FILE NO. A08-007 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE INDOOR UNIT RAV-SM404SDT-E RAV-SM454SDT-E RAV-SM564SDT-E OUTDOOR UNIT RAV-SP404AT-E RAV-SP404ATZ-E RAV-SP404ATZG-E RAV-SP564AT-E RAV-SP564ATZ-E RAV-SP564ATZG-E RAV-SP454AT-E RAV-SP454ATZ-E RAV-SP454ATZG-E RAV-SP804AT-E RAV-SP804ATZ-E RAV-SP804ATZG-E R410A PRINTED IN JAPAN, Jan.
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 SAFETY CAUTION .....
7. REFRIGERANT R410A ............................................................................ 33 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. Safety During Installation/Servicing ............................................................... 33 Refrigerant Piping Installation ....................................................................... 33 Tools .................................................................................................................. 37 Recharging of Refrigerant....................
SAFETY CAUTION The important contents concerned to the safety are described on the product itself and on this Service Manual. Please read this Service Manual after understanding the described items thoroughly in the following contents (Indications/Illustrated marks), and keep them.
WARNING Check earth wires. Before troubleshooting or repair work, check the earth wire is connected to the earth terminals of the main unit, otherwise an electric shock is caused when a leak occurs. If the earth wire is not correctly connected, contact an electric engineer for rework. Do not modify the products. Do not also disassemble or modify the parts. It may cause a fire, electric shock or injury. Prohibition of modification. Use specified parts. Do not bring a child close to the equipment. ∗).
WARNING Insulator check Ventilation After the work has finished, be sure to use an insulation tester set (500V Megger) to check the resistance is 2MΩ or more between the charge section and the non-charge metal section (Earth position). If the resistance value is low, a disaster such as a leak or electric shock is caused at user’s side. When the refrigerant gas leaks during work, execute ventilation. If the refrigerant gas touches to a fire, poisonous gas generates.
• New Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer. 1. Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of refrigerant, the refrigerating oil has been also changed.
4. Tools 1. Required Tools for R410A Mixing of different types of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.
1. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Air Discharge Cassette Type Indoor unit RAV-SM564UT-E RAV-SM804UT-E RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Model Outdoor unit Cooling capacity (kW) 5.3 7.1 Heating capacity (kW) 5.6 8.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor 6.82 – 6.25 8.72 – 7.99 (kW) 1.47 1.86 (%) 98 97 3.61 3.82 A A 5.61 – 5.14 8.95 – 8.20 (kW) 1.21 1.91 (%) 98 97 4.63 4.
1-1-2. Concealed Duct Type Indoor unit RAV-SM562BT-E RAV-SM802BT-E RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Model Outdoor unit Cooling capacity (kW) 5.0 7.1 Heating capacity (kW) 5.6 8.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor 7.24 – 6.63 10.36 – 9.49 (kW) 1.56 2.21 (%) 98 97 3.21 3.21 A A 7.19 – 6.59 10.36 – 9.49 (kW) 1.55 2.21 (%) 98 97 3.61 3.62 A A 13.60 20.
1-1-3. Under Ceiling Type Indoor unit RAV-SM562CT-E RAV-SM802CT-E RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Model Outdoor unit Cooling capacity (kW) 5.0 7.1 Heating capacity (kW) 5.6 8.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor 7.24 – 6.63 10.36 – 9.49 (kW) 1.56 2.21 (%) 98 97 3.21 3.21 A A 6.82 – 6.25 10.12 – 9.28 (kW) 1.47 2.16 (%) 98 97 3.81 3.70 A A 13.50 20.
1-1-4. High Wall Type Indoor unit RAV-SM562KRT-E RAV-SM802KRT-E RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Model Outdoor unit Cooling capacity (kW) 5.0 6.9 Heating capacity (kW) 5.6 8.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor 7.24 – 6.63 11.25 – 10.31 (kW) 1.56 2.40 (%) 98 97 3.21 2.88 A C 7.19 – 6.59 11.25 – 10.31 (kW) 1.55 2.40 (%) 98 97 3.61 3.33 A C 13.40 20.
1-1-5. Compact 4-Way Air Discharge Cassette Type (600 × 600) Model Indoor unit RAV-SM 402MUT-E 452MUT-E 562MUT-E Outdoor unit RAV-SP 404AT(Z)(ZG)-E 454AT(Z)(ZG)-E 564AT(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 (A) Power consumption Cooling Power factor 5.05 – 4.63 5.82 – 5.33 7.24 – 6.63 (kW) 1.00 1.19 1.56 (%) 90 93 98 3.60 3.36 3.21 A A A 4.79 – 4.39 5.
Model Indoor unit 1 RAV-SM402MUT-E Indoor unit 2 RAV-SM402MUT-E Outdoor unit RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) 7.1 Heating capacity (kW) 8.0 Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 2.21 (%) 97 EER 3.21 Energy efficiency class ∗ Electrical characteristics Running current A (A) Power consumption Heating Power factor 2.16 (%) 97 3.
1-1-6. Slim Duct Type Indoor unit RAV-SM 404SDT-E 454SDT-E 564SDT-E Outdoor unit RAV-SP 404AT(Z)(ZG)-E 454AT(Z)(ZG)-E 564AT(Z)(ZG)-E Model 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 (A) Power consumption Cooling Power factor 5.20 – 4.77 5.87 – 5.38 7.24 – 6.63 (kW) 1.03 1.20 1.56 (%) 90 93 98 3.50 3.33 3.21 A A A 4.94 – 4.53 5.62 – 5.15 6.68 – 6.12 (kW) 1.00 1.
Model Indoor unit 1 RAV-SM404SDT-E Indoor unit 2 RAV-SM404SDT-E Outdoor unit RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) 7.1 Heating capacity (kW) 8.0 Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 2.21 (%) 97 EER 3.21 Energy efficiency class ∗ Electrical characteristics Running current A (A) Power consumption Heating Power factor 2.16 (%) 97 3.
1-2. Outdoor Unit Model name Outdoor unit RAV-SP 404AT(Z)(ZG)-E 454AT(Z)(ZG)-E 564AT(Z)(ZG)-E 804AT(Z)(ZG)-E 1 phase 230V (220 – 240V) 50Hz (Power exclusive to outdoor is required.) Power supply Type Hermetic compressor Compressor Motor (kW) Pole Refrigerant charged (kg) 1.1 1.1 1.1 2.0 4 4 4 4 1.0 1.0 1.4 2.1 Refrigerant control Inter connecting pipe Standard length (m) 7.5 7.5 7.5 7.5 Min. length (m) 5 5 5 5 Max.
1-3. Operation Characteristic Curve • Operation characteristic curve RAV-SP564AT-E, RAV-SP564ATZ-E, RAV-SP564ATZG-E 10 16 9 14 RAV-SM562BT, CT, KRT, MUT-E, RAV-SM564SDT-E 8 RAV-SM562BT, CT, KRT, MUT-E, RAV-SM564SDT-E 12 10 6 Current (A) Current (A) 7 5 4 8 6 RAV-SM564UT-E RAV-SM564UT-E 3 4 • Conditions Indoor : DB27˚C/WB19˚C Outdoor : DB35˚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.
2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1.
