Toshiba RAV-GM1601ATJP-E, Service Manual

Page 1: ...SERVICE MANUAL OUTDOOR UNIT DIGITAL INVERTER RAV GM1601ATP E TR RAV GM1601ATJP E AIR CONDITIONER SPLIT TYPE R32 March 2020 FILE NO SVM 20046 ...

Page 2: ... Calling of Error History 74 9 2 Group Control Operation 74 9 3 Outdoor Unit 76 Original instruction Adoption of R32 Refrigerant This air conditioner adopts the HFC refrigerant R32 which does not destroy the ozone layer This outdoor unit is designed exclusively for use with R32 refrigerant Be sure to use in combination with a R32 refrigerant indoor unit 6 8 Tolerance of Pipe Length and Pipe Head 3...

Page 3: ...r Corporation or alternatively he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations The qualified service person who is allowed to do the electrical work involved in installation repair relocation and removal has the qualifications pertaining to this electrical work as...

Page 4: ...n the following contents Indications Illustrated marks and keep them Explanation of indications Indication DANGER WARNING CAUTION Explanation Indicates contents assumed that an imminent danger causing a death or serious injury of the repair engineers and the third parties when an incorrect work has been executed Indicates possibilities assumed that a danger causing a death or serious injury of the...

Page 5: ...ING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing WARNING Moving parts Do not operate unit with grille removed Stop the unit before the servicing CAUTION High temperature parts You might get burned when removing this panel WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing WARNING Moving parts Do not operate unit ...

Page 6: ... Do not touch the aluminum fins of the unit Doing so may result in injury CAUTION BURST HAZARD Open the service valves before the operation otherwise there might be the burst WARNING Capacitor connected within this disconnect or downstream upon shutdown wait 5 minute to allow capacitors to discharge WARNING Open the service valves before the operation otherwise there might be the burst 6 ...

Page 7: ...Under no circumstances must this work be done by an unqualified individual since failure to carry out the work properly may result in electric shocks and or electrical leaks Wear protective gloves and safety work clothing during installation servicing and removal When connecting the electrical wires repairing the electrical parts or undertaking other electrical jobs wear gloves to provide protecti...

Page 8: ...check the earth wire is connected to the earth terminals of the main unit otherwise an electric shock is caused when a leak occurs If the earth wire is not correctly connected contact an electric engineer for rework After completing the repair or relocation work check that the ground wires are connected properly Be sure to connect earth wire Grounding work Incomplete grounding causes an electric s...

Page 9: ...the inside of the refrigerating cycle resulted in cause of breakage or injury Therefore if the refrigerant gas leaks recover the refrigerant in the air conditioner execute vacuuming and then newly recharge the specified amount of liquid refrigerant In this time never charge the refrigerant over the specified amount When recharging the refrigerant in the refrigerating cycle do not mix the refrigera...

Page 10: ... run after repairing piping Connect the pipes surely and there is no leak of refrigerant The valve is opened Running the compressor under condition that the valve closes causes an abnormal high pressure resulted in damage of the parts of the compressor and etc and moreover if there is leak of refrigerant at connecting section of pipes the air is suctioned and causes further abnormal high pressure ...

Page 11: ... the wind of air conditioner otherwise it may cause imperfect combustion When carrying out the pump down work shut down the compressor before disconnecting the refrigerant pipe Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air etc to be sucked in raising the pressure inside the refrigeration cycle to an abnormally high level and p...

Page 12: ...mpressor still operating will cause air etc to be sucked in raising the pressure inside the refrigeration cycle to an abnormally high level and possibly resulting in reputing injury etc Declaration of Conformity Hereby declares that the machinery described below Generic Denomination Model type Commercial name Digital Inverter Series Air Conditioner manufacturer s consent Manufacturer TCF holder TO...

Page 13: ...Specification Model Sound power level dBA Weight kg Cooling Heating RAV GM1601ATP E 72 95 RAV GM1601ATJP E 72 95 RAV GM1601ATP TR 72 95 70 70 70 13 ...

Page 14: ... check for leakage refrigerant or residual refrigerant If the leakage refrigerant comes into contact with fire a poisonous gas may occur or it may cause a fire Keep adequate ventilation during the work 4 When refrigerant gas leaks during work execute ventilation If the leakage refrigerant comes into contact with a fire a poisonous gas may occur or it may cause a fire 5 In places where installing r...

Page 15: ...erant changes and then characteristics of the air conditioner change 3 Pipe Materials For the refrigerant pipes copper pipe and joints are mainly used It is necessary to select the most appropriate pipes to conform to the standard Use clean material in which impurities adhere inside of pipe or joint to a minimum 1 Copper pipe Piping The pipe thickness flare finishing size flare nut and others diff...

Page 16: ...y of burning be sure to use the tools corresponding to R32 Note 4 Like R410 a Vacuum pump adapter needs installing to prevent a Vacuum pump oil mineral oil from flowing backward into the Charge hose Mixing of the Vacuum pump oil into R32 refrigerant may cause a trouble such as generation of sludge clogging of capillary etc Note 5 Be sure to use those tools after confirming they correspond to each ...

