CARRIER TRANSICOLD AIRV 68RV14102A (01) PDF Document

The following are recommended precautions that must be understood and applied during the operation and maintenance of your CARRIER TRANSICOLD AIRV 68RV14102A.

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 the 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 capacitor 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 from 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.

Separate part numbers and serial numbers are provided for the upper and lower unit assemblies. The numbers can be found on plates readable from inside the vehicle.

The first two numbers of the serial number indicate the week the unit was manufactured. For example, 01 would designate the first week of the year, and 52 would designate the last week of the year.

The third and fourth numbers designate the year in which the unit was manufactured. For example, 99 would represent the year 1999, 00 the year 2000, and so on.

The letter Y and all the numbers after it designate the unit serial number. For example, a serial number of 1303Y12345 means the unit was manufactured in the 13th week of 2003 and has the serial number Y12345.

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 to 15/17 ft./lbs.

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

• Locked Rotor Amps – Low Profile High Capacity: 59.0 AMPS

• Fully Loaded Amps – Standard: Cooling – Approx. 12.8 AMPS, Heating – N/A

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

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

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

Compressor – 220 Volts, 50 Cycles, 1 Phase

• Locked Rotor Amps: 23.6 AMPS

Thermostat Range (All Free Blow Units)

• 61° F (16° C) to 89° F (32° C)

Return Air Sensor (Thermistor)

The Return-Air-Sensor (Thermistor) is part of the PCB Main Assembly. The sensor has a yellow coating and protrudes about 3/16 inch through the ceiling panel when installed. Refer to the resistance table for values.

Heat Pump Sensors (Thermistors)

The Heat Pump systems have an (ODA) outdoor air thermistor and a (ODC) outdoor coil thermistor, both located in the upper unit, and a (IDC) indoor coil thermistor located in the ceiling unit. Resistance values for these thermistors can be found in the provided tables.

The Dry Mode function effectively eliminates moisture by operating the compressor and fan motor intermittently, maintaining the room temperature at the 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 the 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 the “Compressor Circuit” being interrupted for an abnormal reason during operation. This can be caused by a 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 returns, check the 115 VAC with an amp meter to determine if the unit’s amp draw (with compressor and fan running) is within specifications according to the unit model.

First, check to see if the filters are clean. Once cleaned, measure the temperature of the air going into the filters and compare it to the air temperature coming out of the unit. For ducted units, 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, 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 the compressor starting to confirm proper operation. Check to see if the probe has been inserted into the coil and if it is properly placed. The probe is 2.5 to 3 inches in length with 2 brown wires.

When the remote control was developed, it was based on the Celsius scale. When converted to Fahrenheit, it stages in 2-degree (F) increments most of the time, and occasionally a 1-degree increment. This is normal and cannot be changed.

Initially, the lowest set point for furnace mode was 63 degrees. Starting with ceiling unit serial numbers after 4204Y, the furnace setpoint was lowered to 45 degrees. The first 2 numbers in the serial number relate to the week of the year manufactured; the 3rd and 4th digits relate to the year of manufacture. For example, 4204Y was manufactured in the 42nd week of 2004.

The manual control Thermostat on a freeblow ceiling unit has a range of 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 the 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.

The temperature is sensed at the ceiling unit, not at the remote control. The temperature offset can be even more in RVs with higher ceilings. This is more common in heat mode, as warm air rises.

If there is no power to the unit, check the following:

1. Reset the master switch.

2. Reset the circuit breaker.

3. If wiring is defective, replace it.

4. Tighten any loose electrical connections.

5. Replace any faulty switches, thermostat, or fan.

6. For Ducted Systems, ensure the 12 VDC power source is connected.

7. For Ducted Systems, replace the 12 VDC in-line fuse if it is open.

If the display is not illuminated, check the 12 Volt DC in-line fuse.

If the display is illuminated, check the 115 Volt AC connections.

This indicates a compressor drive malfunction. Follow these steps:

1. Check the 115 volt AC power source.

2. Momentarily disconnect the 12 VDC power source.

3. Disable the compressor malfunction test switch.

4. Check the AMP draw.

5. Check the temperature difference (ΔT).

Follow these steps:

1. Remove the grill and verify the evaporator coil probe is inserted into the coil.

2. Check the AMP draw.

3. Check the temperature difference (ΔT).

4. If the issue persists, replace the unit.

1. Tighten any loose leads at the compressor terminals.

2. Replace a defective motor overload switch.

3. Replace a defective capacitor.

4. If compressor windings are open, replace the compressor.

5. If the compressor is seized, replace it.

6. Verify the capacitor wiring is correct according to the wiring diagram.

This could be caused by several issues. Here are the probable causes and remedies:

• Loose lead at fan motor: Tighten the lead.

