Toshiba RAV-SP404ATP-E Service Manual Download Page 53

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FILE NO. SVM-12085

: Go on,

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T (Alter

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——

SVM-12085_051-114.indd 53

12/06/12 11:15 AM

Summary of Contents for RAV-SP404ATP-E

Page 1: ...GITAL INVERTER RAV SP404ATP E RAV SP454ATP E RAV SP564ATP E RAV SP564ATJP E RAV SP804ATP E RAV SP804ATJP E AIR CONDITIONER SPLIT TYPE FILE NO SVM 12085 SVM 12085_001 050 indd 1 SVM 12085_001 050 indd 1 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 2: ...7 6 2 Refrigerant Piping Installation 27 6 3 Tools 31 6 4 Recharging of Refrigerant 31 6 5 Brazing of Pipes 32 6 6 Instructions for Re use Piping of R22 or R407C 34 6 7 Replenishing refrigerant 37 7 OUTDOOR CONTROL CIRCUIT 38 7 1 Outdoor Controls 38 7 2 Outdoor Print Circuit Board 45 8 TROUBLESHOOTING 47 8 1 Summary of Troubleshooting 47 8 2 Troubleshooting 49 8 3 Table Inspection of outdoor unit ...

Page 3: ...ted with the knowledge related to this work s The qualified installer who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge relat...

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

Page 5: ...l 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 before the servicing CAUTION High ...

Page 6: ...ervice Manual You may receive an electric shock if the voltage stored in the capacitors has not been sufficiently discharged Place a Work in progress sign near the circuit breaker while the installation maintenance repair or removal work is being carried out There is a danger of electric shocks if the circuit breaker is set to ON by mistake When checking the electric parts removing the cover of th...

Page 7: ...When using a gas stove etc be sure to put out fire before work otherwise the oil mixed with refrigerant gas may catch fire 2 Do not use a welder in the closed room When using it without ventilation carbon monoxide poisoning may be caused 3 Do not bring inflammables close to the refrigerant cycle otherwise fire of the welder may catch the inflammables WARNING General Check earth wires Prohibition o...

Page 8: ...semble 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 a disaster such as a leak or fire is caused at user s side After the work has finished be sure to use an insulation tester set 500V Megger to check the resistance is 1MΩ or more betwee...

Page 9: ...essure inside the refrigeration cycle to an abnormally high level and possibly resulting in reputing injury etc When the service panel of the outdoor 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 ser...

Page 10: ...RAV SP404ATP E RAV SP454ATP E RAV SP564ATP E RAV SP564ATJP E RAV SP804ATP E RAV SP804ATJP E Manufacturer Nick Ball Representative TCF holder Toshiba EMEA Engineering Director Toshiba Carrier UK Ltd Porsham Close Belliver Industrial Estate PLYMOUTH Devon PL6 7DB United Kingdom Authorized Hereby declares that the machinery described below Generic Denomination Air Conditioner Model type Commercial na...

Page 11: ...ower level dBA Cooling Heating Weight kg RAV SP404ATP E RAV SP454ATP E RAV SP564ATP E RAV SP564ATJP E RAV SP804ATP E RAV SP804ATJP E 40 40 44 44 66 66 Under 70 dBA SVM 12085_001 050 indd 11 SVM 12085_001 050 indd 11 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 12: ...s 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 composition of the refrigerant change...

Page 13: ...p by attaching vacuum pump adapter 7 Screwdriver h c n e r w y e k n o M r o r e n n a p S 8 h c n e r w e u q r o T 2 l l i r d e r o c e l o H 9 r e t t u c e p i P 3 m m 4 e d i s e t i s o p p O h c n e r w n o g a x e H 0 1 r e m a e R 4 e r u s a e m e p a T 1 1 r e d n e b e p i P 5 w a s l a t e M 2 1 l a i v l e v e L 6 Also prepare the following equipments for other installation method a...

