FILE NO. A06-005 Revised: Jun, 2008 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE INDOOR UNIT RAV-SM402MUT-E RAV-SM452MUT-E RAV-SM562MUT-E This Service Manual describes contents of the new indoor unit. For the outdoor unit, refer to the Service Manual with FILE NO. A05-001 and A07-003.
Adoption of New Refrigerant This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer. WARNING Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have a service person do it. Do not attempt it yourself. The cleaning diagram for the air filter is there for the service person, and not for the customer. CONTENTS 1. SPECIFICATIONS ..
7. CONTROL BLOCK DIAGRAM ................................................................. 38 7-1. Indoor Control Circuit ....................................................................................... 38 7-2. Control Specifications ...................................................................................... 39 7-3. Indoor Print Circuit Board ................................................................................ 46 8. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS...........
1. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Air Discharge Cassette Type Model Indoor unit RAV- Outdoor unit RAV- SM402MUT-E SM452MUT-E SM562MUT-E SP404AT(Z, ZG)-E SP454AT(Z, ZG)-E SP562AT(Z, ZG)-E Cooling capacity (kW) 3.6 4.0 5.0 Heating capacity (kW) 4.0 4.5 5.6 Power supply 1 phase 230V (220 – 240V) 50Hz Running current Power consumption Cooling Power factor (A) 5.05 – 4.63 5.82 – 5.33 6.6 – 7.15 (kW) 1.00 1.19 1.53 (%) 90 93 97 3.60 3.36 3.
Indoor unit RAV- SM562MUT-E SM562MUT-E RAV- SM562AT-E SM563AT-E Cooling capacity (kW) 5.0 5.0 Heating capacity (kW) 5.6 5.6 Model Outdoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current Power consumption Power factor (A) 7.02 – 7.75 7.02 – 7.75 (kW) 1.61 1.61 (%) 95 95 3.11 3.11 B B 4.0 4.0 7.04 – 7.72 7.04 – 7.72 (kW) 1.61 1.61 (%) 95 95 3.48 3.48 B B 4.5 4.
Indoor unit 1 RAV- SM562MUT-E SM562MUT-E Indoor unit 2 RAV- SM562MUT-E SM562MUT-E Outdoor unit RAV- SP1102AT(Z, ZG)-E SP1104AT(Z, ZG)-E Cooling capacity (kW) 10.0 10.0 Heating capacity (kW) 11.2 11.2 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 10.31 – 11.24 12.51 – 11.47 (kW) 2.4 2.67 (%) 97 97 4.17 3.75 Energy efficiency class ∗ A A Energy rating ∗∗ — — 10.95 – 11.95 12.51 – 11.47 (kW) 2.55 2.67 (%) 97 97 4.
Indoor unit 1 RAV- SM562MUT-E SM562MUT-E Indoor unit 2 RAV- SM562MUT-E SM562MUT-E Outdoor unit RAV- SM1102AT-E SM1103AT-E Cooling capacity (kW) 10.0 10.0 Heating capacity (kW) 11.2 11.2 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 14.96 – 16.32 14.96 – 16.32 (kW) 3.52 3.52 (%) 98 98 2.84 2.84 Energy efficiency class ∗ C C Energy rating ∗∗ — — 13.35 – 14.56 13.35 – 14.56 (kW) 3.14 3.14 (%) 98 98 3.57 3.
Model Indoor unit 1 RAV-SM562MUT-E Indoor unit 2 RAV-SM562MUT-E Indoor unit 3 RAV-SM562MUT-E Outdoor unit RAV-SM1603AT-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.99 (%) 95 EER 2.81 Energy efficiency class ∗ Electrical characteristics Running current C (A) Power consumption Heating Power factor 4.69 (%) 95 3.
1-2. Outdoor Unit Model name Outdoor unit RAV-SP 562AT(Z)(ZG)-E 802AT(Z)(ZG)-E 1 phase 230V (220 – 240V) 50Hz (Power exclusive to outdoor is required.) Power supply Type Compressor Hermetic compressor Motor (kW) Pole Refrigerant charged (kg) 2 2 3.75 3.75 4 4 4 4 1.5 2.1 3.1 3.1 Refrigerant control Inter connecting pipe Pulse motor valve Standard length (m) 7.5 7.5 7.5 7.5 Max.
Model name RAV-SP404AT(Z)(ZG)-E Outdoor unit 1 phase 230V (220 – 240V) 50Hz (Power exclusive to outdoor is required.) Power supply Type Compressor Hermetic compressor Motor (kW) Pole Refrigerant charged (kg) 1.1 1.1 4 4 1.0 1.0 Refrigerant control Inter connecting pipe Pulse motor valve Standard length (m) 7.5 7.5 Max.