2-2. Outdoor Unit RAV-SP404AT(Z)(ZG)-E, RAV-SP454AT(Z)(ZG)-E, RAV-SP564AT(Z)(ZG)-E Drain hole (2-Ø20 × 88 long hole) Drain hole (Ø25) 600 90 A legs 54 306 Ø6 hole pitch 290 8-Ø6 hole (For fixing outdoor unit) 40, 45: 20 56: 27 320 (Long hole pitch For anchor bolt) Connecting pipe port (Liquid flare side: Ø6.4) 2-Ø11 × L14 long hole (For Ø8-Ø10 anchor bolts) 483 257 157 79 108 21 6 21 147 Connecting pipe port (Gas flare side: Ø12.7) 30 B legs 69.
Note 1 —— 2 Power supply inlet hole Drain hole (Ø25 burring hole) 60 B legs A legs 12 Mounting bolt hole (Ø12 × 17 U-shape hole) 39 600 150 Ø38 Kockout hole 40 Air outlet port 383 70 40 75 5-drain hole (Ø20 × 88 burring hole) Mounting bolt hole (Ø12 × 17 long hole) 48 54 46 Air inlet port 34 170 Air inlet port 17.5 365 74 118 128 17.5 200 Details of A legs 96 Details of B legs 900 52 550 320 – 22 – Refrigerant pipe 30 connecting port (Ø9.
RAV-TWP30E2, RAV-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.
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3-1. Indoor Unit • Single type (Combination of 1 indoor unit and 1 outdoor unit) (Indoor unit) Distributor (Strainer incorporated) TCJ sensor Strainer Air heat exchanger TC sensor Heating Cooling Refrigerant pipe at liquid side (Outer dia : ØB) Refrigerant pipe at gas side (Outer dia : ØA) To outdoor unit To outdoor unit Capillary tube specifications Model RAV-SM∗∗∗UT Dimension table Outer diameter of refrigerant pipe Inner dia.
3-2. Outdoor Unit RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E Packed valve Outer dia. ØA Packed valve Outer dia. ØB 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 Heat exchanger Ø8 ripple, 2 rows, 14 steps FP1.3 flat fin Muffler Ø19 × L160 Rotary compressor (DA150A1F-20F) Distributor R410A 1.
RAV-SP564AT-E, RAV-SP564ATZ-E, RAV-SP564ATZG-E PMV (Pulse Motor Valve) (CAM-B30YGTF-2) TO sensor TS sensor TD sensor TE sensor Muffler Ø31.75 × 200L 4-way valve (STF-0213Z) Muffler Ø19.05 × 160L Heat exchanger Ø8 ripple, 2 rows, 20 stages FP1.3, flat fin Strainer Distributor Accumulator (1L) Rotary compressor (DA150A1F-21F) Refrigerant pipe at liquid side Ø6.4 Packed valve Refrigerant pipe at gas side Ø12.
RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E TS sensor TO sensor PMV (Pulse Motor Valve) (CAM-B30YGTF-2) TL sensor Ø2 × Ø3 × 600L Accumulator Sub-ass’y TD sensor Ø2 × Ø3 × 550L Strainer Ø2 × Ø3 × 450L TE sensor 4-way valve (STF-0218G) Ø2 × Ø3 × 450L Muffler Capillary Heat exchanger Ø8, 2 rows, 34 stages FP1.45, flat fin Ø25 × L180 Accumulator (1.8L) Rotary compressor (DA220A2F-22L) Refrigerant pipe at liquid side Ø9.5 Packed valve Ø25 × L210 Refrigerant pipe at gas side Ø15.
4. FAN CHARACTERISTICS 4-1.
5. WIRING DIAGRAM 5-1. Indoor Unit 5-1-1. Slim Duct Type RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E FM DM FS 1 1 3 3 5 5 CN333 (WHI) 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CN510 (WHI) CN504 (WHI) Motor drive circuit 3 3 2 2 1 1 1 2 3 1 2 3 CN334 (WHI) CN34 (RED) CN104 (YEL) 1 1 2 2 CN102 (RED) 1 1 2 2 CN101 (BLK) 1 1 2 2 TA TCJ RED WHI BLK Fuse, F01 T6.3A, 250V~ 1 1 3 3 5 5 BLK 1 2 CN67 (BLK) ~ + ~ – Fuse, F02 T3.
49C Compressor CN300 P04 P05 P06 Q200~205 IGBT P.C. Board (MCC-5009) R221 P25 P24 P23 R220 R320 YEL R319 BRN P22 P21 R219 YEL P20 P35 F03 Fuse T3.15A AC250V C13 CN601 F01 Fuse T25A AC250V Relay 2 2 1 1 P08 Reactor P31 P30 2 1 2 1 PUR 1 1 3 3 BLK Coil for 4-WAY VALVE 1 2 3 1 2 3 : : : : : : BLACK BLUE RED GRAY PINK GREEN GRN/YEL RED Color Identification BLK BLU RED GRY PNK GRN Fuse 250V~ T6.
RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E CM Reactor Reactor (GRY) (WHI) P04 P05 1 1 2 2 3 3 CN300 (WHI) 1 1 2 2 CN609 (BLU) 1 2 3 4 5 6 CN610 (YEL) TL 1 1 2 2 CN604 (WHI) TD 1 1 2 3 3 CN603 (WHI) TO 1 1 2 2 CN602 (YEL) TE 1 1 2 2 CN601 (WHI) TS 1 1 2 3 3 CN600 (WHI) 49C (RED) U (WHI) (WHI) V (BLK) W CN200 CN201 CN202 P06 P07 4 SW804 SW801 SW800 1 ON 2 3 FM (GRY) Control P.C.
6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E No. Parts name Type Specifications SWF-280-60-3 — MDP-1401 — 1 Fan motor 2 Drain pump motor 3 Float switch 4 TA sensor Lead wire length : 328mm 10 kΩ at 25°C 5 TC sensor Ø6 size lead wire length : 1200 mm Vinyl tube (Black) 10 kΩ at 25°C 6 TCJ sensor Ø6 size lead wire length : 1200 mm Vinyl tube (Red) 10 kΩ at 25°C FS-0218-102 — 6-2.
7. 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 7-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A R22 1/4 6.4 0.80 0.80 3/8 9.5 0.80 0.80 1/2 12.7 0.80 0.80 5/8 15.9 1.00 1.00 1. 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.
6˚ to 4 45˚ B A C 43˚ D to 4 5˚ Fig. 7-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22.
7-3. Tools 7-3-1. Required Tools Refer to the “4. Tools” (Page 8) 7-4. 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.
1) Be sure to make setting so that liquid can be charged. 2) 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 7-5-3. Brazing • 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.
7-6. Instructions for Re-use Piping of R22 or R407C Instruction of Works: The existing R22 and R407C piping can be reused for our digital inverter R410A products installations. NOTE) Confirmation of existence of scratch or dent of the former pipes to be applied and also confirmation of reliability of the pipe strength are conventionally referred to the local site. If the definite conditions can be cleared, it is possible to update the existing R22 and R407C pipes to those for R410A models. 7-6-1.
