Toshiba RAV-SP1104AT-E1 Service Manual Download Page 104

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TOSHIBA CARRIER CORPORATION

72-34 Horikawa-cho, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8585, JAPAN

Summary of Contents for RAV-SP1104AT-E1

Page 1: ...R410A PRINTED IN JAPAN Oct 2016 ToMo FILE NO A10 1610 SERVICE MANUAL SPLIT TYPE OUTDOOR UNIT SUPER DIGITAL INVERTER RAV SP1104AT E1 RAV SP1404AT E1 RAV SP1104ATJ E1 RAV SP1404ATJ E1 ...

Page 2: ... Unit Control 31 7 2 Outline of Main Controls 32 8 TROUBLESHOOTING 37 8 1 Summary of Troubleshooting 37 8 2 Troubleshooting 39 9 SETUP AT LOCAL SITE AND OTHERS 61 9 1 Calling of Error History 61 9 2 Group Control Operation 61 9 3 Outdoor Unit 63 9 4 Service Support Function LED Display Switch Operation 64 9 5 Others 65 10 ADDRESS SETUP 70 10 1 Address Setup Procedure 70 10 2 Address Setup Group Co...

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

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

Page 5: ...get burned when removing this panel CAUTION Do not touch the aluminum fins of the unit Doing so may result in injury CAUTION BURST HAZARD Open the service valves before the operation otherwise there might be the burst Description WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing WARNING Moving parts Do not operate unit with grille removed Stop the unit ...

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

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

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

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

Page 10: ...Route de Thil 01120 Montluel FRANCE Hereby declares that the machinery described below Generic Denomination Air Conditioner Model type RAV SP1104AT E1 RAV SP1104ATJ E1 RAV SP1404AT E1 RAV SP1404ATJ E1 Commercial name Super Digital Inverter Series Air Conditioner Complies with the provisions of the Machinery Directive Directive 2006 42 EC and the regulations transposing into national law Note This ...

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

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

Page 13: ... Heat exchanger Connecting pipe Gas side mm 15 9 15 9 Fan unit Fan Propeller fan Sound pressure level Cooling Heating dB A 49 50 51 52 Sound power level Cooling Heating dB A 66 67 68 69 Outside air temperature cooling C Outside air temperature Heating C 15 to 20 C 43 to 15 C Liquid side mm 9 5 9 5 Standard air flow m3 min 101 103 Motor 100 100 W 100 100 Finned tube Outdoor higher m 30 30 Max total...

Page 14: ... 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 variation ratio according to temperature RAV SP1104AT E1 RAV SP1104ATJ E1 RAV SP1404...

Page 15: ... 15 2 CONSTRUCTION VIEWS EXTERNAL VIEWS Outdoor Unit RAV SP1104AT E1 RAV SP1104ATJ E1 RAV SP1404AT E1 RAV SP1404ATJ E1 ...

Page 16: ...0E2 Simultaneous Twin Inner diameter Ø C Inner diameter Ø D Inner diameter Ø D A B Model RBC TWP30E2 Liquid side Gas side TWP50E2 Liquid side Gas side A B C D 36 14 Ø9 5 Ø6 4 43 23 Ø15 9 Ø12 7 34 14 Ø9 5 Ø9 5 44 21 Ø15 9 Ø15 9 ...

Page 17: ... 25 75 3 43 2 2 72 16 53 12 13 97 22 42 19 18 Compressor drive revolution frequency rps 51 55 21 53 26 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 30 24 18 15 15 Standard Cooling Overload Low load Standard Heating Overload Low load Pressure MPa kg cm g Pd Ps Pd Ps 2 57 0 99 26 2 10 1 3 30 1 09 33 7 11 1 1 74 0 7...

Page 18: ...803 1 ON CN701 WHI CN04 WHI 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 supp...