1-3. Operation Characteristic Curve RAV-SM562MUT-E / RAV-SM562AT-E 10 10 8 8 6 6 Current (A) Current (A) 4 • Conditions Indoor : DB27˚C/WB19˚C Outdoor : DB35˚C Air flow : High Pipe length : 7.5m 230V 2 4 • Conditions Indoor : DB20˚C Outdoor : DB7˚C/WB6˚C Air flow : High Pipe length : 7.
RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E 14 16 12 14 10 SP45 12 SP45 Current (A) Current (A) 10 8 6 8 SP40 6 SP40 4 4 • Conditions Indoor : DB27˚C/WB19˚C Outdoor : DB35˚C Air flow : High Pipe length : 7.5m 230V 2 0 0 20 40 50 60 70 80 • Conditions Indoor : DB20˚C Outdoor : DB7˚C/WB6˚C Air flow : High Pipe length : 7.
1-4. Capacity Variation Ratio According to Temperature RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E 105 120 100 110 95 100 90 Capacity ratio (%) Capacity ratio (%) 90 85 80 75 70 65 60 55 80 70 60 50 40 30 20 • Conditions Indoor : DB27˚C/WB19˚C Indoor air flow : High Pipe length : 7.5m 10 50 32 33 34 35 36 37 38 39 40 41 42 43 • Conditions Indoor : DB20˚C Indoor air flow : High Pipe length : 7.
2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Indoor Unit 595 to 660 Ceiling open dimension 1000 or more Check port ( 450) 207 175 149 Space required for installation and servicing 200 Drain-up standing-up size Indoor unit Stand-up 850 or less Stand-up 627.5 or less 1000 or more Check port ( 450) Bottom face of ceiling Note) As ABS is used for the drain discharge port of the main unit, the vinyl chlor paste cannot be used. Use the flexible hose (Band fix) included in the package.
RBC-TWP30E2, RBC-TWP50E2 (Simultaneous Twin) B Inner diameter Ø C Inner diameter Ø D Inner diameter Ø D A A B C D Liquid side 36 14 Ø9.5 Ø6.4 Gas side 43 23 Ø15.9 Ø12.7 Liquid side 34 14 Ø9.5 Ø9.5 Gas side 44 21 Ø15.9 Ø15.
RBC-TRP100E (Simultaneous Triple) Header assembly 300 80 Inner diameter Ø15.9 80 100 Inner diameter Ø25.4 100 Branch pipe assembly 35 80 80 Inner diameter Ø9.52 100 Inner diameter Ø12.7 100 Insulator Gas side socket Liquid side socket Ø15.9 Ø12.7 9 26 24 6 12 46 10 28 Ø9.5 Ø6.4 Ø15.9 Ø25.4 Ø9.5 Ø12.7 (External diameter) (External diameter) (External diameter) (External diameter) 3 pcs. 1 pc. 3 pcs. – 16 – 1 pc.
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3-1. Indoor Unit • Single type (Combination of one indoor unit and one outdoor unit) Distributor (Strainer incorporated) Indoor unit TCJ sensor Air heat exchanger TC sensor Refrigerant pipe at liquid side Outer diameter Ø6.4 To outdoor unit Refrigerant pipe at gas side Outer diameter Ø12.
3-2. Outdoor Unit RAV-SM562MUT-E / RAV-SP562AT-E Pd Packed valve Packed valve Outer dia. Ø12.7 Outer dia. Ø6.4 Modulating (PMV) (SKV-18D26) Strainer TS sensor Ps TO sensor TD sensor Strainer 4-way valve Muffler (STF-0213Z) Accumulator (1500cc) Ø25 × L210 Ø25 × L160 TE sensor Capillary Ø3×Ø2× L530 Heat exchangerØ8 1 row 30 stages FP1.3 flat fin Rotary compressor (DA220A2F-20L) Outdoor unit R410A 1.
RAV-SM562MUT-E / RAV-SM562AT-E Packed valve Packed valve Outer dia. Ø12.7 Outer dia. Ø6.4 PMV (Pulse Motor Valve) (CAM-B30YGTF-1) TS sensor TO sensor 2-step muffler Ø19 .05 × 200L TD sensor Strainer TE sensor 4-way valve (STF-0108Z) Muffler Ø19 × L160 Heat exchanger Ø8 ripple, 2 rows, 14 steps FP1.3 flat fin Distributor Rotary compressor (DA150A1F-20F) Outdoor unit R410A 1.
RAV-SM402MUT-E / RAV-SP404AT-E RAV-SM454MUT-E / RAV-SP454AT-E Packed valve Packed valve Outer dia. Ø12.7 Outer dia. Ø6.4 PMV (Pulse Motor Valve) (CAM-B30YGTF-2) TS sensor TO sensor 2-step muffler Ø19.05 × 200L TD sensor Strainer 4-way valve (STF-0108Z) TE sensor Muffler Ø19 × L160 Heat exchanger Ø8 ripple, 2 rows, 14 steps FP1.3 flat fin Distributor Rotary compressor (DA150A1F-20F) R410A 1.
