90 degrees to the centerline of the tread. Carcass The tire structure, except tread and sidewall rubber which, when inflated, bears the load. Chunking The breaking away of pieces of the tread or sidewall. Cold inflation pressure The pressure in the tire before you drive. Cord The strands forming the plies in the tire. Cord separation The parting of cords from adjacent rubber compounds. Cracking Any parting within the tread, sidewall, or inner liner of the tire extending to cord material. CT A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire. Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine. Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Groove The space between two adjacent tread ribs. Gross Axle Weight Rating The maximum weight that any axle can support, as published on the Certification / VIN label on the front left side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached to the towing vehicle. Gross Vehicle Weight Rating The maximum weight of the fully loaded trailer, as published on the Certification / VIN label. Actual weight determined by weighing trailer on a public scale, without being attached to the towing vehicle. Hitch Weight The downward force exerted on the hitch ball by the trailer coupler. Innerliner The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire. Innerliner separation The parting of the innerliner from cord material in the carcass. Page 59 of 145 Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle. Light truck (LT) tire A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating The maximum load that a tire is rated to carry for a given inflation pressure. Maximum load rating The load rating for a tire at the maximum permissible inflation pressure for that tire. Maximum permissible inflation pressure The maximum cold inflation pressure to which a tire may be inflated. Maximum loaded vehicle weight The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight. Measuring rim The rim on which a tire is fitted for physical dimension requirements. Pin Weight th The downward force applied to the 5 wheel or gooseneck ball, by the trailer kingpin or gooseneck coupler. Non-pneumatic rim A mechanical device which, when a non-pneumatic tire assembly incorporates a wheel, supports the tire, and attaches, either integrally or separably, to the wheel center member and upon which the tire is attached. Non-pneumatic spare tire assembly A non-pneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of this standard. Non-pneumatic tire A mechanical device which transmits, either directly or through a wheel or wheel center member, the vertical load and tractive forces from the roadway to the vehicle, generates the tractive forces that provide the directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those functions. Non-pneumatic tire assembly A non-pneumatic tire, alone or in combination with a wheel or wheel center member, which can be mounted on a vehicle. Normal occupant weight This means 68 kilograms (150 lbs.) times the number of occupants specified in the second column of Table I of 49 CFR 571.110. Occupant distribution The distribution of occupants in a vehicle as specified in the third column of Table I of 49 CFR 571.110. Open splice Any parting at any junction of tread, sidewall, or innerliner that extends to cord material. Outer diameter The overall diameter of an inflated new tire. Overall width Page 60 of 145 The linear distance between the exteriors of the sidewalls of an inflated tire, including elevations due to labeling, decorations, or protective bands or ribs. Ply A layer of rubber-coated parallel cords. Ply separation A parting of rubber compound between adjacent plies. Pneumatic tire A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load. Production options weight The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in curb weight or accessory weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and special trim. Radial ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90 degrees to the centerline of the tread. Recommended inflation pressure This is the inflation pressure provided by the vehicle manufacturer on the Tire Information label and on the Certification / VIN tag. Reinforced tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Rim A metal support for a tire or a tire and tube assembly upon which the tire beads are seated. Rim diameter This means the nominal diameter of the bead seat. Rim size designation This means the rim diameter and width. Rim type designation This means the industry of manufacturer’s designation for a rim by style or code. Rim width This means the nominal distance between rim flanges. Section width The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to labeling, decoration, or protective bands. Sidewall That portion of a tire between the tread and bead. Sidewall separation The parting of the rubber compound from the cord material in the sidewall. Special Trailer (ST) tire The "ST" is an indication the tire is for trailer use only. Test rim The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with that tire. Tread Page 61 of 145 That portion of a tire that comes into contact with the road. Tread rib A tread section running circumferentially around a tire. Tread separation Pulling away of the tread from the tire carcass. Treadwear indicators (TWI) The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread. Vehicle capacity weight The rated cargo and luggage load plus 68 kilograms (150 lbs.) times the vehicle’s designated seating capacity. Vehicle maximum load on the tire The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded vehicle weight and dividing by two. Vehicle normal load on the tire The load on an individual tire that is determined by distributing to each axle its share of the curb weight, accessory weight, and normal occupant weight (distributed in accordance with Table I of CRF 49 571.110) and dividing by 2. Weather side The surface area of the rim not covered by the inflated tire. Wheel center member In the case of a non-pneumatic tire assembly incorporating a wheel, a mechanical device which attaches, either integrally or separably, to the non-pneumatic rim and provides the connection between the nonpneumatic rim and the vehicle; or, in the case of a non-pneumatic tire assembly not incorporating a wheel, a mechanical device which attaches, either integrally or separably, to the non-pneumatic tire and provides the connection between tire and the vehicle. Wheel-holding fixture The fixture used to hold the wheel and tire assembly securely during testing. 1.4. TIRE SAFETY - E VERYTHING RIDES ON IT The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It can be obtained and downloaded from NHTSA, free of charge, from the following web site: http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards, and inspecting tires for cuts, slashes, and other irregularities are the most important things you can do to avoid tire failure, such as tread separation or blowout and flat tires. These actions, along with other care and maintenance activities, can also: Improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve fuel economy Increase the life of your tires. This booklet presents a comprehensive overview of tire safety, including information on the following topics: Basic tire maintenance Uniform Tire Quality Grading System Fundamental characteristics of tires Page 62 of 145 Tire safety tips. Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure. 1.5. SAFETY FIRST–BASIC TIRE M AINTENANCE Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle. Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above, to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and vehicle load limits, avoid road hazards, and regularly inspect your tires. 1.5.1. FINDING YOUR VEHICLE 'S RECOMMENDED TIRE PRESSURE AND L OAD LIMITS Tire information placards and vehicle certification labels contain information on tires and load limits. These labels indicate the vehicle manufacturer's information including: Recommended tire size Recommended tire inflation pressure Vehicle capacity weight (VCW–the maximum occupant and cargo weight a vehicle is designed to carry) Front and rear gross axle weight ratings (GAWR– the maximum weight the axle systems are designed to carry). Both placards and certification labels are permanently attached to the trailer near the left front. 1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air pressure– measured in pounds per square inch (psi)–a tire requires to be properly inflated. (You will also find this number on the vehicle information placard expressed in kilopascals (kpa), which is the metric measure used internationally.) Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle's design load limit, that is, the greatest amount of weight a vehicle can safely carry and the vehicle's tire size. The proper tire pressure for your vehicle is referred to as the "recommended cold inflation pressure." (As you will read below, it is difficult to obtain the recommended tire pressure if your tires are not cold.) Because tires are designed to be used on more than one type of vehicle, tire manufacturers list the "maximum permissible inflation pressure" on the tire sidewall. This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions. 1.5.3. CHECKING TIRE PRESSURE It is important to check your vehicle's tire pressure at least once a month for the following reasons: Most tires may naturally lose air over time. Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when parking. With radial tires, it is usually not possible to determine underinflation by visual inspection. For convenience, purchase a tire pressure gauge to keep in your vehicle. Gauges can be purchased at tire dealerships, auto supply stores, and other retail outlets. The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper psi when a tire is cold. The term cold does not relate to the outside temperature. Rather, a cold tire is one that has not been driven on for at least three hours. When you drive, your tires get warmer, causing the air pressure within them to increase. Therefore, to get an accurate tire pressure reading, you must measure tire pressure when the tires are cold or compensate for the extra pressure in warm tires. Page 63 of 145 1.5.4. STEPS FOR MAINTAINING PROPER TIRE PRESSURE Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification label, or in the owner's manual. Step 2: Record the tire pressure of all tires. Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pressure. Step 4: If the tire pressure is too low, note the difference between the measured tire pressure and the correct tire pressure. These "missing" pounds of pressure are what you will need to add. Step 5: At a service station, add the missing pounds of air pressure to each tire that is underinflated. Step 6: Check all the tires to make sure they have the same air pressure (except in cases in which the front and rear tires are supposed to have different amounts of pressure). If you have been driving your vehicle and think that a tire is underinflated, fill it to the recommended cold inflation pressure indicated on your vehicle's tire information placard or certification label. While your tire may still be slightly underinflated due to the extra pounds of pressure in the warm tire, it is safer to drive with air pressure that is slightly lower than the vehicle manufacturer's recommended cold inflation pressure than to drive with a significantly underinflated tire. Since this is a temporary fix, don't forget to recheck and adjust the tire's pressure when you can obtain a cold reading. 1.5.5. TIRE SIZE To maintain tire safety, purchase new tires that are the same size as the vehicle's original tires or another size recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of the tire you are replacing to find this information. If you have any doubt about the correct size to choose, consult with the tire dealer. 1.5.6. TIRE TREAD The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding, especially when the road is wet or icy. In general, tires are not safe and should be replaced when the tread is worn down to 1/16 of an inch. Tires have built-in treadwear indicators that let you know when it is time to replace your tires. These indicators are raised sections spaced intermittently in the bottom of the tread grooves. When they appear "even" with the outside of the tread, it is time to replace your tires. Another method for checking tread depth is to place a penny in the tread with Lincoln's head upside down and facing you. If you can see the top of Lincoln's head, you are ready for new tires. 1.5.7. TIRE BALANCE AND WHEEL ALIGNMENT To avoid vibration or shaking of the vehicle when a tire rotates, the tire must be properly balanced. This balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel-and-tire assembly. A wheel alignment adjusts the angles of the wheels so that they are positioned correctly relative to the vehicle's frame. This adjustment maximizes the life of your tires. These adjustments require special equipment and should be performed by a qualified technician. 1.5.8. TIRE REPAIR The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected before being plugged and patched. 1.5.9. TIRE FUNDAMENTALS Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall. Page 64 of 145 1.5.9.1. Information on Passenger Vehicle Tires Please refer to the diagram below. P The "P" indicates the tire is for passenger vehicles. Next number This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire. Next number This two-digit number, known as the aspect ratio, gives the tire's ratio of height to width. Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement. R The "R" stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years. Next number This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter. Next number This two- or three-digit number is the tire's load index. It is a measurement of how much weight each tire can support. You may find this information in your owner's manual. If not, contact a local tire dealer. Note: You may not find this information on all tires because it is not required by law. M+S The "M+S" or "M/S" indicates that the tire has some mud and snow capability. Most radial tires have these markings; hence, they have some mud and snow capability. Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time. The ratings range from 99 miles per hour (mph) to 186 mph. These ratings are listed below. Note: You may not find this information on all tires because it is not required by law. Page 65 of 145 Tire Safety Information Letter Rating Q R S T U H V W Y Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168* mph 186* mph * For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR. For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR. U.S. DOT Tire Identification Number This begins with the letters "DOT" and indicates that the tire meets all federal standards. The next two numbers or letters are the plant code where it was manufactured, and the last four numbers represent the week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other numbers are marketing codes used at the manufacturer's discretion. This information is used to contact consumers if a tire defect requires a recall. Tire Ply Composition and Materials Used The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in the tire, which include steel, nylon, polyester, and others. Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire. Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions. 1.5.9.2. UTQGS Information Treadwear Number This number indicates the tire's wear rate. The higher the treadwear number is, the longer it should take for the tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200. Traction Letter This letter indicates a tire's ability to stop on wet pavement. A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest as "AA","A", "B", and "C". Temperature Letter This letter indicates a tire's resistance to heat. The temperature grade is for a tire that is inflated properly and not overloaded. Excessive speed, underinflation or excessive loading, either separately or in combination, can cause heat build-up and possible tire failure. From highest to lowest, a tire's resistance to heat is graded as "A", "B", or "C". Page 66 of 145 1.5.9.3. Additional Information on Light Truck Tires Please refer to the following diagram. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT The "LT" indicates the tire is for light trucks or trailers. ST An "ST" is an indication the tire is for trailer use only. Max. Load Dual kg (lbs) at kPa (psi) Cold This information indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each rear axle (a total of six or more tires on the vehicle). Max. Load Single kg (lbs) at kPa (psi) Cold This information indicates the maximum load and tire pressure when the tire is used as a single. Load Range This information identifies the tire's load-carrying capabilities and its inflation limits. 1.6. TIRE SAFETY TIPS Preventing Tire Damage Slow down if you have to go over a pothole or other object in the road. Do not run over curbs or other foreign objects in the roadway, and try not to strike the curb when parking. Tire Safety Checklist Check tire pressure regularly (at least once a month), including the spare. Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or trauma. Remove bits of glass and foreign objects wedged in the tread. Make sure your tire valves have valve caps. Check tire pressure before going on a long trip. Do not overload your vehicle. Check the Tire Information and Loading Placard or User’s Manual for the maximum recommended load for the vehicle. Page 67 of 145 Page 68 of 145 5 B J M J H I U 5 B J M * H I U Turtle Light Red Running Light Back-Up Light Licence Plate Light Red Running Light Electric Brake Electric Brake Turtle Light Turtle Light Amber Running Light Amber Running Light TOP VIEW 4 J E F 5 3 B J M F S Grey - Turtle Lights Blue - Brake Control Green - Right Turn/Brake Brown - Running Lights Red - Battery Yellow - Left Turn/Brake Orange - Backup White - Ground Junction Box Wiring 7 F I J D M F 4 J E F 5 P X 0 Q U J P O B M O E # B U U F S Z Exterior Light Page 69 of 145 Water Pump Battery Switch Water Heater Optional 110v Inverter Hella Socket 4 Gauge Welding Cable Water Heater Exterior Light USB Charger Stove Switch Water Pump Kitchen Light Shore Power Input To Battery(S) Solar Panel Circuits inside Main Box Shore Power Battery Charger Solar Controller Circuits in Nose Box Charge Circuit 16ga Grey/Red Stripe 16ga Brown Exterior Light DSI Water Heater Switched 16ga Green Kitchen Light DSI Switch 12v Power DSI Water Heater Ground 16ga Blue Stove Switch to Excite Relay 16ga Black Switched Water Pump LED Lighting 12v Switched LED at Kitchen 16ga Grey 16ga Yellow Propane Lock-Off Circuit Ground Kitchen Light Power Water Pump Power DSI Switch Power Kitchen Circuit 16ga Purple 12ga White 12ga Blue USB and Hella Plug at Kitchen Relay Power at Stove Switch Optional Additional Charge Port 12ga Red Wire Color Code Page 70 of 145 Page 71 of 145 PROwatt SW 600 shown. TM PO W ER FA RE U LT MO TE Sine Wave Inverter PROwatt SW 600 PROwatt SW 1000 PROwatt SW 2000 Owner’s Guide TM Page 72 of 145 August 2009 Rev B Product Numbers PROwatt SW 600: 806-1206 PROwatt SW 1000: 806-1210 PROwatt SW 2000: 806-1220 Xantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a world leader in the development, manufacturing and marketing of advanced power electronic products and systems for the renewable and mobile power markets. The company's products convert and control raw electrical power from any central, distributed, renewable, or backup power source into high-quality power required by electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver, Canada, with facilities in the United States, Germany, Spain, and a joint venture in China. Trademarks 975-0529-01-01 TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION; (B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER ’S RISK; AND (C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM. UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”) (A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY Exclusion for Documentation [email protected] www.xantrex.com Web: 1 800 994 7828 (toll free North America) 1 800 670 0707 (toll free North America) 1 408 987 6030 (direct) Email: Fax: Notice of Copyright Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide © August 2009 Xantrex Technology Inc. All rights reserved. No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of: Xantrex Technology Inc., 161-G South Vasco Road, Livermore, California, USA 94551. Xantrex Technology Inc. reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement. Telephone: Contact Information Xantrex, PROwatt, and Smart choice for power are trademarks of Schneider Electric, registered in the U.S. and other countries. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only. 975-0529-01-01 Document Part Number Date and Revision About Xantrex i Page 73 of 145 ii Warnings identify conditions that could result in personal injury or loss of life. WARNING The following conventions are used in this guide. Conventions Used The Guide is intended for users and operators of the PROwatt™ SW Sine Wave Inverter. Audience The Guide provides safety guidelines, as well as information about operating, installing, and troubleshooting the inverter. It does not provide details about particular brands of batteries. You need to consult individual battery manufacturers for this information. Xantrex recommends that installation should be handled by qualified installers including licensed technicians and electricians. Qualified installers have knowledge and experience in installing electrical equipment, knowledge of the applicable installation codes, and awareness of the hazards involved in performing electrical work and how to reduce those hazards. Scope The purpose of this Owner’s Guide is to provide explanations and procedures for operating, installing, maintaining, and troubleshooting the PROwatt™ SW Sine Wave Inverter. Purpose About This Guide Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide The product marking on the left (yellow background, black exclamation point) when found imprinted on electrical and electronic units and appliances means that you are to refer to this guide for cautions and warnings. You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com. Related Information Important: These notes describe things which are important for you to know, however, they are not as serious as a caution or warning. Cautions identify conditions or practices that could result in damage to the unit or other equipment. CAUTION Page 74 of 145 Do not expose the PROwatt™ SW Sine Wave Inverter to rain, snow, spray, or bilge water. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Overheating may result. To avoid a risk of fire and electric shock, make sure that wiring is in good condition, adequately rated, and not undersized. Do not operate the PROwatt™ SW Sine Wave Inverter with damaged or substandard wiring. 975-0529-01-01 2. 1. WARNING: Shock, fire, and heat hazard. Risk of injury to persons. This chapter contains important safety instructions for the PROwatt™ SW Sine Wave Inverter. Before using the PROwatt™ SW Sine Wave Inverter, READ ALL instructions and cautionary markings on or provided with the PROwatt™ SW Sine Wave Inverter, the batteries, and all appropriate sections of this guide. IMPORTANT: READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE REFERENCE. Important Safety Instructions Do not operate the PROwatt™ SW Sine Wave Inverter if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the PROwatt™ SW Sine Wave Inverter is damaged, see the Warranty section. Do not disassemble the PROwatt™ SW Sine Wave Inverter. It contains no user-serviceable parts. See Warranty for instructions on obtaining service. Attempting to service the PROwatt™ SW Sine Wave Inverter yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. To reduce the risk of electrical shock, disconnect DC power from the PROwatt™ SW Sine Wave Inverter before attempting any maintenance or cleaning or working on any circuits connected to the PROwatt™ SW Sine Wave Inverter. Turning off controls will not reduce this risk. 1. iii Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed to reduce the risk of battery explosion. WARNING: Explosion or fire hazard. Precautions When Working With Batteries 5. 4. 3. Page 75 of 145 iv 8. 7. 4. 5. 6. 3. 2. Remove all metal items, like rings, bracelets, and watches when working with lead-acid batteries. Lead-acid batteries produce a short circuit current high enough to weld metal to skin, causing a severe burn. WARNING: Risk of personal injury due to burns or battery acid. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing or using your PROwatt™ SW Sine Wave Inverter. This equipment contains components which tend to produce arcs or sparks. To prevent fire or explosion, do not operate the PROwatt™ SW Sine Wave Inverter in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or other connections between components of the fuel system. Make sure the area around the battery is well ventilated. Never smoke or allow a spark or flame near the engine or batteries. Use caution to reduce the risk or dropping a metal tool on the battery. It could spark or short circuit the battery or other electrical parts and could cause an explosion. If you need to remove a battery, always remove the ground terminal from the battery first. Make sure all accessories are off so you don’t cause a spark. Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Have someone within range of your voice or close enough to come to your aid when you work near a lead-acid battery. 10. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 11. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries. 12. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately. 9. Page 76 of 145 975-0529-01-01 This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference and (2) this device must accept any interference received, including interference that might cause undesired operation. NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. WARNING FCC Statement v Page 77 of 145 Warranty and Return Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Contents Page 78 of 145 975-0529-01-01 This Guide contains information about all three models. Unless specified by the model name, all features, functions, and instructions will pertain to all models. All the models of the inverter will be referred to collectively as PROwatt SW Inverter. There are three PROwatt SW Inverter models in the series namely: • PROwatt SW 600, • PROwatt SW 1000, and • PROwatt SW 2000. PROwatt SW Inverter Series Thank you for purchasing the PROwatt™ SW Sine Wave Inverter. The PROwatt SW Inverter is a high quality, true sine wave output inverter. It is designed to operate AC loads as if these loads were operating from grid/utility supplied power in household AC outlets. To get the most out of your PROwatt™ SW Sine Wave Inverter, carefully read and follow the instructions in this guide. Introduction • 540 watts 900 watts 1800 watts PROwatt SW 600 PROwatt SW 1000 PROwatt SW 2000 3000 watts 2000 watts 1200 watts Surge Power 1 The unit’s low standby battery demand means you don’t have to worry about excessive drain on your battery if you leave the inverter on for a few days. When the inverter is on but no power is being supplied to a load, the inverter draws less than 800 mA from the battery. Continuous Model The PROwatt SW Inverter is a professional-quality, mid-range inverter designed to handle a variety of applications including compact microwaves, TVs, VCRs, coffee makers, and small power tools. • The PROwatt SW Inverter provides optimal continuous power, making it ideal for large single loads, intermittent loads, or multiple smaller loads. • The inverter’s high surge capability lets you handle many hardto-start loads, including large TVs, refrigerators, and freezers. Quality Power Page 79 of 145 Alerts you if the battery has become discharged to 11 V or lower. Low battery voltage alarm 2 De-energizes the AC circuits and thereby protects the user from electric shock if a ground fault occurs. GFCI protection The PROwatt SW Inverter is equipped with the following protection features: Comprehensive Protection Superior features and rugged durability have been combined with ease of use: • The unit is compact, light weight, and easy to install. • You can power loads directly from the dual GFCI-protected AC receptacles on the front panel. • Easy-to-read digital display on the front panel lets you monitor system performance at a glance. • The optional PROwatt Remote Panel lets you control the inverter from a convenient location—up to 25 feet (7.6 m) away—while the inverter itself is mounted out of sight and close to the batteries. • A convenient USB port powers most modern electronic products. Ease of Use Introduction Shuts the inverter down automatically if the input voltage rises to more than 15.5 V. Within five minutes after shutdown, the unit recovers automatically once the battery voltage falls below 15.5 Vdc. After five minutes, the unit turns itself off. Shuts the unit down automatically if a short circuit occurs or if the loads attached to the inverter exceed the operating limits. Turns the inverter off if its temperature rises above an acceptable level. Within five minutes after shutdown, the unit recovers automatically once the temperature of the unit cools down. After five minutes of operating in high temperature, the unit turns itself off. High battery voltage shutdown AC output overload shutdown Over temperature shutdown Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Automatically shuts the inverter down if the battery voltage drops below 10.5 V. This feature protects the battery from being completely discharged. Within five minutes after shutdown, the unit recovers automatically once the battery voltage reaches above 11.5 Vdc. After five minutes, the unit turns itself off. Low battery voltage shutdown Page 80 of 145 975-0529-01-01 The PROwatt SW Inverter can also be installed with the PROwatt Remote Panel that comes with a 25-foot (7.6 m) communications cable (part number 808-9001). For ordering information, please contact Customer Service (see “Contact Information” on page i of this guide). Please reference the part number above when ordering. Optional Accessory Your PROwatt SW Inverter package includes these items: • PROwatt SW Inverter unit, • Owner’s Guide. If any of these materials are missing or are unsatisfactory in any way, please contact Customer Service (see “Contact Information” on page i of this guide). Materials List The following information describes the main features of the PROwatt SW Inverter. We recommend that you familiarize yourself with these features before installing and operating the unit. Features Mounting flanges E OT REM LT FAU Digital Display R WE PO AC Outlets (GFCI-protected) ventilation openings Figure 1 PROwatt SW Inverter (PROwatt SW 600 shown) Optional PROwatt Remote Panel (not shown) DC Input Owner’s Guide 3 Page 81 of 145 POWER REMOTE FAULT 4 5 6 7 Indicator LEDs Green LED indicates that the unit is on and receiving power. When a shutdown occurs due to an error condition the Green LED remains on. Red LED indicates an error or alarm condition. Digital Display Shows input voltage (in volts), output power (in kilowatts), and error code information. 1 2 4 Description Feature Figure 2 PROwatt SW Inverter Front Panel (PROwatt SW 600 shown) 3 2 1 Front Panel Details Features GFCI-protected AC Outlets Equipped with two AC outlets that are protected by a standard Ground Fault Circuit Interruptor (GFCI) device with reset and test buttons. Ventilation Holes Allows internal heat to escape. 6 7 Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide USB Port Powers and charges USB-enabled devices. 5 Remote Switch Port Use to connect the optional PROwatt Remote Panel via a communications cable. Power Switch Button Turns the inverter ON or OFF. 3 4 Description Feature Page 82 of 145 2 3 4 Positive (+) DC Terminal Accepts lug or ring connectors appropriate to the cable size being used. See Table 1 : Voltage Drop Per Foot of DC Cable on page 10 for recommendations. Cooling Fan Automatically turns on when internal temperature reaches more than 122 °F (50 °C). It turns off when the internal temperature falls below 122 °F (50 °C). 1 2 975-0529-01-01 Description Feature Figure 3 PROwatt SW Inverter Back Panel (PROwatt SW 600 shown) 1 Back Panel Details Serial No. Description Chassis Ground (GND) Terminal Negative (–) DC Terminal Accepts lug or ring connectors appropriate to the cable size being used. See Table 1 : Voltage Drop Per Foot of DC Cable on page 10 for recommendations. Feature 3 4 5 Features Page 83 of 145 6 If you do not have some electrical knowledge and knowledge of local electrical codes or are not comfortable installing cables yourself, use a qualified installer including a licensed technician and electrician. Qualified installers have knowledge and experience in installing electrical equipment, knowledge of the applicable installation codes, and awareness of the hazards involved in performing electrical work and how to reduce those hazards. WARNING Determine a charging system. Choose a location. Mount the inverter. Connect the chassis ground. Connect the battery cables. 2. 3. 4. 5. 6. Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Determine battery capacity. 1. Basic Installation Steps • • • • • • Follow all instructions from this guide and instructions including safety guidelines from the battery manufacturer. Installing battery cables require some electrical knowledge and local electrical codes. Adjustable wrench for fastening DC terminal bolts, Two battery cables (copper, appropriately sized according to application) with connectors already crimped by the company or store where you purchased the cables, Ground cable (copper, appropriately sized) for attaching to the ground chassis, DC-rated fuses (and fuse holders), Screwdriver (flathead and Philips), power screwdriver, or power drill for use in mounting the inverter, Mounting screws (4) size #10. Tools and Materials Guidelines Installation Page 84 of 145 975-0529-01-01 The charging system must be appropriate for your particular installation. A well-designed charging system will ensure that power is available when you need it and that your batteries remain in top condition. Inadequate charging will degrade system performance and the wrong type of charger will reduce battery life. For a list of Xantrex Battery Chargers, go to www.xantrex.com or contact Customer Service (see “Contact Information” on page i of this guide). Determine A Charging System The PROwatt SW Inverter must only be connected to a battery that has a nominal output of 12 volts. The PROwatt SW Inverter will: • Not operate if connected to a 6 volt battery and • Be damaged if connected to a 24 volt battery. CAUTION: Risk of inverter damage. Battery type and battery size strongly affect the performance of the PROwatt SW Inverter. Therefore, you need to identify the type of loads your inverter will be powering and how much you will be using them between charges. Once you know how much power you will be using, you can determine how much battery capacity you need. Xantrex recommends that you purchase as much battery capacity as possible. Determine Battery Capacity To reduce the risk of fire, do not cover or obstruct the ventilation openings. Do not install the PROwatt SW Inverter in a zero-clearance compartment. Overheating may result. WARNING Do not install the PROwatt SW Inverter in a wet environment or in any other environment where moisture can occur and enter the inverter enclosure through the ventilation openings. This unit is not intended for marine applications. WARNING: Risk of electrical shock. 