Toshiba RAV-SM404SDT-E Service Manual Download Page 1

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R410A

PRINTED IN JAPAN, Jan., 2009 ToMo

FILE NO. A08-007

SERVICE MANUAL

AIR-CONDITIONER

SPLIT TYPE

INDOOR UNIT

<DIGITAL INVERTER>

RAV-SM404SDT-E
RAV-SM454SDT-E
RAV-SM564SDT-E

OUTDOOR UNIT

<SUPER DIGITAL INVERTER>

RAV-SP404AT-E

RAV-SP454AT-E

RAV-SP404ATZ-E

RAV-SP454ATZ-E

RAV-SP404ATZG-E

RAV-SP454ATZG-E

RAV-SP564AT-E

RAV-SP804AT-E

RAV-SP564ATZ-E

RAV-SP804ATZ-E

RAV-SP564ATZG-E

RAV-SP804ATZG-E

Summary of Contents for RAV-SM404SDT-E

Page 1: ...YPE INDOOR UNIT DIGITAL INVERTER RAV SM404SDT E RAV SM454SDT E RAV SM564SDT E OUTDOOR UNIT SUPER DIGITAL INVERTER RAV SP404AT E RAV SP454AT E RAV SP404ATZ E RAV SP454ATZ E RAV SP404ATZG E RAV SP454ATZG E RAV SP564AT E RAV SP804AT E RAV SP564ATZ E RAV SP804ATZ E RAV SP564ATZG E RAV SP804ATZG E ...

Page 2: ...cleaning diagram for the air filter is there for the service person and not for the customer CONTENTS SAFETY CAUTION 4 1 SPECIFICATIONS 9 1 1 Indoor Unit 9 1 2 Outdoor Unit 17 1 3 Operation Characteristic Curve 18 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 20 2 1 Indoor Unit 20 2 2 Outdoor Unit 21 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 24 3 1 Indoor Unit 24 3 2 Outdoor Unit 25 4 FAN CHARACTERISTICS 28 ...

Page 3: ... Board 68 10 TROUBLESHOOTING 70 10 1 Summary ofTroubleshooting 70 10 2 Troubleshooting 72 11 REPLACEMENT OF SERVICE P C BOARD 107 11 1 Indoort Unit Slim DuctType 107 12 SETUP AT LOCAL SITE AND OTHERS 112 12 1 Indoor Unit Slim DuctType 112 12 2 Setup at Local Site Others 119 12 3 How to Set up Central Control Address Number 121 12 4 Outdoor Unit 126 13 ADDRESS SETUP 134 13 1 Address Setup Procedure...

Page 4: ...r work when an incorrect work has been executed Mark Explanation Indicates prohibited items Forbidden items to do The sentences near an illustrated mark describe the concrete prohibited contents Indicates mandatory items Compulsory items to do The sentences near an illustrated mark describe the concrete mandatory contents Indicates cautions Including danger warning The sentences or illustration ne...

Page 5: ...ed from one of the former R22 For an air conditioner which uses R410A never use other refrigerant than R410A For an air conditioner which uses other refrigerant R22 etc never use R410A If different types of refrigerant are mixed abnormal high pressure generates in the refrigerating cycle and an injury due to breakage may be caused Do not charge refrigerant additionally If charging refrigerant addi...

Page 6: ...t even if the refrigerant leaks If the refrigerant leaks and exceeds the limit density an accident of shortage of oxygen is caused For the installation moving reinstallation work follow to the Installation Manual If an incorrect installation is done a trouble of the refrigerating cycle water leak electric shock or fire is caused After repair work has finished check there is no trouble If check is ...

Page 7: ...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 comp...

Page 8: ...ollowing equipments which serve also for R22 are necessary as the general tools 1 Vacuum pump Use vacuum pump by attaching vacuum pump adapter 7 Screwdriver 2 Torque wrench 8 Spanner or Monkey wrench 3 Pipe cutter 9 Hole core drill 4 Reamer 10 Hexagon wrench Opposite side 4mm 5 Pipe bender 11 Tape measure 6 Level vial 12 Metal saw Also prepare the following equipments for other installation method...

Page 9: ...Heat exchanger Fan Fan unit Standard air flow H M L m min Motor W Air filter Controller Sold separately Sound pressure level H M L dB A Sound power level H M L dB A Gas side mm Connecting pipe Liquid side mm Drain port mm RAV SM564UT E RAV SM804UT E RAV SP564AT Z ZG E RAV SP804AT Z ZG E 5 3 7 1 5 6 8 0 1 phase 230V 220 240V 50Hz 6 82 6 25 8 72 7 99 1 47 1 86 98 97 3 61 3 82 A A 5 61 5 14 8 95 8 20...

Page 10: ...r Sold separately Controller Sold separately Sound pressure level H M L dB A Sound power level H M L dB A Gas side mm Connecting pipe Liquid side mm Drain port mm RAV SM562BT E RAV SM802BT E RAV SP564AT Z ZG E RAV SP804AT Z ZG E 5 0 7 1 5 6 8 0 1 phase 230V 220 240V 50Hz 7 24 6 63 10 36 9 49 1 56 2 21 98 97 3 21 3 21 A A 7 19 6 59 10 36 9 49 1 55 2 21 98 97 3 61 3 62 A A 13 60 20 60 Zinc hot dippi...

Page 11: ...n unit Standard air flow H M L m min Motor W Air filter Controller Sold separately Sound pressure level H M L dB A Sound power level H M L dB A Gas side mm Connecting pipe Liquid side mm Drain port mm RAV SM562CT E RAV SM802CT E RAV SP564AT Z ZG E RAV SP804AT Z ZG E 5 0 7 1 5 6 8 0 1 phase 230V 220 240V 50Hz 7 24 6 63 10 36 9 49 1 56 2 21 98 97 3 21 3 21 A A 6 82 6 25 10 12 9 28 1 47 2 16 98 97 3 ...

Page 12: ...dard air flow H M L m min Motor W Air filter Controller Sold separately Sound pressure level H M L dB A Sound power level H M L dB A Gas side mm Connecting pipe Liquid side mm Drain port mm RAV SM562KRT E RAV SM802KRT E RAV SP564AT Z ZG E RAV SP804AT Z ZG E 5 0 6 9 5 6 8 0 1 phase 230V 220 240V 50Hz 7 24 6 63 11 25 10 31 1 56 2 40 98 97 3 21 2 88 A C 7 19 6 59 11 25 10 31 1 55 2 40 98 97 3 61 3 33...

Page 13: ...ling panel Sold separately kg Heat exchanger Fan Fan unit Standard air flow H M L m min Motor W Air filter Controller Sold separately Sound pressure level H M L dB A Sound power level H M L dB A Gas side mm Connecting pipe Liquid side mm Drain port mm 402MUT E 452MUT E 562MUT E 404AT Z ZG E 454AT Z ZG E 564AT Z ZG E 3 6 4 0 5 0 4 0 4 5 5 6 1 phase 230V 220 240V 50Hz 5 05 4 63 5 82 5 33 7 24 6 63 1...

Page 14: ...n Turbo fan Fan unit Standard air flow H M L m min 11 0 9 2 7 8 Motor W 60 Sound pressure level H M L dB A 40 36 31 Sound power level H M L dB A 55 51 46 Outdoor unit Power supply 1 phase 230V 220 240V 50Hz Standard length m 7 5 Min length m 5 Refrigerant Max total length m 50 Refrigerant charging amount 40g m pipe Charge less up to 30m 31m to 50m Height Outdoor lower m 30 difference Outdoor highe...

