Carrier AirV 68RV11112A User manual

R
Transport Air Conditioning
T--298 Rev G
SERVICE MANUAL
for
MODEL AirV
Rooftop Air Conditioning Systems
Transport Air Conditioning
2P
C
F
H
1
2
BLK
BLU
WHT
WHT
EVAP.
GRN/YEL
WHT
BRN
12
YEL
RED BLU
R
C
S
RED
PTC
BLU
R

SERVICE MANUAL
For
MODELS
68RV11112A
68RV11122A
68RV11302A
68RV14102A
68RV14103A
68RV14113A
68RV14123A
68RV15102A
68RV15103A
AirV
AIR CONDITIONING AND
HEATING EQUIPMENT

T-298
Safety-- i
10/09
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in
this manual. They are recommended precautions that must be understood and applied during operation and
maintenance of the equipment covered herein. The general safety notices are presented in the following three
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 cover assembly before turning the power off, and disconnecting the power supply.
Before disconnecting, discharge capacitors by shorting across the capacitors terminals. (See Paragraph
3.6.8)
When disassembling wiring, use numbered stickers to identify wire leads and terminals. This aids in quick,
accurate reassembly.
Be sure power is turned off before working on motors, controllers, or electrical control switches. Tag any circuit
breakers and power supply to prevent accidental energizing of circuits.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires.
Problems with the system should be diagnosed and any necessary repairs must be performed by qualified
service personnel.
In case of electrical fire, open circuit switch and extinguish with CO2(never use water).
Use dry nitrogen to pressurize the system for leak checking. Be careful not to exceed 150 psig test pressure in
the hermetic compressor.
Coil fins are sharp. Use care when removing the cover form the base pan to avoid personal injury.
Oil vapor in piping stubs can ignite from torch flame and cause serious injury. Exercise extreme care when
brazing, and keep brazing cloth and fire extinguisher handy for emergency use.
Disconnect power to the AirV unit before checking the capacitor.

T--298 Safety-- ii 10/09
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 safety summary in the front of this manual before
performing maintenance on the AirV system
WARNING
Before working on the unit be sure to first disconnect all electric power to the unit to avoid the
possibility of electrical shock and personal injury. Before disconnecting, discharge capaci-
tors by shorting across the capacitors terminals (Refer to paragraph 3.6.8)
WARNING
Shield coils with cardboard to protect hands against injury from sharp metal edges when re-
moving compressor and other components.
WARNING
Oil vapor in piping stubs can ignite from torch flame and cause serious injury. Exercise ex-
treme 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. You could 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
In order for the AirV systems to operate efficiently, a dedicated 115 Volt 20 Amp power con-
nection is required.

T-298
Safety--iii
10/09
CAUTION
Do not use carbon tetrachloride, solvents, or waxes containing solvents to clean plastic sec-
tions.
CAUTION
Coil fins are sharp. Use care when removing the cover form the base pan to avoid personal
injury.
CAUTION
The change from Fahrenheit to Celsius will be permanent. It cannot be changed back to Fahr-
enheit.
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.

iT--298
10/09
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SPECIFIC WARNING AND CAUTION STATEMENTS ii...........................................
SPECIFIC WARNINGS AND CAUTIONS ii......................................................
DESCRIPTION 1--1...............................................................................
1.1 INTRODUCTION 1--1.....................................................................
1.2 SERIAL NUMBER IDENTIFICATION 1--1....................................................
1.3 DESIGN CHANGE DESCRIPTIONS 1--1....................................................
1.4 SYSTEM (UNIT) INSTALLED DIMENSIONS 1--9.............................................
1.5 SERIAL NUMBER LOCATIONS 1--14........................................................
1.6 AirV SYSTEM COMPONENT SPECIFICATIONS 1--15.........................................
1.6.1 Refrigerant Charge 1--15................................................................
1.6.2 Compressor -- 115 Volts, 60 Cycles, 1 Phase 1--15.........................................
1.6.3 Compressor -- 220 Volts, 50 Cycles, 1 Phase 1--15.........................................
1.6.4 Thermostat Range (All Free Blow Units) 1--15..............................................
1.6.5 Return Air Sensor (Thermistor) 1--15......................................................
1.6.6 Heat Pump Sensors (Thermistors) 1--15...................................................
1.7 START--UP 1--15..........................................................................
1.8 Dry Mode Function 1--15....................................................................
1.9 REFRIGERANT CYCLE--STANDARD SYSTEM 1--15..........................................
1.10 REFRIGERANT CYCLE -- HEAT PUMP 1--16.................................................
1.10.1 Cooling 1--16..........................................................................
1.10.2 Heating 1--17..........................................................................
1.11 FREQUENTLY ASKED QUESTIONS AND ANSWERS 1--17....................................
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 HEATER CYCLES 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....................................................