7 The PROwatt SW Inverter contains components that tend to produce arcs or sparks. To prevent fire or explosion, do not install the inverter in compartments containing batteries or flammable materials or in locations that require ignition-protected equipment. CAUTION: Risk of inverter damage. Choose A Location Installation Ambient air temperature should be between 32 ºF and 104 º F (0 ºC and 40 º C)—the cooler the better within this range. Allow at least 2 inches (5 cm) of clearance around the inverter for air flow. Ensure that ventilation openings on the DC end and the bottom of the unit are not obstructed. Do not install the inverter in the same compartment as batteries or in any compartment capable of storing flammable liquids like gasoline. Cool Ventilated Safe 8 Protected from battery gases Do not mount the inverter where it will be exposed to gases produced by the batteries. These gases are very corrosive and prolonged exposure will damage the inverter. Close to battery Do not use excessive DC cable lengths: they increase wire resistance and reduce input power. Do not allow water or other liquids to drop or splash on the inverter. Dry Fasten the inverter to the mounting surface using corrosionresistant hardware sized #10. 4. Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Pilot-drill the four mounting holes. REMOTE FAULT 3. POWER On or under a horizontal surface. DC connections should NOT point up or down. Horizontally on a vertical surface or Hold the inverter against the mounting surface and mark the positions using the mounting flanges as guide. • • Select an appropriate mounting location and orientation. The unit can be oriented in any way, such as: 2. 1. Mount The Inverter REMOTE FAULT Installation POWER Page 85 of 145 Page 86 of 145 975-0529-01-01 Recreational Vehicle Connect the CHASSIS GND screw to the vehicle’s chassis using a minimum 8 AWG copper wirea (preferably with green/yellow insulation). The chassis ground terminal must be connected to a grounding point. The grounding point varies depending on where you install the PROwatt SW Inverter. Follow the guidelines that correspond to your type of installation. The PROwatt SW Inverter has a screw terminal labeled CHASSIS GND on the outside of the rear panel as shown in Figure 3, “PROwatt SW Inverter Back Panel (PROwatt SW 600 shown)” on page 5. Follow the guidelines below to connect the inverter’s chassis to the ground. Grounding Locations Never operate the PROwatt SW Inverter without connecting it to the ground. Electrical shock hazard could result. WARNING: Risk of electrical shock. Connect the Chassis Ground Connect the CHASSIS GND screw to your system’s DC grounding point using a minimum 6 AWG wirea. The system’s grounding point is usually the AC service entrance grounding point or a separate ground rod. For a solar PV (photovoltaic) installation, this is usually the same rod used to ground the PV array. 9 To operate safely and effectively, the PROwatt SW Inverter needs proper DC cables and DC-rated fuse(s). Because the PROwatt SW Inverter has low-voltage and high-current input, low-resistance wiring between the battery and the inverter is essential to deliver the maximum amount of usable energy to your load. Important: Use of a qualified installer strongly recommended. Connect The Battery Cables a.Xantrex recommends that the grounding conductor (grounding wire) should be the same wire size as the DC cables. Fixed Location Installation Page 87 of 145 10 Follow these guidelines and refer to Table 1 : Voltage Drop Per Foot of DC Cable on page 10 to determine battery cable lengths. • Use 4 AWG copper (90 ºC insulation rating) as the smallest battery cable size. This will minimize the voltage drop between the battery and the inverter. If the cables cause an excessive voltage drop, the inverter may shut down when drawing higher currents because the voltage at the inverter input drops below 10.5 volts. • Keep all cables as short as possible, and ensure that each cable between the inverter and the battery is no longer than 6 feet (1.8 m). • Have all wires and cables terminated with correct and appropriately-sized connectors and have the connectors crimped at the place of purchase. • Do not use aluminum. It has about 1/3 more resistance than copper cable of the same size, and it is difficult to make good, low-resistance connections to aluminum wire. Cabling Guidelines Installation 0.000253 0.000201 0.000159 0.000126 0.000100 0.000079 0.000063 0.000050 4 3 2 1 0 2/0 3/0 4/0 0.0030 0.0038 0.0048 0.0060 0.0076 0.0096 0.0121 0.0152 150 1500 0.0050 0.0063 0.0079 0.0100 0.0126 0.0159 0.0201 0.0253 0.0075 0.0095 0.0119 0.0150 0.0189 0.0239 0.0302 0.0380 Voltage Drop per Foot 100 1000 0.0150 0.0189 0.0237 0.0300 0.0378 0.0477 0.0603 0.0759 300 3000 Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Note: Voltage Drop per foot = Current value × Resistance value So for a 600 W inverter output with a DC cable of size 0, multiply the maximum current of 60 A with 0.000100. The result is 0.00600 voltage drop per feet. If the cable is 6 feet long, the total voltage drop is 0.00600 × 6 ( × 2) = 0.072. (Cable length multiplied by 2.) So for a battery operating at 12.6 V at battery terminal the voltage at the inverter terminal drops to 12.53 V. Note: Xantrex recommends a size 0 cable with a maximum cable length of 6 feet (1.8 m). For example: Resistance (ohms/ft) @ 25 °C 60 Current (A) Wire Size (AWG) 600 Inverter Output (W) Table 1 : Voltage Drop Per Foot of DC Cable Page 88 of 145 Once you have determined the total cold cranking amp rating of your batteries, identify the corresponding Ampere Interrupting Capacity (AIC) of the fuse or breaker required for your system by referring to Table 2. For example: • If you are using one battery to power your inverter and its rating is 500, the total cold cranking amp rating is 500. • If you are powering your inverter with two batteries in parallel, and each has a rating of 500, the total cold cranking amp rating is 1000. Note: The cold cranking amp rating of each battery is displayed on the battery case. If it is not, contact the battery manufacturer to find out. Determine the total cold cranking amp rating for your battery(s). 975-0529-01-01 2. 1. To select the correct fuse type and size: Because batteries can produce thousands of amps, you are required to install DC-rated fuses (or circuit breakers) that can safely withstand the short-circuit current batteries can produce. Fuse/Circuit Breaker Sizing Guidelines 3000 5000 651–1100 over 1100 ANL Fuse 80 A 150 A 250 A Model PROwatt SW 600 PROwatt SW 1000 PROwatt SW 2000 250 A 150 A 80 A Class T 1500 650 or less Table 3 Fuse Ratings Ampere Interrupting Capacity (AIC) Total Cold Cranking Amps Table 2 Cold Cranking Amps / AIC 11 Installation Note: The AIC is the amount of battery short-circuit amperage that the fuse can safely withstand. • If the Total Cold Cranking Amps indicate that the AIC is 2,700 amps or less, see Table 3 for the correct ANL fuse. • If the Total Cold Cranking Amps indicate that the AIC is up to 200,000 amps or if you require a “code fuse”, see Table 3 for the correct Class T fuse. Page 89 of 145 FUSE OR CIRCUIT BREAKER FUSE OR CIRCUIT BREAKER DEEP-CYCLE AUXILIARY BATTERY GROUND TO VEHICLE CHASSIS 12 Figure 4 Configuration for Normal Loads TO OTHER DC LOADS GROUND TO VEHICLE CHASSIS ISOLATOR GROUND TO VEHICLE CHASSIS TO VEHICLE VEHICLE STARTING BATTERY FROM ALTERNATOR OR CHARGER Consult the following configurations and determine a match specific to your installation and follow the installation procedure “To connect the battery cables:” that comes next. Cabling Procedure Installation 1 2 ALL OFF BATTERY SELECTOR SWITCH FUSE OR CIRCUIT BREAKER 1 2 ALL OFF DEEP-CYCLE BATTERY DEEP-CYCLE BATTERY ISOLATOR Line up the connectors that will join the cables to the battery, battery selector switch, and fuse (or circuit breaker). 2. Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Make sure the inverter is off and assemble the terminated cables (cables with connectors) that you bought. 1. To connect the battery cables: FUSE OR CIRCUIT BREAKER DEEP-CYCLE BATTERY GROUND TO VEHICLE CHASSIS GROUND TO VEHICLE CHASSIS TO VEHICLE DEEP-CYCLE BATTERY VEHICLE STARTING BATTERY GROUND TO VEHICLE CHASSIS FUSE OR CIRCUIT BREAKER Figure 5 Configuration for Heavy Loads TO OTHER DC LOADS BATTERY SELECTOR SWITCH FUSE OR CIRCUIT BREAKER FROM ALTERNATOR OR CHARGER Page 90 of 145 On the inverter side, attach the connectors of the positive and negative cables into the cabling terminals of the inverter. 5. 975-0529-01-01 Note: Make a secure connection. Loose connectors cause excessive voltage drop and may cause overheated wires and melted insulation. Note: The red terminal is positive (+) and the black terminal is negative (–). Power connections to the PROwatt SW Inverter must be positive to positive and negative to negative. When configuring for heavy loads (see Figure 5), install a battery selector switch and connect it to the DC-rated fuse (or circuit breaker). Alternatively, install a DC-rated circuit breaker that connects to the positive battery terminal. The fuse (or circuit breaker must have an Ampere Interrupting Capacity (AIC) that exceeds the short-circuit current available from the battery. For guidance, see “Cold Cranking Amps / AIC” on page 11. Install a DC-rated fuse on the positive battery terminal. 4. 3. The PROwatt SW Inverter does not come with a DC-rated fuse (or circuit breaker) to safely withstand the shortcircuit current batteries can produce. To avoid the risk of electrical shock or fire, install a DC-rated fuse (and fuse holder) on the positive battery terminal. WARNING: Risk of electrical shock or fire. 6. 13 Do not complete the next step if flammable fumes are present. Explosion or fire may result. Thoroughly ventilate the battery compartment before making this connection. WARNING: Risk of explosion or fire. When configuring for heavy loads (see Figure 5), attach the connector on the positive cable to the battery selector switch that is already connected to the DC-rated fuse (or circuit breaker). Note: Make a secure connection. Loose connectors cause excessive voltage drop and may cause overheated wires and melted insulation. Attach the connector on the positive cable to the DC-rated fuse (or circuit breaker) which is connected to the positive terminal of the battery. A reverse polarity connection (positive to negative) will blow a fuse in the inverter and may permanently damage the unit. Damage caused by a reverse polarity connection is not covered by your warranty. CAUTION: Risk of inverter damage due to reverse polarity. Installation Page 91 of 145 Turn on the inverter. 9. 14 The other indicators should be off. 10. Check the front panel of the inverter. The digital display should show 12–13 volts, depending on the voltage of the battery. If it does not, check your battery and the connection to the inverter. If you have installed a battery selector switch, use it to select one of the batteries or battery banks. Note: This is the last cable connection. You may observe a spark when making this last connection. Note: Make a secure connection. Loose connectors cause excessive voltage drop and may cause overheated wires and melted insulation. Attach the connector on the negative cable to the negative battery terminal. 8. 7. Installation Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Page 92 of 145 Press the inverter’s power switch button (for one second) to turn Off the inverter (from On). 2. 975-0529-01-01 If you are going to operate several loads from the PROwatt SW Inverter, turn them on separately after you have turned the inverter on. This will ensure that the inverter does not have to deliver the starting current for all the loads at once. Operating Several Loads at Once The unit’s power switch when turned off does not disconnect power from the PROwatt SW Inverter. WARNING: Risk of electrical shock. Note: When the inverter’s power switch button is Off, the inverter draws no current from the battery. Press the inverter’s power switch button (for half a second) to turn On the inverter (from Off). 15 Important: Test the GFCI periodically to make sure it is operating correctly. The AC outlets are Ground Fault Circuit Interrupter (GFCI) outlets. This protects you against hazardous electrical shocks that could be caused by dampness, faulty mechanism in the appliance, worn insulation, etc. GFCI-protected outlets cut off hazardous electrical shocks quickly enough so an adult in normal health is not seriously injured (infants and small children may still be affected). GFCI-Protected AC Outlets When the power switch is on but no power is being supplied to a load, the inverter draws less than 800 mA from the battery. This is a low current draw. It would take a week to discharge a 150 Ah battery at this current, so you don’t have to worry about excessive drain on your battery if you leave the inverter switched on for a few days. If you are not planning to recharge your battery within a week or so, switch the inverter off. The power switch on the inverter’s front panel turns the control circuit in the PROwatt SW Inverter on and off. To toggle the inverter on and off from its front panel: 1. Turning the Inverter Off Between Charges Turning the Inverter On and Off Operation Page 93 of 145 Plug a test lamp into the AC outlet. Push the TEST button. 2. 3. If the Green LED is On, it indicates that the unit is On. Under normal operating conditions, the AC outlets and USB port have power. However, even under an error condition such as a shutdown, the Green LED may still remain On. If the Red LED is on, it indicates an error or alarm condition and an error code is displayed on the digital display underneath the LED. 16 • • Under normal operating conditions, the digital display shows the input voltage (in volts) and the output power (in kilowatts). Under error or alarm conditions, the digital display shows an error code and the Red LED turns on. Digital Display • • Indicator LEDs Reading the Front Panel Indicators Note: The RESET button should pop out and the power should turn Off (the lamp should go out). If the lamp remains lit, or if the RESET button does not pop out, the GFCI may not be functioning. If the GFCI trips by itself at any time, reset it and perform the preceding test. Press the unit’s power switch to turn the inverter On. 1. To test (or reset) the GFCI protection: Operation Under voltage alarm and/or Under voltage shutdown Over voltage shutdown Over load shutdown Over temperature shutdown (... (... (... (... Red Red Red Red Remove all AC loads or let the unit cool down for 15 minutes. Press and hold the unit’s power switch to turn it On. 2. 3. Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Press and hold the unit’s power switch to turn it Off. 1. Restarting After an AC Output Shutdown Note: The audio alarm will sound for five minutes. After five minutes, the unit will turn off. Short circuit or output circuit overheat Example: 0.25 Kw (250 watts) ... Green (... Example: 13.5 volts ... Green Red Description Digital Display LED Description of LED and Digital Display Codes Page 94 of 145 540 W 900 W 1800 W PROwatt SW 600 PROwatt SW 1000 PROwatt SW 2000 15 A 7.5 A 4.5 A 13 Vdc Ambient 25 °C (77 °F) Tempera ture 10.5–15.5 V Normal 975-0529-01-01 Voltage Range Operating Condition n/a Comment The input voltage limits are shown in the following table. Input Voltage a.Applies to resistive loads such as incandescent lights. b.Applies to reactive loads such as motors. Power Model a Output Input Currentb Voltage The PROwatt SW Inverter will deliver the following power continuously, depending on input voltage and ambient temperature. The inverter will deliver more than 10% of its continuous power rating for approximately five minutes. The inverter must cool down for 15 minutes before it can resume operation above its continuous power rating. Power Output Operating Limits Voltage is The unit shuts down to 15.5 V or more. protect itself from excessive input voltage. Note: Although the PROwatt SW Inverter incorporates overvoltage protection, it can still be damaged if input voltage exceeds 16 V. 11.5 V High Voltage Shutdown Unit restarts after low voltage shutdown 17 The unit will not restart unless the battery voltage is acceptable for running the load. The unit shuts down to protect the battery from being over-discharged. Voltage is 10.5 V or less. Low Voltage Shutdown Comment The audible low battery alarm sounds. Voltage Range Voltage is 11.0 V or less Low Voltage Alarm n/a Operating Condition 13–14.5 V Peak Performance Operation Page 95 of 145 When possible, recharge your batteries when they are about 50% discharged or earlier. This gives them a much longer life cycle than recharging when they are almost completely discharged. For information about battery chargers, see our web site at www.xantrex.com. USB Loads A lot of USB-powered devices such as portable music (MP3) players, mobile phones, and video game players can be charged and powered safely via the standard USB port. However, some devices such as portable GPS receivers and certain cameras may not work and even cause damage even if you use the USB cable that came with the product. Be sure that the device only accepts 5 volts and can be charged or powered using other sources of power. See the device’s owner’s guide under specifications for information. 18 Some induction motors used in freezers, pumps, and other motoroperated equipment need high surge currents to start. The PROwatt SW Inverter may not be able to start some of these motors even though their rated current draw is within the inverter’s limits. If a motor refuses to start, observe the VOLTS indicator while you are trying to start the motor. If the indicator drops below 11 volts while the PROwatt SW Inverter is trying to start the motor, this may explain why the motor won’t start. Make sure the length and Exceptional Loads Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Routine maintenance is required to keep your PROwatt SW Inverter operating properly. Periodically you should: • Clean the exterior of the unit with a damp cloth to prevent the accumulation of dust and dirt. • Tighten the screws on the DC input terminals. Maintenance Battery Charging Frequency The PROwatt SW Inverter will operate many AC loads within its power rating. However, some appliances and equipment may be difficult to operate. Please see “Exceptional Loads” below carefully. Inverter Loads diameter of the battery cables are appropriate. Check that the battery connections are good and that the battery is fully charged. If the cables are sized correctly, the connections are good, and the battery is charged, but the voltage still drops below 11 volts, you may need to use a larger battery. Operation Page 96 of 145 Under Voltage (low input) shutdown Poor DC wiring and/or poor battery condition Over Voltage (high input) shutdown (... (... with persistent low battery alarm. (... 975-0529-01-01 Possible Cause Condition Troubleshooting Reference Make sure the inverter is connected to a 12 V battery. Use proper cable and make secure connections. Charge the battery or install a new battery. Recharge the battery. Check cables and connection if secure. Solution Do not dismantle the PROwatt SW Inverter. It does not contain any user-serviceable parts. Attempting to service the unit yourself could result in an electrical shock or burn. WARNING: Electrical shock and burn hazard. Troubleshooting (... Normal load is connected then AC output becomes unavailable. (... Heavy load is connected then AC output becomes unavailable. (... Condition Over temperature shutdown Over temperature shutdown Overload shutdown Possible Cause 19 Improve ventilation and make sure the inverter’s ventilation openings are not obstructed. Reduce the ambient temperature, if possible. Allow the inverter to cool off and reduce the load if continuous operation is required. Reduce the load within the inverter’s continuous power rating. Solution Page 97 of 145 Remove the load. Turn the unit off. Let the unit cool down, check the fan for any obstructions and clear it, or reduce the load. Turn the unit back on. Very heavy load Output circuit overheat 20 Check the AC wiring for a short circuit. Short circuit (... No output voltage. Solution Possible Cause Condition Troubleshooting Turn the inverter on. Check wiring to the inverter. Have a qualified service technician check and replace the fuse if necessary. Have a qualified service technician check and replace the fuse, making sure to observe correct polarity. Reset the GFCI. See page 16 for instructions. The GFCI device tripped. Solution The unit is off. No power to the inverter. Inverter fuse open. Reverse DC polarity. Possible Cause Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide The unit is on and running but there is no AC output. No output voltage; no voltage indication. Condition Page 98 of 145 540 W Continuous power 975-0529-01-01 600 W Peak power (5 minutes) 600 900 W 1000 W 1000 10.5 V Low battery cutout AC / USB Output Audible, 11 V Low battery alarm 93 A 10.5–15.5 Vdc 60 A Input current (max at full load) 1200 VA Input voltage range 720 VA Input power (max at full load) 1000 1800 W 2000 W 2000 200 A 2400 VA 2000 32–104 °F (0–40 °C) Operating temperature 600 6.5 lbs. (3.0 kg) 7.2 lbs. (3.3 kg) 10.6 lbs. (4.8 kg) Weight • PROwatt SW 600 • PROwatt SW 1000 • PROwatt SW 2000 DC Input 12.2×8.7×3.5 inch. (31×22×8.9 cm) 14×9×3.5 inch. (35×22×8.5 cm) 13.8×11.8×3.9 inch. (35×30×10 cm) Length × Width × Height • PROwatt SW 600 • PROwatt SW 1000 • PROwatt SW 2000 Physical and Environmental Specifications Note: Specifications are subject to change without prior notice. Specifications 5.8 A < 600 mA Output current (max) No load current draw General Use Power Supplies Electromagnetic Compatibility (EMC) FCC Part 15, Class A 21 Power Converters/Inverters and Power Converter/ Inverter Systems for Land Vehicles and Marine Crafts CSA 107.1-01 UL 458 5th edition Regulatory Approvals 5 Vdc, 500 mA USB Output 60 Hz ±0.5Hz Output frequency Approximately 85–90% True sine wave Output waveform < 800 mA 19.2 A 15 A 3000 W 2000 Efficiency 104–127 Vac 120 Vac RMS ±5% < 600 mA 9.6 A 7.5 A 2000 W 1000 Output voltage range Output voltage (nominal) 4.6 A 1200 W 600 Output current (continuous) Surge power AC / USB Output Page 99 of 145 22 What does this warranty cover and how long does it last? This Limited Warranty is provided by Xantrex Technology Inc. ("Xantrex") and covers defects in workmanship and materials in your PROwatt™ SW Sine Wave Inverter. This warranty period lasts for 24 Months from the date of purchase at the point of sale to you, the original end user customer, unless otherwise agreed in writing (the “Warranty Period”). You will be required to demonstrate proof of purchase to make warranty claims. This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period. Subsequent owners also require original proof of purchase as described in "What proof of purchase is required?" What will Xantrex do? During the Warranty Period Xantrex will, at its option, repair the product (if economically feasible) or replace the defective product free of charge, provided that you notify Xantrex of the product defect within the Warranty Period, and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty. Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and building replacement products. Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement. If Xantrex repairs or replaces a product, its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the Warranty Warranty and Return Information Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call Xantrex or check our website to see if your product can be repaired at one of these facilities. Telephone: 1 800 670 0707 (toll free North America) 1 408 987 6030 (direct) Fax: 1 800 994 7828 (toll free North America) Email: [email protected] Website: www.xantrex.com return shipment to the customer, whichever is greater. All replaced products and all parts removed from repaired products become the property of Xantrex. Xantrex covers both parts and labor necessary to repair the product, and return shipment to the customer via a Xantrex-selected nonexpedited surface freight within the contiguous United States and Canada. Alaska, Hawaii and outside of the United States and Canada are excluded. Contact Xantrex Customer Service for details on freight policy for return shipments from excluded areas. How do you get service? If your product requires troubleshooting or warranty service, contact your merchant. If you are unable to contact your merchant, or the merchant is unable to provide service, contact Xantrex directly at: Page 100 of 145 975-0529-01-01 What does this warranty not cover? Claims are limited to repair and replacement, or if in Xantrex's discretion that is not possible, reimbursement up to the purchase price paid for the product. Xantrex will be liable to you only for direct damages suffered by you and only up to a maximum amount equal to the purchase price of the product. This Limited Warranty does not warrant uninterrupted or error-free operation of the product or cover normal wear and tear of the product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to: a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either internally or externally, or damaged from improper use or use in an unsuitable environment; b) the product if it has been subjected to fire, water, generalized corrosion, biological infestations, or input voltage that creates What proof of purchase is required? In any warranty claim, dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex. Proof of purchase may be in any one of the following forms: • The dated purchase receipt from the original purchase of the product at point of sale to the end user; or • The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM) status; or • The dated invoice or purchase receipt showing the product exchanged under warranty. 23 Warranty and Return Information operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including but not limited to high input voltage from generators and lightning strikes; c) the product if repairs have been done to it other than by Xantrex or its authorized service centers (hereafter "ASCs"); d) the product if it is used as a component part of a product expressly warranted by another manufacturer; e) component parts or monitoring systems supplied by you or purchased by Xantrex at your direction for incorporation into the product; f) the product if its original identification (trade-mark, serial number) markings have been defaced, altered, or removed; g) the product if it is located outside of the country where it was purchased; and h) any consequential losses that are attributable to the product losing power whether by product malfunction, installation error or misuse. Page 101 of 145 24 IN NO EVENT WILL XANTREX BE LIABLE FOR: (a) ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING LOST PROFITS, LOST REVENUES, FAILURE TO REALIZE EXPECTED SAVINGS, OR OTHER COMMERCIAL OR ECONOMIC LOSSES OF ANY KIND, EVEN IF XANTREX HAS BEEN ADVISED, OR HAD REASON TO KNOW, OF THE POSSIBILITY OF SUCH DAMAGE; (b) ANY LIABILITY ARISING IN TORT, WHETHER OR NOT ARISING OUT OF XANTREX'S NEGLIGENCE, AND ALL LOSSES OR DAMAGES TO ANY PROPERTY OR FOR ANY PERSONAL INJURY OR ECONOMIC LOSS OR DAMAGE CAUSED BY THE CONNECTION OF A PRODUCT TO ANY OTHER DEVICE OR SYSTEM; AND (c) ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION OR OPERATION OF THE PRODUCT BY PERSONS NOT AUTHORIZED BY XANTREX. Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide If this product is a consumer product, federal law does not allow an exclusion of implied warranties. To the extent you are entitled to implied warranties under federal law, to the extent permitted by applicable law they are limited to the duration of this Limited Warranty. Some states, provinces and jurisdictions do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you. This Limited Warranty gives you specific legal rights. You may have other rights which may vary from state to state, province to province or jurisdiction to jurisdiction. Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY. Exclusions Disclaimer Warranty and Return Information Page 102 of 145 25 Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to improper packaging. Include the following: • The RMA number supplied by Xantrex Technology Inc. clearly marked on the outside of the box. • A return address where the unit can be shipped. Post office boxes are not acceptable. • A contact telephone number where you can be reached during work hours. • A brief description of the problem. Ship the unit prepaid to the address provided by your Xantrex customer service representative. If you are returning a product from outside of the USA or Canada In addition to the above, you MUST include return freight funds and are fully responsible for all documents, duties, tariffs, and deposits. If you are returning a product to a Xantrex Authorized Service Center (ASC) A Xantrex return material authorization (RMA) number is not required. However, you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility and that the ASC repairs this particular Xantrex product. For those products that are not being repaired in the field and are being returned to Xantrex, before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA) number and the correct factory "Ship To" address. Products must also be shipped prepaid. Product shipments will be refused and returned at your expense if they are unauthorized, returned without an RMA number clearly marked on the outside of the shipping box, if they are shipped collect, or if they are shipped to the wrong location. When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be prepared to supply: • The serial number of your product • Information about the installation and use of the unit • Information about the failure and/or reason for the return • A copy of your dated proof of purchase Record these details on page 26. 975-0529-01-01 Return Procedure Return Material Authorization Policy Warranty and Return Information Page 103 of 145 806-1206 806-1210 806-1220 ______________________ ______________________ ❐ Product Number/s ❐ Purchased From ❐ Purchase Date 26 ❐ Battery/battery bank size has been installed ❐ Length of time inverter RV, truck) ❐ Type of installation (e.g. ______________________ ______________________ ______________________ If you need to contact Customer Service, please record the following details before calling. This information will help our representatives give you better service. ______________________ ❐ Serial Number As soon as you open your PROwatt™ SW Sine Wave Inverter package, record the following information and be sure to keep your proof of purchase. Information About Your System Warranty and Return Information ______________________ ______________________ Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide ________________________________________________ ________________________________________________ ❐ Description of problem when problem occurred ❐ Appliances operating on front panel ______________________ ______________________ ❐ Alarm sounding? ❐ Description of indicators ______________________ ______________________ ❐ DC wiring size and length sealed gel cell, AGM) ❐ Battery type (e.g. flooded, Page 104 of 145 975-0529-01-01 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct 1 800 994 7828 Fax toll free NA [email protected] www.xantrex.com Xantrex Technology Inc. Printed in China Page 105 of 145 Atwood Mobile Products garantit ce produit à l'acheteur initial, suivant les termes stipulés ci-dessous, contre tout défaut de matériel ou de fabrication, pendant une période de deux ans à compter de la date d'achat d’origine. La responsabilité d'Atwood décrite ci-dessous se limite au remplacement, à la réparation ou au remplacement du produit par un produit reconditionné, à la discrétion du fabricant. La présente garantie est annulée si le produit est endommagé du fait d’un accident, d’une utilisation non raisonnable, d’une négligence, d’une modification du produit ou de toute autre cause non liée au matériau ou à un vice de fabrication. La présente garantie ne s'applique qu'à l'acheteur initial et elle est soumise aux conditions suivantes : 1. Pendant une période de deux ans, à compter de la date d'achat, Atwood remplacera tout le chauffe-eau si le réservoir interne fuit pour des raisons de corrosion. La présente garantie couvre les frais raisonnables de maind’œuvre nécessaires au remplacement du chauffe-eau. 2. Pendant deux ans, à compter de la date d'achat, Atwood réparera ou remplacera toute pièce trouvée défectueuse en raison du matériau ou d'un vice de fabrication. La présente garantie couvre les frais raisonnables de main-d’œuvre nécessaires au retrait et au remplacement de la pièce. Les visites pour l’entretien chez le client ne sont pas prises en charge et restent donc la responsabilité du client. 3. La présente garantie ne couvre pas les articles suivants, qui sont considérés comme faisant partie de l’entretien régulier : a. réglage de la pression du gaz b. nettoyage ou remplacement de l’orifice du brûleur c. nettoyage ou réglage du tube du brûleur d. nettoyage ou réglage du conduit e. nettoyage ou réglage de la veilleuse et du thermocouple f. réglage de la soupape de décharge de type pression-température g. remplacement du dispositif de coupure thermique 4. Dans l'éventualité d'une réclamation de garantie, l’acheteur doit contacter, à l'avance, soit un Centre de service Atwood agréé, soit le Service à la clientèle Atwood. La réclamation de garantie doit être exécutée dans un Centre de service Atwood agréé (une liste vous sera fournie gratuitement) ou selon les procédures reconnues par le Service clientèle Atwood (Consumer Service Department) Atwood Mobile Products, 1120 North Main St., Elkhart IN 46514 États-Unis. Téléphone : (574) 264-2131. GARANTIE LIMITÉE POUR CHAUFFE-EAU ATWOOD Atwood Mobile Products warrants to the original owner and subject to the below mentioned conditions, that this product will be free of defects in material or workmanship for a period of two years from the original date of purchase. Atwood’s liability hereunder is limited to the replacement of the product, repair of the product, or replacement of the product with a reconditioned product at the discretion of the manufacturer. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other causes not arising from defects in material workmanship. This warranty extends to the original owner of the product only and is subject to the following conditions: 1. For a period of two years from the date of purchase, Atwood will replace the complete water heater if the inner tank leaks due to corrosion. This warranty includes reasonable labor charges required to replace the complete water heater. 2. For two years from the date of purchase, Atwood will repair or replace any part defective in material or workmanship. This warranty includes reasonable labor charges, required to remove and replace the part. Service calls to customer’s location are not considered part of these charges and are, therefore, the responsibility of the owner. 3. This warranty does not cover the following items classified as normal maintenance: a. adjustment of gas pressure b. cleaning or replacement of burner orifice c. cleaning or adjustment of burner tube d. cleaning or adjustment of flue e. cleaning or adjustment of pilot and thermocouple f. adjustment of pressure-temperature relief valve g. replacement of thermal cut-off device. 