Toshiba RAV-GM1601AT8JP-E Service Manual Download Page 1

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SERVICE MANUAL

AIR-CONDITIONER

(SPLIT TYPE)

OUTDOOR UNIT

<DIGITAL INVERTER>

RAV-GM1601AT8P-E

RAV-GM1601AT8JP-E

RAV-GM1601AT8P-TR

R32

Revised on May, 2020

FILE NO. SVM-20058

-1

Summary of Contents for RAV-GM1601AT8JP-E

Page 1: ...SERVICE MANUAL AIR CONDITIONER SPLIT TYPE OUTDOOR UNIT DIGITAL INVERTER RAV GM1601AT8P E RAV GM1601AT8JP E RAV GM1601AT8P TR R32 Revised on May 2020 FILE NO SVM 20058 1 ...

Page 2: ... 2 Outline of Main Controls 50 3 1 Indoor Unit 24 3 2 Outdoor Unit 26 3 3 Operation Data 26 6 6 Instructions for Re use Piping of R22 or R410A 36 6 6 13 General safety precautions for using R32 refrigerant 46 7 Charging additional refrigerant 39 Original instruction Adoption of R32 Refrigerant This air conditioner adopts the HFC refrigerant R32 which does not destroy the ozone layer This outdoor u...

Page 3: ... 77 9 2 Others 79 11 DETACHMENTS 87 12 EXPLODED VIEWS AND PARTS LIST 98 8 3 Table Inspection of outdoor unit main parts 76 10 ADDRESS SETUP 80 10 1 Address Setup Procedure 80 10 2 Address Setup Group Control 81 10 3 Remote Controller Wiring 84 10 4 Address Setup Manual setting from remote controller 84 10 5 ConfirmationofIndoorUnitNo Position 85 3 ...

Page 4: ... have been trained and is thus thoroughly acquainted with the knowledge related to this work The qualified installer who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus...

Page 5: ...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 6: ...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 7: ... 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 7 ...

Page 8: ...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 9: ...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 10: ...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 11: ... 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 12: ... 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 13: ...pressor 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 Air Conditioner RAV GM1601AT8P E RAV GM1601ATJ8P E RAV GM1601AT8P TR Digital Inverter Seri...

Page 14: ...Specifications Model Sound power level dBA Weight kg Cooling Heating RAV GM1601AT8P E 72 94 RAV GM1601AT8JP E 72 94 RAV GM1601AT8P TR 72 94 70 70 70 14 ...

Page 15: ... 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 16: ...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 17: ...f 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 ref...

Page 18: ...erant charge under long piping connector 35g m Over 30m Height difference Outdoor lower m 30 Outdoor higher m 30 Outer dimension Height mm 1340 Width mm Depth mm Appearance Silky shade Muncel 1Y8 5 0 5 Total weight kg 94 Heat exchanger Finned tube Fan unit Fan Propeller fan Standard air flow high m3 min 138 Motor W 100 Connecting pipe Gas side mm 15 9 Liquid side mm 9 52 Sound pressure level Cooli...

Page 19: ...iping connector 35g m Over 30m 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 91 Heat exchanger Finned tube Fan unit Fan Propeller fan Standard air flow high m3 min 138 Motor W 100 Connecting pipe Gas side mm 15 9 Liquid side mm 9 52 Sound pressure level 53 55 Sound power leve...

Page 20: ...6 0 8 0 12 0 14 0 0 10 20 30 40 50 60 70 80 90 100 Current A Compressor speed RPS Condition Indoor 27 C DB 19 C WB Indoor Air flow volume High Pipe length 7 5m 0 0 2 0 4 0 6 0 8 0 10 0 14 0 0 10 20 30 40 50 60 70 80 90 100 Current A Compressor speed RPS 0 10 20 30 40 50 60 70 80 90 100 110 120 130 15 13 11 9 7 5 3 1 1 3 5 7 9 11 13 15 Capacity ratio Outdoor temperature C Condition Indoor 20 C DB I...

Page 21: ...le Detailes of A legs Refrigerant pipe connecting port dia 9 5 flare at liquid side Refrigerant pipe connecting port dia 19 1 flare at gas side 30 30 18 12 Mouting bolt hole dia 12 x 17 U shape hole Detailes of B legs 320 151 400 Name Note CD Refrigerant piping hole Indoor Outdoor Unit connecting wire inlet hole 0 Power supply inlet hole dia 38 Knockout hole a h 11 1 1 12 64 21 ...