Page 14: ... 21m to 50m 40g m 31m to 50m Height difference Outdoor lower m 30 30 30 30 Outdoor higher m 30 30 30 30 Outer dimension Height mm 550 550 550 890 Width mm 780 780 780 900 Depth mm 290 290 290 320 Appearance Silky shade Muncel 1Y8 5 0 5 Total weight kg 40 40 44 63 Heat exchanger Finned tube Fan unit Fan Propeller fan Standard air flow high m3 min 40 40 40 50 Motor W 43 43 43 63 Connecting pipe Gas ...

Page 15: ...o o C Compressor speed rps 0 20 10 30 40 50 60 70 80 0 10 9 8 7 6 5 3 4 2 1 Current A Current A 0 16 14 12 8 10 6 4 2 0 20 30 10 40 50 60 70 80 90 100 110 120 Compressor speed rps s ONDITIONS Indoor DB27 C WB19 C Outdoor DB35 C Air flow High Pipe length 7 5m 230V s ONDITIONS Indoor DB20 C Outdoor DB7 C WB6 C Air flow High Pipe length 7 5m 230V RAV SM562BT CT KRT MUT E RAV SM564SDT E RAV SM562BT CT...

Page 16: ... E T R K T C T B 4 0 8 M S V A R T R K T C T B 4 0 8 M S V A R T U 4 0 8 M S V A R T U 4 0 8 M S V A R RAV SP80 ATP 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 UTDOOR TEMP C APACITY 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 UTDOOR TEMP C APACITY RATIO s ONDITIONS Indoor DB20 C NDOOR AIR FLOW IGH 0IPE LENGTH M s ONDITIONS Ind...

Page 17: ... 17 FILE NO SVM 12085 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 2 1 RAV SP40 ATP SP45 ATP SP56 ATP SVM 12085_001 050 indd 17 SVM 12085_001 050 indd 17 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 18: ... 18 FILE NO SVM 12085 2 2 RAV SP80 ATP SVM 12085_001 050 indd 18 SVM 12085_001 050 indd 18 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 19: ...r 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 SVM 12085_001 050 indd 19 SVM 12085_001 050 indd 19 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 20: ... exchanger Heating Cooling Indoor unit Refrigerant pipe at liquid 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 s Single type Combination of 1 indoor unit and 1 outdoor unit s Twin type Combination of 2 indoor units and 1 outdoor unit Indoor unit SM40 2 B...

Page 21: ...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 30 24 18 15 15 Standard Cooling Ov...

Page 22: ...ndard 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 20 19 52 45 12 7 13 66 6 37 3 78 20 53 16 78 18 34 18 Compressor d...

Page 23: ...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 TE 70 13 11 39 81 17 14 48 42 7 3 18 74 4 44 3 76 19 52 15 93 18 31 20 Compresso...

Page 24: ... 24 FILE NO SVM 12085 4 WIRING DIAGRAM 4 1 RAV SP40 ATP SP45 ATP SP56 ATP SVM 12085_001 050 indd 24 SVM 12085_001 050 indd 24 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 25: ... 25 FILE NO SVM 12085 4 2 RAV SP80 ATP SVM 12085_001 050 indd 25 SVM 12085_001 050 indd 25 12 06 12 11 06 AM 12 06 12 11 06 AM ...

Page 26: ...t 25 C 13 Compressor thermo Protection CS 12AL OFF 125 4 C ON 90 5 C RAV SP80 ATP No Parts name Type Specifications 1 Compressor DA220A2F 22L 2 Fan motor ICF 280 A60 1 Output 60 W 3 4 way valve coil STF H01AP1874A 4 PMV coil CAM MD12TCTH 6 5 P C board MCC 1571 6 Reactor CH 56 5 8 mH 18 5 A 7 Fuse Mounted on P C board AC250 V 25 A 8 Fuse Mounted on P C board AC250 V 10 A 9 Fuse Mounted on P C board...

Page 27: ...nal 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 is installed in a small room it is necessary to exercis...

Page 28: ... 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 Flare Processing Procedures and Precautions ...

Page 29: ...are 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 dimensions for R22 Nominal diameter 1 4 3 8 ...

Page 30: ...de non removable When choosing the tightening torque comply with values designated by manufacturers Table 6 2 6 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Table 6 2 6 Tightening torque of flare for R410A Reference values Nomina...

Page 31: ... 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 port of the electronic balance and charge liquid refrigerant 1 Never charge refrigerant exceeding the specified amount 2 If...