4. In the event of a warranty claim, the owner must contact, in advance, either an authorized Atwood Service Center or the Atwood Service Department. Warranty claim service must be ATWOOD WATER HEATER LIMITED WARRANTY 16 5. Les pièces retournées (ou le chauffe-eau) doivent être expédiées à Atwood, tout port payé. Un avoir pour les frais d'expédition sera compris avec la réclamation de garantie. Les pièces défectueuses (ou le chauffeeau) deviennent la propriété d’Atwood Mobile Products et doivent être retournées à Consumer Service Department, Atwood Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN 37073 États-Unis. 6. La présente garantie est valide uniquement si l'unité est installée selon les consignes d'installation fournies, en conformité avec les codes locaux et nationaux. 7. La période de garantie pour les pièces de remplacement (ou le chauffeeau) est la période inutilisée de la période de garantie initiale ou quatrevingt-dix (90) jours, selon ce qui est le plus long. 8. Tout dommage ou toute déficience résultant d'une mauvaise utilisation (y compris le manquement à faire effectuer les réparations nécessaires), d'une mauvaise mise en application, de modifications, de dommages causés par l'eau ou par le gel relèvent de la responsabilité de l’acheteur. 9. Atwood n’est aucunement responsable de l’impossibilité d’utiliser le véhicule, de toute perte de temps, de tout dérangement et de tous frais d'essence, de téléphone, de déplacement, de logement, de perte ou de dommages aux biens personnels ou de perte de revenus. Certains États ne permettent pas l’exclusion ou la limitation des dommages accessoires ou indirects ; il est donc possible que les limitations ou exclusions cidessus ne s'appliquent pas à votre cas. 10. Toute garantie implicite est limitée à une période de deux (2) ans. Certains États ne permettent pas de limiter la période d'une garantie implicite, donc il est possible que la limite ci-dessus ne vous concerne pas. La présente garantie vous accorde des droits légaux particuliers mais il est également possible que vous ayiez certains droits supplémentaires, selon les États. 11. Les pièces de remplacement (composantes ou réservoirs) achetées en dehors de la garantie initiale du chauffe-eau sont couvertes par une garantie de 90 jours ; ceci comprend la pièce sans frais et les frais raisonnables de main-d'œuvre découlant du remplacement. Ce chauffe-eau Atwood est conçu pour utilisation en véhicule de plaisance et dans le but de chauffer l'eau comme le stipule la plaque signalétique fixée au chauffe-eau. Toute autre utilisation, à moins d’une autorisation écrite du Service technique Atwood, annule la présente garantie. performed at an authorized Atwood Service Center (a list will be provided at no charge) or as approved by the Consumer Service Department, Atwood Mobile Products, 1120 North Main St., Elkhart, IN 46514 USA. Phone: (574-264-2131). 5. Return parts (or water heater) must be shipped to Atwood “Prepaid”. Credit for shipping costs will be included with the warranty claim. The defective parts (or water heater) become the property of Atwood Mobile Products and must be returned to the Consumer Service Department, Atwood Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN 37073 USA. 6. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes. 7. The warranty period on replacement parts (or water heater) is the unused portion of the original warranty period or ninety (90) days, whichever is greater. 8. Damage or failure resulting from misuse (including failure to seek proper repair service), misapplication, alterations, water damage, or freezing are the owner’s responsibility. 9. Atwood does not assume responsibility for any loss of use of vehicle, loss of time, inconvenience, expense for gasoline, telephone, travel, lodging, loss or damage to personal property or revenues. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. 10. Any implied warranties are limited to two (2) years. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 11. Replacement parts (components or tanks) purchased outside of the original water heater warranty carry a 90 day warranty. This includes the part at no charge and reasonable labor charges to replace it. This Atwood heater is designed for use in recreational vehicles for the purpose of heating water as stated in the “data plate” attached to the water heater. Any other use, unless authorized in writing by the Atwood Engineering Department, voids this warranty. (et Canada) CAUTION avoid possible injury and/or property damage 16˝ 16˝ WIDTH HEIGHT DEPTH 18.5˝ 21.8˝ WARNING FIRE OR EXPLOSION 12.5˝ 15.5˝ 25 lbs 32 lbs SHIPPING WT. 6 GALLON 10 GALLON WHAT TO DO IF YOU SMELL GAS • Evacuate ALL persons from vehicle. • Shut off gas supply at gas container or source. • DO NOT touch any electrical switch, or use any phone or radio in vehicle. • DO NOT start vehicle’s engine or electric generator. • Contact nearest gas supplier or qualified Service Technician for repairs. • If you cannot reach a gas supplier or qualified Service Technician, contact the nearest fire department. • DO NOT turn on gas supply until gas leak(s) has been repaired. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. U If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. 6 GALLON 10 GALLON ALL MODEL DIMENSIONS Installation and service must be performed by a qualified Service Technician, Service Center, OEM or Gas Supplier. avoid possible injury or death WARNING Safety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols. SAFETY ALERT SYMBOLS SERVICE CALLS & QUESTIONS Location and phone numbers of qualified Service Centers can be found at our website http:/www.atwoodmobile.com or call 574-262-2655 to have a Service Center List mailed. This water heater design has been certified by the Canadian Standards Association for installation in recreation vehicles. This water heater is not for use in marine applications. ENGLISH, FRANCAIS 1 MPD 93050 WEIGHT ................................................................ 1 DIMENSIONS .......................................................... 1 MODEL IDENTIFICATION ............................................1 ....................................................4 ....................................................5 E H I6 - EXT® Effective Capacity** Engine Heat Exchanger Electric Gas Electronic XT* calculated gallons of 130˚F moderated water is 9 gallons and 16 gallons. * EXT® indicates Electronic Exothermal (XT) technology. ** Water heater actual capacity is 6 and10 gallon respectively. Effective capacity, G EXPLANATION OF MODEL NUMBER PART IDENTIFICATION FIGURES ................................................................................6-7 ....................................................................8 Water Heater WARRANTY ..............................................................16 Flushing to Remove Unpleasant Odor ..................................................5 Pressure-Temperature Relief Valve Preventative Maintenance ................................................................4 Winterizing (Flushing) Instructions ....................................................5 Maintenance and Care Instructions Consumer Safety Warnings ..............................................................2 How to Operate Your Water Heater ..................................................3-4 Wiring Cutout Chart Pressure - Temperature Relief Valve Water Heater GENERAL INSTALLATION SAFETY INFORMATION WATER HEATER Effective 10/13/09 s)NSTALLATION s/PERATION s-AINTENANCE PATENT # 7,020,386 G16EXT, GE16EXT, GEH16EXT XT® Models: G9EXT, GE9EXT, GEH9EXT 6 & 10 GALLON L.P. GAS WATER HEATER LITERATURE NUMBER Page 106 of 145 - FOLLOW ALL APPLICABLE STATE AND LOCAL CODES - ® • When using Romex with a bare earth ground, take care to position ground wire so it does not contact the heating element terminals. PRODUCT DAMAGE CAUTION COMBINATION GAS/ELECTRIC MODELS are designed to operate with gas, electricity, or a combination of both. • Use electrical metallic tubing, flexible metal conduit, metal clad cable, or nonmetallic-sheathed cable with grounding conductor. Wire must have a capacity of 1400 watts or greater. The wiring method must conform to applicable sections of article 551 of National Electrical Code ANSI/NFPA 70. 1. Refer to Wiring Diagram (FIG 12). Make 120 VAC electrical connections from junction box on back of unit. a. Connect hot lead to (1) Black. b. Connect common lead to (2) White. c. Connect ground wire from electrical service to (3) green ground lead in junction box 3. All wiring must comply with applicable electrical codes. WIRING 1. Locate water heater on floor of coach before erecting side walls. The water heater tank must be permanently supported at the same level as the bottom of sidewall cutout (by the floor or a raised floor) FIG 2. Provide adequate clearance at rear of unit for service of water connections. 2. To install water heater on carpeting, you must install appliance on a metal or wood panel that extends at least three inches beyond the full width and depth of appliance. 3. If the appliance is installed where connection or tank leakage will damage adjacent area, install a drain pan (which can be drained to out side of coach) under water heater. This is a common installation for water heaters. There are other approved methods such as Flush Mount (MPD 93948) installations. Consult with your Field Auditor, Account Manager, or the Atwood Service Department if you have additional questions. GENERAL INSTALLATION • Recreation Vehicles ANSI A119.2/NFPA 501C. • National Fuel Gas Code ANSI Z223.1 and/or CAN/CGA B149 Installation Codes • Federal Mobile Home Construction & Safety Standard, Title 24 CFR, part 3280, or when this Standard is not applicable, the Standard for Manufactured Home Installations (Manufactured Home Sites, Communities and Set-Ups), ANSI A255.1 and/or CAN/CSA-Z240 MH Series, Mobile Homes. • National Electrical Code ANSI/NFPA No. 70 and/or CSA C22.1 • Park Trailers A119.5 • CSA standard Z240 RV Series, Recreational Vehicle. • ASSE Standard 1017 (Mixing Value). • NSF Standard ANSI/NSF 14-2003 (All Hoses and Plastic Fittings). IN THE ABSENCE OF LOCAL CODES OR REGULATIONS, REFER TO CURRENT STANDARDS OF: USA AND CANADA • Install in recreation vehicles only. RV’s are recreation vehicles designed as temporary living quarters for recreation, camping, or travel use having their own power or towed by another vehicle. • All combustion air must be supplied from outside the RV, and all products of combustion must be vented to outside the RV. • DO NOT vent water heater with venting system serving another appliance. • DO NOT vent water heater to an outside enclosed porch area. • Protect building materials from flue gas exhaust. • Install water heater on an exterior wall, with access door opening to outdoors. • DO NOT modify water heater in any way. • DO NOT alter water heater for a positive grounding system. • DO NOT HI-POT water heater unless electronic ignition system (circuit board) has been disconnected. • DO NOT use battery charger to supply power to water heater even when testing. CRITICAL INSTALLATION WARNINGS 2 CUT OUT DIMENSION 1-A 1-B 12-5/8˝ 16-1/4˝ 15-3/4˝ 16-1/4˝ FIG 1. DEPTH 2-C 18.5˝ 21.75˝ 6. Bend all flanges 90˚ along scored lines (FIG 3-A). 7. To prevent water leaks caulk thoroughly around opening, including bend slots. Butyl Tape (1-1/3˝x1/8˝) may be substituted for caulking material. 8. Push unit against caulking, secure 4-corner brackets (FIG 3-B) to coach with No. 8 - 3/4˝ round head screws (not furnished) or equivalent. Complete the installation by inserting the same type of #8 screws in the holes provided around the flange of the water heater housing. Check all gaskets, they must adhere to the pan creating an air tight seal. MINIMUM CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Sides: 0˝ Top: 0˝ Back: 0˝ Bottom: 0˝ CAPACITY Gallon 6 10 CUTOUT (FIG 1 & 2) 5. Erect side walls and cut opening. See chart and Frame with 2x2 lumber (or equivalent). • Do not lift, pull, push or misalign the main burner tube (FIG 3-F). PRODUCT DAMAGE CAUTION CONTINUE GENERAL INSTALLATION 4. Connect both 1/2˝ NPT water lines (FIG 2) hot water outlet female and cold water inlet female and 3/8˝ flared LP gas line to the water heater (FIG 9). a. Allow flexibility in water and gas lines so you can pull unit forward through wall one inch past skin. b. Seal gas line entrance opening (FIG 9) by sliding grommet (9-B) onto 3/8˝ tubing (9-D) before flaring tubing (9-E). Pull gas line and grommet through opening in housing (9-A). Connect flare fitting (9-C) and press grommet into opening. If gas line tubing is already flared, cut grommet on one side. Place split grommet over gas line and press it into opening. c. Always use pipe lubricant on threads when connecting hot and cold water couplings. A suitable plastic fitting is recommended. HEAT EXCHANGE MODELS - FIG 5 1. Push a 5/8˝ diameter coolant system hose (5-A) [with SAE 053 A Type “E”clamp attached] onto heat exchanger tube (5-B) making a tight connection. 2. Spread hose clamp and slide toward heat exchange unit past annular groove (5-C) and release. 3. Continue to HOW TO OPERATE YOUR WATER HEATER and/or Electronic Ignition OPERATION. 1. Refer to Wiring Diagram (FIG 12). Install remote switch in a convenient location. Position wall plate with letters up. Before making connections turn switch OFF. 2. Install wires see FIG 10 & 11. ELECTRONIC IGNITION NOTE: It is recommended unit be connected directly to a 12V DC battery or to filtered side of an AC/DC converter. Avoid connections to unfiltered side of an AC/DC converter whenever possible. Use a minimum of 18 gauge wire, UL and CSA listed. • Label all wires before disconnecting when servicing controls. • Verify proper operation after servicing. ELECTRICAL DAMAGE CAUTION • When a cord and plug connection to the power supply are used on water heater, power cord must be UL listed as suitable for damp locations, hard or extra hard usage. It must be a flexible cord such as type S, SO, ST, STO, SJ, SJT, SJTO, HS or HSO cord as described in National Electrical Code, ANSI/NFPA 70. The length of external cord to water heater, measured to face of attachment plug, shall be no less than 2 feet nor more than 6 feet. Supply cord must be a minimum of 14 AWG and attachment plug must be rated at 15 amps. 15 INTENTIONALLY LEFT BLANK Page 107 of 145 Tank Maintenance ELECTRONIC MODEL—Check electrode for cracks and gap (Spark probe and Ground gap should be 1/8”) PILOT MODEL—Check orifice for contamination. Clean if flame is low, replace assembly if cleaning fails. Check Alignment of Burner tube and Orifice—Must be straight Periodically clean Burner Tube with small brush Check air adjustment of Burner by positioning the air shutter 1/4 open (blue flame with small trace of yellow). Periodically clear all obstructions in Burner Orifice and pilot Assembly (dirt, spider webs, etc.) Winterizing Turn off the main water supply (pump or water hook-up source). Drain the water heater by removing the drain plug. If the water flows sporadically or trickles instead of a steady stream, we recommend the following action: First, open the Pressure/Temperature relief Valve to allow air into the tank and Second, using a small gauge wire or coat hanger, poke through the drain coupling to dislodge any obstructions. With the tank drained, approximately two quarts of water remain in the bottom (note drain plug position in illustration above). This water contains most of the harmful corrosive particles. To remove these materials, Atwood recommends use of a commercially available “RV Water Heater Flushing Tool”. Simply running water through the inlet does not stir up and flush out all sediment. The wand of a flushing tool allows you to move around at different angles inside the tank with a higher pressure water jet, suspending and flushing the materials back out of the drain coupling. Continue flushing until the water being flushed from the drain coupling runs clear. Replace the drain Plug. 14 90091 07/10/2009 Use of Aftermarket Heating Element Devices (Hot Rods) can lead to an out-of-control heating of water in the tank and catastrophic wet side explosion. These devices lack critical safety controls. Personal injury and product damage may result. Replacing the Atwood drain plug with an Anode Rod will damage the coupling with cathodic action and product damage will result. Atwood water heater tanks are constructed of a high strength aluminum. The interior of the tank consists of a .0015 thick, type 7072 clad aluminum (pure aluminum and zinc) fused to the core in the rolling process. This material protects the tank from the affects of heavy metals and salts found throughout North America. It is anodic to these heavy metals and acts much like an anode in a steel glass-lined tank, except it lasts much longer. Use of Aftermarket Heating Elements or Anode Devices are not compatible with Atwood Water Heaters and will void the warranty! If the water heater has been altered the Warranty will be Void Altering Atwood Water Heaters If you experience low flow from the hot water faucet or notice the water is not as hot coming from the water heater, you may have to have the Mixing Valve serviced by a Certified Service Technician. Low flow or cold flow from the XT water heater is a result of corrosion on the seats and/or debris blocking the inlet screen (if equipped) of the mixing valve. When the technician removes the mixing valve, cleans the screen (if equipped) and soaks the valve in a hot white vinegar bath, he will also complete the “Flushing the Tank” procedure as corrosion and sediment from improper “Tank Maintenance” is the cause of this condition. XT Models—Special Requirements A Pressure Temperature Relief Valve, dripping while the water heater is in use, DOES NOT mean it is defective. During normal use, water expands as it is heated in the closed water system. The Atwood water heater is designed with an internal air gap at the top of the tank to absorb the expansion and reduce the dripping. In time, this air gap will be absorbed and need to be restored. To restore the Air Gap: 1. Turn off the main water supply (pump or water hook-up source) and allow water to cool. 2. Open the nearest hot water faucet to the water heater. 3. Pull the handle on the Pressure Temperature Relief Valve straight out and allow water to flow until it stops flowing. 4. Trip the handle on the relief valve allowing it to snap shut, shut off the hot water faucet, turn on the water supply, and turn the water heater on. Test. Dripping Pressure Temperature Relief Valve A “rotten egg odor” (hydrogen sulfide) may be produced when the electro galvanic action of the cladding material releases hydrogen from the water. If sulfur is present in the water supply the two will combine and produce an unpleasant smell. To remedy the problem, first complete the (4) steps in “Flushing the Tank” above. When the tank is flushed, perform the following: 1. Remove the Pressure/Temperature relief Valve. Mix a solution of (4) parts white vinegar to (2) parts water. (For a 6 gallon tank, use (4) gallons of vine gar to (2) gallons of water.) With a funnel, carefully pour the solution into the tank through the P&T coupling. Re-install the P&T Relief Valve. 2. Turn on the water heater and allow the water to heat up through a full cycle (this may take up to 45 minutes.) It is recommended you allow the water heater to operate through 3 or 4 additional heat maintenance cycles. 3. Turn off and allow to cool. When cool, remove the drain plug and drain. Then repeat Steps 3 and 4 of “Flushing the Tank” above. 4. Refill the tank with fresh water that contains no sulfur. Unpleasant Odors Prior to storing your RV, Follow Steps 1-4 of “Flushing the Tank” above. Note: The approximately (2) quarts of water that remains in the bottom of the tank will not cause freeze damage to the tank. Caution!: An un-drained tank, (water level above the drain plug level), will crack the tank in freezing conditions. 4. 3. 1. 2. Flushing the Tank sediment deposits that shorten the life of the tank, element, relief valve, and Mixing Valve (XT Models). (Lack of proper maintenance of the tank will cause Mixing Valves on XT Models to malfunction, requiring costly service procedures to clean and/or replace at the owner’s expense.) Failure to follow these instructions May result in Denial of Your Warranty Coverage! Caution! Always turn off the main water supply (pump or water supply hook-up), allow the water to cool, then drain the tank by removing drain plug. Frequency: Full-Time RV’er, Every (60) days (Southwest US, every (30) days). Part-Time RV’er, Minimum of 2X annually (Southwest, every (90) days). Reason: The Life of the tank and performance of the water heater are directly affected by water quality! High mineral content will cause corrosion and • • • • • • General—Burner Maintenance Preventative Maintenance Requirements—Preservation of Warranty and Water Heater Life Extension DO NOT use matches, candles or other sources of ignition when checking for gas leaks. WARNING Valve is not serviceable, it must be replaced. Replacement by a Certified Service Technician only. Tampering with valve will result in scalding injury. Tampering with valve will void warranty. SCALDING INJURY temperature and pressure relief valve that complies with the standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Systems, ANSI Z21.22. If you use a discharge line, do not use a reducing coupling or other restriction smaller than outlet of relief valve. Allow complete drainage of both valve and line. THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON OTHER THAN REPLACEMENT. This water heater is equipped with a pressure-temperature relief valve. s DO NOT place a valve, plug or reducing coupling on outlet part of EXPLOSION WARNING s Tampering with valve will void warranty. s Valve is not serviceable, it must be replaced. s Tampering with valve will result in scalding injury. SCALDING INJURY WARNING PRESSURE-TEMPERATURE RELIEF VALVE - (FIG 3-G) (moderating) valve which mixes cold water with higher temperature water to moderate outlet water to approximately 130˚F. It is also equipped with a higher temperature thermostat, raising the storage water temperature. THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON OTHER THAN REPLACEMENT. REMOVAL FOR REPLACEMENT BY A CERTIFIED SERVICE TECHNICIAN ONLY. The water heater is equipped with a mixing s s s s MIXING VALVE - (FIG 9) 11. Turn on gas and check water heater and all connections for gas leaks with leak detecting solution. 12. Fill water heater tank, check all connections for water leaks. s FIRE AND/OR EXPLOSION WARNING 9. Attach access door. a. Snap hinge pin (FIG 3-C) into clip (FIG 3-D). b. Slide cover (FIG 3-E) onto hinge pin. c. Slide hinge pin into cover, snapping into clip at same time (FIG 3-D). NOTE: To remove hinge pin, support access cover and apply force to corner of hinge pin. 10. Disconnect unit and its individual shut-off valve from gas supply line during any pressure testing of system in excess of 1/2 PSIG (3.4 kPa, 14˝ water column [W.C.]). DO NOT set inlet pressure higher than maximum indicated on rating plate of gas valve (13˝ W.C.). Isolate unit from gas supply line by closing its individual manual shutoff valve during any pressure testing b 1/2 psig. 3 Do not smoke or have any flame near an open faucet. FIRE CAUTION HOW TO OPERATE YOUR WATER HEATER s Do not operate without water in tank. PRODUCT FAILURE CAUTION s Do not tamper with orifice or mixing valve. SCALDING INJURY WARNING If hydrogen gas is present, you will probably hear sounds like air escaping through the pipe as water begins to flow. If water heater has not been used for more than two weeks, hydrogen gas may form in water line. Under these conditions to reduce the risk of injury, open hot water faucet for several minutes at kitchen sink before you use any electrical appliance connected to hot water system. s s store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Should overheating occur, or gas supply fail to shut off, turn gas OFF at the LP tank. On ELECTRONIC IGNITION MODEL turn operating switch to OFF position and remove red wire from left hand terminal of ECO switch or turn gas OFF at the LP tank. s Use with LP gas only. s Shut off gas appliances when refueling. s Turn gas OFF at the LP tank when vehicle is in motion. This disables all gas appliances. Gas appliances must never be operated while vehicle is in motion. Unpredictable wind currents may be created which could cause flame reversal in the burner tube, which could result in fire damage. The thermal cut off fuse could also be unnecessarily activated resulting in a complete shutdown of the water heater requiring replacement of the thermal cut off. See maintenance of electronic ignition water heaters for further explanation of the thermal cut off. s LP tanks must be filled by a qualified gas supplier only. s DO NOT EXPLOSION OR FIRE WARNING CONSUMER SAFETY WARNINGS Your ATWOOD WATER HEATER is now ready for operation. Continue to HOW TO OPERATE YOUR WATER HEATER. FOR REPLACEMENT PARTS: s DO NOT install anything less than a combination temperature-pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of product of listed equipment or materials, as meeting requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. Valve must have a maximum set pressure not to exceed 150 psi. s Install valve into opening provided and marked for this purpose on water heater. s Installation must conform with local codes or in the absence of local codes, American National Standard for Recreational Vehicles, ANSI A119.2/NFPA 50IC. s For an external electrical source, ground this unit in accordance with National Electrical Code ANSI/NFPA70. Page 108 of 145 The use of any aftermarket heating element devices may also result in damage to components or water heater. Atwood’s written warranty states - “failure or damage resulting from any alteration to our water heater is the owner’s responsibility”. Any alteration, like the addition of an aftermarket heating element device, will void the warranty. heating of water tank and a catastrophic wet side explosion. s Use of Aftermarket heating elements can lead to an out of control controls. s DO NOT USE Aftermarket heating elements, they can lack critical safety s DO NOT alter water heater, it will void warranty. EXPLOSION / BURN INJURY WARNING AFTERMARKET WATER HEATING ELEMENT DEVICES material, and flammable liquids and vapors. s Keep control compartment clean and free of gasoline, combustible s Shut off gas supply at LP container before disconnecting a gas line. FIRE OR EXPLOSION WARNING Location and phone numbers of qualified Service Centers can be found at our website http:/www.atwoodmobile.com or call 574-262-2655 to have a Service Center List mailed. SERVICE CALLS & QUESTIONS MAINTENANCE AND CARE INSTRUCTIONS Read MAINTENANCE AND CARE INSTRUCTIONS . The unit can be run in both gas and electric modes simultaneously for quick recovery. note: if the gas fails to ignite, the gas mode will lockout, but the lockout lamp will not illuminate since the electric mode is still operational. Should you notice slow recovery, indicating the gas is not working, turn the electric switch off. The lamp will then illuminate indicating a lockout has occurred on the gas side. Correct the problem and turn the switches back on. GAS/ELECTRIC OPERATION. ELECTRIC OPERATION. When the electric switch is turned on, the relay at the rear of the unit will close and pass 110vac to the element. If the thermostat were to fail, the ECO will open and lockout the system. To correct, check the thermostat to assure good contact with the tank and reset the control by turning the electric switch off, then on. When the gas switch is turned on, the unit will make three attempts to light. If for any reason there is no ignition, the unit will lockout and the red lockout lamp will illuminate. If the thermostat fails, the ECO will also lockout the unit, requiring resetting. Determine the reason for no ignition, correct it, and reset the gas ignition sequence by turning the switch off, then on. 4 ELECTRONIC IGNITION MAINTENANCE GAS/ELECTRIC COMBINATION FUNCTION removing drain plug to flush tank. s Turn off water heater and allow time for water to cool before WARNING SCALDING INJURY WATER HEATER TANK CARE HOW TO CLEAN ELECTRONIC IGNITION MODEL 1. Check main burner orifice. 2. Clean and adjust main burner. 3. Main burner and valve manifold must align with each other 4. Check electrode for cracked porcelain (FIG 4-E). 5. Check electrode for proper gap - 1/8” between electrode and ground. 6. If module board functions intermittently, remove board and clean terminal block with pencil eraser ( FIG 3-H). Spiders, mud wasps, and other insects can build nests in the burner tube. This will cause poor combustion, delayed ignition or ignition outside combustion tube. Listen for a change in burner sounds or in flame appearance from a hard blue flame to a soft lazy flame or one that is very yellow. These are indications of an obstruction in burner tube (FIG 4-C). Inspect and clean on a regular basis. a. Remove air shutter screw (FIG 4-A) and slide air shutter (FIG 4-B) down burner tube. b. Run a flexible wire brush down burner tube ( FIG 4-D) until it is visible at end of burner tube. c. Vacuum burner where it enters combustion tube. d. Return air shutter to original position and replace screw. e. The orifice, burner tube and shutter must be aligned so that the shutter is not binding on the air tube. PREVENTATIVE MAINTENANCE s The water heater comes factory-equipped with a fused circuit board, which will protect the circuit board from wiring shorts. If the fuse should activate, the water heater will not operate. Before replacing the fuse, check for a short external to the board. Once the short is corrected, replace the 2 amp fuse with a mini ATO style fuse. Do not install a fuse larger than 3 amps. s If the fuse is good and the unit is inoperative, check for excessively high voltage to the unit (more than 14 volts). s If the previous two steps did not solve the problem, check the thermal cut-off (FIG 3-I). The thermal cutoff is a device installed in the power supply line. This device will shut off electrical power and stop heater operation when activated. For example, if an obstruction within the flue tube should occur, as described in the Preventative Maintenance section, the burner flame/heat may contact the cutoff, resulting in a melting of the fuse element incorporated in the thermal cutoff. In order to restore power and proper operation of the water heater, the obstruction must be removed and the thermal cutoff must be replaced. s LP and Water system must be turned on. s Have gas pressure tested periodically. Should be set at 11 inches of water column with three appliances running. s Drain water heater at regular intervals (at least one time during the year). s Drain water heater before storing RV for the winter or when the possibility of freezing exists. s Keep vent and combustion air grill clear of any obstructions. s Periodically, compare flame of main burners with FIG 4 and main burner adjustments in HOW TO OPERATE YOUR WATER HEATER. s Presence of soot indicates the need to adjust flame. 1. Refer to WIRING DIAGRAM FIG12. Place remote switch in ON position. 2. For complete shut-down and before servicing: a. Place remote switch in OFF position. b. Remove red wire from left hand terminal of ECO switch (ECO to valve). 3. If heater fails to operate due to high water temperature, a lockout condition occurs (indicator light on). After water cools, reset switch in OFF position for at least 30 seconds, then turn to ON position. 4. If a lockout condition persists contact an Atwood Service Center. Read MAINTENANCE AND CARE INSTRUCTIONS & ELECTRONIC IGNITION MAINTENANCE GAS OPERATION. GENERAL INFORMATION ELECTRONIC IGNITION OPERATION pression-température et de rétablir l’intervalle d'air. L'eau contenue dans le réservoir doit être froide. s Couper le chauffe-eau avant d'ouvrir la soupape de décharge de type BRÛLURES AVERTISSEMENT Lorsqu’une soupape de décharge de type pression-température goutte pendant le fonctionnement du chauffe-eau, cela NE SIGNIFIE PAS qu’elle est défectueuse. La soupape de décharge goutte parfois, du fait d'une expansion naturelle de l'eau, lorsque celle-ci est chauffée à l'intérieur du réseau d’alimentation en eau d'un véhicule de plaisance. Le réservoir du chauffe-eau Atwood comporte un intervalle d'air interne en haut du réservoir, permettant de réduire les risques d’égouttement. Au fil du temps, l'expansion de l'eau absorbe cet air et l’intervalle doit être rétabli. sur la sortie de la soupape de décharge de type pression-température. s Ne pas placer de robinet, de bouchon ou de raccord de réduction EXPLOSION AVERTISSEMENT s Toucher à la soupape annulera la garantie. s La soupape ne se prête pas aux réparations, elle devra être remplacée. s Toucher à la soupape risque de provoquer des brûlures. BRÛLURES AVERTISSEMENT SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE Pour assurer le meilleur rendement de votre chauffe-eau et prolonger la vie du réservoir, évacuer et rincer régulièrement le réservoir du chauffe-eau. Avant le rangement à long terme ou avant l’arrivée du gel, évacuer et rincer le réservoir. 1. Couper l'alimentation principale en eau (la pompe ou la source d'apport en eau). 2. Évacuer l'eau du réservoir du chauffe-eau en retirant le bouchon de vidange. Si l'eau coule de façon irrégulière ou goutte au lieu de couler à jet normal, nous vous conseillons tout d’abord d’ouvrir la soupape de décharge de type pression-température, pour permettre à l'air d’entrer dans le réservoir. Ensuite, à l'aide d'un fil de fer de petit diamètre ou d'un porte-manteau, piquer à l’intérieur de l’orifice d'évacuation, de façon à éliminer toute obstruction. 3. Une fois le réservoir vide, étant donné l'emplacement du bouchon de vidange, il restera environ 2 litres d'eau dans le réservoir. Cette eau contient la plus grande partie des particules corrosives dangereuses. Pour retirer ces particules corrosives dangereuses, rincer le réservoir soit avec de l’air, soit avec de l’eau. Que vous utilisiez de l'air ou de l’eau sous pression, l’application peut se faire soit par l'entrée, soit par la sortie située à l'arrière du réservoir ou de la soupape de décharge de type pression-température. (En cas d’utilisation de la soupape de décharge de type pression-température, il faudra d'abord retirer le rebord de sécurité). La pression force l’eau et les particules corrosives restantes à s’évacuer. En cas d’utilisation d’eau sous pression, pomper de l'eau fraîche dans le réservoir à l'aide d'une pompe transportée ou utiliser de l'eau externe pendant 90 secondes, de façon à permettre à l'eau fraîche de remuer l'eau stagnante se trouvant au fond du réservoir et de propulser les dépôts par l’orifice d’évacuation. Continuer à rajouter de l’eau et à évacuer, jusqu'à ce que l’eau restant dans le réservoir ne comporte plus aucune particule. 4. Replacer le bouchon de vidange et fermer la soupape de décharge de type pression-température. La quantité d’eau (environ 2 litres) restant au fond du réservoir suite à la vidange ne causera pas de dommage au réservoir en cas de gel. INSTRUCTIONS POUR L'HIVERNAGE (RINÇAGE) 13 Il faudra pomper de l’eau claire dans le réservoir, soit avec la pompe transportée à bord, soit avec de l’eau sous pression externe. Continuer le processus de rinçage pendant environ cinq minutes ; ceci permet à l’eau claire de remuer l'eau stagnante du fond du réservoir et de pousser les dépôts par l’orifice d’évacuation. 4. Replacer le bouchon de vidange et la soupape de décharge de type pression-température. 