How To Install an Ibis 3 Air Conditioner

Article by - Caravans Plus

Read Time: 11 mins

The instructions included with the Air Conditioner are fully included below, plus additional notes (shown in italics) made during an original installation, plus photos taken during the installation.

The time taken to install in approximately 2-3 hours with one person, however it is recommended to get assistance by one other person to lift the roof unit onto the roof unless you have a fork lift or similar lifting device.

The photos included show the removal of an existing roof hatch and installation using the same roof hole that was designed to suit an air conditioner, with roof strengthening and power cable already included in the original roof. It would be similar to replacing an old air conditioner.

The Aircommand Ibis 3 air conditioning unit was designed for installation on the roof of a caravan or recreational vehicle to provide reverse cycle heating and cooling. The unit is intended for vehicles with roofs that are from 25 to 85mm thick. The unit must be installed so that it is within +/- 5 degrees of the horizontal plane.

It is important that this installation manual is properly read and understood before installation. The unit must be installed by a qualified tradesperson. Failure to properly install the unit or attempting to modify it in any way can be extremely hazardous and may result in property damage and personal injury.

Aircommand will not be held responsible for problems relating to incorrect or improper installation methods.

Packing list

The components of your Ibis 3 will be contained in 2 cartons. Unpack the carton when you are ready to install and check that the contents are as below:

BEFORE INSTALLATION YOU MUST COMPLETE THE FOLLOWING STEPS

Checked that roof thickness is between 25 - 85mm. If roof is greater than 85mm thick you will need an Ibis 3 Thick roof adapter (Part No 8102007) from Aircommand. Note that this measurement must include any 'H-Frames' used.
'H-Frame' is a steel or aluminium supporting frame that may be needed to strengthen the roof to support the extra weight. They are fixed above the existing roof with the ends extending to the edge of the roof. In many modern caravans or motorhomes strengthening may already be included within the existing roof cavity.

Confirmed that the unit will be within +/- 5 degrees of the horizontal plane.

Roof strength has been assessed.

Position of the unit has been assessed for clearance on the roof and ceiling.

The installation hole will not cut through any wiring in the roof.

Mains power or battery driven inverter power supply has been isolated.

Selected the correct sealant for your application.

Safe work method for lifting unit onto the roof top has been assessed.

Installation must conform to local wiring regulations.
DO NOT attempt to modify or add components to the installation procedure.
This equipment must only be serviced by a licensed refrigeration mechanic.
If your installation varies from the method outlined please contact Aircommand for specialty advice.

WARNING

The unit weighs approximately 46kg, ensure a two person lift or use a mechanical hoist to avoid the risk of injury.
Failure to properly install the unit or attempting to modify it in any way can be extremely hazardous and may result in property damage and/or personal injury.

Aircommand will not be held responsible for issues arising from incorrect or improper installation methods.

INSTALLATION

Mark out the position of the unit based on the following important requirements:

Before cutting holes through the roof ensure that mains power or battery driven inverters are disconnected

The unit requires a 360 x 360mm square hole for installation.

The Ibis 3 should be placed as close as possible to the centre of the caravan or RV so that conditioned air can circulate evenly.

Ensure that the air outlets will not be blowing directly onto obstructions.

Consideration should be given to service access. Ensure that location of hatches, solar panels, antennas etc will not prevent access for service personnel.

The roof MUST be strong enough to support the weight of the unit (46kg). Contact your caravan manufacturer to confirm that this load can be supported by the roof.

EXTERNAL CLEARANCE. The path of the outside fan exhaust must be free. A gap of at least 50mm is required between the roof top unit and any obstructions.Figure 1

External clearances diagram — Figure 1 - Foot print of the roof top air conditioner over 360 x 360mm mounting hole. The area at the back (shown in cross hatch) must be kept free of obstructions.

INTERNAL CLEARANCE The inside plenum has a foot print of 535 x 535 mm centered around the installation hole. Figure 2

Internal clearances diagram — Figure 2- Inside plenum foot print.

The installation hole must be boxed up with material that is strong enough to withstand the compression from the hold down bolts. 20mm wide timber would be required at a minimum.

Contact Aircommand if your installation differs significantly from that prescribed above.

1a. Remove Old Air Conditioner

WARNING
Ensure power is disconnected completely from the Caravan or Motorhome during removal

Removal of all brands begins from the inside of your RV

Remove any screw covers, screws and mounting bolts.

240V disconnection should only be done by a qualified electrician

1b. Remove 360mm square hatch

WARNING
Ensure roof strengthening exists inside roof cavity, if not a 'H-Frame' may be required

Remove Screws — Above - Remove any screws that hold the existing hatch

Remove Existing Seal — Above - Using a sharp knife, break the existing silicone or chalking seal

Hatch removed — Above - Remove existing seal and clean with metho. Note the 240V wiring that was included in the ceiling, but is not yet connected to caravan circuit breaker

1c. Cut installation hole - for new locations

WARNING
There may be electrical wiring located in the ceiling space. Ensure that power is properly disconnected at the supply (mains and/or battery). Failure to do so may result in personal injury or death.

Once the position of the unit has been determined cut out the 360 x 360 installation hole and boxed up.

Ensure that the main power supply for the unit has been led through and is available for connection.

The installation hole must be sealed from the ceiling space to prevent air conditioned air leaking into the ceiling cavity.

2. Attach BLACK weather collar to roof

Locate the weather collar (Item #1).