Page 19: ...temp sensor Td sensor Heat exchanger mid Temp sensor TL sensor Compressor thermo Protection Type DA422A3F 25M ICF 280 A100 1 CH 62 VHV 01AP552B1 UKV A038 MCC 1571 US 622 Specifications Output 100W 5 7mH 18 5A AC240V DC12V AC220 240V AC250V 25A AC250V 10A AC250V 3 15A 10 kΩ at 25 C 10 kΩ at 25 C 50 kΩ at 25 C 10 kΩ at 25 C OFF 125 4 C ON 90 5 C 5 SPECIFICATIONS OF ELECTRICAL PARTS Outdoor Unit Part...

Page 20: ...cle 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 refrigeran...

Page 21: ...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 22: ...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 6 2 4 Flare and flare nut dimensions for R410A Table 6 2 5 Flare and flare nut dimension...

Page 23: ...e flare nut may crack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 6 2 6 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Table 6 2 6 Tightening torque of flar...

Page 24: ...rigerant 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 connecti...

Page 25: ...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 26: ...efore use a flux which does not contain chlorine 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 6 5 3 Brazing As brazing work requires sophisticated techniques experiences based upon a theoretical knowledge it must be performed by a person qualified In order to prevent the oxide film from occurring...

Page 27: ...ge 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 series PVE...

Page 28: ... 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 to 6 HP 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 content...

Page 29: ...ponds to any of the following 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 th...

Page 30: ... power of the air conditioner 2 Select the FAN mode for indoor unit operation with the remote controller 3 Set SW804 on the P C board of the outdoor unit to all OFF and then push SW801 for one second or more The air conditioner enters the forced cooling mode for up to 10 minutes Operation or handling the valve to recover refrigerant during this time period 4 Upon completion of refrigerant recovery...

Page 31: ...r connector TL CN604 White TD CN603 White TO CN602 Yellow TE CN601 White TS CN600 White Fan motor output Lower side CN300 White Fan motor output Upper side CN400 White Compressor output terminal CN202 CN201 CN200 Electrolytic condenser 4 way valve protective fuse F700 250V 3 15A Plastic case Power supply protective fuse F01 250V 25A Inter unit cable protective fuse F03 250V 25A Inter unit cable co...

Page 32: ...here is no error in the resistance value or the refrigerating cycle of each sensor after repair and then start the operation 2 Discharge temperature release control 1 When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control this control lowers the operation frequency It subdivides the frequency control up to 0 6Hz to stabilize the cycle 2 When the dis...

Page 33: ...ntly stain on filter of the suction part of the indoor unit is considered Clean the filter and then restart the operation WE tap 1 tap 20 sec Up to the maximum revolution frequency of each zone Revolution frequency hold 1 tap 20 sec Up to the minimum revolution frequency of each zone TL C 58 55 38 35 2 taps 20 sec Up to W1 Stop timer count 1 tap 20 sec Up to the maximum tap of each zone 2 taps 20 ...

Page 34: ...hort intermittent operation preventive control 1 For 3 to 10 minutes after operation start in some cases the compressor does not stop to protect the compressor even if receiving the thermostat OFF signal from indoor However it is not abnormal status The operation continuance differs according to the operation status 2 When the operation stops by the remote controller the operation does not continu...

Page 35: ...peration zone e point or lower where it returned after 2 minutes 30 seconds 4 The error count when the compressor stopped with 2 is cleared after the operation continued for 10 minutes If the error count becomes 10 without clearing the error is determined and reactivation is not performed 5 For the error display contents confirm on the check code list Abnormal stop Frequency normal down Frequency ...

Page 36: ...has started are stored in memory as TE0 and To0 respectively 4 The time of above d can be changed by exchanging jumper J805 and J806 of the outdoor control P C board Setting at shipment 150 minutes 0 10 15 39 45 55 d min TE C 2 5 10 23 A zone B zone C zone D zone A zone B zone C zone D zone Start of heating operation A zone B zone C zone D zone In normalTo In abnormalTo When status TE0 TE To0 To 3...