Page 17: ...frigerant charge under long piping connector 35g m 31m to 50m Height difference Outdoor lower m 30 Outdoor higher m 30 Outer dimension Height mm 1340 Width mm 900 Depth mm 320 Appearance Silky shade Muncel 1Y8 5 0 5 Total weight kg 95 Heat exchanger Finned tube Fan unit Fan Propeller fan Standard air flow high m3 min 115 Motor W 100 100 Connecting pipe Gas side mm 15 9 Liquid side mm 6 4 Sound pre...

Page 18: ...20 0 22 0 24 0 26 0 28 0 30 0 32 0 0 10 20 30 70 80 90 100 Current A 40 50 60 Compressor speed RPS 4 6 8 8 4 3 3 9 9 5 3 5 3 2 10 4 2 5 2 0 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 Capacity ratio Outdoor temperature C Condition Indoor 27 C DB 19 C WB Indoor Air flow volume High 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Capacity ra...

Page 19: ...0 52 70 96 320 39 12 75 200 60 Air inlet port Air inlet port Air outlet port Drain hole Ø28 88 Drain hole Ø25 Mounting bolt hole Ø12 17 long hole Mounting bolt hole Ø12 17 U shape hole B legs Details of A legs Details of B legs A legs Name Note Refrigerant piping hole Indoor Outdoor unit connecting wire inlet hole Power supply inlet hole Ø38 Kockout hole 1 2 Refrigerant pipe connecting port Ø9 5 f...

Page 20: ...Simultaneous Twin Inner diameter Ø C Inner diameter Ø D Inner diameter Ø D A B Model RBC TWP30E2 Liquid side Gas side TWP50E2 Liquid side Gas side A B C D 36 14 Ø9 5 Ø6 4 43 23 Ø15 9 Ø12 7 34 14 Ø9 5 Ø9 5 44 21 Ø15 9 Ø15 9 20 ...

Page 21: ...5 External diameter Ø12 7 External diameter Inner diameter Ø25 4 Inner diameter Ø12 7 Inner diameter Ø15 9 Inner diameter Ø9 52 Insulator 300 80 80 100 80 80 100 Ø12 7 Ø15 9 Ø6 4 Ø9 5 100 28 10 46 12 24 6 26 9 100 35 3 pcs 3 pcs 1 pc 1 pc Liquid side Branch pipe assembly Gas side socket Liquid side socket 21 ...

Page 22: ...ted Strainer Heating Cooling TCJ sensor TC sensor Air heat exchanger To outdoor unit To outdoor unit ë Single type Combination of 1 indoor unit and 1 outdoor unit 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3 1 Indoor Unit Indoor unit RM160 type Outer diameter of refrigerant pipe Gas side ØA Liquid side ØB 15 9 9 5 Dimension table 22 ...

Page 23: ...sensor TC sensor Refrigerant pipe at gas side Outer diameter Ø15 9 Distributor To outdoor unit Distributor Refrigerant pipe at liquid side Outer diameter Ø9 5 To outdoor unit Indoor C unit TCJ sensor TC sensor Indoor B unit TCJ sensor Air heat exchanger TC sensor Distributor Strainer incorporated Branch pipe To outdoor unit Indoor A unit TCJ sensor Air heat exchanger TC sensor Distributor Strainer...

Page 24: ...p Hz Fan Temp MPa kg cm2 G Pd Ps Pd Ps TD TS TC TE In Out Cooling Standard 2 86 0 85 29 2 8 7 91 8 8 39 68 HIGH 27 19 35 Overload 3 40 0 97 34 7 9 9 82 12 15 54 67 HIGH 32 23 46 Low load 2 92 0 74 29 8 7 5 66 3 4 47 30 LOW 18 13 15 Heating Standard 2 97 0 63 50 3 6 4 88 1 49 3 68 HIGH 20 7 6 Overload 3 10 1 12 30 6 11 4 86 19 52 16 27 LOW 27 24 18 Low load 2 22 0 26 22 6 2 6 84 18 36 17 81 HIGH 15...

Page 25: ... YEL t t t t 2 1 1 2 2 1 U t CN609 BLU 1 2 3 1 2 3 2 1 3 3 CN700 WHI 63H P t 49C BLK Fuse 3 15A 250V 1 2 3 4 5 6 CN710 WHI GRN The high voltage circuit is incorporated Be careful to do the check service as the electric shock may be caused in case of touching parts on the P C Board by hand CN690 3 MS YEL D804 YEL YEL YEL D802 YEL D800 D805 GRN MCC 1646 Display P C Board block earth GRN GREEN GRY GR...

Page 26: ... Z T R 8 88 10 01mH 16A 7 P C board MCC 1758 8 Fuse Mounted on P C board AC250 V 50 A 9 Fuse AC250 V 10 A 10 Fuse Mounted on P C board AC250 V 3 15 A 11 Outdoor temp sensor TO sensor 10 kΩ at 25 C 12 Heat exchanger temp sensor TE sensor 10 kΩ at 25 C 13 Suction temp sensor TS sensor 10 kΩ at 25 C 14 Discharge temp sensor TD sensor 50 kΩ at 25 C 15 Heat exchanger temp sensor TL sensor 50 kΩ at 25 C...

