Carrier T 298 Users Manual

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RTransport Air Conditioning

T--298 Rev D

SERVICE MANUAL

for

MODEL AirV

Rooftop Air Conditioning Systems

RTransport Air Conditioning

CFH

BLK

BLU

WHT

EVAP.

GRN/YEL

WHTBRN

12YEL

RED BLU

RED

PTC

BLU

SERVICE MANUAL

For

MODELS

68RV11302A

68RV14102A

68RV14103A

68RV14112A

68RV15102A

68RV15103A

AirV

AIR CONDITIONING AND

HEATING EQUIPMENT

T-298

Safety-- i

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautionsappearing elsewherein

this manual. They are recommended precautions that must be understood and applied during operation and

maintenanceoftheequipmentcoveredherein.Thegeneralsafetynoticesarepresentedinthefollowingthree

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

assemblyor theupper unit cover assembly beforeturning thepower 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,orelectricalcontrolswitches.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 CO2(never use water).

Usedrynitrogentopressurizethesystemforleakchecking.Becarefulnottoexceed150psigtest pressurein

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

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

Beforeworkingontheunitbesuretofirstdisconnectallelectricpowertotheunittoavoidthe

possibility of electrical shock and personal injury. Before disconnecting, discharge capaci-

tors by shorting across the capacitors terminals (Refer to paragraph 3.5.8)

WARNING

Shield coils with cardboard to protecthands againstinjuryfromsharp metaledgeswhen 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 foremergency

use.

WARNING

Disconnect power to the AirV unit before checking the capacitor.

WARNING

Do not touch the metal of thescrewdriverwhen 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

Do not use carbon tetrachloride, solvents, or waxes containing solventsto clean plastic sec-

tions.

T-298

Safety--iii

CAUTION

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

injury.

CAUTION

ThechangefromFahrenheittoCelsiuswillbepermanent.ItcannotbechangedbacktoFahr-

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

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 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....................................................

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...............................................................

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

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 START-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 DISPLAY 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......................................................

iii T--298

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..................................................

T--298

LIST OF FIGURES

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

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

Figure 3-28 Upper Scroll Assembly Keeper Tab 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

1-1

SECTION 1

DESCRIPTION

1.1 INTRODUCTION

This manualcontains 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

UpperUnit andtheCeilingunit.TheUpperUnitcontains

the refrigeration system while the Ceiling Unit contains

thecontrolsandvents.TheCeilingUnitsareavailablein

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.

OperationoftheAirVunitsiscontrolledautomaticallyby

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

A serial numberof 1303Y12345 designatesthat theunit

was manufactured the 13th week of 2003 and the serial

number is Y12345.

MODEL No.

Part No.

VOLTS

CAPACITY

AMPS

DATE OF Mfg

SERIAL No.

DESIGN PSIG HIGH 350 LO 150

RLA

FLA

R--22

USE CEILING ASSY/ANY

COMPRESSOR

FAN MOTOR

68RV14102A

99--00468--01

115

1hz 60

13,500 Btu/h

3,955 W

13.5 A

05/03

1303Y12345

15.9

0.45

12.5

2.58

99--00469--01

Carrier

Air Conditioning

Division of Carrier Corporation

USE AMP20

TIME DELAY FUSE OR

CIRCUIT BREAKER

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 white ducted ceiling color wascut--in.

0703Y & 1903Y New style PCB -- Cool Mode -- Control

& Power Assembly (Fans shut off in auto mode).

0803Y & 2603Y New style PCB -- Heat Pump -- Control

& Power Assembly (Fans shut off in auto mode).

4204Y Minimumfurnacesetpointloweredfrom 63°Fto

45°F.

