Toshiba Carrier RAV-SP180AT2-UL, Carrier RAV-SP300AT2-UL, Carrier RAV-SP240AT2-UL, Carrier RAV-SP360AT2-UL, Carrier RAV-SP420AT2-UL Service Manual

Download

R410A

FILE NO. A09-010-2

Revised : Feb. 2010

PRINTED IN JAPAN, Dec., 2009 ToMo

SERVICE MANUAL

SPLIT TYPE

REVISION 2 : Jan.2012

Re-edit version.( file volume down) Contents have NOT been changed.

OUTDOOR UNIT

RAV-SP180AT2-UL (2 HP) RAV-SP240AT2-UL (3 HP) RAV-SP300AT2-UL (4 HP) RAV-SP360AT2-UL (4, 5 HP) RAV-SP420AT2-UL (5 HP)

– 2 –

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.

– 3 –

CONTENTS

SAFETY CAUTION ............................................................................................ 4

1. SPECIFICATIONS ...................................................................................... 9

1-1. Outdoor Unit........................................................................................................ 9

1-2. Operation Characteristic Curve ....................................................................... 10

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)....................................... 12

2-1. Outdoor Unit...................................................................................................... 12

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM .............................. 15

3-1. Indoor Unit......................................................................................................... 15

3-2. Outdoor Unit...................................................................................................... 16

4. WIRING DIAGRAM ................................................................................... 19

4-1. Outdoor Unit...................................................................................................... 19

5. SPECIFICATIONS OF ELECTRICAL PARTS .......................................... 22

5-1. Outdoor Unit (Parts Ratings) ........................................................................... 22

6. REFRIGERANT R410A ............................................................................ 23

6-1. Safety During Installation/Servicing ............................................................... 23

6-2. Refrigerant Piping Installation ....................................................................... 23

6-3. Tools .................................................................................................................. 27

6-4. Recharging of Refrigerant................................................................................ 27

6-5. Brazing of Pipes................................................................................................ 28

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS ........... 30

7-1. Print Circuit Board <MCC-1571> ..................................................................... 30

7-2. Outline of Main Controls .................................................................................. 32

8. TROUBLESHOOTING .............................................................................. 45

8-1. Summary of Troubleshooting........................................................................... 45

8-2. Troubleshooting ................................................................................................ 47

9. REPLACEMENT OF SERVICE P.C. BOARD............................................ 74

9-1. Outdoor Unit...................................................................................................... 74

10. SETUP AT LOCAL SITE AND OTHERS .................................................. 75

10-1. Outdoor Unit...................................................................................................... 75

11. DETACHMENTS ....................................................................................... 83

11-1. Outdoor Unit..................................................................................................... 83

12. EXPLODED VIEWS AND PARTS LIST .................................................. 107

12-1. Outdoor Unit.................................................................................................... 107

– 4 –

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.

[Explanation of indications]

∗ Property damage : Enlarged damage concerned to property, furniture, and domestic animal/pet

[Explanation of illustrated marks]

[Confirmation of warning label on the main unit]

Confirm that labels are indicated on the specified positions (Refer to the Parts disassembly diagram (Outdoor unit).)

If removing the label during parts replace, stick it as the original.

Indication

DANGER

WARNING

CAUTION

Explanation

Indicates contents assumed that an imminent danger causing a death or serious injury of the repair engineers and the third parties when an incorrect work has been executed.

Indicates possibilities assumed that a danger causing a death or serious injury of the repair engineers, the third parties, and the users due to troubles of the product after work when an incorrect work has been executed.

Indicates contents assumed that an injury or property damage (∗) may be caused on the repair engineers, the third parties, and the users due to troubles of the product after work when an incorrect work has been executed.

Mark Explanation

Indicates prohibited items (Forbidden items to do) The sentences near an illustrated mark describe the concrete prohibited contents.

Indicates mandatory items (Compulsory items to do) The sentences near an illustrated mark describe the concrete mandatory contents.

Indicates cautions (Including danger/warning) The sentences or illustration near or in an illustrated mark describe the concrete cautious contents.

Turn off breaker.

Execute discharge

between terminals.

Prohibition

Turn “OFF” the breaker before removing the front panel and cabinet, otherwise an electric shock is caused by high voltage resulted in a death or injury.

During operation, a high voltage with 400V or higher of circuit (∗) at secondary circuit of the high-voltage transformer is applied.

If touching a high voltage with the naked hands or body, an electric shock is caused even if using an electric insulator.

∗ : For details, refer to the electric wiring diagram.

When removing the front panel or cabinet, execute short-circuit and discharge between high-voltage capacitor terminals.

If discharge is not executed, an electric shock is caused by high voltage resulted in a death or injury. After turning off the breaker, high voltage also keeps to apply to the high-voltage capacitor.

Do not turn on the breaker under condition that the front panel and cabinet are removed.

An electric shock is caused by high voltage resulted in a death or injury.

DANGER

– 5 –

Check earth wires.

Prohibition of modification.

Use specified parts.

Do not bring a child

close to the equipment.

Insulating measures

No fire

Refrigerant

Assembly/Cabling

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.

For spare parts, use those specified (

∗∗

∗).

If unspecified parts are used, a fire or electric shock may be caused.

∗: For details, refer to the parts list.

Before troubleshooting or repair work, do not bring a third party (a child, etc.) except the repair engineers close to the equipment.

It causes an injury with tools or disassembled parts. Please inform the users so that the third party (a child, etc.) does not approach the equipment.

Connect the cut-off lead wires with crimp contact, etc, put the closed end side upward and then apply a water-cut method, otherwise a leak or production of fire is caused at the users’ side.

When repairing the refrigerating cycle, take the following measures.

1) Be attentive to fire around the cycle. When using a gas stove, etc, be sure to put out fire before work; otherwise the oil mixed with refrigerant gas may catch fire.

2) Do not use a welder in the closed room. When using it without ventilation, carbon monoxide poisoning may be caused.

3) Do not bring inflammables close to the refrigerant cycle, otherwise fire of the welder may catch the inflammables.

Check the used refrigerant name and use tools and materials of the parts which match with it.

For the products which use R410A refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see. To prevent miss-charging, the route of the service port is changed from one of the former R22.

For an air conditioner which uses R410A, never use other refrigerant than R410A. For an air conditioner which uses other refrigerant (R22, etc.), never use R410A.

If different types of refrigerant are mixed, abnormal high pressure generates in the refrigerating cycle and an injury due to breakage may be caused.

Do not charge refrigerant additionally.

If charging refrigerant additionally when refrigerant gas leaks, the refrigerant composition in the refrigerating cycle changes resulted in change of air conditioner characteristics or refrigerant over the specified standard amount is charged and an abnormal high pressure is applied to the inside of the refrigerating cycle resulted in cause of breakage or injury. Therefore if the refrigerant gas leaks, recover the refrigerant in the air conditioner, execute vacuuming, and then newly recharge the specified amount of liquid refrigerant. In this time, never charge the refrigerant over the specified amount.

When recharging the refrigerant in the refrigerating cycle, do not mix the refrigerant or air other than R410A into the specified refrigerant.

If air or others is mixed with the refrigerant, abnormal high pressure generates in the refrigerating cycle resulted in cause of injury due to breakage.

After installation work, check the refrigerant gas does not leak.

If the refrigerant gas leaks in the room, poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.

Never recover the refrigerant into the outdoor unit.

When the equipment is moved or repaired, be sure to recover the refrigerant with recovering device. The refrigerant cannot be recovered in the outdoor unit; otherwise a serious accident such as breakage or injury is caused.

After repair work, surely assemble the disassembled parts, and connect and lead the removed wires as before. Perform the work so that the cabinet or panel does not catch the inner wires.

If incorrect assembly or incorrect wire connection was done, a disaster such as a leak or fire is caused at user’s side.

WARNING

– 6 –

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. A case of leakage of the refrigerant and the closed room full with gas is dangerous because a shortage of oxygen occurs. Be sure to execute ventilation.

When checking the circuit inevitably under condition of the power-ON, use rubber gloves and others not to touch to the charging section.

If touching to the charging section, an electric shock may be caused.

When the refrigerant gas leaks, find up the leaked position and repair it surely.

If the leaked position cannot be found up and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. The poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.

When installing equipment which includes a large amount of charged refrigerant such as a multi air conditioner in a sub-room, it is necessary that the density does not the limit even if the refrigerant leaks.

If the refrigerant leaks and exceeds the limit density, an accident of shortage of oxygen is caused.

For the installation/moving/reinstallation work, follow to the Installation Manual.

If an incorrect installation is done, a trouble of the refrigerating cycle, water leak, electric shock or fire is caused.

After repair work has finished, check there is no trouble.

If check is not executed, a fire, electric shock or injury may be caused. For a check, turn off the power breaker.

After repair work (installation of front panel and cabinet) has finished, execute a test run to check there is no generation of smoke or abnormal sound.

If check is not executed, a fire or an electric shock is caused. Before test run, install the front panel and cabinet.

Check the following items after reinstallation.

1) The earth wire is correctly connected.

2) The power cord is not caught in the product.

3) There is no inclination or unsteadiness and the installation is stable. If check is not executed, a fire, an electric shock or an injury is caused.

Insulator check

Ventilation

Be attentive to

electric shock

Compulsion

Check after repair

Check after reinstallation

WARNING

Put on gloves

Cooling check

Be sure to put on the gloves (∗) and a long sleeved shirt: otherwise an injury may be caused with the parts, etc.

(∗) Heavy gloves such as work gloves

When the power was turned on, start to work after the equipment has been sufficiently cooled.