Page 15: ...nd Under air inlet H M L dB A pressure level Back air inlet H M L dB A Sound Under air inlet H M L dB A power level Back air inlet H M L dB A Gas side mm Connecting pipe Liquid side mm Drain port mm 404SDT E 454SDT E 564SDT E 404AT Z ZG E 454AT Z ZG E 564AT Z ZG E 3 6 4 0 5 0 4 0 4 5 5 6 1 phase 230V 220 240V 50Hz 5 20 4 77 5 87 5 38 7 24 6 63 1 03 1 20 1 56 90 93 98 3 50 3 33 3 21 A A A 4 94 4 53...

Page 16: ...11 5 10 0 8 7 Motor W 60 Sound Under air inlet H M L dB A 39 36 33 pressure level Back air inlet H M L dB A 30 28 26 Sound Under air inlet H M L dB A 54 51 48 power level Back air inlet H M L dB A 45 43 41 Outdoor unit Power supply 1 phase 230V 220 240V 50Hz Standard length m 7 5 Min length m 5 Refrigerant Max total length m 50 Refrigerant charging amount 40g m pipe Charge less up to 30m 31m to 50...

Page 17: ...pressure level Cooling Heating dB A Sound power level Cooling Heating dB A Outside air temperature Cooling C Outside air temperature Heating C 404AT Z ZG E 454AT Z ZG E 564AT Z ZG E 804AT Z ZG E 1 phase 230V 220 240V 50Hz Power exclusive to outdoor is required Hermetic compressor 1 1 1 1 1 1 2 0 4 4 4 4 1 0 1 0 1 4 2 1 Pulse motor valve 7 5 7 5 7 5 7 5 5 5 5 5 30 30 50 50 20g m 20g m 20g m 40g m 2...

Page 18: ...peed rps Current A Current A Compressor speed rps Conditions Indoor DB27 C WB19 C Outdoor DB35 C Air flow High Pipe length 7 5m 230V Conditions Indoor DB20 C Outdoor DB7 C WB6 C Air flow High Pipe length 7 5m 230V Conditions Indoor DB27 C WB19 C Outdoor DB35 C Air flow High Pipe length 7 5m 230V Conditions Indoor DB20 C Outdoor DB7 C WB6 C Air flow High Pipe length 7 5m 230V RAV SM562BT CT KRT MUT...

Page 19: ...P40 SP40 SP45 SP45 SP40 SP40 SP45 SP45 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 Outdoor temp C Capacity ratio 0 10 20 30 40 50 60 70 80 90 100 110 120 14 16 18 20 12 10 8 6 4 2 0 2 4 6 8 10 Outdoor temp C Capacity ratio Conditions Indoor DB20 C Indoor air flow High Pipe length 7 5m Conditions Indoor DB27 C WB19 C Indoor air flow High Pipe length 7 5m Capacity varia...

Page 20: ...ide 57 210 845 168 inside 21 21 21 120 805 19 645 168 20 Air filter Refrigerant piping Drain up port Hung up plate Fresh air inlet knock out hole 80 59 80 4 Ø4 Ø 9 2 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 2 1 Indoor Unit RAV SM404SDT E RAV SM454SDT E RAV SM564SDT E ...

Page 21: ...ssing 500 780 32 71 21 157 79 Charge port Earth terminal 320 600 483 257 2 Ø11 14 U shape holes For Ø8 Ø10 anchor bolt Suction port Discharge port Discharge port Minimum distance up to wall 2 Ø11 14 long hole For Ø8 Ø10 anchor bolt 500 or more 150 or more 300 or more 150 or more 600 320 320 3 3 54 38 54 38 R15 2 Ø6 hole Product external line Product external line Ø11 14 U shape hole Ø11 14 U shape...

Page 22: ...tely 12 Ø3 emboss Z views Z 5 drain hole Ø20 88 burring hole Mounting bolt hole Ø12 17 long hole Mounting bolt hole Ø12 17 U shape hole Details of A legs Details of B legs Air outlet port Air inlet port Air inlet port Drain hole Ø25 burring hole 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 pi...

Page 23: ...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 24: ...side Outer dia ØB Refrigerant pipe at gas side Outer dia ØA Distributor Strainer incorporated Strainer Heating Cooling TCJ sensor TC sensor Air heat exchanger To outdoor unit To outdoor unit 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3 1 Indoor Unit Single type Combination of 1 indoor unit and 1 outdoor unit Twin type Combination of 2 indoor units and 1 outdoor unit Indoor unit SM40 2 Branch pipe RB...

Page 25: ... 1 3 39 1 03 34 6 10 5 1 95 0 26 19 9 2 7 Pipe surface temperature C Discharge Suction Indoor heat Outdoor heat exchanger exchanger TD TS TC TE 61 12 11 43 77 14 15 50 36 4 2 8 65 7 39 4 83 20 54 16 90 17 32 19 Compressor drive revolution frequency rps 47 50 44 49 49 90 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 3...

Page 26: ...75 200L Muffler Ø19 05 160L PMV Pulse Motor Valve CAM B30YGTF 2 Standard Cooling Overload Low load Standard Heating Overload Low load Pressure MPa kg cm g Pd Ps Pd Ps 2 87 1 00 29 3 10 2 3 57 1 10 36 4 11 2 1 71 0 76 17 4 7 8 2 26 0 68 23 1 6 9 3 25 1 14 33 2 11 6 2 00 0 25 20 4 2 6 Pipe surface temperature C Discharge Suction Indoor heat Outdoor heat exchanger exchanger TD TS TC TE 72 16 13 42 88...

Page 27: ...2 Ø3 450L Ø2 Ø3 450L Ø25 L210 Muffler Muffler PMV Pulse Motor Valve CAM B30YGTF 2 Standard Cooling Overload Low load Standard Heating Overload Low load Pressure MPa kg cm g Pd Ps Pd Ps 2 79 0 89 27 3 8 7 3 53 1 07 34 6 10 5 1 71 0 72 16 8 7 1 2 65 0 68 26 0 6 7 3 20 1 11 31 4 10 9 2 33 0 21 22 8 2 1 Pipe surface temperature C Discharge Suction Indoor heat Outdoor heat exchanger exchanger TD TS TC ...

Page 28: ...a Lower limit of external static pressure 20Pa Upper limit of external static pressure 35Pa Upper limit of external static pressure 50Pa Standard air volume 690m h Air volume m h External static pressure Pa High 50Pa High 35Pa High 10Pa High 20Pa 400 0 10 20 30 40 50 60 500 600 700 900 800 Low 10Pa Low 20Pa Low 35Pa Low 50Pa Lower limit of external static pressure 50Pa Lower limit of external stat...

Page 29: ...red remote controller Indoor unit earth screw Outdoor unit earth screw Serial signal Signal phase 220 240V 50Hz Outdoor unit Adapter for wireless remote controller Connection interface Option P C board MCC 1440 Terminal for central remote controller BLK BLK BLK Fuse F01 T6 3A 250V P01 CN66 WHI CN67 BLK T10 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 4 2 1 2 1 3 2 1 5 6 4 3 2 1 5 6 4 3 2 1 3 1 3 2 1 3 1 2 1 2 ...

Page 30: ... 3 1 1 2 2 3 3 1 1 1 1 2 2 3 3 1 1 TE Condenser pipe temp sensor For optional P C Board Reactor Reactor Coil for 4 WAY VALVE F01 Fuse T25A AC250V F03 Fuse T3 15A AC250V Fuse 250V T6 3A To indoor Power supply 220 240V 50Hz RED BLK P30 P31 CN605 BLK P11 RED Compressor WHI BLK P04 P05 P06 P19 P34 DB01 DB02 C12 C14 L03 C13 P35 P20 P21 P22 P23 P24 P25 ORN YEL YEL BRN YEL P18 P08 SW802 MCC 1530 Sub P C ...