Page 22: ...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 22 ...

Page 23: ...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 23 ...

Page 24: ...or 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 incorporated Refrigerant pipe at liquid side Outer diameter Ø6 4 Refrigerant pipe at gas side Outer diameter Ø12 7 Refrigerant pipe at liquid side Outer diameter Ø6 4 Refrigerant pipe at gas side Outer diameter Ø12 7 Refrigerant pi...

Page 25: ...erant pipe at liquid side Outer diameter Ø6 4 Refrigerant pipe at gas side Outer diameter Ø12 7 Refrigerant pipe at liquid side Outer diameter Ø6 4 Refrigerant pipe at gas side Outer diameter Ø12 7 Air heat exchanger Air heat exchanger Air heat exchanger Indoor B unit TCJ sensor TC sensor Refrigerant pipeat gas side Outer diameter Ø15 9 Distributor To outdoor unit Distributor Refrigerant pipeat li...

Page 26: ...8 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 15 4 poles are provided to this compressor The compressor frequency Hz measured with a clamp meter is 2 ...

Page 27: ... UNIT 3 2 1 1 5 CN03 3 WHI BRW 49C 63H MCC 1626 F01 Symbol CN CM TS PMV FM1 FM2 L CM TD High pressure switch RB TB2 TE TO TB1 Compressor case thermostat Parts name Compressor Connector Terminal block power supply Rush current protect resistor Reactor for compressor Fan motor Pulse motor valve Heat exchange temp sensor Pipe temp sensor Discharge Pipe temp sensor Suction Air temp sensor Terminal blo...

Page 28: ...t 25 C 11 Suction temp sensor TS sensor 10 kΩ at 25 C 12 Heat exchanger sensor TE sensor 10 kΩ at 25 C 14 Fuse Mounted on P C board MCC 1626 50T 100H T10A 250V 15 Fuse Mounted on P C board MCC 1626 SLT6 3A T6 3A 250V 16 Fuse Mounted on P C board MCC 1626 SCT 3 15A 3 15A 250V 17 Fuse Mounted on P C board MCC 1627 50T P 063HF GF_001 C4 T6 3A 250V 18 Fuse Mounted on P C board MCC 1627 GAC1 31 5A 31 5...

Page 29: ...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 30: ...cket joints Nominal diameter Reference outer diameter of copper pipe jointed mm Minimum joint thickness mm 1 4 6 4 0 5 3 8 9 5 0 60 1 2 12 7 0 70 5 8 15 9 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 the installed ...

Page 31: ...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 32: ... 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 33: ...ve for charging Electronic balance for refrigerant charging Opened OUTDOOR unit Closed Service port Recover the refrigerant and check no refrigerant remains in the equipment 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 comp...

Page 34: ...e of flux coincides with the brazing temperature Due to a wide effective temperature range flux is hard to carbonize It is easy to remove slag after brazing The corrosive action to the treated metal and brazing filler is minimum It excels in coating performance and is harmless to the human body As the flux works in a complicated manner as described above it is necessary to select an adequate type ...

Page 35: ...low meter to the cylinder 3 Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas 4 When the Nitrogen gas is flowing be sure to keep the piping end open 5 Adjust the flow rate of Nitrogen gas so that it is lower than 0 05 m Hr or 0 02 MPa 0 2kgf cm by means of the reducing valve 6 After performing the step...

Page 36: ...and R410A pipes to those for R32 models 3 When the outdoor unit was left with the pipes disconnected or the gas leaked from the pipes and the pipes were not repaired and refilled There is the possibility of rain water or air including moisture entering the pipe 4 When refrigerant cannot be recovered using a refrigerant recovery unit There is the possibility that a large quantity of dirty oil or mo...

Page 37: ...to muddy and black color After the existing air conditioner operated in cooling mode for approx 30 minutes or longer recover the refrigerant For cooling the pipes and recovering of oil s Refrigerant recovery Pump down method Remove the existing air conditioner from the piping and carry out flashing nitrogen pressure 0 5 Mpa to remove the remains inside of the pipe Note In case of twin also be sure...