As temperature of the compressor pipes and others became high due to cooling/heating operation, a burn may be caused.

CAUTION

– 7 –

• 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.

Therefore, be sure that water, dust, the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with new refrigerant during installation work or service work.

If an incorrect work or incorrect service is performed, there is a possibility to cause a serious accident.

Use the tools and materials exclusive to R410A to purpose a safe work.

2. Cautions on Installation/Service

1) Do not mix the other refrigerant or refrigerating oil.

For the tools exclusive to R410A, shapes of all the joints including the service port differ from those of the former refrigerant in order to prevent mixture of them.

2) As the use pressure of the new refrigerant is high, use material thickness of the pipe and tools which are specified for R410A.

3) In the installation time, use clean pipe materials and work with great attention so that water and others do not mix in because pipes are affected by impurities such as water, oxide scales, oil, etc.

Use the clean pipes.

Be sure to brazing with flowing nitrogen gas. (Never use gas other than nitrogen gas.)

4) For the earth protection, use a vacuum pump for air purge.

5) R410A refrigerant is azeotropic mixture type refrigerant.

Therefore use liquid type to charge the refrigerant. (If using gas for charging, composition of the refrigerant changes and then characteristics of the air conditioner change.)

3. Pipe Materials

For the refrigerant pipes, copper pipe and joints are mainly used.

It is necessary to select the most appropriate pipes to conform to the standard.

Use clean material in which impurities adhere inside of pipe or joint to a minimum.

1) Copper pipe

The pipe thickness, flare finishing size, flare nut and others differ according to a refrigerant type.

When using a long copper pipe for R410A, it is recommended to select “Copper or copper-base pipe without seam” and one with bonded oil amount 0.0001 lbs / 32’ 10” (40 mg / 10 m) or less.

Also do not use crushed, deformed, discolored (especially inside) pipes. (Impurities cause clogging of expansion valves and capillary tubes.)

Use the flare nuts which are attached to the air conditioner unit.

2) Joint

The flare joint and socket joint are used for joints of the copper pipe.

The joints are rarely used for installation of the air conditioner. However clear impurities when using them.

– 8 –

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) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))

2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)

3) Tools commonly used for R410A and for conventional refrigerant (R22)

The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

NOTE

When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

1) Vacuum pump. Use vacuum pump by attaching vacuum pump adapter.

2) Torque wrench 8) Spanner or Monkey wrench

3) Pipe cutter 9) Hole core drill

4) Reamer 10) Hexagon wrench (Opposite side 4mm)

5) Pipe benderr 11) Tape measure

6) Level vial 12) Metal saw

7) Screwdriver (+, –)

Also prepare the following equipments for other installation method and run check.

1) Clamp meter 3) Insulation resistance tester (Megger)

2) Thermometer 4) Electroscope

No.

Used tool

Flare tool

Copper pipe gauge for adjusting projection margin

Torque wrench

Gauge manifold

Charge hose

Vacuum pump adapter

Electronic balance for refrigerant charging

Refrigerant cylinder

Leakage detector

Usage

Pipe flaring

Flaring by conventional flare tool

Tightening of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating

Refrigerant charge

Gas leakage check

R410A

air conditioner installation

Existence of Whether conven-

new equipment tional equipment

for R410A can be used

Yes *(Note)

Ye s N o

Ye s Ye s

Ye s N o

Conventional air

conditioner installation

Whether conventional

equipment can be used

Ye s

*(Note)

Ye s

– 9 –

1. SPECIFICATIONS

1-1. Outdoor Unit

Size

Outdoor model RAV-

Outdoor Min - Max DB ∗1 (°F)

Operating

Cooling Indoor Min - Max DB (°F)

Indoor Min - Max WB (°F)

range

Heating

Outdoor WB Min - Max (°F)

Indoor DB Min - Max (°F)

Standard Piping Length (ft.)

Min. Piping Length (ft.)

Max. Piping Length (ft.)

Lift (Outdoor below Indoor) (ft.)

Piping

Lift (Outdoor above Indoor) (ft.)

Gas Pipe (Size / connection type)

Liquid Pipe (Size / connection type)

Additional refrigerant charge under long piping connection

Voltage

Electrical Maximum Running Current Amps (A)

Fuse Rating ∗2

Type

Compressor Motor (kw)

Pole

Height (in.)

Dimensions Width (in.)

Length (in.)

Outdoor Weight -Gross / Net (lbs.)

Refrigerant charged

Appearance (Munsell symbol)

Sound Pressure (dBa)

018 024 030 036 042

SP180AT2-UL SP240AT2-UL SP300AT2-UL SP360AT2-UL SP420AT2-UL

23 to 109.4

69.8 to 89.6

59 to 75.2

–4 to 59

59 to 86

16’ 5” 16’ 5” 9’ 8” 9’ 8” 9’ 8”

164’ 1” 164’ 1” 246’ 1” 246’ 1” 246’ 1”

98’ 5”

1/2” 5/8” 5/8” 5/8” 5/8”

1/4” 3/8” 3/8” 3/8” 3/8”

0.22 oz / ft 0.43 oz / ft 0.43 oz / ft

(65’7”ft to164’1”ft) (98’5”ft to 164’1”ft) (98’5”ft to 246’1”ft)

208 V / 230 V-1-60 Hz

17 24 24 24 24

30 40 40 40 40

Hermetic compressor

1.1 2 3.75 3.75 3.75

44444

21.7 35.0 52.8 52.8 52.8

30.7 35.4 35.4 35.4 35.4

11.4 12.6 12.6 12.6 12.6

98 / 105 144.5 / 157 211.5 / 226 211.5 / 226 211.5 / 226

3.1 4.6 6.8 6.8 6.8

Silky shade (Muncel 1Y8.5/0.5)

48 / 49 49 / 50 50 / 51 52 / 52 52 / 52

∗1 When installed a duct or wind shield so that it is not affected by the wind.

The minimum outside temperature will be 5°F

∗2 UL value

– 10 –

1-2. Operation Characteristic CurveRAV*

• Operation characteristic curve <Super Digital Inverter>

RAV-SP180AT2-UL

02010 30 40 50 60 70 80

0 203040506070809010011012010

Compressor speed (rps)

Current (A)

Compressor speed (rps)

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Outdoor : DB 95˚F (35˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

• Conditions Indoor : DB 68˚F (20˚C) Outdoor : DB 44.6˚F (7˚C)/ WB 42.8˚F (6˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

RAV-SP240CT, KRT-UL

RAV-SP240UT-UL

RAV-SP240CT, KRT-UL

RAV-SP240UT-UL

RAV-SP240AT2-UL

Compressor speed (rps)

02010 30 40 50 60 70 80

Current (A)

0203010 40 50 60 70 80 90 100 110120

Compressor speed (rps)

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Outdoor : DB 95˚F (35˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

• Conditions Indoor : DB 68˚F (20˚C) Outdoor : DB 44.6˚F (7˚C)/ WB 42.8˚F (6˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

RAV-SP180CT, KRT-UL

RAV-SP180UT-UL

RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL

RAV-SP180UT-UL

– 11 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

020406080

Compressor speed (rps)

Current (A)

020406080

Compressor speed (rps)

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Outdoor : DB 95˚F (35˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

• Conditions Indoor : DB 68˚F (20˚C) Outdoor : DB 44.6˚F (7˚C)/ WB 42.8˚F (6˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

RAV-SP300AT2-UL

RAV-SP360AT2-UL,

RAV-SP420AT2-UL

RAV-SP300AT2-UL

RAV-SP360AT2-UL,

RAV-SP420AT2-UL

RAV-SP300AT2-UL

RAV-SP360AT2-UL, RAV-SP420AT2-UL

RAV-SP300AT2-UL

RAV-SP360AT2-UL, RAV-SP420AT2-UL

• Capacity variation ratio according to temperature

RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

100

105

89.6

(32)

91.4 (33)

93.2 (34)95(35)

96.8 (36)

98.6 (37)

100.4 (38)

102.2 (39)

104 (40)

105.8 (41)

107.6 (42)

109.4 (43)

Outdoor temp. ˚F (˚C)

Capacity ratio (%)

100

110

120

6.8

(–14)

3.2

(–16)

–0.4

(–18)

–4

(–20)

10.4

(–12)14(–10)

17.6 (–8)

21.2 (–6)

24.8 (–4)

28.4 (–2)32(0)

35.6 (2)

39.2 (4)

42.8 (6)

46.4 (8)50(10)

Outdoor temp. ˚F (˚C)

Capacity ratio (%)

• Conditions Indoor : DB 68˚F (20˚C) Indoor air flow : High Pipe length :

295.3” (7.5m)

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Indoor air flow : High Pipe length :

295.3” (7.5m)

– 12 –

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

2-1. Outdoor Unit

RAV-SP180AT2-UL

– 13 –

RAV-SP240AT2-UL

– 14 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

– 15 –

(Indoor unit)

Refrigerant pipe at liquid side (Outer dia : ØB)

Refrigerant pipe at gas side (Outer dia : ØA)

Distributor (Strainer incorporated)

Strainer

Heating Cooling

TCJ sensor

TC sensor

Air heat

exchanger

To outdoor unit

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Indoor Unit

• Single type (Combination of 1 indoor unit and 1 outdoor unit)

Dimension table

Indoor unit

RAV-SP180AT2-UL

RAV-SP240, 300, 360, 420AT2-UL

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

1/2” (12.7) 1/4” (6.4)

5/8” (15.9) 3/8” (9.5)