4. WIRING DIAGRAM 4-1. Indoor Unit 4-1-1. Compact 4-way Cassette Type TA FS CN34 (RED) 3 3 2 2 1 1 LM1 5 4 3 2 1 LM2 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 TC Connection interface (option) 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 1 2 1 2 CN104 (YEL) CN102 (RED) CN101 (BLK) CN80 (GRN) CN73 (RED) CN70 (WHI) (EXCT) MCC-1402 5 4 3 2 1 CN33 (WHI) 5 4 3 2 1 TCJ Control P.C.
• Single type • Twin type Power supply 220-240V Single phase 50Hz Power supply 220-240V Single phase 50Hz Outdoor unit Outdoor unit L N L N 1 2 3 1 2 3 Indoor A B unit 1 2 3 1 2 3 Indoor unit No.1 (Master) A B Earth screw 1 2 3 Indoor unit No.2 (Sub) A B A B Wired remote controller A B Wired remote controller • Triple type Power supply 220-240V Single phase 50Hz Outdoor unit L N 1 2 3 1 2 3 Indoor unit No.
5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Indoor Unit No. Parts name 1 Fan motor (for indoor) 2 Thermo.
6. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer. The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant (R22).
Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A R22 1/4 6.35 0.80 0.80 3/8 9.52 0.80 0.80 1/2 12.70 0.80 0.80 5/8 15.88 1.00 1.00 2) Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.
c) Insertion of Flare Nut d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool. Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment. ØD A Fig.
Table 6-2-6 Flare and flare nut dimensions for R22 Nominal diameter Outer diameter (mm) Thickness (mm) 1/4 6.35 3/8 Dimension (mm) Flare nut width (mm) A B C D 0.8 9.0 9.2 6.5 13 17 9.52 0.8 13.0 13.5 9.7 20 22 1/2 12.70 0.8 16.2 16.0 12.9 20 24 5/8 15.88 1.0 19.4 19.0 16.0 23 27 3/4 19.05 1.0 23.3 24.0 19.2 34 36 6˚ to 4 45˚ B A C 43˚ D to 4 5˚ Fig.
6-3. Tools 6-3-1. Required Tools The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened. The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc.
6-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment. When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch. Connect the charge hose to packed valve service port at the outdoor unit’s gas side.
Be sure to make setting so that liquid can be charged. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.
2) Characteristics required for flux • Activated temperature of flux coincides with the brazing temperature. • Due to a wide effective temperature range, flux is hard to carbonize. • It is easy to remove slag after brazing. • The corrosive action to the treated metal and brazing filler is minimum. • It excels in coating performance and is harmless to the human body.
6-6. Tolerance of Pipe Length and Pipe Head n Twin system Total length (L + a or L + b) 50 m Branch pipe length (a, b) 15 m Maximum difference between indoor units (b – a, or a - b) 10 m Between indoor units ( ∆ h) 0.
n Triple system Total length (L + a, L +b, L+c) 50 m Branch pipe length (a, b, c) 15 m Maximum difference between indoor units (|a – b|, |b – c|, |c – d|) 10 m Between indoor units ( ∆ h) 0.
6-7. Additional Refrigerant Amount n Twin system Do not remove the refrigerant even if the additional refrigerant amount becomes minus result as a result of calculations by the following formula and operate the air conditioner as it is.
n Triple system Do not remove the refrigerant even if the additional refrigerant amount becomes minus result as a result of calculations by the following formula and operate the air conditioner as it is.
6-8. Piping Materials and Sizes n Twin system Use copper tube of Copper and copper alloy seamless pipes and tubes, with 40mg/10m or less in the amount of oil stuck on inner walls of pipe and 0.8mm in pipe wall thickness for diameters for diameters 6.4, 9.5 and 12.7mm and 1.0mm, for diameter 15.9mm. Never use pipes of thin wall thickness such as 0.7mm. In parentheres ( ) are wall thickness Main pipe Ø15.9 (1.0) Branch pipe Ø12.7 (0.8) Main pipe Ø9.5 (0.8) Branch pipe Ø6.4 (0.
6-9. Branch Pipe n Twin system Now the refrigerant pipe is installed using branch pipes supplied as accessories. • Bend and adjust the refrigerant piping so that the branch pipes and pipe after branching become horizontal. • Fix the branch pipes onto a wall in a ceiling or onto a column. • Provide a straight pipe longer than 500mm in length as the main piping of the branches. OK OK 500mm or more Horizontal NO GOOG Horizontal NO GOOG Inclination Inclination 6-10.
7. CONTROL BLOCK DIAGRAM 7-1. Indoor Control Circuit Main (Sub) master remote controller *1 Connection Interface is attached to master unit. (In case of group control operation) Display LCD Weekly timer LCD driver Function setup CPU *2 Weekly timer is not connectable to the sub remote controller.
