C4000 Cave Wave Air Command Air Conditioning Unit Instructions

C4000 Cave Wave Air Command Air Conditioning

Specifications

• Model: C4000, C4050, C4080
• Input Voltage: DC12V/24/48V
• Operating Current: 20A-60/10-33/5-18A
• Cooling Capacity: 9000/10000/11000 BTU
• Air Flow Rate: 250 CFM
• Rated Power: 650/750/850W
• Refrigerant: R410a 425g
• Noise Level: Eco mode: 45dB, Boost mode: 56dB
• Roof Unit Dimension: W35.4 x L35.8 x H7.1
• Air Distribution Box Dimension: W20.5 x L19.7 x H2.0
• Weight: 75Ib

Product Usage Instructions

Installation Guidelines

BEFORE INSTALLATION: It is crucial to follow the recommended guidelines for installation to prevent any issues. Cave Wave will not be responsible for problems arising from incorrect installation methods. Ensure that the installation instructions have been properly read and understood. Installation must conform to Local wiring codes and regulations or, in the absence of local codes, the Standard on Recreational Vehicles, NFPA 1192. and National Electrical Code NFPA 70. DO NOT attempt to modify or add components to the installation procedure. This equipment must only be serviced by a licensed refrigeration mechanic to maintain warranty coverage. If your installation varies from the method outlined please contact Cave Wave for specialty advice.\ Cave Wave will not be held responsible for problems relating to incorrect or improper installation methods.

GENERAL INFORMATION

PURPOSE
This Cave Wave Air Command air conditioning unit is designed for installation on the roof of a recreational vehicle, trailer, or a truck to provide cooling for your vehicle.

• The roof must be capable of supporting the weight of the unit which is 75lbs.
• The absolute minimum thickness of the roof must not be less than 1 inch (25mm).
• The maximum thickness of the roof must not exceed 5 inches (125mm).
• Trimming of the duct work and/or bolts may be necessary depending on the roof thickness.

It is important that the unit is installed properly and according to the recommended guidelines.

ENSURING EFFECTIVE OPERATION
The effectiveness of the air conditioner is dependent on several factors e.g. size and heat load of the vehicle. When a Cave Wave unit is installed, Cave Wave assumes that thevehicle is well insulated with 1 inch (25mm) foam minimum in all walls and roof, that the windows are of moderate size (preferably double glazed) and the roof vents are airtight when closed.

Other methods of reducing heat load include:

• Closing all doors, hatches, windows and blinds
• Turning off appliances that might increase the heat load
• Ensuring the vehicle is parked in a shaded position. In periods of extremely high temperature, it’s recommended to start the air conditioner earlier in the morning to greatly improve its ability to cope with the expected high heat load.

CONDENSATION
In areas of high humidity, the humid air within the RV will cause “sweating” or condensation in parts of the unit as the humid warm air contacts the colder air discharge system. If this occurs please ensure the following:

• Closingall doors, hatches, windows and blinds to limit theingress of warm humid air.
• Increase the Fan Speed to increase airflow and reduce the condensation.

Main Components
The unit comprises various components including the air distribution box, roof unit, and more. Ensure proper positioning and clearance as specified in the manual.

INSTALLATION POSITION

GENERAL SPECIFICATIONS

Overall Dimensions

• Height – 9.1 inch
• Width – 35.4 inch
• Length – 35.8 inch

TOP VIEW

BOTTOM VIEW

Model

| ****

C4000,C4050,C4080

---|---

Input Voltage

| ****

DC12V/24/48V

Operating Current

| ****

20A-60/10-33/5-18A

Cooling Capacity

| ****

9000/10000/11000 BTU

Air Flow Rate

| ****

250 CFM

Rated Power

| ****

650/750/850W

Refrigerant

| ****

R410a 425g

Noise Level

| Eco mode: 45dB Boost mode:56dB

Roof Unit Dimension

| W35.4” x L35.8” x H7.1”

Air Distribution Box Dimension

| ****

W20.5” x L19.7” x H2.0”

Weight

| ****

75Ib

Ensuring Effective Operation
To ensure optimal performance, factors like vehicle insulation, window types, and heat load need to be considered. Proper insulation and minimizing heat load will enhance the air conditioner’s efficiency.

Condensation Management
In high humidity areas, condensation may occur. To reduce this, ensure proper ventilation by closing doors and increasing fan speed to enhance airflow and minimize condensation.