– 16 –

3-2. Outdoor Unit

RAV-SP180AT2-UL

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

416.2 145.0 2.87 1.00

517.7 159.5 3.57 1.10

248.0 110.2 1.71 0.76

327.7 98.6 2.26 0.68

471.3 165.3 3.25 1.14

290.0 36.3 2.00 0.25

Pipe surface temperature °F (°C)

Discharge Suction

Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TE)

161.6 60.8 55.4 107.6 (72) (16) (13) (42)

190.4 68 66.2 125.6 (88) (20) (19) (52)

113.0 53.6 44.6 55.4 (45) (12) ( 7) (13)

150.8 42.8 98.6 37.4 (66) ( 6) (37) ( 3)

172.4 68.0 127.4 60.8 (78) (20) (53) (16)

172.4 –0.4 93.2 –0.4 (78) (–18) (34) (–18)

Compressor

drive revolution

frequency

(rps)

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F °C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68/– 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

TE sensor

TO sensor

sensorTDsensor

Heat exchanger

Ø8 ripple, 2 rows, 20 stages

FP1.3, flat fin

Accumulator

(1L)

Rotary compressor

(DA150A1F-21F)

Strainer

Refrigerant pipe at liquid side Ø6.4 Packed valve

Refrigerant pipe at gas side Ø12.7 Packed valve

Distributor

In cooling operation In heating operation

4-way valve

(STF-0213Z)

2-step muffler

Ø25 × 200L

Muffler

Ø31.75 × 200L

Muffler

Ø19.05 × 160L

PMV (Pulse Motor Valve) (CAM-B30YGTF-2)

Revised : Feb. 2010

– 17 –

RAV-SP240AT2-UL

Capillary

Refrigerant pipe at liquid side Ø9.5 Packed valve

Refrigerant pipe at gas side Ø15.9 Ball valve

Strainer

sensor

TS sensor

TO sensor TL sensor

TE sensor

Heat exchanger

Ø8, 2 rows, 34 stages

FP1.45, flat fin

Accumulator

(1.8L)

Accumulator

Sub-ass’y

Rotary compressor

(DA220A2F-22L)

In cooling operation In heating operation

4-way valve

(STF-0218G)

Ø25 × L180

Ø2 × Ø3 × 600L

Ø2 × Ø3 × 550L

Ø2 × Ø3 × 450L

Ø25 × L210

Muffler

PMV

(Pulse Motor Valve)

(CAM-B30YGTF-2)

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

404.6 129.1 2.79 0.89

511.9 155.2 3.53 1.07

248.0 104.4 1.71 0.72

384.3 98.6 2.65 0.68

464.0 161.0 3.2 1.11

337.9 30.5 2.33 0.21

Pipe surface temperature °F (°C)

Discharge Suction Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TE)

158.0 55.4 51.8 102.2 (70) (13) (11) (39)

177.8 62.6 57.2 118.4 (81) (17) (14) (48)

107.6 44.6 37.4 64.4 (42) ( 7) ( 3) (18)

165.2 39.2 111.2 37.4 (74) ( 4) (44) ( 3)

168.8 66.2 125.6 59 (76) (19) (52) (15)

199.4 –0.4 87.8 –4 (93) (–18) (31) (–20)

Compressor

drive revolution

frequency

(rps)

58.2

65.0

30.0

61.5

28.0

99.6

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F °C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

Revised : Feb. 2010

– 18 –

In cooling operation In heating operation

Ø25 × L180

Ø25 × L210

TS sensor

TO sensor

TE sensor

TD sensor

TL sensor

Cooling: High pressure Heating: Low pressure

Cooling: Low pressure Heating: High pressure

Check joint

Heat exchanger

Ø8, 2 rows, 52 stages

FP1.45, flat fin

Accumulator

(2500cc)

Rotary compressor

(DA422A3F-25M)

PMV

Capillary Ø4 ×Ø3 (6 pcs.)

Strainer

Refrigerant pipe at liquid side Ø9.5 Packed valve

Refrigerant pipe at gas side Ø15.9 Ball valve

Distributor

Muffler

RAV-SP300AT2-UL

∗ This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp

meter becomes 2 times of No. of compressor revolutions (rps).

RAV-SP360AT2-UL, RAV-SP420AT2-UL

∗ This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp

meter becomes 2 times of No. of compressor revolutions (rps).

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

372.7 143.6 2.57 0.99

478.5 158.1 3.30 1.09

252.3 108.8 1.74 0.75

336.4 105.9 2.32 0.73

466.9 169.7 3.22 1.17

314.7 43.5 2.17 0.30

Pipe surface temperature °F (°C)

Discharge Suction

Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TL) (TE)

150.8 57.2 53.6 111.2 104.0 (66) (14) (12) (44) (38)

172.4 48.2 55.4 120.2 109.4 (78) ( 9) (13) (49) (43)

114.8 44.6 41.0 89.6 77.0 (46) ( 7) ( 5) (32) (25)

149.0 37.4 102.2 35.6 37.4 (65) ( 3) (39) ( 2) ( 3)

163.4 66.2 129.2 57.2 59.0 (73) (19) (54) (14) (15)

188.6 5 100.4 6.8 8.6 (87) (–15) (38) (–14) (–13)

Compressor

drive revolution

frequency

(rps)

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F (°C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68/– 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

394.4 130.5 2.72 0.90

484.3 155.2 3.34 1.07

253.8 110.2 1.75 0.76

375.6 100.1 2.59 0.69

453.9 152.3 3.13 1.05

348.0 30.45 2.40 0.21

Pipe surface temperature °F (°C)

Discharge Suction

Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TL) (TE)

163.4 53.6 50 114.8 100.4 (73) (12) (10) (46) (38)

176.0 48.2 55.4 123.8 113.0 (80) ( 9) (13) (51) (45)

116.6 46.4 42.8 91.4 77.0 (47) ( 8) ( 6) (33) (25)

167 37.4 109.4 35.6 35.6 (45) ( 3) (43) ( 2) ( 2)

161.6 60.8 127.4 53.6 55.4 (72) (16) (53) (12) (13)

206.6 –7.6 107.6 –2.2 –0.4 (97) (–22) (42) (–19) (–18)

Compressor

drive revolution

frequency

(rps)

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F (°C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68/– 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

– 19 –

4. WIRING DIAGRAM

4-1. Outdoor Unit

RAV-SP180AT2-UL

Color

Identification

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY PNK : PINK GRN : GREEN WHI : WHITE BRN : BROWN ORN : ORANGE YEL : YELLOW PUR : PURPLE

NOTE

CM : Compressor PMV : Pulse Motor Valve FM : Fan Motor TE : Heat Exchanger Temp. Sensor TD : Discharge Temp. Sensor TO : Outdoor Temp. Sensor TS : Suction Temp. Sensor IGBT : Insulated Gate Bipolar Transistor DB : Rectifier CT : Curreut Transformer 49C : Compressor Case Thermostat HP SW : High pressure switch

CAUTION : HIGH VOLTAGE

The high voltage circuit is incorporated. Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand.

The 4-way valve coil is turned on while the cooling operation

Varistor

For optional

P.C. Board

(MCC-5009)

P34

P35

P18

P19

P08

P11

P32 CN701

WHI

RED

WHI

P31 P30

BLK

ORN

BLK

WHI

P7 P03 P10 P02 CN806P33

P20

P21

P22

P23

P24

P25

YEL

BRN

YEL

ORN

DB01

DB02

Relay

Q404

Q200~205

IGBT

Q300~305

MOS-FET

R221

RED

Compressor

WHI

BLK

P04 P05 P06

212 3 3

121

232 1 1

4 4

232 1 1

1 1

2 2 1 1

1 1

CN300

CN700

CN603

CN602

CN601

CN600

CN500

BLK WHI

ORN

49C

BLK

RED

Fan motor

Pulse

motor valve

PMV

HP SW

R220

R219

L03 C13

C12

C14

R321

R320

R319

Surge

absorber

F03

Fuse, T3.15A

AC250V

F01

Fuse, T25A

AC250V

Powe r

relay

Reactor

121

1 2 3 4 5

212

113

L2L1L2L1

22113

Reactor

(Suction pipe temp. sensor)

(Discharge pipe temp. sensor)

(Outdoor temp. sensor)

(Condenser pipe temp. sensor)

112

Coil for

4-way valve

To indoor Power supply

208/230-1-60

CN605

BLK

SW802

MCC-1530

Sub P.C. Board

RED

PUR

GRN/YEL

WHI

BLK

22113

1 1

High voltage

1. indicates the terminal block. Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

– 20 –

RAV-SP240AT2-UL

Color

Identification

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY WHI : WHITE YEL : YELLOW

Control P.C. Board

MCC-1571

(GRY) (GRY) (WHI) U(WHI)

P04 P05 P06 P07

P09

P02P01

CN201 CN202CN200

HP SW

(RED) (WHI) (BLK)

(BLK)

(RED) (WHI)

(GRY)

(WHI)

(RED)

(BLK)

Reactor Reactor

1 1 2 2

1 2 3 4 5 6

1 1 2 2

1 1

3 3

1 1

1 2 3 4 5 6 1 2 3

1 341 4

1 4

1 7

716

3 3

V W

L/F

49C

1 1 2 2

CN300

(WHI)

CN690

(RED)

CN609

(BLU)

CN610

(YEL)

CN604

(WHI)

CN603

(WHI)

CN602

(YEL)

CN601

(WHI)

CN600

(WHI)

CN710

(WHI)

CN704

(BLU)

RY704

SW802

SW803

CN701

(WHI)

