Toshiba RAV-SP1104AT8-E1, Service Manual

Page 1: ...UAL SPLIT TYPE OUTDOOR UNIT SUPER DIGITAL INVERTER RAV SP1104AT8 E1 RAV SP1104AT8 TR1 RAV SP1104AT8J E1 RAV SP1104AT8J TR1 RAV SP1404AT8 E1 RAV SP1404AT8 TR1 RAV SP1404AT8J E1 RAV SP1404AT8J TR1 RAV SP1604AT8 E1 RAV SP1604AT8 TR1 RAV SP1604AT8J E1 RAV SP1604AT8J TR1 ...

Page 2: ... AND CONTROL SPECIFICATIONS 31 7 1 Outdoor Unit Control 31 7 2 Outline of Main Controls 35 8 TROUBLESHOOTING 40 8 1 Summary of Troubleshooting 40 8 2 Troubleshooting 42 9 SETUP AT LOCAL SITE AND OTHERS 65 9 1 Calling of Error History 65 9 2 Group Control Operation 65 9 3 Outdoor Unit 67 10 ADDRESS SETUP 74 10 1 Address Setup Procedure 74 10 2 Address Setup Group Control 75 10 3 Remote Controller W...

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: ...y in 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 ...

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

Page 6: ...stry as protective gear to undertake the work When working at heights put a sign in place so that no one will approach the work location before proceeding with the work Parts and other objects may fall from above possibly injuring a person below Do not touch the aluminum fin of the outdoor unit You may injure yourself if you do so If the fin must be touched for some reason first put on protective ...

Page 7: ...epair or relocation work check that the ground wires are connected properly Be sure to connect earth wire Grounding work Incomplete grounding causes an electric shock Do not connect ground wires to gas pipes water pipes and lightning rods or ground wires for telephone wires Do not modify the products Do not also disassemble or modify the parts It may cause a fire electric shock or injury When any ...

Page 8: ... refrigerant with recovering device The refrigerant cannot be recovered in the outdoor unit otherwise a serious accident such as breakage or injury is caused After repair work surely assemble the disassembled parts and connect and lead the removed wires as before Perform the work so that the cabinet or panel does not catch the inner wires If incorrect assembly or incorrect wire connection was done...

Page 9: ... unit is to be opened in order for the compressor or the area around this part to be repaired immediately after the air conditioner has been shut down set the circuit breaker to the OFF position and then wait at least 10 minutes before opening the service panel If you fail to heed this warning you will run the risk of burning yourself because the compressor pipes and other parts will be very hot t...

Page 10: ...ribed below Generic Denomination Air Conditioner Model type RAV SP1104AT8 E1 RAV SP1104AT8J E1 RAV SP1404AT8 E1 RAV SP1404AT8J E1 RAV SP1604AT8 E1 RAV SP1604AT8J E1 RAV SP1104AT8 TR1 RAV SP1104AT8J TR1 RAV SP1404AT8 TR1 RAV SP1404AT8J TR1 RAV SP1604AT8 TR1 RAV SP1604AT8J TR1 Commercial name Super Digital Inverter Series Air Conditioner Complies with the provisions of the Machinery Directive Direct...

Page 11: ...d others do not mix in because pipes are affected by impurities such as water oxide scales oil etc Use the clean pipes Be sure to brazing with flowing nitrogen gas Never use gas other than nitrogen gas 4 For the earth protection use a vacuum pump for air purge 5 R410A refrigerant is azeotropic mixture type refrigerant Therefore use liquid type to charge the refrigerant If using gas for charging co...

Page 12: ...ng of flare nut Evacuating refrigerant charge run check etc Vacuum evacuating Refrigerant charge Refrigerant charge Gas leakage check R410A air conditioner installation Existence of Whether conventional new equipment for R410A equipment can be used Yes Note Yes Note Yes No Yes No Yes No Yes Yes Yes No Yes No Conventional air conditioner installation Whether conventional equipment can be used Yes N...

Page 13: ...8 5 0 5 Heat exchanger Connecting pipe Gas side mm 15 9 15 9 Fan unit Fan Propeller fan 15 9 Sound pressure level Cooling Heating dB A 49 50 51 52 Sound power level Cooling Heating dB A 66 67 68 69 68 70 Outside air temperature cooling C Outside air temperature Heating C 15 to 20 C 46 to 15 C 51 53 Liquid side mm 9 5 9 5 9 5 Standard air flow m3 min 101 103 103 Motor 100 100 W 100 100 100 100 Finn...

Page 14: ...racteristic Curve Operation characteristic curve 50Hz Super Digital Inverter RAV SP1104AT8 J E1 TR1 RAV SP1404AT8 J E1 TR1 RAV SP1604AT8 J E1 TR1 Cooling Heating Capacity variation ratio according to temperature RAV SP1104AT8 J E1 TR1 RAV SP1404AT8 J E1 TR1 RAV SP1604AT8 J E1 TR1 Cooling Heating 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Outdoor temp C Capac...

Page 15: ... 15 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 2 1 Outdoor Unit RAV SP1104AT8 J E1 TR1 RAV SP1404AT8 J E1 TR1 RAV SP1604AT8 J E1 TR1 ...

Page 16: ...0E2 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 ...

Page 17: ...uid side socket Ø15 9 External diameter Ø9 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 Ø6 4 Ø9 5 100 28 10 24 8 26 9 100 35 3 pcs 3 pcs 1 pc 1 pc 1 pc Ø25 4 External diameter Ø15 9 46 12 1 pc ...