Page 31: ...I 1 1 2 2 3 3 Fuse F03 T10A 250V Fuse F01 T25A 250V L N 1 2 3 1 2 3 Outdoor unit Indoor unit 1 indicates the terminal block Alphanumeric characters in the cycle indicate the terminal No 2 The two dot chain line indicates the wiring procured locally 3 indicates the P C board 4 For the indoor unit circuit refer to the wiring diagram of the indoor unit Earth screw Power supply 220 240V 50Hz Earth scr...

Page 32: ...02E1 US 622 CAM MD12TF 12 Specifications Output Rated 43 W 3 phase 4P 1100 W 10mH 16A 10 kΩ at 25 C 10 kΩ at 25 C 10 kΩ at 25 C 50 kΩ at 25 C T3 15A AC 250V AC240V OFF 125 4 C ON 90 5 C 6 2 Outdoor Unit Parts Ratings RAV SP404AT E RAV SP404ATZ E RAV SP404ATZG E RAV SP454AT E RAV SP454ATZ E RAV SP454ATZG E RAV SP564AT E RAV SP564ATZ E RAV SP564ATZG E RAV SP804AT E RAV SP804ATZ E RAV SP804ATZG E No ...

Page 33: ...e 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 refrigerant ...

Page 34: ...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 35: ...5 0 to 0 5 0 to 0 5 Conventional flare tool R410A Clutch type Wing nut type 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 2 0 to 2 5 1 0 to 1 5 2 0 to 2 5 Conventional flare tool R22 Clutch type Wing nut type 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 5 to 2 0 0 5 to 1 0 1 5 to 2 0 Table 7 2 4 Flare and flare nut dimensions for R410A Table 7 2 5 Flare and flare nut dimension...

Page 36: ...e flare nut may crack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 7 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 7 2 6 Tightening torque of flar...

Page 37: ...gerant 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 connecting...

Page 38: ...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 solder ability 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 we...

Page 39: ...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 7 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 40: ... a large quantity of sparkle remained wear out powder is observed the cause of trouble will occur 8 Installation and removal of the air conditioner are repeated with temporary installation by lease and etc 9 In case that type of the refrigerator oil of the existing air conditioner is other than the following oil Mineral oil Suniso Freol S MS Synthetic oil alkyl benzene HAB Barrel freeze ester seri...

Page 41: ...e for R410A Airtight test Vacuum dry Refrigerant charge Gas leak check In case that the gas pipe Ø19 mm is used for the outdoor unit of SM803 3 HP or higher Gas pipe size of our R410A model 3 is Ø15 9 mm 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 i...

Page 42: ... any of the follow ing do not use it Install a new pipe instead The pipe has been open disconnected from indoor unit or outdoor unit for a long period The pipe has been connected to an outdoor unit that does not use refrigerant R22 R410A or R407C The existing pipe must have a wall thickness equal to or larger than the following thickness Never use any pipe with a wall thickness less than these thi...

Page 43: ...f the weekly timer to the sub remote controller is unavailable Same as left 2 3 Follower A B A B Same as left 2 2 Follower A B DC5V DC5V Indoor unit 1 Master Indoor control P C board MCC 1570 Drain pump Indoor fan motor MCU Driver Humidifier output DC12V DC5V DC20V Outside output Remote controller communication circuit Display LCD Function setup Key switch CN2 CN1 3 MCU Display LED Display LCD LCD...

Page 44: ...me as left 2 3 Follower A B Same as left 2 2 Follower A B Indoor unit 1 Master Indoor control P C board MCC 1570 Drain pump Indoor fan motor MCU Driver Humidifier output DC12V DC5V DC20V A B Outside output Remote controller communication circuit Receive circuit Function setup SW Grille up down SW MCU Buzzer Display LED DC5V Temporary operation SW Power circuit Remote controller communication circu...

Page 45: ...e master remote controller Same as left 2 3 Follower A B A B A B A B Same as left 2 2 Follower A B DC5V DC5V Indoor unit 1 Master Indoor control P C board MCC 1570 Drain pump Indoor fan motor MCU Driver Humidifier output DC12V DC5V DC20V Outside output Remote controller communication circuit Display LCD Function setup Key switch CN2 CN1 3 MCU Display LED Display LCD LCD driver MCU Power circuit Re...

Page 46: ...he operation mode is selected Remote controller command STOP FAN COOL DRY HEAT AUTO Control outline Air conditioner stops Fan operation Cooling operation Dry operation Heating operation COOL HEAT operation mode is automatically selected by Ta Ts and To for operation The operation is performed as shown in the following figure according to Ta value at the first time only In the range of Ts α 1 Ta Ts...

Page 47: ...ried room temperature value are calculated to obtain the correction value of the frequency command and then the present frequency command is corrected Ts n Ta n Room temp difference n Counts of detection Ta n Ta n 1 Varied room temp value n 1 Counts of detection of 1 minute before 4 Dry operation The frequency correction control is same as those of the cooling operation However the maximum frequen...

Page 48: ...ion has started select a downward slope for the air speed that is the high position If the temperature is just on the difference boundary the air speed does not change Mode in the parentheses indicates one in automatic cooling operation HEAT Value in the parentheses indicates one when thermostat of the remote controller works Value without parentheses indicates one when thermostat of the body work...

Page 49: ...emarks Selection of high static pressure type Item code 5d or selection of high static pressure on P C board SW501 Tap F1 F2 F3 F4 F5 F6 F7 F8 F9 FA FB FC FD SM40 SM45 SM56 Revolution speed rpm 1260 1260 1320 1180 1180 1220 1120 1120 1220 1040 1040 1220 1020 1020 1180 990 990 1180 960 960 1180 950 950 1040 910 910 990 870 870 990 840 840 880 790 790 820 550 550 550 Item code 5d SW501 1 2 Tap F1 F2...

Page 50: ...frequency changes every 30 seconds while operation is performed in J zone In K zone time counting is interrupted and the operation is held When I zone is detected the timer is cleared and the operation returns to the normal operation If the commanded frequency becomes S0 because the operation continues in J zone the return temperature A is raised from 5 C to 12 C until I zone is detected and the i...

Page 51: ...tart of the operation or after operation start temperature is controlled between values in parentheses of A and B 1 In cooling operation including Dry operation the drain pump is usually operated 2 If the float switch works while drain pump drives the compressor stops the drain pump continues the operation and a check code is output 3 If the float switch works while drain pump stops the compressor...

Page 52: ...r when the specified time 2500H has passed and it is displayed on LCD 2 When the filter reset signal has been received from the remote controller time of the calculation timer is cleared In this case the measurement time is reset if the specified time has passed and display on LCD disappears Command frequency is approximately S7 FILTER goes on No 12 Item HA control Outline of specifications 1 This...

Page 53: ...d on the remote controller In case of the wireless type the display lamp does not change but the contents are same If operating an item which is prohibited by the central control mode from the remote controller it is notified with the receive sound Pi Pi Pi Pi Pi 5 times 1 Selecting AUTO mode enables an energy saving to be operated 2 The setup temperature is shifted corrected in the range not to l...

Page 54: ... contents of save operation of Installation Manual 20 8 C heating Frost protective operation 1 This functional is intended for the cold latitudes and performs objective heating operation 8 C heating operation 2 This function is valid only for combination with the outdoor units Super Digital Inverter SDI 4 series outdoor units 3 Using the indoor DN code D1 1 bit Valid Invalid of this function is se...

Page 55: ...ation setting by FAN button on the remote controller is performed on the remote controller DN 31 0000 0001 HA ON OFF input J01 YES NO Pulse At shipment from factory Static input selection Permission Prohibition of remote controller operation stop is performed by input Operation ON Answer back of HA Warning output ON ON when outdoor unit is defrosted ON when real thermostat is on Compressor ON ON w...