Page 37: ... in heating operation Does not outside low temperature operation control work in cooling operation Is not defrost operation performed 4 ON OFF operation cannot be performed from remote controller Is not the control operation performed from outside remote side Is not automatic address being set up When the power is turned on at the first time or when indoor unit address setting is changed the opera...

Page 38: ...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 39: ...ving 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 indoor m...

Page 40: ...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 Outdoor unit low pressure sy...

Page 41: ...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 42: ...d operation time Filter sign time Indoor discharge temperature 1 Unit C C C C rpm 100h 1h C Outdoor unit data Item code 60 61 62 63 65 6A 6D 70 72 73 F1 Data name Outdoor heat exchanger Coil temperature TE Outside temperature TO Compressor discharge temperature TD Compressor suction temperature TS Heat sink temperature THS Operation current 1 10 Outdoor heat exchanger Coil temperature TL Compresso...

Page 43: ...hort 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 Misconnection of outdoor heat exchanger temp sensor and suction temp sensor was detected Outdoor P C board part EEPROM error was detected When reached min Hz by current release control short ci...

Page 44: ... 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 45: ...etection 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 detected Displayed when error is de...

Page 46: ...cted 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 full open of service valve 4 Check PMV Pulse Motor Valve 5 Check broken pipe 1 Check power s...

Page 47: ...ndoor P C board Defect Replace Check outdoor P C board Defect Replace Correct wiring and inter unit cable Is setting of group address of remote controller correct Are inner wiring and inter unit cables 1 2 3 normal Are CN04 connection and wiring of terminal blocks 1 2 3 normal Does D502 Orange LED flash after power supply is turned on again YES YES YES YES NO NO NO NO Check code E04 Outdoor LED di...

Page 48: ...splay 2 z z z z z Display 1 Display 2 z z z z Display 1 Display 2 z z z z z Display 1 Display 2 z z z Display 1 Display 2 z z z z Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp sensor TD error There is a possibility that it is one of the following errors Confirm LED on outdoor P C board to judge which error it is Heat exchanger temp sensor TE e...

Page 49: ...TS sensor normal Is CN602 connection normal Is resistance value of TO sensor normal Is CN600 connection normal Is resistance value of TS sensor normal Is CN601 connection normal Is resistance value of TE sensor normal YES YES YES YES YES NO NO NO NO NO Check code F08 F12 F13 F15 F31 Outdoor LED display Display 1 Display 2 z z z z z z Display 1 Display 2 z z z z z Display 1 Display 2 z z z z Displa...

Page 50: ...eactor lead Power supply lead Is wire connection normal 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 Outdoor...

Page 51: ...service P C board Is valve fully opened Is PMV normal Is there no gas leak Is it not refrigerant shortage Are CN609 connection and case thermostat normal Is cooling heating operation available when short circuiting case thermostat YES YES YES YES YES NO NO NO NO NO Check code H04 L10 Outdoor LED display Display 1 Display 2 z z z z z z z Display 1 Display 2 z z z z z Check and troubleshooting Item ...

Page 52: ... possibility 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 MCU Heat sink temp sensor TH error Refer to F13 column EEPROM error Refer to F31 column Unset mod...

Page 53: ...ply voltage AC198 to 264V YES NO Check code P03 P04 P05 Outdoor LED display Display 1 Display 2 z z z z Display 1 Display 2 z z z z z z z Display 1 Display 2 z z z z Display 1 Display 2 z z z z Display 1 Display 2 z z z z Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp error There is a possibility that it is one of the following errors Confirm L...

Page 54: ...ge refrigerant Is there no crushed pipe Is valve fully opened Is PMV normal Is there no gas leak Is refrigerant charge amount adequate Check temp sensor TD sensor CN603 TS sensor CN600 Is not the ventilation flue of the heat sink blocked Is not the fan blocked Short circuit etc Apply radiation grease to objective part Retightening of screws Be sure not to forget to attach insulating sheet between ...