Page 27: ...cle may become abnormally high so that a rupture or personal injury may be caused After completion of installation work check to make sure that there is no refrigeration gas leakage If the refrigerant gas leaks into the room coming into contact with fire in the fan driven heater space heater etc a poisonous gas may occur 6 When an air conditioning system charged with a large volume of refrigerant ...

Page 28: ...cknesses of socket joints Nominal diameter 1 4 3 8 1 2 5 8 Reference outer diameter of copper pipe jointed mm 6 4 9 5 12 7 15 9 Minimum joint thickness mm 0 50 0 60 0 70 0 80 6 2 2 Processing of Piping Materials When performing the refrigerant piping installation care should be taken to ensure that water or dust does not enter the pipe interior that no other oil other than lubricating oils used in...

Page 29: ...diameter 1 4 3 8 1 2 5 8 3 4 Outer diameter mm 6 4 9 5 12 7 15 9 19 1 Thickness mm 0 8 0 8 0 8 1 0 1 2 Dimension mm A B B C 9 1 9 2 6 5 13 13 2 13 5 9 7 20 16 6 16 0 12 9 23 19 7 19 0 16 0 25 24 0 19 2 28 Flare nut width mm 17 22 26 29 36 Nominal diameter 1 4 3 8 1 2 5 8 3 4 Outer diameter mm 6 4 9 5 12 7 15 9 19 1 Thickness mm 0 8 0 8 0 8 1 0 1 2 A mm Flare tool for R410A R22 clutch type 0 to 0 5...

Page 30: ... torque wrenches available on the market N m kgf m 16 1 6 18 1 8 42 4 2 55 5 5 65 6 5 68 to 82 6 8 to 8 2 R410A or R32 Reference values 2 Flare Connecting Procedures and Precautions a Make sure that the flare and union portions do not have any scar or dust etc b Correctly align the processed flare surface with the union axis c Tighten the flare with designated torque by means of a torque wrench Th...

Page 31: ...minutes and ensure that the compound gauge s pointer does not return Set the refrigerant cylinder to the electronic balance connect the connecting hose to the cylinder and the connecting port of the electronic balance and charge liquid refrigerant INDOOR unit Liquid side Refrigerant cylinder With siphon pipe Check valve Gas side Open Close valve for charging Electronic balance for refrigerant char...

Page 32: ...an alloy of tin and lead Since it is weak in adhesive strength do not use it for refrigerant pipes 1 Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution which may cause a gas leakage Therefore use any other type of brazing filler at a hot spring resort etc and coat the surface with a paint 2 When performing brazing again at time of servicing use ...

Page 33: ...5 1 Prevention of oxidation during brazing 1 Do not enter flux into the refrigeration cycle 2 3 When chlorine contained in the flux remains within the pipe the lubricating oil deteriorates Therefore use a flux which does not contain chlorine When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 6 5 3 Brazin...

Page 34: ...pipe model name RBC TWP30E RBC TWP50E RBC TRP100E On the existing air conditioner for simultaneous operation system twin system there are cases of branch pipes being used that have insufficient compressive strength In such case please change the piping to a branch pipe for R32 or R410A 6 6 4 Curing of pipes When removing and opening the indoor or outdoor unit for a long time cure the pipes as foll...

Page 35: ...LVSOD V LQGLFDWHG ZKHQ VWHS LV WDNHQ GLVSOD V LQGLFDWHG ZKHQ VWHS LV WDNHQ 3UHVV 6 WR VHW WR UDSLG IODVKLQJ DFK WLPH 6 LV SUHVVHG LV VZLWFKHG EHWZHHQ UDSLG IODVKLQJ DQG 2 LJ ROG GRZQ 6 IRU DW OHDVW VHFRQGV DQG FKHFN WKDW IODVKHV VORZO DQG WKDW OLJKWV LJ ROG GRZQ 6 DQG 6 VLPXOWDQHRXVO IRU DW OHDVW VHFRQGV WR UHWXUQ WKH GLVSOD V WR WKH LQLWLDO VWDWXV 7KH H LVWLQJ SLSLQJ LV QRZ VXSSRUWHG E WDNLQJ WKH...

Page 36: ...thicknesses due to insufficient pressure capacity 6 6 7 Recovering Refrigerant Use the refrigerant recovery equipment to recover the refrigerant 6 7 Charging additional refrigerant Amount of additional refrigerant shall be restricted by the following explanation to ensure the reliability Miss charging leads to the abnormal high pressure in the refrigerant cycle causing a rupture a injury and a com...

Page 37: ... the same level the difference in level should be limited to 0 5m or less 3 Be certain to install Units A and B in the same room Units A and B cannot be operated independently each other Total length L a or L b Pipe length Branch pipe length a b one way Maximum difference between indoor units b a or a b Refrigerant pipe specification Height Between indoor units h Between indoor unit When outdoor u...

Page 38: ...e in level should be limited to 0 5 m or less 3 Be certain to install Units A and B and C in the same room Units A B and C cannot be operated independently each other Total length L a L b L c Pipe length Branch pipe length a b c one way Maximum difference between indoor units a b b c c d Refrigerant pipe specification Height Between indoor units h Between indoor unit When outdoor unit heigher H di...