Page 56: ...AC230V Optional power supply CN309 Yellow AC230V DC fan return CN334 White High ceiling select switch SW501 HA T10 CN61 Yellow DC12V Serial receive LED D14 Orange Serial send LED D15 Green Sub bus communication LED D504 Green Micro computer operation LED D501 Red Optional output CN60 White DC12 Humidifier CN66 White DC12V Fan drive CN32 White DC12V TC sensor CN101 Black DC5V EXCT CN73 Red DC5V Aut...

Page 57: ...d 96 C for heating operation respectively in SP80 REQUIREMENT A sensor trouble may cause a liquid back flow or abnormal overheat resulting in excessive shortening of the compressor life In a case of trouble on the compressor be sure to check there 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 ...

Page 58: ...evolution frequency hold Operation with the maximum tap of each zone Operation with WF Normal fan control by TE sensor 1 tap 20 sec Down to the minimum revolution frequency of each zone TE C TD C 85 80 75 65 32 29 3 1 Cooling fan control SP56 The outdoor fan is controlled by TE sensor TO sensor and the operation frequency It is controlled by every 1 tap of DC fan control 15 taps Only for 60 second...

Page 59: ...OFF without error display The compressor restarts after approx 2 minutes 30 seconds and this intermittent operation is not abnormal In case that the status in item generates frequently stain on filter of the suction part of the indoor unit is considered Clean the filter and then restart the operation 4 Coil heating control 1 This control function heats the compressor by turning on the stopped comp...

Page 60: ... 10 minutes after operation start in some cases the compressor does not stop to protect the compressor even if receiving the THERMO 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 control No of revolutions of the compress...

Page 61: ...error count 8 was found determine an error and restart operation is not performed 4 For the error display contents confirm on the check code list 9 High pressure release control SP80 only 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 heat...

Page 62: ...hen the heating operation starts The minimum TE value and To value between 10 and 15 minutes after heating operation has started are stored in memory as TE0 and To0 respectively 0 10 15 29 35 91 min TE C 4 6 10 25 A zone A zone B zone B zone C zone C zone Start of heating operation D zone D zone A zone B zone C zone D zone In normal To In abnormal To When status TE0 TE To0 To 3 C When status TE0 T...

Page 63: ...mpressor protective control SP80 only 1 This control purposes to raise the operation frequency until 45Hz for 2 minutes in order to protect the compressor Prevention of oil accumulation in the refrigerating cycle when the status that the operation frequency is 45Hz or less has continued for 10 hours was calculated The operation frequency follows the normal indoor command after controlling 2 Althou...

Page 64: ...45 COOL HEAT 10 13 10 50 I1 I1 0 5 Current A 117 107 103 100 93 TD C Frequency down Normal operation Hold Hold Error stop P03 display with 8 times error count Frequency down Frequency slow down Frequency holding Frequency slow up Up to command As command is In case of RAV SP40 and SP45 models 1 Pulse Motor Valve PMV control 1 For PMV with 50 to 500 pulses during operation respectively 2 In cooling...

Page 65: ...p which corresponds to the zone in the following table After then the fan is controlled by TE sensor temperature Considering a case that TE sensor has come out of the holder the fan is controlled so that revolution frequency of the fan increases regardless of TE if temperature of TD sensor has risen SP40 SP45 W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF 200 300 350 410 480 500 560 640 670 700 750 ...

Page 66: ... operation is not abnormal When the above status occurs frequently it is considered that the filter of suction part of the indoor unit is stain Clean the filter and then restart the operation 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 slackness of the refrigerant inside of the compressor 2...

Page 67: ...5 C or lower After defrost operation has finished the compressor and the outdoor fan start heating operation after stopped for approx 40 seconds Start of heating operation 0 10 15 29 35 min TE C 4 6 10 25 A z A zone one C z C zone one D z D zone one A zone C zone B z B zone one B zone The minimum TE value between 10 and 15 minutes after heating operation has started is stored in memory as TE0 A zo...

Page 68: ... 1P L phase power supply lead Black N phase power supply lead White Serial lead Orange Reactor lead connector White CN300 Fan motor connector CN602 Outdoor temperature TO sensor connector CN806 Optional connector CN600 Heat exchange temperature TE sensor connector CN603 Suction temperature TS sensor connector CN601 Discharge temperature TD sensor connector CN701 4 way valve connector RY701 4 way v...

Page 69: ...ED D800 to 804 Yellow D805 Green Initial set SW SW802 Power circuit protective fuse F100 250V 3 15A plastic case Fan motor output CN300 White Compressor output terminals CN202 CN201 CN200 Electrolytic capacitors Reactor connecting connectors Power supply connecting lead wire P01 Red P02 White Lead wire for grounding P09 Black PMV connector CN710 White Inter unit wire connector CN04 White 4 way val...

Page 70: ...k 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 oper...

Page 71: ...r 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...

Page 72: ...ceiving 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 master 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 indoo...

Page 73: ...ror Heat exchanger sensor TA error Discharge temp sensor TD error Temp sensor TE error Temp 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 Compressor lock Current detection circuit error Outdoor compressor system error 1 Case thermostat worked Du...

Page 74: ...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 75: ...individual indoor unit Indoor group address is unset Capacity of indoor unit is unset Duplicated setting of central control system address Abnormal stop by outside error CN80 input An error of indoor AC fan was detected Fan motor thermal relay worked Float switch worked Indoor DC fan error Over current Lock etc was detected In heating operation an error was detected by temp down of indoor heat exc...

Page 76: ...or 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 Misconnec...

Page 77: ... 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 78: ...d 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 Judgment and measures 1 Check cable...

Page 79: ...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 80: ...after compressor start up Current detection circuit error Status of air conditioner Stop Stop Stop Stop Stop Continue Stop Stop Stop Stop Stop Stop Stop 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 ...

Page 81: ...ed Displayed when error is detected Displayed when error is detected Displayed when error is detected Judgment and measures 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 whether the service valve is fully opened 4 Check PMV Pulse Motor Valve 5 Check broken pipe 1 ...

Page 82: ...connection or contact error of connector on harness from terminal block of indoor unit Check power connection of indoor unit Turn on power again Check indoor P C board MCC 1570 Defect Replace Check remote controller P C board Defect Replace Correct as a master unit and a follower unit Check remote controller P C board Defect Replace Correct a master unit a follower unit Remote controller address c...

Page 83: ...502 Orange LED flash after power supply turned on again Check indoor P C board Defect Replace Check indoor control P C board MCC 1570 Defect Replace Check power supply voltage Correct lines Check and eliminate noise etc Check outdoor P C board Defect Replace Check indoor P C board Defect Replace Correct wiring of connector and terminal blocks Correct wiring and inter unit cables Check Item code 14...

Page 84: ...r outdoor inter unit cable Serial signal line Check power connection status of indoor unit Connect again Correct connection of connector Check circuit wiring Correct inter unit cable of remote controller YES YES YES YES YES YES NO NO NO NO NO NO E18 error E08 L03 L07 L08 error E08 Duplicated indoor unit No L03 There are 2 or more master units in a group control L07 There is 1 or more group address...

Page 85: ...b remote controller in main and sub remote controllers Are wiring connections to communication lines U3 and U4 normal Check central controller including network adapter and indoor P C board MCC 1570 Defect Replace Correct wiring connection Correct central control system address Check indoor P C board MCC 1570 Defect Replace Check outside devices Defect Replace Check indoor P C board MCC 1570 Defec...

Page 86: ...p unit side shorted Resistance value 0 Is connection of float switch connector Indoor control board CN34 normal Replace TA sensor Correct connection of connector Check the drain pipe etc Replace drain pump Check wiring Replace drain pump and indoor P C board MCC 1570 Correct connection of connector Check indoor P C board MCC 1570 Defect Replace Check and correct wiring and wire circuit YES YES YES...