7-2. Control Specifications No. 1 2 Item When power supply is reset Operation mode selection Outline of specifications 1) Distinction of outdoor units When the power supply is reset, the outdoors are distinguished, and control is exchanged according to the distinguished result. 2) Setting of speed of the indoor fan/setting whether to adjust air direction or not. Based on EEPROM data, speed of the indoor fan or setting whether to adjust air direction or not is selected.
No. 3 Item Room temperature control Outline of specifications Remarks 1) Adjustment range Remote controller setup temperature (°C) COOL/ DRY Heating operation Auto operation Wired type 18 to 29 18 to 29 18 to 29 Wireless type 18 to 30 16 to 30 17 to 27 2) Using the item code 06, the setup temperature in heating operation can be compensated. Setup data Setup temp.
No. Item 5 Air speed selection (Continued) Remarks Outline of specifications Ta (˚C) L(L) L(H) H(H) (-0.5) –1.0 (0) Tsh (+0.5) +1.0 (+1.0) +2.0 (+1.5) +3.0 E H (HH) D HH (HH) C B (+2.0) +4.0 A Value in the parentheses indicates one when thermostat of the remote controller works. Value without parentheses indicates one when thermostat of the body works. • If the air speed has been changed once, it is not changed for 1 minute.
No. 6 Item Cool air discharge preventive control Outline of specifications Remarks 1) In heating operation, the indoor fan is controlled based on the detected temperature of Tc sensor or Tcj sensor. As shown below, the Tc (˚C) Tcj upper limit of the HH 32 revolution frequency H 30 L is determined. E zone In D or E zone, the priority is given to setup of air volume exchange. In A and B zones, [PRE-HEAT] is displayed.
No. Item Outline of specifications 9 Drain pump control 1) In cooling operation (including Dry operation), the drain pump is usually operated. 2) If the float switch operates while drain pump operates, the compressor stops, the drain pump continues the operation, and a check code is output. 3) If the float switch operates while drain pump stops, the compressor stops and the drain pump operates. If the float switch keeps operating for approx. 4 minutes, a check code is output.
No. 12 Item Frequency fixed operation (Test run) Outline of specifications Remarks 1. When pushing [CHECK] button for 4 seconds or more, [TEST] is displayed on the display screen and the mode enters in Test run mode. 2. Push [ON/OFF] button. 3. Using [MODE] button, change the mode from [COOL] to [HEAT]. • Do not use other mode than [COOL]/[HEAT] mode. • During test run operation, the temperature cannot be adjusted. • An error is detected as usual.
No. 14 Item Central control mode selection Outline of specifications Remarks 1) Setting at the central controller side enables to select the contents which can be operated on the remote controller at indoor unit side. 2) RBC-AMT31E, RBC-AMT32E [Last push priority] : The operation contents can be selected from both remote controller and central controller of the indoor unit side, and the operation is performed with the contents selected at the last.
Connection interface DC fan output Indoor/Outdoor inter-unit cable Optional power supply – 46 – Remote controller power supply LED DC fan return *1 Drain pump output Float SW Fan output HA (T10) TA sensor Optional output Louver (Used only for 4-way Air Discharge Cassette Type, Under Ceiling type) TCJ sensor EXCT DISP Used for CHK servicing Remote controller inter-unit cable TC sensor 7-3. Indoor Print Circuit Board EEPROM 7-3-1.
8. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 8-1. Indoor Control Circuit 8-1-1. Outline of Main Controls 1. Pulse Motor Valve (P.M.V.) control 1) 2) 3) 4) PMV is controlled with 50 to 500 pulses during operation, respectively. In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor. In heating operation, PMV is controlled with the temperature difference between TS sensor and TE sensor.
8-1-2. Indoor P.C. Board Optional Connector Specifications Function Option output Outside error input Filter option error Connector No. CN60 CN80 CN70 CHK Operation check CN71 DISP display mode CN72 EXCT demand CN73 Pin No. Specifications Remarks 1 DC12V (COM) 2 Defrost output ON during defrost operation of outdoor unit 3 Thermo.
9. TROUBLESHOOTING 9-1. Summary of Troubleshooting 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, radio cutting pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1. Compressor does not operate.
1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, radio cutting pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1. Compressor does not operate.
9-2. Check Code List Error mode detected by indoor and outdoor units Wireless sensor lamp display Wired remote controller Operation Timer Ready Check code ¥ l l E03 ¥ : Flash, ¡ : Go on, l : Go off Diagnostic function Judgment and measures – 51 – Status of air conditioner Condition Stop (Automatic reset) Displayed when error is detected 1. Check cables of remote controller and communication adapters.
¥ : Flash, ¡ : Go on, l : Go off Wireless sensor lamp display Wired remote controller Operation Timer Ready Check code ¥ l ¥ L09 l ¥ l L29 ¥ ¡ ¥ L30 ¥ ¡ ¥ L31 No check code is displayed.