• Defective or burned out motor: Replace the motor.

• Outdoor air restricted or recirculating: Check for a dirty condenser coil, ensure proper clearance around the unit, and remove any obstructions.

• Overcharge or noncondensables in system: Check the AMP draw.

• Restricted discharge line: Check for an obstruction in the line, check the temperature difference (ΔT), and replace the unit if necessary.

• Defective motor overload switch: Replace the switch.

• Defective run capacitor: Replace the capacitor.

• Defective compressor bearings or valves: Replace the unit.

• Greatly restricted evaporator air, iced evaporator coil: Defrost the evaporator coil.

• Low refrigerant charge: Replace the unit.

• Evaporator capillary restricted: Replace the unit.

• Liquid line restricted: Replace the unit.

• Compressor hot: Verify the refrigerant charge, check the AMP draw, and check the temperature difference (ΔT).

• Weak or inconsistent line power: Check the line voltage at the time of compressor start-up.

• Dirty evaporator coil: Clean as required.

• Iced evaporator coil, slightly low refrigerant charge: Defrost or recharge.

• Improper fan operation: Verify fan rotation (refer to the wiring diagram).

• Defective fan motor: Replace the fan motor.

• Return air filter is dirty: Remove and clean the filters.

• Outside Air Restricted: Check for obstruction at the coil and remedy as required.

• Dirty coil: Clean the coil.

• Defective fan motor: Replace the fan motor.

• Unit undersized: Re-evaluate the unit for proper capacity.

• Capillary restricted: Check the AMP draw, check the temperature difference (ΔT), and replace the unit if necessary.

• Unit overcharged: Check the AMP draw, check the temperature difference (ΔT), and replace the unit if necessary.

• Low evaporator airflow: Clean the filter and/or evaporator coil.

• Defective electrical connections: Check connections per the wiring diagram and tighten any loose connections.

• Dirty filter: Clean or replace the filter.

• Blocked evaporator air inlet (indoor): Remove the blockage.

• Low airflow due to fan motor speed: Check the fan motor. Repair or replace as necessary.

• Ceiling grill not properly aligned: Align the ceiling grill.

• Linkage in upper control box stuck: Align and lubricate the linkage.

• Air sweep motor failure: Replace the motor.

Verify that the vehicle is level. Tighten the unit mounting bolts evenly or replace the unit gasket.

If there is no heat from the heat strip, perform the following checks:

1. Verify the AMP draw (should be 13.8 AMP).

2. Verify the resistance through the heating element (should be 9 OHM).

3. Check the bi-metal switch. If it is open, replace the switch.

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

• Reversing valve not operating: Check for 115 volts at the reversing valve coil, check for a reversing valve restriction, and verify compressor operation.

• Outdoor coil icing: Check the 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 GREEN operation indicator LED will flash if there is a problem. 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 and condenser coils. Hold a flashlight behind the coil to see if all spaces are clear. Dust accumulation reduces airflow and cooling capacity. Both coils can be vacuumed when dry or brushed with a stiff brush and blown out with compressed air. Thoroughly clean the base pan, motors, fan wheels, and other components. Clean the cover and ceiling grill with mild detergents. CAUTION: Do not use carbon tetrachloride, solvents, or waxes containing solvents to clean plastic sections.

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: Ensure the unit is secure on the roof according to installation instructions. Check fans to ensure they are correctly positioned and tight on the shaft.

Leaks: Check any connections that show evidence of oil or leaks. Check gaskets for possible air leakage.

Controls: Check the unit to ensure all controls are functioning correctly and 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 them:

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.

WARNING: Disconnect power to the AirV unit before checking the capacitor. 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. WARNING: Do not touch the metal of the screwdriver when discharging the capacitor. You could receive a shock.

b. After the capacitor has been discharged and all wires are removed, 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 there is no 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.

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

WARNING: Before installing the thermostat, turn off all power to the unit. There may be more than one power disconnect. Electrical shock can cause personal injury or death.

