Carrier T-298 User Manual

2P

1

2

BLK

BLU

Transport Air Conditioning

Transport Air Conditioning

R

R

BRN

WHT

GRN/YEL

WHT

F

C

H

EVAP.

RED

WHT

YEL

2

1

C

RED

R

BLU

S

BLU

PTC

SERVICE MANUAL

for

Rooftop Air Conditioning Systems

T--298 Rev D

MODEL AirV

SERVICE MANUAL

For

AirV

AIR CONDITIONING AND

HEATING EQUIPMENT

MODELS

68RV11302A
68RV14102A
68RV14103A

68RV14112A
68RV15102A
68RV15103A

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautionsappearing elsewhere in
this manual. They are recommended precautions that must be understood and applied during operation and
maintenanceoftheequipmentcoveredherein.Thegeneralsafety notices arepresentedinthefollowingthree
sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific
warnings and cautions appearing elsewhere in the manual follows the general safety notices.

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 coverassembly beforeturningthe power off, and disconnecting the power supply.
Before disconnecting, discharge capacitors by shorting across the capacitors terminals. (See Paragraph

3.5.8)
When disassembling wiring, use numbered stickers to identify wire leads and terminals. This aids in quick,

accurate reassembly.
Besurepoweristurnedoffbeforeworkingonmotors,controllers, or electricalcontrolswitches.Taganycircuit

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 CO
Usedrynitrogentopressurizethesystemforleakchecking. Be careful not to exceed150psigtestpressurein

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.

(never use water).

2

Safety-- i

T-298

SPECIFIC WARNING AND CAUTION STATEMENTS

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the
equipment covered herein.

SPECIFIC WARNINGS AND CAUTIONS

WARNING

Be sure to observe warnings listed in the safetysummary in the front of this manualbefore
performing maintenance on the AirV system

WARNING

Beforeworkingonthe unitbesuretofirstdisconnectall electricpowertotheunitto avoidthe
possibilityof electrical shock and personalinjury. Before disconnecting, discharge capaci-
tors by shorting across the capacitors terminals (Refer to paragraph 3.5.8)

WARNING

Shieldcoilswithcardboard to protecthandsagainstinjuryfromsharpmetaledgeswhen re­moving compressor and other components.

WARNING

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.

WARNING

Disconnect power to the AirV unit before checking the capacitor.

WARNING

Do not touch the metal of the screwdriver when discharging the capacitor.Y oucould receive
a shock.

WARNING

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

CAUTION

Do not use carbon tetrachloride, solvents, or waxes containing solvents to clean plastic sec­tions.

T--298

Safety-- ii

CAUTION

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

CAUTION

ThechangefromFahrenheittoCelsiuswill bepermanent.Itcannotbechangedbackto Fahr­enheit.

CAUTION

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

CAUTION

Improper wiring or installation may damage thermostat. Wiring must conform to local and
national electrical codes.

Safety--iii

T-298

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

DESCRIPTION 1-1...............................................................................

1.1 INTRODUCTION 1-1.....................................................................

1.2 SERIAL NUMBER IDENTIFICATION 1-1....................................................

1.3 DESIGN CHANGE DESCRIPTIONS 1-1....................................................

1.4 AirV SYSTEM COMPONENT SPECIFICATIONS 1-9.........................................

1.4.1 Refrigerant Charge 1-9................................................................

1.4.2 Compressor - 115 Volts, 60 Cycles, 1 Phase 1-9..........................................

1.4.3 Compressor - 220 Volts, 50 Cycles, 1 Phase 1-9..........................................

1.4.4 Thermostat Range (All Free Blow Units) 1-9..............................................

1.5 START-UP 1-9...........................................................................

1.6 REFRIGERANT CYCLE-STANDARD SYSTEM 1-9...........................................

1.7 REFRIGERANT CYCLE - HEAT PUMP 1-10..................................................

1.7.1 Cooling 1-10..........................................................................

1.7.2 Heating 1-11..........................................................................

TROUBLESHOOTING 2-1.........................................................................

2.1 NO POWER TO UNIT 2-1.................................................................

2.2 DUCTED UNIT WILL NOT OPERATE 2-1...................................................

2.3 DUCTED UNIT WILL NOT COOL 2-1.......................................................

2.4 COMPRESSOR POWER SUPPLY OPEN 2-1...............................................

2.5 COMPRESSOR RUNS BUT CYCLES, FAN OPERATING ERRATICALLY 2-1....................

2.6 CYCLES ON COMPRESSOR OVERLOAD 2-2..............................................

2.7 INSUFFICIENT COOLING, COOLING AIR NOT ADEQUATE 2-2..............................

2.8 CONDENSER AIR NOT ADEQUATE 2-2....................................................

2.9 INSUFFICIENT COOLING 2-2.............................................................

2.10 COMPRESSOR FLOODING 2-2...........................................................

2.11 HEATERCYCLES ON LIMIT SWITCH (HEAT/ COOL VERSION ONLY) 2-2.....................

2.12 AIR SWEEP NOT WORKING (FREE BLOW VERSION ONLY) 2-2.............................

2.13 WATER LEAKAGE 2-2....................................................................

2.14 INADEQUATE HEAT (FREE-BLOW HEAT ONLY) 2-3........................................

2.15 INADEQUATE HEAT (HEAT-PUMP) 2-3....................................................

Clearing Diagnostic Alarms 2-3...................................................................

SERVICE AND MAINTENANCE 3-1................................................................

3.1 PREVENTATIVE MAINTENANCE 3-1......................................................

3.2 SERVICE - GENERAL 3-1................................................................

3.3 CEILING UNIT - FREE BLOW SYSTEMS 3-1...............................................

3.3.1 Filter Removal 3-1....................................................................

3.3.2 Ceiling Grill Removal 3-1..............................................................

3.3.3 Ceiling Panel Removal 3-2.............................................................

3.3.4 Master Control Switch 3-2.............................................................

3.3.5 Air Sweep Switch Removal 3-2.........................................................

3.3.6 Indoor Thermostat Removal 3-3........................................................

3.3.7 Air Sweep Removal

3.3.8 Heat Strip Assembly Removal 3-3......................................................

3-3...............................................................

i

T--298

TABLE OF CONTENTS - Continued

3.4 CEILING UNIT - DUCTED SYSTEMS 3-4...................................................

3.4.1 Filter Removal 3-4....................................................................

3.4.2 Ceiling Grill Removal 3-4..............................................................

3.4.3 Control Box Assembly Removal 3-4.....................................................

3.4.4 Main PCB Board Removal 3-5..........................................................

3.4.5 PCB Display Removal 3-5.............................................................

3.4.6 Fuse Removal 3-5....................................................................

3.5 SERVICE - UPPER UNIT - STANDARD, HC & HP 3-5........................................

3.5.1 Exterior Cover Removal 3-5............................................................

3.5.2 Compressor Replacement 3-6..........................................................

3.5.3 Control Box Assembly Removal 3-6.....................................................

3.5.4 Upper Scroll Assembly Removal 3-7....................................................

3.5.5 Motor Assembly and Condenser Fan Removal 3-7........................................

3.5.6 Evaporator Blower Wheel Adjustment or Removal 3-8.....................................

3.5.7 Air Handling System Removal 3-8......................................................

3.5.8 Capacitor Troubleshooting 3-9..........................................................

3.5.9 Capacitor Testing and Replacement 3-9.................................................

3.5.10 Positive Temperature Coefficient Thermister (PTC) (Start Thermistor) Troubleshooting 3-9.....

3.5.11 Line Voltage - 10% 3-9................................................................

3.6 SERVICE - UPPER UNIT - LOW PROFILE 3-10..............................................

3.6.1 Exterior Cover Removal 3-10............................................................

3.6.2 Upper Scroll Assembly Removal 3-10....................................................

3.6.3 Condenser Fan Assembly Removal 3-11..................................................

3.6.4 Condenser Motor Removal 3-12.........................................................

3.6.5 Evaporator Motor/Blower Assembly Removal 3-12.........................................

3.6.6 Compressor Replacement 3-13..........................................................

3.6.7 Capacitor Removal 3-13................................................................

3.6.8 Remote Control (Fahrenheit to Celsius) 3-13..............................................

3.7 THERMOSTAT INSTALLATION AND STAR T-UP INSTRUCTIONS (WALL MOUNTED) 3-15........

3.7.1 Introduction 3-15......................................................................

3.7.2 Installation 3-15.......................................................................

3.7.3 Thermostat Location 3-15...............................................................

3.7.4 Install Thermostat - 12VDC 3-15.........................................................

3.8 LCD DISPLA Y 3-15.......................................................................

3.8.1 Cool Only Thermostat 3-15.............................................................

3.8.2 Heat/Cool Thermostat 3-15.............................................................

3.9 SET THERMOSTAT CONFIGURATION 3-15.................................................

3.9.1 Enter Configuration Mode 3-15..........................................................

3.10 CHECK THERMOSTAT OPERATION 3-16...................................................

3.10.1 Fan Operation (Cool Only) 3-16..........................................................

3.10.2 Fan Operation (Heat/Cool) 3-16.........................................................

3.10.3 Cooling Operation (Cool Only) 3-16......................................................

3.10.4 Cooling Operation (Heat/Cool) 3-16......................................................

3.10.5 Heating Operation (Heat/Cool) 3-16......................................................

T--298

ii

TABLE OF CONTENTS - Continued

3.11 CHECK THERMOSTAT OPERATION 3-16...................................................

3.11.1 Temperature Display 3-16...............................................................

3.11.2 Timeguard Timer 3-17..................................................................

3.11.3 Cycle Timer 3-17......................................................................

3.11.4 Minimum On Timer 3-17................................................................

3.11.5 Error Messages 3-17...................................................................

WIRING SCHEMATICS 4-1........................................................................

4.1 INTRODUCTION 4-1.....................................................................

LIST OF FIGURES

FIGURE NUMBER Page

Figure 1-1 Model/Serial Number Plate (Typical) 1-1...................................................

Figure 1-2 Roof Unit Component Identification 1-3....................................................

Figure 1-3 Ceiling Unit Component Identification (Free-Blow) 1-4.......................................

Figure 1-4 Component Identification - Low Profile - Upper Unit 1-5......................................

Figure 1-5 Component Listing-Ceiling Unit For Ducted Systems 1-6....................................

Figure 1-6 Ducted System Air Flow Arrangement 1-7.................................................

Figure 1-7 Serial Number Locations 1-8.............................................................

Figure 1-8 Refrigerant Flow Schematic (Standard System) 1-9.........................................

Figure 1-9 Refrigerant Flow Schematic - Heat Pump - (Cool Mode) 1-10.................................

Figure 1-10 Refrigerant Flow Schematic - Heat Pump - (Heat Mode) 1-11................................

Figure 3-1 Filter Removal - Free Blow 3-1...........................................................

Figure 3-2 Ceiling Grill - Free Blow 3-2..............................................................

Figure 3-3 Ceiling Panel Assembly 3-2..............................................................