Error mode detected by remote controller Wireless sensor lamp display Operation — Timer Wired remote controller Ready Check code — No check code is displayed. (Remote controller does not operate.) — ¥ : Flash, ¡ : Go on, l : Go off Diagnostic function Status of air conditioner Cause of operation No communication with master indoor unit • Remote controller cable is not correctly connected. • Power of indoor unit is not turned on. • Automatic address cannot be completed.
9-3. Error Mode Detected by LED on Outdoor P.C. Board RAV-SP562AT-E only • When multiple errors are detected, the latest error is displayed. • When LED display is ¡ (Go on), there is the main cause of trouble on the objective part of control at CDB side and the unit stops. • When LED display is ¥ (Flash), there is the main cause of trouble on the objective part of control at IPDU side and the unit stops.
9-4. Troubleshooting Procedure for Each Check Code 9-4-1. Check Code [E01 error] NO Correct inter-unit cable of remote controller. Is inter-unit cable of A and B normal? YES Is there no disconnection or contact error of connector on harness from terminal block of indoor unit? YES Correct connection of connector. Check circuit cables. NO Check power connection of indoor unit. (Turn on power again.) NO Check indoor P.C. board (MCC-1402).
[E04 error] NO Does outdoor unit operate? YES NO Is setup of group address correct? Check item code [14]. YES NO Correct inter-unit cable. Are 1, 2, 3 inter-unit cables normal? YES Are connections from connectors of inter-terminal blocks (1, 2, 3) of indoor/outdoor units normal? NO Correct connection of connector. YES Does voltage between 2 and 3 of inter-terminal blocks (1, 2, 3) of indoor unit vary?* Check indoor P.C. board (MCC-1402).
[E10 error] Check indoor control P.C. board (MCC-1402). Defect → Replace [E18 error] NO Correct inter-unit cable of remote controller. Is inter-unit cable of A and B normal? YES Is there no disconnection or contact error of connector on harness from terminal block of indoor unit? YES Correct connection of connector. Check circuit cables. NO NO YES Is group control operation? Is power of all indoor units turned on? NO Check indoor P.C. board (MCC-1402).
[L20 error] NO Correct cable connection Are cable connections to communication line U3, U4 normal? YES YES Are not multiple same central control network addresses connected? Correct central control network address. NO Check central controller (including connection interface) indoor P.C. board. Defect → Replace. [L30 error] NO Check indoor P.C. board (MCC-1402). Defect → Replace NO Check outside devices.
[P12 error] Turn off the power. Are not there connections errors or disconnection on connectors CN333 and CN334 of indoor unit P.C. board (MCC-1402)? YES Correct connection of connector. NO Remove connectors CN333 and CN334 of indoor unit P.C. board (MCC-1402). Does the fan rotate without trouble when handling the fan with hands? NO Replace indoor fan motor.
[P22 error] Are connections of CN301 and CN300 of P.C. board correct? YES Does the fan rotate without trouble when handling the fan with hands under condition of removing CN301 and CN300 from P.C. board? CN301, ∗ CN303 NO YES The status that the resistance values between leads below are 50 to 80Ω for 40Ω motor (ICF-140-40) and 25 to 55Ω for 60Ω motor (ICF-140-60-1) is normal.
[P19 error] Is operation of 4-way valve normal? NO Is voltage applied to 4-way valve coil terminal in heating operation? YES NO NO YES Is flow of refrigerant by electron expansion valve normal? Check 4-way valve Defect → Replace YES Check and replace electron expansion valve. NO Is circuit cable normal? YES NO Are characteristics of TC sensor resistance value normal? Check and correct circuit. YES * Refer to Characteristics-2. NO Check CDB P.C. board. Replace TC sensor. YES Check CDB P.C.
[F01 error] Is connection of TCJ sensor connector (Indoor P.C. board CN102) normal? NO Correct connection of connector. YES Are characteristics of TCJ sensor resistance value normal? NO Replace TCJ sensor. ∗ Refer to Characteristics-2. YES Check indoor P.C. board (MCC-1402). Defect → Replace [P26 error] NO Improve the power supply line. Is power voltage normal? YES Are connections of cabling/connector normal? Check and correct circuit cables. Correct connection of connector.
[P29 error] NO Are connections of cable/connector normal? Check and correct circuit cabling such as cabling to compressor. YES NO Is compressor normal? YES YES Compressor error → Replace Is not earthed? NO Is not winding shorted? (Is resistance between windings 0.6 to 1.2Ω?) YES Compressor error → Replace NO YES Is not winding opened? Compressor error → Replace NO Check IPDU P.C. board. Defect → Replace ∗ For RAV-SM562AT-E, RAV-SM563AT-E, RAV-SP404AT-E, RAV-SP454AT-E, replace control P.C.
[F06 error] Are connections of TE/TS sensor connectors of CDB CN604/CN605 normal? NO Correct connection of connector. YES ∗ (For RAV-SM562AT-E, RAV-SM563AT-E, RAV-SP404AT-E, RAV-SP454AT-E, CN600 TE sensor and CN603 TS sensor) Are characteristics of TE/TS sensor resistance values normal? NO Replace TE and TS sensors. YES Check CDB. Defect → Replace ∗ Refer to Characteristics-3. [F04 error] Is connection of TD sensor connector of CDB CN600 normal? NO Correct connection of connector.