5. Remplir le réservoir avec de l’eau claire ne contenant pas de souffre. Le chauffe-eau Atwood est conçu pour être utilisé dans les véhicules de plaisance. Si vous utilisez votre véhicule fréquemment ou pour des périodes prolongées, rincer le chauffe-eau plusieurs fois par an permettra de prolonger la vie du réservoir d’approvisionnement. POUR RINCER LE RÉSERVOIR AVEC DE L’EAU SOUS PRESSION : L’air sous pression devra passer par le raccord de la soupape de décharge de type pression-température. Le robinet de vidange ouvert, l’air sous pression forcera l’eau restante à s’écouler de l’unité. POUR RINCER LE RÉSERVOIR AVEC DE L’AIR SOUS PRESSION : Une odeur d’œuf pourri (sulfure d’hydrogène) pourra se dégager du fait de l’action électrogalvanique du matériau de gainage qui dégage de l’hydrogène de l’eau. En cas de présence de souffre dans l’alimentation en eau, l’eau et le souffre se mélangent pour donner une odeur désagréable. 1. Couper l’alimentation principale en eau. Évacuer l’eau du réservoir du chauffe-eau et réinstaller le bouchon de vidange. Retirer la soupape de décharge de type pression-température. Préparer une solution de 4 parts de vinaigre blanc pour 2 parts d’eau. (Pour un réservoir de 10 gallons, utiliser 6 gallons de vinaigre et 3 gallons d’eau.) Au moyen d’un entonnoir, verser la solution à l’intérieur du réservoir, avec précaution. 2. Effectuer 4 à 5 cycles du chauffe-eau avec la solution indiquée cidessus en laissant fonctionner normalement. 3. Retirer le bouchon de vidange et évacuer toute l’eau du réservoir. Rincer le chauffe-eau pour en éliminer tout sédiment. Il est possible de rincer le réservoir avec de l’air sous pression ou avec de l’eau claire. Appliquer la pression soit sur les clapets d’arrivée ou de sortie à l’arrière du réservoir, soit au raccord de la soupape de décharge de type pression-température se trouvant à l’avant de l’unité. RINCER POUR ÉLIMINER LES MAUVAISES ODEURS s Installer une soupape de décharge de type pression-température dans la conduite d’arrivée d'eau froide du chauffe-eau et fixer une conduite d’évacuation sur la vanne extérieure du véhicule. Régler la limite sur 100 à 125 psi. s Installer un réservoir d’expansion de type membrane dans la conduite d’arrivée d'eau froide. Le réservoir devra permettre une dilatation d’environ 15 oz d'eau et une mise sous pression égale à la pression de l'alimentation en eau. Ces dispositifs sont disponibles chez un plombier ou dans un Centre de service. Lorsque la soupape de décharge de type pression-température s’écoule à nouveau, répéter la procédure ci-dessus. Pour une solution permanente, nous vous conseillons l'une des choses suivantes : s Faire fonctionner manuellement la soupape de décharge de type pression-température au moins une fois par an (FIG 3-G). POUR RÉTABLIR L'INTERVALLE D'AIR, SUIVRE LES ÉTAPES SUIVANTES : 1. Couper l'alimentation principale en eau (la pompe ou la source d'apport en eau). 2. Laisser l’eau refroidir ou la laisser couler jusqu’à ce qu’elle soit froide. 3. Ouvrir le robinet d’eau chaude le plus proche du chauffe-eau. 4. Tirer la poignée de la soupape de décharge de type pressiontempérature vers soi et laisser l'eau couler, jusqu'à ce qu'elle s'arrête. 5. Laisser la soupape de décharge de type pression-température revenir brusquement en position fermée ; fermer le robinet ; ouvrir l'alimentation en eau. 6. Allumer le chauffe-eau et le tester. Page 109 of 145 L'utilisation d'éléments de chauffe provenant de fabricants de marché secondaire pourra également entraîner des endommagements des composantes ou du chauffe-eau. La garantie écrite Atwood stipule que « la responsabilité d'un mauvais fonctionnement ou de dommages causés par une modification au chauffe-eau revient à le risque de perte de contrôle du chauffage du réservoir à eau et d’explosion d'eau catastrophique. s L'utilisation d'éléments de chauffe de marché secondaire comporte risquent de ne pas avoir fait l’objet de certains contrôles de sécurité importants. s NE PAS modifier le chauffe-eau, sous peine d’annuler la garantie. s NE PAS utiliser d'éléments de chauffe de marché secondaire, car ils EXPLOSION / BRÛLURES AVERTISSEMENT ÉLÉMENTS DE CHAUFFE D'EAU DE MARCHÉ SECONDAIRE comporte pas de carburant, de matériaux combustibles ou de liquides ou vapeurs inflammables. s S’assurer que le compartiment de commande est propre et ne avant de débrancher la conduite de gaz. s Fermer l'alimentation en gaz au niveau du réservoir de propane liquide INCENDIE OU EXPLOSION AVERTISSEMENT Les adresses et les numéros de téléphone des centres de service agréés se trouvent sur notre site Internet http:/www.atwoodmobile.com ou composer le 574-262-2655 pour recevoir la liste par courrier. APPELS ET QUESTIONS D’ENTRETIEN INSTRUCTIONS POUR L'ENTRETIEN Lire les INSTRUCTIONS POUR L’ENTRETIEN. FONCTIONNEMENT GAZ-ÉLECTRICITÉ. L’unité peut fonctionner à la fois en mode gaz et en mode électrique simultanément, ce qui permet d’éviter les interruptions prolongées. Remarque : si le gaz ne s’allume pas, le mode de fonctionnement au gaz se verrouille, mais le voyant lumineux de verrouillage ne s’allume pas pour autant, étant donné que le mode électrique est encore en marche. Si vous remarquez une interruption prolongée indiquant que le gaz ne fonctionne pas, mettre l’interrupteur électrique sur la position éteinte (OFF). Le voyant s’allume alors, indiquant qu’un verrouillage vient de se produire du côté gaz. Rectifier le problème et remettre les interrupteurs sur la position allumée (ON). FONCTIONNEMENT ÉLECTRIQUE. Lorsque l’interrupteur à électricité est ouvert, le relais situé à l’arrière de l’unité se ferme, envoyant un courant de 110 VCA vers l’élément. Si le thermostat ne fonctionne pas, l’ECO s’ouvre et verrouille le système. Pour remédier à ce problème, vérifier le thermostat et s’assurer qu’il existe un contact stable avec le réservoir, puis réinitialiser la commande en mettant l’interrupteur électrique en position éteinte (OFF), puis allumée (ON). FONCTIONNEMENT AU GAZ. Lorsque l’interrupteur à gaz est ouvert, l’unité tentera de s’allumer trois fois. Dans le cas où, pour une raison quelconque, l’allumage ne se produit pas, l’unité se verrouille et le voyant lumineux de verrouillage s’allume au rouge. Dans le cas où le thermostat ne fonctionne pas, l’ECO verrouille également l’unité et la remise à zéro est alors obligatoire. Identifier la raison pour laquelle l’allumage ne s’effectue pas, rectifier l’erreur et réinitialiser le processus d’allumage en éteignant, puis en rallumant l’interrupteur. FONCTION COMBINÉE GAZ-ÉLECTRICITÉ Lire les INSTRUCTIONS POUR L’ENTRETIEN et L'ENTRETIEN DE L'ALLUMAGE ÉLECTRONIQUE. 1. Consulter le SCHÉMA DE CÂBLAGE FIG 12. Mettre la commande à distance en position allumée (ON). 2. Pour éteindre complètement l'unité et avant d’effectuer des réparations : a. Mettre la commande à distance en position éteinte (OFF). b. Enlever le fil rouge de la borne gauche de l'interrupteur ECO (ECO au robinet). 3. Si le chauffe-eau ne fonctionne pas car la température de l’eau est trop élevée, il se verrouille (voyant lumineux allumé). Une fois l'eau refroidie, remettre l'interrupteur en position éteinte (OFF) pendant au moins 30 secondes, puis repasser à la position allumée (ON). 4. Si le verrouillage persiste, contacter un centre de service Atwood. FONCTIONNEMENT DE L'ALLUMAGE ÉLECTRONIQUE 12 d'enlever le bouchon de vidange et de rincer le réservoir. s Éteindre le chauffe-eau et attendre que l'eau refroidisse avant AVERTISSEMENT BRÛLURES ENTRETIEN DU RÉSERVOIR DU CHAUFFE-EAU COMMENT NETTOYER LES MODÈLES À ALLUMAGE ÉLECTRONIQUE 1. Vérifier l'orifice du brûleur principal. 2. Nettoyer et régler le brûleur principal. 3. Le brûleur principal et les voies de la soupape doivent être alignés. 4. Vérifier que la porcelaine de l'électrode ne comporte pas de fissures (FIG 4-E). 5. Vérifier que l’écart entre l’électrode et le sol est bien de 1/8 po. 6. Lorsque la carte des modules fonctionne en alternance, enlever la carte et nettoyer la plaque à bornes avec une gomme pour crayon (FIG 3-H). Araignées, guêpes et autres insectes font parfois leur nid dans le tube du brûleur. Cela risque de causer une mauvaise combustion, un retard dans l’allumage ou un allumage à l'extérieur du tube de combustion. Prêter attention à tout changement du son produit par le brûleur et de l'apparence de la flamme (molle, calme et jaune vif plutôt que drue et bleue). Cela indique que le tube du brûleur est obstrué (FIG 4-C). Inspecter et nettoyer régulièrement. a. Retirer la vis de l’obturateur d'air (FIG 4-A) et glisser l’obturateur d'air (FIG 4-B) le long du tube du brûleur. b. Introduire une brosse métallique flexible à l’intérieur du tube du brûleur (FIG 4-D), jusqu'à ce qu'elle ressorte par l'autre extrémité du tube. c. Nettoyer le brûleur à l’aide d'un aspirateur, à l'endroit où il s’insère dans le tube de combustion. d. Remettre l’obturateur d'air dans sa position d'origine et replacer la vis. e. The orifice, burner tube and shutter nmust be aligned so that the shutter is not binding on the air tube. ENTRETIEN PRÉVENTIF s A l’usine, votre chauffe-eau a été équipé d’une carte imprimée à fusible. Ce fusible protège la carte imprimée des courts-circuits pouvant survenir dans les câblages. Si le fusible venait à s’activer, le chauffe-eau ne pourrait pas fonctionner. Avant de remplacer le fusible, vérifier que le court-circuit n’est pas externe à la carte imprimée. Une fois le court-circuit réparé, remplacer le fusible de 2 ampères par un fusible mini de type ATO. Ne pas installer de fusible de plus de 3 ampères. s Si le fusible est bon mais que l’unité ne fonctionne pas, vérifier que la tension du courant alimentant l’unité n’est pas trop élevée (plus de 14 volts). s Si les deux étapes précédentes ne résolvent pas le problème, vérifier le système de coupure thermique (FIG 3-I). Le système de coupure thermique est installé dans le tuyau d’alimentation. Ce dispositif, une fois déclenché, coupe l’arrivée du courant électrique et le fonctionnement du chauffe-eau. Par exemple, en cas d’obstruction dans le tube d’évacuation, comme le décrit la section d’Entretien préventif, la flamme et la chaleur du brûleur risquent d’entrer en contact avec le système de coupure, ce qui fera fondre l’élément du fusible incorporé dans le système de coupure thermique. Pour rétablir l’électricité et le bon fonctionnement du chauffe-eau, l’obstruction doit être éliminée et le système de coupure thermique doit être remplacé. ENTRETIEN DE L'ALLUMAGE ÉLECTRONIQUE s Le système de propane liquide et le système à eau doivent être allumés. s Faire tester la pression du gaz régulièrement. La pression doit être réglée sur 11 po. de colonne d'eau, lorsque 3 appareils fonctionnent. s La pression d’admission minimale ne doit pas dépasser 14 po. de colonne d’eau. s Évacuer l'eau contenue dans le chauffe-eau à intervalles réguliers (au moins une fois par an). s Évacuer l'eau contenue dans le chauffe-eau avant de garer votre véhicule de plaisance pour l'hiver ou lorsqu’il existe un risque de gel. s S’assurer que l'évacuation et la grille d'air de combustion ne comportent aucune obstruction. s Comparer régulièrement la flamme des brûleurs principaux à la FIG 4 et aux réglages du brûleur principal dans la section COMMENT UTILISER VOTRE CHAUFFE-EAU. INFORMATIONS GÉNÉRALES l’acheteur ». Toute modification, telle que, par exemple, le rajout d'un élément de chauffe de marché secondaire, annule la garantie. TO REPLACE THE AIR GAP FOLLOW THESE STEPS: 1. Turn off main water supply (the pump or water hook up source). 2. Let water cool or let run until cool. 3. Open the hot water faucet closest to the water heater. 4. Pull handle of pressure temperature relief valve straight out and allow water to flow until it stops. 5. Allow pressure temperature relief valve to snap shut; close faucet; turn on water supply. 6. Turn on water heater and test. valve to establish air space. Storage water must be cool. s Turn off water heater before opening pressure-temperature relief SCALDING INJURY WARNING A Pressure Temperature Relief Valve, dripping while the water heater is running, DOES NOT mean it is defective. During normal expansion of water, as it is heated in the closed water system of a recreation vehicle, the Pressure Temperature Relief Valve will sometimes drip. The Atwood water heater tank is designed with an internal air gap at the top of the tank to reduce the possibility of dripping. In time, the expanding water will absorb this air and it must be restored. pressure-temperature relief valve. s Do not place a valve, plug or reducing coupling on outlet part of EXPLOSION WARNING s Tampering with valve will void warranty. s Valve is not serviceable, it must be replaced. s Tampering with valve will result in scalding injury. SCALDING INJURY WARNING PRESSURE-TEMPERATURE RELIEF VALVE To insure the best performance of your water heater and add to the life of the tank, periodically drain and flush the water heater tank. Before long term storage or freezing weather drain and flush the tank. 1. Turn off main water supply (the pump or water supply (the pump or water hook up source). 2. Drain Water Heater Tank by removing the drain plug. If the water flows sporadically or trickles instead of a steady stream of water, we recommend the following action; first open the Pressure Temperature Relief Valve to allow air into the tank and secondly, take a small gauge wire or coat hanger and poke through the drain opening to eliminate any obstructions. 3. After draining the tank, because of the placement of the Drain Plug, approximately two quarts of water will remain in the tank. This water contains most of the harmful corrosive particles. To remove these harmful corrosive particles flush the tank with either air or water. Whether using air or water pressure, it may be applied through the inlet or outlet on the rear of the tank or the Pressure Temperature Relief Valve. (If using the Pressure Temperature Relief Valve the Support Flange must be removed). The pressure will force out the remaining water and the corrosive particles. If you use water pressure, pump fresh water into the tank with the assistance of the on-board pump or use external water for 90 seconds to allow the fresh water to agitate the stagnant water on the bottom of the tank and force deposits through the drain opening. Continue repeating adding water and draining until the particles have been cleared from the water remaining in the tank. 4. Replace the Drain Plug and close the Pressure Temperature Relieve Valve. The approximately two quarts of water remining in the tank after draining will not cause damage to the tank should freezing occur. WINTERIZING (FLUSHING) INSTRUCTIONS 5 A rotten egg odor (hydrogen sulfide) may be produced when the electro galvanic action of the cladding material releases hydrogen from the water. If sulfur is present in the water supply the two will combine and produce an unpleasant smell. 1. Turn off main water supply. Drain the water heater tank and reinstall drain plug. Remove the pressure-temperature relief valve. Mix solution of 4 parts white vinegar to two parts water. (For a 10 gallon tank, use 6 gallons vinegar to 3 gallons water). With a funnel, carefully pour solution into tank. 2. Cycle water heater with the above solution, letting it run under normal operation 4-5 times. 3. Remove the drain plug and thoroughly drain all water from the tank. Flush the water heater to remove any sediment. you may flush the tank with air pressure or fresh water. Pressure may be applied through either the inlet or outlet valve on the rear of the tank or through the pressure-temperature relief valve coupling located on the front of the unit. TO FLUSH TANK WITH AIR PRESSURE: Insert your air pressure through the pressure-temperature relief valve coupling. With the drain valve open, the air pressure will force the remaining water out of the unit. TO FLUSH TANK WITH WATER PRESSURE: Fresh water should be pumped into the tank with either the onboard pump or external water pressure. Continue this flushing process for approximately five minutes, allowing the fresh water to agitate the stagnant water on the bottom of the tank and forcing the deposits through the drain opening. 4. Replace drain plug and pressure-temperature relief valve. 5. Refill tank with fresh water that contains no sulphur. The Atwood water heater is designed for use in a recreation vehicle. If you use your vehicle frequently or for long periods of time, flushing the water heater several times a year will prolong the life of the storage tank. FLUSHING TO REMOVE UNPLEASANT ODOR s At least once a year manually operate pressure-temperature relief valve (FIG 3-G). When pressure-temperature relief valve discharges again, repeat above procedure. For a permanent solution, we recommend one of the following: s Install a pressure relief valve in cold water inlet line to water heater and attach a drain line from valve to outside of coach. Set to relieve at 100-125 PSI. s Install a diaphragm-type expansion tank in cold water inlet line. Tank should be sized to allow for expansion of approximately 15 oz. of water and pre-charged to a pressure equal to water supply pressure. These devices can be obtained from a plumbing contractor or Service Center. 5 Page 110 of 145 % 1 & % " & # # $ # $ ' 3 " " 6 ' * ( ) From the Pump 2 4 Cold Water Inlet Hot Water Outlet " # $ STRAIGHT SECTION VIEW & % $ Ne pas fumer ou tenir de flamme à proximité d'un robinet ouvert. L’hydrogène est hautement inflammable. INCENDIE ATTENTION COMMENT UTILISER VOTRE CHAUFFE-EAU BRÛLURES AVERTISSEMENT Si le chauffe-eau n'a pas été utilisé pendant plus de deux semaines, il est possible que de l'hydrogène se soit formé dans la conduite d'eau. Dans ces conditions, avant d'utiliser tout appareil électrique branché sur le système d'eau chaude, faire couler l'eau du robinet d'eau chaude de l’évier de la cuisine pendant plusieurs minutes pour réduire le risque de blessures. En cas de présence d’hydrogène, vous entendrez probablement l'air s'échapper du tuyau, lorsque l'eau commence à couler. s s s NE PAS entreposer ou utiliser de carburant ou tout autre liquide ou toute vapeur inflammables à proximité de cet appareil ou de tout autre appareil. s En cas de surchauffe ou si l'alimentation en gaz ne s'arrête pas convenablement, fermer le gaz au niveau du réservoir de propane liquide. Sur le MODÈLE À ALLUMAGE ÉLECTRONIQUE, mettre l'interrupteur de commande en position arrêt (OFF) et retirer le fil rouge de la borne gauche de l'interrupteur ECO ou fermer le gaz au niveau du réservoir de propane liquide (OFF). s Utiliser uniquement avec du gaz de propane liquide. s Lors du ré-approvisionnement en carburant, éteindre les appareils à gaz. s Éteindre le gaz au niveau du réservoir à propane liquide, lorsque le véhicule est en déplacement. Cela permet de désactiver tous les appareils à gaz. Les appareils à gaz ne doivent jamais fonctionner lorsque le véhicule se déplace. Des mouvements d'air imprévisibles risqueraient d’entraîner un retour de flamme dans le tube du brûleur, ce qui pourra causer des endommagements par le feu. Le fusible de coupure thermique pourra également être activé accidentellement et éteindre complètement le chauffe-eau. Le système de coupure thermique devra alors être remplacé. Consulter l'entretien des chauffes-eau à allumage électronique pour plus de détails sur la coupure thermique. s Les réservoirs à propane liquide devront être remplis uniquement par un fournisseur en gaz qualifié. EXPLOSION OU INCENDIE AVERTISSEMENT CONSIGNES DE SÉCURITÉ DESTINÉES AU CONSOMMATEUR Votre CHAUFFE-EAU ATWOOD est maintenant prêt à fonctionner. Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU. PIÈCES DE RECHANGE : s Installer AU MINIMUM une soupape de décharge combinée de type température-pression, homologuée par un laboratoire de test reconnu au niveau national, qui inspecte régulièrement les produits d’équipement ou de matériaux concernés, selon les normes pour les soupapes de décharge et les mécanismes de coupure automatique de l’alimentation en gaz pour systèmes à eau chaude ANSI Z21.22. Le réglage de la pression de la soupape ne doit pas dépasser 150 psi. s Installer la soupape dans l'ouverture prévue et marquée à cet effet sur le chauffe-eau. s L'installation doit être conforme aux codes locaux ou, faute de codes locaux, à la norme américaine nationale pour véhicules de plaisance ANSI A119.2/NFPA 50IC. s En cas de source électrique externe, cet appareil doit être mis à la terre selon le Code électrique national ANSI/NFPA70. s Ne pas toucher l'orifice ou le robinet mélangeur. décharge de type pression-température en conformité avec la norme sur les soupapes de décharge et les mécanismes de coupure automatique de l'alimentation en gaz pour systèmes à eau chaude ANSI Z21.22. ATTENTION En cas d’utilisation d’un tuyau d'écoulement, ne pas utiliser de PANNE DE L'APPAREIL raccord réducteur ou toute autre restriction qui soit inférieure en s Ne pas faire fonctionner sans eau dans le réservoir. diamètre à la sortie de la soupape de décharge. Laisser la soupape et 11 la conduite s'écouler complètement. LA SOUPAPE EST UN ÉLÉMENT DE SÉCURITÉ ET NE DOIT PAS ÊTRE RETIRÉE SAUF EN CAS DE REMPLACEMENT. Ce chauffe-eau est équipé d'une soupape de sur la sortie ou l’admission de la soupape de décharge. s NE PAS placer de robinet, de bouchon ou de raccord de réduction EXPLOSION AVERTISSEMENT s Toucher à la soupape annulera la garantie. s La soupape ne se prête pas aux réparations, elle devra être remplacée. s Toucher à la soupape risque de provoquer des brûlures. BRÛLURES AVERTISSEMENT SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE - (FIG 3-G) chauffe-eau est équipé d'un robinet mélangeur (régulateur) qui mélange l’eau froide avec de l’eau à plus haute température, de façon à obtenir une température de l’eau de sortie de 130ºF environ. Il est également équipé d’un thermostat à plus haute température qui permet d’augmenter la température de l’eau d’approvisionnement. CETTE SOUPAPE EST UN ÉLÉMENT DE SÉCURITÉ QUI DEVRA ÊTRE RETIRÉ UNIQUEMENT EN CAS DE REMPLACEMENT. LE RETRAIT, À DES FINS DE REMPLACEMENT, DOIT UNIQUEMENT ÊTRE EFFECTUÉ PAR UN TECHNICIEN D’ENTRETIEN QUALIFIÉ. Ce s Toucher à la soupape risque de provoquer des brûlures. s Toucher à la soupape annulera la garantie. qualifié. s La soupape ne se prête pas aux réparations ; elle devra être remplacée. s Le remplacement doit uniquement être fait par un technicien d’entretien BRÛLURES AVERTISSEMENT ROBINET DE MÉLANGE - (FIG 9) 11. Ouvrir l'alimentation en gaz et s’assurer que le chauffe-eau et les différents raccords de gaz ne comportent pas de fuites, à l'aide d'une solution de détection de fuites. 12. Remplir le réservoir du chauffe-eau ; vérifier que les différents raccords ne comportent pas de fuites d’eau. s NE PAS utiliser d'allumettes, de bougies ou toute autre source d'allumage pour contrôler la présence éventuelle de fuites de gaz. INCENDIE ET/OU EXPLOSION AVERTISSEMENT 8. Pousser l'unité contre le mastic, fixer les 4 équerres de fixation (FIG 3-B) au véhicule à l'aide de vis à tête ronde No. 8, de 3/4 po. (nonfournies) ou l’équivalent. Terminer l'installation en insérant le même type de vis No. 8 dans les orifices situés sur le bord du logement du chauffe-eau. Check all gaskets, they must adher to the pan creating an air tight seal. 9. Fixer la trappe d'accès. a. Enfoncer l'axe de la charnière (FIG 3-C) dans le logement de la charnière (FIG 3-D). b. Faire glisser le couvercle (FIG 3-E) sur l'axe de la charnière. c. Glisser l’axe de la charnière dans le couvercle, tout en l'enfonçant dans le logement de la charnière (FIG 3-D). REMARQUE : pour retirer l'axe de la charnière, soutenir le couvercle d'accès et appuyer sur le coin de l'axe de la charnière. 10. Débrancher l'unité et son robinet d'arrêt individuel de la conduite d’alimentation en gaz lors de tout test de pression du système audelà de 3,4 kPa (12 psi), 14 po. de colonne d'eau (C.E.). NE PAS régler la pression d’admission au-delà du maximum indiqué sur la plaque signalétique du clapet à gaz (13 po. C.E.). Isoler l'unité de la conduite d'alimentation en gaz en fermant le robinet d'arrêt manuel individuel lors de tout test de pression supérieur ou égal à 3,4 kPa (12 psi). Page 111 of 145 s Lorsqu'on utilise Romex® avec une mise à la terre nue, faire attention de placer le fil de mise à la terre de manière à ce qu’il n’entre pas en contact avec les bornes de l’élément de chauffe. ENDOMMAGEMENT DU PRODUIT ATTENTION électriques en vigueur. LES MODÈLES COMBINÉS GAZ-ÉLECTRICITÉ sont conçus pour fonctionner au gaz, à l'électricité ou aux deux. s Utiliser un conduit électrique métallique, un conduit métallique souple, un câble à blindage métallique ou un câble blindé nonmétallique avec fil de masse. Le fil doit avoir une capacité supérieure ou égale à 1400 watts. La méthode de câblage doit être conforme aux sections en vigueur de l'article 551 du Code électrique national ANSI/NFPA 70. 1. Consulter le Schéma électrique (FIG 12). Effectuer les branchements de 120 VCA à partir du boîtier de dérivation situé au dos de l'appareil. a. Brancher le fil de phase sur le noir (1). b. Brancher le fil neutre sur le blanc (2). c. Brancher le fil de masse de l'alimentation électrique sur le fil de masse vert (3) du boîtier de dérivation 3. CÂBLAGE - Tous les câblages doivent être conformes aux codes Cette méthode d’installation est l’une des plus répandues pour les chauffe-eau. Il existe d’autres méthodes homologuées telles que les installations d’encastrements (MPD 93948). Consulter votre inspecteur sur le terrain, votre responsable de compte ou le service à la clientèle Atwood pour toute question supplémentaire. 1. Poser le chauffe-eau sur le sol du véhicule, avant de construire les parois latérales. Le réservoir du chauffe-eau doit toujours être positionné au même niveau que le bas de la découpe de la paroi latérale (au sol ou sur un support surélevé) FIG 2. Laisser suffisamment d’espace à l'arrière de l’unité pour permettre les réparations des raccordements d’eau. 2. L’ installation du chauffe-eau sur de la moquette doit se faire avec un panneau en métal ou en bois de 7 ou 8 cm plus large et plus profond que la taille totale de l'appareil. 3. Si l’appareil est installé dans un lieu où le branchement et les fuites du réservoir risquent d’endommager les zones environnantes, installer sous le chauffe-eau un système d'écoulement (permettant l’évacuation vers l'extérieur du véhicule). INSTALLATION GÉNÉRALE USA ET CANADA - SUIVRE LES CODES NATIONAUX ET LOCAUX EN VIGUEUR - À DÉFAUT DE CODES OU RÉGLEMENTATIONS LOCAUX, SE REPORTER AUX NORMES ACTUELLES DE : U Véhicules de plaisance ANSI A119.2/NFPA 501C. U Code national de carburant et de gaz ANSI Z223.1 et/ou codes d'installation CAN/CGA B149. U Norme fédérale de sécurité et de construction de maisons mobiles, titre 24 CFR, partie 3280 ; lorsque cette norme n’est pas applicable, utiliser la norme d’installation de maisons préfabriquées (Sites de maisons préfabriquées, collectivités et installation), ANSI A255.1 et/ou la série CAN/CSA-Z240 MH, maisons mobiles. U Code électrique national ANSI/NFPA No. 70 et/ou CSA C22.1. U Caravanes de parc A119.5. U Norme CSA de série Z240 RV, véhicules de plaisance. U Norme ASSE 1017 (valeur de mélange). U Norme NSF ANSI/NSF 14-2003 (tous les tuyaux et raccords en plastique). s Installer dans les véhicules de plaisance uniquement. Les véhicules de plaisance sont conçus comme résidences temporaires pour les vacances, le camping ou les voyages ; ils fonctionnent de façon autonome ou sont parfois remorqués par un autre véhicule. s Tout l'air de combustion doit provenir de l'extérieur du véhicule de plaisance et tous les produits de la combustion doivent être évacués vers l'extérieur. s NE PAS évacuer l'air du chauffe-eau par un système d'évacuation servant à un autre appareil. s NE PAS évacuer l'air du chauffe-eau vers un espace extérieur couvert. s Protéger les matériaux de construction des gaz de carneau. s Installer le chauffe-eau sur un mur extérieur, avec une trappe d'accès donnant vers l'extérieur. s NE modifier le chauffe-eau en AUCUNE façon. s NE PAS modifier le chauffe-eau pour une mise à la terre positive. s NE PAS faire d’essai diélectrique du chauffe-eau sans avoir débranché l'allumage électronique (carte de circuit imprimé). s NE PAS utiliser de chargeur de batterie pour alimenter le chauffeeau, même lors des essais. AVERTISSEMENTS IMPORTANTS POUR L'INSTALLATION NE PAS soulever, tirer ou pousser le tube du brûleur principal (FIG 3-F). 1-B 16-1/4po. 16-1/4PO. DIMENSION DE LA DÉCOUPE 1-A 12-5/8po. 15-3/4PO. (FIG 1 & 2) 2-C 18,5po. 21,75PO. PROFONDEUR Haut : Bas : 0 po. 0 po. 6. Suivre les marques et plier tous les rebords à 90º (FIG 3-A). 7. Pour éviter les fuites d'eau, appliquer du mastic tout autour de l'ouverture, y compris dans les fentes de pliage. Il est possible de substituer une bande adhésive de butyle au mastic (1-1/3 po. x 1/8 10 po.). Côtés : 0 po. Arrière : 0 po. DISTANCE MINIMALE PAR RAPPORT À TOUT MATÉRIAU DE CONSTRUCTION COMBUSTIBLE Gallons 6 10 CAPACITÉ DÉCOUPE 5. Construire les parois latérales et découper l'ouverture. Cf. tableau et FIG 1. Utiliser des montants de 2x2 (ou équivalent) pour l'encadrement. s ENDOMMAGEMENT DU PRODUIT ATTENTION CONTINUER L'INSTALLATION GÉNÉRALE 4. Brancher les deux conduites d'eau de 1/2 po. NPT (FIG 2), sortie femelle d'eau chaude et entrée femelle d'eau froide, et la conduite de gaz PL évasée de 3/8 po. au chauffe-eau (FIG 9). a. Permettre une flexibilité suffisante des conduites d'eau et de gaz, de façon à pouvoir tirer l’unité en avant par le mur, à deux ou trois centimètres de l’enveloppe extérieure. b. Étanchéiser le passage de la conduite de gaz (FIG 9) en glissant l'œillet (9-B) sur le tube de 3/8 po. (9-D) avant de l’évaser (9-E). Tirer la conduite de gaz et l’œillet par l'ouverture du logement (9A). Brancher le raccord conique (9-C) et enfoncer l’œillet dans l'ouverture. Si la conduite de gaz est déjà évasée, couper l’œillet d'un côté. Placer l’œillet fendu sur la conduite de gaz et l'enfoncer dans l'ouverture. c. Toujours appliquer du lubrifiant de tuyau sur le filet lorsqu’on raccorde les accouplements d'eau chaude et d’eau froide. Un raccord en plastique adapté est préconisé. MODÈLES D’ÉCHANGE DE CHALEUR - FIG 5 1. Pousser un tuyau de système de refroidissement (glycol) d’un diamètre de 5/8 po. (5-A) [avec un collier SAE 053 A type « E » ] sur le tube de l'échangeur de chaleur (5-B) et effectuer un raccordement serré. 2. Ouvrir le collier et le faire glisser vers l'échangeur de chaleur, audelà de la rainure annulaire (5-C), puis relâcher. 3. Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU et/ou FONCTIONNEMENT de l’allumage électronique. 1. Consulter le Schéma électrique (FIG 12). Installer l'interrupteur de commande à distance, dans un lieu accessible. Positionner la plaque murale, les lettres debout. Avant d’effectuer les branchements, mettre l'interrupteur en position d’arrêt (OFF). 2. Brancher les fils Cf. FIG 10 & 11. ALLUMAGE ÉLECTRONIQUE REMARQUE : il est recommandé de brancher l'unité directement sur une batterie de 12 VCC ou en aval du filtre du convertisseur électrique CACC. Éviter à tout prix les branchements en amont du convertisseur CA-CC. Utiliser un fil d’un calibre minimal de 18, homologué UL et CSA. sAprès toute réparation, vérifier le bon fonctionnement de l'unité. les déconnecter. sLors de la réparation des commandes, étiqueter tous les fils avant de ENDOMMAGEMENTS ÉLECTRIQUES ATTENTION s Lorsqu’on utilise une connexion avec fil et fiche pour alimenter le chauffe-eau, le fil doit être homologué UL et convenir aux lieux humides et aux usages intenses et super intenses. Le fil doit être souple, de type S, SO, ST, STO, SJ, SJT, SJTO, HS ou HSO, en conformité avec le Code électrique national, ANSI/NFPA 70. La longueur du fil externe menant au chauffe-eau ne doit pas dépasser 6 pieds et ne doit pas être inférieure à 2 pieds, lorsqu’elle est mesurée à partir de la fiche. Le calibre minimum du fil d'alimentation électrique doit être de 14 AWG et la fiche doit posséder une capacité nominale de 15 ampères. 6 O F F O N 4 5 6 BALL VALVE MIXING VALVE 7 3 IN USE WINTERIZED + BALL VALVE – MIXING VALVE Page 112 of 145 1 NS NS 18 19 20 21A 21B 22 1 12 13 15 16 17 1 2 3 4A 4B 9 11 REFERENCE ITEM 90034 92249 93849 90029 90030 90031 90032 90960 91857 91604 90028 93844 91959 91859 91226 93191 93866 93868 91547 6 GALLON 22 LITRES 90033 90034 92690 92249 93849 90029 90030 90031 90960 91857 91604 90028 93844 91959 91859 91226 93191 93866 93868 91547 10 GALLON 38 LITRES ÉCHANGE DE CHALEUR Réservoir HEAT EXCHANGE Tank 8 GAZ – ÉLECTRICITÉ COMBINÉS Réservoir Élément de chauffe et joint Relais Robinet mélangeur Robinet à bille Raccord en T Tuyau 9 po. (6 gallons) Tuyau 12 po. (10 gallons) Raccord en coude Kit de vanne de remplacement 10 gallons ALLUMAGE PAR ÉTINCELLE Réservoir Boîtier du conduit Bouchon de vidange Soupape pression-température !/2po. NPT Soupape pression-température 3/4po. NPT Électrovanne Interrupteur Marche/Arrêt noir Interrupteur Marche/Arrêt blanc Circuit imprimé Faisceau électrique Coupure thermique Détecteur d'étincelle Thermostat ECO (kit) 22 19 20 21B 18 21A 20 19 22 SPARK IGNITION Tank Flue Box Assembly Drain Plug Pressure-Temperature Relief Valve !/2” NPT Pressure-Temperature Relief Valve 3/4” NPT Solenoid Valve Black on-Off Switch White On-Off Switch Circuit Board Wiring Harness Thermal Cut Off Spark Probe ECO/T-STAT (kit) 16 17 15 12 13 GAZ-ÉLECTRICITÉ COMBINÉS ALLUMAGE PAR ÉTINCELLES ÉCHANGE DE CHALEUR IDENTIFICATION DES PIÈCES COMBINATION GAS/ELECTRIC Tank Heating Element & Gasket Relay Mixing Valve Ball Valve Tee 9” Hose (6 gallon) 12” Hose (10 gallon) Elbow 10 Gal Replacement Valve Kit All tanks includes styrofoam jacket = Tous les réservoirs comprennent une chemise de polystyrène. Order by model Commander selon le modèle order by color Commander selon la couleur 11 9 3 2 4 1 8 SPARK IGNITION HEAT EXCHANGE COMBINATION GAS/ELECTRIC PART IDENTIFICATION (et Canada) 16po. 16PO. AVERTISSEMENT 18,5po. 21,8PO. 6 GALLON 10 GALLONS INCENDIE OU EXPLOSION 12,5po. 15,5PO. 25 lbs 32 LBS POIDS À L'ENVOI QUE FAIRE SI VOUS SENTEZ DU GAZ ? • Évacuer TOUS les passagers du véhicule. • Couper l'alimentation en gaz au niveau du réservoir ou à la source. • NE toucher AUCUN interrupteur électrique, n’utiliser ni le téléphone, ni la radio à l'intérieur du véhicule. • NE PAS démarrer le véhicule ou le générateur électrique. • Contacter le fournisseur en gaz ou le technicien d’entretien qualifié le plus proche pour effectuer toute réparation. • S’il est impossible de joindre un fournisseur en gaz ou un technicien d’entretien qualifié, contacter la caserne de pompiers la plus proche. • NE PAS ouvrir l'alimentation en gaz avant que la ou les fuites soient réparées. Ne pas entreposer ni utiliser de carburant ou autres liquides et vapeurs inflammables à proximité de cet appareil ou de tout autre appareil. ce manuel risque d’entraîner un incendie ou une explosion et des dégâts matériels, des blessures, voire la perte de vie humaine. UÊNe pas suivre à la lettre les instructions contenues dans 10 GALLONS 6 GALLONS TOUS MODÈLES /LARGEUR /HAUTEUR /PROFONDEUR DIMENSIONS L'installation et l'entretien doivent être effectués par un technicien d’entretien qualifié, un centre de service, un équipementier ou un fournisseur de gaz. ou les accidents mortels ATTENTION Évite les blessures potentielles et/ou les dommages matériels Évite les blessures potentielles AVERTISSEMENT Les symboles d'alerte de sécurité vous avertissent des dangers possibles. Respecter tous les messages de sécurité qui font suite à ces symboles. SYMBOLES D'ALERTE DE SÉCURITÉ APPELS ET QUESTIONS D’ENTRETIEN Les adresses et les numéros de téléphone des Centres de service agréés se trouvent sur notre site Internet à www.atwoodmobile.com ou composer le 574-262-2655 pour recevoir la liste par courrier. La conception de ce chauffe-eau a été homologuée par l’Association canadienne de normalisation pour installation à l'intérieur de véhicules de plaisance. Ce chauffe-eau n'a pas été conçu pour usage sur bateaux. ENGLISH, FRANÇAIS 9 MPD 93050 POIDS .................................................................. 1 IDENTIFICATION DU MODÈLE ..................................1 DIMENSIONS ........................................................ 