CN04

(WHI)

1 1 2 2

Fuse, F03

T10A, 250V~

Fuse, F01

T25A, 250V~

L1L

Outdoor unit

Indoor unit

Earth screw

Power supply 208/230-1-60

Earth

screw

Earth

screw

3 5

20SFPMW

2 3 41

2 3 4

SW804 SW801 SW800

2 3 4

1. indicates the terminal block. Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

High voltage

Symbol

CM FM

PMV

TS TE TL

20SF

49C

HP SW

RY L/F

Parts name

Compressor Fan Motor Pulse Motor Valve Pipe temp. sensor (Discharge) Pipe temp. sensor (Suction) Heat exchanger sensor 1 Heat exchanger sensor 2 Outside temp. sensor 4-way valve coil Compressor case thermostat High pressure switch Relay Line Filter

– 21 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Color

Identification

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY WHI : WHITE YEL : YELLOW

Control P.C. Board

MCC-1570

(GRY) (GRY) (WHI) U(WHI)

CN400

(WHI)

P04 P05 P06 P07

P09

P02P01

CN201 CN202CN200

49C

(RED) (WHI) (BLK)

(BLK)

(RED) (WHI)

(GRY)

(WHI)

(RED)

(BLK)

Reactor

1 1

2 2

1 1 2 2

1 2 3 4 5 6

1 1 2 2

1 1

3 3

1 1

1 2 3 4 5 6 1 2 3

1 341 4

1 4

1 7

716

3 3

V W

L/F

FM01

CN300

(WHI)

CN609

(BLU)

CN690

(RED)

CN610

(YEL)

CN604

(WHI)

CN603

(WHI)

CN602

(YEL)

CN601

(WHI)

CN600

(WHI)

CN710

(WHI)

CN704

(BLU)

RY704

SW802

SW803

CN701

(WHI)

CN04 (WHI)

1 1 2 2

Fuse, F03

T10A, 250V~

Fuse, F01

T25A, 250V~

L1L

Outdoor unit

Indoor unit

1. indicates the terminal block. Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

Earth screw

Power supply 208/230-1-60

Earth

screw

Earth

screw

3 5

20SFPMW

FM02

2 3 41

2 3 4

SW804 SW801 SW800

2 3 4

HP SW

Symbol

FM01, 02

PMV

TD TS TE TL TO

20SF

49C

HP SW

L/F

Parts name

High voltage

– 22 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Outdoor Unit (Parts Ratings)

RAV-SP180AT2-UL

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

RAV-SP240AT2-UL

No.

1 2 3 4 5 6 7 8 9

Parts name

Fan motor Compressor Reactor Outdoor temp. sensor (To sensor) Heat exchanger sensor (Te sensor) Suction temp. sensor (Ts sensor) Discharge temp. sensor (Td sensor) Fuse (Switching power (Protect)) Fuse (Inverter, input (Current protect)) 4-way valve solenoid coil

Compressor thermo. (Protection)

Coil (Pulse Motor Valve)

Pressure switch

Type

ICF-140-43-4R

DA150A1F-21F

CH-57

— — — — — —

STF-01AJ502E1

US-622

CAM-MD12TF-12

ACB-4UB82W

Specifications

Output (Rated) 43 W 3 phase, 4P, 1100 W 10mH, 16A 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 50 kΩ at 77°F (25°C) T3.15 A, AC 250 V AC 240 V, 25 A

—

OFF : 257 ± 39.2°F (125 ± 4°C), ON : 194 ± 41°F (90 ± 5°C)

—

OFF : 601.8 + 0

601.8 – 29 psi ⎛4.15 + 0.2 MPa⎞

601.8 – 29 psi ⎝4.15 – 0.2 MPa⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

No.

1 2 3 4 5 6 7 8

9 10 11 12 13

Parts name

Compressor Outdoor fan motor Reactor 4-way valve coil PMV coil P.C. board Fuse (Mounted on P.C. board) Fuse (Mounted on P.C. board) Fuse (Mounted on P.C. board) Outdoor temp. sensor (TO sensor) Heat exchanger sensor (Te sensor) Discharge temp. sensor (Td sensor) Heat exchanger mid. Temp sensor (TL sensor)

Compressor thermo. (Protection)

Pressure switch

Type

DA422A3F-25M

ICF-280-A100-1

CH-62

VHV-01AP552B1

UKV-A038

MCC-1571

— — — — — — —

US-622

ACB-4UB82W

Specifications

—

Output 100W

5.7mH, 18.5A AC240V DC12V AC208 / 230 V AC250V, 25A AC250V, 10A AC250V, 3.15A 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 50 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C) OFF : 601.8 + 0

601.8 – 29 psi ⎛4.15 + 0.2 MPa⎞

601.8 – 29 psi ⎝4.15 – 0.2 MPa⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

No.

9 10 11 12 13

Parts name

Compressor thermo. (Protection)

Pressure switch

Type

DA220A2F-22L

ICF-280-A60-1

CH-56

VHV-01AP552B1

CAM-MD12TF-15

MCC-1571

— — — — — — —

US-622

ACB-4UB82W

Specifications

—

Output 60 W

5.8 mH, 18.5 A AC200 – 240 V DC12 V AC208 / 230 V AC250 V, 25 A AC250 V, 10 A AC250 V, 3.15 A 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 50 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C) OFF : 601.8 + 0

601.8 – 29 psi ⎛4.15 + 0.2 MPa⎞

601.8 – 29 psi ⎝4.15 – 0.2 MPa⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

– 23 –

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). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

The next section describes the precautions for air conditioner using the new refrigerant.

Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

6-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

1. Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A.

If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.

2. Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R410A.

The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant.

To prevent mischarging, the diameter of the service port differs from that of R22.

3. If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire, a poisonous gas may occur.

4. When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle.

Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused.

5. After completion of installation work, check to make sure that there is no refrigeration gas leakage.

If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

6. When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

7. Be sure to carry out installation or removal according to the installation manual.

Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc.

8. Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair may result in water leakage, electric shock and fire, etc.

6-2. Refrigerant Piping Installation

6-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes and joints are mainly used.

Copper pipes and joints suitable for the refrigerant must be chosen and installed.

Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

1. Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 0.0001 lbs / 32’ 10” (40 mg/10 m).

Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table 6-2-1. Never use copper pipes thinner than 0.03” (0.8 mm) even when it is available on the market.

– 24 –

Table 6-2-1 Thicknesses of annealed copper pipes

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.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 6-2-3 to 6-2-5 below.

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 0.79” (20 mm). Thicknesses of socket joints are as shown in Table 6-2-2.

Table 6-2-2 Minimum thicknesses of socket joints

6-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner is used, and that refrigerant does not leak.

When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

1. Flare Processing Procedures and Precautions

a) Cutting the Pipe

By means of a pipe cutter, slowly cut the pipe so that it is not deformed.

b) Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur.

Carefully remove all burrs and clean the cut surface before installation.

Outer diameter (In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Thickness (In (mm))

R410A R22

0.03” (0.80) 0.03” (0.80)

0.04” (1.00) 0.04” (1.00)

Reference outer diameter of copper pipe jointed

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Minimum joint thickness

(In (mm))

0.02” (0.50)

0.02” (0.60)

0.03” (0.70)

0.03” (0.80)

– 25 –

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.

Fig. 6-2-1 Flare processing dimensions

Table 6-2-3 Dimensions related to flare processing for R410A / R22

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Thickness

(In (mm))

0.03” (0.8)

0.04” (1.0)

Flare tool for

R410A, R22clutch type

0 – 0.02” (0 – 0.5)

Conventional flare tool (R410A)

Clutch type Wing nut type

0.04” – 0.06” (1.0 – 1.5) 0.06” – 0.08” (1.5 – 2.0)

0.04” – 0.06” (1.0 – 1.5) 0.08” – 0.10” (2.0 – 2.5)

Table 6-2-4 Flare and flare nut dimensions for R410A

Table 6-2-5 Flare and flare nut dimensions for R22

A (In (mm))

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Thickness

(In (mm))

0.03” (0.8)

0.04” (1.0)

Dimension (In (mm))

ABCD

0.36” (9.1) 0.36” (9.2) 0.26” (6.5) 0.51” (13)

0.52” (13.2) 0.53” (13.5) 0.38” (9.7) 0.79” (20)

0.65” (16.6) 0.63” (16.0) 0.51” (12.9) 0.91” (23)

0.78” (19.7) 0.75” (19.0) 0.63” (16.0) 0.98” (25)

Flare nut width

(In (mm))

0.67” (17)

0.87” (22)

1.02” (26)

1.14” (29)

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

3/4” (19.0)

Thickness

(In (mm))

0.03” (0.8)

0.04” (1.0)

Dimension (In (mm))

ABCD

0.36” (9.1) 0.36” (9.2) 0.26” (6.5) 0.51” (13)

0.51” (13.0) 0.53” (13.5) 0.38” (9.7) 0.79” (20)

0.64” (16.2) 0.63” (16.0) 0.51” (12.9) 0.79” (20)

0.76” (19.4) 0.75” (19.0) 0.63” (16.0) 0.91” (23)

0.92” (23.3) 0.94” (24.0) 0.76” (19.2) 1.34” (34)

Flare nut width

(In (mm))

0.67” (17)

0.87” (22)

0.94” (24)

1.06” (27)

1.42” (36)

ØD

– 26 –

43˚to 45˚

45˚to 46˚

B A

Fig. 6-2-2 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.

Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable.

When choosing the tightening torque, comply with values designated by manufacturers.