Figure 3-4 Ceiling Panel With Heat Option 3-2.......................................................

Figure 3-5 Control Box Assembly - Free Blow 3-2....................................................

Figure 3-6 Indoor Thermostat 3-3..................................................................

Figure 3-7 Air sweep motor 3-3....................................................................

Figure 3-8 Heat Strip Assembly 3-3................................................................

Figure 3-9 Filter Removal - Ducted Unit 3-4.........................................................

Figure 3-10 Ceiling Grill - Ducted 3-4...............................................................

Figure 3-11 Control Box & PCB Cover 3-4...........................................................

Figure 3-12 Control Box Assembly - Ducted 3-5......................................................

Figure 3-13 Main/Display PCB’s 3-5................................................................

Figure 3-14 Cover Assembly - Standard 3-5.........................................................

Figure 3-15 Control Box 3-6.......................................................................

Figure 3-16 Control Box Removal 3-6...............................................................

Figure 3-17 Water Cover Removal 3-6..............................................................

Figure 3-18 Upper Scroll Assembly 3-7.............................................................

Figure 3-19 Motor Assembly 3-7...................................................................

Figure 3-20 Spring Clamp Removal 3-7.............................................................

Figure 3-21 Motor Clip Removal 3-7................................................................

Figure 3-22 Condenser Fan Removal 3-8...........................................................

Figure 3-23 Blower Wheel 3-8.....................................................................

Figure 3-24 Condenser With Motor Assembly & Compressor 3-8.......................................

Figure 3-25 Set-Up For Discharging a Capacitor 3-9..................................................

iii

T--298

LIST OF FIGURES

Figure 3-26 Cover Assembly - Low Profile 3-10.......................................................

Figure 3-27 Upper Scroll Assembly Locking T abs (b.) & Screw Locations (c.) 3-10.........................

Figure 3-28 Upper Scroll Assembly Keeper T ab Release 3-10...........................................

Figure 3-29 Upper Scroll & Control Box Cover Removed 3-11...........................................

Figure 3-30 Condenser Fan Assembly & Retaining Ring 3-11...........................................

Figure 3-31 Condenser Fan Motor & Fan Assembly Stop 3-11..........................................

Figure 3-32 Condenser Fan Motor & Fan Assembly Tab 3-11...........................................

Figure 3-33 Condenser Motor Ground 3-12...........................................................

Figure 3-34 Evaporator Motor Locking Tabs 3-12......................................................

Figure 3-35 Evaporator Motor/Blower Assembly In Cradle 3-12.........................................

Figure 3-36 Evaporator Blower Wheel (Flush With End Of Motor Shaft) 3-13..............................

Figure 3-37 Control Box Assembly With Capacitor 3-13................................................

Figure 3-38 Remote Control Components 3-14........................................................

Figure 3-39 Remote Control PCB (FR9 Location) 3-14.................................................

Figure 3-40 Wall Thermostat Wiring Diagram - Cool Only Model 3-17....................................

Figure 3-41 Wall Thermostat Wiring Diagram - Heat/Cool Model 3-18....................................

Figure 4-1 Upper Unit Schematic - Standard & HC 4-1................................................

Figure 4-2 Upper Unit Schematic - Low Profile 4-1...................................................

Figure 4-3 Ceiling Unit Schematic - Cooling Only 4-2.................................................

Figure 4-4 Ceiling Unit Schematic - Heat/Cool 4-2....................................................

Figure 4-5 Ceiling Unit, Standard - Ducted 4-2.......................................................

Figure 4-6 Heat Pump - Upper Unit - Free Blow 4-3..................................................

Figure 4-7 Heat Pump - Ceiling Unit - Free Blow 4-3..................................................

Figure 4-8 Heat Pump - Upper Unit - Ducted 4-4.....................................................

Figure 4-9 Heat Pump - Ceiling Unit - Ducted 4-4....................................................

LIST OF TABLES

TABLE NUMBER Page

Table 1-1 Model Chart 1-2.........................................................................

Table 1-2 Additional Support Manuals 1-3............................................................

Table 2-1 System Self-diagnostics Function (Ducted Remote) 2-4.......................................

T--298

iv

SECTION 1

DESCRIPTION

1.1 INTRODUCTION

This manual contains service instructions and electrical
data for the AirV, Carrier Transport Air Conditioning’s
Recreational Vehicle air conditioning unit.

The AirV units are two piece systems, consisting of the
UpperUnitandtheCeilingunit.TheUpperUnitcontains
the refrigeration system while the Ceiling Unit contains
thecontrols andvents. The Ceiling Units are availablein
a free--blow or ducted configuration.

The free--blow units (see Figure 1-2) deliver air to the
vehicle by means of front and rear end vents and one
downward vent (air shower). The vents may all be
opened or closed to direct air as desired. The front and
rear vents are fitted with motorized dampers that
oscillates to produce an “air--sweep” effect. These units
may be fitted with optional electric heat.

Theductedunits(seeFigure 1-5andFigure 1-6)deliver
air through ducting built in the vehicle ceiling. These
units are fitted with a 12 VDC microprocessor control
system, a display panel (PCB display) and a remote
controller. These units may be wired to provide
thermostatic control of the vehicle furnace.

Carrier’s AirV air conditioning models include cooling
only units, heating/cooling units, and heat pump units.
The cooling only units are available with free blow or
ducted air delivery. Cooling units with heat strips are
available for free blow only.

Operation of the AirV units is controlled automatically by
the temperature controller (thermostat), which
maintains the vehicle’s interior temperature at the
desired set point. Free Blow, cool--only units are
available with a wall mounted thermostat.

Table 1-1 lists model numbers and descriptions of the
AirV units, and Table 1-2 lists additional support
manuals that are available.

1.2 SERIAL NUMBER IDENTIFICATION

Separatepartnumbersandserialnumbersareprovided
for the upper and lower unit assemblies The numbers
may be found on a plate readable from inside the
vehicle, See Figure 1-7.

The first two numbers of the serial number, see
Figure 3-22, is theweektheunitwasmanufactured. 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 designates the
unit serial number. Example: Y43210

Aserialnumber of 1303Y12345 designates that the unit
was manufactured the 13th week of 2003 and the serial
number is Y12345.

Carrier

Air Conditioning

C

Division ofCarrier Corporation

USE AMP20

TIME DELAY FUSE OR

CIRCUIT BREAKER

COMPRESSOR

FAN MOTOR

USE CEILING ASSY/ANY

DATEOFMfg

DESIGN PSIG HIGH 350 LO 150

R--22

MODEL No.

Part No.

VOLTS

CAPACITY

AMPS

SERIAL No.

68RV14102A
99--00468-- 01

115

ph

1

13,500
3,955

13.5
05/03

1303Y12345

oz
kg

RLA

FLA

99--00469-- 01

15.9

0.45

12.5

2.58

hz

V

60

Btu/h

W

A

Figure 1-1 Model/Serial Number Plate (Typical)

1.3 DESIGN CHANGE DESCRIPTIONS

The following list provides a description of changes in
design and serial number breaks for those changes.

1400Y A diode was added to the Ducted Ceiling
assembly control board to stop DC ripple from the
converters,

2900Y Cover screw coating was changed in order to
eliminate corrosion.

3400Y The plastic shroud was modified to improve
drainage.

5100Y A new compressor and capacitor is introduced,
improving stability and increasing capacity.

1201Y The temperature sensor was moved to the grill
to improve temperature sensing during furnace mode,

2501Y The dual air sweep was added.
4501Y A switch was added to skip compressor

malfunction test.
4601Y Change in material was made in order to

strengthen the fan propeller.
4901Y The mounting bolt lengths were increased 3/4

inch.

4901Y The polar whiteducted ceiling color was cut--in.
0703Y & 1903Y Newstyle PCB -- Cool Mode -- Control

& Power Assembly (Fans shut off in auto mode).
0803Y & 2603Y Newstyle PCB -- Heat Pump -- Control

& Power Assembly (Fans shut off in auto mode).
4204Y Minimumfurnacesetpoint loweredfrom 63°Fto

45°F.

1-1

T--298

Table 1-1. Model Chart

115VStandardSyste

m

220VStandardSyste

m

5.3Cool

y

HighCapacit

y

R

V

A

A

R

V

B

A

R

V

A

A

R

V

C

A

UPPER UNIT (ROOF)

Model Number Part Number Voltage Amps Color

115VStandard System

68RV14102A

220VStandard System

68RV11302A

HighCapacit

68RV15102A

Heat Pump

Systems

68RV14112A

LOW PROFILE

68RV15103A

LOW PROFILE

68RV14103A

(Free Blow -- High Capacity)

99--00468--00 1 15/1/60 12.8 White
99--00468--01 1 15/1/60 12.8 Ivory
99--00468--02 220/1/50
99--00468--03 220/1/50

5.3 Cool

6.7 Heat

99--00468--08 1 15/1/60 14.5 White
99--00468--09 1 15/1/60 14.5 Ivory
99--00468--04

(Free Blow)

99--00468--05

(Free Blow)

99--00468--06

(Ducted)

99--00468--07

(Ducted)

99--00468--10

99--00468--12

(Free Blow -- Standard)

1 15/1/60

1 15/1/60

1 15/1/60

1 15/1/60

1 15/1/60

1 15/1/60

12.7 Cool

10.9 Heat

12.7 Cool

10.9 Heat

12.7 Cool

10.9 Heat

12.7 Cool

10.9 Heat

15.1 Cool

13.8 Heat

15.0 Cool

13.7 Heat

White

Ivory

White

Ivory

White

Ivory

White

White

CEILING UNIT

Model Number Part Number Voltage Color Options Interface

68

68

0010

0010

99--00469--00 1 15/1/60 White Cool Only Free Blow
99--00469--01 1 15/1/60 Ivory Cool Only Free Blow
99--00469--02 1 15/1/60 White Heat/Cool Free Blow
99--00469--03 1 15/1/60 Ivory Heat/Cool Free Blow

68RV0010KA 99--00469--06 1 15/1/60 (12VDC) White Cool Only Ducted
68

0030

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

68

0012

99--00469--11 115/1/60 White Heat Pump Free Blow

99--00469--12 1 15/1/60 Ivory Heat Pump Free Blow

68RV0011LA 99--00469--13 1 15/1/60 (12VDC) White Heat Pump Ducted
68RV0010AB 99--00469--23 1 15/1/60 White Cool Only Free Blow
68RV0010AB 99--00469--24 1 15/1/60 Ivory Cool Only Free Blow
68RV0010BB 99--00469--25 1 15/1/60 White Heat/Cool Free Blow
68RV0010BB 99--00469--26 1 15/1/60 Ivory Heat/Cool Free Blow

68RV0040MA 99--00469--22 115/1/60 White Cool Only

68RV0010DB 99--00469--29 115/1/60 White Cool Only

Ducted

Wall Thermostat

Free Blow

Wall Thermostat

T--298

1-2

Table 1-2 Additional Support Manuals

MANUAL--FORM NO.