Page 18: ...21 43 26 96 Indoor fan HIGH HIGH LOW HIGH LOW HIGH Indoor Outdoor temp conditions DB WB C Indoor Outdoor 27 19 35 32 24 43 18 15 5 5 20 7 6 30 24 18 15 15 Standard Cooling Overload Low load Standard Heating Overload Low load Pressure MPa kg cm g Pd Ps Pd Ps 2 77 0 87 28 3 8 9 3 50 0 98 35 7 10 0 1 75 0 76 17 9 7 8 2 66 0 67 27 1 6 8 3 13 1 05 31 9 10 7 2 48 0 20 25 3 2 0 Pipe surface temperature C...

Page 19: ... 19 4 WIRING DIAGRAM 4 1 Outdoor Unit RAV SP1104AT8 J E1 TR1 RAV SP1404AT8 J E1 TR1 RAV SP1604AT8 J E1 TR1 ...

Page 20: ... C board MCC 1596 Fuse Mounted on P C board MCC 1597 Fuse Mounted on P C board MCC 1597 Fuse Mounted on P C board MCC 1599 Fuse Mounted on P C board MCC 1600 Relay Posistor Compressor thermo Type DA422A3F 27M ICF 280 A100 1 STF 01AJ502E1 UKV A038 ACB 4UB83W CH 78 CH 68 CH 56 MCC 1596 MCC 1597 MCC 1599 MCC 1600 TLC 10A GAC1 31 5A SCT 3 15A GDM 250V 15A SCT 3 15A FJL 250V 3 15A ET 6 3A EL200 240A2 F...

Page 21: ... cycle may become abnormally high so that a rupture or personal injury may be caused 5 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 refrige...

Page 22: ...be taken to ensure that water or dust does not enter the pipe interior that no other oil other than lubricating oils used in the installed air conditioner is used and that refrigerant does not leak When using lubricating oils in the piping processing use such lubricating oils whose water content has been removed When stored be sure to seal the container with an airtight cap or any other cover 1 Fl...

Page 23: ...m 0 8 0 8 0 8 1 0 1 0 Dimension mm A B C D 9 1 9 2 6 5 13 13 0 13 5 9 7 20 16 2 16 0 12 9 20 19 4 19 0 16 0 23 23 3 24 0 19 2 34 Flare nut width mm 17 22 24 27 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 Dimension mm A B C D 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...

Page 24: ...rack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 6 2 6 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Table 6 2 6 Tightening torque of flare for R410A Refer...

Page 25: ... refrigerant in the cycle When the compound gauge s pointer has indicated 0 1 Mpa 76 cmHg place the handle Low in the fully closed position and turn off the vacuum pump s power switch Keep the status as it is for 1 to 2 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 conn...

Page 26: ...oy mainly composed of silver and copper It is used to join iron copper or copper alloy and is relatively expensive though it excels in solderability 2 Phosphor bronze brazing filler Phosphor bronze brazing filler is generally used to join copper or copper alloy 3 Low temperature brazing filler Low temperature brazing filler is generally called solder and is an alloy of tin and lead Since it is wea...

Page 27: ...efore use a flux which does not contain chlorine 3 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 Brazing As brazing work requires sophisticated techniques experiences based upon a theoretical knowledge it must be performed by a person qualified In order to prevent the oxide film from occurring...

Page 28: ...sibility that copper green rust generated 6 Check the oil when the existing air conditioner was removed after refrigerant had been recovered In this case if the oil is judged as clearly different compared with normal oil The refrigerator oil is copper rust green There is possibility that moisture is mixed with the oil and rust generates inside of the pipe There is discolored oil a large quantity o...

Page 29: ...g size to size for R410A Airtight test Vacuum dry Refrigerant charge Gas leak check When using a Ø19 1 mm pipe for the gas pipe of the first branching pipe machining size due to pipe compression Turn the existing pipe switch on the cycle control P C board of the outdoor unit to ON side At shipment from factory OFF ON for existing pipe Refer to the table below Be sure to set the contents in the tab...

Page 30: ...existing Ø19 1 mm pipe set bit 3 of SW802 switch for existing pipe on the P C board of the outdoor unit to ON In this case the heating performance may be reduced depending on the outside air temperature and room temperature Reference outside diameter mm Ø9 5 Ø15 9 Ø19 1 Wall thickness mm 0 8 1 0 1 0 SW802 When shipped from factory When using existing pipe 1 2 3 4 ON 1 2 3 4 ON 6 6 7 Recovery Metho...

Page 31: ...e Connector for MCC 1597 CN502 CN13 Black Terminal for power relay F02 Electric circuit protective fuse 500V 31 5A CN12 White Terminal for MCC 1600 CN17 F01 Electric circuit protective fuse 500V 31 5A CN11 Red Terminal for power relay CN04 Red Terminal for PTC thermistor CN19 Yellow CN20 Yellow Terminal for reactor CH78 CN211 Red CN212 White CN213 Black Compressor output terminal ...

Page 32: ... for MCC 1599 CN802 CN602 Black Connector for MCC 1600 CN51 F500 Electric circuit protective fuse 250V 15A P501 Black Lead wire for grounding CN505 Red Connector for MCC 1596 CN851 CN502 White Connector for MCC 1596 CN101 CN700 Blue Fan motor output Lower side CN500 Red Connector for MCC 1600 CN23 and reactor CH68 ...