1 ............................................................4 ................................5 E H I6 - EXT® Capacité utile** Échangeur de chaleur du moteur Électrique Gaz T* Électronique sur la base des gallons d’eau à 130º F, est de 9 et 16 gallons. * EXT® se rapporte à la technologie électronique exothermique (XT). ** La capacité réelle du chauffe-eau est de 6 ou 10 gallons. La capacité utile, calculée G EXPLICATION DU NUMÉRO DE MODÈLE GARANTIE du chauffe-eau IDENTIFICATION DES PIÈCES ..........................................................8 ............................................................16 Rinçage pour éliminer les mauvaises odeurs ........................................5 FIGURES ..................................................................................6-7 Soupape de sécurité de type pression-température Entretien préventif ........................................................................4 Instructions pour l’hivernage (rinçage) ................................................5 Instructions pour l’entretien Consignes de sécurité destinées au consommateur ................................2 Comment utiliser votre chauffe-eau ................................................3-4 Câblage Tableau de découpe Soupape de sécurité de type pression-température INSTALLATION GÉNÉRALE du chauffe-eau INFORMATIONS SUR LA SÉCURITÉ CHAUFFE EAU En vigueur à partir du 13/10/09 s)NSTALLATION s&ONCTIONNEMENT s%NTrETIEN PATENT # 7,020,386 G16EXT, GE16EXT, GEH16EXT Modèles XT® G9EXT, GE9EXT, GEH9EXT 6 et 10 GALLONS CHAUFFE EAU AU PROPANE LIQUIDE (PL) NUMÉRO DE BROCHURE Page 113 of 145 16 2. Pendant deux ans, à compter de la date d'achat, Atwood réparera ou remplacera toute pièce trouvée défectueuse en raison du matériau ou d'un vice de fabrication. La présente garantie couvre les frais raisonnables de main-d’œuvre nécessaires au retrait et au remplacement de la pièce. Les visites pour l’entretien chez le client ne sont pas prises en charge et restent donc la responsabilité du client. 4. Dans l'éventualité d'une réclamation de garantie, l’acheteur doit contacter, à l'avance, soit un centre de service Atwood agréé, soit le Service à la clientèle Atwood. La réclamation de garantie doit être exécutée dans un centre de service Atwood agréé (une liste vous sera fournie gratuitement) ou selon les procédures reconnues par le Service clientèle Atwood (Consumer Service Department) Atwood Mobile Ce chauffe-eau Atwood est conçu pour utilisation en véhicule de plaisance et dans le but de chauffer l'eau comme le stipule la plaque signalétique fixée au chauffe-eau. Toute autre utilisation, à moins d’une autorisation écrite du Service technique Atwood, annule la présente garantie. 11. Les pièces de remplacement (composantes ou réservoirs) achetées en dehors de la garantie initiale du chauffe-eau sont couvertes par une garantie de 90 jours ; ceci comprend la pièce sans frais et les frais raisonnables de main-d'œuvre découlant du remplacement. 10. Toute garantie implicite est limitée à une période de deux (2) ans. Certains États ne permettent pas de limiter la période d'une garantie implicite, donc il est possible que la limite ci-dessus ne vous concerne pas. La présente garantie vous accorde des droits légaux particuliers mais il est également possible que vous ayiez certains droits supplémentaires, selon les États. 9. Atwood n’est aucunement responsable de l’impossibilité d’utiliser le véhicule, de toute perte de temps, de tout dérangement et de tous frais d'essence, de téléphone, de déplacement, de logement, de perte ou de dommages aux biens personnels ou de perte de revenus. Certains États ne permettent pas l’exclusion ou la limitation des dommages accessoires ou indirects ; il est donc possible que les limitations ou exclusions ci-dessus ne s'appliquent pas à votre cas. 3. La présente garantie ne couvre pas les articles suivants, qui sont considérés comme faisant partie de l’entretien régulier : a. réglage de la pression du gaz b. nettoyage ou remplacement de l’orifice du brûleur. c. nettoyage ou réglage du tube du brûleur d. nettoyage ou réglage du conduit e. nettoyage ou réglage de la veilleuse et du thermocouple f. réglage de la soupape de décharge de type pression-température g. remplacement du dispositif de coupure thermique 8. Tout dommage ou toute déficience résultant d'une mauvaise utilisation (y compris le manquement à faire effectuer les réparations nécessaires), d'une mauvaise mise en application, de modifications, de dommages causés par l'eau ou par le gel relèvent de la responsabilité de l’acheteur. 7. La période de garantie pour les pièces de remplacement (ou le chauffeeau) est la période inutilisée de la période de garantie initiale. 6. La présente garantie s'applique uniquement si l'unité est installée selon les consignes d'installation fournies, en conformité avec les codes locaux et nationaux. 5. Les pièces retournées (ou le chauffe-eau) doivent être expédiées à Atwood, tout port payé. Un avoir pour les frais d'expédition sera compris avec la réclamation de garantie. Les pièces défectueuses (ou le chauffe-eau) deviennent la propriété d’Atwood Mobile Products et doivent être retournées à Consumer Service Department, Atwood Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN 37073 ÉtatsUnis. Products, 1120 North Main, Elkhart IN États-Unis. Téléphone : (574) 264-2131. performed at an authorized Atwood Service Center (a list will be provided at no charge) or as approved by the Consumer Service Department, Atwood Mobile Products, 1120 North Main St., Elkhart, IN 46514 USA. Phone: (574-264-2131). 5. Return parts (or water heater) must be shipped to Atwood “Prepaid”. Credit for shipping costs will be included with the warranty claim. The defective parts (or water heater) become the property of Atwood Mobile Products and must be returned to the Consumer Service Department, Atwood Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN 37073 USA. 6. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes. 7. The warranty period on replacement parts (or water heater) is the unused portion of the original warranty period or ninety (90) days, whichever is greater. 8. Damage or failure resulting from misuse (including failure to seek proper repair service), misapplication, alterations, water damage, or freezing are the owner’s responsibility. 9. Atwood does not assume responsibility for any loss of use of vehicle, loss of time, inconvenience, expense for gasoline, telephone, travel, lodging, loss or damage to personal property or revenues. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. 10. Any implied warranties are limited to two (2) years. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 11. Replacement parts (components or tanks) purchased outside of the original water heater warranty carry a 90 day warranty. This includes the part at no charge and reasonable labor charges to replace it. This Atwood heater is designed for use in recreational vehicles for the purpose of heating water as stated in the “data plate” attached to the water heater. Any other use, unless authorized in writing by the Atwood Engineering Department, voids this warranty. 1. Pendant une période de deux ans, à compter de la date d'achat, Atwood remplacera tout le chauffe-eau si le réservoir interne fuit pour des raisons de corrosion. La présente garantie couvre les frais raisonnables de main-d’œuvre nécessaires au remplacement du chauffe-eau. La responsabilité d'Atwood décrite ci-dessous se limite au remplacement ou à la réparation du produit par un produit reconditionné, à la discrétion du fabricant. La présente garantie est annulée si le produit est endommagé du fait d’un accident, d’une utilisation non raisonnable, d’une négligence, d’une modification du produit ou de tout autre cause non liée au matériau ou à un vice de fabrication. La présente garantie ne s'applique qu'à l'acheteur initial et elle est soumise aux conditions suivantes : Atwood Mobile Products garantit ce produit à l'acheteur initial, suivant les termes stipulés ci-dessous, contre tout défaut de matériel ou de fabrication, pendant une période de deux ans à compter de la date d'achat. GARANTIE LIMITÉE POUR CHAUFFE-EAU ATWOOD Atwood Mobile Products warrants to the original owner and subject to the below mentioned conditions, that this product will be free of defects in material or workmanship for a period of two years from the original date of purchase. Atwood’s liability hereunder is limited to the replacement of the product, repair of the product, or replacement of the product with a reconditioned product at the discretion of the manufacturer. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other causes not arising from defects in material workmanship. This warranty extends to the original owner of the product only and is subject to the following conditions: 1. For a period of two years from the date of purchase, Atwood will replace the complete water heater if the inner tank leaks due to corrosion. This warranty includes reasonable labor charges required to replace the complete water heater. 2. For two years from the date of purchase, Atwood will repair or replace any part defective in material or workmanship. This warranty includes reasonable labor charges, required to remove and replace the part. Service calls to customer’s location are not considered part of these charges and are, therefore, the responsibility of the owner. 3. This warranty does not cover the following items classified as normal maintenance: a. adjustment of gas pressure b. cleaning or replacement of burner orifice c. cleaning or adjustment of burner tube d. cleaning or adjustment of flue e. cleaning or adjustment of pilot and thermocouple f. adjustment of pressure-temperature relief valve g. replacement of thermal cut-off device. 4. In the event of a warranty claim, the owner must contact, in advance, either an authorized Atwood Service Center or the Atwood Service Department. Warranty claim service must be ATWOOD WATER HEATER LIMITED WARRANTY (et Canada) avoid possible injury and/or property damage CAUTION WHAT TO DO IF YOU SMELL GAS • Evacuate ALL persons from vehicle. • Shut off gas supply at gas container or source. • DO NOT touch any electrical switch, or use any phone or radio in vehicle. • DO NOT start vehicle’s engine or electric generator. • Contact nearest gas supplier or qualified Service Technician for repairs. • If you cannot reach a gas supplier or qualified Service Technician, contact the nearest fire department. • DO NOT turn on gas supply until gas leak(s) has been repaired. ➤ Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. WARNING FIRE OR EXPLOSION Installation and service must be performed by a qualified Service Technician, Service Center, OEM or Gas Supplier. avoid possible injury or death WARNING Safety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols. SAFETY ALERT SYMBOLS SERVICE CALLS & QUESTIONS Location and phone numbers of qualified Service Centers can be found at our website http:/www.atwoodmobile.com or call 574-264-2131 to have a Service Center List mailed. This water heater design has been certified by the Canadian Standards Association for installation in recreation vehicles. This water heater is not for use in marine applications. ENGLISH, FRANCAIS 9 1 MPD 93756 Effective 11/19/07 ..........................................................4-5 H 6 AA - 8 E/P Electronic Ignition or Pilot Relight Revision (NUMBER) Heating Element (SCREW-IN OR BOLT-ON) 4 - 6 - 10 gallon capacity Engine Heat Exchange Combination Gas and AC Electric Gas (PROPANE) - IF YOUR MODEL NUMBER IS NOT LISTEDOlder revision numbers may be 3, 4, 6, 7, 8 or 9 (_ _ _ _ _ - X _) C 4 GAL G4-7 6 GALLON 10 GALLON ALL MODEL 16˝ 16˝ WIDTH DIMENSIONS 12.5˝ 15.5˝ HEIGHT Pilot Relight Heat Exchange Electronic Ignition Combination Gas/Electric Electronic Ignition Pilot Ignition TYPE 10 GAL 6 GALLON 10 GALLON 25 lbs 32 lbs SHIPPING WT. G6A-7 GC6AA-8P G10-2 GC10A-2 GC6AA-8 GH6-7 G10-2P GC10A-2P G6A-8E GCH6A-9E G10-3E GCH10A-3E GC6AA-9E GH6-8E GC10A-3E GH10-3E P IN MODEL # - SEE MODEL CLARIFICATION ABOVE H IN MODEL # - SEE MODEL CLARIFICATION ABOVE E IN MODEL # - SEE MODEL CLARIFICATION ABOVE C IN MODEL # - SEE MODEL CLARIFICATION ABOVE 6 GAL MODEL NUMBER CLARIFICATION Regardless of your revision number the current instructions are still generally applicable to your unit. If you have questions contact your dealer, an Atwood Service Center or the Atwood Service Department. G EXPLANATION OF MODEL NUMBER (EXAMPLE) WIRING DIAGRAMS FIGURES 1-11 ............................................................................6 ........................................................................7 PART IDENTIFICATION ..................................................................8-9 Water Heater WARRANTY ..............................................................16 Electronic Ignition Electric Water Heater MAINTENANCE Electronic Ignition Pilot Relight Combination Gas/Electric Water Heater PILOT OPERATION ......................................................3-4 Electronic Ignition wiring installation Pilot Relight wiring installation Heat Exchanger Combination Gas/Electric MODEL IDENTIFICATION ............................................1 DIMENSIONS ..........................................................1 WEIGHT ................................................................1 SAFETY INFORMATION ..................................................................2-4 Water Heater GENERAL INSTALLATION ..............................................2-3 WATER HEATER •Installation •Operation •Maintenance 4 - 6 - 10 GALLON L.P. GAS WATER HEATER LITERATURE NUMBER Page 114 of 145 DO NOT vent water heater to an outside enclosed porch area. DO NOT vent water heater with venting system serving another appliance. DO NOT HI-POT water heater unless electronic ignition system (circuit board) has been disconnected. use battery charger to supply power to water heater even when testing. • • 5. Erect side walls and cut opening. See chart and Frame with 2x2 lumber (or equivalent). FIG • Do not lift, pull or push main burner tube (FIG 9-C). PRODUCT DAMAGE CAUTION 2-A & B. 1. Locate water heater on floor of coach before erecting side walls. The water heater tank must be permanently supported at the same level as the bottom of sidewall cutout (by the floor or a raised floor). 2. To install water heater on carpeting, you must install appliance on a metal or wood panel that extends at least three inches beyond the full width and depth of appliance. 3. If water heater is installed where leakage of connections or tank will damage adjacent area, install a drain pan which can be drained to out side of coach, under water heater. 4. Connect both 1/2˝ NPT water lines - hot water outlet female (FIG 1-A) and cold water inlet female (FIG 1-B) and 3/8˝ flared LP gas lines (FIG 1-C). a. Allow flexibility in water and gas lines so you can pull unit forward through wall one inch past skin (FIG 2. b. Seal gas line entrance opening by sliding grommet (FIG 1-D) onto 3/8˝ tubing (FIG 1-F) before flaring tubing (FIG 1-F). Pull gas line and grommet through opening in housing (FIG 1-C). Connect flare fitting (FIG 1-E) and press grommet into opening. If gas line tubing is already flared, cut grommet on one side. Place split grommet over gas line and press it into opening. c. Always use pipe lubricant on threads when connecting hot and cold water couplings. A suitable plastic fitting is recommended. Below is the most common type of installation for the water heater. However, there are other approved methods such as baggage compartment (refer to MPD 90093) and flush mounting installations (refer to MPD 93948). Consult your Field Auditor, Account Manager, or the Atwood Service Department if you have additional questions. GENERAL INSTALLATION • Recreation Vehicles ANSI A119.2/NFPA 501C. • National Fuel Gas Code ANSI Z223.1 and/or CAN/CGA B149 Installation Codes • Federal Mobile Home Construction & Safety Standard, Title 24 CFR, part 3280, or when this Standard is not applicable, the Standard for Manufactured Home Installations (Manufactured Home Sites, Communities and Set-Ups), ANSI A255.1 and/or CAN/CSA-Z240 MH Series, Mobile Homes. • National Electrical Code ANSI/NFPA No. 70 and/or CSA C22.1 • Park Trailers A119.5 • CSA standard Z240 RV Series, Recreational Vehicle. USA AND CANADA - FOLLOW ALL APPLICABLE STATE AND LOCAL CODES IN THE ABSENCE OF LOCAL CODES OR REGULATIONS, REFER TO CURRENT STANDARDS OF: DO NOT DO NOT • alter water heater for a positive grounding system. DO NOT • modify water heater in any way. • Install water heater on an exterior wall, with access door opening to outdoors. • Protect building materials from flue gas exhaust. • • • All combustion air must be supplied from outside the RV, and all products of combustion must be vented to outside the RV. • Install in recreation vehicles only. RV’s are recreation vehicles designed as temporary living quarters for recreation, camping, or travel use having their own power or towed by another vehicle. CRITICAL INSTALLATION WARNINGS 2 CUT OUT DIMENSION DEPTH WARNING FIRE AND/OR EXPLOSION use matches, candles or other sources of ignition when checking for gas leaks. DO NOT FOR REPLACEMENT PARTS: • DO NOT install anything less than a combination temperature-pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of product of listed equipment or materials, as meeting requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. Valve must have a maximum set pressure not to exceed 150 psi. • Install valve into opening provided and marked for this purpose on water heater. • Installation must conform with local codes or in the absence of local codes, American National Standard for Recreational Vehicles, ANSI A119.2/NFPA 50IC. temperature and pressure relief valve that complies with standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Systems, ANSI Z21.22. If you use a discharge line, do not use a reducing coupling or other restriction smaller than outlet of relief valve. Allow complete drainage of both valve and line. THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON OTHER THAN REPLACEMENT. This water heater is equipped with a pressure temperature relief valve. • DO NOT place a valve, plug or reducing coupling on outlet part of EXPLOSION WARNING • Valve is not serviceable, it must be replaced. • Tampering with valve will result in scalding injury. • Tampering with valve will void warranty. SCALDING INJURY WARNING PRESSURE-TEMPERATURE RELIEF VALVE - (FIG 10) 11. Turn on gas and check water heater and all connections for gas leaks with leak detecting solution. 12. Fill water heater tank, check all connections for water leaks (FIG 1A & B). • 6. Bend all flanges 90˚ along scored lines (FIG 3). 7. To prevent water leaks caulk thoroughly around opening, including bend slots (FIG 3-A). Butyl Tape (1˝x1/8˝) may be substituted for caulking material. 8. Push unit against caulking, secure 4-corner brackets FIG 4-A to coach with No.8 - 3/4˝ round head screws (not furnished) or equivalent. Complete the installation by inserting the same type of #8 screws in the holes provided around the flange of the water heater housing. Check all gaskets, they must adhere to the pan creating an air tight seal. 9. Attach access door (FIG 5). a. Snap hinge pin (FIG 5-A) into clip (FIG 5-B). b. Slide cover (FIG 5-C) onto hinge pin. c. Slide hinge pin into cover, snapping into clip at same time (FIG 5-D). NOTE: To remove hinge pin, support access cover and apply force to corner of hinge pin as shown FIG 5-E. 10. Disconnect unit and its individual shut-off valve from gas supply line during any pressure testing of system in excess of 1/2 PSIG (3.4 kPa, 14˝ water column [W.C.]). DO NOT set inlet pressure higher than maximum indicated on rating plate of gas valve (13˝ W.C.). Isolate unit from gas supply line by closing its individual manual shutoff valve during any pressure testing ) 1/2 psig. Gallon A B C 4-6 12-5/8˝ 16-1/4˝ 17-5/8˝ 10 15-3/4˝ 16-1/4˝ 20-5/8˝ MINIMUM CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Sides: 0˝ Top: 0˝ Back: 0˝ Bottom: 0˝ CAPACITY CUTOUT BRÛLURES • Installer une soupape de décharge de type pression-température dans la conduite d’arrivée d'eau froide du chauffe-eau et fixer une conduite d’évacuation sur la vanne extérieure du véhicule. Régler la limite sur 680 à 850 kPa. • Installer un réservoir d’expansion de type membrane dans la conduite d’arrivée d'eau froide. Le réservoir devrait permettre une dilatation d’environ 426 ml d'eau et une mise sous pression égale à la pression de l'alimentation en eau. Ces dispositifs sont disponibles chez un plombier ou dans un centre de service. Lorsque la soupape de décharge de type pression-température s’écoule à nouveau, répéter la procédure ci-dessus. Pour une solution permanente, nous vous conseillons l'une des choses suivantes : • Faire fonctionner manuellement la soupape de décharge de type pression-température au moins une fois par an (FIG 10). 1. Couper l'alimentation principale en eau (la pompe ou la source d'apport en eau). 2. Laisser l’eau refroidir ou la laisser couler jusqu’à ce qu’elle soit froide. 3. Ouvrir le robinet d’eau chaude le plus proche du chauffe-eau. 4. Tirer la poignée de la soupape de décharge de type pressiontempérature vers soi et laisser l'eau couler, jusqu'à ce qu'elle s'arrête. 5. Laisser la soupape de décharge de type pression-température revenir brusquement en position fermée ; fermer le robinet ; ouvrir l'alimentation en eau. 6. Allumer le chauffe-eau et le tester. POUR RÉTABLIR L'INTERVALLE D'AIR, SUIVRE LES ÉTAPES SUIVANTES : type pression-température et rétablir l’intervalle d'air. L'eau contenue dans le réservoir doit être froide. • Couper le chauffe-eau avant d'ouvrir la soupape de décharge de AVERTISSEMENT Lorsqu’une soupape de décharge de type pression-température goutte pendant le fonctionnement du chauffe-eau, cela NE SIGNIFIE PAS qu’elle est défectueuse. La soupape de décharge goutte parfois, du fait d'une expansion naturelle de l'eau lorsque celle-ci est chauffée à l'intérieur du réseau d’alimentation en eau d'un véhicule de plaisance. Le réservoir du chauffe-eau Atwood comporte un intervalle d'air interne en haut du réservoir, permettant de réduire les risques d’égouttement. Au fil du temps, l'expansion de l'eau absorbe cet air et l’intervalle doit être rétabli. sur la sortie de la soupape de décharge de type pression-température. • Ne pas placer de robinet, de bouchon ou de raccord de réduction EXPLOSION AVERTISSEMENT SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE 15 POUR RINCER LE RÉSERVOIR AVEC DE L’EAU SOUS PRESSION : Il faudra pomper de l’eau fraîche dans le réservoir, soit avec la pompe transportée à bord, soit avec de l’eau sous pression externe. Continuer le processus de rinçage pendant environ 5 minutes ; ceci permet à l’eau fraîche de remuer l'eau stagnante du fond du réservoir et de pousser les dépôts par l’orifice d’évacuation. 4. Replacer le bouchon de vidange et la soupape de décharge de type pression-température. 5. Remplir le réservoir avec de l’eau fraîche ne contenant pas de souffre. Le chauffe-eau Atwood est conçu pour être utilisé dans les véhicules de plaisance. Si vous utilisez votre véhicule fréquemment ou pour des périodes prolongées, rincer le chauffe-eau plusieurs fois par an permettra de prolonger la vie du réservoir d’approvisionnement. L’air sous pression devra passer par le raccord de la soupape de décharge de type pression-température. Le robinet de vidange ouvert, l’air sous pression forcera l’eau restante à s’écouler de l’unité. POUR RINCER LE RÉSERVOIR AVEC DE L’AIR SOUS PRESSION : Une odeur d’œuf pourri (sulfure d’hydrogène) pourra se dégager du fait de l’action électrogalvanique du matériau de gainage qui dégage de l’hydrogène de l’eau. En cas de présence de souffre dans l’alimentation en eau, l’eau et le souffre se mélangent pour donner une odeur désagréable. 1. Couper l’alimentation principale en eau. Évacuer l’eau du réservoir du chauffe-eau et réinstaller le bouchon de vidange. Retirer la soupape de décharge de type pression-température. Préparer une solution de 4 parts de vinaigre blanc pour 2 parts d’eau. Au moyen d’un entonnoir, verser la solution à l’intérieur du réservoir, avec précaution. 2. Effectuer 4 à 5 cycles du chauffe-eau avec la solution indiquée cidessus en le laisser fonctionner normalement. 3. Retirer le bouchon de vidange et évacuer toute l’eau du réservoir. Rincer le chauffe-eau pour en éliminer tout sédiment. Il est possible de rincer le réservoir avec de l’air sous pression ou avec de l’eau fraîche. Appliquer la pression soit sur les clapets d’arrivée ou de sortie à l’arrière du réservoir, soit au raccord de la soupape de décharge de type pression-température se trouvant à l’avant de l’unité. RINCER POUR ÉLIMINER LES MAUVAISES ODEURS Page 115 of 145 Araignées, guêpes et autres insectes font parfois leur nid dans le tube du brûleur. Cela risque de causer une mauvaise combustion, un retard dans l’allumage ou un allumage à l'extérieur du tube de combustion. Prêter attention à tout changement du son produit par le brûleur et de l'apparence de la flamme (molle, calme et jaune vif plutôt que drue et bleue). Cela indique que le tube du brûleur est obstrué (FIG 9-C). Inspecter et nettoyer régulièrement. a. Retirer la vis de l’obturateur d'air (FIG 9-A) et glisser l’obturateur d'air (FIG 9-B) le long du tube du brûleur. b. Introduire une brosse métallique flexible à l’intérieur du tube du brûleur (FIG 9-C), jusqu'à ce qu'elle ressorte par l'autre extrémité du tube. ENTRETIEN PRÉVENTIF • A l’usine, votre chauffe-eau a été équipé d’une carte imprimée à fusible. Ce fusible protège la carte imprimée des courts-circuits pouvant survenir dans les câblages. Si le fusible venait à s’activer, le chauffe-eau ne pourrait pas fonctionner. Avant de remplacer le fusible, vérifier que le court-circuit n’est pas externe à la carte imprimée. Une fois le court-circuit réparé, remplacer le fusible de 2 ampères par un fusible mini de type ATO. Ne pas installer de fusible de plus de 3 ampères. • Si le fusible est bon mais que l’unité ne fonctionne pas, vérifier que la tension du courant alimentant l’unité n’est pas trop élevé (plus de 14 volts). • Si les deux étapes précédentes ne résolvent pas le problème, vérifier le système de coupure thermique. Le système de coupure thermique est installé dans le tuyau d’alimentation. Ce dispositif, une fois déclenché, coupe l’arrivée du courant électrique et le fonctionnement du chauffe-eau. Par exemple, en cas d’obstruction dans le tube d’évacuation, comme le décrit la section d’Entretien préventif, la flamme et la chaleur du brûleur risquent d’entrer en contact avec le système de coupure ce qui fera fondre l’élément du fusible incorporé dans le système de coupure thermique. Pour rétablir l’électricité et le bon fonctionnement du chauffe-eau, l’obstruction doit être éliminée et le système de coupure thermique doit être remplacé. ENTRETIEN DE L'ALLUMAGE ÉLECTRONIQUE • Le système de propane liquide et le système à eau doivent être allumés. • Faire tester la pression du gaz régulièrement. La pression doit être réglée à 279 mm de colonne d'eau, lorsque 3 appareils fonctionnent. • Évacuer l'eau contenue dans le chauffe-eau à intervalles réguliers (au moins une fois par an). • Évacuer l'eau contenue dans le chauffe-eau avant de garer votre véhicule de plaisance pour l'hiver ou lorsqu’il existe un risque de gel. • S’assurer que l'évacuation et la grille d'air de combustion ne comportent aucune obstruction. • Comparer régulièrement la flamme du brûleur principal et les flammes des veilleuses à la FIG 9 et les réglages du brûleur principal avec la section COMMENT UTILISER VOTRE CHAUFFE-EAU. • Lorsque vous n'utilisez pas le chauffe-eau, régler le levier (White Rogers) ou le cadran (Robertshaw) du thermostat à la position la plus basse possible. Cela réduira les effets de la température extérieure sur le calibrage du mécanisme de commande de la température. INFORMATIONS GÉNÉRALES L'utilisation d'éléments de chauffe provenant de fabricants de marché secondaire pourra également entraîner des endommagements des composantes ou du chauffe-eau. La garantie écrite Atwood stipule que « la responsabilité d'un mauvais fonctionnement ou de dommages causés par une modification au chauffe-eau revient à l’acheteur ». Toute modification, telle que, par exemple, le rajout d'un élément de chauffe de marché secondaire, annule la garantie. • L'utilisation d'éléments de chauffe de marché secondaire comporte le risque de perte de contrôle du chauffage du réservoir à eau et d’explosion d'eau catastrophique. risquent de ne pas avoir fait l’objet de certains contrôles de sécurité importants. • NE PAS modifier le chauffe-eau, sous peine d’annuler la garantie. • NE PAS utiliser d'éléments de chauffe de marché secondaire, car ils EXPLOSION / BRÛLURES AVERTISSEMENT ÉLÉMENTS DE CHAUFFE D'EAU DE MARCHÉ SECONDAIRE 14 Pour assurer le meilleur rendement de votre chauffe-eau et prolonger la vie du réservoir, évacuer et rincer régulièrement le réservoir du chauffe-eau. Avant le rangement à long terme ou avant l’arrivée du gel, évacuer et rincer le réservoir. 1. Couper l'alimentation principale en eau (la pompe ou la source d'apport en eau). 2. Évacuer l'eau du réservoir du chauffe-eau en retirant le bouchon de vidange. Si l'eau coule de façon irrégulière ou goutte au lieu de couler à jet normal, nous vous conseillons tout d’abord d’ouvrir la soupape de décharge de type pression-température, pour permettre à l'air d’entrer dans le réservoir. Ensuite, à l'aide d'un fil de fer de petit diamètre ou d'un porte-manteau, piquer à l’intérieur de l’orifice d'évacuation, de façon à éliminer toute obstruction. 3. Une fois le réservoir vide, étant donné l'emplacement du bouchon de vidange, il restera environ 2 litres d'eau dans le réservoir. Cette eau contient la plus grande partie des particules corrosives dangereuses. Pour retirer ces particules corrosives dangereuses, rincer le réservoir soit avec de l’air, soit avec de l’eau. Que vous utilisiez de l'air ou de l’eau sous pression, l’application peut se faire soit par l'entrée, soit par la sortie située à l'arrière du réservoir ou de la soupape de décharge de type pression-température. (En cas d’utilisation de la soupape de décharge de type pressiontempérature, il faudra d'abord retirer le rebord de sécurité). La pression force l’eau et les particules corrosives restantes à s’évacuer. En cas d’utilisation d’eau sous pression, pomper de l'eau fraîche dans le réservoir à l'aide d'une pompe transportée ou utiliser de l'eau externe pendant 90 secondes, de façon à permettre à l'eau fraîche de remuer l'eau stagnante se trouvant au fond du réservoir et de propulser les dépôts par l’orifice d’évacuation. Continuer à rajouter de l’eau et à évacuer, jusqu'à ce que l’eau restant dans le réservoir ne comporte plus aucune particule. 4. Replacer le bouchon de vidange et fermer la soupape de décharge de type pression-température. La quantité d’eau (environ 2 litres) restant au fond du réservoir suite à la vidange ne causera pas de dommage au réservoir en cas de gel. INSTRUCTIONS POUR L'HIVERNAGE (RINÇAGE) d'enlever le bouchon de vidange et de rincer le réservoir. • Éteindre le chauffe-eau et attendre que l'eau refroidisse avant BRÛLURES AVERTISSEMENT ENTRETIEN DU RÉSERVOIR DU CHAUFFE-EAU Vérifier l'orifice du brûleur principal. Nettoyer et régler le brûleur principal. Le brûleur principal et les voies du clapet doivent être alignés. Vérifier que la porcelaine de l'électrode ne comporte pas de fissures. 5. Vérifier que l’écart entre l’électrode et le sol est bien de 3,1 mm. 6. Lorsque la carte des modules fonctionne en alternance, enlever la carte et nettoyer la plaque à bornes avec une gomme pour crayon. 1. 2. 3. 4. COMMENT NETTOYER LES MODÈLES À ALLUMAGE ÉLECTRONIQUE 1. Vérifier que l'orifice du brûleur principal et l'assemblage de la veilleuse ne comportent aucune contamination (saleté, toiles d'araignées, etc.). 2. Nettoyer le tube du brûleur principal avec une petite brosse. 3. Réglage du brûleur principal – ouvrir l’obturateur d'air à un quart. 4. Flamme de la veilleuse basse. Vérifier qu’il n’y ait pas de contamination – si elle est propre, remplacer l'orifice de la veilleuse. COMMENT NETTOYER LES MODÈLES À VEILLEUSE c. Nettoyer le brûleur à l’aide d'un aspirateur, à l'endroit où il s’insère dans le tube de combustion. d. Remettre l’obturateur d'air dans sa position d'origine et replacer la vis. e. The orifice, burner tube and shutter nmust be aligned so that the shutter is not binding on the air tube. ELECTRONIC IGNITION - WIRING INSTRUCTIONS 1. Install unit according to GENERAL INSTALLATION instructions. NOTE: It is recommended unit be connected directly to a 12V DC battery or to filtered side of an AC/DC converter. Avoid connections to unfiltered side of an AC/DC converter whenever possible. Use a minimum of 18 gauge wire, UL and CSA listed. Refer to WIRING DIAGRAM. Install remote switch in a convenient location. Position wall plate with letters up. Before making connections turn switch OFF. The switch is off when the button is depressed towards terminal see wiring diagram. Operation using gas continue to HOW TO OPERATE YOUR WATER HEATER, electrically continue to COMBINATION Gas/Electric OPERATION. • Label all wires before disconnecting when servicing controls. • Verify proper operation after servicing. ELECTRICAL DAMAGE CAUTION • Use electrical metallic tubing, flexible metal conduit, metal clad cable, or nonmetallic-sheathed cable with grounding conductor. Wire must have a capacity of 1500 watts or greater. The wiring method must conform to applicable sections of article 551 of National Electrical Code ANSI/NFPA 70. 2. Refer to Wiring Diagram. Make 120 VAC electrical connections from junction box on back of unit. a. Connect hot lead to (1) Black. b. Connect common lead to (2) White. c. Connect ground wire from electrical service to (3) green ground lead in junction box 3. Place switch in “OFF” position. • When a cord and plug connection to the power supply are used on water heater, power cord must be UL listed as suitable for damp locations, hard or extra hard usage. It must be a flexible cord such as type S, SO, ST, STO, SJ, SJT, SJTO, HS or HSO cord as described in National Electrical Code, ANSI/NFPA 70. The length of external cord to water heater, measured to face of attachment plug, shall be no less than 2 feet nor more than 6 feet. Supply cord must be a minimum of 14 AWG and attachment plug must be rated at 15 amps. • When using Romex® with a bare earth ground, take care to position ground wire so it does not contact the heating element terminals. CAUTION PRODUCT DAMAGE For COMBINATION GAS/ELECTRIC MODELS continue — This water heater is designed to operate with gas, electricity, or a combination of both. Provide adequate clearance at rear of unit for service of water connections and operation of manually re-setable high temperature limit switch on combination gas/electric units. 1. Follow GENERAL INSTALLATION instructions. NOTE: All wiring must comply with applicable electrical codes. For HEAT EXCHANGE continue — 1. Push 5/8˝ dia. 2 or 3 coolant system hose with SAE 053 A Type “E”clamp attached (FIG 6-E) onto heat exchange tube as far as possible (FIG 6-B). 2. Spread hose clamp and slide toward heat exchange unit past annular groove (FIG 6-C) and release. 3. Continue to HOW TO OPERATE YOUR WATER HEATER and/or Electronic Ignition OPERATION. • For an external electrical source, ground this unit in accordance with National Electrical Code ANSI/NFPA70. Your Atwood gas water heater is now ready for operation. Continue to HOW TO OPERATE YOUR WATER HEATER. Electronic Ignition continue to Electronic Ignition WIRING INSTRUCTIONS. Pilot Relight continue to Pilot Relight WIRING INSTRUCTIONS. 3 FIRE Do not smoke or have any flame near an open faucet. 