CARRIER TRANSICOLD AIRV 68RV14103A (01) PDF Document

The following are recommended precautions that must be understood and applied during operation and maintenance of the CARRIER TRANSICOLD AIRV 68RV14103A.

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.

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.

The serial number indicates when the unit was manufactured.

The first two numbers of the serial number represent the week the unit was manufactured (e.g., 01 for the first week, 52 for the last week).

The third and fourth numbers designate the year of manufacture (e.g., 99 for 1999, 03 for 2003).

For example, a serial number of 1303Y12345 means the unit was manufactured in the 13th week of 2003.

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

The cooling cycle is energized when the thermostat calls for cooling. The main components are the compressor, air-cooled condenser coil, strainer, capillary tube, evaporator coil, and accumulator.

The compressor raises the pressure and temperature of the refrigerant and forces it into the condenser coil. The condenser fan circulates surrounding air over the outside of the coil tubes, causing the refrigerant to cool and liquefy. The liquid refrigerant then flows through a strainer to the capillary tube, which meters the flow to the evaporator coil, reducing its pressure and temperature.

The evaporator blower pulls vehicle air through the filters and across the evaporator coil. The low temperature liquid refrigerant in the coil tubes absorbs heat from the air, causing the refrigerant to vaporize. This cools the air, which is then circulated back into the vehicle. The low-pressure vapor refrigerant passes into the accumulator, which ensures only vapor returns to the compressor to repeat the cycle.

When the thermostat calls for cooling, the system controls are positioned for “normal” refrigerant flow. The main components are the compressor, reversing valve, air-cooled outdoor coil, strainer, capillary tube, indoor coil, and accumulator.

The compressor raises the pressure and temperature of the refrigerant, forcing it through the reversing valve into the outdoor coil. The outdoor fan circulates air over the coil, causing the refrigerant to cool and liquefy. The liquid refrigerant flows through a strainer to the capillary tube, which meters its flow to the indoor coil, reducing its pressure and temperature.

The indoor blower pulls air across the indoor coil. The cold liquid refrigerant inside absorbs heat from the air, cooling the air that is then circulated into the vehicle. This heat absorption causes the refrigerant to vaporize. The resulting low-pressure vapor passes into the accumulator, which ensures only vapor returns to the compressor, where the cycle repeats.

When the thermostat calls for heat, the system controls are positioned for “reverse” refrigerant flow. The main components are the compressor, reversing valve, indoor coil, capillary tube, strainer, air-cooled outdoor coil, and accumulator.

The compressor raises the pressure and temperature of the refrigerant, forcing it through the reversing valve into the indoor coil. The indoor blower pulls air from the vehicle across the indoor coil. The hot refrigerant gas inside the coil transfers heat to the air, warming the air that is circulated back into the vehicle. This heat removal causes the refrigerant to liquefy.

The liquid refrigerant then flows through a strainer to the outdoor coil via the capillary tube, which reduces its pressure and temperature. The outdoor fan circulates air across the outdoor coil. The cold liquid refrigerant inside absorbs heat from the outdoor air, causing the refrigerant to vaporize. This low-pressure vapor passes into the accumulator, which ensures only vapor returns to the compressor, where the cycle repeats.

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 a “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 amp draw (with compressor and fan running) is within specifications according to the unit model (Refer to Table 1-1).

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. 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 in Table 1-1.

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’s positioned properly. The probe is 2.5 to 3 inches in length with 2 brown wires.

When the remote control was developed, it was done using the Celsius scale. When converted to Fahrenheit, it will stage in 2 degree (F) increments most times, 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. Example: 4204Y was manufactured the 42nd week of 2004.

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.

No, wall mounted thermostats are only available for Freeblow and Ducted Cool Only units.

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.

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

For ducted units, the GREEN operation indicator LED will flash if there is a problem. Refer to the table for diagnostic information.