Page 33: ...2 Red Connector for MCC 1600 CN10 and CN19 CN802 White Connector for MCC 1597 CN504 CN708 Blue Connector for power relay coil CN608 White Connector for MCC 1600 CN50 Temp sensor connector CN604 White TL sensor CN603 White TD sensor CN602 Yellow TO sensor CN601 White TE sensor CN600 White TS sensor Specific operation switch SW801 SW804 SW805 SW806 Display select switch SW800 SW803 Initial setting s...

Page 34: ...tor protective fuse 250V 6 3A CN07 Black Power supply terminal L3 F03 Varistor protective fuse 250V 6 3A CN20 White Power supply terminal L2 CN08 Gray Neutral terminal CN10 Red Terminal for MCC 1599 CN02 and Terminal for PTC thermistor CN16 Red Terminal for power relay CN17 White Terminal for MCC 1596 CN02 CN18 Black Terminal for power relay CN19 Gray Terminal for MCC 1599 CN02 CN09 Brown Terminal...

Page 35: ...here is no error in the resistance value or 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 operation frequency It subdivides the frequency control up to 0 6Hz to stabilize the cycle 2 When the dis...

Page 36: ...y stain on filter of the suction part of the indoor unit is considered Clean the filter and then restart the operation WE tap 1 tap 20 sec Up to the maximum revolution frequency of each zone Revolution frequency hold 1 tap 20 sec Up to the minimum revolution frequency of each zone TL C 58 55 38 35 2 taps 20 sec Up to W1 Stop timer count 1 tap 20 sec Up to the maximum tap of each zone 2 taps 20 sec...

Page 37: ...ration preventive control 1 For 3 to 10 minutes after operation start in some cases the compressor does not stop to protect the compressor even if receiving the thermostat OFF signal from indoor However it is not abnormal status The operation continuance differs according to the operation status 2 When the operation stops by the remote controller the operation does not continue 6 Current release c...

Page 38: ...t or lower where it returned after 2 minutes 30 seconds 4 The error count when the compressor stopped with 2 is cleared after the operation continued for 10 minutes If the error count becomes 10 without clearing the error is determined and reactivation is not performed 5 For the error display contents confirm on the check code list Abnormal stop Frequency normal down Frequency slow down Frequency ...

Page 39: ... zone B zone B zone C zone C zone D zone D zone A zone B zone C zone D zone Start of heating operation J805 J806 d 150 minutes Setting at shipment 90 minutes 60 minutes 30 minutes Short circuit Open A zone B zone C zone D zone In normal To In abnormal To When status TEO TE ToO To 3 C When status TEO TE 3 C continued for 20 seconds continued for 20 seconds When status TEO TE ToO To 2 C When status ...

Page 40: ... in heating operation Does not outside low temperature operation control work in cooling operation Is not defrost operation performed 4 ON OFF operation cannot be performed from remote controller Is not the control operation performed from outside remote side Is not automatic address being set up When the power is turned on at the first time or when indoor unit address setting is changed the opera...

Page 41: ...Is not forced operation performed Is not the control operation performed from outside remote side Is not automatic address being set up Is not being carried out a test run 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 unit correct 2 Troubleshooting procedure When the power is turned on at the f...

Page 42: ...eiving unit and indoor unit Receiving error Receiving unit Miswiring or wire connection error Sending error Communication stop between receiving unit and indoor unit Duplicated indoor unit No Setup error Duplicated header units of remote controller Communication error between CPUs on indoor unit P C board Wire connection error between indoor units Indoor power OFF Communication stop between indoor...

Page 43: ...mp sensor TL error Temp sensor TO error Sensor error of outdoor unit 1 Temp sensor TS error Temp sensor TH error Temp Sensor miswiring TE TS Indoor EEPROM error Outdoor EEPROM error Compressor break down Outdoor compressor system error 1 Compressor lock Current detection circuit error Power supply outdoor P C board error Case thermostat worked Compressor overheat outdoor wiring error PS pressure s...

Page 44: ...on Timer Ready Simultaneous flash Operation Timer Ready Alternate flash Check code Cause of trouble occurrence During test run Disagreement of cool heat Automatic cool heat setting to automatic cool heat prohibited model or setting of heating to cooling only model ...

Page 45: ... time Filter sign time Indoor discharge temperature 1 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 THS Operation current 1 10 Outdoor heat exchanger Coil temperature TL Compressor operation f...

Page 46: ...tdoor Explanation of error contents Open Short of discharge temp sensor was detected Open Short of heat exchanger temp sensor was detected Miswiring between TE sensor and TS sensor Open Short of outside temp sensor was detected Open Short of heat exchanger temp sensor was detected Open Short of suction temp sensor was detected Open Short of heat sink temp sensor Board installed was detected Miscon...

Page 47: ... Detection Indoor Indoor Indoor Indoor Indoor Indoor Indoor Indoor Network adapter Network adapter Center Network adapter Center Network adapter Explanation of error contents Open Short of heat exchanger TCJ was detected Open Short of heat exchanger TC was detected Open Short of room temp TA was detected EEPROM error Other error may be detected If no error automatic address is repeated Indoor AC f...

Page 48: ...splayed 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 Judgment and measures 1 Check cables of...

Page 49: ... Stop Stop Stop 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 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 w...

Page 50: ...of 3 phase power supply 2 Black lead wire to be connected to CN03 of MCC 1596 does not pass through T611 1 Check refrigerating cycle Gas leak 2 Trouble of electronic expansion valve 3 Check discharge temp sensor TD 1 Check case thermostat and connector 2 Check gas leak recharge 3 Check full open of service valve 4 Check PMV Pulse Motor Valve 5 Check broken pipe 1 Check service valves are fully ope...

