Carrier Air 5 Manual

							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 illuminated1. 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 cooling1. 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 wired1. 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 ornoncondensablesin system
5. Restricted discharge line
6. Defective motor overload switch1.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-- 2982-2 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 power1. 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 dirty1. 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 motor1. Check for obstruction at coil. Remedy as required.
2. Clean coil.
3. Replace fan motor.
2.9 INSUFFICIENT COOLING
1. Unit undersized
2. Capillary restricted1. 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 connections1. 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 speed1. 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 failure1. 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-- 2982-4 Table 2--1 System Self--diagnostics Function (Ducted Remote)
Flashes
Error Codes
(Priority)
Error Contents
(Malfunction)
Display PatternAllowed Modes
21ROOM AIR THERM-
ISTOR FAILURE
3sec
.3sec
.
0.5 sec.
(Twice)FAN Mode
32INDOOR COIL
THERMISTOR FAIL-
URE
3sec
.3sec.
0.5 sec (3
Ti m e s )FAN Mode
FURNACE Mode
43OUTDOOR COIL
THERMISTOR
FAILURE
3sec.3sec
.
0.5 sec. (4
Ti m e s )FAN Mode
FURNACE Mode
54COMPRESSOR
DRIVE
MALFUNCTION
3sec
.3sec
.
0.5 sec. (5
Ti m e s )FAN Mode
FURNACE Mode
65REVERSING 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
Continuous7THERMISTOR
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.
Check fans to insure that they are correctly positioned in
the center of the orifice, and tight on the shaft.
Leaks-- Check any connections that show evidence of
oil or leaks. 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 the possibility of electrical shock and
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
edges when 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-- 2983-2 d. To replace the grill, place the grill up against the ceil-
ing panel and align the screw holes in the grill with the
ceiling panel.
e. Replace 4 screws.
Mounting
Screws
Figure 3-2 Ceiling Grill -- Free Blow
3.3.3 Ceiling Panel Removal
To remove the ceiling panel (Figure 3-3) do the
following:
a. Remove the ceiling grill. (Refer to paragraph 3.3.2.)
b. Remove 5 screws securing the duct plate to the ceil-
ing panel.
c. Remove 4 mounting bolts making sure to support the
weight of the ceiling panel.
d. Disconnect the unit harnesses and main power wires
from the ceiling panel.
e. Lower the ceiling panel from the air conditioning unit.
f. Reverse above procedure for reassembly.
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
SwitchThermostat
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.Remove 2 screws that secure the indoor thermostat to
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-- 2983-4 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
To remove the ceiling grill (Figure 3-- 10) do the following:
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, (two are
under the filters) making sure to 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 panel and align the screw holes in the grill with the
ceiling panel.
f. Replace 4 screws and 2 filters.
3.4.3 Control Box Assembly Removal
To remove the control box assembly (Figure 3-11 &
Figure 3-12) do the following:
a. Remove ceiling grill. Refer to paragraph 3.4.2.
b. Disconnect 115 volt (AC) and 12 volt (DC) power
wires.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. Pull control box assembly from the ducted ceiling unit.
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
ConnectorsFurnace
Wires (blue)
#1
#2
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. Gently push holding clip away from PCB main assem-
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
#3
#4
Figure 3-13 Main/Display PCB’s3.4.5 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. Turn fuse holder in direction of arrow (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
Coil fins are sharp. Use care when removing
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 lift the exterior cover off of the unit base pan
assembly.
d. Reverse above procedure for reassembly.
Cover Screws
Figure 3-14 Cover Assembly -- Standard 
						

							T-- 2983-6 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 to paragraph 3.5.1. Dis-
connect all wiring from the compressor.
c. Apply field-- supplied, line-- tap-- valves to the suction
and discharge lines as close to the compressor as
possible.
d. Recover the refrigerant charge from the unit. After re-
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 a nitrogen supply to the unit at one of the line
-- 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 and discharge
lines. Carefully braze the holes closed from where the
line-- tap-- valves were removed.
h. Clean system: add or replace liquid line filter drier. For
proper cleaning and flushing use a UL approved re-
frigerant recycling system.
i. Install new compressor and braze into place with
field-- supplied copper slip couplings.
j.Connect wiring: replace wire terminals if necessary.
k. Proceed with evacuation and charging (15.9 OZ. --
.45 KG R22). Pinch off lines where angle valves were
added. Cut off angle valves above pinch-- off , and
braze tubes.
l. Start up unit.
3.5.3 Control Box Assembly Removal
To remove the control box assembly, do the following:
a. Remove exterior cover assembly. Refer to paragraph
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