7-6-5. Final Installation Checks Is there no scratch or dent on the existing pipes? Existing pipe: NO * Use a new pipes. NO Is it possible to operate the existing air conditioner? YES ∗ After the existing air conditioner operated in cooling mode for approx. 30 minutes or longer*, recover the refrigerant. ∗ For cooling the pipes and recovering of oil • Refrigerant recovery: Pump down method Nitrogen gas pressure 0.
7-6-6. Handling of Existing Pipe RAV-SP804AT-E • To use an existing Ø19.1 mm pipe, set bit 3 of SW802 (switch for existing pipe) on the P.C. board of the outdoor unit to ON. In this case, the heating performance may be reduced depending on the outside air temperature and room temperature.
8. INDOOR CONTROL CIRCUIT (Slim Duct Type) 8-1. Indoor Controller Block Diagram 8-1-1. Connection of Wired Remote Controller Wired remote controller (Max. 2 units) Display LCD Weekly timer Display LCD Function setup Display LED MCU LCD driver Key switch Function setup CN2 MCU CN1 Key switch DC5V Remote controller communication circuit Indoor unit #1 (Master) A Power circuit DC5V ∗3 Power circuit Secondary battery #2 (Follower) A B #3 (Follower) B A B Indoor control P.C.
8-1-2. Connection of Wireless Remote Controller Kit Indoor unit #1 (Master) Wireless remote controller kit Receiver P.C. board (MCC-1504) Display LED Receive circuit Function setup SW Buzzer Grille up/down SW MCU DC5V Power circuit Remote controller communication circuit A Temporary operation SW #2 (Follower) A B #3 (Follower) B A B Indoor control P.C.
8-1-3. Connection of Both Wired Remote Controller and Wireless Remote Controller Kit Indoor unit #1 (Master) Master wired remote controller (Max. 2 units) Wireless remote controller kit Receiver P.C.
8-2. Indoor Controls (Slim Duct Type) No. 1 2 Item When power supply is reset Operation mode selection 1) Distinction of outdoor unit When the power supply is reset, the outdoors are distinguished and the control is selected according to the distinguished result. 2) Setting of indoor fan speed and existence of air direction adjustment Based on EEPROM data, select setting of the indoor fan speed and the existence of air direction adjustment. STOP Control outline Air conditioner stops.
No. 3 Item Room temp. control (Continued) Outline of specifications Remarks 2) Using the Item code 06, the setup temperature in heating operation can be corrected. Setup data 0 2 4 6 Setup temp. correction +0°C +2°C +4°C +6°C Shift of suction temperature in heating operation Setting at shipment Setup data 4 Automatic capacity control (GA control) 5 Automatic cooling/heating control 2 1) Based on the difference between Ta and Ts, the operation frequency is instructed to the outdoor unit.
No. Item 6 Air speed selection Remarks Outline of specifications 1) Operation with (HH), (H), (L) or [AUTO] mode is carried out by the command from the remote controller. 2) When the air speed mode [AUTO] is selected, the air speed varies by the difference between Ta and Ts. HH > H+ > H > L+ > L > UL Ta (˚C) HH (HH) A B C H+ (HH) D +3.0 +2.5 +2.0 +1.5 +1.0 +0.5 Tsc –0.
No.
No. 7 Item Cool air discharge preventive control Outline of specifications 1) In heating operation, the indoor fan is controlled based on the detected temperature of Tc sensor or Tcj sensor. As shown below, the upper limit of the revolution frequency is restricted. However B zone is assumed as C zone for 6 minutes and after when the compressor activated. In defrost operation, the control value of Tc is shifted by 6°C.
No. Item Outline of specifications 9 High-temp. release control 1) The heating operation is performed as follows based on the detected temperature of Tc sensor or Tcj sensor. • When [M] zone is detected, the commanded frequency is decreased from the real operation frequency. After then the commanded frequency changes every 30 seconds while operation is performed in [M] zone. • In [N] zone, the commanded frequency is held.
No. Item Outline of specifications Remarks 12 HA control 1) This control is connected to TV control or remote start/ stop I/F, etc, and start/stop are available by HA signal input from the remote position. 2) This control outputs start/stop status to HA output terminal. 3) I/O specifications conform to JEMA regulations. 4) This control outputs [Operation OFF (STOP) signal] to HA output terminal while self-cleaning works.
No. Item Outline of specifications Remarks 15 Central control mode selection 1) Setting at the centerl controller side enables to select the contents which can be operated on the remote controller at indoor unit side. 2) Setup contents • 64 line central controller (TCB-SC642TLE2) [Individual]: Operated on the remote controller (Priority to second pushing) [Central 1]: ON/OFF operation cannot be operated on the remote controller. [Central 2]: ON/OFF, mode selection, temp.
No. 18 Item DC motor Outline of specifications Remarks 1) When the fan operation has started, positioning of the stator and the rotor are performed. (Moves slightly with tap sound) 2) The motor operates according to the command from the indoor controller. Notes) • When the fan rotates while the air conditioner stops due to entering of outside air, etc, the air conditioner may operate while the fan motor stops. • When a fan lock is found, the air conditioner stops, and an error is displayed.
Connector No. Humidifier output (∗) CN66 Intilation output HA Option output – 55 – Outside error input AUTO up/down grille (∗) CN32 CN61 CN60 CN80 CN20 Specifications Pin No. CN70 CHK Operation check CN71 DISP Exhibition mode CN72 EXCT Demand CN73 Humidifier output is ON when heating operation is performed, when thermostat is on, when the fan is on. ∗ The setting of Humidifier provided + Drain pump ON is performed by short-circuit of CN70 or from the remote controller.
Indoor/Outdoor inter-unit cable CN67 (Black), AC230V Serial receive LED D14 (Orange) DC fan return CN334 (White) DC fan output CN333 (White) Micro computer operation LED D501 (Red) HA (T10) CN61 (Yellow), DC12V Remote controller CN41 (Blue), DC20V High ceiling select switch SW501 Louver CN510 (White), DC12V Optional output CN60 (White), DC12 Humidifier CN66 (White), DC12V Fan drive CN32 (White), DC12V TC sensor CN101 (Black), DC5V – 56 – TA sensor CN104 (Yellow), DC5V TCJ sensor CN102 (Red), DC5V
9. OUTDOOR CONTROL CIRCUIT 9-1. Outdoor Controls 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between (SP56: 20 to 500, SP80: 30 to 500) pulsed during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming (SP56: 2 to 5K, SP80: 1 to 4K) as the target value.
3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF SP56 200 250 300 400 480 500 520 560 640 670 700 750 800 880 980 SP80 200 230 260 300 340 380 420 460 520 570 600 630 670 710 740 3-1) Cooling fan control 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).
3-2) Heating fan control TE [˚C] 24 21 18 15 The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (Control from minimum W1 to maximum (according to the following table)) For 3 minutes after the operation has started, the maximum fan tap corresponding to the zone in the following table is fixed and then the fan is controlled by temperature of TE sensor. When TE ≥ 24°C continues for 5 minutes, the compressor stops.
• Power-ON condition TD < 30˚C TE [˚C] (Normal time) 0 No power REQUIREMENT –1 Continuous power-ON Output [10W or equivalent] –6 In some cases, the sound of power-ON may be heard. It is not abnormal.
