CARRIER TRANSICOLD AIRV 68RV15102A (01) PDF Document

The following are recommended precautions that must be understood and applied during the operation and maintenance of the CARRIER TRANSICOLD AIRV 68RV15102A.

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 the 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.

To interpret the serial number on your CARRIER TRANSICOLD AIRV 68RV15102A:

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. Example: Y43210

As a full example, a serial number of 1303Y12345 designates that the unit was manufactured in the 13th week of 2003 and the serial number is 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.

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)

The Dry Mode function on the CARRIER TRANSICOLD AIRV 68RV15102A 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 of the system are the compressor, air-cooled condenser coil, strainer, capillary tube, evaporator coil, and accumulator.

1. The compressor raises the pressure and temperature of the refrigerant and forces it through the discharge line into the condenser coil.

2. The condenser fan circulates surrounding air over the outside of the coil tubes. Heat is transferred from the refrigerant gas to the air, causing the refrigerant to liquefy.

3. Liquid refrigerant leaves the coil and flows through a strainer to the capillary tube. The strainer removes impurities.

4. The capillary tube meters the flow of liquid refrigerant to the evaporator coil, causing a reduction in pressure and temperature.

5. The evaporator blower pulls vehicle air through filters and then through the evaporator coil.

6. The low-pressure, low-temperature liquid in the evaporator coil is colder than the air circulated over it. Heat transfers from the air to the refrigerant, cooling the air that is circulated into the vehicle.

7. This heat transfer causes the liquid refrigerant to vaporize. This low-temperature, low-pressure vapor passes into the accumulator, which ensures only vapor refrigerant is returned to the compressor, where the cycle repeats.

Cooling Mode:

The cooling cycle for the heat pump is similar to the standard system. The system controls are positioned for “normal” refrigerant flow, with the compressor discharge delivered to the outdoor coil and liquid delivered to the indoor coil. The main components are the compressor, reversing valve, outdoor coil, strainer, capillary tube, indoor coil, and accumulator. The process involves compressing refrigerant, cooling it in the outdoor coil to liquefy, metering it through the capillary tube, and then evaporating it in the indoor coil to absorb heat from the vehicle’s interior, thus providing cool air.

Heating Mode:

The heating cycle is energized when the thermostat calls for heat. The system controls are positioned for “reverse” refrigerant flow.

1. The compressor raises the pressure and temperature of the refrigerant and forces it through the discharge line and reversing valve into the indoor coil.

2. The indoor blower pulls vehicle air through the filters and over the indoor coil. Heat is transferred from the hot refrigerant gas to the air, heating the vehicle’s interior. This causes the refrigerant to liquefy.

3. The liquid refrigerant flows through the strainer to the outdoor coil.

4. The capillary tube meters the flow to the outdoor coil, reducing its pressure and temperature.

5. The low-pressure liquid in the outdoor coil is colder than the outside air. Heat from the outdoor air is transferred to the refrigerant, causing it to vaporize.

6. This low-pressure vapor passes into the accumulator, which ensures only vapor returns to the compressor to repeat the cycle.

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 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.

First, check to see if the 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. For a ducted unit, 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 the compressor start-up to confirm proper operation. Check to see if the probe has been inserted into the coil and if it is properly positioned. 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.

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.

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.

Here are common issues and remedies for the CARRIER TRANSICOLD AIRV 68RV15102A:

NO POWER TO UNIT

1. Reset master switch.

2. Reset circuit breaker.

3. Replace wiring.

4. Tighten connections.

5. Replace defective components.

6. (Ducted System) Connect to 12 VDC power source.

7. (Ducted) Replace fuse.

DUCTED UNIT WILL NOT OPERATE

1. (Display not illuminated) Check 12 Volt DC in-line fuse.

2. (Display illuminated) Check 115 Volt AC Connections.