Table 6-2-6 shows reference values.

NOTE

When applying oil to the flare surface, be sure to use oil designated by the manufacturer.

If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

Table 6-2-6 Tightening torque of flare for R410A [Reference values]

Outer diameter (In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Tightening torque (ft • lbs (N • m))

10 – 13 (14 – 18)

24 – 31 (33 – 42)

37 – 46 (50 – 62)

50 – 60 (68 – 82)

– 27 –

6-3. Tools

6-3-1. Required Tools

Refer to the “4. Tools” (Page 8)

6-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.

(INDOOR unit)

(Liquid side)

Refrigerant cylinder

(With siphon pipe)

Check valve

(Gas side)

Open/Close valve

for charging

Electronic balance for refrigerant charging

Opened

(OUTDOOR unit)

Closed

Service port

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

Recover the refrigerant, and check no refrigerant remains in the equipment.

(For refrigerant charging, see the figure below.)

Connect the charge hose of the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

When the compound gauge’s pointer has indicated –101 kpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge

liquid refrigerant.

1) Never charge refrigerant exceeding the specified amount.

2) If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3) Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

Fig. 6-4-1 Configuration of refrigerant charging

– 28 –

Gauge manifold

[ Cylinder with siphon ] [ Cylinder without siphon ]

OUTDOOR unit

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

Refrigerant

cylinder

Electronic

balance

Siphon

R410A refrigerant is HFC mixed refrigerant.

Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

Fig. 6-4-2

6-5. Brazing of Pipes

6-5-1. Materials for Brazing

1. Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper.

It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

2. Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

3. Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead.

Since it is weak in adhesive strength, do not use it for refrigerant pipes.

1) Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2) When performing brazing again at time of servicing, use the same type of brazing filler.

6-5-2. Flux

1. Reason why flux is necessary

• By removing the oxide film and any foreign

matter on the metal surface, it assists the flow of brazing filler.

• In the brazing process, it prevents the metal

surface from being oxidized.

• By reducing the brazing filler's surface tension,

the brazing filler adheres better to the treated metal.

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.

– 29 –

Nitrogen gas

cylinder

Pipe

Flow meter

Stop valve

From Nitrogen cylinder

Nitrogen gas

Rubber plug

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.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

3. Types of flux

• Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 1,472°F (800°C).

• Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

4. Piping materials for brazing and used brazing filler/flux

1) Do not enter flux into the refrigeration cycle.

2) When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates.

Therefore, use a flux which does not contain chlorine.

3) When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

4) Remove the flux after brazing.

6-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas flow.

Never use gas other than Nitrogen gas.

1. Brazing method to prevent oxidation

1) Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3) Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4) When the Nitrogen gas is flowing, be sure to keep the piping end open.

5) Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m³/Hr or 2.9 psi (0.02 MPa) by means of the reducing valve.

6) After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7) Remove the flux completely after brazing.

Fig. 6-5-1 Prevention of oxidation during brazing

Piping

material

Copper - Copper

Copper - Iron

Iron - Iron

Used brazing

filler

Phosphor copper

Silver

Used

flux

Do not use

Paste flux

Vapor flux

– 30 –

F01, 02, 25A fuse Lead wire for grounding

(Black)

DB01:

Single-phase rectifier diode

Comp. lead

(Red) (White) (Black)

DB02:

High power factor diode

Q404:

High power factor circuit IGBT

F03: 3.15A fuse

C12, 13, 14

electrolytic capacitor

CN500:

Case thermo. or

High pressure SW

Fan drive circuit

Q300 to Q305: FET (QTY: 6P)

12V

GND

IC800: MCU

CN700:

PMV connector

CN605:

Sub SW board connector

Comp. drive circuit

Q200 to Q205: IGBT (QTY: 6P)

IC200: Drive IC (QTY: 1P)

L-phase power supply lead

(Black)

N-phase power supply lead

(White)

Serial lead (Orange)

Reactor lead connector

(White)

CN300:

Fan motor connector

CN602:

Outdoor temperature

(TO) sensor connector

CN806:

Optional connector

CN600:

Heat exchange temperature

(TE) sensor connector

CN603:

Suction temperature

(TS) sensor connector

CN601:

Discharge temperature

(TD) sensor connector

CN701:

4-way valve connector

RY701:

4-way valve relay

IC800: MCU

DB01:

Single-phase rectifier diode

F03: 3.15A fuse

C12, 13, 14

electrolytic capacitor

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS

7-1. Print Circuit Board

<MCC-5009>

RAV-SP180AT2-UL

– 31 –

<MCC-1571>

RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Case thermostat connector CN609 (Blue)

High pressure SW CN690 (Red)

Power supply circuit protective fuse F100 250V, 3.15A, Plastic case)

4-way valve connector CN701 (White)

Compressor ON output connector CN704 (Blue)

Heater output connector CN610 (Gray)

Outside input connector CN610 (Yellow)

Specific operation switch SW801 SW804

Display select switch SW800 SW803

Power-ON, error display LED D800 to 804 (Yellow) D805 (Green)

PMV connector CN710 (White)

Initial setting switch SW802

Indoor/Outdoor communication signal LED D503 (Green, Outdoor → Indoor) D502 (Orange, Indoor → Outdoor)

Temp. sensor connector TL CN604 (White) TD CN603 (White) TO CN602 (Yellow) TE CN601 (White) TS CN600 (White)

Fan motor output (Lower side) CN300 (White)

Fan motor output (Upper side) CN400 (White)

Compressor output terminal CN202 CN201 CN200

Electrolytic condenser

4-way valve protective fuse F700 (250V, 3.15A, Plastic case)

Power supply protective fuse F01 (250V, 25A)

Inter-unit cable protective fuse F03 (250V, 25A)

Inter-unit cable connector CN04 (White)

Lead wire for connection of power supply P01 (Red) P02 (White)

Connector

for reactor

Connector for reactor

Connector

for reactor

Connector for reactor

Lead wire

for grounding

P09 (Black)

Lead wire for grounding P09 (Black)

– 32 –

7-2. Outline of Main Controls

RAV-SP180AT2-UL

1. PMV (Pulse Motor Valve) control

1) PMV is controlled between (20 to 500) pulsed during operation.

2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming (2 to 5K) as the target value.

3) In heating operation, PMV is usually controlled with the temperature difference between TS sensor and TE sensor aiming (–2 to 4K) as the target value.

4) When the cycle excessively heated in both cooling and heating operation, PMV is controlled by TD sensor.

The target value is 213.8°F (101°C) for both cooling and heating operations.

REQUIREMENT

A sensor trouble may cause a liquid back-flow or abnormal overheat resulting in excessive shortening of the compressor life.

In a case of trouble on the compressor, be sure to check there is no error in the resistance value or the refrigerating cycle of each sensor after repair and then start the operation.

2. Discharge temperature release control

1) When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control, this control lowers the operation frequency.

It subdivides the frequency control up to 0.6Hz to stabilize the cycle.

2) When the discharge temperature detected an abnormal stop zone, the compressor stops and then restarts after 2 minutes 30 seconds.

The error counting is cleared when the operation continued for A minutes. If the error is detected by B times without clearing, the error is determined and restarting is not performed.

∗ The cause is considered as excessively little amount of refrigerant, PMV error or clogging of the cycle.

3) For displayed contents of error, confirm on the check code list.

SP180

A 6

B 8

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up

(Up to command)

As command is

Abnormal stop

TD ˚F (˚C)

242.6 (117)

224.6 (107)

221.0 (105)

215.6 (102)

199.4 (93)

– 33 –

3. Outdoor fan control

Revolution frequency allocation of fan taps [rpm]

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).

Only for 60 seconds after start-up of operation, it is fixed by the maximum fan tap corresponded to the zone in the following table, and then the fan is controlled by temperature of TE sensor.

When temperature of TD sensor became high sufficiently, it is controlled so that the fan revolution frequency will become higher ignoring TE sensor temperature.

+1 tap / 20 sec

Up to the maximum

revolution frequency of each zone

∗ Operation with W1 in case of fan-OFF

Revolution frequency hold

Operation with the maximum tap of each zone

Operation with WF

Normal fan control by TE sensor

–1 tap / 20 sec

Down to the minimum

revolution frequency of each zone

˚F (˚C)

185 (85)

176 (80)

167 (75)

149 (65)

89.6 (32)

84.2 (29)

RAV-SP

180AT2-UL

W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF

200 250 300 400 480 500 520 560 640 670 700 750 800 880 980

Temp. range

100.4°F (38°C) ≤ TO

82.4°F (28°C) ≤ TO < 100.4°F (38°C)

59°F (15°C) ≤ TO < 82.4°F (28°C)

41.9°F (5.5°C) ≤ TO < 59°F (15°C)

32°F (0°C) ≤ TO < 41.9°F (5.5°C)

23°F (–5°C) ≤ TO < 32°F (0°C)

TO < 23°F (–5°C)

TO error

20 Hz or lower 20Hz to 45Hz 45Hz or higher

Min. Max. Min. Max. Min. Max.

W6 WB W7 WE W9 WF

W5 WA W6 WD W8 WE

W3 W7 W4 W9 W6 WB

W2 W5 W3 W7 W5 W9

W1 W3 W2 W5 W3 W7

W1 W2 W1 W3 W2 W4

OFF OFF OFF OFF W1 W3

W1 WB W1 WE W1 WF

– 34 –

3-2) Heating fan control

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 ≥ 75.2°F (24°C) continues for 5 minutes, the compressor stops.

