CARRIER TRANSICOLD AIRV 68RV11112A (01) PDF Document

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands clear of the evaporator blower and condenser fan.

No work should be performed on the unit until all circuit breakers and start-stop switches are turned off, and power supply is disconnected.

Always work in pairs. Never work alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator blower & condenser fan. Do not remove the ceiling grill assembly or the upper unit cover assembly before turning the power off, and disconnecting the power supply. Before disconnecting, discharge capacitors by shorting across the capacitors terminals.

When disassembling wiring, use numbered stickers to identify wire leads and terminals. This aids in quick, accurate reassembly.

Be sure power is turned off before working on motors, controllers, or electrical control switches. Tag any circuit breakers and power supply to prevent accidental energizing of circuits.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed and any necessary repairs must be performed by qualified service personnel.

In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).

Use dry nitrogen to pressurize the system for leak checking. Be careful not to exceed 150 psig test pressure in the hermetic compressor.

Coil fins are sharp. Use care when removing the cover form the base pan to avoid personal injury.

Oil vapor in piping stubs can ignite from torch flame and cause serious injury. Exercise extreme care when brazing, and keep brazing cloth and fire extinguisher handy for emergency use.

Disconnect power to the AirV unit before checking the capacitor.

Refrigerant Charge

Standard – High Capacity – Heat Pump: R-22 15.9 Ounces

Low Profile (All): R-22 16.9 Ounces

Compressor – 115 Volts, 60 Cycles, 1 Phase

Note: AirV Compressor mounting bolts must be torqued 15/17 ft./lbs.

1. Locked Rotor Amps – Standard – High Capacity – Heat Pump: 60.0 AMPS

2. Locked Rotor Amps – Low Profile High Capacity: 59.0 AMPS

3. Fully Loaded Amps – Standard: Cooling – Approximate 12.8 AMPS, Heating – N/A

4. Fully Loaded Amps – High Capacity: Cooling – Approx. 14.1 AMPS, Heating – Approx. 11 AMPS

5. Fully Loaded Amps – Low Profile: Cooling – Approx. 13.4 AMPS, Heating – Approx. 13.8 AMPS

6. Fully Loaded Amps – Heat Pump: Cooling – Approx. 12.9 AMPS, Heating – Approx. 13.8 AMPS

Compressor – 220 Volts, 50 Cycles, 1 Phase

1. Locked Rotor Amps: 23.6 AMPS

Thermostat Range (All Free Blow Units)

61° F (16° C) to 89° F (32° C)

This operation effectively eliminates moisture by operating the compressor and fan motor intermittently, so that the room temperature is maintained at set temperature. The compressor will be “on” for 5 minutes, then “off” for 5 minutes. The system fan motor will operate on low speed.

Note: The unit determines Dry Mode by sensing Room Temperature every 5 minutes (a 3-minute minimum operation of the compressor is not applied).

No. The addition of a heat strip requires a new ceiling assembly (Pt# 99-00469-02). The Master Switch and Thermostat have additional functions to accommodate heat. The Thermostat is dual position (SPDT) contacts as opposed to single position (SPST).

The heat strip is secured for shipping purposes. Remove the heat strip, flip it over and mount it in the airflow. When properly installed in this manner the interface cable will reach.

The system has locked out due to “Compressor Circuit” being interrupted for an abnormal reason during operation. This can be caused by power interruption or voltage drop (Brown-Out). The electronics monitor the voltage to the unit and will lock-out for safety. To ‘re-set”, disconnect the 12 VDC from the electronic controls for 15 seconds and re-connect. If the alarm comes back in, check the 115 VAC with an amp meter to determine if the unit amp draw (with compressor and fan running) is within specifications according to the unit model.

Check to see if filters are clean. Once cleaned, take the temperature of the air going into the filters and compare it to the air temperature coming out of the unit (if ducted, take the reading as close as possible to the unit air outlet). The temperature difference (Delta-T) should be 20 to 25 degrees. This test requires the interior temperature to be warm enough to provide a good heat load to the air conditioning system. If the interior temperature is cold, the temperature drop may not be as high as 20 to 25 degrees. If the temperature drop is not as described above, take an amp draw on the unit’s 115 VAC and compare it to the correct model specifications.

There is a temperature sensor probe that should be inserted into the indoor (evaporator) coil at the time of installation. It needs to see a temperature drop within 5 minutes of compressor start-up to confirm proper operation. Check to see if the probe has been inserted into the coil and if it is properly inserted. The probe is 2.5 to 3 inches in length with 2 brown wires.