Page 39: ... main piping length kg γ γ γ γ γ Additional refrigerant amount per meter of actual branch piping length kg L Actual length of main piping m a b Actual length of branch piping m CAUTION 1 Be certain to wire the additional refrigerant amount pipe length actual length head and other specification on the nameplate put on the outdoor unit for recording 2 Seal the correct amount of additional refrigeran...

Page 40: ...n piping length kg γ γ γ γ γ Additional refrigerant amount per meter of actual branch piping length kg L Actual length of main piping m a b c Actual length of branch piping m CAUTION 1 Be certain to wire the additional refrigerant amount pipe length actual length head and other specification on the nameplate put on the outdoor unit for recording 2 Seal the correct amount of additional refrigerant ...

Page 41: ...loy seamless pipes and tubes with 40 mg 10 m or less in the amount of oil stuck on inner walls of pipe and 0 8 mm in pipe wall thickness for diameters 6 4 9 5 and 12 7 mm and 1 0 mm for diameter 15 9 mm Never use pipes of thin wall thickness such as 0 7 mm Between outdoor unit and distributor Unit mm Pipe wall thickness Between distributor and indoor unit Unit mm Pipe wall thickness Pipe side Gas ...

Page 42: ...n 500 mm in length as the main piping of the branches How to install distributor Restrictions in length of the straight area of the branch pipe main pipe side Provide a straight area of 500 mm or more on the main pipe side of the branch pipe for both gas pipe and liquid pipe sides n Air Purging For the complete information read the installation manual for outdoor units of air conditioner Horizonta...

Page 43: ...le refrigerants In addition a set of calibrated weighing scales shall be available and in good working order Hoses shall be complete with leak free disconnect couplings and in good condition Before using recovery machine check that it is satisfactory working order has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant...

Page 44: ...rtening of the compressor life In a case of trouble on the compressor be sure to check there is no error in the resistance value an the refrigerating cycle of each sensor after repair and then start the operation 2 Discharge temperature release control 1 When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control this control lowers the compressor freque...

Page 45: ...ntrolled by TL sensor TO sensor and compressor frequency An outdoor fan is controlled at 1 tap interval of DC fan control 2 At the start time the fan is fixed for 60 seconds only with the maximum fan tap corresponded to the zone in the following table but it is controlled with TL sensor temperature after then 1 tap 20 sec Up to the maximum rotational frequency of each zone Rotational frequency hol...

Page 46: ... C 15 C 24 C Temp range 20 4 Hz or lower 20 4Hz to 45 0Hz 45 0Hz or higher Max Max Max 10 C TO WA WB WC 5 C TO 10 C WC WC WC 3 C TO 5 C WC WC WE 10 C TO 3 C WE WE WE TO 10 C WE WE WE TO error WE WE WE 5 Coil heating control 1 This control function heats the compressor by turning on the stopped compressor instead of a case heater It purposes to prevent stagnation of the refrigerant inside of the co...

Page 47: ...ents confirm on the check code list 9 High pressure release control 1 The operation frequency is controlled to restrain abnormal rising of high pressure by TL sensor in cooling operation and TC sensor in heating operation 2 When TL sensor in cooling operation or TC sensor in heating operation detects abnormal temperature of the stop zone stop the compressor and the error count becomes 1 3 When the...

Page 48: ...0 seconds A zone When status of TEO TE 3 C continued for 20 seconds When status of TEO TE ToO TO 2 C continued for 20 seconds B zone When status of TEO TE 2 C continued for 20 seconds C zone When status of TE 23C continued for 20 seconds D zone When compressor operation status with TE 2 C is added by d times 11 High pressure switch 1 When the high pressure switch operates the operation of the comp...

Page 49: ...r Compressor CN710 Pulse Motor Valve CN600 TS sensor connector CN601 TE sensor connector CN602 TO sensor connector CN603 TD sensor connector CN604 TL sensor connector F03 Fuse 10A F01 Fuse 50A CN807 Connector for display Lead and connector for Reactor Lead for ground Black N phase power supply White L phase power supply Black Serial lead Gray CN200 CN202 Compressor 49 ...

Page 50: ...anges When high temperature release operation control is working in heating operation When outside low temperature operation control is working in cooling operation When defrost operation is being performed 4 ON OFF operation cannot be performed from remote controller When the control operation is being performed from outside remote side When automatic address is being set up When the power is tur...

Page 51: ...d 4 ON OFF operation cannot be performed from remote controller When forced operation is being performed When the control operation is being performed from outside remote side When automatic address being set up When the test run is being performed by operation of the outdoor controller a Did you return the cabling to the initial positions b Are connecting cables between indoor unit and receiving ...

Page 52: ...n erorr Communication stop between indoor and outdoor units Overflow was detected Protective device of indoor unit worked Indoor DC fan error Outdoor unit discharge temp sensor error Case thermostat operation High pressure protective operation High pressure SW system error Power supply error Power supply error Heat sink overheat error Gas leak detection 4 way valve inverse error Indoor or outdoor ...

Page 53: ... exchanger sensor TA error Discharge temp sensor TD error Temp sensor TE TS TL error Heat exchanger temp sensor TL error Outside air temp sensor TO error Suction temp sensor TS error Heat sink temp sensor TH error Miss mounting of temp sensor TE TS Indoor EEPROM error Outdoor EEPROM error Compressor break down Outdoor compressor system error Compressor lock Outdoor unit current detection circuit e...