1. Turn gas control valve knob (FIG 7-B or FIG 8-B) to OFF position. 2. Wait at least five minutes to allow accumulated gas in burner compartment to escape. 3. Water heater may be equipped with a White Rodgers® or Robertshaw Unitrol® Control. PILOT OPERATION • Do not operate without water in tank. CAUTION PRODUCT FAILURE • Do not tamper with pilot orifice. WARNING SCALDING INJURY If hydrogen gas is present, you will probably hear sounds like air escaping through the pipe as water begins to flow. If water heater has not been used for more than two weeks, hydrogen gas may form in water line. Under these conditions to reduce the risk of injury, open hot water faucet for several minutes at kitchen sink before you use any electrical appliance connected to hot water system. • CAUTION HOW TO OPERATE YOUR WATER HEATER store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. • Should overheating occur, or gas supply fail to shut off, turn OFF manual gas control valve to appliance, or turn gas OFF at the LP tank. On ELECTRONIC IGNITION MODEL turn operating switch to OFF position and remove red wire from left hand terminal of ECO switch or turn gas OFF at the LP tank. • Use with LP gas only. • Shut off gas appliances and pilot lights when refueling. • On PILOT RELIGHT MODELS, turn off the ignition module when refueling gasoline tanks or LP tanks. • Turn gas OFF at the LP tank when vehicle is in motion. This disables all gas appliances and pilot lights. Gas appliances must never be operated while vehicle is in motion. Unpredictable wind currents may be created which could cause flame reversal in the burner tube, which could result in fire damage. The thermal cut off fuse could also be unnecessarily activated resulting in a complete shutdown of the water heater requiring replacement of the thermal cut off. See maintenance of electronic ignition water heaters for further explanation of the thermal cut off. • LP tanks must be filled by a qualified gas supplier only. • DO NOT WARNING EXPLOSION OR FIRE CONSUMER SAFETY WARNINGS 1. Install unit according to GENERAL INSTALLATION instructions. 2. Refer to Wiring Diagram. Use 18 gauge wire, UL/CSA listed. 3. Read PILOT & PILOT RELIGHT OPERATIONS. PILOT RELIGHT - WIRING INSTRUCTION 2. Installing wires: a. blue lead to switch terminal (6) on indicator light of switch b. terminal (4) on indicator light of switch to negative battery terminal c. green lead to negative battery terminal d. brown lead on water heater to terminal (3) on switch e. terminal 2 on switch to positive battery terminal. 3. Read ELECTRONIC IGNITION OPERATION. Page 116 of 145 1. For gas operation refer to Pilot, Pilot Relight or Electronic Ignition OPERATION section (as applicable). 2. For electrical operation use switch at the rear of water heater. 3. Completely fill tank with water. COMBO gas/electric ELECTRIC OPERATION 1. Turn the switch located on the spark module to the ON position. 2. Read PILOT OPERATION instructions. 3. For complete shut down, turn lighting control knob on thermostat and spark module switch to the OFF position. Read MAINTENANCE AND CARE INSTRUCTIONS PILOT RELIGHT OPERATION 1. Refer to WIRING DIAGRAM. Place remote switch in ON position. 2. If remote switch light stays on longer than 15 seconds, place remote switch in OFF position and wait 5 minutes. 3. Repeat step one. 4. For complete shut-down and before servicing: a. Place remote switch in OFF position. b. Remove red wire from left hand terminal of ECO switch (ECO to valve). 5. If heater fails to operate due to high water temperature, a lockout condition occurs (indicator light on). After water cools, reset switch in OFF position for at least 30 seconds, then turn to ON position. 6. If a lockout condition persists contact an Atwood Service Center. Read MAINTENANCE AND CARE INSTRUCTIONS & ELECTRONIC IGNITION MAINTENANCE ELECTRONIC IGNITION OPERATION Read MAINTENANCE AND CARE INSTRUCTIONS 5. To Adjust Main Burner (FIG 9): a. Loosen air shutter screw (FIG 9-A). b. Slide air shutter (FIG 9-B) to right until some yellow appears in main burner flame. c. Move air shutter (FIG 9-B) to left until yellow disappears. d. Retighten air shutter screw (FIG 9-A). The temperature knob or lever is factory adjusted to its lowest dial setting. We recommended the mid-point position between warm and hot, as noted above. This will provide for energy efficient operation and sufficient hot water. Valves for reducing point of use temperature by mixing cold and hot water are available. Consult a licensed plumber or local plumbing authority. excessively hot water. • Setting temperature control dial at a higher position will produce SCALDING INJURY WARNING 4. For complete shut down and before servicing, turn gas control knob (FIG 7-B or FIG 8-B) to OFF position. When water heater is not in use set temperature control lever (White Rogers®) or dial (Robertshaw®) to lowest possible position. FOR A ROBERTSHAW UNITROL® (FIG 8) a. Turn lighting control dial (FIG 8-B) to PILOT position. b. Depress and hold reset push button (FIG 8-A) while lighting pilot burner (FIG 9-D). c. Allow pilot to burn 30 seconds before releasing reset push button. d. If pilot does not remain lit, repeat operation allowing longer period before releasing reset push button. e. Turn lighting control dial (FIG 8-B) to ON position. f. Set temperature control dial (FIG 8-C) at mid-point position between warm and hot. g. Close access door. FOR WHITE RODGERS® CONTROL (FIG 7) a. Turn lighting control knob (FIG 7-B) to PILOT position and hold against stop while lighting pilot burner (FIG 9-D). b. Allow pilot to burn 30 seconds then release lighting control knob. c. Turn lighting control knob (FIG 7-B) to ON position. d. If pilot does not remain lit, repeat operation allowing longer period before releasing lighting control knob. e. Set temperature selection lever (FIG 7-A) at mark between warm and hot position. f. Close access door. 4 • The water heater comes factory-equipped with a fused circuit board, which will protect the circuit board from wiring shorts. If the fuse should activate, the water heater will not operate. Before replacing the fuse, check for a short external to the board. Once the short is corrected, replace the 2 amp fuse with a mini ATO style fuse. Do not install a fuse larger than 3 amps. • If the fuse is good and the unit is inoperative, check for excessively high voltage to the unit (more than 14 volts). • If the previous two steps did not solve the problem, check the thermal cut-off. The thermal cutoff is a device installed in the power supply line. This device will shut off electrical power and stop heater operation when activated. For example, if an obstruction within the flue tube should occur, such as described above in the Preventative maintenance section, the burner flame/heat may contact the cutoff, resulting in a melting of the fuse element incorporated in the thermal cutoff. In order to restore power and proper operation of the water heater, the obstruction must be removed and the thermal cutoff must be replaced. ELECTRONIC IGNITION MAINTENANCE • LP and Water system must be turned on. • Have gas pressure tested periodically. Should be set at 11 inches of water column with three appliances running. • Drain water heater at regular intervals (at least one time during the year). • Drain water heater before storing RV for the winter or when the possibility of freezing exists. • Keep vent and combustion air grill clear of any obstructions. • Periodically, compare flame of main and pilot burners with FIG ➈ and main burner adjustments in HOW TO OPERATE YOUR WATER HEATER. • When water heater is not in use set temperature control lever (White Rogers) or dial (Robertshaw) to lowest possible position. This will reduce the effects of low outdoor temperatures on calibration of temperature control mechanism. • Presence of soot indicates the need to adjust flue. GENERAL INFORMATION The use of any aftermarket heating element devices may also result in damage to components or water heater. Atwood’s written warranty states - “failure or damage resulting from any alteration to our water heater is the owner’s responsibility”. Any alteration, like the addition of an aftermarket heating element device, will void the warranty. heating of water tank and a catastrophic wet side explosion. • Use of Aftermarket heating elements can lead to an out of control controls. • DO NOT alter water heater, it will void warranty. • DO NOT USE Aftermarket heating elements, they can lack critical safety EXPLOSION / BURN INJURY WARNING AFTERMARKET WATER HEATING ELEMENT DEVICES material, and flammable liquids and vapors. • Shut off gas supply at LP container before disconnecting a gas line. • Keep control compartment clean and free of gasoline, combustible FIRE OR EXPLOSION WARNING Location and phone numbers of qualified Service Centers can be found at our website http:/www.atwoodmobile.com or call 574-264-2131 to have a Service Center List mailed. SERVICE CALLS & QUESTIONS MAINTENANCE AND CARE INSTRUCTIONS 4. Turn switch ON (FIG 11-B) (located at rear of water heater). NOTE: Turning power on to heater without water covering heating element may burn out element and void warranty. 5. Check for proper operation. Water temperature is set at 140°F (60°C). 6. If the manual reset high temperature limit switch should operate, reset switch (FIG 11-A) by depressing with pencil or other nonmetallic object. If still experiencing problems contact an authorized Atwood Service Center or Atwood Service Department. Read MAINTENANCE AND CARE INSTRUCTIONS. 5. Réglage du brûleur principal (FIG 9) : 1. Desserrer la vis de l’obturateur d'air (FIG 9-A). 2. Faire glisser l’obturateur d'air (FIG 9-B) vers la droite, jusqu'à ce que du jaune apparaisse dans la flamme du brûleur principal. Le bouton ou le levier de commande de la température est réglé au plus bas à l'usine. Comme indiqué ci-dessus, nous vous conseillons d’utiliser un réglage moyen, entre chaud et très chaud. Cela permet un fonctionnement éconergétique, tout en garantissant que l’eau est suffisamment chaude. Il est possible d'installer des robinets mélangeurs, permettant de régler la température de l'eau au point d'utilisation. S’adresser à un plombier agréé ou aux autorités locales de plomberie. l'eau brûlante. • Régler le cadran à une température plus élevée aura pour résultat de BRÛLURES AVERTISSEMENT 4. Pour éteindre complètement l'unité ou pour toute réparation, placer le robinet de commande du gaz (FIG 7-B ou FIG 8-B) sur la position éteinte (OFF). Lors des périodes de non-utilisation du chauffe-eau, régler le levier (White Rogers®) ou le cadran (Robertshaw®) du thermostat sur la position la plus basse possible. POUR LES COMMANDES ROBERTSHAW UNITROL® (FIG 8) a. Tourner le cadran de réglage de l'allumage (FIG 8-B) sur la position VEILLEUSE (PILOT). b. Appuyer sur le bouton-poussoir de réarmement (FIG 8-A) et le maintenir appuyé, tout en allumant le brûleur de la veilleuse (FIG 9-D). c. Laisser la veilleuse brûler pendant 30 secondes avant de relâcher le bouton-poussoir de réarmement. d. Si la veilleuse ne reste pas allumée, répéter l'opération en gardant le bouton-poussoir de réarmement appuyé plus longtemps. e. Mettre le cadran de réglage de l'allumage (FIG 8-B) en position allumée (ON). f. Régler le cadran du thermostat (FIG 8-C) à une température moyenne, entre chaud (warm) et très chaud (hot). g. Fermer la trappe d'accès. POUR LES COMMANDES WHITE RODGERS® (FIG 7) a. Tourner le bouton de commande de l’allumage (FIG 7-B) en position VEILLEUSE (PILOT) et le maintenir contre la butée pendant l'allumage de la veilleuse (FIG 9-D). b. Laisser la veilleuse brûler pendant 30 secondes puis relâcher le bouton de commande de l'allumage. c. Mettre le bouton de commande de l’allumage (FIG 7-B) en position allumée (ON). d. Si la veilleuse ne reste pas allumée, répéter l'opération en gardant le bouton de commande de l’allumage appuyé plus longtemps. e. Positionner le levier du thermostat (FIG 7-A) sur le repère situé entre la position chaude (WARM) et très chaude (HOT). f. Fermer la trappe d'accès. 1. Mettre le robinet de commande du gaz (FIG 7-B ou FIG 8-B) en position arrêt (OFF). 2. Attendre au moins 5 minutes pour permettre au gaz accumulé dans le compartiment du brûleur de s'échapper. 3. Le chauffe-eau pourra comporter une commande White Rodgers®‚ ou une commande Robertshaw Unitrol® FIG 7. FONCTIONNEMENT DE LA VEILLEUSE • Ne pas faire fonctionner sans eau dans le réservoir. PANNE DE L'APPAREIL ATTENTION • Ne pas toucher l'orifice de la veilleuse. BRÛLURES AVERTISSEMENT En cas de présence d’hydrogène dans les conduites, vous entendrez probablement l'air s'échapper du tuyau, lorsque l'eau commence à couler. 13 comporte pas de carburant, de matériaux combustibles ou de liquides ou vapeurs inflammables. • S’assurer que le compartiment de commande est propre et ne avant de débrancher la conduite de gaz. • Fermer l'alimentation en gaz au niveau du réservoir de propane liquide AVERTISSEMENT INCENDIE OU EXPLOSION Les adresses et les numéros de téléphone des centres de service agréés se trouvent sur notre site Internet http:/www.atwoodmobile.com ou composer le 574-264-2131 pour recevoir la liste par courrier. APPELS ET QUESTIONS D’ENTRETIEN INSTRUCTIONS POUR L'ENTRETIEN Lire LES INSTRUCTIONS POUR L’ENTRENTIEN. 1. Pour le fonctionnement au gaz, se reporter à la section FONCTIONNEMENT de la veilleuse, FONCTIONNEMENT du rallumage de la veilleuse ou FONCTIONNEMENT de l’allumage électronique (le cas échéant). 2. Pour le fonctionnement électrique, utiliser l'interrupteur situé à l'arrière du chauffe-eau 3. Remplir complètement le réservoir avec de l'eau. 4. Mettre l'interrupteur situé à l'arrière du chauffe-eau en position allumée (ON) (FIG 11-B). REMARQUE : allumer l’élément chauffant sans l’immerger dans l'eau risque de brûler l'élément et donc d’annuler la garantie. 5. Vérifier le bon fonctionnement de l'unité. La température de l'eau est réglée sur 60°C. 6. Si l'interrupteur limiteur de haute température à réarmement manuel se déclenche, réarmer l'interrupteur (FIG 11-A) en appuyant dessus à l'aide d'un crayon ou de tout autre objet non métallique. Si les problèmes persistent, contacter un centre de service agréé Atwood ou le centre de service à la clientèle Atwood. FONCTION COMBINÉE gaz-électricité Lire LES INSTRUCTIONS POUR L'ENTRETIEN 1. Mettre l'interrupteur situé sur le module d'allumage en position allumée (ON). 2. Lire les instructions FONCTIONNEMENT DE LA VEILLEUSE. 3. Pour éteindre complètement l'unité, mettre le bouton de commande de l'allumage situé sur le thermostat et sur le module d'allumage en position éteinte (OFF). FONCTIONNEMENT DU RALLUMAGE DE LA VEILLEUSE 1. Consulter le SCHÉMA DE CÂBLAGE. Mettre la commande à distance en position allumée (ON). 2. Si la commande à distance reste allumée pendant plus de 15 secondes, la placer en position éteinte (OFF) et attendre 5 minutes. 3. Répéter la première étape. 4. Pour éteindre complètement l'unité et avant d’effectuer des réparations : a. Mettre la commande à distance en position éteinte (OFF). b. Enlever le fil rouge de la borne gauche de l'interrupteur ECO (ECO au robinet). 5. Si le chauffe-eau ne fonctionne pas car la température de l’eau est trop élevée, il se verrouille (voyant lumineux allumé). Une fois l'eau refroidie, remettre l'interrupteur en position éteinte (OFF) pendant au moins 30 secondes, puis repasser à la position allumée (ON). 6. Si le verrouillage persiste, contacter un centre de service Atwood. Lire les INSTRUCTIONS POUR L’ENTRETIEN et L'ENTRETIEN DE L'ALLUMAGE ÉLECTRONIQUE. FONCTIONNEMENT DE L'ALLUMAGE ÉLECTRONIQUE LIRE LES INSTRUCTIONS POUR L'ENTRETIEN 3. Glisser l’obturateur d'air (FIG 9-B) vers la gauche jusqu'à ce que le jaune disparaisse. 4. Resserrer la vis de l’obturateur d'air (FIG 9-A). Page 117 of 145 • Après toute réparation, vérifier le bon fonctionnement de l'unité. les déconnecter. • Lors de la réparation des commandes, étiqueter tous les fils avant de ENDOMMAGEMENTS ÉLECTRIQUES ATTENTION • Utiliser un conduit électrique métallique, un conduit métallique souple, un câble à blindage métallique ou un câble blindé non-métallique avec fil de masse. Le fil doit avoir une capacité supérieure ou égale à 1500 watts. La méthode de câblage doit être conforme aux sections applicables de l'article 551 du Code électrique national ANSI/NFPA 70. 2. Consulter le schéma électrique. Faire les branchements de 120 VCA à partir du boîtier de dérivation au dos de l'appareil. a. Brancher le fil de phase sur le noir (1). b. Brancher le fil neutre sur le blanc (2). c. Brancher le fil de masse de l'alimentation électrique sur le fil de masse vert (3) à l'intérieur du boîtier de dérivation 3. Mettre l’interrupteur en position arrêt (OFF). • Lorsque vous effectuez une connexion avec un fil et une fiche, pour alimenter le chauffe-eau, le fil doit être homologué UL et convenir aux lieux humides et aux usages intenses et super intenses. Le fil doit être souple, de type S, SO, ST, STO, SJ, SJT, SJTO, HS ou HSO, selon les normes du Code électrique national, ANSI/NFPA 70. La longueur du fil menant au chauffe-eau, mesurée à partir de la fiche, ne doit pas dépasser 1,8 m, ni être inférieure à 0,6 m. Le fil d'alimentation électrique doit avoir une taille minimale de 14 AWG et la fiche doit posséder une capacité nominale de 15 ampères. • Lorsque vous utilisez du Romex® avec une mise à la terre nue, faire attention de placer le fil de mise à la terre de manière à ce qu’il n’entre pas en contact avec les bornes de l’élément chauffant. ENDOMMAGEMENTS DU PRODUIT ATTENTION Suite pour les MODÈLES COMBINÉS GAZ-ÉLECTRICITÉ — Ce chauffe-eau a été conçu pour fonctionner au gaz, à l'électricité ou aux deux. Laisser suffisamment d’espace à l’arrière de l'unité pour réparer les raccordements de l'eau et pour régler l'interrupteur limiteur de haute température à réarmement manuel, pour les unités combinées gaz-électricité. 1. Suivre les instructions d'INSTALLATION GÉNÉRALE. REMARQUE : tout le câblage doit être conforme aux codes électriques en vigueur. Continuer pour l'ÉCHANGE DE CHALEUR — 1. Pousser un tuyau de système de refroidissement 2 ou 3 d’un diamètre de 1,6 cm avec un collier SAE 053 Type E attaché aussi loin que possible (FIG 6-E) sur le tube de l'échangeur (FIG 6-B). 2. Ouvrir le collier, le faire glisser vers l'échangeur de chaleur, au-delà de la rainure annulaire (FIG 6-C), puis le relâcher. 3. Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU et/ou FONCTIONNEMENT de l’allumage électronique. Pour le rallumage de la veilleuse, passer à INSTRUCTIONS DE CÂBLAGE pour le rallumage de la veilleuse. Pour l’allumage électronique, passer à INSTRUCTIONS DE CÂBLAGE pour l’allumage électronique. Votre chauffe-eau à gaz Atwood est maintenant prêt à fonctionner. Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU. PIÈCES DE RECHANGE : • Installer AU MINIMUM une soupape de décharge combinée de type température-pression homologuée par un laboratoire de test reconnu au niveau national, qui inspecte régulièrement les produits d’équipement ou de matériaux concernés, selon les normes pour les soupapes de décharge et les mécanismes de coupure automatique de l’alimentation en gaz pour systèmes à eau chaude ANSI Z21.22. Le réglage de la pression de la soupape ne doit pas dépasser 1034 kPa. • Installer la soupape dans l'ouverture prévue et marquée à cet effet sur le chauffe-eau. • L'installation doit être conforme aux codes locaux ou, faute de codes locaux, à la norme américaine nationale pour véhicules de plaisance ANSI A119.2/NFPA 50IC. • En cas de source électrique externe, cet appareil doit être mis à la terre selon le Code électrique national ANSI/NFPA70. En cas d’utilisation d’un tuyau d'écoulement, ne pas utiliser de raccord réducteur ou toute autre restriction qui soit inférieure en diamètre à la sortie de la soupape de décharge. Laisser la soupape et la conduite s'écouler complètement. 12 Ne pas fumer ou tenir de flamme à proximité d'un robinet ouvert. INCENDIE ATTENTION COMMENT UTILISER VOTRE CHAUFFE-EAU Si le chauffe-eau n'a pas été utilisé pendant plus de deux semaines, il est possible que de l'hydrogène se soit formé dans la conduite d'eau. Dans ces conditions, avant d'utiliser tout appareil électrique branché sur le système d'eau chaude, faire couler l'eau du robinet d'eau chaude de l’évier de la cuisine pendant plusieurs minutes pour réduire le risque de blessures. • • NE PAS entreposer ou utiliser de carburant ou tout autre liquide ou vapeurs inflammables à proximité de cet appareil ou de tout autre appareil. • En cas de surchauffe ou si l'alimentation en gaz ne s'arrête pas convenablement, mettre le robinet d'alimentation en gaz de l’unité en position arrêt (OFF) ou fermer le gaz au niveau du réservoir de propane liquide. Sur le MODÈLE À ALLUMAGE ÉLECTRONIQUE, mettre l'interrupteur de commande en position arrêt (OFF) et retirer le fil rouge de la borne gauche de l'interrupteur ECO ou fermer le gaz au niveau du réservoir de propane liquide. • Utiliser uniquement avec du gaz de propane liquide. • Lors du ré-approvisionnement en carburant, éteindre les appareils à gaz et les veilleuses. • Sur les MODÈLES AVEC RALLUMAGE DE LA VEILLEUSE, éteindre le module d'allumage lors du ré-approvisionnement en carburant dans les réservoirs à carburant ou à propane liquide. • Éteindre le gaz au niveau du réservoir à propane liquide, lorsque le véhicule est en déplacement. Cela permet de désactiver tous les appareils et toutes les veilleuses. Les appareils à gaz ne doivent jamais fonctionner lorsque le véhicule se déplace. Des mouvements d'air imprévisibles risqueraient d’entraîner un retour de flamme dans le tube du brûleur, ce qui pourra causer des endommagements par le feu. Le fusible de coupure thermique pourra également être activé accidentellement et éteindre complètement le chauffe-eau. Le système de coupure thermique devra alors être remplacé. Consulter l'entretien des chauffes-eau à allumage électronique pour plus de détails sur la coupure thermique. • Les réservoirs à propane liquide devront être remplis uniquement par un fournisseur en gaz qualifié. EXPLOSION OU INCENDIE AVERTISSEMENT CONSIGNES DE SÉCURITÉ DESTINÉES AU CONSOMMATEUR 1. Installer l'unité selon les instructions d'INSTALLATION GÉNÉRALE. 2. Consulter le schéma électrique. Utiliser du fil de taille 18 homologué UL et CSA. 3. Lire FONCTIONNEMENT DE LA VEILLEUSE et FONCTIONNEMENT DU RALLUMAGE DE LA VEILLEUSE. INSTRUCTIONS DE CÂBLAGE POUR LE RALLUMAGE DE LA VEILLEUSE INSTRUCTIONS DE CÂBLAGE POUR L'ALLUMAGE ÉLECTRONIQUE 1. IInstaller l'unité selon les instructions d'INSTALLATION GÉNÉRALE. REMARQUE : il est recommandé de brancher l'unité directement sur une batterie de 12 VCC ou en aval du filtre du convertisseur électrique CACC. Éviter, autant que possible, tout branchement en amont du convertisseur CA-CC. Utiliser un fil de taille 18 homologué UL et CSA. Consulter le SCHÉMA ÉLECTRIQUE. Installer l'interrupteur de commande à distance dans un endroit pratique. Positionner la plaque murale, les lettres debout. Avant d’effectuer le branchement, mettre l'interrupteur en position arrêt (OFF). L'interrupteur est en arrêt (OFF) lorsque le bouton est enfoncé vers la broche (3). 2. Branchement des fils : a. Le fil bleu sur la broche de l'interrupteur (6), sur le voyant lumineux de l'interrupteur. b. La broche (4) du voyant de l'interrupteur sur la borne négative de la batterie. c. Le fil vert sur la borne négative de la batterie. d. Le fil marron du chauffe-eau sur la broche (3) de l'interrupteur. e. La broche (2) de l'interrupteur sur la borne positive de la batterie. 3. Lire FONCTIONNEMENT DE L'ALLUMAGE ÉLECTRONIQUE. Pour le fonctionnement au gaz, passer à COMMENT UTILISER VOTRE CHAUFFE-EAU, et pour le fonctionnement électrique, passer à FONCTIONNEMENT COMBINÉ gaz-électricité. To insure the best performance of your water heater and add to the life of the tank, periodically drain and flush the water heater tank. Before long term storage or freezing weather drain and flush the tank. 1. Turn off main water supply (the pump or water supply (the pump or water hook up source). 2. Drain Water Heater Tank by removing the drain plug. If the water flows sporadically or trickles instead of a steady stream of water, we recommend the following action; first open the Pressure Temperature Relief Valve to allow air into the tank and secondly, take a small gauge wire or coat hanger and poke through the drain opening to eliminate any obstructions. 3. After draining the tank, because of the placement of the Drain Plug, approximately two quarts of water will remain in the tank. This water contains most of the harmful corrosive particles. To remove these harmful corrosive particles flush the tank with either air or water. Whether using air or water pressure, it may be applied through the inlet or outlet on the rear of the tank or the Pressure Temperature Relief Valve. (If using the Pressure Temperature Relief Valve the Support Flange must be removed). The pressure will force out the remaining water and the corrosive particles. If you use water pressure, pump fresh water into the tank with the assistance of the on-board pump or use external water for 90 seconds to allow the fresh water to agitate the stagnant water on the bottom of the tank and force deposits through the drain opening. Continue repeating adding water and draining until the particles have been cleared from the water remaining in the tank. 4. Replace the Drain Plug and close the Pressure Temperature Relieve Valve. The approximately two quarts of water remining in the tank after draining will not cause damage to the tank should freezing occur. WINTERIZING (FLUSHING) INSTRUCTIONS removing drain plug to flush tank. • Turn off water heater and allow time for water to cool before WARNING SCALDING INJURY WATER HEATER TANK CARE Check main burner orifice. Clean and adjust main burner. Main burner and valve manifold must align with each other Check electrode for cracked porcelain. Check electrode for proper gap - 1/8” between electrode and ground. 6. If module board functions intermittently, remove board and clean terminal block with pencil eraser. 1. 2. 3. 4. 5. HOW TO CLEAN ELECTRONIC IGNITION MODEL 1. Check main burner orifice and pilot assembly for contamination (dirt, spider webs, etc.). 2. Clean main burner tube with small brush. 3. Main burner adjustment - open air shutter 1/4 way. 4. Low pilot flame. Check for contamination - if clean have the pilot orifice replaced. HOW TO CLEAN PILOT MODELS Spiders, mud wasps, and other insects can build nests in burner tube. This causes poor combustion, delayed ignition or ignition outside combustion tube. Listen for a change in burner sounds or in flame appearance from a hard blue flame to a soft lazy flame or one that is very yellow. These are indications of an obstruction in burner tube (FIG 9-C). Inspect and clean on a regular basis. a. Remove air shutter screw (FIG 9-A) and slide air shutter (FIG 9-B) down burner tube. b. Run a flexible wire brush down burner tube (FIG 9-C) until it is visible at end of burner tube. c. Vacuum burner where it enters combustion tube. d. Return air shutter to original position and replace screw. e. The orifice, burner tube and shutter must be aligned so that the shutter is not binding on the air tube. PREVENTATIVE MAINTENANCE 5 A rotten egg odor (hydrogen sulfide) may be produced when the electro galvanic action of the cladding material releases hydrogen from the water. if sulfur is present in the water supply the two will combine and produce an unpleasant smell. 1. Turn off main water supply. Drain the water heater tank and reinstall drain plug. Remove the pressure-temperature relief valve. Mix solution of 4 parts white vinegar to two parts water. With a funnel, carefully pour solution into tank. 2. Cycle water heater with the above solution, letting it run under normal operation 4-5 times. 3. Remove the drain plug and thoroughly drain all water from the tank. Flush the water heater to remove any sediment. You may flush the tank with air pressure or fresh water. pressure may be applied through either the inlet or outlet valves on the rear of the tank or through the pressuretemperature relief valve coupling located on the front of the unit. TO FLUSH TANK WITH AIR PRESSURE: Insert your air pressure through the pressure-temperature relief valve coupling. With the drain valve open, the air pressure will force the remaining water out of the unit. To flush tank with water pressure: Fresh water should be pumped into the tank with either the onboard pump or external water pressure. Continue this flushing process for approximately 5 minutes, allowing the fresh water to agitate the stagnant water on the bottom of the tank and forcing the deposits through the drain opening. 4. Replace drain plug and pressure-temperature relief valve. 5. Refill tank with fresh water that contains no sulphur. The Atwood water heater is designed for use in a recreation vehicle. If you use your vehicle frequently or for long periods of time, flushing the water heater several times a year will prolong the life of the storage tank. FLUSHING TO REMOVE UNPLEASANT ODOR TO REPLACE THE AIR GAP FOLLOW THESE STEPS: 1. Turn off main water supply (the pump or water hook up source). 2. Let water cool or let run until cool. 3. Open the hot water faucet closest to the water heater. 4. Pull handle of pressure temperature relief valve straight out and allow water to flow until it stops. 5. Allow pressure temperature relief valve to snap shut; close faucet; turn on water supply. 6. Turn on water heater and test. • At least once a year manually operate pressure-temperature relief valve (FIG 10). When pressure-temperature relief valve discharges again, repeat above procedure. For a permanent solution, we recommend one of the following: • Install a pressure relief valve in cold water inlet line to water heater and attach a drain line from valve to outside of coach. Set to relieve at 100-125 PSI. • Install a diaphragm-type expansion tank in cold water inlet line. Tank should be sized to allow for expansion of approximately 15 oz. of water and pre-charged to a pressure equal to water supply pressure. These devices can be obtained from a plumbing contractor or service center. valve to establish air space. Storage water must be cool. • Turn off water heater before opening pressure-temperature relief SCALDING INJURY WARNING A Pressure Temperature Relief Valve, dripping while the water heater is running, DOES NOT mean it is defective. During normal expansion of water, as it is heated in the closed water system of a recreation vehicle, the Pressure Temperature Relief Valve will sometimes drip. The Atwood water heater tank is designed with an internal air gap at the top of the tank to reduce the possibility of dripping. In time, the expanding water will absorb this air and it must be restored. pressure-temperature relief valve. • Do not place a valve, plug or reducing coupling on outlet part of EXPLOSION WARNING PRESSURE-TEMPERATURE RELIEF VALVE Page 118 of 145 10 7 4 1 6 GAL. SHOWN A B A A C B D E F 11 A 8 5 2 A A C D B B 6 B C A 6 GALLON B E C 11 B A 9 A 6 D E E B A 6 GAL. SHOWN 3 A C C F D 10 GALLON B AVERTISSEMENTS IMPORTANTS POUR L'INSTALLATION 1. Poser le chauffe-eau par terre, dans le véhicule, avant de construire les parois latérales. Le réservoir du chauffe-eau doit toujours être positionné au même niveau que le bas de la découpe de la paroi latérale (au sol ou sur un support surélevé). 2. L’ installation du chauffe-eau sur de la moquette doit se faire sur un panneau en métal ou en bois de 7 ou 8 cm plus large et plus profond que la taille totale de l'appareil. 3. Si l’appareil est installé dans un lieu où le branchement et les fuites du réservoir risquent d’endommager les zones environnantes, installer sous le chauffe-eau un système d'écoulement donnant vers l'extérieur du véhicule. 4. Brancher les deux conduites d'eau de 1,27 cm NPT - sortie femelle d'eau chaude (FIG 1-A) et entrée femelle d'eau froide (FIG 1-B), ainsi que les conduites de gaz PL évasées de 0,95 cm (FIG 1-C). a. Permettre une certaine flexibilité des conduites d'eau et de gaz pour pouvoir tirer l’unité en avant, par le mur à 2,5 cm au-delà de l’enveloppe extérieure (FIG 2). b. Étanchéiser l'ouverture d’admission de la conduite de gaz en glissant l’œillet (FIG 1-D) sur le tube de 9,5 mm (FIG 1-F) avant de l'évaser (FIG 1-F). Faire passer la conduite de gaz et l’œillet par l'ouverture du logement (FIG 1-C). Brancher le raccord conique (FIG 1-E) et enfoncer l’œillet dans l'ouverture. Si la conduite de gaz est déjà évasée, couper l’œillet d'un côté. Placer l’œillet fendu sur la conduite de gaz et l'enfoncer dans l'ouverture. c. Toujours mettre du lubrifiant de tuyau sur le filet, lorsqu’on relie les accouplements d'eau chaude et d’eau froide. L’utilisation d’un raccord en plastique adapté est préférable. Cette méthode d’installation est l’une des plus répandue pour les chauffe-eau. Il existe d’autres méthodes homologuées telles que les installations de compartiment à bagages (Cf. MPD 90093) ou d’encastrements (Cf. MPD 93948). Consulter votre inspecteur sur le terrain, votre responsable de compte ou le service à la clientèle Atwood pour toute question supplémentaire. INSTALLATION GÉNÉRALE • Véhicules de plaisance ANSI A119.2/NFPA 501C. • Code national de carburant et de gaz ANSI Z223.1 et/ou codes d'installation CAN/CGA B149. Norme fédérale de sécurité et de construction de maisons mobiles, titre 24 CFR, partie 3280 ; lorsque cette norme n’est pas applicable, utiliser la norme d’installation de maisons préfabriquées (Manufactured Home Sites, Communities and Set-Ups), ANSI A255.1 et/ou la série CAN/CSA-Z240 MH, maisons mobiles. • Code électrique national ANSI/NFPA No. 70 et/ou CSA C22.1. • Caravanes de parc A119.5. • Norme CSA de série Z240 RV, véhicules de plaisance. USA ET CANADA - SUIVRE LES CODES NATIONAUX ET LOCAUX EN VIGUEUR - À DÉFAUT DE CODES OU RÉGLEMENTATIONS LOCAUX, SE REPORTER AUX NORMES ACTUELLES DE : • Installer dans les véhicules de plaisance uniquement. Les véhicules de plaisance sont conçus comme résidences temporaires pour les vacances, le camping ou les voyages ; ils fonctionnent de façon autonome ou sont parfois remorqués par un autre véhicule. • Tout l'air de combustion doit provenir de l'extérieur du véhicule de plaisance et tous les produits de la combustion doivent être évacués vers l'extérieur du véhicule de plaisance. • NE PAS évacuer l'air du chauffe-eau par un système d'évacuation servant à un autre appareil. • NE PAS évacuer l'air du chauffe-eau vers un espace extérieur couvert. • Protéger les matériaux de construction des gaz de carneau. • IInstaller le chauffe-eau sur un mur extérieur, avec une trappe d'accès donnant vers l'extérieur. • NE modifier le chauffe-eau en AUCUNE façon. • NE PAS modifier le chauffe-eau pour une mise à la terre positive. • NE PAS faire d’essai diélectrique du chauffe-eau sans avoir débranché l'allumage électronique (carte de circuit imprimé). • NE PAS utiliser de chargeur de batterie pour alimenter le chauffeeau, même lors des essais. 11 B 41 cm 42,5 cm DIMENSION DE LA DÉCOUPE A 32 cm 40 cm C 44,75 cm 52,4 cm PROFONDEUR Haut : Bas : 0 cm 0 cm décharge de type pression-température en conformité avec les normes sur les soupapes de décharge et les mécanismes de coupure automatique de l'alimentation en gaz pour systèmes à eau chaude ANSI Z21.22. LA SOUPAPE EST UN ELEMENT DE SÉCURITÉ ET NE DOIT PAS ÊTRE RETIRÉE SAUF EN CAS DE REMPLACEMENT. Ce chauffe-eau est équipé d'une soupape de sur la sortie de la soupape de décharge. • NE PAS placer de robinet, de bouchon ou de raccord de réduction AVERTISSEMENT EXPLOSION • La soupape ne se prête pas aux réparations, elle devra être remplacée. • Toucher à la soupape risque de provoquer des brûlures. • Toucher à la soupape annulera la garantie. AVERTISSEMENT BRÛLURES SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE - (FIG 10) 11. Ouvrir l'alimentation en gaz et s’assurer que le chauffe-eau et les différents raccords de gaz ne comportent pas de fuites, à l'aide d'une solution de détection de fuites. 