The collar has one side marked "THIS SIDE UP". This top side will point to the sky. Figure 3

Figure 3 - Top side of weather collar showing THIS SIDE UP also has 4 grey foam strips around each bolt hole

The other side, the underside will be sealed onto the roof. Figure 4

Figure 4 - The underside of the weather collar

Select a suitable sealant for bonding the weather collar to the caravan roof. The collar is made from glass filled Nylon-6,6. Consult your specialist adhesive supplier about the correct sealant to use for your application. Follow all directions on the MSDS particularly those regarding PPE, safe use & disposal.

Apply the recommended sealant to the underside of the weather collar. Figure 5

Flip the weather collar over and firmly press the sealant side to the roof of the caravan.

Apply a circle of sealant around each of the four bolt holes. Figure 6a

Apply sealant to edge of the weather collar where it meets the roof sheet Figure 6b

Figure 6a - Sealant around bolt holes on the top side

Seal roof sheet to weather collar — Figure 6a - Sealant around bolt holes on the top side

If the collar is a sloppy fit inside the hole, secure it in place with 2 corner screws, seal those screws. This makes it easier to centre the roof unit onto the fixed collar

The weather collar is now ready for the roof top unit.

3. Position roof top unit

Use approved methods to lift the unit - 46kg. We recommend 2 people for this step

Position the unit over the 360 x 360mm hole with the weather collar installed. Figure 7

Lower the unit so that it engages with the collar.

Move inside the caravan.

Note position of the electrical power supply entering the 360 x 360 hole. If the roof is thin (25- 30mm) you may have to put a notch in the duct & brace part in order to lead the cable through.

4. Electrical supply

This unit MUST be installed in accordance with AS/NZ 3001:2008 "Electrical installations - transportable structures & vehicles including their site supplies'. Ensure that power is properly disconnected at the supply (mains and/or battery). Failure to do so may result in personal injury or death. This connection can only be done by a suitably licensed electrical tradesperson.

From inside the caravan look up and locate the unit's connection point. Figure 8

Undo the 2 screws securing the connection box. Pull the box out to allow for easier access. Prepare cable, connect conductors to appropriate terminals. Tighten cable gland. Replace connection box and secure with both screws.

Wire connection — Figure 8a - Hard wire connection point

5. Secure unit to roof

Assemble the M8 bolts, washers and hold down bars. (Item #3)

Raise the Duct and brace (Item #2) towards the installed unit.

Insert the M8 Bolt assembly through the corner holes. Figure 9

Engage the bolts into the unit.

Ensure that the hold down bars are aligned with their recess.

Tighten the 4 bolts evenly.
Tighten the bolts to 12 - 14 Nm torque. Do not exceed 14 Nm.
If required #8 x 3/4" pan head screws can be used to further secure the edges of the Duct and brace (Item #2) to the ceiling. Insert screws through the 2 holes on two of the sides.

Figure 9a- Assemble Bolt, washer & bar into duct & brace

Tighten bolts — Figure 9a- Assemble Bolt, washer & bar into duct & brace

6. Connect return air duct

Reach up between the diagonal arms of the duct & brace. Grasp the white plastic collar on the end of the concertina duct.

Pull the collar downwards until it engages with the central duct. Figure 10

Pull until the collar snaps into place with the 4 catches on the diagonal arms.

Connect duct — Figure 10a - Engage central duct

7. Attach plenum assembly

Locate the Plenum assembly (Item #4) and remove the filter (Item #5). See Figure 16

Locate 4 of the M4 x 25 metal threads

Connect the control cable that leads from the plenum to the roof top unit. Ensure the plug mates with the socket and catch is engaged. Figure 11

Connect harness — Figure 11a - Connect control cable

Raise the plenum assembly towards the roof top installation.

Engage a M4 x 25 metal thread into one of the 4 holes in the corner of the filter recess.

Raise the plenum and engage the screw into its mating hole on the diagonal arm of the brace. Figure 12

Repeat for 3 other threads.

Tighten screws until the plenum has been pulled up to the ceiling.

Figure 12a - Connect plenum cover to brace arms with 4 M4 x 20 metal threads

In some installations the ceiling may be uneven and one or more sides of the plenum will require additional fixtures. Figure 13

IF REQUIRED .....

Screw in #8 x 1/2" countersunk wood screws provided.

Tighten until gap is gone.

Install cover caps.

Figure 13 - Extra screws to close gap around plenum

8. Install return air filter

Locate the return air filter. (Item #5).

Align the tabs on one side of the filter body with matching slots in the plenum. Insert the filter into the recess in the plenum. Figure 14

Figure 14 - Insert filter tabs into slots

Push the filter upwards until both catches engage and hold the filter in place. Figure 15

Inside view of fitted — Figure 15 - Push upwards

Your Installation Is Now Complete

To remove the filter
1. Push both tabs inwards
2. Swing down

Air Conditioner fitted to the roof — Above - The completed installation, cleanup roof and test unit.

Was this helpful?

3 Comments

Greg


not sure if its normal but whenever the power supply is switched on the aircon starts by itself, this is a problem as I leave the power connected while it is stored in a shed and whenever there is a blackout and the power is restored the a/c starts is there a fix for this thanks

17 Feb 2020 (8:59 pm)

0 1
Dirk


How does the H frame installation work? measurements etc

1 Nov 2020 (10:07 pm)

17 3
Dirk


I want to make a H Frame out of Stainless steel can I get measurements for one or do I have to buy galvanized?

1 Nov 2020 (10:12 pm)

0 7