Page 54: ...ime Indoor discharge temperature 1 4 way only Unit C C C C rpm 100h 1h C Outdoor unit data CODE No 60 61 62 63 65 6A 6D 70 72 73 F1 Data name Outdoor heat exchanger Coil temperature TE Outside temperature TO Compressor discharge temperature TD Compressor suction temperature TS Heat sink temperature TH Operation current 1 10 Outdoor heat exchanger Coil temperature TL Compressor operation frequency ...

Page 55: ...art error was detected EEPROM error Heat sink temp sensor TH error 2 Outdoor unit Unset model type of service P C board 3 Outdoor Heat sink overheat error Gas leak detection or 4 way valve system error 1E P03 ALT Outdoor unit Discharge temp error Outdoor Error was detected by discharge temp release control 21 P04 ALT Outdoor unit High pressure SW system error Outdoor High pressure protection switc...

Page 56: ...be performed 96 L03 SIM Duplicated indoor master units Indoor There are multiple master units in a group 99 L07 SIM There is group cable in individual indoor unit Indoor When even one group connection indoor unit exists in individual indoor unit 99 L08 SIM Unset indoor group address Indoor Indoor address group was unset 46 L09 SIM Unset indoor capacity Indoor Capacity of indoor unit was unset 66 L...

Page 57: ...o address setup mode Resetting of address 1 Set indoor capacity CODE No DN 11 1 Check outside devices 2 Check indoor P C board 1 Trouble of drain pump 2 Clogging of drain pump 3 Check float switch 4 5 Check Application control kit of indoor unit Check indoor P C board 1 Position detection error 2 Over current protective circuit of indoor fan driving unit operated 3 Indoor fan locked 4 Check indoor...

Page 58: ...isplayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Judgmentandmeasures 1 Check discharge ...

Page 59: ... service valve 4 Check PMV Pulse Motor Valve 5 Check broken pipe AC current detection circuit 1 Check refrigerating cycle Gas leak 2 Check PMV Pulse Motor Valve 3 Check discharge temp sensor TD 1 Check service valves are fully opened Gas side Liquid side 2 Check outdoor fan operation 3 Check motor error of outdoor fan 4 Check clogging of outdoor PMV 5 Check clogging of heat exchanger in indoor out...

Page 60: ...tion continues If center exists operation continues Stop Sub unit continues operation Continues By remote controller Continuation Stop According to each case Condition Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Judgment and measures Power supply...

Page 61: ...t exchanger temperature sensor TE error Heat exchanger temperature sensor TL error Outside temperature sensor TO error Suction temperature sensor TS error Heat sink temperature sensor TH error Miss mounting of sensor TE TS EEPROM error Compressor breakdown Compressor lock Current detection circuit error Case thermostat activated Unset model type Communication error between MCUs Discharge temperatu...

Page 62: ...lashing and that D805 is lit up If D800 to D804 are slowly flashing or D805 is flashing then push and hold down SW01 and SW02 at the same time for at least 5 seconds D800 to D804 will turn off or be rapidly flashing and D805 will change to flashing 2 Push and hold down SW01 for at least 5 seconds D804 will start slowly flashing 3 Push SW01 several times until reaching the LED indication D800 to D8...

Page 63: ... F07 Heat exchanger temp sensor TL trouble Is connection of CN604 correct Is resistance value of TL sensor correct YES NO Correct connector Replace TL sensor Check outdoor P C board Failure Replace F12 Suction temp sensor TS trouble Is connection of CN600 correct Is resistance value of TS sensor correct YES NO Correct connector Replace TS sensor Check outdoor P C board Failure Replace F08 Outside ...

Page 64: ...ensor correct YES NO Correct connector Replace TE sensor Check outdoor P C board Failure Replace Is connection of CN601 correct Is resistance value of TE sensor correct YES H01 Compressor break down Is power supply voltage normal AC198 to 264V NO Correct power supply line NO Check wire connection and correct it YES Is wire connection correct Compressor lead P C board side Compressor side Reactor l...

Page 65: ...rant stagnation YES Does PMV correctly operate YES H03 Current detection circuit trouble Are CN609 connection and case thermostat correct H04 Case thermostat operation NO Open service valve fully NO YES YES Check outdoor P C board Failure Replace When replacing outdoor P C board replace the fuse NO When shorting the case thermostat can you perform the cooling heating operation NO Correct connector...

Page 66: ... Replace the PMV Replace TD sensor YES Remove and improve the cause of overload NO Check outdoor P C board Failure Replace NO Fault part repair Recharge refrigerant Is connection of CN603 correct Is resistance value of TD sensor correct YES NO Is PMV normal YES YES Does an abnormal overload happen YES Confirmation of electrical work etc Does the supply voltage drop or rise AC198 to 264V P05 Powers...

Page 67: ...heck outdoor P C board Failure Replace OK Is service valve fully opened NO Is there crushed pipe YES Apply radiation grease to objective retightening of screw NO Remove blocking matter Short circuit improvement YES NO P07 Heat sink overheat trouble Is there any looseness in the screw stop of the motor drive element IC201 of the outdoor P C board the sub heat sink and the diode bridge Are radiation...