71LC6A54310 AirV 115 Volts--Free Blow (Cool Only) Owner’s Guide

71LH6A54070 AirV 115 Volts--Free Blow (Heat--Cool) Owner’s Guide
71LD6A54070 AirV 115 Volts--Ducted (Cool Only) Owner’s Guide
71LH6A54070 AirV 220 Volts--Free Blow (Heat--Cool) Owner’s Guide

71RQ6A5401A AirV 115 Volts--Free Blow (Heat Pump) Owner’s Guide
71DQ6A5401A AirV 115 Volts--Ducted (Heat Pump) Owner’s Guide

71DW6A54070 AirV 115 Volts--Ducted Wired Thermostat Owner’s Guide

71LC6A54310 AirV 115 Volts--Free Blow (Cool Only) Owner’s Guide

71LH6A54070 AirV 115 Volts--Free Blow (Heat--Cool) Owner’s Guide

71RW6A54310 AirV 115 Volts--Free Blow Wired Thermostat Owner’s Guide

T--298PL AirV Service Parts ALL

62--50455--00 Basic refrigeration Service Training ALL

EQUIPMENT COVERED TYPE OF MANUAL (For) PART NO.

99--00469--00
99--00469--01

99--00469--02
99--00469--03

99--00469--06
99--00469--08

99--00469--09
99--00469--11

99--00469--12
99--00469--13
99--00469--22
99--00469--23

99--00469--24
99--00469--25

99--00469--26
99--00469--29

1

2

3

4

5

1. Cover

2. Condenser

3. Evaporator

4. Compressor

5. Base Pan

Figure 1-2 Roof Unit Component Identification

1-3

T--298

1

2

3

4

1. Ceiling Panel Assembly

2. Control Box Cover

Figure 1-3 Ceiling Unit Component Identification (Free--Blow)

T--298

3. Control Assembly

4. Ceiling Grill Assembly

1-4

1

2

3

9

8

5

6

4

7

10

11

1. Cover Assembly

2. Scroll Assembly -- Upper

3. Condenser Fan

4. Condenser Motor

5. Evaporator Motor

6. Evaporator Blower Wheel

Figure 1-4 Component Identification -- Low Profile -- Upper Unit

7. Condenser Coil

8. Scroll Assembly -- Lower

9. Evaporator Coil

10. Compressor
1 1. Base Pan Assembly

See Figure 1-3 for Ceiling Package (Free--Blow)

1-5

T--298

1

2

3

12

11

10

4

5

6

7

9

8

1. Telescoping Divider (3 different sizes available)

2. Divider Assembly

3. Frame Panel, Insulation Assembly

4. Control Box Assembly

5. Control Box Cover

6. Suction Packing Assembly

Figure 1-5 Component Listing--Ceiling Unit For Ducted Systems

T--298

7. Remote Control Assembly

8. Remote Control Bracket Assembly

9. Filter Assemblies (2)

10. PCB Cover
1 1. PCB Main Assembly

12. PCB Display

1-6

1

4

5

SCHEMATIC VIEW

1

2

3

5

1

SUPPLY AIR

4

INSTALLED VIEW

1. Vehicle Duct System (Connection)

2. Telescoping Divider (3 different sizes available)

3. Return Air Suction Area

Figure 1-6 Ducted System Air Flow Arrangement

SUPPLY AIR

2

3

RETURN AIR

4. Control Box Assembly

5. Supply Air Discharge Area

1-7

T--298

Serial number
of Upper Unit

Serial Number
of Ceiling Unit

Free Blow Type

Upper Unit

Ceiling Unit

(Cover Removed)

Bottom of
Upper Unit

Serial Number of

Ceiling Unit

(Side of Control Box)

Ceiling Assembly Frame

Ducted Type

T--298

Serial Number
of Upper Unit

Figure 1-7 Serial Number Locations

1-8

Bottom View After Installation

(With Grille Removed)

1.4 AirV SYSTEM COMPONENT SPECIFI­CATIONS

1.4.1 Refrigerant Charge

Standard -- High Capacity -- Heat Pump

R--22 -- 15.9 Ounces

Low Profile (All)

R--22 -- 16.9 Ounces

1.4.2 Compressor -- 115 Volts, 60 Cycles, 1 Phase

a. Locked Rotor Amps -- Standard -- High

Capacity -- Heat Pump

64.5 AMPS6

b. Locked Rotor Amps -- Low Profile

High Capacity

59.0 AMPS

c. Fully Loaded Amps -- Standard

Cooling -- Approximate 12.8 AMPS
Heating -- N/A

d.Fully Loaded Amps -- High Capacity

Cooling -- Approx. 14.5 AMPS
Heating -- Approx. 11 AMPS

e. Fully Loaded Amps -- Low Profile

Cooling -- Approx. 14.1 AMPS
Heating -- Approx. 13.8 AMPS

f. Fully Loaded Amps -- Heat Pump

Cooling -- Approx. 12.8 AMPS
Heating -- Approx. 11 AMPS

1.4.3 Compressor -- 220 Volts, 50 Cycles, 1 Phase
a. Locked Rotor Amps

23.6 AMPS

1.4.4 Thermostat Range (All Free Blow Units)

61° F(16° C) to 89° F(32° C)

1.5 ST ART--UP

Refer to operating instructions in Owners Guide (see
Table 1-2) packaged with the vehicle system.

DISCHARGE
LIQUID

SUCTION

COMPRESSOR

Figure 1-8 Refrigerant Flow Schematic (Standard System)

1.6 REFRIGERANT CYCLE--STANDARD SYSTEM

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

The compressor raises the pressure and the
temperature of the refrigerant and forces it through the
discharge line into the condenser coil. (See Figure 1-8.)

The condenser fan circulates surrounding air (which is
at a temperature lower than the refrigerant) over the
outside of the coil tubes. Heat transfer is established
from the refrigerant (inside the tubes) to the air (flowing
over the tubes). The tubes have fins designed to
improve the transfer of heat from the refrigerant gas to
the air. This removal of heat causes the refrigerant to
liquefy, thus liquid refrigerant leaves the coil and flows
through a strainer to the capillary tube. The strainer
removes any impurities within the refrigerant system.

The capillary tube meters the flow of liquid refrigerant to
the evaporator coil. As the refrigerant flows through the
capillary tube, there is a reduction in pressure and
temperature.

CAPILLARY
TUBE

EVAPORATOR

ACCUMULATOR

CONDENSER

STRAINER

Theevaporator blower (fan)pullsvehicleairthroughthe
filters, which remove particulate matter, and then pass
the cleaned air through the evaporator coil.

The low pressure, low temperature liquid that flows into
the evaporator coil tubes is colder than the air that is
circulated over the tubes. Heat transfer is established
from the vehicle air (flowing over the tubes) to the
refrigerant (flowing inside the tubes). The evaporator
coil tubes have aluminum fins to increase heat transfer
from the air to the refrigerant; therefore the cooler air is
circulated to the interior of the vehicle.

The transfer of heat from the air to the low temperature
liquid refrigerant in the indoor coil causes the liquid to
vaporize. This low temperature, low pressure vapor
passes into the accumulator. The accumulator is
designed with the inlet tube delivering refrigerant to the
bottom of the tank and the outlet tube taking refrigerant
form the top of the tank. This arrangement ensures that
only vapor refrigerant is returned to the compressor,
where the cycle repeats.

When ventilation only is selected, the indoor fan
functions to circulate air throughout the vehicle. The
refrigerant cycle will remain off.

1-9

T--298

1.7 REFRIGERANT CYCLE -- HEAT PUMP

DISCHARGE
LIQUID

SUCTION

ACCUMULATOR

COMPRESSOR

Figure 1-9 Refrigerant Flow Schematic -- Heat Pump -- (Cool Mode)

1.7.1 Cooling

The cooling cycle is energized when the thermostat,
located in the ceiling unit, calls for cooling 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. (See Figure 1-9.)

The main components of the system are the
compressor, reversing valve, air-cooled outdoor coil,
strainer,capillary tube, indoor coil, and theaccumulator.

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

The outdoor fan circulates surrounding air (which is at a
temperature lower than the refrigerant)over the outside
of the coil tubes. Heat transfer is established from the
refrigerant (inside the tubes) to the outdoor air (flowing
over the tubes). The tubes have fins designed to
improve the transfer of heat from the refrigerant gas to
the air; this removal of heat causes the refrigerant to
liquefy, thus liquid refrigerant leaves the coil and flows
through the strainer to the capillary tube. The strainer
removes any impurities within the refrigerant system.

The capillary tube meters the flow of liquid refrigerant to
the indoor coil. As the refrigerant flows through the

CAPILLARY

INDOOR COIL

REVERSING VALVE

OUTDOOR COIL

TUBE

STRAINER

capillary tube, there is a reduction in pressure and
temperature.

The indoor blower (fan) pulls inside air through the
filters, which remove particulate matter, and then pass
the cleaned air through the indoor coil.

The low pressure, low temperature liquid that flows into
the indoor coil tubes is colder than the air that is
circulated over the tubes. Heat transfer is established
from the indoor air (flowing over the tubes) to the
refrigerant (flowing inside the tubes). The indoor coil
tubes have aluminum fins toincrease heat transfer from
the air to the refrigerant; therefore the cooler air is
circulated to the interior of the vehicle.

The transfer of heat from the air to the low temperature
liquid refrigerant in the indoor coil causes the liquid to
vaporize. This low temperature, low pressure vapor
passes into the accumulator. The accumulator is
designed with the inlet tube delivering refrigerant to the
bottom of the tank and the outlet tube taking refrigerant
form the top of the tank. This arrangement ensures that
only vapor refrigerant is returned to the compressor,
where the cycle repeats.

When ventilation only is selected, the indoor fan
functions to circulate air throughout the vehicle. The
refrigerant cycle will remain off.

T--298

1-10

DISCHARGE
LIQUID

SUCTION

CAPILLARY

INDOOR COIL

REVERSING VALVE

ACCUMULATOR

COMPRESSOR

OUTDOOR COIL

TUBE

Figure 1-10 Refrigerant Flow Schematic -- Heat Pump -- (Heat Mode)

STRAINER

1.7.2 Heating

The heating cycle is energized when the thermostat,
located in the ceiling unit, calls for heat The system
controls are positioned for “reverse” refrigerant flow,
with the compressor discharge delivered to the indoor
coil and liquid delivered to the outdoor coil. (See
Figure 1-10.)

The main components of the system are the
compressor, reversing valve, indoor coil, capillary tube,
strainer, air-cooled outdoor coil, and the accumulator.

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

The indoor blower (fan) pulls inside air through the
filters, which remove particulate matter, and then pass
the cleaned air through the indoor coil.

Thevehicle air (which is at a temperature lower than the
refrigerant) passes over the outside of the coil tubes.
Heat transfer is established from the refrigerant (inside
thetubes) to thevehicleair(flowingoverthetubes).The
tubes have fins designed to improve the transfer of heat
from the refrigerant gas to the air; this removal of heat
causes the refrigerant to liquefy, thus liquid refrigerant
leaves the coil and flows through the strainer to the

outdoor coil. The strainer removes any impurities within
the refrigerant system.