Thermostat Location:

• Mount approximately 5 feet (1.5m) from the floor, on an inside partitioning wall in a frequently used room.

• Avoid mounting near windows, outside walls, doors, direct heat sources, supply/return air grilles, or in areas with poor air circulation.

Installation Steps:

a. Turn off all power to the unit.

b. If replacing an old thermostat, remove it, disconnect wires one at a time, and record the wire color and terminal marking for each.

c. Separate the front and back pieces of the new thermostat plastic case.

d. Route thermostat wires through the hole in the back piece. Level it against the wall and mark the wall through the 2 mounting holes.

e. Drill two 3/16 inch mounting holes in the wall where marked.

f. Secure the back plastic to the wall with the 2 anchors and screws provided.

g. Connect wires to the proper terminals of the connector block in the front piece.

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

i. Snap the front and back pieces of plastic together.

j. Turn on power to the unit.

To enter configuration mode, press and hold the FAN button for approximately 10 seconds until the room temperature disappears and the display reads ‘A’. While in configuration mode, you can adjust three options: Anticipator (A), Fahrenheit/Celsius (d), and Room Temperature Offset (oF).

A. ANTICIPATOR – Value Adjustment:

This controls sensitivity and cycle rate. Higher numbers (1-3) decrease sensitivity. The factory default is 2. To adjust:

1. Enter configuration mode.

2. Use UP & DOWN buttons to display ‘A’.

3. Press MODE once to display the current value.

4. Use UP & DOWN buttons to change the value.

5. Press MODE to return to ‘A’.

d. Fahrenheit/Celsius Selection:

To select:

1. Enter configuration mode.

2. Use UP & DOWN buttons to display ‘d’.

3. Press MODE once to display ‘F’ or ‘C’.

4. Use UP & DOWN buttons to change between F & C.

5. Press MODE to return to ‘d’.

oF. Room Temperature Offset Adjust Selection:

This adds or subtracts degrees (-5 to +5) from the actual temperature reading. The factory default is 0. To select:

1. Enter configuration mode.

2. Use UP & DOWN buttons to display ‘oF’.

3. Press MODE once to display the offset value.

4. Use UP & DOWN buttons to select a value between -5 and 5.

5. Press MODE to return to ‘oF’.

To exit configuration mode, press the FAN button or wait for two minutes.

Temperature Display: The thermostat displays the room temperature. When UP or DOWN is pressed, ‘SET’ appears with the set point. After 5 seconds of inactivity, it returns to showing room temperature.

Timeguard Timer: A 3-minute timeguard is active upon power-up and any time the compressor turns off. Pressing UP and FAN simultaneously overrides the timer for 1 cycle.

Cycle Timer: The thermostat allows a maximum of 4 equipment cycles per hour. A 15-minute timer starts when an output is turned on, preventing it from turning back on too soon.

Minimum On Timer: Once the equipment turns on, it will remain on for a minimum of 2 minutes, unless the set point or mode is changed.

Error Messages:

• E4: Internal memory failure. Replace the thermostat.

• — (two dashes): Cannot read room temperature. Replace the thermostat.

Table 1-1 Model Chart – UPPER UNIT (ROOF)