DUCTED UNIT WILL NOT COOL

1. (Green LED light flashes 5 times) Check 115 volt AC power source, momentarily disconnect 12 VDC power source, disable compressor malfunction test switch, check AMP draw, check Δ T.

2. (Unit cools for a few moments then stops) Remove grill, verify evaporator coil probe is inserted into coil, check AMP draw, check Δ T, replace unit.

COMPRESSOR POWER SUPPLY OPEN

1. Tighten leads at compressor terminals.

2. Replace defective motor overload switch.

3. Replace defective capacitor.

4. Replace compressor if windings are open.

5. Replace seized compressor.

6. Verify capacitor wiring.

COMPRESSOR RUNS BUT CYCLES, FAN OPERATING ERRATICALLY

1. Tighten lead at fan motor.

2. Replace defective or burned out motor.

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

4. Check AMP draw.

5. Check for obstruction in discharge line, check Δ T, replace unit.

6. Replace defective motor overload switch.

CYCLES ON COMPRESSOR OVERLOAD

1. Replace defective run capacitor.

2. Replace unit if compressor bearings or valves are defective.

3. Defrost iced evaporator coil.

4. Replace unit for low refrigerant charge.

5. Replace unit for restricted evaporator capillary.

6. Replace unit for restricted liquid line.

7. Verify refrigerant charge, check AMP draw, check Δ T.

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

INSUFFICIENT COOLING, COOLING AIR NOT ADEQUATE

1. Clean dirty evaporator coil.

2. Defrost or Recharge for iced evaporator coil/low charge.

3. Verify fan rotation.

4. Replace defective fan motor.

5. Remove and clean dirty return air filters.

CONDENSER AIR NOT ADEQUATE

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

2. Clean dirty coil.

3. Replace defective fan motor.

INSUFFICIENT COOLING

1. Re-evaluate unit for proper capacity.

2. Check AMP draw, check Δ T, replace unit for restricted capillary.

COMPRESSOR FLOODING

1. (Unit overcharged) Check AMP draw, check Δ T, replace unit.

2. Clean filter and/or evaporator coil for low airflow.

3. Check connections per wiring diagram and tighten any loose connections.

HEATER CYCLES ON LIMIT SWITCH (HEAT/COOL VERSION ONLY)

1. Clean or replace dirty filter.

2. Remove blockage from evaporator air inlet.

3. Check fan motor. Repair or replace as necessary for low airflow.

AIR SWEEP NOT WORKING (FREE BLOW VERSION ONLY)

1. Align ceiling grill.

2. Align and lubricate linkage in upper control box.

3. Replace motor if air sweep motor fails.

WATER LEAKAGE

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

INADEQUATE HEAT (FREE-BLOW HEAT ONLY)

1. Verify AMP draw (13.8 AMP). Verify resistance through heating element (9 OHM). Check bi-metal switch; if open, replace switch.

INADEQUATE HEAT (HEAT-PUMP)

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

1. (Reversing valve not operating) Check for 115 volts at reversing valve coil, check for reversing valve restriction, verify compressor operation.

2. (Outdoor coil icing) 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 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 obstructs airflow and reduces cooling capacity. Both coils may 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.

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. Check fans to ensure they are correctly positioned in the center of the orifice 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 unit operation is normal. Vibrations can cause unwanted noise. Also, 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:

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 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 the 4 screws.

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.

a. Remove the ceiling grill.

b. Disconnect 115 volt (AC) and 12 volt (DC) power wires.

c. Remove two screws securing the control box cover to the control box assembly.

d. Remove the control box assembly cover.

e. Disconnect the blue furnace wires.

f. Unplug two connectors from the upper unit.

g. Unplug DC power plug #1 (red/yellow/black wires).

h. Unplug relay signal plug #2 (brown/red/orange/yellow wires).

i. While supporting the control box assembly, remove the two screws securing it to the ducted ceiling unit.

j. Pull the control box assembly from the ducted ceiling unit.

k. Reverse the above procedure to reassemble.