The capillary tube meters the flow of liquid refrigerant to
the outdoor coil. As the refrigerant flows through the
capillary tube, there is a reduction in pressure and
temperature.

The low pressure, low temperature liquid that flows into
the outdoor coil tubes is colder than the outdoor air that
is circulated over thetubes. Heat transfer isestablished
from the outdoor air (flowing over the tubes) to the
refrigerant (flowing inside the tubes). The outdoor coil
tubes have aluminum fins toincrease heat transfer from
the air to the refrigerant.

The transfer of heat from the air to the low temperature
liquid refrigerant in the outdoor coil causes the liquid to
vaporize. This low temperature, low pressure vapor
passes into the accumulator. The accumulator is
designed with the inlet tube delivering refrigerant to the
bottom of the tank and the outlet tube taking refrigerant
form the top of the tank. This arrangement ensures that
only vapor refrigerant is returned to the compressor,
where the cycle repeats.

When ventilation only is selected, the indoor fan
functions to circulate air throughout the vehicle. The
refrigerant cycle will remain off.

1-11

T--298

SECTION 2

TROUBLESHOOTING

For ducted units, the green operation indicator LED (SeeFigure 3-9) will flash if there is a problem.
Refer to Table 2--1 for diagnostic information.

SYMPTOM AND PROBABLE CAUSE

2.1 NO POWER TO UNIT

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)

2.2 DUCTED UNIT WILL NOT OPERATE

1. Display not illuminated

2. Display illuminated

2.3 DUCTED UNIT WILL NOT COOL

1. Green LED light flashes 5 times

2. Unit cools for a few moments then stops cooling

2.4 COMPRESSOR POWER SUPPLY OPEN

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

2.5 COMPRESSOR RUNS BUT CYCLES, FAN OPERATING ERRATICALLY

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

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

1. Check 12 Volt DC in--line fuse

2. Check 1 15 Volt AC Connections

1. Check 1 15 volt AC power source
Momentarily disconnect 12 VDC power source
Disable compressor malfunction test switch.

Check AMP draw.

Check ∆ T

2. Remove grill, verify evaporator coil probe is
inserted into coil.

Check AMP draw.
Check ∆ T
Replace unit

1. Tighten leads

2. Replace switch

3. Replace capacitor -- Refer to Paragraph 3.5.8

4. Replace compressor

5. Replace compressor

6. Verify capacitor wiring (Refer to wiring diagram)

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 ∆ T.
Replace unit.

6. Replace switch.

PROBABLE REMEDY

2-1

T--298

SYSTEM AND PROBABLE CAUSE

PROBABLE REMEDY

2.6 CYCLES ON COMPRESSOR OVERLOAD

1. Defective run capacitor

2. Defective compressor bearings or valves

3. Greatly restricted evaporator air, iced evaporator

1. Replace capacitor -- Refer to Paragraph 3.5.8

2. Replace unit.

3. Defrost evaporator coil.

coil.

4. Low refrigerant charge

5. Evaporator capillary restricted

6. Liquid line restricted

7. Compressor hot

4. Replace unit.

5. Replace unit.

6. Replace unit.

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

8. Weak or inconsistent line power

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

2.7 INSUFFICIENT COOLING, COOLING AIR NOT ADEQUATE

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

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 (Refer to paragraphs 3.3.1

& 3.4.1)

2.8 CONDENSER AIR NOT ADEQUATE

1. Outside Air Restricted

2. Dirty coil

3. Defective fan motor

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

2. Clean coil.

3. Replace fan motor.

2.9 INSUFFICIENT COOLING

1. Unit undersized

2. Capillary restricted

1. Re--evaluate unit for proper capacity.

2. Check AMP draw.
Check ∆ T.
Replace unit.

2.10 COMPRESSOR FLOODING

1. Unit overcharged

1. Check AMP draw.
Check ∆ T.
Replace unit.

2. Low evaporator airflow

3. Defective electrical connections

2. Clean filter and/or evaporator coil.

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

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

1. Dirty filter

2. Blocked evaporator air inlet (indoor)

3. Low airflow due to fan motor speed

1. Clean or replace filter.

2. Remove blockage.

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

2.12 AIR SWEEP NOT WORKING (FREE BLOW VERSION ONLY)

1. Ceiling grill not properly aligned

2. Linkage in upper control box stuck

3. Air sweep motor failure

1. Align ceiling grill.

2. Align and lubricate linkage.

3. Replace motor.

2.13 WATER LEAKAGE

1. Water dripping from ceiling unit. 1. Verify vehicle is level
Tighten unit mounting bolts evenly or replace unit

gasket.

T--298

2-2

SYSTEM AND PROBABLE CAUSE

2.14 INADEQUATE HEAT (FREE--BLOW HEAT ONLY)

1. No heat from heat strip. 1. Verify AMP draw . ( 13.8 AMP)
Verify resistance through heating element. (9 OHM)
Check bi--metal switch. If open, replace switch.

2.15 INADEQUATE HEAT (HEAT--PUMP)

NOTE: Allow unit to operate 15 minutes after switch-

ing from cooling mode.

1. Reversing valve not operating

2. Outdoor coil icing.

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

2. Check outdoor coil sensor

PROBABLE REMEDY

Clearing Diagnostic Alarms

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.

2-3

T--298

Table 2--1 System Self--diagnostics Function (Ducted Remote)

Flashes

2

Error Codes

(Priority)

1 ROOM AIR THERM-

Error Contents

(Malfunction)

ISTOR FAILURE

3 2 INDOOR COIL

THERMISTOR FAIL-

URE

4 3 OUTDOOR COIL

THERMISTOR

FAILURE

5 4 COMPRESSOR

DRIVE

MALFUNCTION

Display Pattern Allowed Modes

FAN Mode

FAN Mode

3sec
.

0.5 sec (3
Times)

0.5 sec.
(Twice)

3sec
.

FURNACE Mode

3sec
.

0.5 sec. (4
Times)

3sec.

FAN Mode

FURNACE Mode

3sec.

0.5 sec. (5
Times)

3sec
.

FAN Mode

FURNACE Mode

6 5 REVERSING VALVE

DRIVE MAL--

FUNCTION

1

6 DISCHARGE AIR

THERMISTOR FAIL-

URE

Continuous 7 THERMISTOR

WIRING WRONG

(only in cooling

test mode)

3sec
.

3sec
.

3sec
.

0.5 sec.
(6Times)

0.5 sec.
(Once)

3sec.3sec

.

0.5 sec. (Continu­ous)

3sec
.

3sec
.

FAN Mode

FURNACE Mode

FAN Mode

FURNACE Mode

FAN Mode

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.

T--298

2-4

SECTION 3

SERVICE AND MAINTENANCE

3.1 PREVENTA TIVE MAINTENANCE
Cleaning--Clean evaporator coil and condenser coil.

Hold flashlight behind coil to see if all spaces are clear.
Dust accumulation obstructs or reduces airflow and
results in 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 base pan, motors, fan wheels, and
other components.

Clean cover and ceiling grill. Mild detergents reduce
electrostatic charges on plastic sections of the grill and
are good cleaners.

WARNING

Before working on the unit be sure to first
disconnect all electric power to the unit to
avoidthepossibilityofelectricalshockand
personal injury. Before disconnecting, dis-

charge capacitors by shorting across the
capacitors terminals (Refer to paragraph

3.5.8)

WARNING

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--Make sure unit is secure on roof according

to installation instructions provided in Owner’s Guide.
Checkfanstoinsurethatthey arecorrectly positionedin
the center of the orifice, and tight on the shaft.

Leaks--Check any connections that show evidence of
oil or leaks. When unit is properly installed (refer to
Owner’sGuide) check gaskets for possible air leakage.

Controls--Check 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 side of the unit.

Shield coils with cardboard to protect
hands against injury from sharp metal
edges when removing compressor and oth­er components.

3.3 CEILING UNIT -- FREE BLOW SYSTEMS

3.3.1 Filter Removal

The filters (Figure 3-1) are located in the ceiling grill. To
remove the filters, do the following:

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

ceiling grill.
b. Pull filter completely out of the filter slot.
c. Vacuum filter or wash filter in luke--warm water.

Shake off excess water and dry thoroughly.
d. Replace filter by sliding the filter into the filter slot in

the ceiling grill until the filter frame is flush with the in-

terior grill.

Filters

NOTE

For proper cleaning and flushing, use a UL
approved refrigerant recovery/recycling
system.

NOTE

Refrigerant removal must always include
recovering the refrigerant, not allowing it to
escape to the atmosphere.

3.2 SERVICE -- GENERAL
General Notes—These Service Instructions are

provided to assist the trained and qualified Carrier
service technician in repairing or replacing components
of the AirV units.

Figure 3-1 Filter Removal -- Free Blow

3.3.2 Ceiling Grill Removal

To remove the ceiling grill (Figure 3-2) do the following:
a. Before working on 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.

3-1

T--298

d. To replace the grill, place the grill up against the ceil-

ingpanelandalignthescrew holes in thegrill with the
ceiling panel.

e. Replace 4 screws.

Mounting

Screws

Figure 3-2 Ceiling Grill -- Free Blow

3.3.3 Ceiling Panel Removal

To remove the ceiling panel (Figure 3-3) do the
following:

a. Remove the ceiling grill. (Refer to paragraph 3.3.2.)
b. Remove 5 screws securing the duct plate to the ceil-

ing panel.

Heat Strip
Connection

Heater Assembly

Option

Figure 3-4 Ceiling Panel With Heat Option

3.3.4 Master Control Switch

To remove the master control switch, do the following:
a. Remove ceiling grill. (Refer to paragraph 3.3.2.)
b. Remove 5 screws that secure the control assembly

(Item 2, Figure 1-3) to the control box cover.

c. Remove the master control switch knob by grabbing

the outside edge of the knob and pulling it off of the
switch stem.

d. Remove 2 screws securing the master control switch

to the control assembly.

e. Carefully disconnect wires from the master control

switch. Label wires to aid in reassembly.

f. Reverse above procedure for reassembly.

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 above procedure for reassembly.

Air Sweep Cam

Serial/Model
Number Tag

Duct Plate &
Mounting Holes

Mounting Bolts

Junction Box

Figure 3-3 Ceiling Panel Assembly

Junction Box

Air Sweep Switch

With Cover

Thermostat

Master Control

Switch

Figure 3-5 Control Box Assembly -- Free Blow

3.3.5 Air Sweep Switch Removal

To remove the air sweep switch, do the following:
a. Remove ceiling grill. (Refer to paragraph 3.3.2.)
b. Remove 5 screws securing the control assembly

(Item 2, Figure 1-3) to the control box cover.
c. Disconnect wires from the air sweep switch.
d. Pinch tabs on either end of the switch and slide out of

lower control box cover.
e. Reverse above procedure for reassembly.