The manual control Thermostat on a freeblow ceiling unit is 61 to 89 degrees F.

Yes, the Freeblow unit is designed to have the fan run continuously.

The blinking red light indicates that 12 VDC is installed and powered to the unit controls. If there is no light blinking, the unit controls will not operate the 115 VAC equipment.

Each unit should have a dedicated 20 Amp (12 gauge wire with ground) protected circuit.

Not necessarily. Heat strips manufactured after 3507Y are equipped with a manual reset overload protector. Remove required components to access the electrical connections at the heat strip assembly. On the back of the overload protector, there is a “RED” reset button. Push the button in until it clicks to reset. If no reset button is present the unit was manufactured prior to 3507Y. Check the element for an open circuit or a resistance value of 9 Ohms.

If your unit has no power, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Master switch off

2. Open circuit breaker

3. Defective wiring

4. Loose electrical connections

5. Faulty switches, thermostat, or fan

6. 12 VDC not connected (Ducted System)

7. 12 VDC in-line fuse open (Ducted)

Probable Remedy:

1. Reset master switch

2. Reset circuit breaker

3. Replace wiring

4. Tighten connections

5. Replace defective components

6. Connect to 12 VDC power source

7. Replace fuse

If the ducted unit will not operate, check the following:

Symptom and Probable Cause:

1. Display not illuminated

2. Display illuminated

Probable Remedy:

1. Check 12 Volt DC in-line fuse

2. Check 115 Volt AC Connections

If the ducted unit will not cool, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Green LED light flashes 5 times

2. Unit cools for a few moments then stops cooling

Probable Remedy:

1. Check 115 volt AC power source. Momentarily disconnect 12 VDC power source. Disable compressor malfunction test switch. Check AMP draw. Check Δ T.

2. Remove grill, verify evaporator coil probe is inserted into coil. Check AMP draw. Check Δ T. Replace unit.

If you suspect an open compressor power supply, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Loose leads at compressor terminals

2. Defective motor overload switch

3. Defective capacitor

4. Open compressor windings

5. Seized compressor

6. Capacitor incorrectly wired

Probable Remedy:

1. Tighten leads

2. Replace switch

3. Replace capacitor

4. Replace compressor

5. Replace compressor

6. Verify capacitor wiring (Refer to wiring diagram)

If the compressor runs but cycles and the fan operates erratically, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Loose lead at fan motor

2. Defective or burned out motor

3. Outdoor air restricted or recirculating

4. Overcharge or noncondensables in system

5. Restricted discharge line

6. Defective motor overload switch

Probable Remedy:

1. Tighten lead.

2. Replace motor.

3. Check for dirty condenser coil, proper clearance around unit, remove any obstructions.

4. Check AMP draw

5. Check for obstruction in line. Check Δ T. Replace unit.

6. Replace switch.

If the unit is cycling on compressor overload, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Defective run capacitor

2. Defective compressor bearings or valves

3. Greatly restricted evaporator air, iced evaporator coil.

4. Low refrigerant charge

5. Evaporator capillary restricted

6. Liquid line restricted

7. Compressor hot

8. Weak or inconsistent line power

Probable Remedy:

1. Replace capacitor.

2. Replace unit.

3. Defrost evaporator coil.

4. Replace unit.

5. Replace unit.

6. Replace unit.

7. Verify refrigerant charge. Check AMP draw. Check Δ T.

8. Check line voltage at time of compressor start-up.

If you are experiencing insufficient cooling, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Dirty evaporator coil

2. Iced evaporator coil, slightly low refrigerant charge

3. Improper fan operation

4. Defective fan motor

5. Return air filter is dirty

Probable Remedy:

1. Clean as required.

2. Defrost or Recharge.

3. Verify fan rotation (Refer to wiring diagram)

4. Replace fan motor.

5. Remove and clean filters

If condenser air is not adequate, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Outside Air Restricted

2. Dirty coil

3. Defective fan motor

Probable Remedy:

1. Check for obstruction at coil. Remedy as required.

2. Clean coil.

3. Replace fan motor.

If the heater is cycling on the limit switch, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Dirty filter

2. Blocked evaporator air inlet (indoor)

3. Low airflow due to fan motor speed

Probable Remedy:

1. Clean or replace filter.

2. Remove blockage.

3. Check fan motor. Repair or replace as necessary.

If the air sweep is not working, check for the following issues and apply the corresponding remedy:

Symptom and Probable Cause:

1. Ceiling grill not properly aligned

2. Linkage in upper control box stuck

3. Air sweep motor failure

Probable Remedy:

1. Align ceiling grill.

2. Align and lubricate linkage.

3. Replace motor.

If water is dripping from the ceiling unit, verify the vehicle is level. Tighten the unit mounting bolts evenly or replace the unit gasket.