The Return-Air Sensor (Thermistor 12-50084-00) is located in the ceiling assembly. To check its resistance:

1. Remove 4 screws from the ceiling cover.

2. Remove 3 screws holding the PCB cover.

3. Un-plug the thermistor plug from the PC board.

4. Check the thermistor resistance using the following table:

°C	°F	Resistance (K-Ohms)	°C	°F	Resistance (Ohms)
5	41.0	12.07	25	77.0	5.369
6	43.0	11.57	26	78.5	5.168
7	44.5	11.09	27	80.0	4.976
8	46.5	10.63	28	82.5	4.792
9	48.0	10.19	29	84.0	4.616
10	50.0	9.771	30	86.0	4.447
11	52.0	9.373	31	87.5	4.286
12	53.5	8.993	32	89.5	4.131
13	55.5	8.631	33	91.5	3.982
14	57.0	8.286	34	93.0	3.840
15	59.0	7.956	35	95.0	3.703
16	61.0	7.641	36	96.5	3.573
17	62.5	7.341	37	98.5	3.447
18	64.5	7.054	38	100.5	3.326
19	66.0	6.779	39	102.0	3.211
20	68.0	6.517	40	104.0	3.100
21	69.5	6.267	41	105.5	2.993
22	71.5	6.027	42	107.5	2.890
23	73.5	5.798	43	109.5	2.792
24	75.0	5.579	44	111.0	2.698

Capacitors showing signs of leaks or bulging should be replaced immediately. To test a capacitor, it 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. WARNING: Do not touch the metal of the screwdriver or tool used when discharging the capacitor, as you could receive a shock.

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.

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.

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

e. Locate FR9 on the PCB board.

f. Carefully cut the FR9 jumper wire.

g. Reverse the above procedure for reassembly.

Read all instructions before starting the installation.

Thermostat Location:

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 wall), and on a section of wall without pipes or duct work. Do NOT mount it close to a window, outside wall, direct heat sources, supply/return grilles, or in areas with poor 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. Do not let wires fall back into the wall.

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

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

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

f. Secure the back piece to the wall with the provided anchors and screws, ensuring wires extend through the hole.

g. Connect the wires to the proper terminals on 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 the thermostat together.

j. Turn on power to the unit.

Enter Configuration Mode:

Press and hold the FAN button for approximately 10 seconds until the room temperature display disappears and reads “A”. You are now in configuration mode. If no button is pressed for two minutes, the thermostat will exit configuration mode.

While in configuration mode, you have three options:

A – Anticipator Value Adjustment:

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

1. Enter configuration mode.

2. Use UP & DOWN buttons to display “A”.

3. Press MODE to display the current value.

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

5. Press MODE to return to “A” or FAN to exit.

d – Fahrenheit/Celsius Selection:

To select between F and C:

1. Enter configuration mode.

2. Use UP & DOWN buttons to display “d”.

3. Press MODE to display the current selection (F or C).

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

5. Press MODE to return to “d” or FAN to exit.

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 adjust:

1. Enter configuration mode.

2. Use UP & DOWN buttons to display “oF”.

3. Press MODE 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” or FAN to exit.

Temperature Display:

The thermostat displays the room temperature. When the UP or DOWN button is pressed, the word “SET” appears, and the display shows the current set point. After 5 seconds of no button presses, the display returns to showing the room temperature.

Fan Operation (Cool Only):

1. Press FAN button to start fan operation. “Lo” is displayed for 5 seconds indicating Fan Low Speed.

2. Press FAN button again. “Hi” is displayed for 5 seconds indicating Fan High Speed.

3. Press FAN button again to stop fan operation.

Fan Operation (Heat/Cool):

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

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

3. Press FAN button again to stop fan operation.

Cooling Operation (Cool Only or Heat/Cool):

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

2. Press the DOWN button until the LCD readout reads 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 the MODE button until HEAT is displayed.

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