Page 38: ... to the flare surface Trial run Airtight test Vacuum dry Refrigerant charge Gas leak check H A Piping necessary to change the flare nut machining size due to pipe compression 1 Flare nut width H 2 Flare machining size A mm 36 Ø19 0 29 Ø15 9 26 27 24 Ø12 7 22 Ø9 5 17 Ø6 4 Same as above Copper pipe outer dia For R22 For R410A Same as above mm 24 0 Ø19 0 19 7 Ø15 9 16 6 Ø12 7 13 2 Ø9 5 9 1 23 3 19 4 ...

Page 39: ...essure 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 compressor malfunction 6 7 1 Assumed ...

Page 40: ... 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 41: ...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 42: ... 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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...O CN602 TE CN601 High pressure SW CN501 UART communication Jumper select LED Display Case thermo Relay output PMV coil output CN851 J800 J806 D800 805 CN500 CN502 CN701 Fuse for Indoor Unit F02 Connection with indoor unit CN03 Power supply Fan output CN300 st CN04 Power supply CN05 DC280V CN02 TL CN604 Coil valve 4 way out put CN700 47 ...

Page 48: ...C thermistor P06 Earth P05 Power supply L1 P01 Power supply L3 P03 Power supply L2 P02 UART Communication CN852 Reactor connecting terminal CN07 Compressor output U phase CN200 Compressor output V phase CN201 Compressor output W phase CN202 Jumper lead from P18 CN19 Reactor connecting terminal CN08 Relay Input CN11 48 ...

Page 49: ...7 1 3 P C board for 2 fan drive MCC 1603 DC280V CN101 UART Communication CN02 DC280V CN100 UART Communication CN01 Fan output Lower CN350 nd LED Display D840 SW01 49 ...

Page 50: ...sor 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 discharge temperature detected an abnormal stop zone the compressor stops and then...

Page 51: ...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 TE sensor temperature after then 1 tap 20 sec Up to the maximum rotational frequency of each zone Rotational frequency hold 1 tap 20 sec Up to the minimum rotational frequency of each zone WF tap TE 55 C 38 C 35 C 58 C COOL I1...

Page 52: ...C 18 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 th...

Page 53: ...play contents 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...

Page 54: ...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 55: ...ion s Does not outside low temperature operation control work in cooling operation s Is not defrost operation performed 4 ON OFF operation cannot be performed from remote controller s Is not the control operation performed from outside remote side s 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 operation canno...

Page 56: ...oller s Is not forced operation performed s Is not the control operation performed from outside remote side s Is not automatic address being set up s 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 turn...

Page 57: ...its of remote controller Setup error E09 E10 Communication error between CPUs on indoor unit P C board E18 Wire connection error between indoor units Indoor power OFF Communication stop between indoor master and follower or between main and sub indoor twin Operation Timer Ready Flash E04 Miswiring between indoor unit and outdoor unit or connection error Communication stop between indoor and outdoo...

Page 58: ...or EEPROM error MCC 1626 Operation Timer Ready Flash H01 Compressor break down Compressor lock Outdoor compressor system error H02 H03 Current detection circuit error Outdoor P C board error H04 Case thermostat operation Outdoor compressor overheat error Outdoor unit connection error Operation Timer Ready Simultaneous flash L03 Duplicated header indoor units AUTO address If group construction and ...

Page 59: ...Cause of trouble occurrence Operation Timer Ready Simultaneous flash During test run Operation Timer Ready Alternate flash Disagreement of cool heat Automatic cool heat setting to automatic cool heat prohibited model or setting of heating to cooling only model 59 ...

Page 60: ...uit error 44 H04 Outdoor unit case thermostat worked Outdoor Case thermostat worked 88 L10 SIM Outdoor unit Unset model type of service P C board Outdoor When outdoor service P C board was used model type select jumper setting was inappropriate 1C L29 SIM Outdoor unit Communication error between MCUs Outdoor Communication error between MCUs EEPROM MCC 1603 error EEPROM MCC 1627 error 1E P03 ALT Ou...

Page 61: ... MCC 1626 L10 Unset jumper of service P C board Stop Displayed when error is detected 1 Outdoor service P C board Check model type setting jumper wire L29 Communication error between MCUs of outdoor unit Stop Displayed when error is detected 1 Check outdoor P C board 2 Check connection between outdoor P C boards 3 Check EEPROM on MCC 1627 4 Check EEPROM on MCC 1603 H01 Compressor break down Althou...