T--298 1-2

Table 1-1. Model Chart

UPPER UNIT (ROOF)

Model Number Part Number Voltage Amps Color

115

Standard S

stem 99--00468--00 115/1/60 12.8 White

68RV14102A 99--00468--01 115/1/60 12.8 Ivory

220

Standard S

stem 99--00468--02 220/1/50 5.3 Cool White

68RV11302A 99--00468--03 220/1/50

6.7 Heat Ivory

hCa

acit

99--00468--08 115/1/60 14.5 White

68RV15102A 99--00468--09 115/1/60 14.5 Ivory

99--00468--04

(Free Blow) 115/1/60 12.7 Cool

10.9 Heat White

Heat Pump

99--00468--05

(Free Blow) 115/1/60 12.7 Cool

10.9 Heat Ivory

Systems

68RV14112A 99--00468--06

(Ducted) 115/1/60 12.7 Cool

10.9 Heat White

99--00468--07

(Ducted) 115/1/60 12.7 Cool

10.9 Heat Ivory

LOW PROFILE

68RV15103A 99--00468--10

(Free Blow -- High Capacity) 115/1/60 15.1 Cool

13.8 Heat White

LOW PROFILE

68RV14103A 99--00468--12

(Free Blow -- Standard) 115/1/60 15.0 Cool

13.7 Heat White

CEILING UNIT

Model Number Part Number Voltage Color Options Interface

99--00469--00 115/1/60 White Cool Only Free Blow

0010

99--00469--01 115/1/60 Ivory Cool Only Free Blow

99--00469--02 115/1/60 White Heat/Cool Free Blow

0010

99--00469--03 115/1/60 Ivory Heat/Cool Free Blow

68RV0010KA 99--00469--06 115/1/60 (12VDC) White Cool Only Ducted

99--00469--04 220/1/50 White Cool Only Free Blow

0030

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

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

0012

99--00469--12 115/1/60 Ivory Heat Pump Free Blow

68RV0011LA 99--00469--13 115/1/60 (12VDC) White Heat Pump Ducted

68RV0010AB 99--00469--23 115/1/60 White Cool Only Free Blow

68RV0010AB 99--00469--24 115/1/60 Ivory Cool Only Free Blow

68RV0010BB 99--00469--25 115/1/60 White Heat/Cool Free Blow

68RV0010BB 99--00469--26 115/1/60 Ivory Heat/Cool Free Blow

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

Wall Thermostat

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

Wall Thermostat

T--298

1-3

Table 1-2 Additional Support Manuals

MANUAL--FORM NO. EQUIPMENT COVERED TYPE OF MANUAL (For) PART NO.

71LC6A54310 AirV 115 Volts--Free Blow (Cool Only) Owner’s Guide 99--00469--00

99--00469--01

71LH6A54070 AirV 115 Volts--Free Blow (Heat--Cool) Owner’s Guide 99--00469--02

99--00469--03

71LD6A54070 AirV 115 Volts--Ducted (Cool Only) Owner’s Guide 99--00469--06

71LH6A54070 AirV 220 Volts--Free Blow (Heat--Cool) Owner’s Guide 99--00469--08

99--00469--09

71RQ6A5401A AirV 115 Volts--Free Blow (Heat Pump) Owner’s Guide 99--00469--11

99--00469--12

71DQ6A5401A AirV 115 Volts--Ducted (Heat Pump) Owner’s Guide 99--00469--13

71DW6A54070 AirV 115 Volts--Ducted Wired Thermostat Owner’s Guide 99--00469--22

71LC6A54310 AirV 115 Volts--Free Blow (Cool Only) Owner’s Guide 99--00469--23

99--00469--24

71LH6A54070 AirV 115 Volts--Free Blow (Heat--Cool) Owner’s Guide 99--00469--25

99--00469--26

71RW6A54310 AirV 115 Volts--Free Blow Wired Thermostat Owner’s Guide 99--00469--29

T--298PL AirV Service Parts ALL

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

1. Cover

2. Condenser

3. Evaporator

4. Compressor

5. Base Pan

Figure 1-2 Roof Unit Component Identification

T--298 1-4

1. Ceiling Panel Assembly

2. Control Box Cover 3. Control Assembly

4. Ceiling Grill Assembly

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

T--298

1-5

1. Cover Assembly

2. Scroll Assembly -- Upper

3. Condenser Fan

4. Condenser Motor

5. Evaporator Motor

6. Evaporator Blower Wheel

7. Condenser Coil

8. Scroll Assembly -- Lower

9. Evaporator Coil

10. Compressor

11. Base Pan Assembly

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

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

T--298 1-6

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

7. Remote Control Assembly

8. Remote Control Bracket Assembly

9. Filter Assemblies (2)

10. PCB Cover

11. PCB Main Assembly

12. PCB Display

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

T--298

1-7

SCHEMATIC VIEW

INSTALLED VIEW

5SUPPLY AIR

RETURN AIR

SUPPLY AIR

1. Vehicle Duct System (Connection)

2. Telescoping Divider (3 different sizes available)

3. Return Air Suction Area

4. Control Box Assembly

5. Supply Air Discharge Area

Figure 1-6 Ducted System Air Flow Arrangement

T--298 1-8

Serial Number

of Ceiling Unit

Serial number

of Upper Unit

Upper Unit

Ceiling Unit

(Cover Removed)