12. Remplir le réservoir du chauffe-eau ; vérifier que les différents raccords ne comportent pas de fuites d’eau (FIG 1 A & B). • NE PAS utiliser d'allumettes, de bougies ou toute autre source d'allumage pour contrôler la présence éventuelle de fuites de gaz. INCENDIE ET/OU EXPLOSION AVERTISSEMENT 6. Suivre les marques et plier tous les rebords à 90º (FIG 3). 7. Pour éviter les fuites d'eau, appliquer du mastic tout autour de l'ouverture, y compris dans les fentes de pliage (FIG 3-A). Il est possible de substituer une bande adhésive de butyle au mastic (2,54 cm x 0,3 cm). 8. Pousser l'unité contre le mastic, fixer les 4 équerres de fixation (FIG 4-A) au véhicule à l'aide de vis à tête ronde No.8, de 1,9 cm (nonfournies) ou l’équivalent. Terminer l'installation en insérant le même type de vis No. 8 dans les orifices situés sur le bord du logement du chauffe-eau. Check all gaskets, they must adher to the pan creating an air tight seal. 9. Fixer la trappe d'accès (FIG 5). a. Enfoncer l'axe de la charnière (FIG 5-A) dans le logement de la charnière (FIG 5-B). b. Faire glisser le couvercle (FIG 5-C) sur l'axe de la charnière. c. Glisser l’axe de la charnière dans le couvercle, tout en l'enfonçant dans le logement de la charnière (FIG 5-D). REMARQUE : pour retirer l'axe de la charnière, soutenir le couvercle d'accès et appuyer sur le coin de l'axe de la charnière, comme le montre l’illustration FIG 5-E. 10. Débrancher l'unité et son robinet d'arrêt individuel de la conduite d’alimentation en gaz lors de tout test de pression du système audelà de 3,4 kPa, 355 mm de colonne d'eau (C.E.). NE PAS régler la pression d’admission au-delà du maximum indiqué sur la plaque signalétique du clapet à gaz (330 mm C.E.). Isoler l'unité de la conduite d'alimentation en gaz en fermant le robinet d'arrêt manuel individuel lors de tout test de pression supérieur ou égal à 3,4 kPa. Côtés : 0 cm Arrière : 0 cm DISTANCE MINIMALE PAR RAPPORT À TOUT MATÉRIAU DE CONSTRUCTION COMBUSTIBLE LITRES 15 - 22 38 CAPACITE DÉCOUPE 5. Construire les parois latérales et découper l'ouverture. Cf. tableau et FIG 2 A & B. Utiliser des montants de 2x2 (ou équivalent) pour l'encadrement. • Ne pas soulever, tirer ou pousser le tube du brûleur principal (FIG 3-F). ATTENTION ENDOMMAGEMENT DU PRODUIT Page 119 of 145 (et Canada) évite les blessures corporelles et/ou les dommages matériels ATTENTION QUE FAIRE SI VOUS SENTEZ DU GAZ ? • Evacuer TOUS les passagers du véhicule. • Couper l'alimentation en gaz au niveau du réservoir ou à la source. • NE toucher AUCUN interrupteur électrique, n’utiliser ni le téléphone, ni la radio à l'intérieur du véhicule. • NE PAS démarrer le véhicule ou le générateur électrique. • Contacter le fournisseur en gaz ou le technicien d’entretien qualifié le plus proche pour effectuer toute réparation. • S’il est impossible de joindre un fournisseur en gaz ou un technicien d’entretien qualifié, contacter la caserne de pompiers la plus proche. • NE PAS ouvrir l'alimentation en gaz avant que la ou les fuites soient réparées. ➤ Ne pas entreposer ni utiliser de carburant ou autres liquides et vapeurs inflammables à proximité de cet appareil ou de tout autre appareil. • Ne pas suivre à la lettre les instructions contenues dans ce manuel risque d’entraîner un incendie ou une explosion et des dégâts matériels, des blessures voire la perte de vie humaine. INCENDIE OU EXPLOSION AVERTISSEMENT L'installation et l'entretien doivent être effectués par un technicien d’entretien qualifié, un centre de service, un équipementier ou un fournisseur de gaz. évite les blessures corporelles ou les accidents mortels AVERTISSEMENT Les symboles d'alerte de sécurité vous avertissent des dangers personnels potentiels. Obéir à tous les messages de sécurité qui suivent ces symboles. SYMBOLES D'ALERTE DE SÉCURITÉ APPELS ET QUESTIONS D’ENTRETIEN Les adresses et les numéros de téléphone des centres de service agréés se trouvent sur notre site Internet à http:/www.atwoodmobile.com ou composer le 574-264-2131 pour recevoir la liste par courrier. La conception de ce chauffe-eau a été homologuée par l’Association canadienne de normalisation pour installation à l'intérieur de véhicules de plaisance. Ce chauffe-eau n'a pas été conçu pour usage sur bateaux. ENGLISH, FRANCAIS 9 10 ..................................10 DIMENSIONS ......................................................10 POIDS ................................................................10 IDENTIFICATION DU MODÈLE ........................................................13-15 ......................12-13 H 6 AA - 8 E/P Allumage électronique ou rallumage de la veilleuse Révision (NUMÉRO) Elément chauffant (À VIS OU À BOULON) Capacité de 15, 22 ou 38 litres Échangeur de chaleur du moteur Combiné gaz et électricité (CA) Gaz (PROPANE) - SI VOTRE NUMÉRO DE MODÈLE N'APPARAÎT PAS SUR LA LISTE Les numéros reflétant une révision plus ancienne pourront être le 3, 4, 6, 7, 8 ou 9 (_ _ _ _ _ - X _) C l 15 LITRES 38 LITRES 22 LITRES TOUS MODÈLES DIMENSIONS 22 LITRES 38 LITRES HAUTEUR 38 LITRES 22 LITRES 11,34 KG 14,5 KG POIDS A L'ENVOI G6A-7 GC6AA-8P G10-2 GC10-2 GC6AA-8 GH6-7 G10-2P GC10-2P G6A-8E GCH6A-9E G10-3E GCH10A-3E GC6AA-9E GH6-8E GC10A-3E GH10-3E P SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS H SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS E SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS C SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS 40.6 CM 31.8 CM 40.6 CM 39.4 CM LARGEUR Allumage de G4-7 la veilleuse Allumage électronique Rallumage de la veilleuse Échange de chaleur Allumage électronique Combinaison gaz-électricité TYPE EXPLICATION DU NUMÉRO DE MODÈLE Quel que soit votre numéro de révision, les présentes instructions sont généralement valables pour votre unité. Pour toute question, contacter votre distributeur, un centre de service Atwood ou le service à la clientèle Atwood. G EXPLICATION DU NUMÉRO DE MODÈLE (EXEMPLE) ............................................................................16 SCHÉMAS ÉLECTRIQUES ............................................................8-9 IDENTIFICATION DES PIÈCES ..........................................................6 SCHEMAS ELECTRIQUES ................................................................7 FIGURES 1-11 Allumage électronique Électrique CHAUFFE-EAU ENTRETIEN Allumage électronique Rallumage de la veilleuse Combinaison gaz-électricité CHAUFFE-EAU FONCTIONNEMENT DE LA VEILLEUSE Installation du câblage pour l'allumage électronique Installation du câblage pour le rallumage de la veilleuse Échangeur de chaleur Combinaison gaz-électricité INFORMATIONS SUR LA SÉCURITÉ ............................................11-13 CHAUFFE-EAU INSTALLATION GÉNÉRALE ......................................11-12 CHAUFFE-EAU En vigueur à partir du 19/11/07 •Installation •Fonctionnement •Entretien 15 – 22 – 38 LITRES CHAUFFE EAU AU PROPANE LIQUIDE (PL) MPD 93756 COMBINAISON gazélectricité RALLUMAGE DE VEILLEUSE ALLUMAGE ÉLECTRONIQUE COMBO gas/electric PILOT RELIGHT SPARK IGNITION BLACK Manual Reset High Temperature Limit Switch Fixed Thermostat BLEU ( 3 )-VERT Fil de masse VERT VERT MARRON NOIR Masse NOIR (3) (2) 7 Interrupteur limiteur haute température à réarmement manuel Thermostat fixe Fil de haute tension vers l’électrode du brûleur Élement ( 2 )-BLANC ( 1 )-NOIR Fil neutre MARRON Interrupteur Module d’étincelle Décharger et détecter (4) Coupure thermique Interrupteur à distance (6) Voyant lumineux de non allumage Thermostat de commande à température fixe MARRON (3) (2) CAUTION BATTERY ELECTRICAL DAMAGE BL U BR GRE E OW EN N (6 (4 ) (3 ) (2 ) ) REMOTE SWITCH INTERRUPTEUR À DISTANCE (6 (4 ) (3 ) (2 ) ) ATTENTION DOMMAGES ÉLECTRIQUES BATTERIE BATTERY V ROU ERT GE BATTERIE • Lors de la réparation des commandes, étiqueter tous les fils avant de les déconnecter. • Après toute réparation, vérifier au bon fonctionnement de l'unité. 12 V c. c. BL E BR VER U UN T GRE RED EN • Label all wires before disconnecting when servicing controls. • Verify proper operation after servicing. 12 volt DC SCHÉMAS ÉLECTRIQUES Interrupteur ECO Fil de phase VERT ROUGE BLACK Ground Switch Les lignes en pointillés sont branchées par le client ROUGE Électrovannes à gaz ( 2 )-WHITE GREEN GREEN BROWN High Voltage Lead to Burner Electrode Element ( 3 )-GREEN Ground Lead ( 1 )-BLACK Spark Module Common Lead Hot Lead GREEN RED BROWN Thermal Cut-Off (4) Non-Ignition Light (6) Fixed Temperature Control Thermostat BROWN BLUE ECO Switch Spark & Sense RED Remote Switch WIRING DIAGRAMS Dotted lines are wired by customer Gas Solenoid Valves RED ROUGE NUMERO DE BROCHURE GREEN VERT MPD 56281 LP GAS DROP-IN COOKTOPS 9 D, DA, DA-PE Except HP Models PROTECTED BY U.S. PATENTS D393,774, D393,567, D393,501, D393,502 ENGLISH •Installation •Operation •Maintenance Effective 12/13/07 SAFETY ALERT SYMBOLS WARNING Safety Symbols alerting you to potential personal safety hazards. Obey all safety messages following these symbols. WARNING avoid possible injury or death CAUTION avoid possible injury and/or property damage FOR YOUR SAFETY READ ALL INSTRUCTIONS BEFORE OPERATING APPLIANCE Installer: Consumer: Provide these instructions to the consumer. Keep documents for future reference. WARNING FIRE OR EXPLOSION FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS • Open windows. • DO NOT touch any electrical switch, or use any phone or radio in vehicle. • Extinquish any open flame. • Evacuate ALL persons from vehicle. • Shut off gas supply at gas container or source. • DO NOT start vehicle’s engine or electric generator. • Contact nearest gas supplier or qualified Service Technician for repairs. • If you cannot reach a gas supplier or qualified Service Technician, contact the nearest fire department. • DO NOT turn on gas supply until gas leak(s) has been repaired. FOR YOUR SAFETY ➤ Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WARNING • Improper installation, adjustment, service or maintenance can cause injury, property damage or death. Refer to this manual. For assistance or additional information, consult a qualified installer, service agency, manufacturer or the gas supplier. WARNING EXPLOSION OR FIRE • Shut off all gas appliances and pilot lights when refueling gasoline tanks, LP tanks or when vehicle is in motion. • Atwood/Wedgewood gas operated cooking appliances are for use with LP gas only, and for installation in recreational vehicles only (e.g. travel trailers, motor homes, tent campers, etc.). CARBON MONOXIDE POISONING • Do not use any cooking appliance for space heating because of potential danger to occupants of the vehicle and damage to operating components of the cooktop. • A window or air vent should be open slightly while using any cooking appliance. Gas flame consumes oxygen which must be replaced to assure proper combustion. NOTE TO CONSUMER: Have the installer or dealer show you where the main gas shut off valve is located so that you will know how and where to turn off the gas supply when necessary. CONTENTS Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Cabinet & Counter Cut Out Chart . . . . . . . . . . . . . . . . . . . .2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 INSTALLATION Appliance intended for use inside or temporary use outside the recreational vehicle. Appliance for use only with recreational vehicle with which it is supplied. Do not store appliance outdoors. Electronic Ignition models are for indoor use only. Installation must conform with local codes or in the absence of local codes, with the American National Standard for Recreational Vehicles, ANSI/A119.2 and Article 551, ANSI/NFPA 70. In Canada, installation must conform with CSA Z240.4.2-M. WARNING FIRE, EXPLOSION, BURN INJURY CARBON MONOXIDE POISONING • The cooking appliance must be completely separated and/or sealed from other air moving or air consuming devices such as, but not limited to, furnaces, microwave ovens, clothes dryers, cooling fans and doors or drawers in common cabinets. Failure to do so will affect the appliance(s) combustion air supply by creating either a negative or positive draft. • NEGATIVE DRAFT caused by air moving appliances may draw the top burner flame down into or toward the cooktop resulting in cooktop damage, burn hazard, explosion possibility and/or carbon monoxide buildup. • POSITIVE DRAFT may blow out the top burner flame during use resulting in an explosion and/or fire hazard and/or injury to the occupants of the vehicle. • Do not operate the appliance in excessive windy conditions as this may cause a negative or positive draft. Page 120 of 145 8. Turn on the gas supply. 1. For proper operation of your cooking appliance: THE CABINET MUST BE • properly constructed. • squared to the countertop and cabinet face THE OPENING IN CABINET MUST BE • level from side to side and front to rear 2. The cabinet opening must be constructed so that no combustible material can be placed next to the cooktop sides. If there is a gap between the cooktop and an adjacent cabinet, the gap must be closed prior to installing the cooktop. WARNING EXPLOSION OR FIRE • Do not use matches, candles or other sources of ignition to test fittings and gas lines for leaks. 9. Check all connections for gas leaks using a non-corrosive leak detection fluid. Do not use a soap and water solution. Leak test in excess of 8 oz. per square inch (1/2 psi) of air pressure will invalidate warranty. WARNING 10. a. D-26SV: Attach cam lock fastener (supplied) to a bracket constructed by the manufacturer (not supplied). Determine area to mount bracket in upper portion of van that is secure and unobstructed. Unfold the cover and guards to determine the location of the keyhole shaped slot in the upper guard. Attach assembly. Apply control label to counter before installing burner knobs. b. Drop-In: Remove the cooktop top and burner grates from packaging and install grates: FIRE • 30 inches is the minimum vertical distance to combustible material above the cooktop stove. This distance may be reduced by using non-combustible construction in accordance with Table 26.7.2 in ANSI A119.2. 3. Cabinet dimensions needed for each model are shown in CABINET & COUNTER CUT OUT CHART. The cabinet cut-out must be located with respect to the minimum clearances to combustible materials as noted. When planning the location consider curtains or other combustible materials installed around the cooktop. 4. When the cabinet has been prepared according to the dimensions given and the gas line is in place, remove the cooktop from its packaging and position the cooktop in the opening. 5. Verify that the cooktop is level from side to side and front to rear. 6. Drop-In: Secure the burner box assembly in place with wood screws (not supplied). D26-SV: Slip right hand of unit under counter so that the valve shafts protrude through the two 1˝ diameter holes in the counter. Secure to the counter with (4) sheet metal screws (not supplied). D26-SLG: Drop unit into cutout, secure to counter with (4) #6 flat head wood screws (not supplied). 7. Make the gas connection. All openings in the cabinetry around the gas line must be closed at time of installation. DA-PE models with electronic ignition: Complete the electrical connections as shown in the WIRING DIAGRAM. For galley slide-out applications, it is highly recommended that the negative 12 volt connection be connected directly to the battery. Voltage supply must be between 9 and 13 VDC. Appliance electrical rating is 12VDC, 0.6A during sparking. 11. a. SINGLE & DUAL RECTANGULAR WIRE grate models 3 burner Install the rubber feet on corner grate legs, and install the grates on the stove top. From the underside of the cooktop, install the spring clips over the protruding grate legs. Squeeze the edges of the clips together and slip over the ends of the burner grate as needed. 2 burner Install rubber feet on corner grate legs. From the top, press spring clips into holes of cooktop. Install grate onto cooktop, engaging middle legs into spring clips. b. ROUND WIRE grate models squeeze opposite sides of the grate together and insert the legs into the holes in the stove top from above the stove top. c. STAMPED STEEL grate models place one side of the grate in the burner well, ensuring that the clip engages the emboss in the side. Gently press the other end of the grate downward to “snap” the grate into place. 12. REPLACE THE COOKTOP TOP Drop-In: Position the cooktop top in place; install the thumb screws (supplied) through the cooktop top. Tighten securely. On DAS models, press the top downward until it “snaps” in place on both sides. Slide the knobs over the valve stems to complete the installation. Your cooktop is now ready for operation. CAUTION PRODUCT DAMAGE HAZARD • Connect to 12VDC service only. • Do not connect to a circuit fused for more than 3 amps. • Do not hi-pot cooktop unless electronic ignition system has been disconnected. FM IN D . G MIN . A CABINET & COUNTER CUT OUT CHART D M E N. I M C CUT OUT DIMENSIONS ◆Minimum dimension EM . CM B E MIN . IN. IN. MIN . J D-26SLG Models D, DA D, DA Models - 2 Burners D , DA Models - 3 Burners D-26SLG D-26SV IAM A B 11-5/8˝ 16-1/16˝ 19˝ 11-5/8˝ 16-3/8˝ 19-3/16˝ 14-1/8˝ 16-3/8˝ C 2-1/4˝ ◆ 2-1/2˝ ◆ 5/8˝ ◆ 4-3/8˝ ◆ I A H D-26SV D 3-1/8˝ 3-1/8˝ 4-1/2˝ 3-1/8˝ ETE C MIN A B 1" D MIN . B F IN. FM IN D . G E ◗ ◗ ◗ ◗ 3/4˝ 2-3/8˝ 3/4˝ 1˝ F ◆ ◆ ◆ ◆ 4-3/4˝ 4˝ 2-3/4˝ 1-1/8˝ ◆ ◆ ◆ ◆ G H I J 3˝ 4-1/4˝ 3-1/4˝ 4-3/4˝ 2-1/4˝ ◗ Overall depth of cooktop 2 Page 121 of 145 R 1. Check that gas is on at shutoff valve. BURNER OPERATION 2. LIGHTING Top Burners: a. All burner controls operate counter-clockwise and must be pressed inward (toward the cooktop) to turn ON or LITE. Do not attempt to light more than one burner at a time. b. IMMEDIATELY light the burner by holding a lit match or a handheld spark igniter designed for this purpose near the burner ports. c. To extinguish the top burner flame, turn the appropriate burner knob clockwise to OFF. WARNING BURN INJURY, FIRE AND/OR EXPLOSION • Do not heat unopened containers. They could explode. The hot contents may cause burns and container particles may cause injury. • Do not use the cooktop for warming or heating the vehicle. You could be burned or injured, or a fire could start. • Do not store flammable materials on, in, or near cooktop. Any fumes can create an explosion and/or fire hazard. • Do not operate cooktop if it is damaged or not working properly. • Know where your vehicle’s main LP gas shutoff is located. • Verify sufficient gas supply before attempting to light any top burner. Air in the gas supply line will significantly delay burner ignition, and a burner may light unexpectedly as the air in the line clears out and is replaced by LP gas; this unexpected ignition may burn you. Air may be introduced into the supply line when the vehicle gas bottle is replaced, during servicing of other gas appliances, etc. • If any burner should extinguish (after initially lighting or due to accidental blow-out), turn all burner knobs clockwise to OFF and WAIT FIVE (5) MINUTES before again attempting to light the burner. • Do not touch top burners, burner grates, or areas near top burners during and after use. Do not let clothing or other flammable materials contact top burners or areas near top burners until they have sufficient time to cool. • Pans must be large enough to contain food. Heavy splattering or spillovers left on the cooktop can ignite and burn you. • Be sure that glass cooking utensils are safe for use on the cooktop. Only certain kinds of glass utensils are suitable for surface or top burner use without breaking due to sudden changes in temperature. • Never leave top burners unattended. A boil over may result, causing smoke or grease spillovers that may ignite. • Turn pan handles inward, but not over other top burners. This reduces the chance of burns due to bumping pan. • Grease is flammable. Never allow grease to collect around top burners or on cooktop surface. Wipe spillovers immediately. • Do not use water on grease fires. Never pick up a flaming pan. Smother a flaming pan with a tight-fitting lid or cookie sheet. Flaming grease outside of the pan can be extinguished with baking soda or a multipurpose dry chemical or foam-type fire extinguisher. • Use care when lighting a top burner by hand. If the burner lights unexpectedly, or your hand is close to burner, you may be burned. • Burner flame should not extend beyond the edge of the cooking utensil. The flame could burn you and cause poor cooking results. • Control knobs must be turned OFF when not cooking. Someone could be burned or a fire may start if a burner is accidentally left ON. • Do not touch top burners, burner grates, or areas near top burners during and after use. Do not let clothing or other flammable materials contact top burners or areas near top burners until they have sufficient time to cool. • Pans must be large enough to contain food. Heavy splattering or spillovers left on the cooktop can ignite and burn you. • Be sure that glass cooking utensils are safe for use on the cooktop. Only certain kinds of glass utensils are suitable for surface or top burner use without breaking due to sudden changes in temperature. • Never leave top burners unattended. A boil over may result, causing smoke or grease spillovers that may ignite. • Turn pan handles inward, but not over other top burners. This reduces the chance of burns due to bumping pan. • Grease is flammable. Never allow grease to collect around top burners or on cooktop surface. Wipe spillovers immediately. • Do not use water on grease fires. Never pick up a flaming pan. Smother a flaming pan with a tight-fitting lid or cookie sheet. Flaming grease outside of the pan can be extinguished with baking soda or a multipurpose dry chemical or foam-type fire extinguisher. • Use care when lighting a top burner by hand. If the burner lights unexpectedly, or your hand is close to burner, you may be burned. • Burner flame should not extend beyond the edge of the cooking utensil. The flame could burn you and cause poor cooking results. • Control knobs must be turned OFF when not cooking. Someone could be burned or a fire may start if a burner is accidentally left ON. LIGHTING Top Burners with electronic ignition: a. Turn the appropriate burner knob counterclockwise to ON or LITE. This will automatically activate the ignition system, and all burners will begin to spark repeatedly. This is the “clicking” sound you will hear. The burner will light within five (5) seconds. b. To extinguish the top burner flame, turn the appropriate burner knob clockwise to OFF. c. If 12 VDC power is not available to the ignition module for any reason, the top burners may be lit manually. See instructions in “Lighting Top Burners”. CAUTION PRODUCT DAMAGE HAZARD • Do not cook with the control knob set in the LITE position. Damage to the ignition module and burner electrodes may result. • Do not use oversized cookware. The pan should not be more than one inch larger than the burner grate. The maximum pan size is a 10-inch skillet. Oversized cookware will cause excessive heat build-up in the stove top and will result in damage to the burner grate, burner and cooktop. • Do not use a broiler pan, griddle, or any other large utensil which covers more than one (1) top burner at a time. This will create excessive heat which may cause melting, sooting or discoloration damage to the burner grates, cooktop top, or utensils. • Do not leave an empty utensil, or one which has boiled dry, on a hot top burner. The utensil could overheat and damage the utensil or the cooking appliance. STORAGE Dry all surfaces and burner box, then spray surfaces with PAM or oil base substance to preserve the surface from rusting during storage. Before using, clean oil off surface of appliance. MAINTENANCE The owner’s cooking habits and cleanliness will affect the operation of the cooktop. Proper installation and care will help keep your cooktop looking and operating like new. Most cleaning can be performed using normal household items. WARNING BURN INJURY, FIRE AND/OR EXPLOSION • All controls must be OFF, the cooktop cool before cleaning. • All cooktop surfaces, burner grates and burners must be cool before cleaning or disassembling cooktop. • Do not use oven cleaners, bleach, or rust removers on the cooktop or burner grates. • Do not obstruct the flow of combustion and ventilation air. • Keep appliance area clear of combustible materials, gasoline and other flammable vapors and liquids. CONNECTION DIAGRAM FOR ELECTRONIC IGNITION MODELS 12 volt Burner Valve Switches Battery R + – R R G G W Connector Ignition Module R = RED Wire G = GREEN Wire W = WHITE Wire = Wire Connection - - = Wired by Installer W Top Burners 3 Page 122 of 145 2. To remove the burner grates: a. On models with round wire grates, squeeze opposite sides of the grate together and lift free of the cooktop top. b. On 2 burner models with rectangular wire grates, pull grate straight up releasing them from spring clips. c. On 3 burner models with rectangular wire grates, remove the cooktop top (see Step 1 above). From the underside of the cooktop top, remove the clips from the grates by squeezing the ends of the clips together to release the tension on the grate. d. On models with stamped steel grates, pull up on one end of grate to “unsnap” it from cooktop. e. Replacement is a reversal of the above procedure. CAUTION PRODUCT DAMAGE HAZARD • Clean all surfaces quickly after boil overs or spillovers. • Use warm soapy water only to clean the burner grates, cooktops, painted surfaces, porcelain surfaces, stainless steel surfaces and plastic items on your cooktop. Do not use grit or acidtype cleaners. • Do not use steel wool or abrasive cleaners, they will damage your cooktop. Use only non-abrasive plastic scrubbing pads. • Do not allow foods containing acids (such as lemon or tomato juice, or vinegar) to remain on porcelain or painted surfaces. Acids may remove the glossy finish. Wipe up egg spills when cooktop is cool. • Do not wash warm porcelain surfaces. Allow porcelain to cool before cleaning. You may burn yourself, or porcelain may crack. • Pitting and discoloration will result if spills are allowed to remain for any length of time on stainless steel. • Do not allow spillovers to remain on burner caps. Caps could be permanently stained if spillovers are not cleaned up promptly. ALL COOKTOPS If any of the burner ports or the orifices are clogged, carefully clean with a toothpick. Never use a wire brush or metallic item for cleaning burner ports or orifices. Never use any brush which may “shed” bristles, which may become lodged in the orifice or burner ports and cause a fire or explosion. DROP-IN COOKTOPS: 1. To remove the stove top: a. Remove the two (2) side screws, if provided, from the cooktop. Lift the cooktop clear of the burner box. Replacement is a reversal of this procedure. b. On DA models, pull the knobs straight up, removing them from the valve stems, before removing the stove top. c. On DAS models, remove knobs, then “unsnap” top by inserting finger(s) in valve stem openings and pulling up. COOKING APPLIANCE LIMITED WARRANTY 4. Return parts must be shipped to Atwood Mobile Products “prepaid”. Credit for shipping costs will be included with the warranty claim. The defective parts become the property of Atwood Mobile Products and must be returned to the Consumer Service Department, Atwood Mobile Products, Greenbrier Operations, 6320 Kelly Willis Road, Greenbrier, TN 37073 USA. 5. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes. 6. The warranty on replacement parts is the unused portion of the original warranty period. 7. Damage or failure resulting from misuse (including failure to seek proper repair service) misapplication, alterations, water damage or freezing are owner’s responsibility. 8. Atwood does not assume responsibility for any loss of use of vehicle, loss of time, inconvenience, expense for gasoline, telephone, travel, lodging, loss or damage to personal property or revenues. Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. 9. Any implied warranties are limited to two (2) years. Some States do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which may vary, from State to State. 10. Replacement parts purchased outside the original cooking warranty carry a 90 day warranty. This includes the part at no charge and reasonable labor charges to replace it. This Atwood product is designed for use in recreation vehicles for the purpose as stated in the ‘data plate’. Any other use, unless authorized in writing by the Atwood Engineering Department, voids the warranty. Atwood/Wedgewood Vision Products include range/oven, drop-in, slide-in and high pressure stoves. Atwood Mobile Products warrants to the original owner and subject to the below mentioned conditions, that this product will be free of defects in material or workmanship for a period of two years from the original date of purchase. Atwood’s liability hereunder is limited to the replacement of the product, repair of the product, or replacement of the product with a reconditioned product at the discretion of the manufacturer. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other causes not arising from defects in material workmanship. This warranty extends to the original owner of the product only and is subject to the following conditions: 1. For two years from the date of purchase Atwood warrants that this product will be free of defects in material and workmanship with the exceptions noted below. This warranty includes reasonable labor charges required to remove and replace the part. Service calls to the customer’s location are not considered part of these charges and are therefore the responsibility of the owner. 2. This warranty does not cover the following items classified as normal maintenance and/or customer damage. a. Damage, discoloration or scratches to porcelain enamel or other finishes from improper use and care. b. adjustment of gas pressure c. cleaning or adjustment of any burners d. cleaning or replacement of burner orifices e. cleaning or adjustment of pilot and thermocouple f. damage to glass g. products purchased for commercial, industrial or rental use. 3. In the event of warranty claim the owner must contact in advance either an authorized Atwood Service Station or the Atwood Service Department. Warranty claim service must be performed at an authorized Atwood Service Station (a list will be provided at no charge) or as approved by the Atwood Service Department Atwood Mobile Products, 1120 North Main, Elkhart, IN 46514 USA. Phone 574-264-2131. 4 Page 123 of 145 D-21 / D-26 D-26 SLG D-26 SV 1 12 12 11 11 11 12 13 13 15 15 17 17 14 18 18 19 19 24 20 26 15 17 24 27 25 25 28 29 18 19 20 26 20 28 29 25 28 30 WEDGEWOOD DROP-IN’S D-21 / D-26 D-26 SV D-31 D-26SLG 12 11 2 13 9 10 15 17 18 21 23 D-21 / D-31 22 26 27 5 24 25 28 29 5 Page 124 of 145 DROP-IN COOKTOP PARTS IDENTIFICATION PIÈCES DÉTACHÉES TABLE DE CUISSON ENCASTRABLE ITEM D-21 D-26 D-26SV D-26SLG D-31 DA-21 DA-31 DA-31PE DESCRIPTION 1 ................................................56204 ..................................................................................................COVER 2 ...... 53304 ..........53304..........53304 ..................................................................................................DESIGNER GRATE 5 ......51007 (2)..............................................51007 (3) ........................................................................MEDALLION GRATE 6 ..........................................................................................53436 ........................................................STAMPED STEEL GRATE 7..............................................................................................................53437 ........53437 ..................STAMPED STEEL GRATE, REAR 8..............................................................................................................53438 ........53438 ..................STAMPED STEEL GRATE, FRONT 9 ......53008 (4) ......53008 (4)....53008 (4)....53008 (8) ........................................................................GRATE BOOT 10 ......53301 (2) ......53301 (2)....53301 (2)....50005 (4) ........................................................................GRATE CLIP 11 ......52537............52537..........52537 ........52537 ............52016 ........52016 ....................................THUMB SCREW (2) 12 ......52434............52434..........52434 ........52434 ............52434 ........52434 ....................................WASHER, NYLON (2) 13 ......✵ ..................✵ ................52444 ........✵ ....................✵ ................✵ ..............