7. Current release value shift control 1) This control purposes to prevent troubles of the electronic parts such as the compressor driving elements and the compressor during cooling operation. 2) The current release control value (11) is selected from the following table according to TO sensor value. Current release control value (11) [A] Temperature range SP56 SP80 50°C ≤ TO 7.80 9.5 45°C ≤ TO < 50°C 7.80 9.5 39°C ≤ TO < 45°C 9.30 13.0 TO < 39°C 10.80 16.0 TO error 7.80 9.5 8.
10. Defrost control 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 12°C or continued 5°C £ TE < 12°C for 80 seconds. The defrost operation also finishes when it continued for 15 minutes even if TE sensor temperature was 5°C or lower. 3) After defrost operation was reset, the compressor stopped for approx. 40 seconds and then the heating operation starts.
1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 12°C or higher for 3 seconds or continued 7°C ≤ TE < 12°C for 1 minute. The defrost operation also finishes when it continued for 10 minutes even if TE sensor temperature was 7°C or lower. 3) After defrost operation was reset, the compressor stopped for approx. 40 seconds and then the heating operation starts.
1. Pulse Motor Valve (PMV) control 1) 2) 3) 4) For PMV 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. For the temperature difference in items 2) and 3), 1 to 5K is aimed as the target in both cooling and heating operations.
4. Outdoor fan control Allocations of fan tap revolutions [rpm] SP40, SP45 W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF 200 300 350 410 480 500 560 640 670 700 750 800 800 840 840 1) Cooling fan control The outdoor fan is controlled by TE, TD, and TO sensors and also revolution frequency of the operation. The outdoor is controlled by every 1 tap of DC fan control (15 taps).
2) Heating fan control The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (From Min. W1 to Max. are controlled according to the following table.) During 3 minutes after start-up, the fan is fixed with the maximum fan tap corresponding to zone in the following table. After then the fan is controlled by temperature of TE sensor. If status, TE > 24°C continues for 5 minutes, the operation stops.
6. Defrost control In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition in A zone to C zone. The defrost operation is immediately finished if TE sensor temperature has become 12°C or more, or it also is finished when condition of 5°C < TE < 12°C has continued for 80 seconds. The defrost operation is also finished when defrost operation has continued for 15 minutes even if TE sensor temperature has become 5°C or lower.
F03: 3.15A fuse DB01: Single-phase rectifier diode L-phase power supply lead (Black) N-phase power supply lead (White) Serial lead (Orange) Reactor lead connector (White) – 68 – CN701: 4-way valve connector RY701: 4-way valve relay CN300: Fan motor connector CN602: Outdoor temperature (TO) sensor connector 12V GND CN806: Optional connector CN600: Heat exchange temperature (TE) sensor connector 5V IC800: MCU CN603: Suction temperature (TS) sensor connector Comp.
RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E Fan motor output CN300 (White) Power circuit protective fuse F100 (250V, 3.
10. TROUBLESHOOTING 10-1. 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.
10-2. Troubleshooting 10-2-1. Outline of judgment The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method. Method to judge the erroneous position by flashing indication on the display part of the indoor unit (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
Lamp indication Operation Timer Ready Check code F01 F02 P10 Alternate flash Cause of trouble occurrence Heat exchanger sensor (TCJ) error Heat exchanger sensor (TC) error Heat exchanger sensor (TA) error Indoor unit sensor error F04 F06 Operation Timer Ready F07 F08 F12 Alternate flash F13 Discharge temp. sensor (TD) error Temp. sensor (TE) error Temp. sensor (TL) error Temp. sensor (TO) error Temp. sensor (TS) error Temp. sensor (TH) error Temp.
10-2-2.
10-2-3.
Check Code List (Outdoor) ALT (Alternate): Alternate flashing when there are two flashing LED Remote controller indication F04 Sensor lamp part Block indication Operation Timer Ready Flash ALT ¥ ¥ ¡ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¡ L29 ¥ P03 E01 ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ E02 ¥ F06 F08 F07 F12 F13 F15 F31 H01 H02 H03 H04 L10 – 76 – P04 P05 P07 P15 P20 P22 P26 P29 E03 E04 E08 E09 E10 E18 L03 L07 L08 L09 L30 P19 ¥ ¥ ¥ ¥ ¥ ¥ ¥ l l l l ¥ l ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¡ ¡ ¡ ¡ ¡ ¡ ¡ l l l l Representative defectiv
ALT (Alternate): Alternate flashing when there are two flashing LED Remote controller indication F01 F02 F10 F29 P01 P10 P12 P31 — Sensor lamp part Block indication Operation Timer Ready Flash ALT ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ SIM ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ l l l — l By unit with warning No. — L20 l l l l ALT — ¥ ¡ — Representative defective position Detection Indoor unit Heat exchanger sensor (TCJ) error Indoor unit Heat exchanger sensor (TC) error Indoor unit Room temp.
Error mode detected by indoor unit Operation of diagnostic function Check code Cause of operation E03 No communication from remote controller (including wireless) and communication adapter E04 The serial signal is not output from outdoor unit to indoor unit. • Miswiring of inter-unit wire • Defective serial sending circuit on outdoor P.C. board • Defective serial receiving circuit on indoor P.C.
Error mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Check code Cause of operation Status of air conditioner Judgment and measures Condition Power supply error of remote controller, Indoor EEPROM error 1. Check remote controller inter-unit wiring. 2. Check remote controller. 3. Check indoor power wiring. 4. Check indoor P.C. board. 5. Check indoor EEPROM. (including socket insertion) → Automatic address repeating phenomenon generates.
Error mode detected by outdoor unit The check code has been ramified from “4 series” and after. The ramified check code is displayed only when both the indoor unit and the outdoor unit are “4 series” and after. (Ex. Combination of RAV-SM804UT-E with RAV-SP804AT-E) When the indoor unit is 3 series and before, the conventional check code is displayed. (Ex. Combination of RAV-SM802BT-E and RAV-SP804AT-E: Outdoor unit only is “4 series”.
Operation of diagnostic function Check code Indoor unit before 3 series after 4 series P03 P03 P04 H04 Judgment and measures Cause of operation Status of air conditioner Condition Discharge temp. error ∗ Discharge temp. (TD) detected temperature over the specified temp. Stop Displayed when error is detected Case thermostat operation ∗ Abnormal overheat of compressor 1. Check refrigerating cycle (Gas leak) 2. Trouble of electronic expansion valve 3. Check discharge temp. sensor (TD). 1.
10-2-4. Diagnostic Procedure for Each Check Code (Indoor Unit) Check code [E01 error] Is inter-unit cable of A and B normal? NO Correct inter-unit cable of remote controller YES Correct connection of connector. Check circuit wiring. NO Check power connection of indoor unit. (Turn on power again.) NO Check indoor P.C. board (MCC-1570). Defect → Replace YES Correct a master unit/a follower unit.
[E04 error] NO Does outdoor operate? Is group address setup of remote controller correct? YES NO Check Item code [14]. YES Are wiring in indoor unit and 1, 2, 3 inter-unit cables correct? NO Correct wiring and inter-unit cables. NO Correct wiring of connector and terminal blocks. NO Check indoor P.C. board. Defect → Replace YES Are wirings of terminal blocks (1, 2, 3) wired to CN04 normal? YES Does D502 (Orange LED) flash after power supply turned on again? YES Check indoor P.C. board.