T--298

3-2

3.3.6 Indoor Thermostat Removal

To remove the indoor thermostat (Figure 3-6) do the
following:

a. Remove ceiling grille. (Refer to paragraph 3.3.2.)
b. Remove 5 screws securing the control assembly

(item 3, Figure 1-3) to the control box cover.

c. Remove the indoor thermostat knob by grabbing the

outside edge of the knob and pulling it off of the ther­mostat stem.

d.Remove2screwsthatsecuretheindoorthermostatto

the lower control box cover.

e. Carefully disconnect the 2 wires from the indoorther-

mostat.
f. Remove the sensing bulb from the plastic clip.
g. Carefully slide the sensing bulb through the rubber

grommet.
h. Remove the thermostat from the control assembly.
i. Reverse above procedure for reassembly.

Thermostat

Air Sweep Motor

Figure 3-7 Air sweep motor

3.3.8 Heat Strip Assembly Removal

To remove the heat strip assembly (Figure 3-8) do the
following:

a. Remove ceiling grille. (Refer to paragraph 3.3.2.)
b. Unplug electrical connection at air sweep motor as-

sembly.

c. Remove two screws securing heat strip assembly to

the ceiling panel assembly.

d. Slide heat strip assembly away from air sweep motor

assembly and pull down, easing the the electrical
connection through the access hole.

e. Reverse the procedures for reassembly.

Sensing Bulb

Figure 3-6 Indoor Thermostat

3.3.7 Air Sweep Removal

To remove the air sweep, do the following:
a. Remove ceiling grille. (Refer to paragraph 3.3.2.)
b. Remove cam (See Figure 3-3) from air sweep motor

shaft.
c. Remove 4 screws securing air sweep motor bracket

to the ceiling panel assembly.
d. Carefully disconnect air sweep motor wire termina-

tions.
e. Remove 2 screws securing air sweep motor

(Figure 3-7) to control box and remove motor.
f. Reverse above procedure for reassembly.

Heat Strip

Figure 3-8 Heat Strip Assembly

3-3

T--298

3.4 CEILING UNIT -- DUCTED SYSTEMS

3.4.1 Filter Removal

The filters (Figure 3-9) are located in the ceiling grill. To
remove the filters, do the following:

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

ceiling grill.
b. Pull filter completely out of the filter slot.
c. Vacuum filter or wash filter in luke--warm water.

Shake off excess water and dry thoroughly.
d. Replace filter by sliding the filter into the filter slot in

the ceiling grill until the filter frame is flush with the in-

terior grill.

c. Remove two screws securing control box cover to

control box assembly. See Figure 3-11.

d. Remove control box assembly cover.

Mounting Screws

Filters

Operation Indicators

Figure 3-9 Filter Removal -- Ducted Unit

3.4.2 Ceiling Grill Removal

Toremovetheceilinggrill(Figure3--10)dothefollowing:
a. Before working on unit place the master switch in the

OFF position and disconnect all electrical power.
b. Remove filters (Refer to paragraph 3.4.1).
c. Remove 4 screws located on the ceilinggrill, (two are

underthefilters) making sure to support the weightof

the grill.
d. Lower the ceiling grill from the ceiling panel.
e. To replace the grill, place the grill up against the ceil-

ingpanelandalignthescrew holes in thegrill with the

ceiling panel.
f. Replace 4 screws and 2 filters.

3.4.3 Control Box Assembly Removal

To remove the control box assembly (Figure 3-11 &
Figure 3-12) do the following:

a. Remove ceiling grill. Refer to paragraph 3.4.2.
b. Disconnect 115 volt (AC) and 12 volt (DC) power

wires.

Figure 3-10 Ceiling Grill -- Ducted

e. Disconnect blue furnace wires.
f. Unplug two connectors from upper unit.
g. Unplug DC power plug #1 (red/yellow/black wires)

SeeFigure3-12

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

yellow wires). See Figure 3-12

i. While supporting control box assembly remove two

screws securing control box assembly to ducted ceil-

ing unit.
j. Pull controlboxassemblyfromtheductedceilingunit.
k. Reverse above procedure to reassemble.

Control Box

Control Box
Cover Screws

Fuse

PCB Cover

PCB Cover

Screws

Figure 3-11 Control Box & PCB Cover

T--298

3-4

1 15V AC

3.4.5 PCB Display Removal

To remove the PCB display assembly (Figure 3-13) do

the following.

12V DC

a. Remove ceiling grill. Refer to paragraph 3.4.2.
b. Push large clip away from PCB display assembly.

Fuse

Upper Unit
Connectors

Figure 3-12 Control Box Assembly -- Ducted

3.4.4 Main PCB Board Removal

To remove the Main PCB board (Figure 3-13) do the
following:

a. Remove ceiling grill. Refer to paragraph 3.4.2.
b. Remove three screws securing the PCB cover to the

ducted ceiling unit.

c. Carefully turn over the PCB cover exposing the PCB

main and the PCB display assemblies.

d. Gentlypushholdingclipaway from PCB mainassem-

bly.
e. Lift PCB main assembly from PCB cover assembly.
f. Unplug display wiring plug #4. Figure 3-13

#2

#1

Furnace
Wires (blue)

c. Push center clip towards large clip.
d. Pull PCB display assembly from PCB cover.
e. Unplug display wiring from PCB main assembly.
f. Reverse above procedures of reassembly.

3.4.6 Fuse Removal

To remove the fuse (Figure 3-11) do the following:
a. Remove ceiling grill. Refer to paragraph 3.4.2.
b. Turnfuseholderindirectionofarrow(counter--clock--

wise).
c. Pull fuse from fuse holder.
d. Test and/or replace.
e. Reverse above procedures for reassembly.

3.5 SERVICE -- UPPER UNIT -- STANDARD,

HC&HP

3.5.1 Exterior Cover Removal

CAUTION

g. Unplug thermistor/thermostat wiring plug #3.

Figure 3-13
h. Unplug power wiring plug #1. Figure 3-12
i. Unplug signal wiring plug #2. Figure 3-12
j. Reverse above procedures for reassembly.

Holding Clips

PCB Display

PCB Main

#4

Coil fins are sharp. Usecarewhenremoving
the cover form the base pan to avoid per­sonal injury.

To remove the exterior cover, do the following:
a. Before working on unit place the master switch in the

OFF position and disconnect all electrical power.

b. Remove 15 screws securing the unit cover to the

base pan assembly. See Figure 3-14.

c. Carefully lift the exterior cover off of theunit base pan

assembly.

d. Reverse above procedure for reassembly.

#3

Figure 3-13 Main/Display PCB’s

3-5

Cover Screws

Figure 3-14 Cover Assembly -- Standard

T--298

3.5.2 Compressor Replacement

Observe the same procedures for rotary compressors
as for reciprocating compressors.

a. Follow all safety codes. Reminder: use protective

goggles, work gloves, and water soaked quenching
cloth.

b. Remove exterior cover.refer toparagraph 3.5.1.Dis-

connect all wiring from the compressor.

c. Apply field--supplied, line--tap--valves to the suction

and discharge lines as close to the compressor as
possible.

d. Recover therefrigerant charge from the unit. Afterre-

covering,cut the discharge and suction line process
tubes below the tube crimps. If you choose a good
tubing location for cutting the refrigeration lines ini­tially, the location is easily accessible when making
the final joints.

WARNING

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.

Control Box

Screws

Figure 3-15 Control Box

Water
Cover

e. Connectanitrogen supply to theunitatoneoftheline

--tap--valve connectors (5--psig maximum flow), leav­ing the other connector open to the atmosphere.

Braze angle valves with stubs to each process tube.
f. Remove compressor from unit (3 bolts).
g. Remove line--tap--valves from suction and discharge

lines.Carefullybrazetheholesclosedfromwherethe

line--tap--valves were removed.
h. Cleansystem:addorreplaceliquidlinefilter drier.For

proper cleaning and flushing use a UL approved re-

frigerant recycling system.
i. Install new compressor and braze into place with

field--supplied copper slip couplings.
j.Connect wiring: replace wire terminals if necessary.
k. Proceed with evacuation and charging (15.9 OZ. --

.45 KG R22). Pinch off lines where angle valves were

added. Cut off angle valves above pinch--off , and

braze tubes.
l. Start up unit.

3.5.3 Control Box Assembly Removal

To remove the control box assembly, do the following:
a. Removeexterior cover assembly.Refertoparagraph

3.5.1.

b. Remove 2 screws securing control box assembly to

the lower scroll assembly. (SeeFigure 3-15.)

Figure 3-16 Control Box Removal

c. Slide control box out of the lower scroll assembly.

(See Figure 3-16.)

d. To open control box remove 2 screws securing the

water cover to the control box cover.

e. Gently lift the water cover off of the control box. (See

Figure 3-17.)

f. Reverse above procedure for reassembly.

Control Box
Cover

Figure 3-17 Water Cover Removal

T--298

3-6

3.5.4 Upper Scroll Assembly Removal

a. Removeexterior cover assembly.Refertoparagraph

3.5.1.

b. Remove 4 screws securing upper scroll assembly to

the lower scroll assembly. (See Figure 3-18)

c. Gently pry 4 snap clips open and lift the upper scroll

assembly off of the lower scroll assembly.

d. Reverse above procedure for reassembly.

Screws
4 Places

i. Remove condenser fan from motor shaft and lift fan

out through the top of the condenser orifice. (See

Figure 3-22)
j. Remove motor assembly.
k.Reverse above procedure for reassembly.

Ground screw

Motor Ground
Lead

Figure 3-19 Motor Assembly

Snap Clip
4 Places

Figure 3-18 Upper Scroll Assembly

3.5.5 Motor Assembly and Condenser Fan
Removal

a. Removeexterior cover assembly.Refertoparagraph

3.5.1.

b. Remove control box assembly. Refer to paragraph

3.5.3.

c. Remove upper scroll assembly. Refer to paragraph

3.5.4.

d. Remove 4 screws securing the condenser cover to

the condenser orifice. (See Figure 3-24.)

e. Carefully disconnect motor wire terminations from

within the control box.

f. Remove 1 screw securing the motor ground lead to

the motor bracket assembly. (See Figure 3-19)

g. Using flat--nosed pliers, depress the motor spring

clamp and slide it off of the condenser fan (See
Figure 3-20).

h. Liftandslidemotortowardsevaporatorcoiltoremove

condenser fan from the motor shaft.

Spring Clamp

Figure 3-20 Spring Clamp Removal

Motor Clip

Figure 3-21 Motor Clip Removal

3-7

T--298

Condenser Fan

3.5.7 Air Handling System Removal

a. Removeexterior cover assembly.Refertoparagraph

3.5.1.

b. Remove control box assembly. Refer to paragraph

3.5.3.

c. Remove upper scroll assembly. Refer to paragraph

3.5.4.
d. Remove motor assembly. Refer to paragraph 3.5.5.
e. Remove 8 screws securing lower scroll assembly to

the base pan assembly.

f. Remove 1 screw from clamp securing suction tubeto

the base pan assembly.

g. Remove 3 nuts securing the compressor to the base

pan assembly.

h. Remove 2 screws securing the condenser orifice to

the base pan assembly.