MODEL NUMBER	PART NUMBER	CONFIGURATION	VOLTAGE	AMPS	COLOR
68RV14102A	99-00468-00	STANDARD A/C	115/1/60	12.8	WHITE
	99-00468-01	STANDARD A/C	115/1/60	12.8	IVORY
	99-00469-20	STANDARD A/C	115/1/60	12.8	BLACK
68RV11302A	99-00468-02	STANDARD A/C	220/1/50	5.3 COOL	WHITE
	99-00468-03	STANDARD A/C	220/1/50	6.7 HEAT	IVORY
68RV15102A	99-00468-08	HIGH-CAPACITY	115/1/60	14.1	WHITE
	99-00468-09	HIGH-CAPACITY	115/1/60	14.1	IVORY
	99-00468-28	HIGH-CAPACITY	115/1/60	14.1	BLACK
HEAT PUMP 68RV11122A	99-00468-04	HEAT PUMP FREE-BLOW	115/1/60	12.7 COOL 10.9 HEAT	WHITE
	99-00468-05	HEAT PUMP FREE-BLOW	115/1/60	12.7 COOL 10.9 HEAT	IVORY
	99-00468-24	HEAT PUMP FREE-BLOW	115/1/60	12.7 COOL 10.9 HEAT	BLACK
HEAT PUMP 68RV11112A	99-00468-06	HEAT PUMP DUCTED	115/1/60	12.7 COOL 10.9 HEAT	WHITE
	99-00468-07	HEAT PUMP DUCTED	115/1/60	12.7 COOL 10.9 HEAT	IVORY
	99-00468-26	HEAT PUMP DUCTED	115/1/60	12.7 COOL 10.9 HEAT	BLACK
LOW PROFILE 68RV15103A	99-00468-10	FREE-BLOW HIGH CAPACITY	115/1/60	14.1 COOL 13.8 HEAT	WHITE
	99-00468-32	FREE-BLOW HIGH CAPACITY	115/1/60	14.1 COOL 13.8 HEAT	BLACK
LOW PROFILE 68RV14103A	99-00468-12	FREE-BLOW STANDARD	115/1/60	13.4 COOL 13.8 HEAT	WHITE
	99-00468-30	FREE-BLOW STANDARD	115/1/60	13.4 COOL 13.8 HEAT	BLACK
LOW PROFILE 68RV14113A	99-00468-13	HEAT PUMP HIGH CAPACITY	115/1/60	14.5 COOL 13.8 HEAT	WHITE
	99-00468-33	HEAT PUMP DUCTED	115/1/60	12.7 COOL 10.9 HEAT	BLACK
LOW PROFILE 68RV14123A	99-00468-11	HEAT PUMP FREE-BLOW	115/1/60	12.7 COOL 10.9 HEAT	WHITE

TABLE 1-2 MODEL CHART – CEILING UNIT

MODEL NUMBER	PART NUMBER	VOLTAGE	COLOR	OPTIONS	INTERFACE
68RV0010AA	99-00469-00	115/1/60	White	Cool Only	Free-Blow
	99-00469-01	115/1/60	Ivory	Cool Only	Free-Blow
68RV0010BA	99-00469-02	115/1/60	White	Heat/Cool	Free-Blow
	99-00469-03	115/1/60	Ivory	Heat/Cool	Free-Blow
68RV0010ΚΑ	99-00469-06	115/1/60 (12VDC)	White	Cool Only	Ducted
68RV0030AA	99-00469-04	220/1/50	White	Cool Only	Free-Blow
	99-00469-05	220/1/50	Ivory	Cool Only	Free-Blow
68RV0030BA	99-00469-08	220/1/50	White	Heat/Cool	Free-Blow
68RV0030KA	99-00469-10	220/1/50	White	Cool Only	Ducted
68RV0012CA	99-00469-11	115/1/60	White	Heat Pump	Free-Blow
	99-00469-12	115/1/60	Ivory	Heat Pump	Free-Blow
68RV0011LA	99-00469-13	115/1/60 (12VDC)	White	Heat Pump	Ducted
68RV0010EA	99-00469-17	115/1/60 (12VDC)	White	Heat/Cool	Free-Blow Wall Thermostat
68RV0040MA	99-00469-22	115/1/60	White	Cool Only	Ducted Wall Thermostat
68RV0010AB (Phased Out)	99-00469-23	115/1/60	White	Cool Only	Free-Blow
	99-00469-24	115/1/60	Ivory	Cool Only	Free-Blow
68RV0010BB (Phased Out)	99-00469-25	115/1/60	White	Heat/Cool	Free-Blow
	99-00469-26	115/1/60	Ivory	Heat/Cool	Free-Blow
68RV0010DB	99-00469-29	115/1/60	White	Cool Only	Free-Blow Wall Thermostat
68RV0010EB	99-00469-31	115/1/60	White	Heat/Cool	Free-Blow Wall Thermostat
68RV0012FB	99-00469-33	115/1/60	White	Heat Pump	Free-Blow Wall Thermostat
68RV0010KS	99-00469-35	115/1/60	White	Cool Only Thick Roof Kit	Ducted Remote
68RV0011KS	99-00469-36	115/1/60	White	Heat Pump Thick Roof Kit	Ducted Remote
68RV0010MS (Phased Out)	99-00469-37	115/1/60	White	Cool Only Thick Roof Kit	Ducted W/Wall Sensor
68RV0011OS (Phased Out)	99-00469-38	115/1/60	White	Heat Pump Thick Roof Kit	Ducted W/Wall Sensor