Carrier Air 5 Manual

							R
Transport Air Conditioning
T--298 Rev D
SERVICE MANUAL
for
MODEL AirV
Rooftop Air Conditioning Systems
R
Transport Air Conditioning
2P
CF
H
1
2BLK
BLU
WHT
WHT EVAP.GRN/YEL
WHTBRN
12YEL
RED
BLU
R
C
S
RED
PTCBLU 
						

							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 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
3.5.8)
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 beperformed byqualified
service personnel.
In case of electrical fire, open circuit switch and extinguish with CO
2(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 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 3.5.8)
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
Do not use carbon tetrachloride, solvents, or waxes containing solvents to 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
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
TABLE OF CONTENTS
PARAGRAPH NUMBERPage
DESCRIPTION1-1 ...............................................................................
1.1 INTRODUCTION1-1 .....................................................................
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 Charge1-9 ................................................................
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-UP1-9 ...........................................................................
1.6 REFRIGERANT CYCLE-STANDARD SYSTEM 1-9...........................................
1.7 REFRIGERANT CYCLE - HEAT PUMP 1-10..................................................
1.7.1 Cooling1-10 ..........................................................................
1.7.2 Heating1-11 ..........................................................................
TROUBLESHOOTING2-1 .........................................................................
2.1 NO POWER TO UNIT2-1 .................................................................
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 COOLING2-2 .............................................................
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 LEAKAGE2-2 ....................................................................
2.14 INADEQUATE HEAT (FREE-BLOW HEAT ONLY) 2-3........................................
2.15 INADEQUATE HEAT (HEAT-PUMP) 2-3....................................................
Clearing Diagnostic Alarms2-3 ...................................................................
SERVICE AND MAINTENANCE3-1 ................................................................
3.1 PREVENTATIVE MAINTENANCE 3-1......................................................
3.2 SERVICE - GENERAL3-1 ................................................................
3.3 CEILING UNIT - FREE BLOW SYSTEMS 3-1...............................................
3.3.1 Filter Removal3-1 ....................................................................
3.3.2 Ceiling Grill Removal3-1 ..............................................................
3.3.3 Ceiling Panel Removal3-2 .............................................................
3.3.4 Master Control Switch3-2 .............................................................
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...................................................... 
						

							ii T-- 298
TABLE OF CONTENTS - Continued
3.4 CEILING UNIT - DUCTED SYSTEMS 3-4...................................................
3.4.1 Filter Removal3-4 ....................................................................
3.4.2 Ceiling Grill Removal3-4 ..............................................................
3.4.3 Control Box Assembly Removal 3-4.....................................................
3.4.4 Main PCB Board Removal 3-5..........................................................
3.4.5 PCB Display Removal3-5 .............................................................
3.4.6 Fuse Removal3-5 ....................................................................
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 Removal3-13 ................................................................
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 Introduction3-15 ......................................................................
3.7.2 Installation3-15 .......................................................................
3.7.3 Thermostat Location3-15 ...............................................................
3.7.4 Install Thermostat - 12VDC 3-15.........................................................
3.8 LCD DISPLAY3-15 .......................................................................
3.8.1 Cool Only Thermostat3-15 .............................................................
3.8.2 Heat/Cool Thermostat3-15 .............................................................
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...................................................... 
						

							iiiT-- 298
TABLE OF CONTENTS - Continued
3.11 CHECK THERMOSTAT OPERATION 3-16...................................................
3.11.1 Temperature Display3-16 ...............................................................
3.11.2 Timeguard Timer3-17 ..................................................................
3.11.3 Cycle Timer3-17 ......................................................................
3.11.4 Minimum On Timer3-17 ................................................................
3.11.5 Error Messages3-17 ...................................................................
WIRING SCHEMATICS4-1 ........................................................................
4.1 INTRODUCTION4-1 .....................................................................
LIST OF FIGURES
FIGURE NUMBERPage
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 Locations1-8 .............................................................
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 Blow3-2 ..............................................................
Figure 3-3 Ceiling Panel Assembly3-2 ..............................................................
Figure 3-4 Ceiling Panel With Heat Option 3-2.......................................................
Figure 3-5 Control Box Assembly - Free Blow 3-2....................................................
Figure 3-6 Indoor Thermostat3-3 ..................................................................
Figure 3-7 Air sweep motor3-3 ....................................................................
Figure 3-8 Heat Strip Assembly3-3 ................................................................
Figure 3-9 Filter Removal - Ducted Unit 3-4.........................................................
Figure 3-10 Ceiling Grill - Ducted3-4 ...............................................................
Figure 3-11 Control Box & PCB Cover 3-4...........................................................
Figure 3-12 Control Box Assembly - Ducted 3-5......................................................
Figure 3-13 Main/Display PCB’s3-5 ................................................................
Figure 3-14 Cover Assembly - Standard 3-5.........................................................
Figure 3-15 Control Box3-6 .......................................................................
Figure 3-16 Control Box Removal3-6 ...............................................................
Figure 3-17 Water Cover Removal3-6 ..............................................................
Figure 3-18 Upper Scroll Assembly3-7 .............................................................
Figure 3-19 Motor Assembly3-7 ...................................................................
Figure 3-20 Spring Clamp Removal3-7 .............................................................
Figure 3-21 Motor Clip Removal3-7 ................................................................
Figure 3-22 Condenser Fan Removal3-8 ...........................................................
Figure 3-23 Blower Wheel3-8 .....................................................................
Figure 3-24 Condenser With Motor Assembly & Compressor 3-8.......................................
Figure 3-25 Set-Up For Discharging a Capacitor 3-9.................................................. 
						