Page 87: ... the resistance value below SM40 SM45 SM56 SM80 Approx 70 to 100Ω SM110 SM140 SM160 Approx 27 to 40Ω Is not grounded between cabinet and It should be 10MΩ or more 2 Resistance value confirmation of the fan motor position detection circuit Is not status between Yellow lead and Pink lead opened or shorted The resistance should be approx 5k to 20kΩ 3 Confirmation of the fan motor position detection s...

Page 88: ...eplace TC sensor Check indoor P C board MCC 1570 Defect Replace Correct connection of connector Are characteristics of TCJ sensor resistance value normal Is connection of TCJ sensor connector CN102 on Indoor P C board correct Refer to TCJ sensor Temperature Resistance value characteristic table Replace TCJ sensor Check indoor main P C board MCC 1570 Defect Replace YES YES YES YES NO NO NO NO F01 e...

Page 89: ...B terminal blocks Correct communication line of remote controller 1 Is connection of connector normal Check power supply transformer on TCC LINK adapter P C board MCC 1440 Defect Replace Can the other indoor units be normally controlled from the central controller Or is the operation status of indoor unit reflected 1 TCC LINK central CN51 of TCC LINK adapter P C board MCC 1440 and CN050 of indoor ...

Page 90: ...ated during operation of the air conditioner Replace the service P C board When EEPROM was not inserted when power supply turned on or when the EEPROM data read write operation is impossible at all the automatic address mode is repeated In this time 97 error is displayed on the central controller P31 error Follower indoor unit When the master unit of a group operation detected E03 L03 L07 or L08 e...

Page 91: ...5 Diagnostic Procedure for Each Check Code Outdoor Unit 1 This section describes the diagnostic method for each check code displayed on the wired remote controller 2 When APPLICATION CONTROL KIT TCB PCOS1E2 sold separately is connected the error contents can be judged by LED on the APPLICATION CONTROL KIT In this case turn off both bit 1 and 2 of DIP switch 01 on the All purpose control kit Check ...

Page 92: ...ect Correct connector Sensor error Replace Check outdoor P C board Defect Replace TE TS sensor Check PMV Defective Replace Is wiring connection correct Compressor lead P C board side Compressor side Reactor cord Power supply lead Is wiring connection correct Compressor lead P C board side Compressor side Reactor cord Power supply lead YES NO YES NO YES YES YES YES YES YES YES NO NO NO YES NO NO NO...

Page 93: ... Correct connector Sensor error Replace Check outdoor P C board Defect Replace Confirm power supply construction etc Check outdoor P C board Defect Replace YES YES YES YES NO YES NO YES NO NO NO YES NO YES NO NO Check code H03 APPLICATION CONTROL KIT LED display D01 D02 D03 D04 Red Yellow Yellow Yellow l l Check Countermeasures Part without special mention indicates a part of the outdoor unit Powe...

Page 94: ...efective Replace Correct power line Correct wiring YES NO YES YES YES YES NO YES NO NO NO NO NO YES YES NO After pulling out the connector of the fan motor CN300 rotate its shaft by hands Can it rotate smoothly Is the fan motor coil resistance within the range described below Between red and white lead 18 to 30Ω Between white and black lead 18 to 30Ω Between black and red lead 18 to 30Ω Check code...

Page 95: ...ffer from that of LED How to check LED display on outdoor P C board Dip switch setup When turning on 1 only of SW803 the latest error is displayed As the memory is stored it can be confirmed even if the power supply is turned off once excluding outside temp sensor TO error When the work finished or the outdoor temp sensor TO error was found turn off all of SW803 The error which occurs at present i...

Page 96: ...splay 2 l l l l l Display 1 Display 2 l l l l Display 1 Display 2 l l l l l Display 1 Display 2 l l l Display 1 Display 2 l l l l 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 temp sensor TE e...

Page 97: ...orrect Is connection of CN602 correct Is resistance value of TO sensor correct Is connection of CN600 correct Is resistance value of TS sensor correct Is connection of CN601 correct Is resistance value of TE sensor correct YES YES YES YES YES NO NO NO NO NO Check code F08 F12 F13 F15 F31 Outdoor LED display Display 1 Display 2 l l l l l l Display 1 Display 2 l l l l l Display 1 Display 2 l l l l D...

Page 98: ...side Reactor lead Power supply lead Is wire connection correct Compressor lead Board side Compressor side Reactor lead Power supply lead Compressor lock Replace Check outdoor P C board Defect Replace Check TE TS sensors and PMV Defect Replace Check outdoor P C board Defect Replace Check outdoor P C board Defect Replace YES YES YES YES YES YES YES YES NO NO NO NO NO NO NO NO Check code H01 H02 H03 ...

Page 99: ...ervice P C board Is service valve fully opened Is PMV under correct conditions Is there gas leak Is there refrigerant shortage Are CN609 connection and case thermostat correct Short each pins of CN609 Can compressor operate YES YES NO YES YES NO NO YES NO NO Check code H04 L10 Outdoor LED display Display 1 Display 2 l l l l l l l Display 1 Display 2 l l l l l Check and troubleshooting Item without...

Page 100: ...lity that it is one of the following errors Confirm LED on outdoor P C board to judge which error it is Communication 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 MCUs Heat sink temp sensor TH error Refer to F13 column EEPROM error Refer to F31 column Unset model type...

Page 101: ...mains voltage correct 198 to 264V NO YES Check code P03 P04 P05 Outdoor LED display Display 1 Display 2 l l l l Display 1 Display 2 l l l l l l l Display 1 Display 2 l l l l Display 1 Display 2 l l l l Display 1 Display 2 l l l l Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp error There is a possibility that it is one of the following errors C...

Page 102: ... Is service valve fully opened Is PMV under correct conditions Is there gas leak Is there refrigerant shortage Check temp sensor TD sensor CN603 TS sensor CN600 Does something block the ventilation around the heat sink Does something block air flow from the fan Apply radiation grease to objective parts Retightening of screws Be sure not to forget to attach insulating sheet between heat sink and Q3...

Page 103: ...y valve reversal error Check method of outdoor P C board operation Self holding valve type 1 Set SW804 of Dip switch as the following figure and then push SW801 for approx 1 second to check exchange operation to cooling cycle heating cycle Power is turned on for approx 10 seconds In case of operating with the coil of 4 way valve connected to CN701 take interval over 1 minute before re operation ot...

Page 104: ...rigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defect Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defect Eliminate interfering element Eliminate interfering element Heating season Heating operation Cooling season Cooling operation Is there anything which interfere heat exchange of outdoor unit Clogging of heat exch...

Page 105: ...ED display Display 1 Display 2 l l l Display 1 Display 2 l l l Display 1 Display 2 l l Display 1 Display 2 l l Check and troubleshooting Item without special mention Indicates part of outdoor unit Fan system error Single operation check for outdoor fan 1 Set Dip switch of SW804 as the following figure and then push SW801 for approx 1 second to check single operation of outdoor fan Use this method ...

Page 106: ...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 05 105 6 58 61 62 36 66 26 47 0...

Page 107: ...No Group header unit follower unit settings and perform the cooling cycle confirmation through the trial operation Replacement procedures CASE 1 Before replacement the indoor unit can be turned on and the setting data can be read out by wired remote control operation EEPROM data read out 1 ò Replacement of P C board for Indoor unit servicing and power on 2 ò Writing the read out EEPROM data 3 ò Po...

Page 108: ... P C board to the P C board for indoor unit servicing At this time perform the same setting of the jumper wire J01 setting cut switch SW501 short circuit connector CN34 as the setting of the P C board before replacement Step 2 According to the system configuration turn on the indoor unit following to the either methods shown below a Single operation Indoor unit is used as standalone Turn on the in...

Page 109: ...or indoor unit servicing are the factory set values Specify the indoor unit No with its P C board replaced to the P C board for indoor unit servicing You cannot perform this operation if is displayed Step 3 Select the CODE No DN can be selected by pushing the button for the temperature setting 3 Set the indoor unit type and capacity The factory set values shall be written to the EEPROM by changing...