Page 51: ...ntroller side Status of air conditioner Stop Stop Automatic reset If center exists operation continues Stop Automatic reset If center exists operation continues Stop Sub unit continues operation Stop Automatic reset 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 Dis...

Page 52: ...rd Defect Replace Check outdoor P C board MCC 1599 Defect Replace Correct wiring and inter unit cable Is setting of group address of remote controller correct Are inner wiring and inter unit cables 1 2 3 normal Are connection of CN01 of MCC 1599 and wiring of terminal blocks 1 2 3 normal Does D502 Orange LED flash after power supply is turned on again YES YES YES YES NO NO NO NO Check code E04 Out...

Page 53: ...z Display 1 Display 2 z z z z z Display 1 Display 2 z z z z Display 1 Display 2 z z z z z Display 1 Display 2 z z z Display 1 Display 2 z z z z Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp sensor TD error There is a possibility that it is one of the following errors Confirm LED on outdoor P C board to judge which error it is Heat exchanger te...

Page 54: ... 1599 Defect Replace Is CN602 connection normal Is resistance value of TO sensor normal YES NO Correct connector Sensor error Replace Check outdoor P C board MCC 1599 Defect Replace Is CN600 connection normal Is resistance value of TS sensor normal YES NO Check outdoor P C board MCC 1599 Defect Replace Check outdoor P C board MCC 1599 Defect Replace Correct connector Sensor error Replace Correct c...

Page 55: ... AC342 to 457V Is wire connection normal Compressor lead Board side Compressor side Reactor lead Power supply lead YES YES YES NO NO NO H02 Display 1 Display 2 z z z z z z z Compressor lock Check wire connection and correct it Correct power supply line Is compressor normal Is there no refrigerant stagnation Does PMV normally operate Is power supply voltage normal AC342 to 457V Is wire connection n...

Page 56: ... Open valve fully Repair defectives position Recharge refrigerant Check outdoor P C board MCC 1599 Defect Replace Correct connector Case thermostat error Replace Is valve fully opened Is PMV normal Is there no gas leak Is it not refrigerant shortage Is cooling heating operation available when short circuiting case thermostat Are CN609 connection and case thermostat normal YES YES YES YES YES NO NO...

Page 57: ...on error between MCU Heat sing temp sensor TH error EEPROM error Unset model type Heat sink overheat error Gas leak detection 4 way valve inverse error Communication error between MCU 1 Connection check between CN802 of MCC 1599 and CN504 of MCC 1597 and also connection check between CN505 of MCC 1597 and CN851 of MCC 1596 2 Check outdoor P C board MCC 1596 MCC 1597 MCC 1599 Defect Replace Heat si...

Page 58: ...ak Is refrigerant charge amount adequate YES YES NO YES NO NO NO YES Connection of connectors Fan IPDU Fan motor Wiring Is circuit wiring normal Is there no fan breakage or coming off Is service valve fully opened Does cooling outdoor fan normally operate B Cooling operation B Cooling operation C Heating operation Doesn t high pressure switch operate Are parts of high pressure switch normal Reset ...

Page 59: ...efer to P20 column Are characteristics of TC and TCJ sensor resistance value normal Are connections of connectors capacitors and fan motor normal Heating operation Does the heating indoor fan normally operate Clogging by refrigerant overcharge Pipe breakage Abnormal overload C Is there any element which blocks indoor heat exchanger Filter clogging Clogging of heat exchanger Short circuit Eliminati...

Page 60: ... of motor drive element of outdoor P C board MCC 1596 Q201 Did not forget to apply radiation grease to rear side of Q201 Open valve fully Correct and replace piping Correct connector Sensor error Replace Check outdoor P C board MCC 1599 Defect Replace Correct defective position Replace defective part Repair defective position Recharge refrigerant Error OK YES YES YES YES NO NO NO NO Is there no cr...

Page 61: ...rigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defective position Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defective position Eliminate interfering element Eliminate interfering element Heating season Heating operation Cooling season Cooling operation Is there no element which interfere heat exchange of outdoor ...

Page 62: ... Display 1 Display 2 z z z Display 1 Display 2 z z z Display 1 Display 2 z z Display 1 Display 2 z z Check and troubleshooting Item without special mention Indicates part of outdoor unit Fan system error Single operation check for outdoor fan 1 Set SW804 of Dip switch as the following figure and then push SW801 for approx 1 second to check single operation of outdoor fan Use this method to check w...

Page 63: ...ndard value Maximum value 32 33 33 80 35 30 19 63 20 35 21 09 12 23 12 59 12 95 9 75 10 00 10 25 7 764 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 10...

Page 64: ...del STF 01AJ502E1 Checking procedure Measure the resistance value of each winding by using the tester Position Red White White Black Black Red Resistance value 0 79 0 04 Ω Under 20 C Measure the resistance value of each winding by using the tester Position Red White White Black Black Red Resistance value 14 8 1 5 Ω Under 20 C Measure the resistance value of each winding by using the tester Resista...

Page 65: ...3 1 SET TIME TIMER SET TEST FILTER L L RESET TEMP CL FAN SAVE A A SWING FIX VENT MODE ON OFF UNIT LOUVER T 9 1 Calling of Error History 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 01 is displayed and then the content of the latest alarm is displayed The ...

Page 66: ...roller Remote 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 wh...