ii
T--298 10/09
TABLE OF CONTENTS -- Continued:
SERVICE AND MAINTENANCE 3--1................................................................
3.1 PREVENTATIVE MAINTENANCE 3--1......................................................
3.2 OPERATING INSTRUCTIONS 3--1.........................................................
3.3 SERVICE -- GENERAL 3--1................................................................
3.4 CEILING UNIT -- FREE BLOW SYSTEMS 3--1...............................................
3.4.1 Filter Removal 3--1....................................................................
3.4.2 Ceiling Grill Removal 3--2..............................................................
3.4.3 Ceiling Panel Removal 3--2.............................................................
3.4.4 Master Control Switch 3--2.............................................................
3.4.5 Air Sweep Switch Removal 3--2.........................................................
3.4.6 Indoor Thermostat Removal 3--3........................................................
3.4.7 Air Sweep Removal 3--3...............................................................
3.4.8 Heat Strip Assembly Removal 3--3......................................................
3.5 CEILING UNIT -- DUCTED SYSTEMS 3--4...................................................
3.5.1 Filter Removal 3--4....................................................................
3.5.2 Ceiling Grill Removal 3--4..............................................................
3.5.3 Control Box Assembly Removal 3--4.....................................................
3.5.4 Main PCB Board Removal 3--5..........................................................
3.5.5 PCB Display Removal 3--5.............................................................
3.5.6 Fuse Removal 3--5....................................................................
3.5.7 Dip Switch Functions 3--6..............................................................
3.5.8 Return Air Thermistor 3--6..............................................................
3.5.9 Heat Pump Thermistors 3--7............................................................
3.6 SERVICE -- UPPER UNIT -- STANDARD, HC & HP 3--8.......................................
3.6.1 Exterior Cover Removal 3--8............................................................
3.6.2 Compressor Replacement 3--8..........................................................
3.6.3 Control Box Assembly Removal 3--8.....................................................
3.6.4 Upper Scroll Assembly Removal 3--8....................................................
3.6.5 Motor Assembly and Condenser Fan Removal 3--9........................................
3.6.6 Evaporator Blower Wheel Adjustment or Removal 3--10.....................................
3.6.7 Air Handling System Removal 3--10......................................................
3.6.8 Capacitor Troubleshooting 3--10..........................................................
3.6.9 Capacitor Testing and Replacement 3--11.................................................
3.6.10 Positive Temperature Coefficient Thermistor (PTC) (Start Thermistor) Troubleshooting 3--11.....
3.6.11 Line Voltage -- 10% 3--11................................................................
3.7 SERVICE -- UPPER UNIT -- LOW PROFILE 3--12.............................................
3.7.1 Exterior Cover Removal 3--12............................................................
3.7.2 Upper Scroll Assembly Removal 3--12....................................................
3.7.3 Condenser Fan Assembly Removal 3--13..................................................
3.7.4 Condenser Motor Removal 3--14.........................................................
3.7.5 Evaporator Motor/Blower Assembly Removal 3--14.........................................
3.7.6 Compressor Replacement 3--15..........................................................
3.7.7 Capacitor Removal 3--15................................................................
3.7.8 Remote Control (Fahrenheit to Celsius) 3--15..............................................

iii T--298
10/09
TABLE OF CONTENTS -- Continued:
3.8 THERMOSTAT INSTALLATION AND START--UP INSTRUCTIONS (WALL MOUNTED) 3--17.......
3.8.1 Introduction 3--17......................................................................
3.8.2 Installation 3--17.......................................................................
3.8.3 Thermostat Location 3--17...............................................................
3.8.4 Install Thermostat -- 12VDC 3--17........................................................
3.9 LCD DISPLAY 3--17.......................................................................
3.9.1 Cool Only Thermostat (Part No. 1110--421) 3--17...........................................
3.9.2 Heat/Cool Thermostat (Part No. 1110--420) 3--17...........................................
3.10 SET THERMOSTAT CONFIGURATION 3--17.................................................
3.10.1 Enter Configuration Mode 3--17..........................................................
3.11 CHECK THERMOSTAT OPERATION 3--18...................................................
3.11.1 Fan Operation (Cool Only) 3--18..........................................................
3.11.2 Fan Operation (Heat/Cool) 3--18.........................................................
3.11.3 Cooling Operation (Cool Only) 3--18......................................................
3.11.4 Cooling Operation (Heat/Cool) 3--18......................................................
3.11.5 Heating Operation (Heat/Cool) 3--18......................................................
3.12 CHECK THERMOSTAT OPERATION 3--18...................................................
3.12.1 Temperature Display 3--18...............................................................
3.12.2 Timeguard Timer 3--19..................................................................
3.12.3 Cycle Timer 3--19......................................................................
3.12.4 Minimum On Timer 3--19................................................................
3.12.5 Error Messages 3--19...................................................................
WIRING SCHEMATICS 4--1........................................................................
4.1 INTRODUCTION 4--1.....................................................................
4.2 WALL MOUNTED THERMOSTATS 4--6.....................................................
4.3 WALL--MOUNTED SENSOR FOR REMOTE CONTROL 4--6...................................
LIST OF FIGURES
Figure 1--1 Model/Serial Number Plate (Typical) 1--1..................................................
Figure 1--2 Roof Unit (Standard) Component Identification 1--5.........................................
Figure 1--3 Ceiling Unit Component Identification (Free--Blow) 1--6......................................
Figure 1--4 Component Identification -- Low Profile -- Upper Unit 1--7....................................
Figure 1--5 Component Listing--Ceiling Unit For Ducted Systems 1--8....................................
Figure 1--6 Unit Dimensions -- Top View -- Upper Unit (Roof) Installed 1--9................................
Figure 1--7 Unit Dimensions -- Standard -- Side View -- Roof + Ceiling 1--10...............................
Figure 1--8 Unit Dimensions -- Low Profile -- Side View -- Roof + Ceiling 1--11.............................
Figure 1--9 Unit Dimensions -- Ceiling Unit -- Bottom View 1--12..........................................
Figure 1--10 Ducted System Air Flow Arrangement 1--13................................................
Figure 1--11 Serial Number Locations (Free--Blow) 1--14................................................
Figure 1--12 Serial Number Locations (Ducted) 1--14...................................................
Figure 1--13 Refrigerant Flow Schematic (Standard System) 1--15.......................................
Figure 1--14 Refrigerant Flow Schematic -- Heat Pump -- (Cool Mode) 1--16...............................
Figure 1--15 Refrigerant Flow Schematic -- Heat Pump -- (Heat Mode) 1--17...............................