Page 110: ...he temperature setting As described above check the setting data and modify to the data put down in 1 Step 8 Repeat the steps 6 and 7 Step 9 After the setting completes push TEST button to return to the normal stop status It takes approx 1 min until the remote control operation is available again The CODE No DN are ranged from to The CODE No DN is not limited to be serial No Even after modifying t...

Page 111: ...te controller operation save function Frost protection function Setting data Factory set value Depending on Type 0000 standard 0099 Not determined 0002 2 C flooring installation type 0 0000 Heat pump Depending on model type Depending on capacity type 0099 Not determined 0099 Not determined 0099 Not determined 0003 3 deg Ts 1 5 0000 None 0002 Humidifier 0000 Thermo ON 0000 Not available 0000 Body s...

Page 112: ...For wired remote controller only Preparation in advance 1 Push TEST SET CL buttons simultaneously for 4 seconds or more on the remote controller Push buttons while the air conditioner stops The first displayed unit No is the master indoor unit address in the group control 2 Every pushing UNIT button the indoor unit No in the group control is displayed one after the other Select a main indoor unit ...

Page 113: ...It flashes while receiving the serial signal from the outdoor unit Hardware 6 D15 Green It flashes while sending the serial signal to the outdoor unit Hardware 12 1 4 Function Selection Setup Procedure Perform setting while the air conditioner stops 1 Push TEST SET CL buttons simultaneously for 4 seconds or more The first displayed unit No is the master indoor unit address in the group control In ...

Page 114: ... No 1 unit to 0030 No 30 unit 0001 No 1 unit to 0064 No 64 unit 0000 Individual 0001 Master unit in group 0002 Follower unit in group 0000 0 deg to 0010 10 deg Cool heat are reversed with Data value 2 against the set temperature 0000 None 0001 Provided 0000 Filter input 0001 Alarm input Air cleaner etc 0002 Humidifier input 0000 Indoor thermostat ON 0001 ON receiving output of outdoor compressor 0...

Page 115: ... 2 1 2 Remote controller Inside of the rear side Sub remote controller Master remote controller DIP switch 2 remote controller control Controlled by 2 remote controllers This control is to operate 1 or multiple indoor units are operated by 2 remote controllers Max 2 remote controllers are connectable When connected 2 remote controllers operate an indoor unit Wireless remote controller How to set w...

Page 116: ...outdoor units can be monitored ò 4 Pushing TEST button returns the status to the usual display 1 The indoor discharge temperature of item code F8 is the estimated value from TC or TCJ sensor Use this value to check discharge temperature at test run A discharge temperature sensor is not provided to this model The data value of each item is not the real time but value delayed by a few seconds to ten...

Page 117: ...dual Master of twin controls room temperature according to setting on the remote controller System example 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 settin...

Page 118: ...o 5 minutes Normal Gr normal 1 There is no duplicated indoor unit address 2 There is no invalid indoor unit address 3 Individual unit and master follower units are not intermingled 4 Only a unit for individual 5 A master indoor unit and 1 or more follower indoor units for Gr Automatic address judgment Initial communication Usual regular communication By feed unit Power ON Gr construction check Sys...

Page 119: ... TCC LINK communication circuit Terminal resistance TCC LINK adapter P C board MCC 1440 Indoor unit TCC LINK Communication units Total 64 units Communication distance 2000 m CN050 CN041 Terminal block A B Central controller Indoor units in all refrigerant lines Max 64 units If mixed with multi model Link wiring multi indoor units are included However group sub units and twin sub units of customize...

Page 120: ...is product sold separately Remote controller Indoor outdoor inter unit wire AC230V serial Central control system wiring Master unit Master unit Sub unit Sub unit Wiring for No 1 and 2 only Remote controller Remote controller Remote controller Remote controller Remote controller wiring Group operation Max 8 units Twin operation OFF at shipment from factory OFF at shipment from factory Line address ...

Page 121: ...h TEST VENT buttons for 4 seconds or more When group control is executed first the unit No is displayed and all the indoor units in the group control are selected In this time fans of all the selected indoor units are turned on Fig 1 Keep displayed status without pushing UNIT LOUVER button In case of individual remote controller which is not group controlled Line address and Indoor unit address ar...

Page 122: ...ow to set contents of save operation In combination with outdoor units before 4 series the displayed setup value exchanges but the real operation is 75 fixed 1 Push SAVE for 4 seconds or more during stop of the operation flashes 2 Push UNIT LOUVER At the left side of the button and select the unit to be set Every pushing the button the unit No changes The fan of the selected unit rotates and the l...

Page 123: ...ocedure 5 Push SET button When the display changes from flashing to lit the setup is completed To change settings of another indoor unit repeat from Procedure 2 To change other settings of the selected indoor unit repeat from Procedure 3 Use SET button to clear the settings To make settings after SET button was pushed repeat from Procedure 2 Procedure 6 When settings have been completed push TEST ...

Page 124: ... also be changed with the switch on the indoor microcomputer P C board However once the setting is changed setting to 0001 or 0006 is possible but setting to 0000 requires a setting data change to 0000 using the wired remote controller separately sold with the normal switch setting factory setting To restore the factory settings To return the DIP switch settings to the factory settings set SW501 1...

Page 125: ... ture to be set up from the table below n How to set up power saving mode 1 Push SAVE button for at least four seconds when the air conditioner is not working flashes Indicates CODE No C2 2 Select an indoor unit to be set by pushing UNIT LOUVER left side of the button Each time you push the button unit numbers change as follows The fan of the selected unit runs 3 Adjust the power save setting by p...

Page 126: ... the indoor unit and then turn off the power supply 1 2 3 4 ON 1 2 3 4 ON 1 2 3 4 ON D800 D801 D802 D803 D804 D805 SW801 Push for 1 second W804 All OFF As initial status The D805 Green LED flashes NOTE The electric portion of the refrigerant recovery SW on the sub board is electrified therefore be careful to an electric shock SP80 1 Set the mode of the indoor unit to fan mode 2 Set all DIP switch ...

Page 127: ...ion is performed with Max Upper fan 890 rpm Lower fan 910 rpm WF In this case the upper limit value of static pressure for duct is 5Pa or less on 25 C degrees and please use straight duct In this case the outdoor noise level may increase Turn the switch to ON when Ø19 1 is used for the existing pipe In this case the heating capacity may lower according to outside temp and indoor temp in heating op...

Page 128: ... Part No D502 D503 D800 to D804 D805 Specifications Orange LED Green LED Yellow LED Green LED Operation contents Indoor Outdoor communication Serial communication signal display Receive signal from indoor signal Indoor Outdoor communication Serial communication signal display Send signal from outdoor signal Error display When all SW803 are OFF or when any of D800 to D804 goes on LED displays that ...

Page 129: ...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 which is...

Page 130: ...ller may differ according to type of indoor model multiple codes are described Display 1 Initial display lllll ll ll l l l l Display 2 SW800 operation lllll ll ll l ll ll lll l ll l l l l llll l lll lll ll ll l l l l lll l ll ll l ll ll l l l l l l Error contents Normal Discharge temp sensor TD error Heat exchanger temp sensor TE error Heat exchanger temp sensor TL error Outside temp sensor TO err...

Page 131: ... 34 35 to 39 40 to 44 45 to 49 50 to 54 55 to 59 60 to 64 65 to 69 70 to 74 75 to 79 80 to 84 85 to 89 90 to 94 95 to 99 100 to 104 105 to 109 110 to 114 115 to 119 Over 120 Sensor error unconnected Current A 0 to 0 9 1 to 1 9 2 to 2 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...