Page 67: ...ve function The control to lower the compressor frequency Approx 10 is performed by indoor heat exchanger temp in heating operation When snow enters from clearance of the fan guard or heat exchanger into blast path and it is accumulated the control to prevent generation of motor lock is validated When outside temp is below 4 C though the compressor stops the outdoor fan operates with W5 The defros...

Page 68: ...03 are OFF or when any of D800 to D804 goes on LED displays that the outdoor controller detects an error When status of SW803 is other than OFF various indications are displayed Power ON display When the power of the outdoor unit is turned on LED goes on When SW801 and SW804 operate the specific operation LED flashes Part No SW800 SW803 SW801 SW804 SW802 Specifications Pushdown button switch DIP s...

Page 69: ...test error including present After error status was cleared the error which generated before can be confirmed by this setting Reconfirmation is available even if power supply was turned off once If an error generates at present the same contents as those of error which is generating at present are displayed Only error of TO sensor is not displayed by this setting Confirm it by setting of error whi...

Page 70: ...isplay 1 Initial display zzzzz zz zz z z z z Display 2 SW800 operation zzzzz zz zz z zz zz zzz z zz z z z z zzzz z zzz zzz zz zz z zz z zzz zz zz z zz zz z zz zz z z z z z z Error contents Normal Discharge temp sensor TD error Heat exchanger temp sensor TE error Heat exchanger temp sensor TL error Outside temp sensor TO error Suction temp sensor TS error Heat sink temp sensor TH error Heat exchang...

Page 71: ...9 3 to 3 9 4 to 4 9 5 to 5 9 6 to 6 9 7 to 7 9 8 to 8 9 9 to 9 9 10 to 10 9 11 to 11 9 12 to 12 9 13 to 13 9 14 to 14 9 15 to 15 9 16 to 16 9 17 to 17 9 18 to 18 9 19 to 19 9 20 to 20 9 21 to 21 9 22 to 22 9 23 to 23 9 24 to 24 9 25 to 25 9 26 to 26 9 27 to 27 9 28 to 28 9 29 to 29 9 30 to 30 9 Over 31 Compressor operation frequency rpm 0 to 4 5 to 9 10 to 14 15 to 19 20 to 24 25 to 29 30 to 34 35...

Page 72: ...est run by this setting cannot be cleared on the indoor remote controller Be sure to clear the test run by operation of the outdoor unit Push SW801 again for 1 second SW804 Operation when pushdown button switch SW801 is pushed Refrigerant recovery operation The outdoor unit performs cooling operation The indoor unit does not work by this operation alone Therefore operate the fan beforehand Indoor ...

Page 73: ...ol Outside output relay operation RY704 CN704 Turn on relay for outside output RY704 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control Forced start command The indoor unit connected to the system is forcedly started The indoor unit starts operation by setting of the operation mode on the remote controller Forced stop command The indoor unit connected to...

Page 74: ... and 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...

Page 75: ...ervice 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 ad dress within the minimum unit which configures one of the refrigerating cycles...

Page 76: ...data thermo status of the follower Without identical line address indoor outdoor serial and then finally controls the outdoor compressor matching with its own thermo status The header unit sends this command information to the 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 op...

Page 77: ...eader 1 1 1 2 1 1 Sub Follower 10 2 3 Automatic Address Example from Unset Address No miswiring 1 Standard One outdoor unit 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 is necessary Manuall...

Page 78: ...g diagram Simultaneous triple system SP160 only Simultaneous twin system A B 1 1 L1 L2 2 2 3 3 380 415 V 3N 50Hz 380 V 3N 60Hz Remote controller Remote controller wiring Indoor side Indoor Outdoor connecting wires Outdoor side L3 N A B 1 2 3 A B 1 1 L1 L2 2 2 3 3 380 415 V 3N 50Hz 380 V 3N 60Hz Remote controller Remote controller wiring Indoor side Indoor Outdoor connecting wires Outdoor side Remo...

Page 79: ...EST buttons simultaneously for 4 seconds or more 2 Line address Using the temperature setup buttons set 12 12 12 12 12 to the CODE No 3 Using timer time buttons set the line address 4 Push SET button OK when display goes on 5 Indoor unit address Using the temperature setup buttons set 13 13 13 13 13 to the CODE No 6 Using timer time buttons set 1 to the line address 7 Push SET button OK when displ...

Page 80: ...ed to the identical remote controller Group control unit other unit numbers are also displayed every pushing UNIT LOUVER button 2 To know the position of indoor unit body by address To confirm the unit No in the group control Follow to the procedure during operation in this procedure the indoor units in group control stop Procedure The indoor unit numbers in the group control are successively disp...

Page 81: ...ailure to clean the indoor outdoor units regularly will cause shortage of capacity freezing water leakage or trouble on the compressor Part name Heat exchanger Fan motor Filter Fan Suction Discharge grille Drain pan Face panel Louver External appearance Object Indoor Outdoor Contents of check Blocking with dust damage check Audibility for sound Visual check for dirt and breakage Visual check for s...

Page 82: ...re J804 to J811 SW802 DIP switch SW803 SW804 SW805 Function Model switching Settings Settings LED indication switching Special operations for service Special operations for service Setting Cut these jumper wires according to the following table Set these jumper wires to the settings of the P C board before replacement Set SW802 to the setting of the P C board before replacement Set SW803 to all OF...

Page 83: ...service compressor Leakage check Vacuuming Charge the refrigerant END Turn off the leakage breaker NO Open PMV forcedly and then recover refrigerant using a refrigerant recovery unit Never 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 unav...