Unit Installation
Follow the detailed instructions provided in the manual for installing the Cave Wave air conditioner on the roof of your recreational vehicle, trailer, or truck. Pay attention to roof thickness, weight support, and necessary trimming of duct work and bolts. Before beginning, mark out the position of the unit considering the following important re- quirements:

• The air conditioner should be situated as ascentrally as possible on the vehicle, to ensure even air distribution.
• The front of the unit MUST face the direction of travel; failure to follow this instruction will result in damage to the condenser fans.
• When considering the installation position remember to check for clearance around the plenum inside the vehicle.
• Avoid an installation position where a bulkhead, cupboard or light fitting could interfere with the discharge air flow from the plenum.

CAUTION

• Contact Cave Wave if your installation differs significantly.

ASSESS ROOF STRENGTH

• The roof members MUST be strong enough to support the weight of the unit 75 lbs without any roof deflection that will cause”pooling” of water around the unit. Contact your RV manufacturer to confirm the max load theroof is able to handle. If in any doubt considerthe use of an external “H” frame.
• If the roof does not have an existing hole one must be cut.
• Contact your RV manufacturer for the best method to cut through the roof.
• The square hole in the roof (14″ x 14″) MUST be boxed up with the gasket to provide a structure strong enough to withstand the compression of the installation bolts. This is also to ensure that air is not drawn from the roof cavity (Fig 3 & 4).
• Longitudinals MUST be fixed securely to the transverse roof members to transfer load (see Fig 3).

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

TIP: Always use crawl boards across the roof to avoid damage

POSITION UNIT ON ROOF

• Remove the air conditioner from the carton.
• Position the unit over the gasket so that the corners of the square hole in the RV roof line up with the corners of the square hole underneath the air conditioner.

TIP: Have one person inside the RV looking through the hole while the other is on the roof adjusting the position of the unit.

CUT FROM THE ROOF

• If the roof does not have an existing hole one must be cut.

To layout locations measure from references that are identifiable from both inside and outside. Use the gasket as a template to find a location between the crossbeams.

NOTICE: Crossbeams may not shown on the outside of the rooftop.

• Under the roof, use the gasket as a template to mark the inner edge of the gasket to draw a 14″ x14″ square, and drill four indicator holes in each corner of the square.
• On top of the roof, use the holes as a guide to line up the gasket, and trace around the edge again. Use tape to mark, and follow the trace lines cut through the ceiling.
• Tossed the cutout and used a hand file to deburr the edges.
• Spray paint on the perimeter to seal up the exposed metal and side.

NOTICE: Stay well clear of tanks, fuel lines, and wiring.

NOTICE: Be careful cutting the top. The steel is thin and unbraced enough that the blade will try and pull it to flex or bend.

TIP: Always use crawl boards across the roof to avoid damage

• Clean the mating surface, lay down thick adhesive sealant, and then place the gasket on the top and position it correctly around the hole.

NOTE: Laid down sealant carefully, and selected goop that is non-reactive to the metal roof.

CAUTION
The unit weights approximately 75lbs. Ensure a two person lift or use a mechanical hoist to avoid the risk of injury.

• DO NOT slide the unit on the roof, this may damage the gasket and result in leaks.
• Grab the bottom two sides of the unit to lift it, and place it over.
• Four M8 mounting holes on the chassis underneath the air conditioner will line up with- the corners of the square roof hole.

ATTACH ADAPTER TO UNIT

• Screw adapter to the underside of unit with the 4 screws provided (this step can also be done before the unit is positioned on the roof but be careful not to damage it while fitting)

WARNING
Ensure that power is properly disconnected at the supply (mains and/or battery). Failure to do so may result in damage to the unit and personal injury or death.

CONNECT ELECTRICAL SUPPLY
Installation must conform to local wiring codes and regulations or, in the absence of local codes, the Standard on Recreational Vehicles, NFPA 1192. and National Electrical Code NFPA 70.

• Connect DC power supply to wire leads from roof unit.

NOTE:

• Overheat protection: Red wire connector with 2 white wires
• Thermostats connector: White wire connectorwith 2 black wires
• Motorized directional vents: 5-Pin-Connector with 5 wires(blue, pink, yellow, orange, red)
• Power control: 4-Pin-Connector with 4 wires (purple, green, black, red)
• Evaporator fan: 6-Pin-Connector with 4 wires (blue, white, black, pink)

NOTICE: The 6-Pin connector only has 4 wires.