Figure 3-22 Condenser Fan Removal

3.5.6 Evaporator Blower Wheel Adjustment or
Removal

a. Remove exterior cover assembly. Refer to Exterior

Cover Assembly Removal instructions 3.5.1

b. Remove control box assembly. Refer to Control Box

Assembly Removal instructions 3.5.3

c. Remove upper scrollassembly.Refer to Upper Scroll

Assembly Removal instructions 3.5.4

d. Loosen motor assembly. Refer to Motor Assembly

Removal instructions 3.5.5.

e. Mark shaft at a point where wheel hub and motor

shaft meet to aid in reassembly.(See Figure 3-23.)

f. Remove 1 set screw holding the blower wheel to the

motor shaft. (See Figure 3-23)
g. Slide off blower wheel from motor shaft
h. Reverse above procedure for reassembly.

Set Screw

i. Remove 2 screws securing the condenser coil as-

sembly to the base pan assembly.

j. Carefully lift the entire assembly off of the base pan

assembly.

k. Reverse the above procedure for reassembly,ensur-

ing that the air handling system is positioned correct­ly. Tighten all screws.

Compressor

Condenser Cover

Condenser

Cover Screws

Motor Assembly

T--298

Figure 3-23 Blower Wheel

Base Pan

Base Pan

Figure 3-24 Condenser With Motor Assembly &

Compressor

3-8

3.5.8 Capacitor Troubleshooting

WARNING

WARNING

Disconnect power to the AirV unit before
checking the capacitor.

To test capacitor to determine if good, open or shorted,
an ohm meter can be used. Todetermine a capacitor’s
capacitance, a capacitor meter is required.

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

3.5.9 Capacitor Testing and Replacement

Capacitors must be discharged properly before testing.
a. Place a 20,000 ohm, 2 watt resistor across the termi-

nals of the capacitor for approximately 30 seconds
(See Figure 3-25 for a suggested tool).

INSULATED SCREWDRIVER

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

b. After the capacitor has been dischargedand all wires

removed from the capacitor terminals, use an ohm-­meter 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. Iftheohmmeterfirst reads 0, then rises towardinfinity

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.

20,000 -- OHM
2 -- WATTRESISTOR

CLIP TO
SCREWDRIVER

Figure 3-25 Set--Up For Discharging a Capacitor

3.5.10 Positive Temperature Coefficient Thermister
(PTC) (Start Thermistor) Troubleshooting

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 havecontinuity, it must bereplaced.
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.

ATTACH TO CLEAN UNPAINTED
METAL PART OF UNIT FRAME

TOUCH TO CAPACITOR TERMINALS
TO DISCHARGE CAPACITOR

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.

3.5.11 Line Voltage -- 10%

Line voltage should be checked during peak electrical
load periods.

With the AirV unit onandthecompressoroperating,use
a voltmeter to check the voltage being supplied to the
AirV unit. The voltage must be within 10% of the units
required voltage. A voltage drop greater than 10% will
cause a premature compressor failure and needs to be
corrected immediately.

3-9

T--298

3.6 SERVICE -- UPPER UNIT -- LOW PROFILE

3.6.1 Exterior Cover Removal

CAUTION

b. b.

Coil fins are sharp. Usecarewhenremoving
the cover form the base pan to avoid per­sonal injury.

To remove the exterior cover, do the following:
a. Before working on unit place the master switch in the

OFF position and disconnect all electrical power.

b. Remove (8) screws securing the unit cover to the

base pan assembly. See Figure 3-26.

c. Carefully lift the exterior cover off of theunit base pan

assembly.

d. Reverse above procedure for reassembly.

Screws

Screws

b.

b.

c.

b.

Figure 3-27 Upper Scroll Assembly

Locking Tabs (b.) & Screw Locations (c.)

b.

Figure 3-26 Cover Assembly -- Low Profile

3.6.2 Upper Scroll Assembly Removal

To remove the upper scroll assembly, do the following:
a. Removeexterior cover assembly.Refertoparagraph

3.6.1.

b. Releasethe(2)front,(2)rear,(1) left sideand(1)right

sidelockingtabs(SeeFigure 3-27) bypullingbackon
the tabs (See Figure 3-28).

c. Remove the screw (1) from the control box cover

(See Figure 3-27).

d. With all (6) locking tabs released and control box

screw removed, lift the upper scroll assembly off of
the lower scroll assembly.

e. Reverse above procedure for reassembly.Ensure all

(6) locking tabs snap shut & lock.

Figure 3-28 Upper Scroll Assembly

Keeper Tab Release

T--298

3-10

Evaporator Coil

Condenser Coil

Retaining

Ring

Figure 3-30 Condenser Fan Assembly

& Retaining Ring

Fan Stop

Figure 3-29 Upper Scroll & Control Box

Cover Removed

3.6.3 Condenser Fan Assembly Removal

To remove condenser fan assembly, do the following:
a. Perform steps outlined in Section 3.6.2.
b. Depress and remove Retaining Ring (See

Figure 3-30).
c. Using both hands, carefully pull up on fan assembly

until it is free of the motor shaft.
d. When replacing the fan assembly make sure the fan

assembly is against the stop on the shaft (See

Figure 3-31)

13MM

Bolt

Condenser Motor

Grommet

Figure 3-31 Condenser Fan Motor

& Fan Assembly Stop

Tab

13MM

Bolt

e. Push back on tab to allow fan assembly to rest

against stop (See Figure 3-32). Fan assembly will

now be flush with the end of the motor shaft.
f. Reverse above procedure for reassembly.

3-11

Figure 3-32 Condenser Fan Motor

& Fan Assembly Tab

T--298

3.6.4 Condenser Motor Removal

To remove condenser fan motor, do the following:
a. Perform steps outlined in Section 3.6.2.
b. Remove (3) 13MM bolts (See Figure 3-31).
c. Remove (3) Grommets. Inspect, replace or reuse.
d. Cut Tie--Wraps & discard (2 locations). When re-

assembling, tie--wrap at same 2 locations.

e. Remove ground wire from compressor bracket (See

Figure 3-33).

f. Un--plug (yellow/brown/white) from control box as-

sembly.

g. Reverse above procedure for reassembly.

Cond. Motor
Ground Screw

Blower Side Locking T abs

Outside Locking T abs

Comp. Mounting Bolt

Figure 3-33 Condenser Motor Ground

3.6.5 Evaporator Motor/Blower Assembly
Removal

To remove the evaporator motor, do the following:
a. Perform steps outlined in Section 3.6.2.
b. Pull back on and release the (4) locking tabs. There

are 2 on each side of the control box assembly. (See
Figure 3-34).

c. Lift control box assembly from lower scroll assembly,

exposing evaporator motor.

d. Un--plug (black/blue/white/brown) evaporator motor

from control box assembly.

e. Remove ground wire (green/yellow) from motor

housing.

f. Lift motor/blower assembly from lower scroll assem-

bly cradle.

g. Carefully remove the blower wheelfrom theevapora-

tor motor shaft by pushing out from the motor side.

Figure 3-34 Evaporator Motor Locking Tabs

Lower Scroll

Assembly

Capacitor

Cradle

Figure 3-35 Evaporator Motor/Blower Assembly

In Cradle

T--298

3-12

NOTE

When reassembling the blower wheel on to
the motor shaft ensure that the blower
wheel is flush with the end of the motor
shaft (SeeFigure 3-36).

h. Reverse above procedure for reassembly.

NOTE

When placing the evaporator motor/blower
assembly back into the lower scroll assem­bly cradle, make sure that the assembly is
seated securely in the cradle.
(See Figure 3-35).

3.6.6 Compressor Replacement

Perform the procedures outlined in Section 3.5.2
There are 4 bolts with the Low Profile Compressor.
The system charge for the Low Profile unit is 16.9 OZ.

3.6.7 Capacitor Removal

To remove the capacitor, do the following:

Wheel Flush With Motor Shaft

Figure 3-36 Evaporator Blower Wheel

(Flush With End Of Motor Shaft)

Upper Scroll Assembly

a. Perform steps a., b. & c. as outlined in Section 3.6.5.
b. Perform steps outlined in Sections 3.5.8 & 3.5.9.
c. The Low Profile Capacitor is removed from the con-

trol box assembly by pushing on the capacitor from
under the control box assembly (See Figure 3-35).

Control Box Assembly

Capacitor

Terminal Block

Figure 3-37 Control Box Assembly With Capacitor

3.6.8 Remote Control (Fahrenheit to Celsius)

All Remote Control Assemblies in the United States are
pre--set to display in Fahrenheit degrees (see
Figure 3-38). To change from a Fahrenheit display to a
Celsius display do the following:

3-13

CAUTION

The change from Fahrenheit to Celsiuswill
bepermanent.Itcannotbechangedbackto
Fahrenheit.

T--298

a. Remove the batteries from the remote control.
b. Carefully remove the remotecover by insertinganar-

row 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 (see Figure 3-39).

f. Carefully cut the FR9 jumper wire.
g. Reverse above procedure for reassembly.

CAUTION

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

BATTERIES

&

COVER

Battery Springs

PCB

COVER

Figure 3-38 Remote Control Components

Spring Holders

BODY

T--298

PCB

FR9

Figure 3-39 Remote Control PCB (FR9 Location)

3-14

3.7 THERMOSTAT INSTALLATION AND START-­UP INSTRUCTIONS (WALL MOUNTED)

3.7.1 Introduction

The thermostat is a wall mounted, low--voltage
thermostat which maintains room temperature by
controlling the operation of a heating and air
conditioning system. Batteries are not required;
temperature and mode settings are preserved with the
power off.

2.Disconnect wires from existing thermostat, one at
a time. Be careful not to allow wires to fall back into
the wall.

3.As each wire is disconnected, record wire color
and terminal marking.

4.Discard or recycle old thermostat.

NOTE

Mercuryisahazardouswasteandmustbedes­posed of properly.

CAUTION

Improperwiring orinstallationmaydamage
thermostat. Wiring must conform to local
and national electrical codes.

WARNING

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

3.7.2 Installation

NOTE

Readallinstructionsbeforestarting theinstalla­tion.

NOTE

The thermostat requires no batteries. The ther­mostat is not a power stealing device and
MUST have both R and C connected.

c. Seperate the front and back pieces of plastic.
d. Route thermostat wires through hole in back piece of

plastic. Level plastic against wall (for aesthetic value
only -- thermostat need not be leveled for proper op­eration) and mark wall through 2 mounting holes.

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

marked.

NOTE

Mounting holes on thermostat are designed to
fit on a horizontal J--Box.

f. Securebackplasticto wallwith2anchorsandscrews

provided,makingsureallwiresextendthroughholein
plastic.

g. Connect wires to proper terminal of the connector

block in the front piece of plastic.

h. Pusr any excess wire back into wall. Excess wire in-

side the thermostat plastic case can interfere with
proper air flow across the temperature sensor. Seal
hole in wall to prevent air leaks. Leaks can effect op-

eration.
i. Snap front and back pieces of plastic together.
j. Turn on power to the unit.