Page 84: ...llation tool connection sections are different from those of the conventional refrigerant Accordingly the following exclusive tools are required for the new refrigerant R410A Required Tools Equipment and Precautions for Use Prepare the tools and equipment listed in the following table before starting the installation work Newly prepared tools and equipment must be used exclusively Legend Prepared ...

Page 85: ... g Charge the refrigerant accurately Overcharging may cause serious trouble with the compressor Do not connect a refrigerant pipe that is shorter than 3 m This may cause a malfunction of the compressor or other devices Airtight test 1 Before starting an airtight test further tighten the spindle valves on the gas and liquid sides 2 Pressurize the pipe with nitrogen gas charged from the service port...

Page 86: ... or on the high stories of a building secure normal fan operation by using a duct or wind shield 3 When installing the outdoor unit in a location that is constantly exposed to strong winds such as on the upper stairs or rooftop of a building apply the windproofing measures referred to in the following examples 1 Install the unit so that its discharge port faces the wall of the building Keep a dist...

Page 87: ...plate of the outdoor unit When installing the foundation for an outdoor unit with downward piping consider the piping work Set the out margin of the anchor bolt to 15 mm or less When water is to be drained through the drain hose attach the following drain nipple and waterproof rubber cap and use the drain hose Inner diam 16 mm sold on the market Also seal knockout hole and the screws securely with...

Page 88: ...ss Ø15 9 mm 1 0 mm Flaring 1 Cut the pipe with a pipe cutter Be sure to remove burrs that may cause a gas leak 2 Insert a flare nut into the pipe and then flare the pipe Use the flare nuts supplied with the air conditioner or those for R410A Insert a flare nut into the pipe and flare the pipe As the flaring sizes of R410A differ from those of refrigerant R22 the flare tools newly manufactured for ...

Page 89: ...or outdoor H m Total length L Indoor unit Upper Outdoor unit Lower 75 30 30 Pipe diameter mm Number of bent portions Gas side Liquid side 10 or less Ø15 9 Ø9 5 System Model Allowable pipe length m Height difference m Total length 1 2 1 3 1 4 Maximum Distributed pipes 2 3 4 Maximum Distributed pipes 3 2 4 2 4 3 Maximum Indoor outdoor H Indoor indoor Δh Indoor unit Upper Outdoor unit Upper TWIN SP11...

Page 90: ...r and gauge manifold correctly referring to the manuals supplied with each tool before using them Check that the vacuum pump oil is filled up to the specified line of the oil gauge 2 When air is not charged check again whether the connecting port of the discharge hose which has a projection to push the valve core is firmly connected to the charge port How to open the Valve Open or close the valve ...

Page 91: ...el Wiring between Indoor Unit and Outdoor Unit The dashed lines show on site wiring Connect the indoor outdoor connecting wires to the identical terminal numbers on the terminal block of each unit Incorrect connection may cause a failure For the air conditioner connect a power wire with the following specifications Number of wire wire size How to wire 1 Connect the connecting wire to the terminal ...

Page 92: ... controller wiring Indoor side Indoor Outdoor connecting wires Outdoor side Indoor side Remotecontroller inter unit wiring Indoorpower inter unit wiring Power supply A B 1 2 3 A B 1 1 2 2 3 3 A B 1 2 3 L1 L2 L3 N Remote controller Remote controller wiring Indoor side Indoor Outdoor connecting wires Outdoor side Remote controller inter unit wiring Remotecontroller inter unit wiring Power supply Ind...

Page 93: ...e connected securely without leaks That the valve is open If the compressor is operated with the valve closed the outdoor unit will become overpressurized which may damage the compressor or other components If there is a leak at a connection air can be sucked in and the internal pressure further increases which may cause a burst or injury Operate the air conditioner in the correct procedure as spe...

Page 94: ... for 1 second or more The air conditioner enters the forced cooling mode for up to 10 minutes Operate or handle the valve to recover refrigerant during this time period 4 Upon completion of refrigerant recovery close the valve and press SW801 for at least 1 second to stop operation 5 Turn off the power DANGER Be careful of electric shock because the P C board has an electrical current running thro...

Page 95: ...ng pipes should not be reused as they are Clean the existing pipes or exchange them with new pipes 1 When a scratch or dent is heavy be sure to use new pipes for the refrigerant piping works 2 When the existing pipe thickness is thinner than the specified Pipe diameter and thickness be sure to use new pipes for the refrigerant piping works The operating pressure of R410A is high 1 6 times that of ...

Page 96: ... size to size for R410A In case that a gas pipe Ø19 mm or bigger is used for the outdoor unit of SP80 3 HP Our R410A model 3 to 6 HP gas pipe size is Ø15 9 mm After the existing air conditioner is operated in cooling mode for approx 30 minutes or longer recover the refrigerant For cleaning the pipes and recovering oil Refrigerant recovery Pump down method Airtight test Vacuum dry Refrigerant charg...

Page 97: ...r outdoor connecting wire from the cord clamp and the terminal 3 Remove the top plate Hexagonal screws Ø4 10 5 pcs 2 Attachment 1 Attach the top plate Hexagonal screws Ø4 10 5 pcs 2 Connect the power supply cable and the indoor outdoor connecting wire to the terminal and then fix with the cord clamp CAUTION The power supply cable and the indoor outdoor connecting wire must be affixed along the cro...