Page 32: ...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 weak in adhesive strengt...

Page 33: ...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 in the pipe interior during...

Page 34: ...l 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 only of ether series s Winding insulation of the compressor may become inferior NOT...

Page 35: ... dry Refrigerant charge Gas leak check In case that the gas pipe Ø19 mm is used for the outdoor unit of SP80 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 in the table below in order to res...

Page 36: ...se it Install a new pipe instead s The pipe has been open disconnected from indoor unit or outdoor unit for a long period s The pipe has been connected to an outdoor unit that does not use refrigerant R22 R410A or R407C s The existing pipe must have a wall thickness equal to or larger than the following thickness s Never use any pipe with a wall thickness less than these thicknesses due to insuffi...

Page 37: ...and replenish the refrigerant Restrictions for the amount of additional charging a The amount of refrigerant additionally charged shall not exceed 10 of that specified If the situation is not solved with such amount recover the refrigerant completely and charge the specified amount b In case of slow leakage upon installation and the pipe connection length of not over 15m further tighten the flare ...

Page 38: ...ause 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 control 1 When the discharge temperature did not fall or the discharge temperature r...

Page 39: ...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 SP40 to 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 seconds after start up of operation it is fixed by...

Page 40: ...ressor 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 compressor instead of a case heater It...

Page 41: ...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 compressor is controlled by AC current value detected by the outdoor P C board so that the input current of the...

Page 42: ...e 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 heating operation detects abnormal t...

Page 43: ...n 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 o T l a m r o n b a n I o T l a m r o n n I When status TE0 TE To0 To 3 C When status TE0 TE 3 C s d n o c e s 0 2 r o f d e u n i t n o c s d n o c...

Page 44: ...eration 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 Although the compressor may stop by THERMO OFF control when the room temperature va...

Page 45: ...C200 Drive IC QTY 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 connec...

Page 46: ...ctive 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 valve protective fuse F700 250V 3 15A plastic case Inter unit wire protectiv...

Page 47: ...in cooling operation s Is not defrost operation performed 4 ON OFF operation cannot be performed from remote controller s Is not the control operation performed from outside remote side s Is not automatic address being set up When the power is turned on at the first time or when indoor unit address setting is changed the operation cannot be performed for maximum approx 5 minutes after power ON s I...

Page 48: ...performed s Is not the control operation performed from outside remote side s Is not automatic address being set up s Is not being carried out a test run by operation of the outdoor controller a Did you return the cabling to the initial positions b Are connecting cables between indoor unit and receiving unit correct 2 Troubleshooting procedure When the power is turned on at the first time or when ...

Page 49: ...nit 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 master and follower or between main and sub indoor twi...

Page 50: ...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 Duplicated master indoor units There ...

Page 51: ...peration 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 SVM 12085_051 114 indd 51 SVM 12085_051 114 indd 51 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 52: ...etected 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 Misconnection of outdoor heat exchanger temp sensor and suction temp sensor was det...

Page 53: ...r 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 fan error was detected Fan thermal relay work...

Page 54: ...ed Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Judgment and measures 1 Check cables of remote controller and commu...

Page 55: ...ditioner 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 Displayed when error is detected D...

Page 56: ...cted Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected...

Page 57: ...tected 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 Check power supply voltage AC198 to 264V 1 Check outdoor heat ...

Page 58: ...ach 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 code E04 APPLICATION CONTROL...

Page 59: ...nsor 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 NO NO Check code F08 AP...

Page 60: ...nsor 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 Check Countermeasures Part without special mention indicates a part of the outdoor unit Power supply error Current de...

Page 61: ...er 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 P19 APPLICATION CONTROL KIT...

Page 62: ...check LED display on outdoor P C board Dip switch setup s 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 s When the work finished or the outdoor temp sensor TO error was found turn off all of SW803 The error which occurs at present is displayed Latest error ...

Page 63: ...play 2 Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp sensor TD error s 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 error Heat exchanger temp sensor TL error Suction temp sensor ...

Page 64: ...ction 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 Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 Check ...

Page 65: ...ad 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 Outdoor LED dis...

Page 66: ...vice 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 Display 1 Display 2 Check and troubleshooting Item without special mention Indicates part of outdoor unit...

Page 67: ...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 Refer to L10 column Heat sink overheat error Refer to P...

Page 68: ...e correct 198 to 264V NO YES Check code P03 P04 P05 Outdoor LED display Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 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 LED on outdoor P C board to judge which error it is...

Page 69: ... 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 Q300 Error OK NO YES YES YES YES...

Page 70: ...tdoor 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 s Power is turned on for approx 10 seconds s In case of operating with the coil of 4 way valve connected to CN701 take interval over 1 minute before re operation otherwise it may cause overheat of the ...

Page 71: ...ipe 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 s LOGGING OF HEAT exchanger s 3HOrt circuit Is there any...

Page 72: ...ay 2 Display 1 Display 2 Display 1 Display 2 Display 1 Display 2 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 to check which fan upper or lower fan has a tr...

Page 73: ...5 3 312 3 451 3 594 2 236 2 343 2 454 1 540 1 623 1 709 1 082 1 146 1 213 0 7740 0 8237 0 8761 0 5634 0 6023 0 6434 Temperature C 0 10 20 25 30 40 50 60 70 80 90 100 Resistance value kΩ Ω Ω Ω Ω Minimum value Standard value Maximum value 150 5 161 3 172 7 92 76 99 05 105 6 58 61 62 36 66 26 47 01 49 93 52 97 37 93 40 22 42 59 25 12 26 55 28 03 17 00 17 92 18 86 11 74 12 34 12 95 8 269 8 668 9 074 5...

Page 74: ...te Black 3 Compressor Model DA220A2F 22L Measure the resistance value of each winding by using the tester Position Resistance value Red White 0 606 Ω White Black Black Red Under 20 C Red White Black 4 Fan motor Model ICF 140 43 4R Measure the resistance value of each winding by using the tester Position Resistance value Red White 21 00 1 05 Ω White Black Black Red Under 20 C Red White Black 5 Fan ...

Page 75: ... 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 SW804 to OFF Initial status and then push the button switch SW801 for approx 1 second The cooling operation starts During this time D805 Green LED flashes This operation finishes by 10 minutes 3 A...

Page 76: ...ssure 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 operation Turn the switch to ON when using the power save function The control to lower the compressor frequency Ap...

Page 77: ...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 outdoor controller detects an error When status of SW803 is other than OFF various indicat...

Page 78: ...r 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 s If an error generates at present the same contents as those of error which is generating at present are displayed s Only error of TO sensor is not displayed by this setting Confirm it by setting of error which is generating at present Tempera...

Page 79: ...ired remote controller may differ according to type of indoor model multiple codes are described Display 1 Initial display Display 2 SW800 operation Error contents Normal Discharge temp sensor TD error Heat exchanger temp sensor TE error Heat exchanger temp sensor TL error Outside temp sensor TO error Suction temp sensor TS error Heat sink temp sensor TH error Heat exchanger sensor TE TS miswiring...

Page 80: ...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 to 19 9 20 to 20 9 21 to 21 9 22 to 22 9 23 to 23 9 24 to 24 9 25 to 25 9 26 to 26 9 27 to 27 9 28 to 28 ...

Page 81: ...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 9 1 Refrigerant Recovery Control Indoor cooling test run demand The cooling...

Page 82: ...pprox 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 CN703 check Turn on relay for optio...

Page 83: ... 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 s 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 ca...

Page 84: ...pcs 5 Remove the screw between front cabinet and motor base ST1T Ø4 8 2 pcs s EFT SIDE OF FRONT PANEL IS INSERTED INTO side cabinet left Remove by pulling the upper part 2 How to install 1 Insert front panel s hook into side cabinet left 2 Insert side cabinet left s hook into front cabinet s corner hole 3 Insert the removed screws to their positions Hook Motor base Front cabinet left side Front ca...

Page 85: ... 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 capacity it is very dangerous because a large electric spark ...

Page 86: ...ing the connector s ONNECTOR ONNECTION TO COMPRESSOR 3P Relay connector white Warning 1 Reactor 2P Relay connector white Outdoor fan 3P white Warning 1 4 directional valve 3P yellow Warning 1 PMV coil 6P white Warning 1 TD sensor 3P white TS sensor 3P white Warning 1 TE sensor 2P white Warning 1 TO sensor 2P white ASE THERMO 0 LUE Warning 1 Warning 1 Please remove housing part s lock before removi...

Page 87: ...rs 3 Remove inverter box metal plate 4 Remove control board frame from PC board base Remove while heat sink is still attached to control board frame Warning 2 Remove PC board base s hook 4 places hold heat sink pull up 5 Take off 2 screws that connect heat sink and control board frame 6 Install new control board frame Warning 3 When install new control board frame please correctly insert the board...

Page 88: ...g the fan motor and the propeller s 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 3 pcs holding by hands so that the fan motor does not fall NOTE Tighten the flange nut with torque 4 9Nm 50kgf cm Remarks 3 Take off fixed screw for ...

Page 89: ...xchanger 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 reconnecting the lead wires to the compressor terminals after replacement of the compressor be sure to caulk the Faston terminal without loosening 1 Perform works of item 1 of 1 ...

Page 90: ...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 front cabinet Push the hooking claws 10 posit...

Page 91: ... 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 that they do not com...

Page 92: ...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 screws of the side cabinet and the pipe panel Rea...

Page 93: ...s Pan S tight screw for fixing P C board Ø3 20 1 pc 6 Remove 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 t...

Page 94: ...and 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 connector Connected to lead wire White at P...

Page 95: ...o 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 band on the market CAU...

Page 96: ... then remove the compressor lead and also the compressor case thermo 8 Remove TD sensor fixed to the discharge pipe 9 Remove the compressor 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 1Nsm Remarks Compressor lead Ferrite core Compressor lead Ferrite core Control P C board Compressor lead ...

Page 97: ...nt 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 or more so handle it by 2 workers R...

Page 98: ...ensor so that it does not come to contact with the discharge pipe PMV coil lead Pass the soundproof plate inner winding through between compressor and discharge pipe suction pipe and then put it on the other side at this position No 6 Part name Compressor Compressor lead Continued Procedure 2 Mounting of compressor 1 Mount the compressor in the reverse procedure of removal NOTES After exchange of ...

Page 99: ...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 works of 1 of 1 and 3 2 While pulling...

Page 100: ...ut 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 SVM 12085_051 114 indd 100 SVM 12085_051 114 indd...

Page 101: ... 101 FILE NO SVM 12085 11 EXPLODED VIEWS AND PARTS LIST 11 1 RAV SP404ATP E SP454ATP E SVM 12085_051 114 indd 101 SVM 12085_051 114 indd 101 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 102: ...4 CONDENSER ASSEMBLY 1 1 016 43T21375 FAN MOTOR 1 1 017 43T20319 PROPELLER FAN 1 1 018 43T19329 FAN GUARD 1 1 019 43T19331 FIN GUARD 1 1 020 43T58306 REACTOR 2 2 021 43T60420 COMPRESSOR LEAD ASSEMBLY 1 1 022 43T54319 THERMOSTAT BIMETAL 1 1 023 43T50307 HOLDER THERMOSTAT 1 1 024 43T63317 HOLDER SENSOR 1 1 025 43T63323 HOLDER SENSOR 1 1 026 43T63318 HOLDER SENSOR 1 1 027 43T63319 HOLDER SENSOR 1 1 0...