Page 55: ...z Check and troubleshooting Item without special mention Indicates part of outdoor unit 4 way valve inverse error Check method of outdoor P C board operation Self hold 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 When checking again check opera...

Page 56: ...rigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defective position Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defective position Eliminate interfering element Eliminate interfering element Heating season Heating operation Cooling season Cooling operation Is there no element which interfere heat exchange of outdoor ...

Page 57: ...P22 P26 P29 No code Outdoor LED display Display 1 Display 2 z z z Display 1 Display 2 z z z Display 1 Display 2 z z Display 1 Display 2 z z Check and troubleshooting Item without special mention Indicates part of outdoor unit Fan system error Single operation check for outdoor fan 1 Set SW804 of Dip switch as the following figure and then push SW801 for approx 1 second to check single operation of...

Page 58: ...istance value cannot be measured Temperature C 0 10 20 25 30 40 50 60 70 80 90 100 Resistance value kΩ Ω Ω Ω Ω Minimum Standard Maximum value value value 32 33 33 80 35 30 19 63 20 35 21 09 12 23 12 59 12 95 9 75 10 00 10 25 7 764 7 990 8 218 5 013 5 192 5 375 3 312 3 451 3 594 2 236 2 343 2 454 1 540 1 623 1 709 1 082 1 146 1 213 0 7740 0 8237 0 8761 0 5634 0 6023 0 6434 Temperature C 0 10 20 25 ...

Page 59: ...ng 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 indoor master and follower or between main and sub indoor twin Miswiring...

Page 60: ...compressor system error 1 Current detection circuit error Duplicated master indoor units There is indoor unit of group connection AUTO address in individual indoor unit If group construction and Unsetting of group address address are not normal Missed setting when power supply turned on Unset indoor capacity automatically goes to address setup mode Duplicated indoor central addresses Outside inter...

Page 61: ...n set once keep the present status as a rule if the unit No is not duplicated with one of another unit 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 2 3 Operation procedure Returned to usual display 2 3 1 SET TIME TIMER SET TEST FILTER RESET TEMP CL FAN SAVE SWING FIX VENT MODE ON OFF UNIT LOUVER 9 SETUP AT LOCAL SITE AND OTHERS 9 1 Calling of Error ...

Page 62: ... 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 Syst...

Page 63: ...t Add 3 taps to the upper limit value of the outdoor fan tap The operation 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 cap...

Page 64: ...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 the ou...

Page 65: ... 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 generating at present Temperature sensor display The detected value of temperature sensor is displayed Current display The current value which flows in the outdoor unit...

Page 66: ...oller may differ according to type of indoor model multiple codes are described Display 1 Initial display zzzzz zz zz z z z z Display 2 SW800 operation zzzzz zz zz z zz zz zzz z zz z z z z zzzz z zzz zzz zz zz z z z z zzz z zz zz z zz zz z z z z z z Error contents Normal Discharge temp sensor TD error Heat exchanger temp sensor TE error Heat exchanger temp sensor TL error Outside temp sensor TO er...

Page 67: ...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 68: ... 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 11 4 1 Refrigerant Recovery Control Indoor...

Page 69: ...ay RY700 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 SP1104 to RAV SP1404 the part is not mounted so do not operate Heater output relay operation For check RY703 CN7...

Page 70: ... 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 71: ...ervice data Header unit Representative unit Master Twin This unit communicates with the indoor unit follower which serial communicates with the outdoor units and sends receives signal Command from compressor to from the outdoor units as the representative of the cycle control in the indoor units of the identical line ad dress within the minimum unit which configures one of the refrigerating cycles...

Page 72: ...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 73: ...ster Header 1 1 1 2 1 1 Sub Follower 10 2 3 Automatic Address Example from Unset Address No miswiring 1 Standard One outdoor unit Only turning on source power supply Automatic completion 2 Group operation Multiple outdoor units Multiple indoor units with serial communication only without twin Only turning on source power supply Automatic completion 3 Multiple groups operation Change is necessary M...