Page 62: ... specified temp Stop Displayed when error is detected 1 Check gas leak recharge 2 Check full open of service valve 3 Check PMV Pulse Motor Valve 4 Check broken pipe 5 Check discharge temp sensor TD suction temp sensor TS P20 High pressure protective operation During cooling operation outdoor temp sensor TE detected temperature over specified temp Stop Displayed when error is detected 1 Check outdo...

Page 63: ...harge temperature error 18 High pressure SW error 19 Power supply voltage error 20 Heat sink overheating error 22 Gas leak detected 23 High pressure protective operation 24 DC outdoor Fan motor error Upper side 25 DC outdoor Fan motor error Lower side 26 Compressor drive device shot circuit 27 Position detection circuit error 28 Compressor IPDU or other not specially identiﬁed Power supply error O...

Page 64: ...ayed only when the same error occurred continuously by multiple times while LED of the outdoor P C board displays even an error which occurred once Therefore the display on the wired remote controller may differ from that of LED LED display on outdoor P C board Display of error which is generating When even one of D800 to D804 rapid flashing it indicates that an error occurred ە D800 Yellow ە ە D8...

Page 65: ... terminal blocks 1 2 3 correct YES YES YES NO NO NO F04 Discharge temp sensor TD error Is connection of CN603 correct Is resistance value of TD sensor correct Correct connector Sensor error Replace Check outdoor P C board Defect Replace YES NO F06 Heat exchanger temp sensor TE error Is connection of CN601 correct Is resistance value of TE sensor correct Correct connector Sensor error Replace Check...

Page 66: ...tdoor P C board Defect Replace Is connection of CN600 correct Is resistance value of TS sensor correct YES NO F13 Heat sink temp sensor TH error Check outdoor P C board MCC 1627 Defect Replace F15 Miss mounting of heat exchanger sensor TE TS Check outdoor P C board Defect Replace Correct connector Sensor error Replace Correct connector Sensor error Replace Correct sensor mounting Is mounting statu...

Page 67: ...onnection correct Compressor lead P C board side Compressor side Reactor lead Power supply lead YES YES YES NO NO NO H02 Compressor lock Check wire connection and correct it Correct power supply line Is compressor under correct conditions Is there refrigerant stagnation Does PMV correctly operate Is power supply voltage correct AC342 to 457V Is wire connection correct Compressor lead P C board sid...

Page 68: ...thermostat correct Short each pins of CN500 Can compressor operate YES YES NO YES YES NO NO YES NO NO L10 Unset model type Only when service P C board is used Cut jumper line according to the explanation sheet packaged with the service P C board L29 Communication error between MCUs or EEPROM on MCC 1603 error EEPROM on MCC 1627 error Check outdoor P C board Defect Replace P03 Discharge temp error ...

Page 69: ...it Parts check Defective Replace Elimination of blocking element Check outdoor PC board Defective Replace Wiring check Correct Open service valve fully Repair defective position Overcharge of refrigerant Clogging Pipe breakage Abnormal overload YES NO YES YES YES YES NO NO YES High pressure SW system error NO NO NO YES NO Are resistance value of TC and TCJ sensor correct Are connections of connect...

Page 70: ...es something block air flow from the fan Apply radiation grease to objective parts Retightening of screws NO NO YES YES Is the power device on P C board screwed without looseness Q200 of MCC 1627 Are radiation grease properly applied Q200 of MCC 1627 P15 Gas leak detection Check outdoor P C board Defect Replace Repair defective position Replace defective part Repair defective position Recharge ref...

Page 71: ...esistance value of indoor TC and TCJ sensors correct Check and replace of PMV Replace TE sensor Replace TS sensor Replace coil of 4 way valve Replace TC sensor Replace TCJ sensor Is the 4 way valve coil is normal Check the resistance value of 4 way valve coil Does power supply to 4 way valve coil when 4 way valve is operated Check outdoor P C board Check indoor P C board Defect Replace Check 4 way...

Page 72: ...ully opened Is there any defect such as loosening of nut in the outdoor fan Does the outdoor fan perform abnormal operation Is resistance value of TE sensor correct Replace TE sensor Check the same items as P22 error Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defect Eliminate interfering element Is there anything which interfere heat exchange...