Page 98: ...4 pcs 3 Remove the screws for the discharge port cabinet and the bottom plate Hexagonal screw Ø4 10 2 pcs 4 Remove screw for the discharge port cabinet and heat exchanger ST1T Ø4 8 1 pc 5 Remove screw for the discharge port cabinet and the motor base ST1T Ø4 8 2 pcs 6 Remove screws for the discharge port cabinet and the fin guard Hexagonal screw Ø4 10 2 pcs 2 Attachment 1 Attach the discharge port...

Page 99: ...ping panel rear Hexagonal screw Ø4 10 2 pcs 5 Remove screw for the side cabinet and the bottom plate Hexagonal screw Ø4 10 1 pc 6 Remove screws for the side cabinet heat exchanger and the fin guard Hexagonal screw Ø4 10 5 pcs 2 Attachment 1 Temporarily suspend the side cabinet on the inverter assembly using the hook 2 Mount the removed screws in the opposite procedure to that during detachment Rem...

Page 100: ...operation in 1 of c 1 of e above 2 Remove the connectors connected to the Fan IPDU board the connector connected to other components from the control board Interface board CN600 TS sensor 3P White tube Gray CN601 TE sensor 2P White tube Blue CN602 TO sensor 2P Yellow tube Black CN603 TD sensor 3P White tube Red CN604 TL sensor 2P White tube White CN609 Case thermo 2P Blue CN690 High poressure swit...

Page 101: ...Blue CN602 TO sensor 2P Yellow tube Black CN603 TD sensor 3P White tube Red CN604 TL sensor 2P White tube White CN608 Connection with noise filter board 2P White CN609 Case thermo 2P Blue CN690 High pressure switch 3P Green CN700 4 way coil 3P Yellow CN708 Magnet switch 3P Blue CN710 PMV coil 6P White CN802 Connection with Fan IPDU board 5P white Remove connectors after unlocking housing section 3...

Page 102: ...rd 7P Red CN502 Compressor IPDU board 3P White CN504 Interface board 5P Blue CN505 Compressor IPDU board 5P Red CN602 Noise filter board 2P Black CN700 Outdoors lower fan motor 3P Blue CN750 Outdoors upper fan motor 3P White Connectors should be removed after unlocking the housing section 3 Remove screw fixing the earth wire 4 Remove the claw of the support 4 positions fixing the board and the scr...

Page 103: ... lead wires connector to other components from the noise filter board CN05 Power supply terminal block red CN06 Power supply terminal block White CN07 Power supply terminal block Black CN08 Power supply terminal block Gray CN09 Connection to earth Brown CN10 Posister Red CN16 Relay Red CN17 Compressor IPDU board White CN18 Relay Black CN19 Relay Gray CN20 Power supply terminal block White CN23 Fan...

Page 104: ...IPDU board 3P White CN211 Compressor Red CN212 Compressor White CN213 Compressor Black CN851 FAN IPDU board 5P Red Connectors should be removed after unlocking the housing section 4 Slide and remove the inverter assembly IPDU 5 Remove the screws 4 positions fixing the heat sink and the screws 3 positions fixing the compressor IPDU board and then remove the compressor IPDU board 2 Attachment 1 Moun...

Page 105: ...e the connector for the fan motor from the inverter Remove the ferrite core of the lower fan motor because it is used 5 Remove the fan motor lead from the fan motor lead fixed rubber of the penetrated part of the partition board 6 Remove the fixing screws 4 pieces each while supporting the fan motor so that it does not fall down Cautions for assembling of fan motor Tighten the flange nut with 4 95...

Page 106: ...he piping panel Rear Remove the piping panel Rear and screws of the bottom plate Hexagonal screw Ø4 10 2 pcs 5 Remove the sound insulation plate Upper rolling in rolling out 6 Remove the terminal cover of the compressor and then remove the compressor lead and the compressor case thermo 7 Remove TD sensor which is fixed to the discharge pipe 8 Remove the compressor lead Control P C board U CN211 Re...

Page 107: ...ressor in the reverse procedure for removal NOTE After replacement of the compressor be sure to replace the compressor lead Repair part code of compressor lead 43160612 In this time wrap the ferrite core with the compressor lead wire by 1 time As shown in the right figure mount the sound insulation plate rolling in rolling out by passing through it between the compressor and the piping and between...

Page 108: ... then fix it 1 Detachment 1 Carry out works of item 1 of c and 1 of d REQUIREMENT To prevent scratch on the product carry out the work on cardboard cloth etc 2 Remove the discharge port cabinet and then put on it so that the fan guard side directs downward 3 Remove the screw for the bell mouth and fan guard PT2P Ø3 14 and washer 4 pcs 4 Remove the hooking claws 8 positions of the fan guard 2 Attac...

Page 109: ... 109 15 EXPLODED VIEWS AND PARTS LIST Outdoor Unit RAV SP1104AT8 E1 RAV SP1104AT8J E1 RAV SP1104AT8 TR1 RAV SP1104AT8J TR1 ...

Page 110: ...OMPRESSOR DA422A3F 27M THERMOSTAT BIMETAL FILTER N0ISE HOLDER THERMOSTAT NUT FLANGE NUT COMP NUT PANEL FRONT PIPING PANEL BACK PIPING PANEL FRONT PLATE ROOF PANEL SIDE PANEL AIR OUTLET BASE ASSY GUARD FIN SIDE GUARD FIN BACK HANGER GUARD FAN ASSY FAN PROPELLER PB521 BELL MOUTH MOTOR FAN ICF 280 A100 1 A JOINT CHECK VALVE PACKED 9 52 VALVE 4 WAY STF 0401G COIL SOLENOID STF 01AJ502E1 VALVE BALL SBV ...