Page 68: ...ere are any problems with the 4 way valve or 4 way valve coil Method of operation 1 ush ensure that D800 to D804 are off or rapidly flashing and that D805 is lit up If D800 to D804 are slowly flashing or D805 is flashing then push and hold down SW01 and SW02 at the same time for at least 5 seconds D800 to D804 will turn off or rapidly flash and D805 turn on 2 Push and hold down SW01 for at least 5...

Page 69: ...e of TE sensor correct Resistance value measurement Are resistance values of indoor TC and TCJ sensors normal Replace TE sensor Check the same items as P22 trouble Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Failure Fault part repair Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Failure Fault part repair Eliminate interf...

Page 70: ... whether there are any problems with the fan motor Method of operation 1 ush ensure that D800 to D804 are off or rapidly flashing and that D805 is lit up If D800 to D804 are slowly flashing or D805 is flashing then please push and hold down SW01 and SW02 at the same time for at least 5 seconds D800 to D804 will turn off or rapidly flash and D805 turn on 2 Push and hold down SW01 for at least 5 sec...

Page 71: ... board YES Does the same trouble occur in operation without compressor lead Check compressor Layer short etc Failure Replace NO P29 Position detection circuit trouble No code Other trouble Compressor step out from sudden changes in load etc utdoor LED indication occurs but it automatically restarts and does not confirm any trouble M y occur also when the compressor is open phase and wiring disconn...

Page 72: ...764 7 990 8 218 5 013 5 192 5 375 3 312 3 451 3 594 2 236 2 343 2 454 1 540 1 623 1 709 1 082 1 146 1 213 0 7740 0 8237 0 8761 0 5634 0 6023 0 6434 Temperature C 0 10 20 25 30 40 50 60 70 80 90 100 Resistance value kΩ Ω Ω Ω Ω Minimum value Standard value Maximum value 150 5 161 3 172 7 92 76 99 05 105 6 58 61 62 36 66 26 47 01 49 93 52 97 37 93 40 22 42 59 25 12 26 55 28 03 17 00 17 92 18 86 11 74...

Page 73: ... Black Black Red Under 20 C Red White Black 2 Outdoor fan motor Model ICF 280 A100 1 Measure the resistance value of each winding by using the tester Position Resistance value Red White 14 8 1 5Ω White Black Black Red Under 20 C Red White Black 3 4 way valve coil Cooling heating switching Model DXQ 1490 Measure the resistance value of each winding by using the tester Resistance value 9 1 0 36 Ω Un...

Page 74: ...ET TEST FILTER L L RESET TEMP CL FAN SAVE A A SWING FIX VENT MODE ON OFF UNIT LOUVER T Contents The error contents in the past can be called Procedure 1 Push SET TEST buttons simultaneously for 4 seconds or more to call the service check mode Service Check goes on the CODE No is displayed and then the content of the latest alarm is displayed The number and error contents of the indoor unit in whic...

Page 75: ...emote controller operation is available Approx 50 seconds after power ON Regular communication between indoor units Every 30 seconds Master Follower Regular communication on the identical pipe every 30 seconds Twin Master Follower When the above status changes immediately communicates Repetition The unit without power feed waits entirely Waiting status is released by system start Reboot when power...

Page 76: ...o OFF Go ON Go OFF Go ON Go OFF Go ON The initial state of the LED display is as shown on the right with D805 lit up If not in the initial state D805 flashing then it can be returned to the initial state by pushing and holding down SW01 and SW02 at the same time for 5 seconds LED display Initial state D800 to D804 Go Off and flash 5 times sec D805 Go ON D800 D801 D802 D803 D804 D805 Yellow LED Yel...

Page 77: ...peration then can return to step 1 by pressing and holding down SW01 and SW02 at the same time for at least 5 seconds Functions LED display Control content Existing pipe setting D800 D801 D802 D803 D804 Activate when existing Ø19 1 piping is used Note that in this case depending on the outdoor and indoor air temperature the heating capacity may drop Cooling only setting D800 D801 D802 D803 D804 Co...

Page 78: ...efault stings can be restored using the following procedure 1 Ensure the LED display shows the initial state If not then ensure to return it to the initial state Return to default factory setting LED display D800 D801 D802 D803 D804 D805 Go ON Go ON Go OFF Go OFF Flash 5 times sec Sub P C board switch and LED arrangement diagram D800 LED YEL D801 LED YEL D802 LED YEL D803 LED YEL D804 LED YEL D805...

Page 79: ...is currently occurring then the same content will be displayed TO sensor trouble only and thus this setting does not display Check using the current trouble setting Discharge temperature sensor TD indication Displays the discharge temperature sensor TD value Outdoor heat exchanger temperature sensor TE indication Displays the outdoor heat exchanger temperature sensor TE value Outdoor heat exchange...

Page 80: ...ble Gas leak detection 4 way valve reversal trouble High pressure protective operation Fan system trouble Short circuit of compressor drive element Position detection circuit trouble Go ON Go ON Go OFF Go OFF Flash 5 times sec 1 2 2 Latest including current trouble indication LED indication Name of trouble D800 D801 D802 D803 D804 D805 Normal Discharg temp sensor TD trouble Heat exchanger temp sen...