• Connect the red wire connector from rooftop unit to the red connector on the board.
• Connect the white wire connector from rooftop unit to the white connector on the board.
• Connect the 6-Pin-Connector to the 6-Pin Connector on the board.
• Connect the 4-Pin-Connector to the 4-Pin Connector on the board, this 4-Pin-Way socket is beside a 2-Pin-Connector that is not used in this unit.
• Connect the 5-Pin-Connector to the 5-Pin Connector on the board.

NOTICE: the diagram is not drawn to scale, and only intended to indicate the positions and directions of the connections.

WARNING
Ensure that power is properly disconnected at the supply (mains and/or battery). Failure to do so may result in damage to the unit and personal injury or death.

Refer to the connection diagram below.

ASSESS ROOF THICKNESS
Measure the roof thickness and consult the table to check if adjustments to the hold down bolt and duct length are required.

CAUTION
Failure to cut the duct properly can result in an incorrect seal which will adversely affect the units performance

Roof Thickness

-Inch (mm)

–Include ‘H’frame if used.

| Duct length required

– Inch(mm)

| Hold down bolt length required

–Inch (mm)

---|---|---
4.92 (125)| 5.71 (145) as

supplied

| As supplied
3.94 (100)| 4.72 (120) – Cut

.98 (25)

| As supplied
3.15 (80)| 3.94 (100) –

Cut1.77 (45)

| As supplied
2.36 (60)| 3.15 (80) – Cut 2.56 (65)| Cut 1.97 (50)
1.57 (40)| 2.36 (60) – Cut 3.35 (85)| Cut 2.76 (70)
1.0 (25) (absolute minimum)| 1.57 (40) – Cut 3.94 (100)| Cut 3.35 (85)

ASSEMBLE DUCT

• Thread a hold down bar onto the M8 bolt and push the bolt almost all the way into the hole in each corner of the brace.
• Leave a gap between the hold down bar and the recess in the plastic brace. This will allow for easier engagement with the four corresponding threaded holes in the unit.
• Turn the assembly over and add the extension duct to the top of the assembly if needed.
• Avoid tearing or ripping the duct apart.

CAUTION
When attaching the duct to the unit take care to ensure it forms a tight, unbroken seal that doesn’t allow discharge air to escape.

CAUTION
When attaching the duct to the unit take care to ensure it forms a tight, unbroken sealthat doesn’t allow discharge air to escape.

ATTACH DUCT TO UNIT

• Raise the brace assembly and slip the extension duct over the outside diameter of the adapter underneath the rooftop unit.
• Engage and tighten the four M8 bolts with the threaded inserts in the rooftop unit.
• Recommended tightening torque of the bolts is 7 N.m (5.2 lb-ft). As a rough guide the bolts should be tightened so that the unit compressesthe roof seal gasket to approximately half its height.
• As the bolts are tightened ensure that the hold down bars slot into their recesses in thebrace.

CAUTION
When attaching the duct to the unit take care to ensure it forms a tight, unbroken seal that doesn’t allow discharge air to escape.

ATTACH PLENUM COVER -Secure the
main plenum cover to the duct assembly with the 6 screws provided (see picture).TIP: It is important that these screws are not over-tightened otherwise the plenum may crack.

• Place the air filters by sliding them into the plenum until they click into place
• Attach control panel, place the panel by pushing them into the air filters until they click into place
• Your installation is now complete.

MAINTENANCE

PLENUM FILTERS
The plenum filters are the only parts that require routine maintenance. They must be cleaned periodically to ensure that they do not become clogged with dust and other particles and are not covered by Warranty. The state of the filters can be ascertained from its appearance; the filters are translucent, and if they appear clogged, then they should be cleaned. Generally, the filters can be cleaned sufficiently by tapping them together to shake loose the dust and particles trapped inside. If a more thorough cleaning is required, then the filters can be washed out using warm, soapy water. Care must be taken to avoid ripping the fabric. The filters should be cleaned every two weeks or more when in use. Prolonged use, higher concentrations of airborne particles, and various other factors may result in the filters needing to be cleaned more often.  Replacement filters can be ordered directly from Cave Wave.