Page 74: ...ires Outdoor side Indoor side Remote controller inter unit wiring Indoor power inter unit wiring 10 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 conre shield wire Vinyl cord for microphone 0 5 to 2 0 mm to confor...

Page 75: ...ons simultaneously for 4 seconds or more 2 Line address Using the temperature setup buttons set 12 12 12 12 12 to the item code 3 Using timer time buttons set the line address 4 Push SET button OK when display goes on 5 Indoor unit address Using the temperature setup buttons set 13 13 13 13 13 to the item code 6 Using timer time buttons set 1 to the line address 7 Push SET button OK when display g...

Page 76: ...mote controller Group control unit other unit numbers are also displayed every pushing UNIT LOUVER button left side of the 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 di...

Page 77: ...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 78: ...0 SW802 DIP switch SW803 SW804 Function Model switching Settings Settings LED indication switching Special operations for service Setting Cut these jumper wires according to the following table Set these jumper wires to the settings of the P C board before replacement Set SW802 to the setting of the P C board before replacement Set SW803 to all OFF Set SW804 to all OFF 11 REPLACEMENT OF SERVICE P ...

Page 79: ...service compressor Leakage check Vacuuming Charge the refrigerant END Turn off the circuit breaker NO Open PMV forcedly and then recover refrigerant using a refrigerant recovery unit Never recover the refrigerant to the outdoor unit For the refrigerant recovery work during reinstallation of repair work be sure to use the refrigerant recovery unit Recovery of refrigerant to the outdoor unit is unav...

Page 80: ...ctor Gas leak check Prepared newly Vacuum pump Vacuum drying Unusable Vacuum pump with backflow prevention function Vacuum drying R22 Conventional tools Flare tool Flare machining of pipes Usable if dimensions are adjusted Bender Bending pipes R22 Conventional tools Refrigerant recovery equipment Refrigerant recovery For R410A only Torque wrench Tightening flare nuts Exclusive for Ø12 7 mm and Ø15...

Page 81: ...ation free from obstacles near the air inlets and air outlet A location that is not exposed to rain or direct sunlight A location that does not increase the operating noise or vibration of the outdoor unit A location that does not produce any drainage problems from discharged water Do not install the outdoor unit in the following locations A location with a saline atmosphere coastal area or one th...

Page 82: ...two or more units Obstacle also at the above unit Obstacles in both front and rear of unit Open above and to the right and left of the unit The height of an obstacle in both the front and rear of the unit should be lower than the height of the outdoor unit Standard installation 1 Single unit installation 2 Serial installation of two or more units Serial installation in front and rear Open above an...

Page 83: ...f only the end of the fixing leg is supported it may deform Do not support the outdoor unit only with the fixing leg Foundation 15 or less Drain nipple Waterproof rubber cap Waterproof rubber cap Drain nipple Knockout hole 5 REFRIGERANT PIPING Knockout of Pipe Cover Knockout procedure The indoor outdoor connecting pipes can be connected in 4 directions Take off the knockout part of the pipe cover ...

Page 84: ...meter Thickness Ø15 9 mm 1 0 mm Outer diam of copper pipe R410A tool used Conventional tool used R410A 1 0 to 1 5 9 5 0 to 0 5 15 9 Outer dia of copper pipe A 9 5 13 2 15 9 19 7 B A 0 0 4 Tightening of Connecting Part 1 Align the centers of the connecting pipes and fully tighten the flare nut with your fingers Then fix the nut with a wrench as shown in the figure and tighten it with a torque wrenc...

Page 85: ... preserve the terrestrial environment Use a vacuum pump to discharge the air nitrogen etc that remains in the set If air remains the capacity may decrease For the vacuum pump be sure to use one with a backflow preventer so that the oil in the pump does not backflow into the pipe of the air conditioner when the pump stops If oil in the vacuum pump is put in an air conditioner including R410A it may...