iv
T--298 10/09
LIST OF FIGURES -- Continued:
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 Dip Switch Function 3--6...............................................................
Figure 3--15 Cover Assembly -- Standard 3--8........................................................
Figure 3--16 Control Box 3--8......................................................................
Figure 3--17 Control Box Removal 3--8..............................................................
Figure 3--18 Water Cover Removal 3--8.............................................................
Figure 3--19 Upper Scroll Assembly 3--9.............................................................
Figure 3--20 Motor Assembly 3--9...................................................................
Figure 3--21 Spring Clamp Removal 3--9............................................................
Figure 3--22 Motor Clip Removal 3--9...............................................................
Figure 3--23 Condenser Fan Removal 3--10...........................................................
Figure 3--24 Blower Wheel 3--10.....................................................................
Figure 3--25 Condenser With Motor Assembly & Compressor 3--10......................................
Figure 3--26 Set--Up For Discharging a Capacitor 3--11.................................................
Figure 3--27 Cover Assembly -- Low Profile 3--12......................................................
Figure 3--28 Upper Scroll Assembly Locking Tabs (b.) & Screw Locations (c.) 3--12.........................
Figure 3--29 Upper Scroll Assembly Keeper Tab Release 3--12..........................................
Figure 3--30 Upper Scroll & Control Box Cover Removed 3--13..........................................
Figure 3--31 Condenser Fan Assembly& Retaining Ring 3--13...........................................
Figure 3--32 Condenser Fan Motor& Fan Assembly Stop 3--13..........................................
Figure 3--33 Condenser Fan Motor& Fan Assembly Tab 3--13...........................................
Figure 3--34 Condenser Motor Ground 3--14..........................................................
Figure 3--35 Evaporator Motor Locking Tabs 3--14.....................................................
Figure 3--36 Evaporator Motor/Blower Assembly 3--14.................................................
Figure 3--37 Evaporator Blower Wheel 3--15..........................................................
Figure 3--38 Control Box Assembly With Capacitor 3--15................................................
Figure 3--39 Remote Control Components 3--16.......................................................

vT--298
10/09
LIST OF FIGURES -- Continued:
Figure 3--40 Remote Control PCB (FR9 Location) 3--16.................................................
Figure 3--41 Wall Thermostat Wiring Diagram -- Cool Only Model 3--19...................................
Figure 3--42 Wall Thermostat Wiring Diagram -- Heat/Cool Model 3--20...................................
Figure 3--43 (Optional) Wall Thermostat Wiring Diagram -- Heat/Cool Model 3--21..........................
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 -- Standard -- Ducted 4--4.........................................
Figure 4--9 Heat Pump -- Upper Unit -- Low Profile -- Ducted 4--4........................................
Figure 4--10 Heat Pump -- Ceiling Unit -- Ducted 4--5..................................................
Figure 4--11 Ceiling Unit -- Wall Thermostat -- Cool Only -- Ducted & Free Blow 4--5.......................
Figure 4--12 Ceiling Unit -- Wall Thermostat -- Heat/Cool -- Free Blow 4--6...............................
LIST OF TABLES
Table 1--1 Model Chart 1--2.........................................................................
Table1--2MODELCHART 1--3.....................................................................
Table 1--3 ADDITIONAL SUPPORT MANUALS 1--4...................................................
Table 2--1 System Self--diagnostics Function (Ducted Remote) 2--4......................................
Table 3--1 Resistance--Temperature Coefficient 3--6....................................................
Table 3--2 Resistance--Temperature Coefficient (IDC -- ODA -- ODC) 3--7.................................