If you have no heat from the heat strip, verify the AMP draw (13.8 AMP), verify resistance through the heating element (9 OHM), and check the bi-metal switch. If the switch is open, replace it.

Note: Allow the unit to operate 15 minutes after switching from cooling mode.

Symptom and Probable Cause:

1. Reversing valve not operating

2. Outdoor coil icing.

Probable Remedy:

1. Check for 115 volts at reversing valve coil. Check for reversing valve restriction. Verify compressor operation.

2. Check outdoor coil sensor.

When a repair has been accomplished due to a corresponding alarm, the alarm must be cleared. This is done by disconnecting the 12 VDC power to the ducted ceiling assembly for one or two seconds. Once the 12 VDC power is reconnected, the alarm should have been cleared.

The system self-diagnostics function indicates errors through a series of flashes. Refer to the table below to understand the error codes and allowed modes of operation. Note: If more than two errors occur, the highest ranked code is displayed. If the highest ranked error is cleared, the next highest ranked error code is displayed.

Flashes	Error Codes (Priority)	Error Contents (Malfunction)	Allowed Modes
2	1	ROOM AIR THERMISTOR FAILURE	FAN Mode
3	2	INDOOR COIL THERMISTOR FAILURE	FAN Mode, FURNACE Mode
4	3	OUTDOOR COIL THERMISTOR FAILURE	FAN Mode, FURNACE Mode
5	4	COMPRESSOR DRIVE MALFUNCTION	FAN Mode, FURNACE Mode
6	5	REVERSING VALVE DRIVE MALFUNCTION	FAN Mode, FURNACE Mode
1	6	DISCHARGE AIR THERMISTOR FAILURE	FAN Mode, FURNACE Mode
Continuous	7	THERMISTOR WIRING WRONG (only in cooling test mode)	FAN Mode

Cleaning: Clean the evaporator coil and condenser coil. Hold a flashlight behind the coil to see if all spaces are clear. Dust accumulation obstructs or reduces airflow and results in a loss of cooling capacity. Both coils may be vacuumed when dry. Coils may also be brushed with a stiff brush and then blown out with compressed air. Thoroughly clean the base pan, motors, fan wheels, and other components. Clean the cover and ceiling grill. Mild detergents reduce electrostatic charges on plastic sections of the grill and are good cleaners.

Painting: Paint any parts that show evidence of rust with a good rust-prevention paint.

Wiring: Check all wiring for deterioration and all electrical contacts for tightness or corrosion.

Mounting: Make sure the unit is secure on the roof according to installation instructions provided in the Owner’s Guide. Check fans to ensure that they are correctly positioned in the center of the orifice and are tight on the shaft.

Leaks: Check any connections that show evidence of oil or leaks. When the unit is properly installed, check gaskets for possible air leakage.

Controls: Check the unit to ensure all controls are functioning correctly and unit operation is normal. Vibrations can cause unwanted noise. Note: Check to ensure that piping is not vibrating against the side of the unit.

The filters are located in the ceiling grill. To remove the filters, do the following:

a. Grasp the edge of the filter at the recess in the end of the ceiling grill.

b. Pull the filter completely out of the filter slot.

c. Vacuum the filter or wash it in lukewarm water. Shake off excess water and dry thoroughly.

d. Replace the filter by sliding it into the filter slot in the ceiling grill until the filter frame is flush with the interior grill.

To remove the ceiling grill, do the following:

a. Before working on the unit, place the master switch in the OFF position and disconnect all electrical power.

b. Remove 4 screws located on the ceiling grill, making sure to support the weight of the grill.

c. Lower the ceiling grill from the ceiling panel.

d. To replace the grill, place the grill up against the ceiling panel and align the screw holes in the grill with the ceiling panel.

e. Replace 4 screws.

WARNING: Do not touch the metal of the screwdriver when discharging the capacitor. You could receive a shock.