Free Blow Type

Bottom View After Installation

(With Grille Removed)

Ceiling Assembly Frame

Serial Number of

Ceiling Unit

(Side of Control Box)

Bottom of

Upper Unit

Serial Number

of Upper Unit

Ducted Type

Figure 1-7 Serial Number Locations

T--298

1-9

1.4 AirV SYSTEM COMPONENT SPECIFI-

CATIONS

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 START--UP

Refer to operating instructions in Owners Guide (see

Table 1-2) packaged with the vehicle system.

COMPRESSOR

ACCUMULATOR

CONDENSER

EVAPORATOR

CAPILLARY

TUBE

STRAINER

DISCHARGE

SUCTION

LIQUID

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

dischargeline intothe condenser coil. (SeeFigure 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.

Theevaporatorblower(fan)pulls vehicleairthroughthe

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.

T--298 1-10

1.7 REFRIGERANT CYCLE -- HEAT PUMP

STRAINER

OUTDOOR COIL

INDOOR COIL

REVERSING VALVE

ACCUMULATOR

COMPRESSOR

CAPILLARY

TUBE

DISCHARGE

SUCTION

LIQUID

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

controlsarepositionedfor“normal”refrigerantflow,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,capillarytube,indoor coil,andtheaccumulator.

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 thanthe 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 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 havealuminumfins toincreaseheat 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

1-11

COMPRESSOR

ACCUMULATOR

REVERSING VALVE

INDOOR COIL

OUTDOOR COIL

STRAINER

CAPILLARY

TUBE

DISCHARGE

SUCTION

LIQUID

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

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, capillarytube,

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.

The vehicle air(which is ata temperature lower than the

refrigerant) passes over the outside of the coil tubes.

Heat transfer is established from the refrigerant (inside

thetubes)tothevehicleair(flowingoverthetubes).The

tubes have finsdesigned 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 theoutdoor airthat

is circulated over the tubes. Heat transfer is established

from the outdoor air (flowing over the tubes) to the

refrigerant (flowing inside the tubes). The outdoor coil

tubes havealuminumfins toincreaseheat 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.

T--298

2-1

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 PROBABLE REMEDY

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)

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

2.2 DUCTED UNIT WILL NOT OPERATE

1. Display not illuminated

2. Display illuminated 1. Check 12 Volt DC in--line fuse

2. Check 115 Volt AC Connections

2.3 DUCTED UNIT WILL NOT COOL

1. Green LED light flashes 5 times

2. Unit cools for a few moments then stops cooling

1. Check 115 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

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

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)

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.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.

T--298 2-2

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

coil.

4. Low refrigerant charge

5. Evaporator capillary restricted

6. Liquid line restricted

7. Compressor hot

8. Weak or inconsistent line power

1. Replace capacitor -- Refer to Paragraph 3.5.8

2. Replace unit.

3. Defrost evaporator coil.

4. Replace unit.

5. Replace unit.

6. Replace unit.

7. Verify refrigerant charge.

Check AMP draw.

Check ∆T.

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

2. Low evaporator airflow

3. Defective electrical connections

1. Check AMP draw.

Check ∆T.

Replace unit.

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

2-3

SYSTEM AND PROBABLE CAUSE PROBABLE REMEDY

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

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.

T--298 2-4

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

Flashes Error Codes

(Priority) Error Contents

(Malfunction) Display Pattern Allowed Modes

21ROOM AIR THERM-

ISTOR FAILURE

3sec

.3sec

0.5 sec.

(Twice) FAN Mode

3 2 INDOOR COIL

THERMISTOR FAIL-

URE

3sec

.3sec.