Page 73: ...tion Ask repair of power supply Apply radiation grease to objective parts Retightening of screws Remove blocking matter Correct short circuit Replace fan motor Outdoor Fan Motor Lower side error Is AC mains voltage correct AC342 to 457V Is the power device on P C board screwed without looseness IC350 of MCC 1603 Are radiation grease properly applied IC350 of MCC 1603 Does something block the venti...

Page 74: ...ead Check compressor Rear short etc Defect Replace Are connections of compressor lead and reactor correct Check referring to the Wiring diagram NO YES P29 Position detection circuit error Check outdoor P C board Defect Replace No code Other error Compressor disorder due to sudden change of load etc Although the display of outdoor LED outputs the unit automatically restarts and error is not determi...

Page 75: ...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 12 34 12 95...

Page 76: ... 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 822 Measure the resistance value of each winding by using the tester Resistance value 1979 197 Ω Und...

Page 77: ... OUT IN Remote controller 1 1 OUT IN 2 1 Master OUT IN 3 1 OUT IN 4 1 OUT IN 7 1 Max 8 units 1 Display range on remote controller The setup range Operation mode Air volume select Setup temp of the indoor unit which was set to the master unit is reflected on the remote controller 2 Address setup Turn on power of the indoor unit to be controlled in a group within 3 minutes after setting of automatic...

Page 78: ...tion 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 is fed on the way 3 m...

Page 79: ... air conditioner 2 To set the air conditioner to test run mode hold down the Temporary button for more than 10 seconds Then you will hear a Pi sound and the light green light green and light orange lamps will blink quickly to indicate that the air conditioner has gone into a test run mode 3 Wait for one minute to elapse and then close the valve of liquid side 4 It is recommended to attach a pressu...

Page 80: ... 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 81: ...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 82: ... 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 83: ...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 84: ...ddresses of the indoor units will be determined prior to piping work after cabling work Set an indoor unit per a remote controller Turn on power supply Single system Simultaneous twin system A B 1 1 L1 2 2 3 3 L2 L3 N Remote controller Remote controller wiring Indoor side Indoor Outdoor connecting wires Outdoor side Power supply A B 1 2 3 A B 1 1 2 2 3 3 L1 L2 L3 N Remote controller Remote control...

Page 85: ... 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 86: ...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 87: ...ng wire from the cord clamp and the terminals 4 Take off the upper cabinet HEX ST SCREW Ø4 10 5 pcs 2 Attachment 1 Attach the upper cabinet HEX ST SCREW Ø4 10 5 pcs 2 Connect the power supply wire and the indoor outdoor connecting wire to the terminal and mounting with cord clamp CAUTION Using bundling band on the market be sure to fix the power wire and indoor outdoor connecting wire along the cr...

Page 88: ...d the valve fixing plate HEX ST SCREW Ø4 10 2 pcs Take off screws of the side cabinet and the pipe panel Rear HEX ST SCREW Ø4 10 2 pcs Take off screws of the side cabinet and the bottom plate HEX ST SCREW Ø4 10 1 pc 6 Take off screws of the side cabinet and the heat exchanger HEX ST SCREW Ø4 10 3 pcs and ST1T Ø4 14 2 pcs 7 Slide the side cabinet upward and then take off it Hook of inverter 5 Take ...

Page 89: ...he wire Connectors should be removed after unlocking the housing section 4 5 Take off lead of FAN MOTOR LOWER from EDGE SADDLE and WIRE SADDLE Cut the CABLE TIE that cover lead of FAN MOTOR UPPER Take off lead of TD TS TE TL TO Sensor COIL PMV ASM THERMO COMP ASM COIL 4WAY and ASM HP SW from EDGE SADDLE WIRE SADDLE and CABLE CLAMP 6 Take off lead of REACTOR from REACTOR 7 Take off terminal cover o...

Page 90: ... drive MCC 1626 4 2 After take off ASM BOX INV from Unit Take off the connectors that connecting from control board Take off connectors by pulling the connector body Do not pull the wire connectors should be remove after unlocking the housing section CN02 Power supply 2P White CN03 Connection with indoor unit 3P White CN04 Power supply 3P Red CN05 Power supply 2P Red CN502 Relay output 2P white CN...