[E18 error] Is inter-unit cable of A and B normal? NO Correct inter-unit cable of remote controller. YES Correct connection of connector. Check circuit wiring. NO Check power connection status of indoor unit (Connect again).
[L20 error] Are wiring connections to communication lines U3 and U4 normal? NO Correct wiring connection. YES Is not the multiple same central control system addresses connected? YES Correct central control system address. NO Check central controller (including network adapter) and indoor P.C. board (MCC-1570). Defect → Replace [L30 error] Are outside devices of connector CN80 connected? NO Check indoor P.C. board (MCC-1570). Defect → Replace NO Check outside devices.
[P10 error] Is connection of float switch connector (Indoor control board CN34) normal? NO Correct connection of connector. YES NO YES Does float switch work? Is circuit wiring normal? YES NO Check and correct wiring and wire circuit. NO Does drain pump work? YES Is power of drain pump turned on? ∗ NO YES Are connector pins 1 and 2 at drain pump unit side shorted (Resistance value 0)? NO YES Replace drain pump and indoor P.C. board (MCC-1570). Check the drain pipe, etc. Check indoor P.C.
[P12 error] Turn off the power. Is there no connection error or disconnection on connectors CN333 and CN334 of indoor unit P.C. board (MCC-1570)? YES Correct connection of connector. CN333 NO Remove connectors CN333 and CN334 of indoor unit P.C. board (MCC-1570). CN334 Does the fan rotate without trouble when handling the fan with hands? NO Replace indoor fan motor. YES Are resistance values between phases at fan motor connector CN333 motor side of indoor P.C.
[F02 error] Is connection of TC sensor connector (CN101 on Indoor P.C. board) correct? NO Correct connection of connector. YES Are characteristics of TC sensor resistance value normal? YES NO Replace TC sensor. ∗ Refer to Characteristics-2. Check indoor P.C. board (MCC-1570). Defect → Replace [F01 error] Is connection of TCJ sensor connector (CN102 on Indoor P.C. board) correct? NO Correct connection of connector.
[C06 error] (TCC-LINK central controller) NO Are U3 and U4 communication lines normal? Correct communication line. YES NO ∗1 Correct connection of connector. Is connection of connector normal? YES ∗1 TCC-LINK central: CN51 of TCC-LINK adapter P.C. board (MCC-1440) and CN050 of indoor P.C. board NO Are A and B communication lines normal? Check connection of A and B terminal blocks. Correct communication line of remote controller.
[E03 error] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receive a signal from the remote controller (also central controller). Check A and B remote controllers and communication lines of the central control system U3 and U4. As communication is impossible, this check code [E03] is not displayed on the remote controller and the central controller. [E01] is displayed on the remote controller and [C06 error] is displayed on the central controller.
10-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) When “APPLICATION CONTROL KIT” (TCB-PCOS1E2) sold separately is connected, the error contents can be judged by LED on the APPLICATION CONTROL KIT. In this case, turn off both bit 1 and 2 of DIP switch 01 on the All-purpose control kit.
Check code APPLICATION CONTROL KIT LED display [F08] D01 D02 D03 D04 (Red) (Yellow) (Yellow) (Yellow) l ¡ l l Check / Countermeasures (Part without special mention indicates a part of the outdoor unit.) [Outside temp. sensor (TO) error] Is connection of CN602 correct? Is resistance value of TO sensor correct? NO Correct connector. Sensor error → Replace YES Check outdoor P.C. board.
Check code APPLICATION CONTROL KIT LED display [H03] D01 D02 D03 D04 (Red) (Yellow) (Yellow) (Yellow) ¥ l ¥ l Check / Countermeasures (Part without special mention indicates a part of the outdoor unit.) [Power supply error, Current detection circuit error] Are connections of wires correct? Between power cable and terminal block Between outdoor P.C. board and terminal block NO Correct wires YES Check outdoor P.C. board.
Check code APPLICATION CONTROL KIT LED display [P19] — Check / Countermeasures (Part without special mention indicates a part of the outdoor unit.) [4-way reversal error] NO Does 4-way valve work correctly? (Check pipe temperature, etc. during cooling/heating operation.) YES Is coil of 4-way valve electrified during heating mode? NO YES Check outdoor P.C. board. Defect → Replace Check 4-way valve.
10-2-6. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board to narrow the contents to be confirmed. 3) The check code on the remote controller is displayed only when the same error occurred continuously by multiple times while LED of the outdoor P.C.
Check code Outdoor LED display [F04] ¡ ¡ l l ¡ ¡ l l ¥ l l [Discharge temp. sensor (TD) error] Is connection of CN603 correct? Is resistance value of TD sensor correct? NO Correct connector. Sensor error → Replace YES ¡ [F06] Check outdoor P.C. board. Defect → Replace • 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.
Check code Outdoor LED display [F08] ¡ ¡ l l ¡ ¡ l l l ¥ l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Outside temp. sensor (TO) error] Is connection of CN602 correct? Is resistance value of TO sensor correct? NO Correct connector. Sensor error → Replace NO Correct connector. Sensor error → Replace YES ¡ Check outdoor P.C. board.
Check code Outdoor LED display [H01] l l ¡ l ¡ ¡ ¥ l l l l ¡ Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Compressor break down] Is AC mains voltage correct? AC198 to 264V NO Correct power supply line. YES Is wire connection correct? Compressor lead (Board side, Compressor side), Reactor lead, Power supply lead NO Check wire connection and correct it. YES Remove and improve the cause of overload.
Check code Outdoor LED display [H04] l l ¡ l ¡ ¡ l l ¥ l l ¡ Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Case thermostat operation] Are CN609 connection and case thermostat correct? NO Correct connector. Case thermostat error → Replace NO Check outdoor P.C. board. Defect → Replace YES Repair defectives position. Recharge refrigerant. YES Short each pins of CN609.
Check code Outdoor LED display Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) ∗ 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. Communication error between MCU, Heat sing temp.
Check code Outdoor LED display [P03] ¡ ¡ ¡ l ¡ ¡ ¥ ¥ l l l ¡ Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Discharge temp. error] Is there gas leak? Is there refrigerant shortage? YES Repair defective position. Recharge refrigerant. NO Repair defective position. Replace defective part. YES Remove and improve the cause of overload. NO Correct connector.
Check code Outdoor LED display [P07] ¡ ¡ ¡ ¥ ¥ ¥ ¡ ¡ ¡ l l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Heat sink overheat error] Are the power devices on P.C. board screwed without looseness? (Rear sides of Q201, Q300, Q650, DB01, DB02) Are radiation grease properly applied? (Q201, Q650, DB01, DB02) NO YES Apply radiation grease to objective parts. Retightening of screws.
¡ ¡ ¡ ¥ ¥ ¡ ¡ ¥ ¡ l l Does 4-way valve work correctly? (Check pipe temp. etc. in cooling/heating operation.) Temperature sensor check TE sensor CN601 TS sensor CN600 Indoor TC sensor Defect → Correct and repair YES NO Is the coil resistance value of 4-way valve between 1.3kΩ and 1.6 kΩ? NO Replace coil of 4-way valve. YES Check operation of outdoor P.C. board. (See below.) Error Check outdoor P.C. board. Defect → replace OK Check 4-way valve.