0.5 sec (3

Times) FAN Mode

FURNACE Mode

4 3 OUTDOOR COIL

THERMISTOR

FAILURE

3sec. 3sec

0.5 sec. (4

Times) FAN Mode

FURNACE Mode

5 4 COMPRESSOR

DRIVE

MALFUNCTION

3sec

.3sec

0.5 sec. (5

Times) FAN Mode

FURNACE Mode

6 5 REVERSING VALVE

DRIVE MAL--

FUNCTION

3sec

0.5 sec.

(6Times)

3sec

FAN Mode

FURNACE Mode

16DISCHARGE AIR

THERMISTOR FAIL-

URE

3sec

.3sec

0.5 sec.

(Once) FAN Mode

FURNACE Mode

Continuous 7THERMISTOR

WIRING WRONG

(only in cooling

test mode)

3sec

0.5 sec. (Continu-

ous) 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

3-1

SECTION 3

SERVICE AND MAINTENANCE

3.1 PREVENTATIVE 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.

CAUTION

Do not use carbon tetrachloride, solvents,

or waxes containing solvents to clean plas-

tic 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.

Checkfans toinsure thattheyarecorrectlypositionedin

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’s Guide) 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.

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.

WARNING

Before working on the unit be sure to first

disconnect all electric power to the unit to

avoid thepossibilityof electrical shockand

personal injury. Before disconnecting, dis-

charge capacitors by shorting across the

capacitors terminals (Refer to paragraph

3.5.8)

WARNING

Shield coils with cardboard to protect

hands against injury from sharp metal

edgeswhen removing compressor and oth-

er 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

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.

T--298 3-2

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

ing paneland alignthescrew holesin thegrill withthe

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.

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 conditioningunit.

f. Reverse above procedure for reassembly.

Junction Box

Duct Plate &

Mounting Holes

Serial/Model

Number Tag

Air Sweep Cam

Mounting Bolts

Figure 3-3 Ceiling Panel Assembly

Heater Assembly

Option

Heat Strip

Connection

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.

Air Sweep Switch

Master Control

Switch

Thermostat

Junction Box

With Cover

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

3-3

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 ther-

mostat stem.

d.Remove2screwsthatsecuretheindoorthermostatto

the lower control box cover.

e. Carefully disconnect the 2 wires from the indoor ther-

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

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.

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.

Heat Strip

Figure 3-8 Heat Strip Assembly

T--298 3-4

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.

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 ceiling grill, (twoare

under the filters)making sureto support the weight of

the grill.

d. Lower the ceiling grill from the ceiling panel.

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

ing paneland alignthescrew holesin thegrill withthe

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.

c. Remove two screws securing control box cover to

control box assembly. See Figure 3-11.

d. Remove control box assembly cover.

Mounting Screws

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. Pullcontrolboxassemblyfromtheductedceilingunit.

k. Reverse above procedure to reassemble.

Control Box

PCB Cover

Fuse

Control Box

Cover Screws

PCB Cover

Screws

Figure 3-11 Control Box & PCB Cover

T--298

3-5

115V AC

12V DC

Fuse

Upper Unit

Connectors Furnace

Wires (blue)

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. GentlypushholdingclipawayfromPCBmainassem-

bly.

e. Lift PCB main assembly from PCB cover assembly.

f. Unplug display wiring plug #4. Figure 3-13

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

Figure 3-13 Main/Display PCB’s

3.4.5 PCB Display Removal

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

the following.

a. Remove ceiling grill. Refer to paragraph 3.4.2.

b. Push large clip away from PCB display assembly.

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

Coilfinsaresharp.Usecarewhenremoving

the cover form the base pan to avoid per-

sonal 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 lifttheexteriorcover offof the unit basepan

assembly.

d. Reverse above procedure for reassembly.

Cover Screws

Figure 3-14 Cover Assembly -- Standard

T--298 3-6

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. Recovertherefrigerantchargefromtheunit.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 ini-

tially, 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. Exer-

cise extreme care when brazing, and keep

brazing cloth and fire extinguisher handy

for emergency use.

e. Connect anitrogensupplytotheunit atoneof theline

--tap--valve connectors (5--psig maximum flow), leav-

ing 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 anddischarge

lines.Carefullybrazetheholes closedfrom wherethe

line--tap--valves were removed.

h. Cleansystem:addorreplaceliquidlinefilterdrier.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 whereangle 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.)