Page 132: ...2 3 4 1 SW804 ON 2 3 4 1 SW804 ON 2 3 4 1 SW804 ON 2 3 4 1 SW804 ON 2 3 4 1 SW804 ON 2 3 4 1 SW804 ON 2 3 4 1 SW804 ON 2 3 4 1 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 Refer 12 4 1 Refrigerant Recovery Control Indoo...

Page 133: ...700 CN701 between 1 and 4 Voltage Approx 198 to 380V This function works for 10 seconds and then is OFF SV valve relay operation For RY702 CN702 check Turn on SV valve relay RY702 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control For RAV SP1104AT E to RAV SP1404AT E the part is not mounted so do not operate Heater output relay operation For check RY703 ...

Page 134: ... 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 135: ...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 refrigerating cycles...

Page 136: ...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 137: ...ster Header 1 1 1 2 1 1 Sub Follower 13 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 M...

Page 138: ... 13 3 Remote Controller Wiring Strip off approx 9 mm the wire to be connected For single system use non polarity 2 core wire is used for wiring of the remote controller 0 5 mm to 2 0 mm wires For the synchronous twin triple system use 2 core shield wire Vinyl cord for microphone 0 5 to 2 0 mm to conform to the EMC standard Wiring diagram For details of wiring installation of the remote controller ...

Page 139: ...g from remote controller In case that addresses 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 1 Push SET CL TEST buttons simultaneously for 4 seconds or more 2 Line address Using the temperature setup buttons set 12 to the item code 3 Using timer time buttons set the line address 4 Push SET button OK w...

Page 140: ...l 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 displayed and fan louv...

Page 141: ...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 142: ... at the opposite side of the hooks and then fix it to the original position NOTE In case of sucking system from bottom side installation direction is determined Install the air filter so that hooks are aligned at discharge side 1 Detachment 1 Take off fixing screws while holding the plate inlet A with hands to remove it Sucking system from rear side Ø4 10 8 pcs Sucking system from bottom side Ø4 1...

Page 143: ...learance NOTE If there is clearance dust may enter in the electric parts box 1 Detachment 1 Perform works 1 of 2 and 1 of 3 2 Remove clamps and tie wrap at upper part of the photo Drain pump incorporated model 3 positions Natural drain model 2 positions 3 Take off screws fixing E box Ø4 10 2 pcs E box does not fall down under condition that screws are taken off 4 Remove the E box over sheeting met...

Page 144: ...d edge spacer and then remove P C board assembly 2 Attachment 1 Attach P C board assembly to the card edge spacer 2 Using wires connect connectors as before which were disconnected in procedure 1 2 of 5 NOTE Check there is no missing or poor contact of the connectors 1 Detachment 1 Perform work 1 of 2 2 Take off hanging hooks at both sides of the lower fan case to remove fan lower case 3 Remove th...

Page 145: ...ntact of the connectors Check also that the multi blade fan turns surely and smoothly and check together tightening of motor earth 1 Detachment 1 Take off the drain cap and drain the drain water accumulated in the drain pan assembly In case of natural drain model drain the drain water by taking off hose band and drain hose NOTE When taking off drain cap and drain hose be sure receive drain water i...

Page 146: ...pipes are not damaged and then fix it with screws 2 Insert the drain hose into the inlet of drain pump and then fix it with hose band Arrange handle of the hose band at contrary side of heat exchanger side and at direction remote from drain pan assembly 3 Carry out wiring as before and then perform work of procedure 2 of 8 NOTE Finally check whether they correctly operate or not 1 Detachment 1 Rec...

Page 147: ...e the upper cabinet pulling it upward 2 Attachment 1 Attach the waterproof cover CAUTION Be sure to attach a waterproof cover If it is not attached there is a possibility that water enters inside of the outdoor unit 2 Attach the upper cabinet ST1T Ø4 8L 5 pcs Hook the rear side of the upper cabinet to claw of the rear cabinet and then put it on the front cabinet 3 Perform cabling of connecting cab...

Page 148: ... Take off screws of the front cabinet and the bottom plate ST1T Ø4 8L 3 pcs 4 Take off screws of the front cabinet and the motor support ST1T Ø4 8L 2 pcs The left side of the front side if made to insert to the rear cabinet so remove it pulling upward 3 Attachment 1 Insert hook at the left side of the front side into the rear cabinet 2 Hook the lower part at the right side of the front to concavit...

Page 149: ... C14 printed as CAU TION HIGH VOLTAGE electrolytic capaci tor 500µF of P C board WARNING The electrolytic capacitor may not normally discharge according to error contents and the voltage may remain Therefore be sure to discharge the capacitor WARNING For discharging never use a screwdriver and others for short circuiting between and electrodes As the electrolytic capacitor is one with a large capa...

Page 150: ...2P White CN601 TD sensor 3P White CN603 TS sensor 3P White CN602 TO sensor 3P White CN500 Case thermo 2P White CN700 PMV 6P White 2 Remove the inverter box Metal plate 3 Remove the control board assembly from P C board base Remove the heat sink and the control board assembly as they are screwed NOTES 1 CN300 and CN701 etc at the control board assembly side are connectors with locking function Ther...

Page 151: ...4 Take off fixed screw for the valve mounting plate ST1T Ø4 8L 1 pc 1 Perform works of items 1 of 1 and 2 2 Take off the flange nut fixing the fan motor and the propeller Turning it clockwise the flange nut can be loosened To tighten the flange nut turn counterclockwise 3 Remove the propeller fan 4 Disconnect the connector for fan motor from the inverter 5 Take off the fixing screws 2 pcs holding ...

Page 152: ...UTION Pay attention to that flame does not involve 4 way valve or PMV If doing so a malfunction may be caused 7 Take off the fixing screws of the bottom plate and heat exchanger ST1T Ø4 8L 8 Take off the fixing screws of the valve clamping plate to the bottom plate ST1T Ø4 8L 2 pcs 9 Pull upward he refrigerating cycle 10 Take off nut fixing the compressor to the bottom place CAUTION When reconnect...

Page 153: ...orm works of items 1 of 1 and 2 2 Remove the front cabinet and put it down so that fan guard side directs downward CAUTION Perform works on a corrugated cardboard cloth etc to prevent flaw on the product 3 Remove the hooking claws by pushing with minus screwdriver along with the arrow mark in the right figure and remove the fan guard 2 Attachment 1 Insert claws of the fan guard in the hole of the ...

Page 154: ...tach the top plate Hexagonal screw Ø4 10 5 pcs In this time insert the fin guard of rear side between the top plate and the heat exchanger Rear side 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 th...

Page 155: ... Ø4 8 2 pcs 5 Remove screws of the discharge port cabinet and the heat exchanger ST1T Ø4 8 1 pc 6 Remove screws of the discharge port cabinet and the fin guard Hexagonal screw Ø4 10 2 pcs Remarks 1 Carry out work of 1 of 1 2 Remove screws which fix the inverter assembly and the side cabinet ST1T Ø4 8 2 pcs 3 Remove screws of the side cabinet and the valve fixing plate ST1T Ø4 8 2 pcs 4 Remove scre...

Page 156: ...e the control P C board Supporter 5 positions NOTE It is difficult to take out it because of radiator grease for heat sink 7 Mount a new control P C board NOTE Do not forget to attach the aluminum plate Q201 and the insulating sheet Q300 Applying a little of radiator grease at the rear surface of the insulating sheet in advance to adhere to the heat sink makes easy the work Remarks Screw for fixin...

Page 157: ...d bundling band with the bundling band on the market Be careful that the fan motor lead does not come to contact with the reactor body Remarks Reactor relay connector Connected to lead wire White at P C board side Reactor relay connector Connected to lead wire Charcoal gray at P C board side Fan motor lead Bundling band Compressor lead reactor lead Upper reactor Connected to reactor relay connecto...

Page 158: ... 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 that the rector body does not come to contact with the fan motor lead Be sure to bind the removed bundling band with the bundling b...