[L29 error] In the case of SUPER DIGITAL INVERTER Are connections of CDB CN800 and CDB IPDU CN06 connectors normal? NO Correct connection of connector. YES Was the error just after power ON determined? YES NO Are cabling/connector normal? Check cabling between IPDU and CDB and connector. YES NO IPDU P.C. board error Defect → Replace YES Improve and eliminate the cause. Is there no abnormal overload? NO Is IPDU P.C. board come to closely contact with heat sink? NO Correct mounting.
[P03 error] Is protective control such as discharge temprelease control normal? NO Are connections of cable/connector normal? YES NO Correct the cabling and connection of connector. YES Check parts. Defect → Replace NO Check and correct the charged refrigerant amount. Is charged refrigerant amount normal? YES YES Improve and delete the cause Is not abnormal overload? NO Are characteristics of TD sensor resistance value normal? YES NO Replace TD sensor. * Refer to Characteristics-4.
[P04 error] Is high-voltage protective operation by TE sensor normal? NO YES Is connection of cabling connector normal? NO Correct connection of cabling connector. YES Check TE sensor. Defect → Replace NO Does cooling outdoor fan normally operate? YES NO Is connection of connector normal? Correct connection of connector. YES NO Replace fan motor. Is fan motor normal? YES NO Does PMV normally operate? YES Check TE, TC, TS sensors. Replace electron expansion valve.
[C06 error] (Central controller) NO Is U3, U4 communication line normal? Correct communication line. YES Are connections between connectors CN51 of connection interface P.C. board and connectors CN51 of indoor P.C. board normal? NO Correct connection of connector. YES NO Is A, B communication line normal? Check connections of A, B terminal blocks. Correct communication line of remote controller. YES YES Correct power cable.
[E03 error] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receive a signal sent from the main remote controller (and central controller). In this case, check the communication cables of the remote controllers A and B, the central control system X and Y. As communication is disabled, [E03] is not displayed on the main remote controller and the central controller. [E01] is displayed on the main remote controller and [97 error] on the central controller, respectively.
9-4-2.
10. REPLACEMENT OF SERVICE INDOOR P.C. BOARD [Requirement when replacing the service indoor P.C. board assembly] In the non-volatile memory (Hereinafter said EEPROM, IC10) installed on the indoor P.C. board before replacement, the type and capacity code exclusive to the corresponding model have been stored at shipment from the factory and the important setup data such as system/indoor/group address set in (AUTO/MANUAL) mode or setting of high ceiling selection have been stored at installation time.
H1 Readout of the setup data from EEPROM (Data in EEPROM contents, which have been changed at the local site, are read out together with data in EEPROM set at shipment from the factory.) TEST CL SET buttons of the remote controller at the same time for 4 seconds or more. 1 1. Push , , and (Corresponded with No. in Remote controller) When group operation, the master indoor unit address is displayed at the first time. In this time, the item code (DN) is displayed.
r3 Writing of the setup contents to EEPROM (The contents of EEPROM installed on the service P.C. board have been set up at shipment from the factory.) TEST CL SET 1. Push , , and buttons of the remote controller at the same time for 4 seconds or more. 1 (Corresponded with No. in Remote controller ) In group operation control, the master indoor unit No. is displayed at the first time. (If the automatic address setup mode is interrupted in item 2. - a) - 2) in the previous page, the unit No. is displayed.
Memorandum for setup contents (Item code table (Example)) Item DN Memo At shipment 01 Filter sign lighting time According to type 02 Dirty state of filter 0000: Standard 03 Central control address 0099: Unfixed 06 Heating suction temp shift 0002: +2°C (Floor type: 0) 0F Cooling only 0000: Shared for cooling/heating 10 Type According to model type 11 Indoor unit capacity According to capacity type 12 Line address 0099: Unfixed 13 Indoor unit address 0099: Unfixed 14 Group addr
11. SETUP AT LOCAL SITE AND OTHERS 11-1. Indoor Unit 11-1-1. Test Run Setup on Remote Controller 1. When pushing TEST button on the remote controller for 4 seconds or more, “TEST” is displayed on LC display. ON / OFF button. Then push • “TEST” is displayed on LC display during operation of Test Run. • During Test Run, temperature cannot be adjusted but air volume can be selected. • In heating and cooling operation, a command to fix the Test Run frequency is output.
Procedure Description Turn on power of the air conditioner. 1 The operation is not accepted for 5 minutes when power has been turned on at first time after installation, and 1 minute when power has been turned on at the next time and after. After the specified time has passed, perform a test operation. 2 Push [Start/Stop] button and change the operation mode to [COOL] or [HEAT] with [Mode] button. Then change the fan speed to [High] using [Fan] button.