Check code Outdoor LED display [P20] l l ¡ ¡ ¡ ¥ ¡ ¡ ¥ ¡ l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [High pressure protective operation] NO Is service valve fully opened? Open service valve fully. YES Reset the power supply and then perform test run matching to the season.
Check code Outdoor LED display [P22] l ¡ ¡ ¡ ¥ ¥ ¡ ¡ ¥ ¡ l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Fan system error] NO Is AC mains voltage correct? (198 to 264V) Check wiring construction. Ask repair of power supply. YES Rotate shaft of the fan motor by hands during power-OFF.
10-2-7. Diagnostic Procedure for Each Check Code (Outdoor Unit) Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Ω) Resistance value (kΩ Temperature (°C) (Minimum value) (Standard value) (Maximum value) Ω) Resistance value (kΩ Temperature (°C) (Minimum value) (Standard value) (Maximum value) 0 32.33 33.80 35.30 0 10 19.63 20.35 21.09 10 150.5 92.76 161.3 99.05 172.7 20 12.
11. REPLACEMENT OF SERVICE P.C. BOARD 11-1. Indoort Unit (Slim Duct Type) The nonvolatile memory (hereafter called EEPROM, IC503) on the indoor unit P.C.
[1] Setting data read out from EEPROM The setting data modified on the site, other than factory-set value, stored in the EEPROM shall be read out. Step 1 Push SET , CL and TEST button on the remote controller simultaneously for more than 4 seconds. ∗ When the group operation control is performed, the unit No. displayed for the first time is the header unit No. At this time, the CODE No. (DN) shows “ ”.
[3] Writing the setting data to EEPROM The settings stored in the EEPROM of the P.C. board for indoor unit servicing are the factory-set values. Step 1 Push SET , CL and TEST buttons on the remote controller simultaneously for more than 4 seconds.1 ∗ In the group control operation, the unit No. displayed for the first time is the header unit No. At this time, the CODE No. (DN) shows “ ”. Also, the fan of the indoor unit selected starts its operation and the swing operation starts if it has the louvers.
Step 4 Write the on-site setting data to the EEPROM, such as address setting, etc. Perform the steps 1 and 2 above again. Step 5 Change the CODE No. (DN) to “ ” by pushing (this is the setting for the filter sign lighting time.) Step 6 Check the setting data displayed at this time with the setting data put down in [1]. 1. If the setting data is different, modify the setting data by pushing / buttons for the timer setting to the data put down in [1].
Table 1. Setting data (CODE No.
12. SETUP AT LOCAL SITE AND OTHERS 12-1. Indoor Unit (Slim Duct Type) 12-1-1. Test Run Setup on Remote Controller TEST 1. When pushing button on the remote controller for 4 seconds or more, “TEST” is displayed on LC display. ON / OFF Then push button. • “TEST” is displayed on LC display during operation of Test Run. • During Test Run, temperature cannot be adjusted but air volume can be selected.
12-1-3. LED Display on P.C. Board 1. D501 (Red) • It goes on (Goes on by operation of the main microcomputer) at the same time when the power supply is turned on. • It flashes with 1-second interval (every 0.5 second): When there is no EEPROM or writing-in operation fails. • It flashes with 10-seconds interval (every 5 second): During DISP mode • It flashes with 2-seconds interval (every 1 second): While setting of function select (EEPROM) 2.
Function selection item No. (DN) list DN Item Contents 01 Filter sign lighting time 0000: None 0002: 2500H 0004: 10000H 02 Filter stain level 0000: Standard 0001: Heavy stain (Half of standard time) 0000: Standard 03 Central control address 0001: No.1 unit 0099: Undecided 0099: Undecided 06 Heating suction temp.
12-1-5. 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.
12-1-6. 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 is displayed. TEMP.
n Calling of error history The error contents in the past can be called. 1 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.
12-2. Setup at Local Site / Others Model name: TCB-PCNT30TLE2 12-2-1. 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.
4. Wiring specifications No. of wires Size • Use 2-core with no polar wire. Up to 1000m: twisted wire 1.25mm2 2 • Match the length of wire to wire length of the central Up to 2000m: twisted wire 2.0mm2 control system. 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.
6. External view of P.C. board assembly Terminator (SW01) 52 85 7. 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. 12-3. 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.
2. How to confirm the central control address (New function for AMT32E remote controller) It can be confirmed even during operation or stopping. 1 2 3 Push UNIT LOUVER button for 4 seconds or more. ò In the frame at left side of the remote controller screen, the lighting set contents are displayed. During unset time, '' (At shipment from factory) is displayed. ò After lighting display for 3 seconds, the display automatically disappears.
4. When installing separately sold filters REQUIREMENT • When you use this air conditioner for the first time, it takes approx. 5 minutes until the remote controller becomes available after power-on. This is normal. It takes approx. 5 minutes until the remote controller becomes available. Power ON Approx. 5 minutes “SETTING” flashes It takes approx.
n Setup of external static pressure Be sure to set up a tap change based upon the resistance (external static pressure) of the duct to be connected. To set up a tap change, follow to the basic operation procedure (1 → 2 → 3 → 4 → 5 → 6 ). • Specify [5d] to the item code in procedure 3. • For the setup data of procedure 4, select a setup data of the external static pressure to be set up from the following table.
n Change of lighting time of filter sign n How to set up power saving mode According to the installation condition, the lighting time of the filter sign (Notification of filter cleaning) can be changed. Follow to the basic operation procedure (1 → 2 → 3 → 4 → 5 → 6 ). • For the CODE No. in Procedure 3, specify [01]. • For the [Set data] in Procedure 4, select the setup data of filter sign lighting time from the following table.
12-4. Outdoor Unit 12-4-1. Refrigerant Recovery Control The “ozone destruction coefficient” of HFC refrigerant is 0 and the discharge regulation is set as anathermal effect gas. To this model, a switch which can perform the refrigerant recovery (pump down) by the outdoor unit is mounted so that it is easy to react against the environment at reinstalling or rejection time. [Operation method] 1) See the mode of the indoor unit to fan mode.
12-4-2. Various Setting on Outdoor Unit (Existing piping, Power save, Cooling-only, etc.) The following settings are available by DIP switch setup and jumper line setup. Function Setting position Existing piping setup SW801 Control contents Turn off the switches. (Ø19.1 existing pipes cannot be used.) ON Power save setup 1 2 When using the power saving function, turn on switches. The control to lower the compressor frequency (approx. -10%) is performed by indoor heat exchanger temp.
12-4-3. Service Support Function (LED Display, Switch Operation) 1. Outline A various setup and operation check can be performed by DIP switches at 3 positions (SW802, SW803, SW804) and the pushdown button switches (SW800, SW801) at 2 positions. Operation part Part No.
2. Selection of LED display (SW800, SW803 operation) 1) Display selection list The displayed contents of LED D800 to D804 on the outdoor control P.C. board can be exchanged by operation of SW803. Switch Function / Contents Error display (Error generating at present) Error generating at present is displayed. This switch goes off when an error does not generate. Refer to Page 130.