Page 86: ...additional refrigerant to twin system refer to the installation manual supplied with the branching pipe sold separately The refrigerant need not be reduced for a 30 meter or less refrigerant pipe Valve unit Charge port Using a minus screwdriver turn it counterclockwise by 90 until it hits the stopper Full open Flare nut Handle position Closed completely Opened fully Main stopper Movable part of va...

Page 87: ...units H07 RN F or 60245 IEC 66 1 5 mm2 or more When connecting the connecting wire to the outdoor unit terminal prevent water from coming into the outdoor unit Insulate the unsheathed cords conductors with electrical insulation tape Process them so that they do not touch any electrical or metal parts For interconnecting wires do not use a wire joined to another on the way Use wires long enough to ...

Page 88: ... line you may experience an electric shock 9 FINISHING After the refrigerant pipe inter unit wires and drain pipe have been connected cover them with finishing tape and clamp them to the wall with off the shelf support brackets or their equivalent Keep the power wires and indoor outdoor connecting wires off the valve on the gas side or pipes that have no heat insulator 10 TEST RUN Turn on the leak...

Page 89: ...use refrigerant R22 R410A or R407C The existing pipe must have a wall thickness equal to or larger than the following thicknesses Do not use any pipe with a wall thickness less than these thicknesses due to insufficient pressure capacity Reference outside diameter mm Wall thickness mm Ø9 5 0 8 Ø15 9 1 0 Ø19 1 1 0 To use an existing Ø19 1 mm pipe set bit 3 of SW802 switch for existing pipe on the P...

Page 90: ...n and display mode 2 equals the current flashing states of LED800 to LED804 from the following table to identify the error An outside air temperature TO sensor error can be checked only while it occurs OFF ON Flashing The LEDs and DIP switches are located on the lower left of the P C board of the outdoor unit No Cause Display mode 1 Display mode 2 D800 D801 D802 D803 D804 D800 D801 D802 D803 D804 ...

Page 91: ...he existing air conditioner is removed after refrigerant has been recovered Check if the oil is judged to be clearly different from normal oil The refrigerator oil is copper rust green in color There is the possibility that moisture has mixed with the oil and rust has been generated inside the pipe There is discolored oil a large quantity of residue or a bad smell A large quantity of shiny metal d...

Page 92: ...lamp and the terminal 4 Remove the top plate Hexagonal screw Ø4 10 5 pcs 2 Attachment 1 Attach the top plate Hexagonal screw Ø4 10 5 pcs 2 Connect the power supply cable and the indoor outdoor connecting wire to the terminal and then fix them with the cord clamp XREQUIREMENTX For the power supply cable and the indoor outdoor connecting wire be sure fix them using the bundling band on the market al...

Page 93: ...base ST1T Ø4 8 2 pcs 5 Remove screw for the discharge cabinet and the heat exchanger ST1T Ø4 8 1 pc 6 Remove screws for the discharge port cabinet and the fin guard Hexagonal screw Ø4 10 2 pcs 1 Carry out work of 1 of 1 2 Remove the screws which fix the inverter assembly and the side cabinet ST1T Ø4 8 2 pcs 3 Remove the screws for the side cabinet and the valve fixing plate ST1T Ø4 8 2 pcs 4 Remov...

Page 94: ...pressor case thermo Fan motor Unlock the lock of the housing part and then remove the connectors 3 Remove the lead wires connected to the control P C board Compressor lead U CN200 Red V CN201 White W CN202 Black Reactor cord CN05 White CN06 White 4 Remove the earth wire from the control P C board NOTE Be sure not to confuse for Compressor lead V CN201 White Reactor lead CN05 and CN06 Be sure not t...