Page 159: ...ompressor lead Leave the ferrite core attached to the electric parts box as it is Control P C board U CN200 Red V CN201 White W CN202 Black Tightening torque 1 47 0 1N m Remarks Compressor lead Compressor lead Ferrite core Ferrite core Compressor lead Ferrite core Control Control P C board P C board Compressor Compressor lead lead Control P C board Compressor lead Black pipe cover for heat proof b...

Page 160: ...nt when wax melted so take sufficient care CAUTION Note so that the flame does not catch the 4 way valve and PMV An operation may become an error 11 Pull off the discharge pipe and the suction pipe of the refrigerating cycle upward 12 Remove the compressor bolts which fix the compressor to the bottom plate 3 pcs 13 Pull out the compressor toward you X CAUTIONX The weight of the compressor is 15kg ...

Page 161: ...his position side at this position Accumulator Discharge pipe Discharge pipe Discharge pipe Header pipe Suction pipe Discharge pipe Discharge pipe Discharge pipe Black heat proof pipe cover and heat proof bundling band each sensor TL TO TE TD TS sensor PMV coil lead wire Set each sensor so that it does not come to contact with the discharge pipe PMV coil lead Pass the soundproof plate inner windin...

Page 162: ...Turn on 1 and 3 of DIP SW804 on the control P C board of the outdoor unit Keep pushing SW801 on the control P C board of the outdoor unit for 1 second or more After pushing SW801 for 1 second or more turn off the leakage breaker within 2 minutes 4 Refrigerant charging 1 Add the quantity of refrigerant specified by the pipe length into the charge port of the valve Remarks 1 Detachment 1 Carry out w...

Page 163: ...he discharge port cabinet and then put on it so that the fan guard side directs downward 3 Remove 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 CAUTIONX Check that all the hooking claws are fixed at the specified positions Remarks Bell mouth Discharge port cabinet Fan guard Hooking claw ...

Page 164: ...9 204 207 233 236 235 207 217 220 222 216 219 232 205 228 230 204 227 212 214 213 229 201 208 208 225 226 231 213 218 224 234 237 15 EXPLODED VIEWS AND PARTS LIST 15 1 Indoor Unit 15 1 1 RAV SM404SDT E RAV SM454SDT E RAV SM564SDT E ...

Page 165: ...4 43047685 Nut Flare 1 4 IN 225 43047688 Nut Flare 1 2 IN 226 43149353 Socket 1 2 IN 227 43060029 Filter Noise 228 43151287 Switch Float 229 43100320 Plate Inlet A 230 43177012 Pump Drain MDP 1401 231 43147195 Bonnet 1 2 IN 232 43019904 Holder Sensor SUS 233 431S8088 Owner s Manual 234 43166011 Remote controller SX A4EE 235 43166004 Remote controller SX A11JE2 236 43166006 Remote controller WH H1J...

Page 166: ...o 401 43050425 Sensor Ass y Service TC F6 402 43050426 Sensor Service 403 43160565 Terminal Block 3P AC250V 20A 404 43160568 Terminal 2P AC30V DC42V 1A 405 4316V368 P C Board Ass y 220 240V MCC 1570 Model Name RAV SM 404SDT E 454SDT E 564SDT E 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 ...

Page 167: ... 167 4 10 26 32 28 33 22 30 2 3 9 27 8 6 20 7 1 5 25 24 16 17 29 11 30 18 19 12 14 13 15 31 21 15 2 Outdoor Unit 15 2 1 RAV SP454AT E RAV SP454ATZ E RAV SP454ATZG E ...

Page 168: ...21 Reactor 21 4302C068 Motor Fan ICF 140 43 4R 22 43020329 Fan Propeller PJ421 23 43047669 Nut Flange 23 43197164 Nut Flange SUS304 WSB 24 43032441 Nipple Drain 25 43089160 Cap Waterproof 26 43050407 Thermostat Bimetal 27 43063339 Holder Sensor TO 28 43049749 Rubber Cushion 29 43063321 Holder Sensor 4 8 9 52 30 43063322 Holder Sensor 6 11 4 12 7 31 43063325 Holder Sensor 6 6 35 8 32 43063317 Holde...

Page 169: ... 706 43160566 Terminal Block 6P 20A 707 4316V293 P C Board Ass y SW MCC 1530 708 4316V367 P C board Ass y MCC 5009 710 43160571 Fuse Holder 250V 15A 711 43160590 Fuse AC250V 6 3A 712 43158192 Reactor Model Name RAV SP 404AT E 404ARZ E 404ATZG E 454AT E 454ATZ E 454ATZG E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ...

Page 170: ... 170 15 2 2 RAV SP564AT E RAV SP564ATZ E RAV SP564ATZG E 4 12 13 14 19 20 39 40 21 22 34 35 33 32 37 38 10 30 36 15 18 16 17 2 3 9 8 31 6 41 42 24 25 1 5 29 28 7 23 11 26 27 ...

Page 171: ...487 Coil PMV CAM MD12TF 12 23 43058277 Reactor CH 57 Z T 24 4302C068 Motor Fan ICF 140 43 4R 25 43020329 Fan Propeller PJ421 26 43047669 Nut Flange 27 43197164 Nut Flange 28 43032441 Nipple Drain 29 43089160 Cap Waterproof 30 43050407 Thermostat Bimetal 31 43063339 Holder Sensor TO 32 43042485 Rubber Cushion 33 43063321 Holder Sensor 34 43063322 Holder Sensor 35 43063325 Holder Sensor 36 43063317 ...

Page 172: ...board 706 43160566 Terminal block 6P 20A 707 4316V293 P C board Ass y SW MCC 1530 708 4316V384 P C board Ass y MCC 5009 710 43160571 Fuse Holder 15A 250V 711 43160590 Fuse 6 3A 250V AC 712 43158192 Reactor CH 43 Z T Model Name RAV SP 564AT E 564ATZ E 564ATZG E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 705 708 707 712 711 710 706 701 702 703 704 ...

Page 173: ... 173 15 2 3 RAV SP804AT E RAV SP804ATZ E RAV SP804ATZG E 13 19 24 20 7 38 23 21 1 2 16 11 22 9 10 36 8 39 40 25 37 6 27 17 14 18 12 4 26 28 29 35 3 30 31 32 15 34 33 5 ...

Page 174: ...r PB521 23 43122113 Bell mouth 24 4312C042 Motor Fan ICF 280 A60 1 25 43146686 Valve Packed 9 52 26 43146695 Valve Pulse Modulating CAM B30YGTF 2 27 43146724 Valve Ball SBV JA5GTC 1 28 43148232 Accumulator Ass y 1 8L 29 43148233 Accumulator Ass y 1 8L 30 4314G278 Condenser Ass y 31 4314G279 Condenser Ass y 32 4314G280 Condenser Ass y 33 4314N024 Coil Valve 4 Way VHV 01AP552B1 34 4314Q031 Strainer ...

Page 175: ...43160581 Termonal 3P 60A 707 43160589 Fuse 10A 250V AC 708 43163055 Holder Sensor TO 709 43163059 Spacer Bush 710 43163060 Spacer Collar 711 4316V387 P C board Ass y MCC 1571 712 43063322 Holder Sensor TS 713 43063321 Holder Sensor TD Model Name RAV SP 804AT E 804ATZ E 804ATZG E 3 3 3 1 1 1 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 705 709 710 711 707 704 706 703 701 ...

Page 176: ... the number of high concentration buildings however the installation of multi air conditioner systems is on the increase because of the need for effective use of floor space individual control energy conservation by curtailing heat and carrying power etc Most importantly the multi air conditioner system is able to replenish a large amount of refrigerant compared with conventional individual air co...

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Toshiba RAV-SM404SDT-E, Service Manual

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