It is the same status as the normal THERMO OFF without error display. The compressor restarts after approx. 2 minutes 30 seconds and this intermittent operation is not abnormal.

In case that the status in item e generates frequently, stain on filter of the suction part of the indoor unit is considered. Clean the filter and then restart the operation.

–2 taps / 20 sec. (Down to W1)

Stop timer count

+1 tap / 20 sec

(Up to the maximum tap of each zone)

–2 taps / 20 sec. (Down to W1)

–1 tap / 20 sec. (Down to W1)

Revolution frequency hold

TE ˚F (˚C)

75.2 (24)

69.8 (21)

64.4 (18)

59.0 (15)

Temp. range

50°F (10°C) ≤ TO

41.9°F (5.5°C) ≤ TO < 50°F (10°C)

23°F (–5°C) ≤ TO < 41.9°F (5.5°C)

TO < 23°F (–5°C)

TO error

20 Hz or lower

Max.

20Hz to 45Hz

Max.

45Hz or higher

Max.

– 35 –

4. Coil heating control

1) This control function heats the compressor by turning on the stopped compressor instead of a case heater. It purposes to prevent stagnation of the refrigerant inside of the compressor.

2) As usual, turn on power of the compressor for the specified time before a test run after installation; otherwise a trouble of the compressor may be caused.

As same as a test run, it is recommended to turn on power of the compressor beforehand when starting operation after power of the compressor has been interrupted and left as it is for a long time.

3) Using TD sensor and TE sensor, RAV-SP180AT2-UL judges the power-on.

4) The power is turned off when TD is 86°F (30°C) or more.

REQUIREMENT

In some cases, the sound of power-ON may be heard. It is not abnormal.

REQUIREMENT

While heating the coil, the power sound may be heard. However it is not a trouble.

5. Short intermittent operation preventive control

1) For 3 to 10 minutes after operation start, in some cases, the compressor does not stop to protect the compressor even if receiving the THERMO OFF signal from indoor.

However it is not abnormal status. (The operation continuance differs according to the operation status.)

2) When the operation stops by the remote controller, the operation does not continue.

6. Current release control

No. of revolutions of the compressor is controlled by AC current value detected by the outdoor P.C. board so that the input current of the inverter does not exceed the specified value.

Continuous power-ON Output [10W or equivalent]

Continuous power-ON Output [20W or equivalent]

No power

(Normal time)

TE [˚C]

30.2 (–1)

21.2 (–6)

19.4 (–7)

32.0 ( 0)

• Power-ON condition TD < 86˚F (30˚C)

I1–1.0

Current [A]

Normal operation

Frequency down

Hold Hold

Model

I1 value [A]

RAV-SP180AT2-UL

COOL HEAT

10.80 13.05

– 36 –

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 (I1) is selected from the following table according to TO sensor value.

Current release control value (I1)

[A]

8. Over-current protective control

1) When the over-current protective circuit detected an abnormal current, stop the compressor.

2) The compressor restarts after 2 minutes 30 seconds as setting [1] as an error count.

3) When the error count [8] was found, determine an error and restart operation is not performed.

4) For the error display contents, confirm on the check code list.

9. High-pressure SW control

1) The operation frequency is controlled to restrain abnormal rising of high pressure by the High-pressure SW.

2) When cooling operation detects abnormal pressure of the stop zone, stop the compressor and the error count becomes +1.

3) When the compressor stopped with 2), the compressor will restart only when the pressure lowers under the reset pressure after 2 minutes and 30 seconds.

Temperature range

122°F (50°C) ≤ TO

113°F (45°C) ≤ TO < 122°F (50°C)

102.2°F (39°C) ≤ TO < 113°F (45°C)

TO < 102.2°F (39°C)

TO error

RAV-SP180AT2-UL

5.1

7.8

10.8

5.1

4) The error count when the compressor stopped with 2) is cleared after the operation continued for 10 minutes.

If the error count becomes [8] without clearing, the error is determined and reactivation is not performed.

5) For the error display contents, confirm on the check code list.

Pressure of High-pressure switch control

STOP pressure

RESET pressure

601.8

+ 0

⎛ 4.15

.2 psi ⎞

– 29 psi ⎝ –0.2 MPa ⎠

464 ± 29 psi (3.20 ± 0.2 MPa)

10. Auto restart

1) Object

It restarts the operation automatically after resetting the unexpected stop of power supply such as power failure.

2) Contents

After returning from a power failure, the auto restart function reads the operation status from EEPROM and then restarts the operation automatically according to the operation contents.

3) Setup of function exchange by wired remote controller CODE No. (DN): 28

SET DATA

Auto restart

0000

None

0001

Provided

– 37 –

* The minimum TE value and To value between 10 and 15 minutes after heating operation has started

are stored in memory as TE0 and To0, respectively.

0 10 15 29 35 91

[min.]

∗

24.8 (–4)

˚F (˚C)

21.2 (–6)

14 (–10)

–25

A zone

B zone

C zone

Start of heating operation

D zone

A zone

B zone

C zone

D zone

In normal To In abnormal To

When status (TE0 – TE) – (To0 – To) ≥ 37.4°F (3°C) When status (TE0 – TE) ≥ 37.4°F (3°C)

continued for 20 seconds continued for 20 seconds

When status (TE0 – TE) – (To0 – To) ≥ 36.5°F (2.5°C) When status (TE0 – TE) 36.5°F (2.5°C)

continued for 20 seconds continued for 20 seconds

When the status (TE ≤ –14.8°F (–26°C)) continued for 20 seconds

When the status (TE ≤ 14°F (–10°C)) continued for 20 seconds

11. 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 53.6°F (12°C) or continued 41°F (5°C) ≤ TE < 53.6°F (12°C) for 80 seconds. The defrost operation also finishes when it continued for 15 minutes even if TE sensor temperature was 41°F (5°C) or lower.

3) After defrost operation was reset, the compressor stopped for approx. 40 seconds and then the heating operation starts.

– 38 –

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up

(Up to command)

As command is

Abnormal stop

˚F (˚C)

231.8 (111)

228.2 (109)

222.8 (106)

217.4 (103)

204.8 (96)

RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

1. PMV (Pulse Motor Valve) control

1) PMV is controlled between 30 and 500 pulsed during operation.

2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming 1 to 4K as the target value.

3) In heating operation, PMV is usually controlled with the temperature difference between TS sensor and TE sensor aiming –1 to 4K (SP240: 2 to 4K) as the target value.

4) When the cycle excessively heated in both cooling and heating operation, PMV is controlled by TD sensor. The target value is usually 195.8°F (91°C) in cooling operation and 204.8°F (96°C) in heating operation.

REQUIREMENT

A sensor trouble may cause a liquid back-flow or abnormal overheat resulting in excessive shortening of the compressor life. In a case of trouble on the compressor, be sure to check there is no error in the resistance value or the refrigerating cycle of each sensor after repair and then start the operation.

2. Discharge temperature release control

1) When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control, this control lowers the operation frequency. It subdivides the frequency control up to 0.6Hz to stabilize the cycle.

2) When the discharge temperature detected an abnormal stop zone, the compressor stops and then restarts after 2 minutes 30 seconds.

The error counting is cleared when the operation continued for 10 minutes. If the error is detected by 4 times without clearing, the error is determined and restarting is not performed.

∗ The cause is considered as excessively little amount of refrigerant, PMV error or clogging of the cycle.

3) For displayed contents of error, confirm on the check code list.

– 39 –

3. Outdoor fan control

Revolution frequency allocation of fan taps [rpm]

3-1) Cooling fan control

The outdoor fan is controlled by TL sensor, TO sensor and the operation frequency. The outdoor fan is controlled by every 1 tap of DC fan control (SP240: 15 taps, SP300, SP360, SP400: 14 taps).

Only for 60 seconds 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 TL sensor.

WE tap

+1 tap / 20 sec

Up to the maximum

revolution frequency of each zone

Revolution frequency hold

–1 tap / 20 sec

Up to the minimum

revolution frequency of each zone

˚F (˚C)

136.4 (58)

131.0 (55)

100.4 (38)

95.0 (35)

RAV-

SP300AT2-UL SP360AT2-UL SP420AT2-UL

W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE

Up 200 240 240 260 320 380 480 500 530 610 640 660 720 780

Down — — 200 280 360 400 500 520 550 630 660 700 740 820

RAV-

SP240AT2-UL

W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF

200 230 260 300 340 380 420 460 520 570 600 630 670 710 740

∗ : WB for SP300

Temp. range

100.4°F (38°C) ≤ TO

84.2°F (29°C) ≤ TO < 100.4°F (38°C)

59°F (15°C) ≤ TO < 84.2°F (29°C)

41°F (5°C) ≤ TO < 59°F (15°C)

32°F (0°C) ≤ TO < 41°F (5°C)

24.8°F (–4°C) ≤ TO < 32°F (0°C)

TO < 24.8°F (–4°C)

TO error

20 Hz or lower 20Hz to 45Hz 45Hz or higher

Min. Max. Min. Max. Min. Max.

W6 WC W8 WE WA WE

W5 WB W7 WD W9 WD

W4 W8 W6 WA W8 WC

W3 W6 W5 W8 W7 WA

W2 W4 W4 W6 W5 W8

W2 W3 W3 W5 W4 W6

OFF OFF OFF W2 OFF W3

OFF WC OFF WE OFF WE

Temp. range

100.4°F (38°C) ≤ TO

84.2°F (29°C) ≤ TO < 100.4°F (38°C)

59°F (15°C) ≤ TO < 84.2°F (29°C)

41°F (5°C) ≤ TO < 59°F (15°C)

32°F (0°C) ≤ TO < 41°F (5°C)

24.8°F (–4°C) ≤ TO < 32°F (0°C)

TO < 24.8°F (–4°C)

TO error

20 Hz or lower 20Hz to 45Hz 45Hz or higher

Min. Max. Min. Max. Min. Max.