2) Error display The error which is generating at present and the latest error (Latest error information including present) can be confirmed by lighting LED D800 toD804 on the outdoor control P.C. board. a) When all DIP switch SW803 are OFF, the status of error which is generating at present is displayed. b) <1> only of DIP switch SW803 is turned on, the error which generated before (Latest error information including present) is displayed.a) c) If there is an error, any of LED D800 to D804 goes on.
3) Sensor, current, compressor operation frequency, PMV opening display The values detected by the controller, such as temperature sensor or current value are simply confirmed.
4) Specific operation for maintenance check (SW801, SW804) The following specific operations for the maintenance check are performed by operation of SW801 or SW804. a) Select DIP switch SW804. (See table below) b) Push the pushdown button switch SW801 for approx. 1 second. c) The following functions start. While each function starts, LED D805 (Green) flashes. d) When pushing the pushdown button switch SW801 again for approx.
SW804 1 ON 2 3 4 SW804 Operation when pushdown button switch SW801 is pushed 4-way valve relay operation (For RY700, CN70 check) Turn on 4-way valve power relay (RY700). When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control. 1 ON 2 3 4 SW804 1 ON 2 3 4 SW804 Self-hold valve separation operation (Exchange to cooling cycle) Turn on relay RY700. (CN701 between 1) and 4): Voltage=Approx.
13. ADDRESS SETUP 13-1. 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.
13-2. Address Setup & Group Control Indoor unit No. Group address : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) : 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.
13-2-2. Automatic Address Example from Unset Address (No miswiring) 1.
13-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple (1-1) 1-2 Master/Header 1-1 Individual (1-1) (1-2) 1-2 Sub/Header 1-1 Sub/Follower (1-2) (1-3) 1-3 Master/Follower 1-1 Sub/Follower (Master/Header) Only turning on source power supply (Automatic completion) 2.
13-3. Remote Controller Wiring • Strip off approx. 9 mm the wire to be connected. • For single system, use non polarity, 2 core wire is used for wiring of the remote controller. (0.5 mm² to 2.0 mm² wires) • For the synchronous twin, triple system, use 2-core shield wire (Vinyl cord for microphone 0.5 to 2.0 mm²) to conform to the EMC standard.
13-4. 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.
13-5. 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.
Aiming in environmental preservation, it is strictly recommended to clean and maintain the indoor/outdoor units of the operating air conditioning system regularly to secure effective operation of the air conditioner. It is also recommended to maintain the units once a year regularly when operating the air conditioner for a long time. Check periodically signs of rust or scratches, etc. on coating of the outdoor units.
14. DETACHMENTS 14-1. Indoor Unit 14-1-1. Slim Duct Type RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E No. Part name Remarks Procedure REQUIREMENT Be sure to put on gloves at working; otherwise an injury may be caused by parts, etc. • Before replacement of the parts, be sure to stop operation of the air conditioner and turn off switch of the breaker. 1 Air Filter 1.
No. 3 Procedure Part name E-cover Remarks 1. Detachment 1) Perform work 1. of 2 . 2) Take off screws fixing E-cover, and then remove hooks of the hooking part by lifting up. (Ø4 × 10, 2 pcs) 2. Attachment 1) Hang on E-cover to hooks of the hooking part so that it does not fall down. E-cover NOTE) Be sure not to catch TA sensor in the E-cover; otherwise the equipment cannot operate correctly. 2) Using the screws taken off in procedure 1.
No. 5 Part name P.C. board assembly Procedure Remarks 1. Detachment 1) Perform works 1. of 2 , 1. of 3 , and 1. of 4 . 2) Disconnect connectors which are connected from P.C. board assembly to other parts. P.C. board assembly NOTE) Unlock the lock of the housing to disconnect the connectors.
No. 7 Part name Fan motor Procedure Remarks 1. Detachment 1) Perform works 1. of 2 , 1. of 3 , and 1. of 6 . 2) Remove lead wires which are connected to the following connectors of P.C. board assembly. NOTE) Unlock locks of the housing, and then remove the connectors. CN333 : Fan motor power supply (5P: White) CN334 : Detection of fan motor (3P: White) Remove tie wrap which fixes lead wires. 3) Remove the noise filter from lead wire to detect fan motor position.
No. Part name 9 Drain pump, Float switch, Drain hose Procedure Remarks 1. Detachment 1) Perform works in procedures 1. of 2 , 1. of 3 , 1. of 8 . 2) Disconnect lead wires which are connected to the following connectors of P.C. board assembly. Drain hose Hose band Drain pump NOTE) Unlock locks of the housing to remove the connectors. CN34 : float SW (3P: Red) CN504 : Drain pump lead (2P: White) 3) Loosen hose band, remove cap of the drain hose, and take off screws while holding drain pump.
14-2. Outdoor Unit 14-2-1. RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E No. 1 Part name Procedure Common procedure CAUTION Remarks Never forget to put on the gloves at working time, otherwise an injury will be caused by the parts, etc. Valve cover 1. Detachment 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner. 2) Remove the valve cover. (ST1T Ø4 × 8L, 1 pc.
No. Part name 2 Front cabinet Procedure Remarks 1. Detachment 1) Perform work of item 1 of 1 . 2) Remove screws (ST1T Ø4 × 8L, 2 pcs.) of the front cabinet and the inverter cover. 3) Take off screws of the front cabinet and the bottom plate. (ST1T Ø4 × 8L 3 pcs.) 4) Take off screws of the front cabinet and the motor support. (ST1T Ø4 × 8L, 2 pcs.) • The left side of the front side if made to insert to the rear cabinet, so remove it pulling upward.
No. Part name 3 Inverter assembly Remarks Procedure 1. Detachment 1) Perform work of item 1 of 1 . 2) Take off screws of the upper part of the front cabinet. • If removing the inverter cover under this condition, P.C. board can be checked. • If there is no space in the upper part of the upper cabinet, perform work of 2 . Screws Front cabinet Inverter cover CAUTION Be careful to check the inverter because highvoltage circuit is incorporated in it.
No. Part name 4 Control P.C. board assembly Remarks Procedure 1) Disconnect lead wires and connectors connected from the control P.C. board assembly to other parts. 1. Lead wires • Connection with the power terminal block: 3 wires (Black, White, Orange) • Earth wire: 1 wire (Black) 2. Connectors • Connection with compressor: Remove 3P connector.
No. Part name Procedure 5 Rear cabinet 1) Perform works of items 1 of 1 and 2 , 3 . 2) Take off fixed screws for the bottom plate. (ST1T Ø4 × 8L, 3 pcs.) 3) Take off fixed screws for the heat exchanger. (ST1T Ø4 × 8L, 2 pcs.) 4) Take off fixed screw for the valve mounting plate. (ST1T Ø4 × 8L, 1 pc.) 6 Fan motor Remarks 1) Perform works of items 1 of 1 and 2 . 2) Take off the flange nut fixing the fan motor and the propeller. • Turning it clockwise, the flange nut can be loosened.
Remarks No. Part name Procedure 7 Compressor 1) Perform works of items 1 of 1 and 2 , 3 , 4 , 5 . 2) Discharge refrigerant gas. 3) Remove the partition plate. (ST1T Ø4 × 8L, 3 pcs.) 4) Remove the noise-insulator. 5) Remove the terminal covers of the compressor, and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal. 6) Remove pipes connected to the compressor with a burner.