Control Box

Screws

Figure 3-15 Control Box

Water

Cover

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

3-7

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

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.

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.

Motor Ground

Lead

Ground screw

Figure 3-19 Motor Assembly

Spring Clamp

Figure 3-20 Spring Clamp Removal

Motor Clip

Figure 3-21 Motor Clip Removal

T--298 3-8

Condenser Fan

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 scroll assembly. Referto 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

Figure 3-23 Blower Wheel

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 1screw 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.

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 airhandling system is positioned correct-

ly. Tighten all screws.

Condenser Cover

Condenser

Cover Screws

Compressor

Motor Assembly

Base Pan

Figure 3-24 Condenser With Motor Assembly &

Compressor

T--298

3-9

3.5.8 Capacitor Troubleshooting

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. To determine 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).

WARNING

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. Iftheohmmeterfirstreads0, thenrises 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.

CLIP TO

SCREWDRIVER TOUCH TO CAPACITOR TERMINALS

TO DISCHARGE CAPACITOR

20,000 -- OHM

2 -- WATT RESISTOR

INSULATED SCREWDRIVER

ATTACH TO CLEAN UNPAINTED

METAL PART OF UNIT FRAME

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 thePTCdoesnot havecontinuity, itmust 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.

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 occursfor

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.

WiththeAirV 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.

T--298 3-10

3.6 SERVICE -- UPPER UNIT -- LOW PROFILE

3.6.1 Exterior Cover Removal

CAUTION

Coilfinsaresharp.Usecarewhenremoving

the cover form the base pan to avoid per-

sonal 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 lifttheexteriorcover offof the unit basepan

assembly.

d. Reverse above procedure for reassembly.

Screws

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)leftsideand(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.

b. b.

Figure 3-27 Upper Scroll Assembly

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

Figure 3-28 Upper Scroll Assembly

Keeper Tab Release

T--298

3-11

Evaporator Coil

Condenser Coil

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)

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.

Retaining

Ring

Figure 3-30 Condenser Fan Assembly

& Retaining Ring

Fan Stop

Condenser Motor

13MM

Bolt 13MM

Bolt

Grommet

Figure 3-31 Condenser Fan Motor

& Fan Assembly Stop

Tab

Figure 3-32 Condenser Fan Motor

& Fan Assembly Tab

T--298 3-12

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

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. Carefullyremovethe blower wheelfrom the evapora-

tor motor shaft by pushing out from the motor side.

Blower Side Locking Tabs

Outside Locking Tabs

Figure 3-34 Evaporator Motor Locking Tabs

Cradle

Lower Scroll

Assembly

Capacitor

Figure 3-35 Evaporator Motor/Blower Assembly

In Cradle

T--298

3-13

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.

Wheel Flush With Motor Shaft

Figure 3-36 Evaporator Blower Wheel

(Flush With End Of Motor Shaft)

NOTE

When placing the evaporator motor/blower

assembly back into the lower scroll assem-

bly 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:

a. Perform steps a., b. & c. as outlinedin Section3.6.5.

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).

Capacitor

Control Box Assembly

Terminal Block

Upper Scroll Assembly

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:

CAUTION

The change from Fahrenheit to Celsius will

bepermanent. It cannotbechangedbackto

Fahrenheit.

T--298 3-14

a. Remove the batteries from the remote control.

b. Carefullyremovetheremotecoverbyinsertinganar-

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.

PCB

COVER

BODY

BATTERIES

COVER

Battery Springs Spring Holders

Figure 3-38 Remote Control Components

FR9

PCB

Figure 3-39 Remote Control PCB (FR9 Location)

T--298

3-15

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.

CAUTION

Improperwiringorinstallationmaydamage

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

Readallinstructionsbeforestartingtheinstalla-

tion.

NOTE

The thermostat requires no batteries. The ther-

mostat is not a power stealing device and

MUST have both R and C connected.

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,ornextto adoor

leading to the outside.

Exposedtodirectlightandheatfromalamp,sun,fire-

place, 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.

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

Mercuryisahazardouswasteandmustbedes-

posed of properly.