W6 WC W8 WC WA WE

W5 WB W7 WC* W9 WC

W4 W8 W6 WA W8 WC

W3 W6 W5 W8 W7 WA

W2 W4 W4 W6 W5 W8

W2 W3 W3 W5 W4 W6

W1 W2 W1 W4 W2 W6

W1 WC W1 WC W2 WD

<RAV-SP240AT2-UL>

<RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL>

Revised : Feb. 2010

– 40 –

3-2) Heating fan control

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.

Object: RAV-SP300AT2-UL

Object: RAV-SP360AT2-UL, RAV-SP420AT2-UL

–2 taps / 20 sec. (Up to W1)

Stop timer count

+1 tap / 20 sec

(Up to the maximum tap of each zone)

–2 taps / 20 sec. (Up to W1)

–1 tap / 20 sec. (Up to W1)

Revolution frequency hold

˚F (˚C)

75.2 (24)

69.8 (21)

64.4 (18)

59.0 (15)

When TE ≥ 75.2°F (24°C) continues for 5 minutes, the compressor stops. It is the same status as the normal THERMO-OFF without error display.

The compressor restarts after approx. 2 minutes 30 seconds and this intermittent operation is not abnormal.

In case that the status in item

generates frequently, stain on filter of the suction part of the indoor unit is considered. Clean the filter and then restart the operation.

Object: RAV-SP240AT2-UL

Temp. range

50°F (10°C) ≤ TO

41°F (5°C) ≤ TO < 50°F (10°C)

26.6°F (–3°C) ≤ TO < 41°F (5°C)

14°F (–10°C) ≤ TO < 26.6°F (–3°C)

TO < 14°F (–10°C)

TO error

20 Hz or lower 20Hz to 45Hz 45Hz or higher

Max. Max. Max.

W7 W8 W9

W9 WA WB

WB WB WC

WC WC WC

WD WD WD

Temp. range

50°F (10°C) ≤ TO

41°F (5°C) ≤ TO < 50°F (10°C)

26.6°F (–3°C) ≤ TO < 41°F (5°C)

14°F (–10°C) ≤ TO < 26.6°F (–3°C)

TO < 14°F (–10°C)

TO error

20 Hz or lower 20Hz to 45Hz 45Hz or higher

Max. Max. Max.

W7 W8 W9

W9 WA WA

WA WA WB

WB WB WB

WD WD WD

Temp. range

50°F (10°C) ≤ TO

41°F (5°C) ≤ TO < 50°F (10°C)

26.6°F (–3°C) ≤ TO < 41°F (5°C)

14°F (–10°C) ≤ TO < 26.6°F (–3°C)

TO < 14°F (–10°C)

TO error

20 Hz or lower 20Hz to 45Hz 45Hz or higher

Max. Max. Max.

W7 W8 W9

W9 WB WD

WD WD WE

WE WE WE

WF WF WF

– 41 –

4. Coil heating control

1) This control function heats the compressor by turning on the stopped compressor instead of a case heater.

It purposes to prevent stagnation of the refrigerant inside of the compressor.

2) As usual, turn on power of the compressor for the specified time before a test run after installation; otherwise a trouble of the compressor may be caused.

As same as a test run, it is recommended to turn on power of the compressor beforehand when starting operation after power of the compressor has been interrupted and left as it is for a long time.

3) A judgment for electricity is performed by TD and TO sensors.

If TO sensor is defective, a backup control is automatically performed by TE sensor.

For a case of defective TO sensor, judge it with outdoor LED display.

4) For every model, the power is turned off when TD is 86°F (30°C) or more.

REQUIREMENT

While heating the coil, the power sound may be heard. However it is not a trouble.

5. Short intermittent operation preventive control

1) For 3 to 10 minutes after operation start, in some cases, the compressor does not stop to protect the compressor even if receiving the thermostat-OFF signal from indoor.

However it is not abnormal status. (The operation continuance differs according to the operation status.)

2) When the operation stops by the remote controller, the operation does not continue.

6. Current release control

No. of revolutions of the compressor is controlled by AC current value detected by T620 on the outdoor P.C. board so that the input current of the inverter does not exceed the specified value.

Intermittent power-ON 10 minutes: ON / 5 minutes: OFF Output [40W or equivalent]

Continuous power-ON Output [40W or equivalent]

No power

(Normal time) (In defective TO sensor)

˚F (˚C)

59 (15)

50 (10)

46.4 (8)

64.4 (18)

• Power-ON condition TD < 86˚F (30˚C) • Power-ON condition TD < 86˚F (30˚C)

Intermittent power-ON 10 minutes: ON / 5 minutes: OFF Output [40W or equivalent]

Continuous power-ON Output [40W or equivalent]

No power

˚F (˚C)

64.4 (18)

53.6 (12)

50 (10)

68 (20)

I1–1.0

Current [A]

Normal operation

Frequency down

Hold Hold

Objective

model

RAV-

I1 value [A]

SP240AT2-UL

COOL HEAT

16.0 20.0

SP300AT2-UL SP360AT2-UL SP420AT2-UL

COOL HEAT

20.0 20.0

– 42 –

8. Over-current protective control

1) When the over-current protective circuit detected an abnormal current, stop the compressor.

2) The compressor restarts after 2 minutes 30 seconds setting [1] as an error count.

3) When the error count [8] was found, determine an error and restart operation is not performed.

4) For the error display contents, confirm on the check code list.

9. High-pressure SW control

1) The operation frequency is controlled to restrain abnormal rising of high pressure by the High-pressure SW.

2) When cooling operation detects abnormal pressure of the stop zone, stop the compressor and the error count becomes +1.

3) When the compressor stopped with 2), the compressor will restart only when the pressure lowers under the reset pressure after 5 minutes.

STOP pressure

RESET pressure

601.8

+ 0

⎛ 4.15

.2 psi ⎞

– 29 psi ⎝ –0.2 MPa ⎠

464 ± 29 psi (3.20 ± 0.2 MPa)

Pressure of High-pressure switch control

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 (I1) is selected from the following table according to TO sensor value.

Current release control value (I1)

[A]

Temperature range

111.2°F (44°C) ≤ To

102.2°F (39°C) ≤ To < 111.2°F (44°C)

To < 102.2°F (39°C)

TO error

RAV-SP300AT2-UL RAV-SP360AT2-UL RAV-SP420AT2-UL

15.0

17.7

20.0

15.0

4) The error count when the compressor stopped with 2) is cleared after the operation continued for 10 minutes.

If the error count becomes [10] without clearing, the error is determined and reactivation is not performed.

5) For the error display contents, confirm on the check code list.

– 43 –

4) The time of above d can be changed by exchanging jumper [J805] and [J806] of the outdoor control P.C. board. (Setting at shipment: 150 minutes)

A zone

B zone

C zone

D zone

In normal To In abnormal To

When status (TE0 – TE) – (To0 – To) ≥ 37.4°F (3°C) When status (TE0 – TE) ≥ 37.4°F (3°C)

continued for 20 seconds continued for 20 seconds

When status (TE0 – TE) – (To0 – To) ≥ 35.6°F (2°C) When status (TE0 – TE) ≥ 35.6°F (2°C)

continued for 20 seconds continued for 20 seconds

When status (TE ≤ –9.4°F (–23°C)) continued for 20 seconds

When compressor operation status of TE < 28.4°F (–2°C) is calculated by d portion

{

: Short circuit, × : Open

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 53.6°F (12°C) or higher for 3 seconds or continued 44.6°F (7°C) ≤ TE < 53.6°F (12°C) for 1 minute.

The defrost operation also finishes when it continued for 10 minutes even if TE sensor temperature was

44.6°F (7°C) or lower.

3) After defrost operation was reset, the compressor stopped for approx. 40 seconds and then the heating operation starts.

∗ The minimum TE value and To value between 10 and 15 minutes after heating operation has started

are stored in memory as TE0 and To0, respectively.

0 10 15 39 45 55 d

[min.]

∗

TE ˚F (˚C)

28.4 (–2)

23.0 (–5)

14.0 (–10)

–9.4 (–23)

A zone

B zone

C zone

D zone

A zone

B zone

C zone

D zone

Start of heating operation

J805

{

× ×

150 minutes

Setting at shipment

90 minutes

60 minutes

30 minutes

J806

{

– 44 –

11. Compressor protective control <RAV-SP240AT2-UL only>

1) This control purposes to raise the operation frequency until 45Hz for 2 minutes in order to protect the compressor (Prevention of oil accumulation in the refrigerating cycle) when the status that the operation frequency is 45Hz or less has continued for 10 hours was calculated.

The operation frequency follows the normal indoor command after controlling.

2) Although the compressor may stop by THERMO-OFF control when the room temperature varies and then attains the set temperature by this control, it is not abnormal.

3) During this control works, if stopping the operation by the remote controller, the operation does not continue.

12. Auto restart

1) Object

It restarts the operation automatically after resetting the unexpected stop of power supply such as power failure.

2) Contents

After returning from a power failure, the auto restart function reads the operation status from EEPROM and then restarts the operation automatically according to the operation contents.

3) Setup of function exchange by wired remote controller CODE No. (DN): 28

SET DATA

Auto restart

0000

None

0001

Provided

– 45 –

8. TROUBLESHOOTING

8-1. 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.