Page 111: ... 111 711 701 717 713 720 TE TS TO TD TL 718 719 708 709 715 706 707 721 710 718 719 720 702 704 705 714 712 720 Inverter Assembly RAV SP1104AT8 E1 RAV SP1104AT8J E1 RAV SP1104AT8 TR1 RAV SP1104AT8J TR1 ...

Page 112: ...282001 43183020 43F63248 43060700 REACTOR RELAY REACTOR PTC THERMISTOR SENSOR ASSY SERVICE SENSOR ASSY SERVICE TERMINAL BLOCK 3P 20A TERMINAL FUSE BLOCK 30A 250V PC BOARD ASSY MCC 1596 COMP IPDU PC BOARD ASSY MCC 1597 FAN IPDU PC BOARD ASSY MCC 1599 CDB PC BOARD ASSY MCC 1600 N F HOLDER SENSOR TE FUSE BUSHING COLLAR SUPPORTER ASSY FUSE 10A 250V 1 1 1 1 3 2 1 1 1 1 1 1 1 1 3 5 5 2 1 1 1 1 1 3 2 1 1...

Page 113: ... 113 Outdoor Unit RAV SP1404AT8 E1 RAV SP1404AT8J E1 RAV SP1404AT8 TR1 RAV SP1404AT8J TR1 ...

Page 114: ...OMPRESSOR DA422A3F 27M THERMOSTAT BIMETAL FILTER N0ISE HOLDER THERMOSTAT NUT FLANGE NUT COMP NUT PANEL FRONT PIPING PANEL BACK PIPING PANEL FRONT PLATE ROOF PANEL SIDE PANEL AIR OUTLET BASE ASSY GUARD FIN SIDE GUARD FIN BACK HANGER GUARD FAN ASSY FAN PROPELLER PB521 BELL MOUTH MOTOR FAN ICF 280 A100 1 A JOINT CHECK VALVE PACKED 9 52 VALVE 4 WAY STF 0401G COIL SOLENOID STF 01AJ502E1 VALVE BALL SBV ...

Page 115: ... 115 711 701 717 713 720 TE TS TO TD TL 718 719 708 709 715 706 707 721 710 718 719 720 702 704 705 714 712 720 Inverter Unit RAV SP1404AT8 E1 RAV SP1404AT8J E1 RAV SP1404AT8 TR1 RAV SP1404AT8J TR1 ...

Page 116: ...282001 43183020 43F63248 43060700 REACTOR RELAY REACTOR PTC THERMISTOR SENSOR ASSY SERVICE SENSOR ASSY SERVICE TERMINAL BLOCK 3P 20A TERMINAL FUSE BLOCK 30A 250V PC BOARD ASSY MCC 1596 COMP IPDU PC BOARD ASSY MCC 1597 FAN IPDU PC BOARD ASSY MCC 1599 CDB PC BOARD ASSY MCC 1600 N F HOLDER SENSOR TE FUSE BUSHING COLLAR SUPPORTER ASSY FUSE 10A 250V 1 1 1 1 3 2 1 1 1 1 1 1 1 1 3 5 5 2 1 1 1 1 1 3 2 1 1...

Page 117: ... 117 Outdoor Unit RAV SP1604AT8 E1 RAV SP1604AT8J E1 RAV SP1604AT8 TR1 RAV SP1604AT8J TR1 ...

Page 118: ...OMPRESSOR DA422A3F 27M THERMOSTAT BIMETAL FILTER N0ISE HOLDER THERMOSTAT NUT FLANGE NUT COMP NUT PANEL FRONT PIPING PANEL BACK PIPING PANEL FRONT PLATE ROOF PANEL SIDE PANEL AIR OUTLET BASE ASSY GUARD FIN SIDE GUARD FIN BACK HANGER GUARD FAN ASSY FAN PROPELLER PB521 BELL MOUTH MOTOR FAN ICF 280 A100 1 A JOINT CHECK VALVE PACKED 9 52 VALVE 4 WAY STF 0401G COIL SOLENOID STF 01AJ502E1 VALVE BALL SBV ...

Page 119: ... 119 711 701 717 713 720 TE TS TO TD TL 718 719 708 709 715 706 707 721 710 718 719 720 702 704 705 714 712 720 Inverter Unit RAV SP1604AT8 E1 RAV SP1604AT8J E1 RAV SP1604AT8 TR1 RAV SP1604AT8J TR1 ...

Page 120: ...282001 43183020 43F63248 43060700 REACTOR RELAY REACTOR PTC THERMISTOR SENSOR ASSY SERVICE SENSOR ASSY SERVICE TERMINAL BLOCK 3P 20A TERMINAL FUSE BLOCK 30A 250V PC BOARD ASSY MCC 1596 COMP IPDU PC BOARD ASSY MCC 1597 FAN IPDU PC BOARD ASSY MCC 1599 CDB PC BOARD ASSY MCC 1600 N F HOLDER SENSOR TE FUSE BUSHING COLLAR SUPPORTER ASSY FUSE 10A 250V 1 1 1 1 3 2 1 1 1 1 1 1 1 1 3 5 5 2 1 1 1 1 1 3 2 1 1...

Page 121: ...o 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 create an opening with adjacent rooms or install mechanical ventilation combined with a gas leak detection device The concentration is as given below Total amount of refrigera...

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