Carrier Air 5 Manual

							T-- 298 3-7 3.5.4 Upper Scroll Assembly Removal
a. Remove exterior cover assembly. Refer to paragraph
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. Remove exterior cover assembly. Refer to paragraph
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. Lift and slide motor towards evaporator coil to remove
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-- 2983-8
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. Refer to Upper Scroll
Assembly Removal instructions 3.5.4
d. Loosen motor assembly. Refer to Motor Assembly
Removal instructions 3.5.5.
e. Mark shaft at a point where wheel hub and motor
shaft meet to aid in reassembly.(See Figure 3-23.)
f. Remove 1 set screw holding the blower wheel to the
motor shaft. (See Figure 3-23)
g. Slide off blower wheel from motor shaft
h. Reverse above procedure for reassembly.
Set Screw
Figure 3-23 Blower Wheel
3.5.7Air Handling System Removal
a. Remove exterior cover assembly. Refer to paragraph
3.5.1.
b. Remove control box assembly. Refer to paragraph
3.5.3.
c. Remove upper scroll assembly. Refer to paragraph
3.5.4.
d. Remove motor assembly. Refer to paragraph 3.5.5.
e. Remove 8 screws securing lower scroll assembly to
the base pan assembly.
f. Remove 1 screw from clamp securing suction tube to
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 air handling systemis positioned correct-
ly. Tighten all screws.
Condenser Cover
Condenser
Cover Screws
Compressor
Motor Assembly
Base Pan
Base Pan
Figure 3-24 Condenser With Motor Assembly &
Compressor 
						

							T-- 298 3-9
3.5.8Capacitor 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.
3.5.9Capacitor 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 discharged and 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. If the ohmmeter first reads 0, then rises toward infinity
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
SCREWDRIVERTOUCH 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 the PTC does not have continuity, it must be replaced.
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 occurs for
much longer than a second, the PTC is defective and
must be replaced.
3.5.11 Line Voltage -- 10%
Line voltage should be checked during peak electrical
load periods.
With the AirV unit on and the compressor operating, 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-- 2983-10 3.6 SERVICE -- UPPER UNIT -- LOW PROFILE
3.6.1 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 (8) screws securing the unit cover to the
base pan assembly. See Figure 3-26.
c. Carefully lift the exterior cover off of the unit base pan
assembly.
d. Reverse above procedure for reassembly.
Screws
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. Remove exterior cover assembly. Refer to paragraph
3.6.1.
b. Release the (2) front, (2) rear, (1) left side and (1) right
side locking tabs (See Figure 3-27) by pulling back on
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.
b.b.
b.
b.c.
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 Motor13MM
Bolt13MM
Bolt
Grommet
Figure 3-31 Condenser Fan Motor
& Fan Assembly Stop
Ta b
Figure 3-32 Condenser Fan Motor
& Fan Assembly Tab 
						

							T-- 2983-12 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. Carefully remove the blower wheel from 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 outlined in Section 3.6.5.
b. Perform steps outlined in Sections 3.5.8 & 3.5.9.
c. The Low Profile Capacitor is removed from the con-
trol box assembly by pushing on the capacitor from
under the control box assembly (See Figure 3-35).
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
be permanent. It cannot be changed back to
Fahrenheit. 
						

							T-- 2983-14 a. Remove the batteries from the remote control.
b. Carefully remove the remote cover by inserting a nar-
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 SpringsSpring 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
conditioningsystem. Batteriesare not required;
temperature and mode settings are preserved with the
power off.
CAUTION
Improper wiring or installation may damage
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
Read all instructions before starting the installa-
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:
Close to a window, or an outside wall, or next to a door
leading to the outside.
Exposed to direct light and heat from a lamp, 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
Mercury is a hazardous waste and must be des-
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. Secure back plastic to wall with 2 anchors and screws
provided, making sure all wires extend through hole in
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
Enter and hold the FAN button for approximately 10 sec-
onds until room temperature disappears and the display
readsA. You are now in the configuration mode. 
						

							T-- 2983-16 NOTE
If the FAN button is pressed again or if no button
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
This adjustment controls the sensitivity and cycle rate of
the thermostst. Higher numbers decrease the
sensitivity and slow the cycle rate. Lower numbers
increase the sensitivity and increase the cycle rate.
However, a limiting feature will not allow more than 4
equipmentcyclesper hour, regardless of setting. Values
can range from 1 to 3. Factory default setting is 2. This
default selection will provide optimum performance in
nearly all installations. Try it first. Do not change settings
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 A d j u s t :
a. Enter configuration mode (if not already there).
b. Use UP & DOWN buttons to displayA.
c. Press MODE button once to display current value.
d. Use UP & DOWN buttons to move between values.
e. Press MODE buttonto return toA.UP &DOWN
buttons now move between option choicesA,d,oFor
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 displayd.
c. Press MODE button once to display current
selection ofForC.
d. Use UP & DOWN buttons to change betweenF&C.
e. Press MODE buttonto return tod.UP &DOWN
buttons now move between option choices; or press
FAN button to exit configuration mode.
oF. Room Temperature Offset Adjust Selection
The selected number is the number of degrees, plus or
minus, which will be added to the actual temperature.
The numbers can range between -- 5 and +5. Factory
default is 0. This adjusted value will be used as actual
temperature for both display and control action. The
effect is that a positive number selection will make the
room temperature lower, and vice versa. The
thermostat is calibrated within an accuracy of plus or
minus 2 degrees when shipped from the factory; this
adjustment will provide the best accuracy when set to o.
To Select:
a. Enter configuration mode (if not already there).
b. Use UP & DOWN buttons to displayoF.c. Press MODE button once to display offset value.
d. Use UP & DOWN buttons to select a value between
-- 5 and 5.
e. Press MODE buttonto return tooF.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. Press UP button until LCD readout reads 10 degrees
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
UP or DOWN button is pressed. The word SET appears
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.