							iv 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 NUMBERPage
Table 1-1 Model Chart1-2 .........................................................................
Table 1-2 Additional Support Manuals1-3 ............................................................
Table 2-1 System Self-diagnostics Function (Ducted Remote) 2-4....................................... 
						

							T-- 298 1-1
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
This manual contains service instructions and electrical
data for the AirV, Carrier Transport Air Conditioning’s
Recreational Vehicle air conditioning unit.
The AirV units are two piece systems, consisting of the
Upper Unit and the Ceiling unit. The Upper Unit contains
the refrigerationsystem while the Ceiling Unit contains
the controls and vents. The Ceiling Units are available in
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.
The ducted units (see Figure 1-5 and Figure 1-6) deliver
air through ducting built in the vehicle ceiling. These
units are fitted with a 12 VDC microprocessor control
system, a displaypanel (PCB display) and a remote
controller. These units may be wired to provide
thermostatic control of the vehicle furnace.
Carrier ’s AirV air conditioning models include cooling
only units, heating/cooling units, and heat pump units.
The cooling only units are available with free blow or
ducted air delivery. Cooling units with heat strips are
available for free blow only.
Operation of the AirV units is controlled automatically by
the temperature controller (thermostat), which
maintains the vehicle’s interior temperature at the
desired set point. Free Blow, cool-- only units are
available with a wall mounted thermostat.
Table 1-1 lists model numbers and descriptions of the
AirV units, and Table 1-2 lists additional support
manuals that are available.
1.2 SERIAL NUMBER IDENTIFICATION
Separate part numbers and serial numbers are provided
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 the week the unit was manufactured. For
example, 01 would designate the first week of the year
and 52 would designate the last week of the year.
The third and fourth numbers designate the year in
which the unit was manufactured. For example, 99
would represent the year 1999, 00 the year 2000, and
so on.
The letter Y and all the numbers after it designates the
unit serial number. Example: Y43210
A serial number of 1303Y12345 designates that the unit
was manufactured the 13th week of 2003 and the serial
number is Y12345.MODEL No.
Part No.
VOLTS
ph
CAPACITY
AMPS
DATE OF Mfg
SERIAL No.
DESIGN PSIG HIGH 350 LO 150
oz
kg
RLA
FLA R--22
USE CEILING ASSY/ANYCOMPRESSOR
FAN MOTOR
68RV14102A
99 -- 00468 -- 01
V11 5
1
hz60
13,500Btu/h
3,955W
13.5A
05/03
1303Y12345
15.9
0.45
12.5
2.58
99 -- 00469 -- 01
CarrierAir Conditioning
C
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.
1400YA diode was added to the Ducted Ceiling
assembly control board to stop DC ripple from the
converters,
2900YCover screw coating was changed in order to
eliminate corrosion.
3400YThe plastic shroud was modified to improve
drainage.
5100YA new compressor and capacitor is introduced,
improving stability and increasing capacity.
1201YThe temperature sensor was moved to the grill
to improve temperature sensing during furnace mode,
2501YThe dual air sweep was added.
4501YA switch was added to skip compressor
malfunction test.
4601YChange in material was made in order to
strengthen the fan propeller.
4901YThe mounting bolt lengths were increased 3/4
inch.
4901YThe polar white ducted ceiling color was cut-- in.
0703Y & 1903YNew style PCB -- Cool Mode -- Control
& Power Assembly (Fans shut off in auto mode).
0803Y & 2603YNew style PCB -- Heat Pump -- Control
& Power Assembly (Fans shut off in auto mode).
4204YMinimum furnace setpoint lowered from 63°Fto
45°F.