3.8 LCD DISPLAY

3.7.3 Thermostat Location

The thermostat should be mounted:

Approximately 5 foot (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:

Closetoawindow,oranoutsidewall,ornexttoadoor
leading to the outside.

Exposedtodirectlightandheatfromalamp,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.

3.7.4 Install Thermostat -- 12VDC

a. Turn off all power to unit.
b. If an existing thermostat is being replaced:

1.Remove existing thermostat from wall.

3.8.1 Cool Only Thermostat (Part No. 11 10--421)

On power up, the LCD readout will display C (Cool
Only).

3.8.2 Heat/Cool Thermostat (Part No. 1110--420)

On power up, the LCD readout will display HC (Heat/
Cool).

3.9 SET THERMOSTAT CONFIGURATION

While in configuration mode, three option choices can be
made.

A -- Anticipator Value Adjustment
d -- Display Temperature Fahrenheit/Celcius Selection
oF -- Offset Adjustment For Room Temperature

3.9.1 Enter Configuration Mode

EnterandholdtheFANbuttonforapproximately 10 sec­ondsuntilroom temperaturedisappears and the display
reads A. You are now in the configuration mode.

3-15

T--298

NOTE

IftheFANbuttonispressedagainorif nobutton
is pressed for two minutes, the thermostat will
exit the configuration mode and return to nor­mal operation. To re--enter the configuration
mode, the FAN button must be pressed and
held for 10 seconds again.

While in the configuration mode, the following options
are available:

A. ANTICIPATOR -- Value Adjustment

Thisadjustmentcontrolsthesensitivityandcyclerate of
the thermostst. Higher numbers decrease the
sensitivity and slow the cycle rate. Lower numbers
increase the sensitivity and increase the cycle rate.
However, a limiting feature will not allow more than 4
equipmentcyclesperhour,regardlessofsetting.Values
can range from 1 to 3. Factory default setting is 2. This
default selection will provide optimum performance in
nearlyallinstallations.Tryitfirst. Donotchangesettings
unless there is evidence of need to do so. Unlike
conventional anticipators, this setting is not determined
by current draw. There is no need to measure, know,or
compensate for current.

To Adjust:

a. Enter configuration mode (if not already there).
b. Use UP & DOWN buttons to display A.
c. Press MODE button once to display current value.
d. Use UP & DOWN buttons to move betweenvalues.
e. Press MODE buttonto return to A.UP &DOWN

buttons now move between option choices A, d, oF or
press FAN button to exit configuration mode.

d. Fahrenheit/Celsius Selection

This selection operates the thermostat in either
Fahrenheit or Celsius.

To Select:

a. Enter configuration mode (if not already there).
b. Use UP & DOWN buttons to display d.
c. Press MODE button once to display current

selection of F or C.
d. Use UP &DOWNbuttonstochangebetweenF&C.
e. Press MODE buttonto return to d.UP &DOWN

buttons now move between option choices; or press
FAN button to exit configuration mode.

oF. Room Temperature Offset Adjust Selection

The selected number is the number of degrees, plus or
minus, which will be added to the actual temperature.
The numbers can range between --5 and +5. Factory
default is 0. This adjusted value will be used as actual
temperature for both display and control action. The
effect is that a positive number selection will make the
room temperature lower, and vice versa. The
thermostat is calibrated within an accuracy of plus or
minus 2 degrees when shipped from the factory; this
adjustment will provide thebestaccuracy whenset to o.

To Select:

a. Enter configuration mode (if not already there).
b. Use UP & DOWN buttons to display oF .

c. Press MODE button once to display offset value.
d. Use UP & DOWN buttons toselect a value between

--5 and 5.
e. Press MODE buttonto return to oF.UP &DOWN

buttons now move between option choices; or press
FAN button to exit configuration mode.

3.10 CHECK THERMOSTAT OPERATION

3.10.1 Fan Operation (Cool Only)

1. Press FAN button, starting fan operation. FAN an­nunciator turns on; Lo is displayed in the room tem­perature area for 5 seconds indicating Fan Low
Speed.

2. Press FAN button, FAN annunciator remains on; Hi
is displayed in room temperature area for 5 seconds
indicating Fan High Speed.

3. Press FAN button, stopping fan operation. FAN an­nunciator turns off.

3.10.2 Fan Operation (Heat/Cool)

1. Press FAN button, starting low fan (Lo) operation.
FAN annunciator turns on.

2. Press FAN button, starting high fan (Hi) operation.
FAN annunciator remains on.

3. Press FAN button, stopping fan operation. FAN an­nunciator turns off.

3.10.3 Cooling Operation (Cool Only)

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

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

3.10.4 Cooling Operation (Heat/Cool)

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

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

3.10.5 Heating Operation (Heat/Cool)

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

2. PressUPbuttonuntilLCDreadoutreads10degrees
above room temperature. Heating system should
begin to operate within 1 minute.

3.11 CHECK THERMOSTAT OPERATION

3.11.1 Temperature Display

The thermostat will display room temperature until the
UPorDOWN buttonispressed. The word SETappears
when these buttons are pressed and the current set
point is displayed. If no buttons are pressed for 5
seconds, the display will change back to show room
temperature.

T--298

3-16

3.11.2 Timeguard Timer

A 3--minute timeguard is built into the thermostat
immediately upon power up, and any time the
compressor (output “Y”) turns off. The compressor will
notturn on until the timeguardhasexpired. Pressing UP
and FAN buttons simultaneously will override the
timeguard for 1 cycle.

3.11.3 Cycle Timer

In normal cooling (and heating) operation the
thermostat will not allow more than 4 equipment cycles
per hour (or 1 cycle every 15 minutes). Both the “Y”
(cooling) and “W” (heating) outputs have a 15--minute
timer that starts counting down when the output is
turned on, (e.g., if “Y” output is turned on for 9 minutes
and then satisfies, it cannout turn back on for another 6

minutes regardless of demand). However, pressing UP
and F AN buttons simultaneously or changing the set
point will override the timer for 1 cycle.

3.11.4 Minimum On Timer

Oncetheequipmenthasturnedon,itwillremainonfora
minimum of 2 minutes regardless of demand. However,
the equipment can turn off in less than 2 minutes if a
change in set point, or a changein mode occurs.

3.11.5 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.

UPPER UNIT

Motor Comp.

1234 2

1234

POWERBOX

ASSEMBLY

Factory Wiring Field Wiring

1

115V AC High V oltage

J

Power Supply

L

N2

N1

THERMOSTAT

1
2
3
4
5

W

Y

GH

GL

C

COOL (Compressor)

Y

FAN (High)

GH

GL

FAN (Low)

R

12VDC LowVoltage

Power Supply

C

CEILING UNIT

Figure 3-40 Wall Thermostat Wiring Diagram -- Cool Only Model

3-17

T--298

UPPER UNIT

Motor Comp.

1234 21

Factory Wiring Field Wiring

1234

POWERBOX
ASSEMBLY

J

115V AC High V oltage

Power Supply

L

N2

N1

THERMOSTAT

1
2
3

4

5

Blue

1

Blue

2

W

Y

GH

GL

C

TB

COOL (Compressor)

Y

FAN (High)

GH

GL

FAN (Low)

R

C

+ 12VDC

12VDC LowVoltage

Power Supply

12 VDC (Gnd)

T--298

CEILING UNIT

FURNACE

Figure 3-41 Wall Thermostat Wiring Diagram -- Heat/Cool Model

3-18

SECTION 4

WIRING SCHEMATICS

4.1 INTRODUCTION

This Section contains wiring schematics for the AirV units.
Figure 4--1 is the schematic for the standard upper unit assembly and it is applicable to all standard units.
Figure 4--2 is the schematic for the Low Profile upper unit assembly.
Figure 4--3 is the schematic for a free blow ceiling unit without heat while Figure 4--4 is a free blow unit with heat.
Figure 4--5 is for a ducted unit with microprocessor control.
Figure 4--6 is for an Upper Unit Heat Pump with free blowapplication and Figure 4--7 is the matching free blowceiling

unit.
Figure 4--8 is for the Upper Unit Heat Pump ducted application and Figure 4--9 is the matching ducted ceiling unit.
Notethat the ductedunits have 115VACpowerforthecomponents and 12 VDC power for themicroprocessorcontrol

system.
Figure 4--10is for the ductedorfreeblowapplicationthatusesawall--mounted thermostat, with or without thefurnace

option.
Where applicable, diagrams that designate 115Volt, 60 H, 1 Phase, arealsoavailableusing220Volts,50H,1Phase.

Most noteably Figure 4--1 and Figure 4--5.

4P

11

22

PLUG CONNECTS
TO CEILINGUNIT
SEE FIG> 4--3
OR 4--4

3

4

2P

1

2

(UNIT -- 99--00468--10)

4P

2P

1
2

PLUG CONNECTS TO CEILING UNIT.

WIRING.

SEE DIAGRAM SUPPLIED WITH

CEILING UNIT FOR ADDITIONAL

OLP: OVERLOAD PROTECTION
PTC: STARTTHERMISTER
JTB: JOINT TERMINAL BLOCK
FMC: INDOORFAN MOTOR CAPACITOR

1
2
3
4

FAN MOTOR

2P

BLK

BLU

WHT

WHT

YEL

2

1

C

GRN/YEL

BLK

BLU

CONTROL

BOX

YEL

GRN/YEL

EVAP.

OVERLOAD PROTECTOR

(IfUsed)

COMPRESSOR

Figure 4--1 Upper Unit Schematic -- Standard & HC

WHT
BRN

YEL

(IF USED)

1

OLP

4P

1

1

2

2

3

3

4

4

3P

1
2
3

(3)

YEL

1

WHT

2
3

BRN

YEL

C

2

COMPRESSOR

LEGEND

BLK
BLU
WHT

GRN/YEL

FMC

WHT

YEL

YEL

GRN/YEL

BRN

WHT

WHT

RED

R

S

BLK

BLU
WHT
BRN

R

S

BRN

RED

BLU

F

C

H

CAPACITOR

BLU

PTC

INDOOR FANMOTOR

OUTDOOR FANMOTOR

F

C

WHT

RED

BLU

PTC

(IF USED)

CAPACITOR

H

BLURED

GRN/YEL

Figure 4--2 Upper Unit Schematic -- Low Profile

4-1

T--298

{

115 VAC
SUPPLY
WIRE

BLK

SW

GRN/YEL

4

BLK

4P

2

BLU

ASW

ORN

61

YEL

8

2

C

IT

ORN

1

12

2P

ORN

L

WHT

ASM

WHT

GRN/YEL

1

2

3

4

2P

WHT

YEL

1

2

Figure 4--3 Ceiling Unit Schematic -- Cooling Only

SWITCH

POSITION

HIGH FAN
LOW FAN

OFF
LOW COOL
HIGH COOL

ASW

CONTACTS MADE

1--4 . 1--6
1--2 . 1--6

NONE

1--2 . 1--6 . 1--8

1--4 . 1--6 . 1--8

O (OFF)

I(ON)22--1

LEGEND

ASM : AIR SWEEPMOTOR

ASW :AIR SWEEPSWITCH

SEE DIAGRAM SUPPLIED WITH

SW : SWITCH

UPPER UNIT FOR ADDITIONAL WIRING.