Page 91: ...bent during this procedure straighten them so they do not touch other parts 5 2 Take off screw 4 pcs and life the PL FIX CDB up 3 Take off screw for fixing the P C Board for compressor drive with HEAT SINK 4 Take off the P C Board for compressor drive from 3 PCB mounts 5 Take off all the connectors and faston terminals connected to the P C Board Take off connectors by pulling the connector body Do...

Page 92: ... fan motor Tighten the flange nut with 6 86N m 70kgf cm Adjust length on the fan motor lead fixing rubber so that the fan motor lead does not slacken in order not to put the fan motor lead into contact with the propeller fan Attach the fan motor lead fixing rubber to the partition plate so that projection directs to the refrigerating cycle side Be sure to bind the removed bundling band with the bu...

Page 93: ...sor ﬁxed to the discharge pipe 7 Take off the sound insulating plate Upper side Inside outer winding 8 Take off terminal cover from the compressor and then remove the compressor lead and also the ASM THERMO COMP Piping panel Rear Piping panel Front TD sensor 9 Using a burner remove the discharge pipe and the suction pipe connected to the compressor WARNING In case of take off the piping by broilin...

Page 94: ... In this time the compressor lead does not contact with the discharge pipe As shown in the right figure mount the soundproof plate by inserting between the compressor and the piping and between piping and the partition plate Put the compressor lead wire and the compressor case thermo between partition plate and the soundproof as if dropping them in SOUND INSU inside SOUND INSU out side SOUND INSU ...

Page 95: ...chment 1 Carry out works of 1 of 1 and 2 CAUTION To prevent scratching on the product handle the product on a cardboard or cloth 2 Take off the discharge port cabinet and then put on it so that the fan guard side directs downward 3 Take off the hooking claws 8 positions of the fan guard 2 Attachment 1 Push the hooking claws 8 positions with hands from the front side to fix the claws CAUTION Check ...

Page 96: ... the pipe fixing plate ST1T Ø4 10 1 pcs to the assembly of heat exchanger after replacement NOTES Don t remove the cap from the joint of the assembly of heat exchanger maintenance part till you braze And don t neglect the assembly of heat exchanger maintenance part without cap for a long time TO sensor 5 6 Using a burner remove the discharge pipe connected to the ASM COND Take off screws between t...

Page 97: ... take off screws between the inverter cover and the inverter box CTT2T Ø4 10 1 pcs 4 Cut the CABLE TIE that fixate high pressure switch lead line 5 Take off the connector for high pressure switch from the inverter 6 Using a burner take off the High pressure switch High pressure swith connector CABLE TIE CABLE CLAMP High pressure swith Cut CABLE TIE 97 ...

Page 98: ... Unit 12 EXPLODED VIEWS AND PARTS LIST 1 2 3 4 6 5 7 8 11 10 13 14 12 9 15 16 17 18 20 19 21 22 23 24 24 25 26 27 28 30 31 33 34 35 35 35 37 36 38 38 39 40 39 40 41 41 42 42 43 29 45 46 48 50 53 49 52 51 47 98 ...

Page 99: ...T ASSEMBLY 1 1 1 23 43T00783 PARTITION SUB COAT ASSEMBLY 1 1 1 24 43T96305 BUSHING 1 1 1 25 43T00786 AIR OUTLET CABINET 1 1 1 26 43T00784 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 43T00611 ASM CABI UP 1 1 1 31 43T00726 GUARD FIN ASSEMBLY 1 1 1 32 43T00727 GUARD FIN BACK 1 1 1 33 43T22313 BELLMOUTH 1 1 1 ...

Page 100: ...R PC BOARD ASSY FAN LOWER 711 43T50385 703 43T60413 712 43T50376 704 43T60419 713 43T50337 705 43T60331 714 43T50335 706 43T95301 715 43T63335 707 43T95302 716 43T63323 COMP LEAD ASSY TEMPERATURE SENSOR TS TEMPERATURE SENSOR TE SENSOR TD TEMPERATURE SENSOR TO TEMPERATURE SENSOR SENSOR HOLDER HOLDER SENSOR 708 43T50345 FUSE CHINA TERMINAL 4P TERMINAL 3P SUPPORT SPACER SPACER EDGE THERMISTOR PTC Des...

Page 101: ...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 102: ...144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND ...

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