Page 81: ...L D803 YEL D804 YEL D805 GRN Less than 25 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 Sensor trouble 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 or more 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 or more 0 19 20 39 40 59 60 79 80 99 100 119 120 13...

Page 82: ...etected because of refrigerant circulation failures due to PMV Pulse Motor Valve blockages operation failures capillary blockages strainer blockages etc Refrigerant leak detection may not be possible depending on the external air temperature conditions during operation If any refrigerant leaks are detected ensure to identify where the leak is recover the remaining refrigerant and then recharge wit...

Page 83: ...t A sudden change in pressure could occur while the operations are taking place which can be dangerous Note 2 Trial indoor cooling operation request trial indoor heating operation request Caution Forced test operations using this setting cannot be cancelled using the indoor remote control Refer to 6 below Special operations LED display Control content The outdoor unit performs cooling operations I...

Page 84: ...sipation The power saving can be switched to three levels 75 50 and operation stop 2 Night operation Reduces the capacity of the air conditioner by the input signal from a commercially available timer procured locally regardless of the outside air temperature or load to reduce operating noise 3 Compressor output Turns on the no voltage contact output while the compressor is operating 84 ...

Page 85: ... an indoor unit are connected or when an outdoor unit is connected to each indoor unit respectively in the group operation even if multiple refrigerant lines are provided the automatic address setup completes with power ON of the outdoor unit The operation of the remote controller is not accepted while automatic address works Approx 4 to 5 minutes When the following addresses are not stored in the...

Page 86: ...nse to demand of service data Header unit Representative unit Master Twin This unit communicates with the indoor unit follower which serial communicates with the outdoor units and sends receives signal Command from compressor to from the outdoor units as the representative of the cycle control in the indoor units of the identical line address within the minimum unit which configures one of the ref...

Page 87: ... follower unit Follower unit The follower unit receives the indoor unit data from the header With identical line address indoor outdoor serial and then performs the thermo operation synchronized with the header unit The follower unit sends own thermo ON OFF demand to the header unit Example No 1 1 header unit sends receives signal to from No 1 2 and No 1 3 follower units It is not influenced by th...

Page 88: ...Sub Header 1 1 1 2 1 3 1 3 Master Follower 1 1 Sub Follower 1 1 Individual Master Header Max 8 units 1 2 Master Header 1 1 1 2 1 1 Sub Follower Only turning on source power supply Automatic completion 2 Group operation Multiple outdoor units Multiple indoor units with serial communication only without twin Only turning on source power supply Automatic completion 3 Multiple groups operation Change ...

Page 89: ...troller wiring Indoor side Indoor Outdoor connecting wires Outdoor side A B 1 1 L N 2 2 3 3 Power supply Remote controller Remote controller wiring Indoor side Indoor Outdoor connecting wires Outdoor side Example of 2 lines cabling Real line Cabling Broken line Refrigerant pipe For the above example perform setting by connecting singly the wired remote controller without remote controller inter un...

Page 90: ... 10 Push SET button OK when display goes on 11 Push TEST button Setup completes The status returns to the usual stop status 10 5 Confirmation of Indoor Unit No Position 1 To know the indoor unit addresses though position of the indoor unit body is recognized In case of individual operation Wired remote controller indoor unit 1 1 Follow to the procedure during operation Procedure 1 Push ON OFF butt...

Page 91: ...n coating of the outdoor units Repair the defective position or apply the rust resisting paint if necessary If an indoor unit operates for approx 8 hours or more per day usually it is necessary to clean the indoor outdoor units once three months at least These cleaning and maintenance should be carried out by a qualified dealer Although the customer has to pay the charge for the maintenance the li...

Page 92: ...ctric shock may be occurred Assembly steps Front side Back side Guide Hook Guide Hook 1 LED side of P C Board MCC 1646 shall be inserted to hook along the guide of mold 2 Switch side of P C Board MCC 1646 shall be pressed to hook along guide of mold 3 After assembly push SW01 and SW02 to check that switches can be click sound or feeling of click 92 ...

Page 93: ... recover the refrigerant to the outdoor unit For the refrigerant recovery work during reinstallation of repair work be sure to use the refrigerant recovery unit Recovery of refrigerant to the outdoor unit is unavailable otherwise a serious accident such as explosion or injury may be caused 12 HOW TO EXCHANGE COMPRESSOR 12 1 Exchanging Procedure of Compressor Outline 12 2 Exchange of Compressor For...

Page 94: ...the cord clamp and the terminals 4 Remove the top plate Hexagonal screw Ø4 10 5 pcs 2 Attachment 1 Attach the top plate Hexagonal screw Ø4 10 5 pcs 2 Connect the power supply wire and the indoor outdoor connecting wire to the terminal and fix it with cord clamp CAUTION Using bundling band on the market be sure to fix the power wire and indoor outdoor connecting wire along the crossover pipe so tha...