IT : INDOORTHERMOSTAT

PLUG CONNECTS TO UPPER UNIT.

SW

H

L

L1

B

L2

WHT

GRN/YEL

A

YEL

RED

1

3

BLU

BLK
WHT

1

1

3

HT

C

CEC

115 VAC
SUPPLY
WIRE

{

BLK

BLK

LEGEND

IDC Th : INDOoR COIL THERMISTER

RA Th : ROOM AIR THERMISTER

KY : RELAY

DI:DIODE

RATh

IDC Th

BLK

BRN

CN1

1
2
3
4

CONTROL

PCB

ASS’Y

24

135786

CN9

CN9

24135786

DISPLAYPCB AS

ORN

IT

2P

2

BLK

2

BLK

21

ASW

HEATER--ASSY

HEATER

BT

WHT

YEL

BLU

ORN

2P

ORN

112

WHT

ASM

WHT

WHT

GRN/YEL

4P

2P

1

2

3

4

1

PLUG CONNECTS TOUPPER UNIT.

UPPER UNIT FOR ADDITIONAL

2

SEE DIAGRAM SUPPLIEDWITH

Figure 4--4 Ceiling Unit Schematic -- Heat/Cool

23412

BLK

WHT

FUSE

250V 3.15A

D1

CN4

11

2
3
4

5
6

8

11
2
3

CN4

1
2
3
4
5
6
7
8 8

1
2
3

2
3
4

RY3

5
6
77

2
3

GRN/YEL

BLU

WHT

BLK

CN3

213

1Y

RY2

RY4

2

1

CN2

BLU

BLU

SWITCH

POSITION CONTACTS MADE

OFF

LOW FAN
HIGH FAN

LOW COOL

HIGH COOL

HEAT

ASW

LEGEND

WIRING.

RY1

L
N2
N1

2
1

CN1

L1--L .L1--A
L1--H .L1--A

L2--C .L1--L. L1--A. B--3

L2--C .L1--H. L1--A. B--3

L2--HT.L1--L.L1--A.B--1

O (OFF)

1(ON)

ASM AIRSWEEP MOTOR
ASW AIRSWEEP SWITCH
SW SWITCH

IT INDOOR THERMOSTAT
CEC CLOSED END CONNECTOR

BT BIMETAL

BLK

WHT

GRN/YEL

RED
BLK

NONE

2

2--1

115 VAC POWER

12 VDC POWER

(+)
(--)

T--298

Figure 4--5 Ceiling Unit, Standard -- Ducted

4-2

4P
1

2
3
4

BLK
BLU

WHT

GRN/YEL GRN/YEL

4P

1

1

2

2

3

3

4

4

FAN MOTOR

BLK

BLU

WHT

BRN

OLP: OVERLOAD PROTECTION
PTC: STARTTHERMISTER
RVC: REVERSING VALVECOIL

GRN/YEL

BRN

{

PLUG CONNECTS TO CEILING UNIT.

SEE DIAGRAM SUPPLIED WITH

115 VAC
SUPPLY
WIRE

BLK

BRN

EVAP.

BLK

2P

1

212

(IF USED)

1

BLK(BLU)

YEL

2

(3)

WHT

RVC

F

C

WHT

WHT

R

C

S

REDOLP

BLU

H

PTC

CAPACITOR

BLURED

CONTROL

2P
1

2

2P

1

WIRING.

CEILING UNIT FOR ADDITIONAL

2

BOX

RED

FREEZE

SWITCH

COMPRESSOR

Figure 4--6 Heat Pump -- Upper Unit -- Free Blow

BLK

BLK

BLK

SW

L1

L2

B

GRN/YEL

21

C

2

IT

ASW

BLK

BLU

BLK

WHT

ORN

11

2P

BLK

22

WHT

YEL

CEC

2P

ORN

WHT

112

2

WHT

GRN/YEL

ASM

BRN

WHT

H

L

ORN

A

HT

WHT

YEL

RED

HEATER AS

HEATER BT

H

1

33

L

C

1

4P

1

2

3

4

2P
1

2

PLUG CONNECTS TOUPPER UNIT.

2P

1

2

SWITCH

POSITION

OFF
LOW FAN
HIGH FAN

WIRING.

LOW COOL
HIGH COOL

HEATING

ASM: AIRSWEEP MOTOR

UPPER UNIT FOR ADDITIONAL

SEE DIAGRAM SUPPLIEDWITH

ASW: AIRSWEEP SWITCH

SW: SWITCH

IT: INDOOR THERMOSTAT
CEC: CLOSED END CONNECTO R

BT: BIMETAL

ASW

O (OFF)

LEGEND

L1--L .L1--A

L1--H .L1--A

L2--C .L1--L. L1--A. B--3

L2--C .L1--H. L1--A. B--3

L2--HT.L1--L.L1--A.B--1

1(ON)22--1

CONTACTSMADE

NONE

Figure 4--7 Heat Pump -- Ceiling Unit -- Free Blow

4-3

T--298

1

2

3

1

2

3

4

1

2

1

PLUG CONNECTS TO CEILINGUNIT.

SEE DIAGRAM SUPPLIED WITH

2

WIRING.

CEILING UNITFORADDITIONAL

BRN

BLK

BLK

BLU

RED

GRN/YEL

CONTROL

BOX

BLK(BLU)

EVAP.

WHT

YEL

ODC Th

ODA Th

RVC

CN

BLK

1

BLU

2

RED

3

5

6

FAN MOTOR

GRN/YEL

WHT

BRN

BRN

WHT

COMPRESSOR

OLP

(IF USED)

1

YEL

C

2

(3)

CN

LEGEND

CN :HOUSING CONNECTOR
PTC :STARTTHERMISTOR

OLP :OVERLOAD PROTECTOR

RVC :REVERSING VALVE COIL
ODA Th :OUTDOOR AIR THERMISTOR
ODC Th :OUTDOOR COIL THERMISTOR

C

RED

R

S

RED

BLU

PTC

F

H

CAPACITOR

BLU

Figure 4--8 Heat Pump -- Upper Unit -- Ducted

LEGEND

IDC Th: INDOOR COIL THERMISTER
RA Th: ROOM AIR THERMISTER
ODC Th: OUTDOOR COIL THERMISTER

ODA Th :OUTDOOR AIR THERMISTOR

RVC: REVERSING VALVE COIL
D1: DIODE
K: RELAY

RA Th

IDC Th

BLK

BRN

CN1

1

CONTROL PCB

2
3
4

1133576

CN9

CN9

DISPLAYPCBAS

ASS’Y

224

4

8

578

6

PLUG CONNECTS TOUPPER UNIT.

SEE DIAGRAM SUPPLIEDWITH UPPER UNIT

FORADDITIONAL WIRING.

GRN/YEL

CN3CN5

K4K3

FUSE

250V 3.15A

COMPRESSOR

BLK

Y

D1

FURNACE SIGNAL

ODC ODA

BLK

CN5
1

2
3

22
33
44
55
66
7

CN4

1
2
3

CN6

RED

BRN

7

CN4

1
2
33

CN6

RVC MOTOR

WHT

BLK

111
2
3

K7

4
5
6
7
888

POWER PCB ASS’Y

1

K6

2

12

CN2

BLU

11

22

33

41221

BLU

BLK

RED

11

22

34

K2

BLUBLU

Figure 4--9 Heat Pump -- Ceiling Unit -- Ducted

NOTE

*

FACTORY WIRING
FIELD WIRING

*

(115VACHIGHVOLT.)

*

FIELD WIRING

WHT

L

K1

N2
N1

RED

2
1

BLK

CN1

(12VDC LOWVOLT.)

BLK

WHT

GRN/YEL

115VAC POWER

(+)

12VDC POWER

(--)

T--298

4-4

Figure 4--10 Ceiling Unit -- Wall Thermostat -- Ducted & Free Blow

4.2 WALL MOUNTED THERMOSTA TS

For proper wiring of Wall Mounted Thermostats as an accessory, refer to Figure 3-40 (Wall Thermostat Wiring
Diagram -- Cool Only Model) or Figure 3-41 (Wall Thermostat Wiring Diagram -- Heat/Cool Model).

4-5

T--298

INDEX

A

Air Handling System , 3-8
Air Sweep Removal, 3-3
Air Sweep Switch , 3-2

C

Capacitor Testing, 3-9
Capacitor Testing and Replacement, 3-9
Ceiling Grill -- Ducted, 3-4
Ceiling Grill -- Free Blow, 3-1
Ceiling Panel -- Free Blow, 3-2
CEILING UNIT -- DUCTED SYSTEMS, 3-4
CEILING UNIT -- FREE BLOW , 3-1
Cleaning, 3-1
Compressor , 3-6, 3-13
Condenser Fan, 3-7
Control Box -- Ducted, 3-4
Control Box -- Upper Unit, 3-6

I

Indoor Thermostat , 3-3
INTRODUCTION, 1-1, 4-1

L

LCD DISPLAY, 3-15, 3-16
Leaks, 3-1

M

Main Pcb Board, 3-5
Master Control Switch, 3-2
Motor , 3-7
Mounting, 3-1

P

Painting, 3-1
PCB Display , 3-5
PREVENTATIVE MAINTENANCE, 3-1

Controls, 3-1
Cool Only Thermostat, 3-15

D

Design Change, 1-1

E

Evaporator Blower Wheel, 3-8
Exterior Cover, 3-5, 3-10, 3-15

F

Filter Removal -- Free Blow, 3-1
Filter Removal -- Ducted, 3-4
Fuse Removal -- Ducted, 3-5

H

R

REFRIGERANT CYCLE, 1-9, 1-10

S

Serial Number, 1-1
SERVICE -- GENERAL, 3-1
SERVICE -- UPPER UNIT -- LOW PROFILE, 3-10
SERVICE AND MAINTENANCE, 3-1
START--UP, 1-9

T

THERMOSTAT INSTALLATION AND START--UP IN-

STRUCTIONS (WALL MOUNTED), 3-15

TROUBLESHOOTING, 2-1, 2-3

U

Upper Scroll Assembly, 3-7, 3-10, 3-11, 3-12, 3-13

Heat Strip, 3-3
Heat/Cool Thermostat, 3-15

Index -1

W

WIRING SCHEMATICS, 4-1

T--298

Carrier Transport Air Conditioning
50 Grumbacher Road
York PA 17402 USA
Tel: [phone]
Fax: [phone]

A member of the United Technologies Corporation family. Stock symbol UTX
©2006 Carrier Corporation D Printed in U. S. A. 0606

Carrier Transicold Division,
Carrier Corporation
Transport Air Conditioning Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com