✵ ..........................COOK TOP 14 ............................51443 ......................................................................................................................COOKTOP & COVER ASBLY 15 ......53000 (2) ......53000 (2)....53000 (2)....53000 (3) ......56129 (2) ..56129 (3) ..56129 (3)..............BURNER KNOB 17 ......52539............52437..........52437 ........52540 ............57700 ........57051 ........57050 ..................CONTROL LABEL (BLACK) 18 ......52516 ..............................52523 ........52524 ............52516 ........52523 ........52523 ..................MANIFOLD COVER 19 ......56073............56077..........56075 ................................56212 ........................................................BURNER, LEFT 20 ......56074............56078..........56076 ................................56213 ........................................................BURNER, RIGHT 21....................................................................56083 ..............................56215 ........56234 ..................BURNER, LEFT REAR 22....................................................................56082 ..............................56214 ........56235 ..................BURNER, LEFT FRONT 23....................................................................56084 ..............................56216 ........56233 ..................BURNER, RIGHT REAR 24 ......52294............52294..........52294 ........52294 ............52294 ........52294 ........52294 ..................BRASS FITTING 25 ......51062............51062..........51062 ........51062 ............51062 ........51062 ........51062 ..................REGULATOR 26 ......56090 (2) ......56090 (2)........................56090 (1) ......56090 (2) ..56090 (1) ..53114 (1)..............VALVE, 6500 BTUH 27 ................................................56089 (2)....56089 (2) ........................56089 (2) ..53124 (2)..............VALVE, 5200 BTUH 28 ......56079............56079..........56079 ........56080 ............56079 ........50160 ........50160 ..................MANIFOLD PIPE 29 ......56091 (2) ......56091 (2)....56091 (2)....56091 (3) ......56091 (2) ..56091 (3) ..56091 (3)..............BOLT FOR VALVE 30 ................................................56205 ..................................................................................................FRAME 31 ..............................................................................................................................51410 (4)..............CLIP, TOP 32 ..............................................................................................................................56162 ..................12V IGNITION MODULE 33 ..............................................................................................................................57055 (3)..............VALVE IGNITION SWITCH N/S ............................................................................................................................57622 ..................WIRING HARNESS N/S ............................................................................................................................56184 ..................ELECT. IG GROUND LEAD N/S ............................................................................................................................57621 ..................ELECT. IG ELECTRODES LEAD COUVERCLE GRILLE DESIGN GRILLE EN MÉDAILLON GRILLE EN TÔLE GRILLE EN TÔLE, ARRIÈRE GRILLE EN TÔLE, AVANT EMBOUT DE GRILLE ETRIER DE GRILLE VIS À PAPILLON (2) RONDELLE EN NYLON (2) TABLE DE CUISSON TABLE DE CUISSON AVEC COUVERCLE BOUTON DE COMMANDE DE BRÛLEUR ETIQUETTE DE COMMANDE (NOIR) COUVRE-SOUPAPE BRÛLEUR, GAUCHE BRÛLEUR, DROIT BRÛLEUR, ARRIÈRE GAUCHE BRÛLEUR, AVANT GAUCHE BRÛLEUR, ARRIÈRE DROIT RACCORD EN LAITON RÉGULATEUR SOUPAPE, SOUPAPE, 6500 BTUH 5200 BTUH TUYAU DE COLLECTEUR BOULON DE SOUPAPE CHÂSSIS ETRIER, SUPÉRIEUR MODULE D’ALLUMAGE COMMUTATEURS DE LA VALVE CABLE AVEC CONNEXION ÉLECTRONIQUE FIL DE MASSE ÉLECTRONIQUE CABLE ◆ order by color / iquer couleur N/S not shown in illustration / non-représenté DA-21 7 6 DA-31 / DA31PE 8 11 11 12 12 13 13 15 18 ATWOOD DROP-IN’S 17 17 15 18 21 23 22 19 24 25 29 24 20 25 29 28 31 26 27 28 DA-31PE 32 6 Page 125 of 145 LITERATURE NUMBER .1% L.P. GAS ON DEMAND WATER HEATER Models OD45, OD50, OD55 ENGLISH - FRANÇAIS t*OTUBMMBUJPOt0QFSBUJPOt.BJOUFOBODF Effective ..1 5IJTXBUFSIFBUFSEFTJHOIBTCFFODFSUJGJFECZUIF$BOBEJBO 4UBOEBSET"TTPDJBUJPOGPSJOTUBMMBUJPOJOSFDSFBUJPOWFIJDMFT This water heater is not for use in marine applications. Explanation of Model Number: OD_____________________ On Demand 45________________ Input in 1000’s Btu 01__________ Generation SERVICE CALLS & QUESTIONS -PDBUJPOBOEQIPOFOVNCFSTPGRVBMJGJFE4FSWJDF$FOUFSTDBO CFGPVOEBUPVSXFCTJUFIUUQXXXBTLGPSBUXPPEDPNPSDBMM UPMPDBUFB4FSWJDF$FOUFS mCRITICAL INSTALLATION WARNINGS s )NSTALLINRECREATIONVEHICLESONLY26SARERECREATIONVEHICLES DESIGNEDASTEMPORARYLIVINGQUARTERSFORRECREATIONCAMPING ORTRAVELUSEHAVINGTHEIROWNPOWERORTOWEDBYANOTHERVEHICLE SAFETY ALERT SYMBOLS 4BGFUZ4ZNCPMTBMFSUJOHZPVUPQPUFOUJBMQFSTPOBMTBGFUZIB[BSET 0CFZBMMTBGFUZNFTTBHFTGPMMPXJOHUIFTFTZNCPMT mWARNING BWPJEQPTTJCMF JOKVSZPSEFBUI mCAUTION BWPJEQPTTJCMF JOKVSZBOEPSQSPQFSUZEBNBHF s !LLCOMBUSTIONAIRMUSTBESUPPLIEDFROMOUTSIDETHE26ANDALL PRODUCTSOFCOMBUSTIONMUSTBEVENTEDTOOUTSIDETHE26 s $/./4VENTWATERHEATERWITHVENTINGSYSTEMSERVINGANOTHER APPLIANCE s $/./4VENTWATERHEATERTOANOUTSIDEENCLOSEDPORCHAREA s 0ROTECTBUILDINGMATERIALSFROMmUEGASEXHAUST s )NSTALLWATERHEATERONANEXTERIORWALLWITHACCESSDOOROPENINGTO OUTDOORS mWARNING '*3&03&91-04*0/ s $/./4MODIFYWATERHEATERINANYWAY ÊÊUÊÊÊvÊÌ iÊvÀ>ÌÊÊÌ ÃÊ>Õ>ÊÃÊÌÊvÜi`Ê iÝ>VÌÞ]Ê>ÊvÀiÊÀÊiÝ«ÃÊ>ÞÊÀiÃÕÌÊV>ÕÃ}Ê «À«iÀÌÞÊ`>>}i]Ê«iÀÃ>ÊÕÀÞÊÀÊÃÃÊvÊvi° s $/./4ALTERWATERHEATERFORAPOSITIVEGROUNDINGSYSTEM s $/./4()0/4WATERHEATERUNLESSELECTRONICIGNITIONSYSTEM CIRCUITBOARDHASBEENDISCONNECTED s $/./4USEBATTERYCHARGERTOSUPPLYPOWERTOWATERHEATEREVEN WHENTESTING m %POPUTUPSFPSVTFHBTPMJOFPSPUIFSGMBNNBCMFWBQPST BOEMJRVJETJOUIFWJDJOJUZPGUIJTPSBOZPUIFSBQQMJBODF Do not install close to opening door or under room slide-out where the vent or inlet louvers can be obstructed. WHAT TO DO IF YOU SMELL GAS r &WBDVBUF"--QFSTPOTGSPNWFIJDMF 1-Ê>`Ê >>`>ÊqÊÜÊ>Ê>««V>LiÊÃÌ>ÌiÊ>`ÊV>ÊV`iðÊÊÌ iÊ >LÃiViÊvÊV>ÊV`iÃÊÀÊÀi}Õ>ÌÃ]ÊÀiviÀÊÌÊÌ iÊVÕÀÀiÌÊÃÌ>`>À`ÃÊ v\ r 4IVUPGGHBTTVQQMZBUHBTDPOUBJOFSPSTPVSDF r %0/05UPVDIBOZFMFDUSJDBMTXJUDIPSVTFBOZQIPOF PSSBEJPJOWFIJDMF r %0/05TUBSUWFIJDMFTFOHJOFPSFMFDUSJDHFOFSBUPS r $POUBDUOFBSFTUHBTTVQQMJFSPSRVBMJGJFE4FSWJDF 5FDIOJDJBOGPSSFQBJST — Local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code. — Local codes or, in the absence of local codes, the Standard on Recreational Vehicles, NFPA1192 and/or CAN/CSA-Z240 RV. 1/"1/Ê,iµÕÀiiÌà r *GZPVDBOOPUSFBDIBHBTTVQQMJFSPSRVBMJGJFE4FSWJDF 5FDIOJDJBODPOUBDUUIFOFBSFTUGJSFEFQBSUNFOU OEM and Aftermarket – Unit can be installed in Atwood, Suburban and Girard openings. Unit can also be installed through the wall from exterior, or prior to erecting wall into place at OEM manufacturing facility. r %0/05UVSOPOHBTTVQQMZVOUJMHBTMFBLT IBTCFFO SFQBJSFE Atwood 6 Gallon Opening Suburban 6 Gallon Opening Atwood 10 Gallon Opening* Suburban 10 Gallon Opening* m *OTUBMMBUJPOBOETFSWJDFNVTUCFQFSGPSNFECZB RVBMJGJFEJOTUBMMFSTFSWJDFBHFODZPSUIFHBTTVQQMJFS 12.7 H x 16.25 W x 17.62 D 12.7 H x 12.7 W x 19.2 D 15.75 H x 16.2 W x 20.6 D 16.2 H x 16.2 W x 20.5 D *Door/Adapter Kit Required Page 126 of 145 GENERAL INSTALLATION &SFDUUIFTJEFXBMMTBOEDVUUIFPQFOJOHPSPSJFOUUIF QSFGBCSJDBUFEPQFOJOH'SBNFXJUIuYu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i$0-%uBOEi)05uPSJFOUBUJPO$POOFDUu'. GMBSFE-1HBTMJOFUPu.GMBSFEHBTGJUUJOH *OTUBMMBUJPOJOTUBOEBSEHBMMPOXBUFSIFBUFSPQFOJOHXJUI 4UBOEBSE%PPS,JU B "MMPXGMFYJCJMJUZJOXBUFSBOEHBTMJOFTTPUIFVOJU DBOCFQVMMFEUISPVHIUIFTJEFXBMMPQFOJOHBUMFBTF POFJODIQBTUUIFTLJOBMMPXJOHGPSTFBMJOHTUFQ C "TTVSFUIFXBUFSBOEHBTMJOFHSPNNFUTDPOUJOVF UPCFJOUBDUBOEQSPQFSMZJOTFSUFEJOUIFDBTFIPMFT XJUIOPHBQTPSPQFOJOHTXIFSFUIFMJOFQBTTFT UISPVHIUIFDBTF "EBQUFS /05&6TF1&9PSFRVJWBMFOUUVCJOHSBUFEGPSBNJOJNVNPG P'BUQTJ *OTUBMMBUJPOJOTUBOEBSEHBMMPOXBUFSIFBUFSPQFOJOHXJUI -BSHF%PPS"EBQUFS,JU $PME*O (BT$POOFDUJPO 5PQSFWFOUXBUFSMFBLTDBVMLUIPSPVHIMZBSPVOEUIF CBDLTJEFPGUIFGMBOHFTPWFSUIFMBODFECFOETMPUT$BVML UIFQFSJNFUFSPGUIFPQFOJOHPSTVCTUJUVUFuYu#VUZM 5BQF )PU0VU 1VTIUIFVOJUUPUIFXBMMBHBJOTUUIFDBVMLJOHBOETFDVSF UIFDPSOFSCSBDLFUTCFIJOEUIFVOJUGMBOHFTCVUTOVHUP UIFDPSOFSPGUIFFODMPTVSF$PNQMFUFUIFJOTUBMMBUJPO CZJOTFSUJOHTDSFXTJOBMMUIFGMBOHFIPMFT An “air tight” seal must be the final result. m CAUTION 130%6$5%"."(& (BTDPOOFDUJPONVTUCFNBEFVTJOH580 XSFODIFT UPBWPJEUXJTUJOHBOEEBNBHJOHMJOF Damage voids the Warranty! Page 127 of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u8$NBYJNVNu8$ NJOJNVN1SFTTVSFBUPVUMFUPGWBMWFJTGBDUPSZTFUBU u8$ FOR REPLACEMENT PARTS: r %0/05JOTUBMMBOZUIJOHMFTTUIBOBQSFTTVSFSFMJFGWBMWF DFSUJGJFECZBOBUJPOBMMZSFDPHOJ[FEUFTUJOHMBCPSBUPSZ UIBUNBJOUBJOTQFSJPEJDJOTQFDUJPOPGQSPEVDUPGMJTUFE FRVJQNFOUPSNBUFSJBMTBTNFFUJOHSFRVJSFNFOUTGPS3FMJFG 7BMWFTBOE"VUPNBUJD(BT4IVUPGG%FWJDFTPG)PU8BUFS 4VQQMZ4ZTUFNT"/4*;$4"7BMWFNVTUIBWF NBYJNVNTFUQSFTTVSFnot to exceed 100 psi. (BT.BOJGPMEQSFTTVSFUBQPOCVSOFSBTTFNCMZ Model Btu Manifold Pressure #UV u8$u8$ #UV u8$u8$ #UV u8$u8$ r *OTUBMMSFQMBDFNFOUWBMWFJOUPPQFOJOHQSPWJEFEBOE EFTJHOBUFEGPSUIJTQVSQPTFPOXBUFSIFBUFS r *OTUBMMBUJPONVTUDPOGPSNXJUIMPDBMDPEFTPSJOUIF BCTFODFPGMPDBMDPEFT4UBOEBSEPO3FDSFBUJPOBM 7FIJDMFT"/4*"PS$"/$4";37 mWARNING WIRING INSTRUCTIONS r %0/05VTFNBUDIFTDBOEMFTPSPUIFSTPVSDFTPGJHOJUJPO XIFODIFDLJOHGPSHBTMFBLT The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 and/or the CSA C22.1, Canadian Electrical Code. 5VSOPOUIFHBTBOEDIFDLUIFXBUFSIFBUFSBOEBMM DPOOFDUJPOTGPSHBTMFBLTXJUIBMFBLEFUFDUJOHTPMVUJPO *UJTSFRVJSFEUIBUUIFVOJUCFDPOOFDUFEUISPVHIBTXJUDIUIBUJT DPOOFDUFEEJSFDUMZUPB7%$CBUUFSZPSUPUIFGJMUFSFETJEFPG BO"$%$DPOWFSUFS"WPJEVOGJMUFSFEiMJOFBSuWPMUBHFTPVSDFT '*3&"/%03&91-04*0/ 5VSOPOXBUFSTVQQMZMJOFBOEDIFDLGPSXBUFSMFBLT 6TFBNJOJNVNPGHBVHFXJSF6-BOE$4"-JTUFE3FGFS UPUIFWiring Diagram*OTUBMMBSFNPUFTXJUDIJOBDPOWFOJFOU MPDBUJPO1PTJUJPOUIFXBMMQMBUFXJUIUIFMFUUFSTVQ#FGPSF NBLJOHUIFDPOOFDUJPOTUVSOUIFTXJUDIUPUIF0''QPTJUJPO 13&4463&3&-*&'7"-7& 3&%JT7%$1PTJUJWFQPXFS*/ (3&&/JT7%$(SPVOE #-6&JT7%$1PT-PDLPVU-BNQ4JHOBM 4FFJMMVTUSBUJPOPGUZQJDBMTXJUDIDPOGJHVSBUJPO m WARNING 4$"-%*/(*/+63: #-6&'30.8) -0$,065-".1 r 7BMWFJTOPUTFSWJDFBCMFJUNVTUCFSFQMBDFE r 5BNQFSJOHXJUIWBMWFXJMMSFTVMUJOTDBMEJOHJOKVSZ r 5BNQFSJOHXJUIWBMWFXJMMWPJEXBSSBOUZ 7%$ ("403"/(&'30.8) mWARNING &91-04*0/ r %0/05QMBDFBWBMWFQMVHPSSFEVDJOHDPVQMJOHPOPVUMFU QBSUPGQSFTTVSFUFNQFSBUVSFSFMJFGWBMWF m THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON OTHER THAN REPLACEMENT.5IJTXBUFSIFBUFSJTFRVJQQFEXJUIBQSFTTVSF CAUTION &-&$53*$"-%"."(& r -BCFMBMMXJSFQSJPSUPEJTDPOOFDUJPOXIFOTFSWJDJOHDPOUSPMT 8JSJOHFSSPSTDBODBVTFJNQSPQFSBOEEBOHFSPVTPQFSBUJPO r 7FSJGZQSPQFSPQFSBUJPOBGUFSTFSWJDJOH SFMJFGWBMWFUIBUDPNQMJFTXJUIUIFTUBOEBSEGPS3FMJFG7BMWFTBOE "VUPNBUJD (BT 4IVUPGG %FWJDFT GPS )PU 8BUFS 4ZTUFNT "/4* ;$4" Page 138 of 180 Page 128 of 145 #-6& 3&% 1309 1631-& *(/$0/5 3&% 3&-": 3&% &$0 #-6& '64& $0-%1"$, 41"3,4&/4& MPD 90211 '3&&;& 3&% WIRING SCHEMATIC 3&% (3&&/ 015*0/"- )085001&3"5&:0638"5&3)&"5&3 1631-& 015*0/"- #308/ ("47"-7& 3&% 13&4463&48*5$) 3&% #308/ -0$,065 -".1 (3&&/ 7%$ (306/% GENERAL INFORMATION r -1BOE8BUFSTZTUFNNVTUCFUVSOFEPO mCAUTION r )BWFHBTQSFTTVSFUFTUFEQFSJPEJDBMMZ4IPVMECFTFUBU JODIFTPGXBUFSDPMVNOXJUIUISFFBQQMJBODFTSVOOJOH FIRE r %SBJOXBUFSIFBUFSBUSFHVMBSJOUFSWBMTBUMFBTUPOFUJNF EVSJOHUIFZFBS r %0/05TNPLFPGIBWFBOZGMBNFOFBSBOPQFOGBVDFU *GXBUFSIFBUFSIBTOPUCFFOVTFEGPSNPSFUIBOUXPXFFLT IZESPHFOHBTNBZGPSNJOXBUFSMJOF6OEFSUIFTFDPOEJUJPOT UPSFEVDFUIFSJTLPGJOKVSZPQFOIPUXBUFSGBVDFUGPSTFWFSBM NJOVUFTBULJUDIFOTJOLCFGPSFZPVVTFBOZFMFDUSJDBMBQQMJBODF DPOOFDUFEUPIPUXBUFSTZTUFN r %SBJOXBUFSIFBUFSCFGPSFTUPSJOH37GPSUIFXJOUFSPSXIFO UIFQPTTJCJMJUZPGGSFF[JOHFYJTUT r ,FFQWFOUBOEDPNCVTUJPOBJSHSJMMDMFBSPGBOZ PCTUSVDUJPOT ELECTRONIC IGNITION MAINTENANCE *GIZESPHFOHBTJTQSFTFOUZPVXJMMQSPCBCMZIFBSTPVOETMJLFBJS FTDBQJOHUISPVHIUIFQJQFBTXBUFSCFHJOTUPGMPX r 5IFXBUFSIFBUFSDPNFTGBDUPSZFRVJQQFEXJUIBGVTFE DJSDVJUCPBSEXIJDIXJMMQSPUFDUUIFDJSDVJUCPBSEGSPN XJSJOHTIPSUT*GUIFGVTFTIPVMEBDUJWBUFUIFXBUFSIFBUFS XJMMOPUPQFSBUF#FGPSFSFQMBDJOHUIFGVTFDIFDLGPSBTIPSU FYUFSOBMUPUIFCPBSE0ODFUIFTIPSUJTDPSSFDUFESFQMBDF UIFBNQGVTFXJUIBNJOJ"50TUZMFGVTF%POPUJOTUBMMB GVTFMBSHFSUIBOBNQT 1SFTTVSJ[FUIFXBUFSTZTUFNCZUVSOJOHPOQVNQPSDJUZ XBUFSQSFTTVSF 1VSHFBMMBJSGSPNUIFTZTUFNCZUVSOJOHPOUIFGBVDFUT VOUJMBTUFBEZTUSFBNPGXBUFSGMPXT 5VSOPOUIF7%$QPXFSTVQQMZ r *GUIFGVTFJTHPPEBOEUIFVOJUJTJOPQFSBUJWFDIFDLGPS FYDFTTJWFMZIJHIWPMUBHFUPUIFVOJUNPSFUIBOWPMUT 5VSOPOUIF-1TVQQMZBUUIFUBOLBOEUIFNBOVBMHBT WBMWFJGJOTUBMMFE 5IFXBUFSIFBUFSXJMMSFNBJOEPSNBOU VOUJMBXBUFSUBQJTPQFOFEBOEUIFIFBUFSTFOTFTXBUFS GMPXPGBUMFBTU(1. Winter Operation and Winterizing Water Heater *UJTOPUSFDPNNFOEFEUIBUZPVPQFSBUFXBUFSTZTUFNTJOUIF XJOUFS"OZGSFF[JOHPGUIFXBUFSIFBUFSPSPUIFSQMVNCJOH DPNQPOFOUTDBODBVTFTFWFSFEBNBHFUIBUJTOPUDPWFSFE CZXBSSBOUZFor extended cold temperature use, contact Atwood regarding the OPTIONAL Freeze Protection Kit. 5VSOPOUIFIPUXBUFSUBQUPGVMMPQFO5IFIFBUFSXJMMGJSF VQXJUIJOTFWFSBMTFDPOETBOEIPUXBUFSXJMMGMPXGSPNUIF UBQJOUIFUJNFJUUBLFTUPUSBWFSTFUIFMJOFTGSPNUIFIFBUFS UPUIFGBVDFU*GUIJTJTUIFGJSTUVTBHFZPVNBZIBWFUP UVSOUIFXBUFSPOBOEPGGTFWFSBMUJNFTUPQVSHFUIF-1 HBTMJOFTPGBJS *GUIFIFBUFSGBJMTUPMJHIUPSUIFMPDLPVU MBNQPQUJPOBM JMMVNJOBUFTUVSOUIFQPXFSTXJUDI0'' UIFO0/UPSFTFUUIFJHOJUJPODPOUSPM Winter Operation: 5VSOPGGXBUFSQVNQBOEUIFQPXFSBOEHBTUPUIFIFBUFS 0QFOUIFQSFTTVSFSFMJFGWBMWFCZMJGUJOHUIFIBOEMFUPB QPTJUJPOGSPNUIFOPSNBMQPTJUJPO4VNNFS8JOUFSWBMWF TIPVMECFUVSOFEUPUIFi46..&3u QPTJUJPOIPSJ[POUBM 0QFOESBJOWBMWFUIBUXBTJOTUBMMFE BUIPUXBUFSPVUMFUGJUUJOHPGIFBUFS 5PTIVUPGGUIFXBUFSIFBUFSTIVUPGGUIFXBUFS 4IPVMEPWFSIFBUJOHPDDVSPSUIFHBTTVQQMZGBJMUPTIVUPGG UVSOPGGUIFi0/0'uQPXFSTXJUDI 0QFOBUMFBTUPOFIPUBOEDPMEXBUFSUBQJOUIFDPBDI 5IJTTIPVMEESBJOUIFTZTUFN A Note About “Navy Showers” When Dry Camping *UJTSFDPNNFOEFEUPUBLFBTIPXFSKVTUMJLFZPVXPVMEBU IPNF5IBUJTMFBWFUIFXBUFSSVOOJOHUISPVHIUIFFOUJSF TIPXFS5IFIPUXBUFSTZTUFNJTEFTJHOFEUPEFMJWFSB DPOUJOVPVTDPNGPSUBCMFGMPXPGIPUXBUFSBOEUIBUTUIFXBZJU XPSLTCFTU Winterizing Procedure: #FGPSFTUPSJOHUIFTZTUFNGPSUIFXJOUFSUIFQMVNCJOH TZTUFNNVTUCFXJOUFSJ[FE5IJTDBOCFEPOFCZFJUIFSPGUIF GPMMPXJOHNFUIPET "MMXBUFSTIPVMECFESBJOFEGSPNUIFTZTUFN5PEPUIJT PQFOPOFUBQBUBUJNFVTJOHDPNQSFTTFEBJSUPQVSHFUIF TZTUFNPGBMMXBUFS0ODFQVSHFEPQFOUIF1SFTTVSF 3FMJFG7BMWFBOEMFBWFJOUIFPQFOQPTJUJPO 'PMMPXSFDPNNFOEBUJPOTPGZPVSDPBDINBOVGBDUVSFS6TF 37OPOUPYJDBOUJGSFF[F 4IVUUJOHPGGUIFTIPXFSXJUIUIFTIPXFSIFBECVUUPOXBTUFT XBUFS&BDIUJNFUIJTJTEPOFUIFTIPXFSIFBEiUSJDLMFTuGJMMJOH UIFIPUXBUFSMJOFXJUIDPMEXBUFS5IJTDPMEXBUFSIBTUPCF QVSHFEGSPNUIFMJOFFBDIUJNFUIFTIPXFSIFBEJTUVSOFECBDL PO5FTUTIBWFTIPXOUIBUUIJTXJMMOPUTBWFXBUFS Page 129 of 145 8"5&3)&"5&31"354-*45 17 19 20 18 21 3 1B 1A 2 22 23 24 ITEM 7 25 4 DESCRIPTION 12 5 13 6 14 15 8 9 PART # ITEM 10 11 16 DESCRIPTION PART # B #VSOFS"TTZ#UV 0SJGJDF#UV C #VSOFS"TTZ#UV 0SJGJDF#UV #VSOFS.PVOUJOH#SBDLFU 0SJGJDF,GPS15 *ORVJSF *HOJUFS 1SFTTVSF&MCPX"TTZ 1SFTTVSF3FMJFG7BMWF137 /4 4UBOEBSE%PPS,JUTQFDJGZDPMPS *ORVJSF .PEVMBUJOH7BMWF"TTFNCMZ /4 -BSHF%PPS,JUTQFDJGZDPMPS *ORVJSF (BT7BMWF /4 8JOUFS,JU (BT-JOFm#VSOFS 3FMBZ 8BUFS*OMFU5VCF (BT*OMFU5VCF *HOJUJPO$POUSPM 'MVF0VUMFU4DSFFO 'MVF5VCF 1SFTTVSF4XJUDI #MPXFS"TTFNCMZ 'BO#BTF 'MVF)PPE"TTFNCMZ $BTF"TTFNCMZ )FBU&YDIBOHFS &$0 -PX5FNQFSBUVSF4XJUDI Page 130 of 145 TROUBLESHOOTING .PTUQSPCMFNTBSFFBTJMZSFNFEJFECZDPOTVMUJOHUIFUSPVCMF TIPPUJOHHVJEF*GQSPCMFNTTUJMMQFSTJTUDPOUBDU"UXPPEPSBO BVUIPSJ[FETFSWJDFDFOUFS0OMZBRVBMJGJFEUFDIOJDJBOTIPVMEEP BOZXPSLJOWPMWJOHUIFHBTTZTUFN "QFSJPEJDWJTVBMDIFDLPGUIFCVSOFSGMBNFTTIPVMECFEPOF CZPCTFSWJOHUIFGMBNFUISPVHIUIFiQFFQIPMFuJOUIFIFBU FYDIBOHFS5IFSFTIPVMECFCMVFGMBNFXJUINJOJNVNPSOP ZFMMPXUJQQJOH TPUIBUJUJTOPUJODPOUBDUXJUIBOZUIJOHCVUUIFUFSNJOBM #FTVSFUIBUUIFQPXFSWFOUGBOIBTWPMUTUPJUXIFO UIFSFJTXBUFSGMPXJOHBOEUIFSFBSFOPPCTUSVDUJPOTJOUIF GMVFQJQF 4BGFUZQSFTTVSFTXJUDINBZCFPVUPGBEKVTUNFOU$POUBDU "UXPPEPSZPVSOFBSFTUBVUIPSJ[FETFSWJDFSFQSFTFOUBUJWF No Water Flows From Tap When Tap is Turned on. #VSOFSNBJOUFOBODFTIPVMECFQFSGPSNFECZBO"UXPPE "VUIPSJ[FE4FSWJDF5FDIOJDJBO #FTVSFUIBUXBUFSTVQQMZJTUVSOFEPOBOEUIBUUIFSFBSF OPPCTUSVDUJPOT NOTE: The heater is dormant until it senses water flow. When a water tap is turned on to at least .5 GPM the burner will fire until water flow is turned off and the heater again goes dormant. )PUBOEDPMEXBUFSMJOFTDPOOFDUFEUPIFBUFSBSF SFWFSTFE$PSSFDUCZSFWFSTJOHUIFJSQPTJUJPOT Heater Does Not Come On When The Water is turned on. (Power vent not running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iPGGuQPTJUJPO"OPQFOWBMWFDBO BMTPQFSNJUXBUFSUPCZQBTTIFBUFSDBVTJOHJUOPUUPGJSF There Is No Ignition When Water Is On (Power vent is running) #FTVSFUIFHBTWBMWFBUUIFUBOLJTi0OuUIFSFJTHBTJO UIFUBOLBOEUIFHBTMJOFJTQVSHFEPGBMMBJS #FTVSFUIBUXBUFSGMPXJTBUMFBTUHBMMPONJOVUF $IFDLUIBUUIFJHOJUJPOXJSFJTQMVHHFEJOUPUIFTQBSL UPXFSPOUIFJHOJUJPODPOUSPMBOEJTOPUUPVDIJOHBOZUIJOH FMTF $IFDLGMBNFTJUFIPMFUPTFFJGJHOJUFSJTTQBSLJOHGSPNUIF QSPCFUPUIFCVSOFS#FOEJHOJUJPOXJSFUPBEKVTUUPQSPQFS HBQPSDPOUBDU"UXPPEPSZPVSFOFBSFTUBVUIPSJ[FE TFSWJDFSFQSFTFOUBUJWF $IFDLUIBUUIFSFBSFOPDVUTPSCSFBLTJOUIFXJSF"MJHOJU Burner Turns On But Temperature Fluctuates Erratically. .BZCFDBVTFECZFYDFTTJWFSFTUSJDUJPOBUUIFXBUFS PVUMFUTTIPXFSIFBETBFSBUPSTPSXBUFSTUSBJOFST5IFTF TIPVMECFDMFBOFEBOEBOZTIPXFSIFBEGMPXSFTUSJDUPS SFNPWFE 5IFHBTNPEVMBUJOHWBMWFJTPVUPGDBMJCSBUJPO$POTVMU "UXPPE Heater Comes On But Rapidly Cycles On And Off. 8BUFSGMPXJTUPPMPX*ODSFBTFGMPXBUBUBQ$MFBOBMM BFSBUPSTBOETIPXFSIFBETDSFFOTUPBTTVSFBUMFBTU (1.PGXBUFSGMPX 8BUFSQVNQJTOPUGVODUJPOJOHQSPQFSMZ3FQBJSPSSFQMBDF QVNQ *GUIFIFBUFSDZDMFTBTUIFQVNQDZDMFTBQSFTTVSF BDDVNVMBUPSUBOLJTOFFEFEJOUIFXBUFSTZTUFN*GZPV IBWFBOBDDVNVMBUPSUBOLDIFDLUPTFFJGJUIBTCFDPNF GJMMFEXJUIXBUFS*GJUIBTESBJOJUTPUIBUJUDPOUBJOTBJS POMZ "JSJTJOUIFXBUFSMJOF#MFFEBJSCZUVSOJOHPOBMMXBUFS UBQT Burner Ignites But Water Temperature Is Too Low 5IFXBUFSGMPXNBZCFTPIJHIBTUPFYDFFEUIFDBQBDJUZ PGUIFIFBUFSQBSUJDVMBSMZJGZPVSTVQQMZXBUFSJTWFSZDPME 4MPXUIFXBUFSGMPX 5IFHBTQSFTTVSFNBZCFUPPMPX#FTVSFUIFHBTGMPX DPOUSPMWBMWFJTJOGVMMiPOuQPTJUJPO $IFDLUIFHBTQSFTTVSFXIJMFUIFXBUFSJTPOBUGVMMGMPX 5IF-1(QSFTTVSFTIPVMECFUIFiNBOJGPMEQSFTTVSFu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age 131 of 145 $IFDLUIBUUIFiTVNNFSXJOUFSuWBMWFJTJOUIFQSPQFS QPTJUJPOGPSUIFUFNQFSBUVSFPGUIFJODPNJOHXBUFS Water Temperature Too Low at Lower Water Flow Rates $IFDLUIBUUIFiTVNNFSXJOUFSuWBMWFJTJOUIFQSPQFS QPTJUJPOGPSUIFUFNQFSBUVSFPGUIFJODPNJOHXBUFS #FTVSFUPNPNFOUBSJMZUVSOXBUFSGMPXUPIJHIUIFOCBDL UPUIFMPXFSGMPXXIFOUVSOJOHPOBXBUFSGBVDFU5IJTXJMM CSJOHUIFHBTGMPXUPUIFSFRVJSFEIJHIFSTFUUJOH Water Temperature Is Too Hot or No Temperature Control. 'VFMUBOLSFHVMBUPSJTTFUUPPIJHIBOENBOJGPMEQSFTTVSF BTEFTDSJCFEBCPWF)BWFUIFSFHVMBUPSDIFDLFECZB RVBMJGJFEUFDIOJDJBO $IFDLUIBUUIFiTVNNFSXJOUFSuWBMWFJTJOUIFQSPQFS QPTJUJPOGPSUIFUFNQFSBUVSFPGUIFJODPNJOHXBUFS 8BUFSGMPXUPPMPXGPSJODPNJOHXBUFSUFNQFSBUVSF Low Heat Rise and Excessive Water Flow Is Required To Trigger Water Heater *GZPVGJOEUIBUZPVSIFBUFSSFRVJSFTFYDFTTJWFGMPXUPBDUJWBUFJU NVDIPWFSHBMMPOQFSNJOVUF JUJTMJLFMZUIBUZPVIBWFDPME XBUFSCMFFEJOHJOUPUIFIPUXBUFSTJEFPGZPVSXBUFSTZTUFN $IFDLUIBUWBMWFTBOEGBVDFUTBSFDMPTFEXIFOOPUJOVTF *GUIFSFJTBOPOPGGCVUUPOPOZPVSTIPXFSIFBEBMXBZT UVSOUIFXBUFSWBMWFTPGGBGUFSUIFTIPXFSUPQSFWFOUDPME XBUFSGSPNCMFFEJOHJOUPUIFIPUXBUFSTZTUFN5IJTXJMM LFFQUIFIFBUFSGSPNGVODUJPOJOHQSPQFSMZ #FTVSFUIBUUIFCZQBTTWBMWFBUUIFXBUFSQMVNCJOH DPOOFDUJPOTJTJOUIFiPGGuQPTJUJPO"OPQFOWBMWFDBO BMTPQFSNJUXBUFSUPCZQBTTIFBUFSDBVTJOHJUOPUUPGJSF If any problem persists, contact an authorized service center or Atwood. 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Pump: Four chamber diaphragm design; Self-priming up to 6 ft. suction lift; Pump able to run dry without damage; Removable port to hose connectors. Note: The built-in bypass valve eliminates the need for an accumulator tank. Do not install in a system with an accumulator tank. The tank will interfere with the internal bypass valve. Pump Series 4406-XXX Dimensions - Inches (mm) Height Width Length 3.75 (95) 6.3 (160) 8.2 (208) Weight lb. (kg) 3.9 (1.8) MODEL* VOLTS AMP DRAW @ 10 psi (0.7 bar) FLOW GPM (l/min) PRESSURE SWITCH MAX psi (bar) 4406-143 4406-343** 4406-043** 12V dc 24V dc 115V ac 3.9 2.0 0.4 3.3 (12.5) 3.3 (12.5) 3.3 (12.5) 35 (2.4) 35 (2.4) 35 (2.4) * CE fully suppressed models are identified by a prefix “R” and a CE mark on the label. (i.e. R4406-143). Self Declaration Of Conformance (SDOC) is available upon request. **Not listed with IAPMO or CSA OPERATION With pump switch off, and battery fully charged, fill water tank, open all faucets then turn pump switch on. Water will begin to flow, when water is free of air, turn faucets off, remember you are filling the water heater and the toilet and shower lines. When all valves are shut off pump will stop. Should pump fail to stop, turn switch off and see the trouble shooting guide. This motor pump unit is equipped with a thermal overload protection device. In the unlikely event the motor overheats, the pump will shut off. Turn off power to pump until motor cools. Page 133 of 145 City Water Inlet Water Heater C Water Tank Check Valve A Autofill Tank Valve, Plumb to Tank B Do Not Plumb Autofill to Pump Suction Line Flojet Inlet Strainer INSTALLATION STEP I Remove shipping plugs from Quad pump ports. Some water from factory testing may spill out. STEP 2 Install inlet A and discharge B port connectors. Firmly push slide clips C forward to lock port connectors in place. STEP 3 Slide rubber mounts fully into 4 mounting tracks. STEP 4 Mount pump vertically, with pump head down or horizontally in an accessible location. If mounting vertically, motor up, attach motor mounts first, then pump head mounts, while supporting weight of pump. STEP 5 Use 1/2” I.D. flexible hose (preferably braided or reinforced). Use hose clamps on the slip-on barb hose connectors. STEP 6 Install no less than 3/8” I.D. hose for feed lines to fixtures. Use high pressure hose on all city water lines. STEP 7 Install a Flojet strainer in an accessible location (for inspection and cleaning) between the tank and pump inlet. This strainer or equivalent is required for pump warranty to be valid. NOTE: Do not use with an accumulator tank. Black (–) Red (+) (+) (–) Fuse Switch Battery WIRING STEP I Use 14 gauge stranded wire to 20’, 12 gauge to 50’, from power source. STEP 2 Use a 10-15 amp rated on-off switch on the (+) positive (red) motor lead. STEP 3 Install 10-15 amp fuse or breaker between the power source and the positive lead for the -143 models and a 4 amp fuse for -343 models. Page 134 of 145 TROUBLESHOOTING WARNING: BEFORE SERVICING PUMP, TURN OFF PUMP AND DRAIN WATER FROM SYSTEM!! Failure to Prime - Motor operates, but no pump discharge • Restricted intake or discharge line • Air leak in intake line • Debris in pump • Punctured pump diaphragm (pump leaking) • Crack in pump housing Pump Fails to Turn Off After All Fixtures Are Closed • Empty water tank • Insufficient voltage to pump (low battery) • Punctured pump diaphragm (pump leaking) • Discharge line leak • Defective pressure switch Motor falls to turn on • Loose wiring connection • Pump circuit has no power • Blown fuse or open thermal protector • Pressure switch failure • Defective motor Low Flow and Pressure • Air leak at pump intake • Accumulation of debris inside pump and plumbing • Worn pump bearing (excessive noise) • Punctured pump diaphragm (pump leaking) • Defective motor Pulsating Flow - Pump cycles on and off • Restricted pump delivery. Check discharge lines, fittings and valves for clogging or undersizing. 1 9 2 8 3 5 4 7 Includes items 1 thru 4 Quite often when a pump is worn or defective the one failed component has overburdened others. To avoid frequent aggravating repairs, Flojet offers service kit assemblies making repairs as quick and easy as possible. DISASSEMBLE REASSEMBLE Upper Housing 1. Remove switch (9). Disconnect switch wires. Motor 1. Reassemble lower housing assembly (4) to motor. (Follow steps 4 to 10.) Diaphragm 2. Lower housing is assembled with: • Flat side of diaphragm and outer pistons facing motor • Hex stem of inner pistons must be aligned into hex holes in outer pistons (4). • Outer pistons must be aligned with alignment slots on cam assembly making sure screw holes align in cam assembly, otherwise diaphragm will leak. 3. Tighten cam piston screws partially, center piston in diaphragm, then tighten screws securely (18 in. lbs. torque) Lower Housing 4. Reassemble lower housing assembly (4) to motor. 5. Retighten set screw securely. Set screw head must be positioned facing motor covering seam (indentation). (Positioning of this screw is critical to avoid misalignment and subsequent diaphragm damage.) Upper Housing, Check Valve 6. Reassemble upper housing (1) and slide clips (8) 7. Properly seat O-Ring in check valve assembly (2) and check if ferrules and screen are in place on upper housing (1) 8. Install check valve (2) into upper housing (1) and push in. 9. Assemble on to lower housing (4), align 4 screws on to motor by rotating lower housing (4) if necessary to align feet. 10. Tighten screws evenly to 30 in. lbs. torque. Pressure Switch 1. Place switch against front of pump (9), insert screws and take care not to cross thread or strip out threads in housing. 2. Reconnect wires. Upper Housing 2. Loosen but do not remove four pump head screws and carefully remove upper housing assembly (1) 3. Inspect check valve (2) for debris 4. Reassemble new upper housing (1) Check Valve Assembly Follow step 2 3. Replace check valve (2) 4. Reassemble upper housing (1) Lower Housing, Diaphragm, Motor Follow step 2, then slide rubber foot from mounting track. 3. Rotate lower housing (4) so mounting notch opening on lower housing exposes set screw which holds bearing housing to shaft. 4. Loosen this set screw by inserting wrench 1/8” Allen wrench into mounting notch opening. Then, slide lower housing (4) off motor shaft. Diaphragm Cont’d 5. 5. Loosen four cam piston screws with Phillips head screw driver and pull apart cam from inner pistons. (Pistons should always be replaced when a new diaphragm is installed.) Motor Cont’d 5. Replace Motor Page 135 of 145 AUTOMATIC WATER SYSTEM PUMP SERVICE PARTS KEY# DESCRIPTION 0 Service Kit* 1 Upper Housing With Clips 2 Check Valve Assembly 3 Diaphragm Assembly (includes screws) 4 Lower Housing Assembly 5 Motor Motor CE Models Motor 115 Volt a.c. 6 Quad Port x 1/2” HB. Straight Quad Port x 5/8” HB. Straight Quad Port x 3/4” HB. Straight 7 Pump Head Assembly 8 Side Clips (pair) 9 Switch, Pressure MODEL# 4406-343 20409-043 20404-000 20407-030 20403-040 20419-001 2019-009A R2019-008A — 20381-002 20381-003 20381-006 20406-001A 20408-000 02090-104 4406-143 20409-043 20404-000 20407-030 20403-040 20419-001 2009-034A R2009-034A — 20381-002 20381-003 20381-006 20406-001A 20408-000 02090-104 4406-043 20409-043 20404-000 20407-030 20403-040 20419-001 — — 2029-044A 20381-002 20381-003 20381-006 20406-001A 20408-000 02090-104 *Service Kit includes #2, #3, #8 and drive cam assembly. ACCESSORIES QUICK CONNECT PORT SYSTEM 20381-000 20381-002 QUAD PORT x QUAD PORT x 1/2" MALE QEST. 1/2" HOSE BARB STRAIGHT STRAIGHT 20381-003 20381-026 20381-008 20381-009 20381-024 QUAD PORT x QUAD PORT x QUAD PORT x QUAD PORT x QUAD PORT x 5/8" HOSE BARB 10/13mm HOSE BARB 1/2" MALE QEST. 1/2" HOSE BARB 10/13mm HOSE BARB STRAIGHT 90 ELBOW STRAIGHT 90 ELBOW 90 ELBOW The above part numbers are packaged with 2 fittings per bag. STRAINERS Pump Series Strainer Number Inlet Outlet 4406-XXX 1740-012 1740-002 1740-004 1740-014 1/2 Barb 1/2 Barb 1/2 M Qest 1/2 M Qest Quad Port 1/2 Barb 1/2 M Qest Quad Port Screen 40 40 40 40 Mesh Mesh Mesh Mesh WARRANTY RETURN PROCEDURE FLOJET warrants this product to be free of defects in material and/or workmanship for a period of two years after purchase by the customer from FLOJET. During this two year warranty period, FLOJET will at its option, at no charge to the customer, repair or replace this product if found defective in material or workmanship, with a new or reconditioned product, but not to include costs of removal or installation. Prior to returning any product to FLOJET, call customer service for an authorization number. This number must be written on the outside of the shipping package. Place a note inside the package with an explanation regarding the reason for return as well as the authorization number. Include your name, address and phone number. This is only an overview of our limited warranty. If you would like a copy of our warranty, please call or write FLOJET. U.S.A. Flojet 20 Icon Foothill Ranch, CA 92610-3000 Tel: (949) 859-4945 Fax: (949) 859-1153 © Copyright 2001, ITT Industries UNITED KINGDOM Jabsco/Flojet Bingley Road, Hoddesdon Hertfordshire EN11 OBU Tel: +44 (0) 1992 450145 Fax: +44 (0) 1992 467132 Printed in U.S.A. CANADA Fluid Products Canada 55 Royal Road Guelph, Ontario N1H 1T1 Tel: (519) 821-1900 Fax: (519) 821-2569 All Rights Reserved JAPAN NHK Jabsco Company Ltd. 3-21-10, Shin-Yokohama Kohoku-Ku, Yokohama, 222 Tel: 045-475-8906 Fax: 045-475-8908 GERMANY Jabsco GmbH Oststrasse 28 22844 Norderstedt Tel: +49-40-53 53 73-0 Fax: +49-40-53 53 73-11 Form: 81000-233 02/02 Page 136 of 145 Page 137 of 145 Page 138 of 145 12 Volt 10 Amp SOLAR CHARGE CONTROLLER Item 60031 Item 60021 U ser’s Manual Notice D’utilisation Page 139 of 145 12 Volt 10 Amp Solar Charge Controller Maintain 12V batteries in a fully charged state IMPORTANT SAFETY AND OPERATION INSTRUCTIONS SAVE THESE INSTRUCTIONS The charge controller is designed to protect your 12 Volt Lead-acid battery from being overcharged as well as prevent discharge of the battery during nighttime. This controller reduces overall system maintenance and prolongs the battery life. The LCD Display will display the battery voltage (60031 only). This controller is designed to work with all makes of 12 Volt solar panels. This manual contains important safety and operation instructions for the 12 Volt 10 Amp Solar Charge Controller (Item# 60031, and 60021). Keep this manual with or near the controller at all times. WARNINGS- Working with Batteries RISK OF EXPLOSIVE GAS – Working in the vicinity of a lead acid battery is dangerous. Lead acid batteries contain hydrogen-oxygen gases that can cause explosion and sulfuric acid that can cause severe burns. Always work in a well ventilated area. DO NOT SMOKE, OR ALLOW A SPARK OR A FLAME IN THE VICINITY OF A BATTERY! Remove personal metal items such as rings, necklaces, watches, and bracelets when working with a battery. Be extra cautious to reduce risk of dropping a metal tool on to the battery. The battery may spark or short circuit. NEVER CHARGE A FROZEN BATTERY If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, IMMEDIATELY FLOOD EYE WITH RUNNING COLD WATER for at least 10 minutes. GET MEDICAL ATTENTION IMMEDIATELY. • CAUTION: DO NOT EXCEED THE UNIT’S VOLTAGE AND CURRENT RATINGS: Solar array voltage - MAXIMUM INPUT 23 Volts. Charging current - MAXIMUM INPUT 12 Amps. Failure to comply with above warnings may lead to explosion, and or severe injury. BE SURE TO DISCONNECT THE CONTROLLER FROM BATTERY AND SOLAR ARRAY BEFORE PERFORMING ANY MAINTENANCE OR CLEANING DO NOT DISSASSEMBLE THE CONTROLLER INSTALLATION SHOULD BE PERFORMED BY A QUALIFIED PERSON DO NOT DEVIATE FROM WIRING INSTRUCTIONS Page 140 of 145 CONTROLLER DIMENSIONS 60031 Shown FEATURES • Digital Meter (60031 only) – Battery voltage is shown digitally. • Protect and Maintain battery – Protect batteries from overcharging and maintains batteries in fully charged state. • Safety circuit protection – Reverse polarity protection • Reverse leakage protection – Protect batteries from discharge by solar panel • Temperature Protection– Over temperature protection and auto-resume • Status Lights – Easy reading LED indicators. • Mounting Options – Panel mounting / wall mounting. INSTALLATION The solar controller is designed to be panel mounted or wall mounted. Installation • Panel Mounted - The charge controller may be mounted flush with the wall. Flush mounting requires a rectangular cutout in the mounting surface with sufficient space (2-3 inches) behind to accommodate the controller and wiring. • Wall Mounted - The charge controller may also be mounted to the wall without making a cutout. The controller will be raised from the wall; this is the quickest and easiest mounting procedure. Recommended Battery Capacity: 12V 35AH minimum. CONNECTION PROCEDURES (refer to Connection diagram) • Connect the solar panel positive side to the solar controller ARRAY + (this is marked by a “+” tag) using a suitable wire (Be careful DO NOT short circuit the solar array.) • Connect the solar panel negative side to the solar controller ARRAY – (this is marked by a “-“ tag) with a suitable wire. • Connect the battery positive side to the solar controller BATTERY positive side (this is indicated by a red collar) with either the provided “O” rings or a suitable wire (you may strip the “O” rings from the wire without voiding your warranty). • Connect the battery negative side to the solar controller BATTERY NEGATIVE – with a suitable wire. Page 141 of 145 CONNECTION DIAGRAM 60031 Shown Wire size: - Refer to the “WIRE SIZE” chart below to determine the minimum size wire needed for each connection. When using heavy stranded wire, you may need to divide the ends into two groups and straddle the screw on the terminal block. Any wiring variation of size or length can affect performance of the charge controller Length of Wire AWG Battery Connection Distance round trip (wiring provided) < 0.9m (3ft) 18 Solar Array Connection Distance round trip 6m (20ft) 9m (30ft) 12m (40ft) 16 14 12 OPERATION Once properly mounted and connected the charge controller will start charging immediately given adequate solar power. The 12 Volt 10 Amp Solar Charge Controller is based on a three stage charging algorithm, Bulk Charge Mode, Constant Voltage Mode and Float Mode. • PWM constant-voltage regulation to prevent heating and excessive battery gassing. Pulse charging restores full battery capacity. • Float mode: When the battery was fully charged, the battery voltage will reduce to a lower regulated voltage, in which maintains the battery at full charged state safely. NOTE: The Solar Charge Controller will not initiate charge cycle if battery voltage is less than 4.0 Volts. Page 142 of 145 SPECIFICATIONS Technical Specifications PARAMETERS UNITS ELECTRICAL: Normal input (solar cell array voltage) Volt Max. input solar cell array voltage Volt Peak charging current: Amps Current Consumption when connected 12V Array (Battery not present) Current Consumption when connected 12V battery (Array not present) CHARGING CHARACTERISTICS Max. Bulk charging current Constant voltage for Lead-acid battery Float mode voltage LCD METER DISPLAY: (60031 only) Min. LCD Display Voltage Max. LCD Display Voltage PROTECTION: Over temperature protection starting at (Stop charging) Over temperature protection reset at (Restart Charging) MECHANICAL Controller Dimension Controller overall Height Net weight ENVIRONMENTAL CHARACTERISTIC: Operation temperature Storage temperature Operation humidity range DATA 17~22 23 12 mA 55 max. mA 10 max. Amps Volt Volt 10 14.4 +/-0.4 13.5+/-0.4 Volt Volt 6.0 +/-0.4 19.0 +/-0.4 ºC/°F ºC/°F >85/>185 <65/<149 mm mm g 125 (L) x 65(W) Approx. 27 Approx. 300 ºC/°F ºC/°F -5 to 50 / 23 to 122 -10 to70 / 14 to 158 0 to 80% RH MONITORING LED Indicator The 3 LEDs indicate charging status. These functions are described below. Solar Power Indication (POWER LED - red) ON: OFF: Indicates solar panel properly connected and solar power supplied normally. No power available or insufficient voltage to active charge controller. Charging status CHARGING LED - blue; “Float/Maintaining” CHARGE COMPLETE LED - green LED Status Charging Bulk Charge ON Charge Complete “Float/Maintaining” OFF Conditions Indicates the battery is charging, power from the solar array passes unrestricted through to the battery. Page 143 of 145 Solar power Weak Flashing OFF Indicates the solar panel voltage is too low (insufficient sunlight) Float Charge OFF ON Indicates full charge reached, a small “Float” charge continues to optimize battery when you need Digital LCD meter (60031 only) A digital LCD meter is available on this controller; it will continuously display battery voltage. MAINTENANCE 1. Ensure all wire connections are sound and free from corrosion. Tighten the terminal block screws of the array connections. 2. Visual check of solar array and battery output cabling for signs of overheating, damage and cracking. If any wires show damage, replace with a new wire immediately. 3. The above maintenance is recommended to be carried out at least every 3 months TROUBLE SHOOTING Battery won’t charge: • Solar array may be sized incorrectly. A panel with a larger output is required. You may add on to existing panels by wiring additional panels in parallel with the existing panel. • Usage may be too high. The battery is being drawn upon at a faster rate than the solar array is able to produce. A secondary battery may be used, by physically switching the batteries out and allowing one battery to supply power while the other is being charged. • Battery may be too small. In this case it may appear the battery is not charging however it is the reserve that is depleting too quickly. A battery with a larger capacity may be required. A secondary battery may be used, by physically switching the batteries out and allowing one battery to supply power while the other is being charged. A second battery may also be added to the existing battery by wiring the additional battery in parallel to the existing battery. The charge controller need only be connected to one of the batteries in this case. • The battery may be bad. Small level of charge or discharge will greatly affect the battery voltage. Battery needs replacing. • Wires may be incorrectly hooked to the charge controller. Ensure the wires are connected in parallel to the controller and to the correct terminals. Solar Panel has no output: • The solar panel may be seriously affected by the angle of the panel with regards to the sun, and environmental factors. Ensure the surface is clean and free of dust and build up; a clean damp rag may be used to clear the panel of dust. Do not use soap or solvents of any kind. Cloudy conditions will affect the output of the solar panel. • Wires may be incorrectly hooked to the charge controller. Ensure the wires are connected in parallel to the controller and to the correct terminals. Please refer to the Connection Procedures portion of this manual. Warranty This product is covered by a 1 year limited warranty. Sunforce Products Inc warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of one year from date of purchase To obtain warranty service please contact Sunforce Products for further instruction, at 1-888-478-6435 or email [email protected]. Proof of purchase including date, and an explanation of complaint is required for warranty service. Page 144 of 145