MOUNTING BOLTS
Cave Wave suggests that the hold-down bolts are initially checked for tightness within the first three months of installation and thereafter every 12 months if the vehicle is in constant use.

WARNING
Airborne particles can pose a health risk, particularly to young children and the elderly. Ensure that filters are cleaned in a safe and well-ventilated area.

WARNING
Airborne particles can pose a health risk, particularly to young children and the elderly. Ensure that filters are cleaned in a safe and well-ventilated area.

STORAGE
The air conditioner should be run on a routine basis to ensure the components remain in working order. If the vehicle is in storage or is to remain unoccupied for an extended length of time it is recommended that the air conditioner is allowed to run uninterrupted for 20-30 minutes once every six months.

OPERATING INSTRUCTIONS FOR A

CONTROL PANEL

1. POWER ON/OFF

2. Short press to turn on the unit. Long press three (3) seconds to turn off the unit, and

3. long press ten (10) seconds to restart to factory default setting.

4. MODE SETTING
   Press to switch between the operation mode as follows:

5. Output from low to high output: Sleep, Eco, Cooling, Turbo.

6. The mode only changes compressor speed. Fan Speen can be adjusted separately.

7. TEMPERATURE SETTING
   Press to decrease or increase the set temperature.

8. FAN SETTING
   Press to decrease or increase the fan speed.

9. ERROR CODE DISPLAY
   Should there be any fault happen with the main board, the relevant error codewill be shown on the temperature display area and flashes. If there is multiple faults happen at the same time, the error code will be shown one after another. System will alternate the display of error code and room temperature.

Depending on the model of the main board, the error codes available are:

Remote control operation manul
Notice: This is a general-purpose remote. Some button do not apply to this model.

SWITCH DISPLAY UNIT °C/°F
This feature is only available to units that come with a display remote control. When the unit is powered off, on the remote control, short press the mode button and down arrow button at the same time. The display unit on the remote will switch. Turn on the unit with the remote and the unit on the display panel will sync with the remote.

VOLTAGE PROTECTION
Low-voltage protection will auto-shut off the unit when the supplied voltage is lower than the cut-off voltage and the low-voltage red light will light up. The unit will turn on automatically once the supplied voltage is higher than the recover voltage.

EDIT LOW VOLTAGE PROTECTION
Long press the Mode Switch to edit low voltage protection. Press Fan Speed + to increase cut-off voltage. Press Fan Speed – to decrease cut-off voltage. Press Temperature + to increase recover voltage. Press Temperature – to decrease recover voltage.

TROUBLESHOOTING

CONTROL PAD WILL NOT ILLUMINATE WHEN ON/OFF BUTTON IS PRESSED

• Check the circuit breaker is on
• Control cable may be unplugged between outside unit and inside fascia
• Check the power supply to the vehicle

UNIT DOES NOT COOL

• Check the circuit breaker is on
• Control cable may be unplugged between outside unit and inside fascia
• Check the power supply to the vehicle

INSUFFICIENT COOLING CAPACITY

• Ensure return air filters are clean
• Operate the unit on high fan speed to obtain maximum capacity
• Ensure all windows, doors, skylights and hatches are closed and curtains/awnings are used to reduce heat load, check for adequate insulation in the roof & walls

SMALL RATTLING NOISE

• Small rattling noise may be noticeable due to inconsistent temperature within the refrigerant. Increase the fan speed to mitigate the issue.

Location and phone numbers of qualified Service Centers can be found at our website http://www.cavewave.com

1345 Dry Creek Dr #B Longmont,
Colorado, USA 80503
Please Visit: WWW.CAVEWAVE.COM

The latest electronic version of this document is available for download on the product page. We wish you enjoy your Cave Wave air conditioner. For any product questions or issues, you can reach out to us at www.cavewave.com.

FAQ

Q: Where can I find the latest version of the operation manual?
You can download the latest electronic version of the operation manual from the product page on our website at www.cavewave.com.

Q: What should I do if I encounter condensation issues?
If condensation occurs due to high humidity, ensure proper ventilation by closing doors and increasing fan speed to reduce condensation buildup.

Q: How can I improve the efficiency of the air conditioner during extreme heat?
To enhance efficiency during extreme heat, start the air conditioner earlier in the morning and follow other heat load reduction methods like parking in shaded areas and turning off heat-generating appliances.

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