Page 95: ...e plate Ø4 10 2 pcs 4 Remove the screws from the Air out cabinet and the motor base Ø4 10 2 pcs 5 Remove the screws from the Air out cabinet and the heat exchanger Ø4 8 2 pcs Plate stay Fin guard Plate stay Fin guard 2 Attachment Attachment the Plate stay Fin guard in the reverse process of 1 Detachment 1 Following to work of Detachment 1 2 Remove screws for the Plate stay Fin Guard Ø4 x 10 7 pcs ...

Page 96: ...ear Inverter box 5 Fan motor 1 Detachment 1 Following to work of Detachment of 1 2 and 3 2 Make sure that the fan motor and the propeller fan stop 3 Remove flange nut from the fan motor and propeller fan 4 Remove propeller fan 5 Remove inverter box cover from inverter box Ø4 8 1 pcs 6 Remove the connector of fan motor from the inverter box 7 Remove fan motor lead from the fan motor lead fixing rub...

Page 97: ...n motor lead fixing rubber so that the fan motor lead has no slack Attach the fan motor lead fixing rubber to the partition plate so that the projection is on the refrigerant cycle side Ensure to bundle again with a commercially available cable clamp where the cable clamp was removed Fixing rubber Fan motor lead Upper Partition plate Fan motor lead Lower Fixing rubber Partition plate Core clamp Fa...

Page 98: ...emove the sound insulation board Upper Inner and Outer 8 Remove TD sensor from discharge pipe 9 Remove terminal cover of compressor 2 Claws compressor lead and compressor case thermostat 1 Claw 10 Remove the compressor lead from partition plate 11 Remove the discharge and suction pipes connected to the compressor using a burner WARNING When removing the welding part of the suction discharge pipe o...

Page 99: ...t the work 1 Attach the compressor in the reverse process of 1 Detachment Also ensure to replace the compressor lead after replacing the compressor Install the sound insulation board Inner Outer through the space between the compressor and the piping and between the pipes and partition plate as shown on the right 3 Vacuum 1 Connect the vacuum pump to the charge port of the liquid and gas pipe valv...

Page 100: ...emove partition cover and then remove lead wires from terminal 5 Take off screws to remove compressor wire out from terminal at P C board 6 Remove all connectors at bottom left of P C board 1 Detachment 1 Carry out work of 1 of WARNING P C board Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused Screw Inverter box cover Connector Scr...

Page 101: ...two spacers Heatsink Fan and two clamp filters from P C board 2 Attachment Attachment the P C board in the reverse process of 1 Detachment CAUTION Apply thermal grease at mating surface between heat sink fan and Fan IPM chips Be sure that all the connectors are connected correctly and securely inserted If the components bent during this procedure straighten them so they do not touch other parts P ...

Page 102: ...14 EXPLODED VIEWS AND PARTS LIST 102 ...

Page 103: ...ATOR ASSEMBLY 1 1 1 23 43T60520 MOTOR FAN ASSEMBLY 1 1 1 24 43T96305 BUSHING 1 1 1 25 43T00786 AIR OUTLET CABINET 1 1 1 26 43T04443 FRONT PANEL ASSEMBLY 1 1 1 27 43T00785 RIGHT PANEL ASSEMBLY 1 1 1 28 43T00608 ASM COAT P P FR 1 1 1 29 43T00609 ASM COAT P P BK 1 1 1 30 43T00564 UPPER CABINET ASSEMBLY 1 1 1 31 43T00726 GUARD FIN ASSEMBLY 1 1 1 32 43T00727 GUARD FIN BACK 1 1 1 33 43T22313 BELLMOUTH 1...

Page 104: ... CN800 WHI WHI CN801 Q40 C241 C11 C12 C13 C15 CN400 IC400 DB02 CN300 P24 R20 R24 C3 40 IC300 C14 DB04 DB01 WHI CN900 RED WHI CN901 DAC SWRT FLASH CN605 DRC WHI CN603 TD WHI CN604 TL YEL CN602 TO WHI CN601 TE N CN600 TS WHI CN807 CN700 BLU CN881 250VAC T10A 250VAC 50A WHI BLK P01 P02 2 1 3 L N RY01 716 714 715 717 712 711 704 706 709 708 710 701 LED displays Service Switches D800 D801 D803 D805 D80...

Page 105: ... 43T61321 BASE PC BOARD 1 1 1 708 43T60424 ASM SERV Terminal block 3P 60A 1 1 1 709 43T60331 TERMINAL 3P 1 1 1 710 43T60413 FUSE 1 1 1 711 43T50336 TEMPERATURE SENSOR 1 1 1 712 43T50385 TEMPERATURE SENSOR TE 1 1 1 713 43T50337 TEMPERATURE SENSOR TO 1 1 1 714 43T50376 SENSOR TD 1 1 1 715 43T50335 TEMPERATURE SENSOR 1 1 1 716 43T63323 HOLDER SENSOR 1 1 1 717 43T63335 SENSOR HOLDER 1 1 1 Location No ...

Page 106: ...ively Suffocation from leakage of R32 is almost non existent If a conditioner system is to be installed in a small room select a suitable model and installation procedure so that if the refrigerant accidentally leaks out its concentration does not reach the limit and in the event of an emergency measures can be made before injury can occur In a room where the concentration may exceed the limit cre...

Page 107: ...144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND ...