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3

Digital Inverter

Installation Manual

EN-5

EN-6

3

INSTALLATION OF NEW REFRIGERANT AIR 

CONDITIONER

CAUTION

New Refrigerant Air Conditioner Installation 
• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY 

OZONE LAYER. 

R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working 
pressure of R410A refrigerant is approx. 1.6 times as that of refrigerant R22. Accompanied with the adoption of the 
new refrigerant, the refrigerant oil has also been changed. Therefore, during installation work, be sure that water, dust, 
former refrigerant, or refrigerant oil does not enter the new type refrigerant R410A air conditioner cycle.
To prevent mixing of refrigerant or refrigerant oil, the sizes of connecting sections of charging port on main unit and 
installation tools are different from those of the conventional refrigerant units. Accordingly, special tools are required 
for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure 
fittings made for R410A only, so that water and/or dust does not enter.

„

 Required Tools/Equipment and Precautions for Use

Prepare the tools and equipment listed in the following table before starting the installation work. 
Newly prepared tools and equipment must be used exclusively. 

Legend

 : Prepared newly (Use for R410A only. Do not use for refrigerant R22 or R407C etc.) 

 : Conventional tools/equipment are available

Tools/equipment

Use

How to use tools/equipment 

Gauge manifold

Vacuuming/charging refrigerant 
and operation check

 Prepared newly for R410A only 

Charging hose

 Prepared newly for R410A only 

Charging cylinder

Can not be used

Unusable (Use the refrigerant charging measure 
instead.) 

Gas leak detector

Gas leak check

 Prepared newly 

Vacuum pump

Vacuum drying

Unusable 

Vacuum pump with backflow 
prevention function

Vacuum drying

 R22 (Conventional tools) 

„

Refrigerant Piping

New refrigerant (R410A)

When using the conventional piping

• When using the conventional piping with no indication of applicable refrigerant types, be sure to use it with a wall 

thickness of 0.8 mm for Ø12.7 mm, with a wall thickness of 1.2 mm for Ø19.1 mm, and with a wall thickness of 1.0 
mm for Ø28.6 mm (half hard). Do not use the conventional piping with a wall thickness less than these thicknesses 
due to insufficient pressure capacity. 

When using general copper pipes 

• Use general copper pipes with a wall thickness of 0.8 mm for Ø12.7 mm, with a wall thickness of 1.2 mm for Ø19.1 

mm, and with a wall thickness of 1.0 mm for Ø28.6 mm (half hard). 
Do not use any copper pipes with a wall thickness less than these thicknesses. 

Flare nuts and flare machining 

• The flare nuts and flare machining are different from those for the conventional refrigerant.

Use the flare nuts supplied with the air conditioner or those for R410A. 

• Before performing flare machining, carefully read “REFRIGERANT PIPING”.

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 Ø19.1 mm 

Pipe cutter

Cutting pipes

 R22 (Conventional tools) 

Welding machine and nitrogen 
cylinder

Welding pipes

 R22 (Conventional tools) 

Refrigerant charging measure

Charging refrigerant

 R22 (Conventional tools) 

Tools/equipment

Use

How to use tools/equipment 

Содержание RAV-SM2244AT8-A

Страница 1: ...R410A FILE NO A10 028 SERVICE MANUAL SPLIT TYPE OUTDOOR UNIT DIGITAL INVERTER RAV SM2244AT8 A RAV SM2804AT8 A PRINTED IN JAPAN Feb 2011 ToMo ...

Страница 2: ...ter 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 10 1 3 Operation Characteristic Curve 11 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 12 2 1 Outdoor Unit 12 3 OUTDOOR UNIT REFRIGERANTING CYCLE DIAGRAM 13 4 WIRING DIAGRAM 15 4 1 Outdoor Unit 15 5 SPECIFICATIONS OF ELECTRICAL PARTS 16 5 1 Outdoor Unit 16 6 REFRIGERAN...

Страница 3: ...10 1 Address Setup Procedure 70 10 2 Address Setup Group Control 71 10 3 Remote Controller Wiring 74 10 4 Address Setup Manual setting from remote controller 75 10 5 Confirmation of Indoor Unit No Position 76 11 INSTALLATION MANUAL 78 12 REPLACEMENT OF THE SERVICE P C BOARD 4316V392 MCC 1599 94 13 HOW TO EXCHANGE COMPRESSOR 95 13 1 Exchanging Procedure of Compressor Outline 95 13 2 Exchange of Com...

Страница 4: ...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 near...

Страница 5: ...ise abnormally high pressure may be generated in the refrigeration cycle which may result in a failure or explosion of the product or an injury to your body 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 refr...

Страница 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 ...

Страница 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...

Страница 8: ...ts which serve also for R22 are necessary as the general tools 1 Vacuum pump Use vacuum pump by attaching vacuum pump adapter 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 7 Screwdriver Also prepare the following equipments for other installation method and run check 1 ...

Страница 9: ...ger Fan Standard air flow at 137Pa at Mid tap m min Fan unit Fan Speed Motor W External static pressure H M L Pa 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 SM2242DT E RAV SM2802DT E RAV SM2244AT8 A RAV SM2804AT8 A 16 7 20 0 22 4 27 0 1 phase 220 240V 50Hz 5 25 4 81 5 25 4 81 1 12 1 ...

Страница 10: ...nnecting pipe Gas side mm Outdoor unit side Liquid side mm Sound pressure level Cooling Heating dB A Sound power level Cooling Heating dB A Outside air temperature Cooling C Outside air temperature Heating C 2244AT8 A 2804AT8 A 1 phase 380 415V 50Hz Power exclusive to outdoor is required Hermetic compressor 3 75 3 75 4 4 5 9 5 9 Pulse motor valve 70 70 7 5 7 5 30 30 30 30 1540 1540 900 900 320 320...

Страница 11: ...B20 C Outdoor DB7 C WB6 C Air flow High Pipe length 7 5m 400V 50Hz 3 phase SM224 SM224 SM280 SM280 SM224 SM224 SM280 SM280 SM224 SM280 SM224 SM280 Capacity variation ratio according to temperature RAV SM2244AT8 A RAV SM2804AT8 A Cooling Heating 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Outdoor temp C Capacity ratio 0 10 20 30 40 50 60 70 80 90 100 110 120 1...

Страница 12: ... 12 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 2 1 Outdoor Unit ...

Страница 13: ... cool pass TE sensor Distributor PMV 1 PMV 2 Packed valve Ø12 7 Liquid tank Ø45 420 L TL sensor TS sensor Accumulator 8500cc Ø161 6 Cooling Heating TD sensor TO sensor 4 way valve Check joint Low pressure side Solenoid valve Muffler Ø45 230 L Check valve Pressure sensor Compressor DA550A3F 11M Check joint High pressure side Pressure switch Ball valve Ø19 1 P P ...

Страница 14: ...neous twin at a target pipe length Data will change depending on the mounted pipe length or combination with the indoor unit RAV SM2804 series This compressor has a 4 pole motor The value when compressor frequency Hz is measured by a clamp meter is twice the compressor revolution number rps This data is cycle data obtained by combining a four way ceiling cassette simultaneous twin at a target pipe...

Страница 15: ... 15 4 WIRING DIAGRAM 4 1 Outdoor Unit RAV SM2244AT8 A RAV SM2804AT8 A Interface CDB P C board MCC 1599 Noise Filter P C board MCC 1600 Compressor IPDU board MCC 1596 Fan IPDU board MCC 1597 MCC 1436 ...

Страница 16: ...6 Fuse Mounted on P C board MCC 1596 Fuse Mounted on P C board MCC 1597 Fuse Mounted on P C board MCC 1597 Fuse Mounted on P C board MCC 1599 Fuse Mounted on P C board MCC 1600 Relay Posistor Compressor thermo Type DA550A3F 11M ICF 280 A100 1 STF 01AJ502E1 VPV MOAJ524C0 UKV 25D22 ACB 4UB83W CH 44 CH 68 CH 56 MCC 1596 MCC 1597 MCC 1599 MCC 1600 MCC 1436 TLC 25A GAC1 31 5A SCT 31 5A GDM 250V 15A SCT...

Страница 17: ...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 ...

Страница 18: ...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...

Страница 19: ...m 0 8 0 8 0 8 1 0 1 0 Dimension mm A B C D 9 1 9 2 6 5 13 13 0 13 5 9 7 20 16 2 16 0 12 9 20 19 4 19 0 16 0 23 23 3 24 0 19 2 34 Flare nut width mm 17 22 24 27 36 Nominal diameter 1 4 3 8 1 2 5 8 3 4 Outer diameter mm 6 4 9 5 12 7 15 9 19 1 Thickness mm 0 8 0 8 0 8 1 0 1 2 Dimension mm A B C D 9 1 9 2 6 5 13 13 2 13 5 9 7 20 16 6 16 0 12 9 23 19 7 19 0 16 0 25 24 0 19 2 28 Flare nut width mm 17 22...

Страница 20: ...rack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 6 2 6 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Table 6 2 6 Tightening torque of flare for R410A Refer...

Страница 21: ...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...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ... different compared with normal oil The refrigerator oil is copper rust green There is possibility that moisture is mixed with the oil and rust generates inside of the pipe There is discolored oil a large quantity of the remains or bad smell A large quantity of sparkle remained wear out powder is observed in the refrigerator oil 7 The air conditioner which compressor was ex changed due to a faulty...

Страница 25: ...e to flash the branching pipe Connect the indoor outdoor units to the existing pipe Use a flare nut attached to the main unit for the indoor outdoor units Do not use the flare nut of the existing pipe Re machine the flare machining size to size for R410A Airtight test Vacuum dry Refrigerant charge Gas leak check Nitrogen gas pressure 0 5 Mpa H A If there is discharge of remains it is judged that t...

Страница 26: ...welds if any on the pipe for gas leaks There may be a problem with the pressure resis tance of the branching pipes of the existing piping Replace them with branch pipes sold separately When the pipe corresponds to any of the following do not use it Install a new pipe instead The pipe has been opened disconnected from indoor unit or outdoor unit for a long period The pipe has been connected to an o...

Страница 27: ...reactor CH44 CN101 White Connector for MCC 1597 CN502 CN03 Black Terminal for power relay F02 Electric circuit protective fuse 500V 31 5A CN02 White Terminal for MCC 1600 CN17 F01 Electric circuit protective fuse 500V 31 5A CN01 Red Terminal for power relay CN04 Red Terminal for PTC thermistor CN09 Yellow CN10 Yellow Terminal for reactor CH44 CN201 Red CN202 White CN203 Black Compressor output ter...

Страница 28: ... MCC 1599 CN802 CN602 Black Connector for MCC 1600 CN51 F500 Electric circuit protective fuse 250V 15A P501 Black Lead wire for grounding CN505 Red Connector for MCC 1596 CN851 CN502 White Connector for MCC 1596 CN101 CN700 Blue Connector for MCC 1436 CN03 or CN07 CN500 Red Connector for MCC 1600 CN23 and reactor CH68 ...

Страница 29: ...Connector CN01 White Inter unit cable connector CN02 Red Connector for MCC 1600 CN10 and CN19 CN802 White Connector for MCC 1597 CN504 CN708 Blue Connector for power relay coil CN608 White Connector for MCC 1600 CN50 Temp sensor connector CN604 White TL sensor CN603 White TD sensor CN602 Yellow TO sensor CN601 White TE sensor CN600 White TS sensor Specific operation switch SW801 SW804 SW805 SW806 ...

Страница 30: ...tor protective fuse 250V 6 3A CN07 Black Power supply terminal L3 F03 Varistor protective fuse 250V 6 3A CN20 White Power supply terminal L2 CN08 Gray Neutral terminal CN10 Red Terminal for MCC 1599 CN02 and Terminal for PTC thermistor CN16 Red Terminal for power relay CN17 White Terminal for MCC 1596 CN02 CN18 Black Terminal for power relay CN19 Gray Terminal for MCC 1599 CN02 CN09 Brown Terminal...

Страница 31: ...r resulting in dramatic reduction in the durable life of the compressor In the event of malfunction and repair of the compressor restart operation after checking that there are no errors in the resistance values or the refrigerating cycle of each sensor 2 Discharge temperature release control 1 This control lowers the revolution number of the compressor in the event that the discharge temperature ...

Страница 32: ... minutes after start up by a maximum fan tap corresponding to the zones in the table below Thereafter fan control is performed using the temperature from the TE sensor 3 When TE 24 C continues for 5 minutes the compressor is stopped The compressor is placed in the same state as a normal thermostat OFF without an error display The compressor is restarted after approximately 2 minutes 30 seconds and...

Страница 33: ... continues for 20 seconds Status TEO TE 2 C continues for 20 seconds Status TE 23 C continues for 20 seconds When compressor operation status TE 2 C is calculated for d minutes A Zone D Zone B Zone C Zone Normal operation Maintain frequency of current operation Reduce operating frequency Cease reduction of operating frequency and maintain frequency of current operation l1 value A SM224 Type 15 7 S...

Страница 34: ...tinued 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 7 Heat sink temperature detection control 1 IGBT overheating prevention is protective control performed by a thermistor TH sensor in proximity to IGBT 2 When a temperature of TH 83 C is detected the fan tap is...

Страница 35: ... starting operation or when TC 26 C When Ps 0 19 MPa When 4 way valve is OFF during defrost startup When 2 minutes elapsed after four way valve is ON after defrost completion 3 4 When the DOWN zone and the HOLD zone UP prohibition are superimposed for example during current release control or discharge temperature release control DOWN zone and the HOLD zone have priority over oil recovery control ...

Страница 36: ...on of current is determined by TD and TO sensors When the TO sensor is defective a backup control is automatically performed by the TE sensor When TO sensor is defective make a determination using the LED display of the outdoor interface board 4 The power is turned off when TD is 30 C or more 100W Total power consumption of inverter and compressor NOTE While heating and electrifying the winding wi...

Страница 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...

Страница 38: ...nnot be performed from remote controller 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 proce...

Страница 39: ...eiving unit and indoor unit Receiving error Receiving unit Miswiring or wire connection error Sending error Communication stop between receiving unit and indoor unit Duplicated indoor unit No Setup error Duplicated 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...

Страница 40: ... sensor TL error Temp sensor TO error Sensor error of outdoor unit 1 Temp sensor TS error Temp sensor TH error Temp Sensor miswiring TE TS Indoor EEPROM error Outdoor EEPROM error Compressor break down Outdoor compressor system error 1 Compressor lock Current detection circuit error Power supply outdoor P C board error Case thermostat worked Compressor overheat outdoor wiring error PS pressure sen...

Страница 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 ...

Страница 42: ...0h Operation procedure 1 2 3 4 Returned to usual display 2 4 1 3 SET TIME TIMER SET TEST FILTER L L RESET TEMP CL FAN SAVE A A SWING FIX VENT MODE ON OFF UNIT LOUVER T 8 2 3 Monitor Function of Remote Controller Switch Calling of sensor temperature display Contents Each data of the remote controller indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote ...

Страница 43: ...oor 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 Misconne...

Страница 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...

Страница 45: ...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...

Страница 46: ...ed 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 discharge temp sensor TD 2 Check outdoor P C board MCC 1599 1 Check temp sensor ...

Страница 47: ...ror of compressor 4 Check 4 way valve error 5 Check outdoor P C board error 1 Check service valves are fully opened Gas side Liquid side 2 Check clogging of outdoor PMV PMV1 2 3 Check SV2 circuit 4 Check Ps sensor error 5 Check clogging of indoor filter 6 Check clogging of refrigerant pipe 7 Check of outdoor fan operation In heating mode 8 Check short of refrigerant 1 Check refrigerating cycle Gas...

Страница 48: ...ler 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 Displaye...

Страница 49: ...ard Defect Replace Check outdoor P C board MCC 1599 Defect Replace Correct wiring and inter unit cable Is setting of group address of remote controller correct Are inner wiring and inter unit cables 1 2 3 normal Are connection of CN01 of MCC 1599 and wiring of terminal blocks 1 2 3 normal Does D502 Orange LED flash after power supply is turned on again YES YES YES YES NO NO NO NO Check code E04 Ou...

Страница 50: ...l Display 1 Display 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 te...

Страница 51: ... 1599 Defect Replace Is CN602 connection normal Is resistance value of TO sensor normal YES NO Correct connector Sensor error Replace Check outdoor P C board MCC 1599 Defect Replace Is CN600 connection normal Is resistance value of TS sensor normal YES NO Check outdoor P C board MCC 1599 Defect Replace Check outdoor P C board MCC 1599 Defect Replace Correct connector Sensor error Replace Correct c...

Страница 52: ... power supply voltage normal AC342 to 457V Is wire connection normal Compressor lead Board side Compressor side Reactor lead Power supply lead YES YES YES NO NO NO Pressure by pressure gauge Check joint Pressure display on LED display Output power of I F CDB P C board If and and are different an error of the pressure sensor is considered If and are different check I F P C board Connector CN606 Whi...

Страница 53: ...essor lock Replace Check outdoor P C board Defect Replace Check TE TS sensors and PMV Defect Replace Check outdoor P C board MCC 1596 Defect Replace YES YES YES YES YES NO NO NO NO NO Check crushed or broken pipe Defect Correct and Replace Correct defective position Replace defective part Open valve fully Repair defectives position Recharge refrigerant Check outdoor P C board MCC 1599 Defect Repla...

Страница 54: ...efrigerant system connected Are gas pipe liquid pipe and service valve of the outdoor unit fully opened Are parts related to the indoor fan motor normal 1 Connection of connector 2 Capacitor 3 Motor 4 Fan Open the service valve fully Replace low pressure sensor Correct SV2 circuit Correct wiring to regular wiring Shortage of refrigerant blocking pipe breakage Repair the defective position Check in...

Страница 55: ...on error between MCU Heat sing temp sensor TH error EEPROM error Unset model type Heat sink overheat error Gas leak detection 4 way valve inverse error Communication error between MCU 1 Connection check between CN802 of MCC 1599 and CN504 of MCC 1597 and also connection check between CN505 of MCC 1597 and CN851 of MCC 1596 2 Check outdoor P C board MCC 1596 MCC 1597 MCC 1599 Defect Replace Heat si...

Страница 56: ...ak Is refrigerant charge amount adequate YES YES NO YES NO NO NO YES Connection of connectors Fan IPDU Fan motor Wiring Is circuit wiring normal Is there no fan breakage or coming off Is service valve fully opened Does cooling outdoor fan normally operate B Cooling operation B Cooling operation C Heating operation Doesn t high pressure switch operate Are parts of high pressure switch normal Reset ...

Страница 57: ...efer to P20 column Are characteristics of TC and TCJ sensor resistance value normal Are connections of connectors capacitors and fan motor normal Heating operation Does the heating indoor fan normally operate Clogging by refrigerant overcharge Pipe breakage Abnormal overload C Is there any element which blocks indoor heat exchanger Filter clogging Clogging of heat exchanger Short circuit Eliminati...

Страница 58: ... of motor drive element of outdoor P C board MCC 1596 Q201 Did not forget to apply radiation grease to rear side of Q201 Open valve fully Correct and replace piping Correct connector Sensor error Replace Check outdoor P C board MCC 1599 Defect Replace Correct defective position Replace defective part Repair defective position Recharge refrigerant Error OK YES YES YES YES NO NO NO NO Is there no cr...

Страница 59: ...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 ...

Страница 60: ... 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 SW804 of Dip switch as the following figure and then push SW801 for approx 1 second to check single operation of outdoor fan Use this method to check w...

Страница 61: ...ure 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 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...

Страница 62: ...d 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 1 Calling of Error History Contents The error contents in the past can be called Procedure 1 Push SET TEST buttons simultaneously for 4 seconds or more to call the service check mode Service Check goes on the CODE No 01 is displayed and then the content of the latest alarm is dis...

Страница 63: ...troller Remote controller operation is available Approx 50 seconds after power ON Regular communication between indoor units Every 30 seconds Master Follower Regular communication on the identical pipe every 30 seconds Twin Master Follower When the above status changes immediately communicates Repetition The unit without power feed waits entirely Waiting status is released by system start Reboot w...

Страница 64: ...by indoor heat exchanger temp in heating operation When snow enters from clearance of the fan guard or heat exchanger into blast path and it is accumulated the control to prevent generation of motor lock is validated When outside temp is below 0 C though the compressor stops the outdoor fan operates with W5 The defrost interval is cut to shorten it than the standard status For contents of control ...

Страница 65: ...03 are OFF or when any of D800 to D804 goes on LED displays that the outdoor controller detects an error When status of SW803 is other than OFF various indications are displayed Power ON display When the power of the outdoor unit is turned on LED goes on When SW801 and SW804 operate the specific operation LED flashes Part No SW800 SW803 SW801 SW804 SW802 Specifications Pushdown button switch DIP s...

Страница 66: ...test error including present After error status was cleared the error which generated before can be confirmed by this setting Reconfirmation is available even if power supply was turned off once If an error generates at present the same contents as those of error which is generating at present are displayed Only error of TO sensor is not displayed by this setting Confirm it by setting of error whi...

Страница 67: ...l l l l l Display 2 SW800 operation lllll ll ll l ll ll lll l ll l l l l l llll l lll lll ll ll l ll l ll l lll ll ll 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 error Suction temp sensor TS error Heat sink temp sensor TH error Heat exchanger sensor TE TS miswiring Ps...

Страница 68: ... 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 to 19 9 20 to 20 9 21 to 21 9 22 to 22 9 23 to ...

Страница 69: ...door unit Push SW801 again for 1 second SW804 Operation when pushdown button switch SW801 is pushed Refrigerant recovery operation The outdoor unit performs cooling operation The indoor unit does not work by this operation alone Therefore operate the fan beforehand Indoor cooling test run demand The cooling test run is performed Note 1 2 Indoor heating test run demand The heating test run is perfo...

Страница 70: ...3 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control Outside output relay operation RY704 CN704 Turn on relay for outside output RY704 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control Forced start command The indoor unit connected to the system is forcedly started The indoor unit starts operation by setting o...

Страница 71: ... 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...

Страница 72: ...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...

Страница 73: ...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...

Страница 74: ...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...

Страница 75: ...e remote controller refer to the Installation Manual enclosed with the remote controller Use 2 core shield wire MVVS 0 5 to 2 0 mm or more for the remote controller wiring in the simultaneous twin simultaneous triple and simultaneous double twin systems to prevent noise problems Be sure to connect both ends of the shield wire to earth leads Connect earth wires for each indoor unit in the simultane...

Страница 76: ...ting from remote controller 1 Push SET CL TEST buttons simultaneously for 4 seconds or more 2 Line address Using the temperature setup buttons set 12 to the CODE No 3 Using timer time buttons set the line address 4 Push SET button OK when display goes on 5 Indoor unit address Using the temperature setup buttons set 13 to the CODE No 6 Using timer time buttons set 1 to the line address 7 Push SET b...

Страница 77: ...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...

Страница 78: ...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...

Страница 79: ... diameter of Ø28 6 mm but a Ø19 1 mm flare connection is used where the valve is connected Be sure to use the Ø19 1 mm pipe and joint provided as accessories for the pipe connection Before installing the unit check that the unit has the correct model name to prevent the wrong unit from being installed in the wrong place Before proceeding to weld the refrigerant pipe be sure to pass nitrogen throug...

Страница 80: ...ts may occur due to the unit falling If refrigerant gas has leaked during the installation work ventilate the room immediately If the leaked refrigerant gas comes in contact with fire noxious gas may be generated After the installation work confirm that refrigerant gas does not leak If refrigerant gas leaks into the room and flows near a fire source such as a cooking range noxious gas may be gener...

Страница 81: ...only Charging hose Prepared newly for R410A only Charging cylinder Can not be used Unusable Use the refrigerant charging measure instead Gas leak detector Gas leak check Prepared newly Vacuum pump Vacuum drying Unusable Vacuum pump with backflow prevention function Vacuum drying R22 Conventional tools Refrigerant Piping New refrigerant R410A When using the conventional piping When using the conven...

Страница 82: ...location that is durable enough to support the weight of the outdoor unit Insufficient durability may cause the outdoor unit to fall which may result in injury This outdoor unit has a weight of about 135 kg Pay special attention when installing the unit onto a wall surface CAUTION Do not install the outdoor unit in a location that is subject to combustible gas leaks Accumulation of combustible gas...

Страница 83: ...han the height of the outdoor unit 150 or more 500 or more 500 or more 2 Serial installation of 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 installatio...

Страница 84: ... 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 t...

Страница 85: ...eter Thickness Ø12 7 mm 0 8 mm Gas side Outer diameter Thickness Ø19 1 mm 1 2 mm Ø28 6 mm 1 0 mm half hard Outer diam of copper pipe R410A tool used Conventional tool used R410A 1 0 to 1 5 12 7 0 to 0 5 19 1 Outer diam of copper pipe A 12 7 16 6 19 1 24 0 B A 0 0 4 1 Align the provided Ø19 1 mm pipe with the pipe lead out direction and shape it so that its end comes out from the outdoor unit 2 On ...

Страница 86: ...connecting pipes when installing the unit Do not discharge the refrigerant gas to the atmosphere to 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 conditione...

Страница 87: ...REMENT Be sure to use an insulating material which can withstand temperatures above 120 C for the gas side pipe since this pipe will become very hot during heating operations 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 valve Stem Stopper pin ...

Страница 88: ...provided at the installation place 2 Refer to the wiring diagrams of the models concerned for the internal wiring connections of the outdoor unit and indoor units 3 There is no need to perform the P C board settings for the indoor units Electric parts box Cord clamp Pipe hole Pipe valve fixing plate Secure the indoor outdoor connecting wires at side C Side D Space 8 5 mm Side C Space 4 mm Panel Po...

Страница 89: ... the circuit breaker at least 12 hours before starting a test run to protect the compressor during startup To protect the compressor power is supplied from the 380 415 VAC input to the unit to preheat the compressor Check the following before starting a test run That all pipes are connected securely without leaks That the valve is open If the compressor is operated with the valve closed the outdoo...

Страница 90: ...nt pressure capacity Recovering Refrigerant Use the refrigerant recovery equipment to recover the refrigerant Reference outside diameter mm Wall thickness mm Material 6 4 0 8 9 5 0 8 12 7 0 8 15 9 1 0 19 1 1 2 22 2 1 0 Half hard 28 6 1 0 Half hard 14 TROUBLESHOOTING You can perform fault diagnosis of the outdoor unit with the LEDs on the P C board of the outdoor unit in addition to using the check...

Страница 91: ...CU MCU communication error 16 Discharge temperature error 17 Abnormal power open phase detected or abnormal voltage 18 Heat sink overheat 19 Gas leak detected 20 4 way valve reverse error 21 High pressure release operation 22 Outdoor fan motor error 23 Compressor driver short circuit protection 24 Position detection circuit error in one line display OFF ON Flashing The LEDs and DIP switches are lo...

Страница 92: ...is the possibility that copper green rust has been generated 6 When the 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...

Страница 93: ...inside of the pipe Was largely discolored oil or a large quantity of remains discharged When the oil deteriorates the color of the oil changes to a muddy or black color If there is discharge of remains it is judged that a large quantity of remains are present Piping necessary to change the flare nut machining size due to pipe compression Clean the pipes or use new pipes In case of twin pipes also ...

Страница 94: ...d in multi air conditioners is 0 3 kg m3 NOTE 1 If there are 2 or more refrigerating systems in a single refrigerating device the amounts of refrigerant should be as charged in each independent device For the amount of charge in this example The possible amount of leaked refrigerant gas in rooms A B and C is 10 kg The possible amount of leaked refrigerant gas in rooms D E and F is 15 kg Total amou...

Страница 95: ...o J811 J800 to J803 J804 to J806 MCC 1599 Part name J800 to J803 Jumper wire J804 to J811 SW802 DIP switch SW803 SW804 SW805 Function Model switching Settings Settings LED indication switching Special operations for service Special operations for service Setting Cut these jumper wires according to the following table Set these jumper wires to the settings of the P C board before replacement Set SW...

Страница 96: ...ervice compressor Leakage check Vacuuming Charge the refrigerant END Turn off the leakage breaker NO Open PMV forcedly and then recover refrigerant using a refrigerant recovery unit Never recover the refrigerant to the outdoor unit For the refrigerant recovery work during reinstallation of repair work be sure to use the refrigerant recovery unit Recovery of refrigerant to the outdoor unit is unava...

Страница 97: ...or connecting wire to the terminal and then fix with the cord clamp CAUTION The power supply cable and the indoor outdoor connecting wire must be affixed along the crossover pipe using a commercially available bundling band so that they do not make contact with the compres sor gas valve gas pipe and discharge pipe 3 Attach the front panel Hexagonal screws Ø4 10 3 pcs Remarks Service panel Top plat...

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

Страница 99: ...inet and the valve fixing plate ST1T Ø4 10 2 pcs 4 Remove screw for the side cabinet and piping panel rear Hexagonal screw Ø4 10 1 pc 5 Remove screw for the side cabinet and the bottom plate Hexagonal screw Ø4 10 1 pc 6 Remove screws for the side cabinet heat exchanger and the fin guard Hexagonal screw Ø4 10 4 pcs 7 Remove the screw of the holder fixing plate and the side cabinet C type Ø4 8 1 pc ...

Страница 100: ... Blue CN602 TO sensor 2P Orange tube Black CN603 TD sensor 3P White tube Red CN604 TL sensor 2P White tube White CN606 Presure sensor 4P White CN609 Case thermo 2P Blue CN690 High poressure switch 3P Green CN700 4 way coil 2P Yellow CN702 2 way valve coil 3P White CN710 PMV coil 1 6P White CN711 PMV coil 2 6P White Fan IPDU board CN750 Outdoors fan motor 3P White Cut the banding band and remove co...

Страница 101: ...00 4 way coil 2P Yellow CN710 PMV coil 1 6P White CN711 PMV coil 2 6P White CN702 2 way coil 3P White CN606 Pressure sensor 4P White CN690 High pressure switch 3P Green CN802 Connection with Fan IPDU board 5P white CN609 Case thermo 2P Blue CN708 Magnet switch 2P Blue CN608 Connection with noise filter board 2P White CN01 Indoor Outdoor connection terminal 5P White CN02 Power relay 3P Red Remove c...

Страница 102: ...motor 3P White CN500 Connection between reactor and noise filter board 7P Red CN502 Compressor IPDU board 3P White CN602 Noise filter board 2P White CN504 Interface board 5P Blue CN505 Compressor IPDU board 5P Red Connectors should be removed after unlocking the housing section 3 Remove screw fixing the earth wire 4 Remove the claw of the support 3 positions fixing the board and the screw 5 positi...

Страница 103: ...hen slide the inverter assembly front upwardly and remove 3 Remove the lead wires connector to other components from the noise filter board CN05 Power supply terminal block red CN06 Power supply terminal block White CN07 Power supply terminal block Black CN24 Power supply terminal block White CN08 Power supply terminal block Gray CN09 Connection to earth Brown CN50 Interface board 2P White CN51 Fa...

Страница 104: ... fixing the inverter assembly IPDU and then remove the lead wire from the top clamp 4 Slide and remove the inverter assembly IPDU rotate through 90 degrees and place the base facing the front surface 5 Remove the lead wire and connector to other components from the compressor IPDU board CN01 Relay Red CN02 Noise filter board White CN03 Relay Black CN04 Posister Red CN07 Power supply terminal block...

Страница 105: ...4 Remove the connector for the fan motor from the inverter 5 Remove the fan motor lead from the fan motor lead fixing rubber member of the through section of the partitioning board 6 Remove the fixing screws 4 pieces while support ing the fan motor so that it does not fall 2 Attachment 1 Mount the fan motor 2 Mount the individual components in the opposite procedure to that during detachment Point...

Страница 106: ...Remove the terminal cover of the compressor and then remove the compressor lead and the case thermostat CAUTION Ensure that the removed wiring terminals are always insulated with insulation tape The only wiring removed is the wiring for performing exchange of the compressor The power lead connection section of the compressor is a round terminal connection 8 Remove the sensor pipe cover fixed to th...

Страница 107: ...um pump to the charge port and the high pressure check joint of the liquid pipe and the gas pipe valve and then operate the vacuum pump 2 Carry out vacuuming until the vacuum low pressure gauge indicates 1 mmHg CAUTION Before vacuuming open the pulse motor valve fully If the pulse motor valve is closed vacuuming may be impossible of the heat exchanger in the outdoor unit Forcible fully opened meth...

Страница 108: ... work on cardboard cloth etc 2 Remove the discharge port cabinet and place the fan guard side facing upwards 3 Remove the fixing screws for the fan guard Hexagonal screws Ø4 10 2 pcs 4 Remove the discharge port cabinet and then put on it so that the fan guard side faces downward 5 Remove the screws fixing the bellmouth ST1T Ø4 8 2 pcs 6 Remove bellmouth 7 Press and remove hooking claw of fan guard...

Страница 109: ... VIEWS AND PARTS LIST 15 1 Outdoor Unit RAV SM2244AT8 A RAV SM2804AT8 A 43 53 8 41 46 42 13 14 11 12 60 30 40 31 32 7 20 19 35 47 55 9 48 10 49 36 37 18 54 39 4 25 1 45 16 22 58 28 29 38 2 3 5 52 6 51 50 61 15 33 34 57 ...

Страница 110: ...Supporter Pipe DIA 19 0 34 43149320 Rubber Supporter Pipe DIA 8 0 35 43111334 Insulator Sound Up 36 43111335 Insulator Sound In 37 43111336 Insulator Sound Out 38 43100329 Cabinet Ass y Out 39 43100332 Cabinet Ass y Up 40 43100335 Cabinet Ass y Front 41 43100338 Panel Ass y Side 42 43100341 Cabinet Ass y Top 43 43150321 Sensor Ass y Low Pressure NSK BC010F 067 45 43047669 Nut Flange 46 43196113 Bu...

Страница 111: ... 111 15 2 Inverter Assembly RAV SM2244AT8 A RAV SM2804AT8 A TS TE TO TD TL 715 706 707 718 719 718 719 711 702 705 704 722 716 713 709 708 709 701 703 720 720 720 712 714 721 717 710 ...

Страница 112: ...al 4P 30A 710 43060859 Fuse Block 30A 250V FH153 PB 711 4316V390 P C Board Ass y MCC 1596 Comp IPDU 712 4316V391 P C Board Ass y MCC 1597 Fan IPDU 713 4316V392 P C Board Ass y MCC 1599 CDB 714 4316V398 P C Board Ass y MCC 1600 N F 715 43063325 Holder Sensor 6 6 35 8 716 4316V393 P C Board Ass y MCC 1436 717 43160590 Fuse 6 3A AC250V 718 43282001 Bushing 719 43183020 Collar 720 43063248 Supporter A...

Страница 113: ...the number of high concentra tion buildings however the installation of multi air condi tioner 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 c...

Страница 114: ...TOSHIBA CARRIER CORPORATION 23 17 TAKANAWA 3 CHOME MINATOKU TOKYO 108 8580 JAPAN Copyright 1999 to 2009 TOSHIBA CARRIER CORPORATION ALL Rights Reserved ...

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