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 op-

eration) 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. Secureback plastictowallwith2anchors andscrews

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

3.8.1 Cool Only Thermostat (Part No. 1110--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 10sec-

ondsuntilroomtemperaturedisappears andthedisplay

reads A. You are now in the configuration mode.

T--298 3-16

NOTE

IftheFANbuttonispressedagainorif nobutton

is pressed for two minutes, the thermostat will

exit the configuration mode and return to nor-

mal 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

Thisadjustmentcontrolsthesensitivityandcyclerateof

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 tomove between values.

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 For C.

d. UseUP&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

adjustmentwill providethe best accuracy when set 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. UseUP &DOWNbuttonstoselect avaluebetween

--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 an-

nunciator turns on; Lo is displayed in the room tem-

perature 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 an-

nunciator 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 an-

nunciator turns off.

3.10.3 Cooling Operation (Cool Only)

1. Press and release MODE button until COOL is dis-

played.

2. Press DOWN button until LCD readout reads 10 de-

grees below room temperature. Cooling and High

Fan system should begin to operate within 5 min-

utes.

3.10.4 Cooling Operation (Heat/Cool)

1. Press and release MODE button until COOL is dis-

played.

2. Press DOWN button until LCD readout reads 10 de-

grees below room temperature. Cooling and High

Fan system should begin to operate within 5 min-

utes.

3.10.5 Heating Operation (Heat/Cool)

1. Press and release MODE button until HEAT is dis-

played.

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

UPor DOWNbuttonispressed.ThewordSETappears

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

3-17

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

notturnonuntilthetimeguardhasexpired.PressingUP

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 FAN buttons simultaneously or changing the set

point will override the timer for 1 cycle.

3.11.4 Minimum On Timer

Oncethe equipmenthas turnedon,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.

POWERBOX

ASSEMBLY

UPPER UNIT

1234 2 1

1234

COOL (Compressor)

FAN (High)

FAN (Low) 12VDC LowVoltage

Power Supply

CEILING UNIT

Motor Comp.

Factory Wiring Field Wiring

THERMOSTAT

J115V AC High Voltage

Power Supply

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

T--298 3-18

POWERBOX

ASSEMBLY

UPPER UNIT

1234 21

1234

COOL (Compressor)

FAN (High)

FAN (Low) 12VDC LowVoltage

Power Supply

CEILING UNIT FURNACE

+ 12VDC 12 VDC (Gnd)

Motor Comp.

115V AC High Voltage

Power Supply

Factory Wiring Field Wiring

THERMOSTAT

Blue

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

T--298

4-1

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 withfree blow application and Figure 4--7 is the matching free blow ceiling

unit.

Figure 4--8 is for the Upper Unit Heat Pump ducted application and Figure 4--9 is the matching ducted ceiling unit.

Notethattheductedunitshave115VACpower forthecomponentsand12VDCpower for themicroprocessorcontrol

system.

Figure 4--10is fortheductedorfreeblowapplicationthatusesawall--mountedthermostat,withorwithoutthefurnace

option.

Whereapplicable, diagramsthatdesignate115Volt, 60H, 1 Phase, arealsoavailable using220Volts,50H, 1Phase.

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

4P 2P

CFH

BLK

BLU

BLK

BLU

WHT

GRN/YEL

CONTROL

BOX EVAP.

GRN/YEL

WHTBRN

CAPACITOR

YEL

RED BLU

COMPRESSOR

FAN MOTOR

OVERLOAD PROTECTOR

RED

PTC

BLU

PLUG CONNECTS

TO CEILING UNIT

SEE FIG> 4--3

OR 4--4

(If Used)

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

CFH

BLK

BLU

BLK

BLU

WHT

GRN/YEL

WHT

BRN

1(3)

CAPACITOR

YEL

RED

OLP

(IF USED)

BLU

BLURED

COMPRESSOR

OLP: OVERLOAD PROTECTION

PTC: START THERMISTER

JTB: JOINT TERMINAL BLOCK

FMC: INDOOR FAN MOTOR CAPACITOR

PLUG CONNECTS TO CEILING UNIT.

SEE DIAGRAM SUPPLIED WITH

CEILING UNIT FOR ADDITIONAL

WIRING.