Capacitors must be discharged properly before testing.

a. Place a 20,000 ohm, 2 watt resistor across the terminals of the capacitor for approximately 30 seconds.

b. After the capacitor has been discharged and all wires removed from the capacitor terminals, use an ohmmeter to test its resistance.

c. Set the scale to R x 1K or 10K ohm and place the ohmmeter leads across the capacitor terminals.

d. If the ohmmeter first reads 0, then rises toward infinity or some higher resistance, the capacitor is good.

e. If the ohmmeter goes to 0 or a low resistance and stays there, the capacitor is shorted and needs to be replaced.

f. If the ohmmeter reads infinity (OL) the capacitor is open and needs to be replaced.

a. Disconnect power from the AirV unit.

b. Disconnect the wires to the PTC.

c. Using an ohm meter, check for continuity across the PTC. If the PTC does not have continuity, it must be replaced. If continuity exists, reconnect the wires to the PTC.

d. Reconnect power to the AirV unit.

e. Turn on the AirV unit to start.

f. Use a clamp-on amp probe to monitor the amp draw of the compressor during its start-up. When the compressor starts, an amp draw will be indicated for almost a second. If no amp draw is indicated or if the amp draw occurs for much longer than a second, the PTC is defective and must be replaced.

CAUTION: The change from Fahrenheit to Celsius will be permanent. It cannot be changed back to Fahrenheit.

CAUTION: When re-assembling, ensure the battery springs are correctly placed in the battery spring holders.

All Remote Control Assemblies in the United States are pre-set to display in Fahrenheit degrees. To change from a Fahrenheit display to a Celsius display do the following:

a. Remove the batteries from the remote control.

b. Carefully remove the remote cover by inserting a narrow flat object between the cover and remote body and prying apart.

c. Remove the brass screw holding the PCB in place.

d. Carefully remove the PCB board from the remote body, making sure the battery springs release from their holders.

e. Locate FR9 on the PCB board.

f. Carefully cut the FR9 jumper wire.

g. Reverse the above procedure for reassembly.

Thermostat Location:

The thermostat should be mounted approximately 5 feet (1.5m) from the floor, on an inside partitioning wall without pipes or duct work, and close to a frequently used room. It should NOT be mounted near a window, outside wall, direct heat/light source, or in areas with poor air circulation.

Installation (12VDC):

1. Turn off all power to the unit.

2. If replacing an old thermostat, disconnect wires one at a time, recording the wire color and terminal marking. Do not let wires fall back into the wall.

3. Separate the front and back pieces of the thermostat.

4. Route wires through the hole in the back piece, level it against the wall, and mark the 2 mounting holes.

5. Drill two 3/16 inch mounting holes.

6. Secure the back piece to the wall with the provided anchors and screws.

7. Connect wires to the proper terminals on the front piece.

8. Push any excess wire back into the wall and seal the hole to prevent air leaks.

9. Snap the front and back pieces together.

10. Turn on power to the unit.

Set Thermostat Configuration:

To enter configuration mode, press and hold the FAN button for approximately 10 seconds until the display reads A. While in configuration mode, you can make the following adjustments:

A – Anticipator Value Adjustment: Controls sensitivity and cycle rate (1-3, default 2). Higher numbers slow the cycle rate. To adjust, use UP/DOWN buttons to display A, press MODE to show the current value, use UP/DOWN to change it, and press MODE to return to A.

d – Fahrenheit/Celsius Selection: To select, use UP/DOWN buttons to display d, press MODE to show F or C, use UP/DOWN to change it, and press MODE to return to d.

oF – Room Temperature Offset Adjust Selection: Adjusts the displayed temperature by -5 to +5 degrees (default 0). To adjust, use UP/DOWN buttons to display oF, press MODE to show the offset value, use UP/DOWN to change it, and press MODE to return to oF.

Fan Operation (Cool Only):

1. Press FAN button to start low speed (Lo is displayed for 5 seconds).

2. Press FAN button again for high speed (Hi is displayed for 5 seconds).

3. Press FAN button a third time to stop the fan.

Fan Operation (Heat/Cool):

1. Press FAN button to start low fan (Lo).

2. Press FAN button again to start high fan (Hi).

3. Press FAN button a third time to stop the fan.

Cooling Operation (Cool Only or Heat/Cool):

1. Press and release MODE button until COOL is displayed.

2. Press DOWN button until the LCD readout is 10 degrees below room temperature. The cooling and High Fan system should begin to operate within 5 minutes.

Heating Operation (Heat/Cool):

1. Press and release MODE button until HEAT is displayed.

2. Press UP button until the LCD readout is 10 degrees above room temperature. The heating system should begin to operate within 1 minute.