Page 103: ... 103 FILE NO SVM 12085 Inverter assembly TD TS TE TO 705 708 710 704 702 701 703 711 707 712 706 SVM 12085_051 114 indd 103 SVM 12085_051 114 indd 103 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 104: ...Sensor TD 1 1 705 43T62313 Base Plate PC 1 1 706 43T60423 ASM SERV Terminal block 6P 20A 1 1 707 43T6V363 P C board Ass y SW MCC 1530 1 1 708 43T6V362 P C board Ass y MCC 5009 1 1 710 43T60425 Fuse holder 15A 250V 1 1 711 43T60426 Fuse 6 3A 250VAC 1 1 712 43T60422 Reactor CH 76 TM1 1 1 SVM 12085_051 114 indd 104 SVM 12085_051 114 indd 104 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 105: ... 105 FILE NO SVM 12085 11 2 SP564ATP E SP564ATJP E SVM 12085_051 114 indd 105 SVM 12085_051 114 indd 105 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 106: ... PACKED 6 35 DIA 1 1 018 43T43471 CONDENSER ASSEMBLY 1 019 43T43470 CONDENSER ASSEMBLY 1 020 43T21375 FAN MOTOR 1 1 021 43T20319 PROPELLER FAN 1 1 022 43T19329 FAN GUARD 1 1 023 43T19331 FIN GUARD 1 1 024 43T58306 REACTOR 2 2 025 43T60420 COMPRESSOR LEAD ASSEMBLY 1 1 026 43T54319 THERMOSTAT BIMETAL 1 1 027 43T50307 HOLDER THERMOSTAT 1 1 028 43T63317 HOLDER SENSOR 1 1 029 43T63323 HOLDER SENSOR 1 1...

Page 107: ... 107 FILE NO SVM 12085 TD TS TE TO 705 708 710 704 702 701 703 711 707 712 706 Inverter assembly SVM 12085_051 114 indd 107 SVM 12085_051 114 indd 107 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 108: ... Sensor TD 1 1 705 43T62313 Base Plate PC 1 1 706 43T60423 ASM SERV Terminal block 6P 20A 1 1 707 43T6V363 P C board Ass y SW MCC 1530 1 1 708 43T6V362 P C board Ass y MCC 5009 1 1 710 43T60425 Fuse holder 15A 250V 1 1 711 43T60426 Fuse 6 3A 250VAC 1 1 712 43T60422 Reactor CH 76 TM1 1 1 SVM 12085_051 114 indd 108 SVM 12085_051 114 indd 108 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 109: ... 109 FILE NO SVM 12085 11 3 RAV SP804ATP E SP804ATJP E SVM 12085_051 114 indd 109 SVM 12085_051 114 indd 109 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 110: ...15 88 DIA 1 1 019 43T46380 VALVE PACKED 9 52 DIA 1 1 020 43T43472 CONDENSER ASSEMBLY 1 021 43T43473 CONDENSER ASSEMBLY 1 022 43T47372 STRAINER 25 4 DIA 1 1 023 43T47373 STRAINER 12 7 DIA 1 1 024 43T21429 FAN MOTOR 1 1 025 43T20329 PROPELLER FAN 1 1 026 43T19343 FAN GUARD 1 1 027 43T22313 BELLMOUTH 1 1 028 43T19345 FIN GUARD 1 1 029 43T71302 HANDLE 2 2 030 43T60421 COMPRESSOR LEAD ASSEMBLY 1 1 031 ...

Page 111: ... 111 FILE NO SVM 12085 Inverter assembly 1 2 3 705 709 710 711 707 704 706 703 701 708 702 712 713 SVM 12085_051 114 indd 111 SVM 12085_051 114 indd 111 12 06 12 11 15 AM 12 06 12 11 15 AM ...

Page 112: ...5 43T60427 ASM SERV Terminal block 3P 20A 1 1 706 43T60424 ASM SERV Terminal block 3P 60A 1 1 707 43T60413 Fuse 10A 250V AC 1 1 708 43T63335 Holder Sensor TO 1 1 709 43T61315 Spacer Bush 1 1 710 43T61316 Spacer Collar 1 1 711 43T6V361 P C board Ass y MCC 1571 1 1 712 43T63323 Holder Sensor TS 1 1 713 43T63317 Holder Sensor TD 1 1 SVM 12085_051 114 indd 112 SVM 12085_051 114 indd 112 12 06 12 11 15...

Page 113: ...ally 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 refrigerant kg Concentration limit kg m3 Mi...

Page 114: ...ER THAILAND CO LTD 144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND SVM 12085_051 114 indd 114 SVM 12085_051 114 indd 114 12 06 12 11 15 AM 12 06 12 11 15 AM ...

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Summary of Contents for RAV-SP404ATP-E

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Toshiba RAV-SP404ATP-E, Service Manual, Page: 53 / 114

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Summary of Contents for RAV-SP404ATP-E

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