Item No. (DN) table (Selection of function) DN Item Description At shipment 01 Filter sign lighting time 0000 : None 0002 : 2500H (4-Way/Duct/Ceiling Type) 0002 for D.I. and S.D.I. models 02 Dirty state of filter 0000 : Standard 0001 : High degree of dirt (Half of standard time) 0000 : Standard 03 Central control address 0001 : No.1 unit 0099 : Unfixed 06 Heating suction temp shift 0000 : No shift 0002 : +2°C to 0064 : No.
11-1-2. Wiring and Setting of Remote Controller Control 2-remote controller control (Controlled by 2 remote controllers) This control is to operate 1 or multiple indoor units are operated by 2 remote controllers. (Max. 2 remote controllers are connectable.
11-1-3. Monitor Function of Remote Controller Switch n Calling of sensor temperature display Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. 1 2 CL TEST Push + buttons simultaneously for 4 seconds to call the service monitor mode. The service monitor goes on, the master indoor unit No. is displayed at first and then the temperature of item code 00 is displayed. TEMP.
n Calling of error history The error contents in the past can be called. 1 2 3 SET TEST Push + buttons simultaneously for 4 seconds or more to call the service check mode. Service Check goes on, the item code 01 is displayed, and then the content of the latest alarm is displayed. The number and error contents of the indoor unit in which an error occurred are displayed. TEMP.
n Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way Not normal NO 3 minutes elapse Gr construction check YES Normal ∗ Gr normal 1) There is no duplicated indoor unit address. 2) There is no invalid indoor unit address. 3) Individual unit and master/follower units are not intermingled. 4) Only a unit for individual.
11-2. Setup at Local Site / Others Model name: TCB-PCNT30TLE2 and TCB-PX30MUE 11-2-1. TCC-LINK Adapter (For TCC-LINK Central Control) 1. Function This model is an optional P.C. board to connect the indoor unit to TCC-LINK (Central controller). 2. Microprocessor Block Diagram Indoor unit Central controller TCC-LINK adapter P.C. board CN050 Indoor control P.C.
3) Install the spacers and P.C. board that are attached to TCB-PCNT30TLE2, on the Connection Interface Kit. Spacers (Attached to the TCB-PCNT30TLE2) P.C. board (Attached to the TCB-PCNT30TLE2) 4) Remove the 2P terminal block for the communication cable of the electric parts box on the unit, and then replace with the attached 4P terminal block for the communication wires. a) Disconnect the lead wires on the 2P terminal block of the electric parts box from the Faston connector on the unit.
6) Setting for Central Control For Central Control setting, refer to the Installation Manual of the TCB-PCNT30TLE2. 7) After the installation work has been completed, install the Connection Interface Kit cover to the Connection Interface Kit tightened with the two screws (4 ×10). Screw (4 ×10) Connection Interface Kit cover Hook of Connection Interface Kit Screw (4 ×10) 4.
5. Wiring Specifications • Use 2-core with no polar wire. Size No. of wires • Match the length of wire to wire length of the central Up to 1000m: twisted wire 1.25mm2 2 control system. Up to 2000m: twisted wire 2.0mm2 If mixed in the system, the wire length is lengthened with all indoor/outdoor inter-unit wire length at side. • To prevent noise trouble, use 2-core shield wire. • Connect the shield wire by closed-end connection and apply open process (insulating process) to the last terminal.
7. External view of P.C. board assembly Terminator (SW01) 52 85 8. Address setup In addition to set up the central control address, it is necessary to change the indoor unit number. (Line/Indoor/Group address). For details, refer to TCC-LINK Adapter Installation Manual. 11-3. How to Set up Central Control Address Number When connecting the indoor unit to the central control remote controller using TCC-LINK adapter, it is necessary to set up the central control address number.
12. ADDRESS SETUP 12-1. Address Setup Procedure When an outdoor unit 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.
12-2. Address Setup & Group Control Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/from the remote controllers and sub indoor units. (* It has no relation with an indoor unit which communicates serially with the outdoor units.
4. Single group operation • Each indoor unit controls the outdoor unit individually. 2-1 Sub/Header 1-1 Sub/Header 4-1 Master/Header 3-1 Sub/Header 8-1 Sub/Header 5.
12-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple 1-2 Sub/Header 1-1 Sub/Follower 1-2 Master/Header (1-2) (1-3) 1-3 Master/Follower 1-1 Sub/Follower (1-1) (1-2) (1-1) 1-1 Individual (Master/Header) Only turning on source power supply (Automatic completion) 2.
12-3. Address Setup (Manual Setting from Remote Controller) In case that addresses of the indoor units will be determined prior to piping work after cabling work • Set an indoor unit per a remote controller. • Turn on power supply. (Example of 2-lines cabling) (Real line: Cabling, Broken line: Refrigerant pipe) Outdoor Outdoor 1 2 3 1 2 3 1 2 3 1 2 3 2 3 4 5 6 7 8 SET CL TEST Indoor Indoor A B A B A B A B 1 2 2 2 1 2 2 2 2 A B Push + + buttons simultaneously for 4 seconds or more.