INDOOR FAN MOTOR

YEL

WHT

YEL

WHT

YEL

BRN

FMC

YEL

WHT

BRN

OUTDOOR FAN MOTOR

PTC

(IF USED)

LEGEND

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

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

T--298 4-2

GRN/YEL

ORN

WHT

ASM

PLUG CONNECTS TO UPPER UNIT.

SEE DIAGRAM SUPPLIED WITH

UPPER UNIT FOR ADDITIONAL WIRING.

{

ASW O (OFF)

I(ON)

2--1

SWITCH

POSITION CONTACTS MADE

HIGH FAN

LOW FAN

OFF

LOW COOL

1--4 . 1--6

1--2 . 1--6

NONE

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

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

HIGH COOL

ASM : AIR SWEEP MOTOR

ASW : AIR SWEEP SWITCH

SW : SWITCH

IT : INDOOR THERMOSTAT

LEGEND

ORN

BLU

BLK

ORN

SW IT

ASW

YEL

BLK

WHT

YEL

GRN/YEL

115 VAC

SUPPLY

WIRE

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

CEC

PLUG CONNECTS TO UPPER UNIT.

SEE DIAGRAM SUPPLIED WITH

UPPER UNIT FOR ADDITIONAL

WIRING.

GRN/YEL

{

ASW O (OFF)

1(ON)

2--1

SWITCH

POSITION CONTACTS MADE

OFF

LOW FAN

HIGH FAN

LOW COOL

NONE

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

HIGH COOL

HEAT

ASM AIR SWEEP MOTOR

ASW AIR SWEEP SWITCH

SW SWITCH

CEC CLOSED END CONNECTOR

BT BIMETAL

IT INDOOR THERMOSTAT

LEGEND

ORN

BLU

BLK

ORN

WHT

ASM

HEATER--ASSY

IT ASW

YEL

BLK

RED

YEL

BLU

BLK

WHT WHT

WHT

HEATER

115 VAC

SUPPLY

WIRE

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

23412

(--)

(+)

BLK

WHT

BLU

BLK

GRN/YEL

GRN/YEL WHT

WHT

BLU

BLK

RED

CN9

CN9 135786

CN1 CN4

CN4

CN1

CN2

CN3

RY1

RY2

RY3

RY4 250V 3.15A

FUSE

RATh

BRN

BLK

IDC Th

24135786

8 8

DISPLAY PCB AS

CONTROL

PCB

ASS’Y

LEGEND

IDC Th : INDOoR COIL THERMISTER

RA Th : ROOM AIR THERMISTER

KY : RELAY

DI:DIODE

115 VAC POWER

12 VDC POWER

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

T--298

4-3

CONTROL

BOX EVAP.

RVC

CFH

BLK

BLU

BLK

BLU

WHT

BRN

BLK

BLK(BLU)

GRN/YEL GRN/YEL

GRN/YEL

WHT

BRN

1(3)

CAPACITOR

YEL

RED

REDOLP

(IF USED)

BLU

BLURED

PTC

COMPRESSOR

FREEZE

SWITCH

FAN MOTOR

OLP: OVERLOAD PROTECTION

PTC: START THERMISTER

RVC: REVERSING VALVE COIL

PLUG CONNECTS TO CEILING UNIT.

SEE DIAGRAM SUPPLIED WITH

CEILING UNIT FOR ADDITIONAL

WIRING.

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

PLUG CONNECTS TO UPPER UNIT.

SEE DIAGRAM SUPPLIED WITH

UPPER UNIT FOR ADDITIONAL

WIRING.

HEATER AS

HEATER BT

GRN/YEL

{

ORN

WHT

BRN

BLK

WHT

RED

YEL

BLU

BLK

ORN

WHT

BLK

ASM

ASW

L1 L

YEL

BLK

CEC

WHT WHT

SWITCH

POSITION CONTACTS MADE

OFF

LOW FAN

HIGH FAN

LOW COOL

HIGH COOL

HEATING

NONE

L1--L . L1--A

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

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

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

L1--H . L1--A

ASW O (OFF)

1(ON)

2--1

LEGEND

ASM: AIR SWEEP MOTOR

ASW: AIR SWEEP SWITCH

SW: SWITCH

IT: INDOOR THERMOSTAT

CEC: CLOSED END CONNECTOR

BT: BIMETAL

115 VAC

SUPPLY

WIRE

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

T--298 4-4

LEGEND

RVC

PLUG CONNECTS TO CEILING UNIT.