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 following table explains the self-diagnostics function for the ducted remote system. If more than two errors occur, the highest ranked code (lowest priority number) is displayed.

Cleaning: Clean evaporator and condenser coils. Hold a flashlight behind the coil to see if all spaces are clear. Dust accumulation obstructs airflow and reduces cooling capacity. Coils can be vacuumed 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.

Painting: Paint any parts showing 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 that fans are correctly positioned and tight on the shaft.

Leaks: Check any connections for oil or leaks. Check gaskets for possible air leakage.

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

The filters are located in the ceiling grill. To remove them, follow these steps:

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.

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

b. Remove the 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 it up against the ceiling panel and align the screw holes in the grill with the ceiling panel.

e. Replace the 4 screws.

a. Remove the ceiling grill.

b. Remove 5 screws securing the duct plate to the ceiling panel.

c. Remove 4 mounting bolts, making sure to support the weight of the ceiling panel.

d. Disconnect the unit harnesses and main power wires from the ceiling panel.

e. Lower the ceiling panel from the air conditioning unit.

f. Reverse the above procedure for reassembly.

WARNING: Disconnect power to the AirV unit before checking the capacitor. Capacitors must be discharged properly before testing.

Discharging the Capacitor:

a. Place a 20,000 ohm, 2 watt resistor across the terminals of the capacitor for approximately 30 seconds. Do not touch the metal of the tool used when discharging.

Testing the Capacitor:

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.

Capacitors showing signs of leaks or bulging should be replaced immediately.

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.

To change the display, follow these steps:

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

The thermostat should be mounted:

Approximately 5 feet (1.5m) from the floor.

Close to or in a frequently used room, preferably on an inside partitioning wall.

On a section of wall without pipes or duct work.

The thermostat should NOT be mounted:

Close to a window, or an outside wall, or next to a door leading to the outside.

Exposed to direct light and heat from a lamp, sun, fireplace, or other temperature-radiating object which may cause a false reading.

Close to or in direct airflow from supply registers and return-air grilles.

In areas with poor air circulation, such as behind a door or in an alcove.

Fan Operation (Cool Only)

1. Press FAN button to start fan operation. FAN annunciator turns on; Lo is displayed for 5 seconds indicating Fan Low Speed.

2. Press FAN button again; FAN annunciator remains on; Hi is displayed for 5 seconds indicating Fan High Speed.

3. Press FAN button again to stop fan operation. FAN annunciator turns off.

Fan Operation (Heat/Cool)

1. Press FAN button to start low fan (Lo) operation. FAN annunciator turns on.

2. Press FAN button to start high fan (Hi) operation. FAN annunciator remains on.

3. Press FAN button to stop fan operation. FAN annunciator turns off.

Cooling Operation (Cool Only)

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

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

Cooling Operation (Heat/Cool)

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

2. Press DOWN button until LCD readout reads 10 degrees below room temperature. 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 LCD readout reads 10 degrees above room temperature. Heating system should begin to operate within 1 minute.

Timeguard Timer: A 3-minute timeguard is built into the thermostat upon power up and any time the compressor turns off. The compressor will not turn on until the timeguard has expired. Pressing UP and FAN buttons simultaneously will override the timeguard for 1 cycle.

Cycle Timer: In normal operation, the thermostat will not allow more than 4 equipment cycles per hour (1 cycle every 15 minutes). Both the cooling (“Y”) and heating (“W”) outputs have a 15-minute timer. Pressing UP and FAN buttons simultaneously or changing the set point will override the timer for 1 cycle.

Minimum On Timer: Once the equipment has turned on, it will remain on for a minimum of 2 minutes regardless of demand. It can turn off in less than 2 minutes if a change in set point or mode occurs.

Error Messages:

E4 will be displayed if the thermostat has an internal memory failure. If E4 appears, replace the thermostat.

— (two dashes) will be displayed if the thermostat cannot properly read the room temperature. If — appears, replace the thermostat.