Page 95: ...re 2 Reactor 1 Carry out work of 1 of 1 2 Remove the reactor lead connected to the control P C board CN05 White CN06 White 3 Cut the bundling band which bundled the compressor lead and fan motor lead 4 Remove the reactor Trust B tight screw Ø4 6 2 pcs 5 Replace the reactor with a new one NOTE Be sure to bundle the removed bundling band with the bundling band on the market Be careful so that the fa...

Page 96: ...the inverter Remove the ferrite core of the lower fan motor because it is used 5 Remove the fan motor lead from the fan motor lead fixed rubber of the penetrated part of the partition board 6 Remove the fixing screws 4 pieces each while supporting the fan motor so that it does not fall down Cautions for assembling of fan motor Tighten the flange nut with 4 95N m 50kgf cm Adjust length of the fan m...

Page 97: ...g panel Rear and screws of the bottom plate Hexagonal screw Ø4 10 2 pcs 5 Remove the sound insulation plate Upper rolling in rolling out 6 Remove the terminal cover of the com pressor and then remove the compressor lead and the compressor case thermo 7 Remove TD sensor which is fixed to the discharge pipe 8 Remove the compressor lead Leave the ferrite core as it is attached to the electric parts b...

Page 98: ...edure for removal NOTE After replacement of the compressor be sure to replace the compressor lead Repair part code of compressor lead 43160591 In this time wrap the ferrite core with the compressor lead wire by 4 times As shown in the right figure mount the sound insulation plate rolling in rolling out by passing through it between the compressor and the piping and between the piping and the parti...

Page 99: ...n fix it 1 Detachment 1 Carry out works of item 1 of c and 1 of d REQUIREMENT To prevent scratch on the product carry out the work on cardboard cloth etc 2 Remove the discharge port cabinet and then put on it so that the fan guard side directs downward 3 Remove the screw for the bell mouth and fan guard PT2P Ø3 14 and washer 4 pcs 4 Remove the hooking claws 8 positions of the fan guard 2 Attachmen...

Page 100: ... 100 15 EXPLODED VIEWS AND PARTS LIST Outdoor Unit RAV SP1104AT E1 RAV SP1104ATJ E1 RAV SP1404AT E1 RAV SP1404ATJ E1 ...

Page 101: ... NUT COMP PANEL FRONT PIPING PANEL BACK PIPING PANEL FRONT PLATE ROOF PANEL SIDE PANEL AIR OUTLET BASE ASSY GUARD FIN SIDE GUARD FIN BACK HANGER GUARD FAN ASSY FAN PROPELLER PB521 BELL MOUTH MOTOR FAN ICF 280 A100 1 A JOINT CHECK VALVE PACKED 9 52 VALVE 4 WAY STF 0401G VALVE BALL SBV JA5GTC 1 ROHS ACCUMULATOR ASS Y ACCUMULATOR CONDENSER ASSY DOWN CONDENSER ASSY DOWN CONDENSER ASSY UP CONDENSER ASS...

Page 102: ...10 711 43050425 43F63325 43150319 43158190 43160565 43160581 43160589 43163055 43163059 43163060 4316V613 SENSOR ASSY SERVICE HOLDER SENSOR TE SENSOR ASSY SERVICE REACTOR TERMINAL BLOCK 3P 20A TERMINAL FUSE HOLDER SENSOR SPACER BUSH SPACER COLLAR PC BOARD ASSY MCC 1571 3 1 2 2 1 1 1 1 1 1 1 3 1 2 2 1 1 1 1 1 1 1 1104 AT E1 1404 AT E1 3 1 2 2 1 1 1 1 1 1 1 1104 ATJ E1 3 1 2 2 1 1 1 1 1 1 1 1404 ATJ...

Page 103: ...o that if the refrigerant accidentally leaks out its concentration does not reach the limit and in the event of an emergency measures can be made before injury can occur In a room where the concentration may exceed the limit create an opening with adjacent rooms or install mechanical ventilation combined with a gas leak detection device The concentration is as given below Total amount of refrigera...

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Toshiba RAV-SP1104AT-E1, Service Manual

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