SEE DIAGRAM SUPPLIED WITH

CEILING UNIT FOR ADDITIONAL

WIRING.

CFH

OLP :OVERLOAD PROTECTOR

PTC :START THERMISTOR

RVC :REVERSING VALVE COIL

CN :HOUSING CONNECTOR

ODA Th :OUTDOOR AIR THERMISTOR

ODC Th :OUTDOOR COIL THERMISTOR

BLK

BLK(BLU)

CONTROL

BOX EVAP.

BLU

RED

BRN

BLU

WHT

GRN/YEL

WHT

BLK

BRN

1(3)

CAPACITOR

YEL

RED

OLP

(IF USED)

BLU

RED

PTC

COMPRESSOR

FAN MOTOR

ODC Th

ODA Th

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

ODC ODA RVC MOTOR COMPRESSOR

FUSE D1

250V 3.15A

111

7888 7

FURNACE SIGNAL

12VDC POWER

(--)

(+)

115VAC POWER

BLK

WHT

BLK

GRN/YEL

RED

BLU

BLK

RED

BRN

GRN/YEL

WHT

BLK

WHT

BLU BLUBLU

BLK

RED

PLUG CONNECTS TO UPPER UNIT.

SEE DIAGRAM SUPPLIED WITH UPPER UNIT

FOR ADDITIONAL WIRING.

ODA Th :OUTDOOR AIR THERMISTOR

FACTORY WIRING

(12VDC LOW VOLT.)

(115VACHIGHVOLT.)

FIELD WIRING

LEGEND NOTE

CONTROL PCB

POWER PCB ASS’Y

ASS’Y

CN9

DISPLAY PCBAS

CN9

576

578

CN1

CN6

CN5

CN6

CN4

CN1

CN2

CN3CN5

K4K3

K7 K2

41221

RA Th

BRN

BLK

IDC Th

IDC Th: INDOOR COIL THERMISTER

RA Th: ROOM AIR THERMISTER

ODC Th: OUTDOOR COIL THERMISTER

RVC: REVERSING VALVE COIL

D1: DIODE

K: RELAY

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

T--298

4-5

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

4.2 WALL MOUNTED THERMOSTATS

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).

Index -1 T--298

INDEX

Air Handling System , 3-8

Air Sweep Removal, 3-3

Air Sweep Switch , 3-2

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

Controls, 3-1

Cool Only Thermostat, 3-15

Design Change, 1-1

Evaporator Blower Wheel, 3-8

Exterior Cover, 3-5, 3-10, 3-15

Filter Removal -- Free Blow, 3-1

Filter Removal -- Ducted, 3-4

Fuse Removal -- Ducted, 3-5

Heat Strip, 3-3

Heat/Cool Thermostat, 3-15

Indoor Thermostat , 3-3

INTRODUCTION, 1-1, 4-1

LCD DISPLAY, 3-15, 3-16

Leaks, 3-1

Main Pcb Board, 3-5

Master Control Switch, 3-2

Motor , 3-7

Mounting, 3-1

Painting, 3-1

PCB Display , 3-5

PREVENTATIVE MAINTENANCE, 3-1

REFRIGERANT CYCLE, 1-9, 1-10

Serial Number, 1-1

SERVICE -- GENERAL, 3-1

SERVICE -- UPPER UNIT -- LOW PROFILE, 3-10

SERVICE AND MAINTENANCE, 3-1

START--UP, 1-9

THERMOSTAT INSTALLATION AND START--UP IN-

STRUCTIONS (WALL MOUNTED), 3-15

TROUBLESHOOTING, 2-1, 2-3

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

WIRING SCHEMATICS, 4-1

Carrier Transport Air Conditioning

50 Grumbacher Road

York PA 17402 USA

Tel: 1--800--673--2431

Fax: 1--717--764--0401

A member of the United Technologies Corporation family. Stock symbol UTX

Carrier Transicold Division,

Carrier Corporation

Transport Air Conditioning Group

P.O. Box 4805

Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com

Carrier T 298 Users Manual

T--298 to the manual ade90665-5195-4046-a0b1-f9a4d5925d23

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