12-4. Confirmation of Indoor Unit No. Position 1. To know the indoor unit addresses though position of the indoor unit body is recognized • In case of individual operation (Wired remote controller : indoor unit = 1 : 1) (Follow to the procedure during operation) 1 2 ON / OFF Push button if the unit stops. UNIT LOUVER Push button. Unit No. 1-1 is displayed on LCD. (It disappears after several seconds.) The displayed unit No. indicate line address and indoor unit address.
13. DETACHMENTS 13-1. Indoor Unit Ceiling panel: RBC-UM11PG(W)E Preparing work: 1. Before work, be sure to stop the power supply of the air conditioner and turn off switch of the power supply breaker. (Otherwise an electric shock may be caused.) 2. Be sure to put on the gloves when working; otherwise an injury may be caused with parts sharp edges etc. No. Part name 1 Suction grille Procedure Remarks 1.
No. Part name 3 Adjust corner cover Procedure Remarks 1. Detachment 1) Perform work of procedure of 1 -1. 2) Turn clockwise screws (4 positions) at the suction port corner until adjust corner cover rises up. NOTE) 1 When you work, keep the torque at below 12N•m. Do not use an electric screwdriver; otherwise the mechanism of adjust corner cover may be damaged and not be removed. 2 Torque~12N·m 3) Pull downward the risen-up part of adjust corner cover and remove it.
No. Part name 5 Control P.C. board Procedure Remarks 1. Detachment 1) Perform works of procedure 1 -1- and 2 -1. 2) Remove the connectors connected from the control P.C. board to other parts.
No. 6 Part name Electric parts box Procedure Remarks 1. Detachment 1) Perform works of procedure 1 -1-and 2 -1. 2) Remove connectors of the lead wire connected to the following connectors of the control P.C. board.
No. 7 Part name Bell mouth Procedure Remarks 1. Detachment 1) Perform work of procedure 1 -1. 2) Take off the lead wires of the drain pump, float switch, and fan motor from the bell mouth. 3) Take off fixing screws of the bell mouth. (Ø4 × 10, 4 pcs.) Fixing claws for lead wires Bell mouth 2. Attachment 1) Mount the bell mouth with screws. (Ø4 × 10, 4 pcs.) 2) Perform wiring as original before being removed.
No. 9 Part name Fan motor Procedure Remarks 1. Detachment 1) Perform work of procedure 8 . 2) Take off screws fixed with lead holding bracket of the fan motor. (Ø4 × 10, 2 pcs.) 3) Open wiring holding part of the fan motor lead holding bracket and then take off the fan motor lead wire from the bracket. 4) Take off fixing nuts for the fan motor to remove the fan motor.(M 3 pcs.
No. 10 Part name Drain pan Procedure Remarks 1. Detachment 2 screws 1) Perform works of procedure 4 -1 and 7 -1. 2) Remove the drain cap and extract drain water accumulated in the drain pan. NOTE) Soc et of drain Socket drain pan When removing the drain cap, be sure to receive drain water with a bucket, etc. 3) Take off screws fixing the drain pan to remove the drain pan. (Ø4×10, 4 pcs.) Drain Drain pan 2. Attachment 1) Insert the drain cap into the drain pan.
No. 12 Part name Heat exchanger Procedure Remarks 1. Detachment 1) Recover refrigerant gas. 2) Remove the refrigerant pipe at indoor unit side. 3) Perform work of procedure 10 -1. 4) Take off screws (Ø4 × 10, 3 pcs.) fixing the piping cover to remove the piping cover. 5) While holding the heat exchanger, remove fixing band and fixing screws (Ø4 × 10, 3 pcs.) and then remove the heat exchanger. Piping cover 2.
14. EXPLODED VIEWS AND PARTS LIST 14-1. Ceiling Panel RBC-UM11PG(W)E 308 302 307 315 316 309 314 311 304 312 310 313 305 303 306 301 Location No. Part No. 301 302 303 304 305 306 307 308 43109414 4302C059 43180332 43497012 43100322 43107259 43122089 43122090 Description Location No. Part No.
14-2.
Location No. Part No.
402 401 405 404 403 Location No. Part No. 401 43160565 402 43050425 403 404 43050426 43160568 405 4316V323 Description Terminal Block, 3P, AC250V, 20A, Sensor Ass’y, Service TC (F6) Sensor, Service, TA Terminal, 2P, AC30V/DC42V, 1A P.C.
WARNINGS ON REFRIGERANT LEAKAGE Important Check of Concentration Limit The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its concentration will not exceed a set limit. The refrigerant R410A which is used in the air conditioner is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws to be imposed which protect the ozone layer.
TOSHIBA CARRIER CORPORATION 23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN Copyright © 1999 to 2007 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.