No. Part name 9 Pulse Motor Valve (PMV) coil Remarks Procedure 1. Detachment 1) Perform works of items 1 and 2 . 2) Release the coil from the concavity by turning it, and remove coil from the PMV. 2. Attachment 1) Put the coil deep into the bottom position. 2) Fix the coil firmly by turning it to the concavity. PMV coil 10 Fan guard 1. Detachment 1) Perform works of items 1 of 1 and 2 . 2) Remove the front cabinet, and put it down so that fan guard side directs downward.
14-2-2. RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E No. 1 Part name Procedure Common procedure CAUTION Remarks Front panel Be sure to put on the gloves at working time; otherwise an injury may be caused by a part, etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker. 2) Remove the front panel. (Hexagonal screw Ø4 × 10, 2 pcs.) ∗ After removing screws, remove the front panel while pulling it downward.
No. Part name 2 Discharge port cabinet Remarks Procedure 1. Detachment 1) Carry out work of 1 of 1 . 2) Remove screws for the discharge port cabinet and the partition plate. (ST1T Ø4 × 8, 3 pcs.) 3) Remove screws for the discharge port cabinet and the bottom plate. (Hexagonal screw Ø4 × 10, 2 pcs.) 4) Remove screws of the discharge port cabinet and the motor base. (ST1T Ø4 × 8, 2 pcs.) 5) Remove screws of the discharge port cabinet and the heat exchanger. (ST1T Ø4 × 8, 1 pc.
No. Part name 4 Exchange of electric parts Remarks Procedure 1. Control P.C. board 1) Carry out work of 1 of 1 . Compressor lead Control P.C. board WARNING Fan motor Relay connector: 2 positions (1 at rear side) Bundling band (Reactor lead) Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused. 2) Remove the connectors connected to the control P.C. board.
No. Part name 4 Exchange of electric parts (Continued) Remarks Procedure 1. Reactor 1) Carry out works of 1 of 1 and 3 . 2) Remove the relay connector connected to the control P.C. board. 3) Cut off the bundling band binding the compressor lead and the relay connector. 4) Remove each reactor. (Truss B tight screw Ø4 × 6, 2 pcs. each) 5) Attach a new reactor. Reactor relay connector (Connected to lead wire (White) at P.C.
No. Part name 5 Fan motor Remarks Procedure 1) Carry out works of 1 of 1 and 2 . 2) Remove the flange nut fixing the fan motor and the propeller fan. ∗ The flange nut is loosened by turning clockwise. (To tighten it, turn it counterclockwise.) 3) Remove the propeller fan. 4) Remove the connector for fan motor from the inverter. 5) Remove the fan motor lead from the fan motor lead fixing rubber of the penetrated part of the partition plate. 6) Remove the fixing screws (4 pcs.
No. Part name 6 Compressor Compressor lead Remarks Procedure 1. Removal of broken compressor 1) Recover the refrigerant gas. 2) Carry out works of 1 of 1 and 2 , 3 . 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and the bottom plate. (Hexagonal screw Ø4 × 10, 2 pcs.) Remove screws of the piping panel (Front) and the piping panel (Rear). (Hexagonal screw Ø4 × 10, 1 pc.) 4) Remove the piping panel (Rear). Remove screws of the piping panel (Rear) and the bottom plate.
No. Part name 6 Compressor Compressor lead (Continued) Procedure 10) Using a burner, remove the discharge pipe and the suction pipe connected to the compressor. Remarks Remove (Discharge pipe) Remove (Suction pipe) WARNING In case of removing the piping by broiling the welded part with a burner, if the piping includes oil, it may burst into flames at the moment when wax melted, so take sufficient care. CAUTION Note so that the flame does not catch the 4-way valve and PMV.
No. Part name 6 Compressor Compressor lead (Continued) Procedure Remarks 2. Mounting of compressor 1) Mount the compressor in the reverse procedure of removal. Compressor lead Wind the ferrite core with the compressor lead wire by 4 times. NOTES: ∗ After exchange of the compressor, be sure to exchange the compressor lead. (Repair part code of compressor lead: 43160591) In this time, wrap the ferrite core with the compressor lead wire by 4 times.
No. Part name 6 Compressor Compressor lead (Continued) Procedure Remarks 3. Vacuuming 1) Connect the vacuum pump to the charge port of the gas pipe valve and then drive the vacuum pump. 2) Carry out vacuuming until the vacuum low pressure gauge indicates 1 (mmHg). NOTE: Before vacuuming, open PMV fully. If PMV is closed, vacuuming may be impossible between the liquid pipe valve and PMV of the outdoor unit. Forced full-opening method of PMV SW804 SW801 ∗ Turn on the leakage breaker.
No. 8 Part name Fan guard Procedure Remarks 3. Detachment 1) Carry out works of 1 of 1 and 2 . Bell mouth Discharge port cabinet Fan guard Hooking claw CAUTION To prevent scratching on the product, handle the product on a cardboard or cloth. 2) Remove the discharge port cabinet and then put on it so that the fan guard side directs downward. 3) Remove the hooking claws (8 positions) of the fan guard. 2.
15. EXPLODED VIEWS AND PARTS LIST 15-1. Indoor Unit 15-1-1.
Location No. Part No.
404 403 405 401 402 Location No. Part No. 401 43050425 402 Model Name RAV-SM Description 404SDT-E 454SDT-E 564SDT-E Sensor Ass’y, Service TC (F6) 2 2 2 43050426 Sensor, Service 1 1 1 403 43160565 Terminal, Block, 3P, AC250V, 20A 1 1 1 404 43160568 Terminal, 2P, AC30V/DC42V, 1A 1 1 1 405 4316V368 P.C.
15-2. Outdoor Unit 15-2-1.
Location No. Model Name RAV-SP Part No.
705 707 707 712 710 706 711 Location No. Part No. Description Model Name RAV-SP 404AT-E 404ARZ-E 404ATZG-E 454AT-E 454ATZ-E 454ATZG-E 701 43050422 Sensor, TE 1 1 1 1 1 1 702 43050423 Sensor, TS 1 1 1 1 1 1 703 43050427 Sensor, TO 1 1 1 1 1 1 704 43050430 Sensor, TD 1 1 1 1 1 1 705 43062228 Base, P.C.board 1 1 1 1 1 1 706 43160566 Terminal, Block 6P, 20A 1 1 1 1 1 1 707 4316V293 P.C.
15-2-2.
Location No. Part No.
705 708 707 712 706 710 701 702 703 704 Location No. Part No. 701 43050422 702 43050423 703 711 Description Model Name RAV-SP 564AT-E 564ATZ-E 564ATZG-E Sensor, TE 1 1 1 Sensor, TS 1 1 1 43050427 Sensor, TO 1 1 1 704 43050430 Sensor, TD 1 1 1 705 43062228 Base, P.C.board 1 1 1 706 43160566 Terminal block, 6P, 20A 1 1 1 707 4316V293 P.C. board Ass’y, SW, MCC-1530 1 1 1 708 4316V384 P.C.
15-2-3.
Location No. Part No.
709, 710 711 704 707 708 706 705 123 703 702 701 712 713 Location No. Part No.
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 © 2008 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.