• Is not 3-minutes delay (3 minutes after compressor OFF)?

• Is not the outdoor unit in standby status though the remote controller reached the setup temperature?

• Does not timer operate during fan operation?

• Is not an overflow error detected on the indoor unit?

• Is not outside high-temperature operation controlled in heating operation?

2. Indoor fan does not rotate.

• Does not cool air discharge preventive control work in heating operation?

3. Outdoor fan does not rotate or air volume changes.

• Does not high-temperature release operation control work in heating operation?

• Does not outside low-temperature operation control work in cooling operation?

• Is not defrost operation performed?

4. ON/OFF operation cannot be performed from remote controller.

• Is not automatic address being set up? (When the power is turned on at the first time or when indoor unit address setting is changed, the operation cannot be performed for maximum approx. 5 minutes after power-ON.)

• Is not being carried out a test run by operation of the outdoor P.C. board?

b) Did you return the cabling to the initial positions?

c) Are connecting cables of indoor unit and remote controller correct?

2. Troubleshooting procedure

When a trouble occurred, check the parts along with the following procedure.

Trouble Confirmation of check code display Check defective parts.

→ →

NOTE :

For cause of a trouble, power conditions or malfunction/erroneous diagnosis of microcomputer due to outer noise is considered except the items to be checked. If there is any noise source, change the cables of the remote controller to shield cables.

Revised : Feb. 2010

– 46 –

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.

• Is not 3-minutes delay (3 minutes after compressor OFF)?

• Is not the outdoor unit in standby status though the remote controller reached the setup temperature?

• Does not timer operate during fan operation?

• Is not an overflow error detected on the indoor unit?

• Is not outside high-temperature operation controlled in heating operation?

2. Indoor fan does not rotate.

• Does not cool air discharge preventive control work in heating operation?

3. Outdoor fan does not rotate or air volume changes.

• Does not high-temperature release operation control work in heating operation?

• Does not outside low-temperature operation control work in cooling operation?

• Is not defrost operation performed?

4. ON/OFF operation cannot be performed from remote controller.

• Is not forced operation performed?

• Is not the control operation performed from outside/remote side?

• Is not automatic address being set up?

• Is not being carried out a test run by operation of the outdoor controller?

b) Did you return the cabling to the initial positions?

c) Are connecting cables between indoor unit and receiving unit correct?

2. Troubleshooting procedure

(When the power is turned on at the first time or when indoor unit address setting is changed, the operation cannot be performed for maximum approx. 5 minutes after power-ON.)

When a trouble occurred, check the parts along with the following procedure.

1) Outline of judgment

The primary judgment to check where a trouble occurred in indoor unit or outdoor unit is performed with the following method.

Method to judge the erroneous position by flashing indication on the display part of indoor unit (sensors of the receiving unit)

The indoor unit monitors 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.

Trouble

→→

Confirmation of lamp display (When 4-way air discharge cassette type, Under ceiling type wireless remote controller is connected)

Check defective position and parts.

Revised : Feb. 2010

– 47 –

8-2. Troubleshooting

8-2-1. 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.

: Go off, : Go on, : Flash (0.5 sec.)

⎫ ⎪ ⎬ ⎪ ⎭

⎫ ⎬ ⎭

⎫ ⎪ ⎬ ⎪ ⎭

⎫ ⎬ ⎭

⎫ ⎪ ⎬ ⎪ ⎭

∗1: These are representative examples and the check code differs according to the outdoor unit to be combined.

Lamp indication

Operation

Timer Ready

No indication at all

Operation

Timer Ready

Flash

Operation

Timer Ready

Flash

Operation

Timer Ready

Alternate flash

Operation

Timer Ready

Alternate flash

Check code

—

E01

E02

E03

E08

E09

E10

E18

E04

P10

P12

P03

P04

P05

P07

P15

P19

P20

P22

P26

P29

P31

Cause of trouble occurrence

Power supply OFF or miswiring between lamp indication unit and indoor unit

Receiving error

Receiving unit

Miswiring or wire connection error

Sending error

Communication stop

between receiving unit and indoor unit

Duplicated indoor unit No.

Setup error

Duplicated master units of remote controller

Communication error between CPUs on indoor unit P.C. board

Wire connection error between indoor units, Indoor power OFF (Communication stop between indoor header and follower)

Miswiring between indoor unit and outdoor unit or connection erorr (Communication stop between indoor and outdoor units)

Overflow was detected.

Protective device of indoor unit worked.

Indoor DC fan error

Outdoor unit discharge temp. error

Protective device of

∗1

Outdoor high pressure system error

outdoor unit worked.

Negative phase detection error

Heat sink overheat error Outdoor unit error

Gas leak detection error

4-way valve system error (Indoor or outdoor unit judged.)

Outdoor unit high pressure protection

Outdoor unit: Outdoor unit error

Protective device of

Outdoor unit: Inverter Idc operation ∗1

Outdoor unit: Position detection error

outdoor unit worked.

Stopped because of error of other indoor unit in a group (Check codes of E03/L03/L07/L08)

⎫ ⎪ ⎬ ⎪ ⎭

Revised : Feb. 2010

– 48 –

⎫ ⎪ ⎬ ⎪ ⎭

Lamp indication

Operation

Timer Ready

Alternate flash

Operation

Timer Ready

Alternate flash

Operation

Timer Ready

Simultaneous flash

Operation

Timer Ready

Simultaneous flash

Operation

Timer Ready

Flash

Operation

Timer Ready

Simultaneous flash

Operation

Timer Ready

Simultaneous flash

Check code

F01

F02

F10

F04

F06

F07

F08

F12

F13

F15

F29

F31

H01

H02

H03

H04

H06

L03

L07

L08

L09

L10

L20

L29

L30

L31

Cause of trouble occurrence

Heat exchanger sensor (TCJ) error

Heat exchanger sensor (TC) error Indoor unit sensor error

Heat exchanger sensor (TA) error

Discharge temp. sensor (TD) error

Temp. sensor (TE) error

Temp. sensor (TL) error

Temp. sensor (TO) error Sensor error of outdoor unit

Temp. sensor (TS) error

Temp. sensor (TH) error

Temp. Sensor miswiring (TE, TS)

Indoor EEPROM error

Outdoor EEPROM error

Compressor break down

Compressor lock

Outdoor compressor system error

Current detection circuit error

Case thermostat worked.

Outdoor unit low pressure system error

Duplicated header indoor units

There is indoor unit of group connection → AUTO address in individual indoor unit.

∗ If group construction and

Unsetting of group address

address are not normal

Missed setting

when power supply turned on,

(Unset indoor capacity)

automatically goes to address setup mode.

Unset model type (Service board)

Duplicated indoor central addresses

Outdoor unit and other error Others

Outside interlock error

Negative phase error

⎫ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎬ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎭

⎫ ⎪ ⎪ ⎬ ⎪ ⎪ ⎭

⎫ ⎪ ⎪ ⎪ ⎪ ⎬ ⎪ ⎪ ⎪ ⎪ ⎭

⎫ ⎪ ⎪ ⎬ ⎪ ⎪ ⎭

Revised : Feb. 2010

– 49 –

8-2-2. Others (Other than Check Code)

Lamp indication

Operation

Timer Ready

Simultaneous flash

Check code

—

Cause of trouble occurrence

During test run

Revised : Feb. 2010

– 50 –

8-2-3. Check Code List (Outdoor)

{

: Go on,  : Flash, z : Go off

ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED



When this warning was detected before group construction/address check finish at power supply was turned on, the mode shifts automatically to AUTO address setup mode.

Remote controller indication

F04

F06

F08 F07 F12 F13 F15 F31

H01

H02 H03 H04

L10

L29

P03

P04

P05 P07 P15 P20 P22 P26 P29

E01

E02

E03

E04 E08

E09

E10

E18

L03 L07 L08 L09

P19

Sensor lamp part

Block indication

Operation

Timer Ready Flash

{

ALT

{

ALT

{

ALT

{

ALT

{

ALT

{

ALT

{

ALT

{

SIM



{

SIM

{

SIM



ALT



ALT



ALT



ALT



ALT



ALT



ALT



ALT



ALT



SIM



SIM



SIM



SIM



ALT

Representative defective position

Outdoor unit Discharge temp. sensor (TD) error

Outdoor unit Temp. sensor (TE) error

Outdoor unit Outside temp. sensor (TO) error Outdoor unit Temp. sensor (TL) error Outdoor unit Temp. sensor (TS) error Outdoor unit Temp. sensor (TH) error Outdoor unit Misconnection of temp. sensor (TE, TS) Outdoor unit EEPROM error

Outdoor unit Compressor break down

Outdoor unit Compressor lock Outdoor unit Current detection circuit error Outdoor unit Case thermostat operation Outdoor unit Setting error of service P.C. board type

Outdoor unit Other outdoor unit error

Outdoor unit Discharge temp. error Outdoor unit

High pressure system error, Power supply voltage error Power supply error Outdoor unit Heat sink overheat Gas leak detection Outdoor unit High pressure system error Outdoor unit Outdoor fan error Outdoor unit Inverter Idc operation Outdoor unit Position detection error No remote controller master unit

Remote controller communication error

Remote controller send error

Regular communication error between indoor and remote controller

Indoor/Outdoor serial error Duplicated indoor addresses



Duplicated main remote controllers

Communication error between CPU Regular communication error between header and

follower indoor units Duplicated indoor header units



There is group cable in individual indoor unit.



Unset indoor group address



Unset indoor capacity

4-way valve inverse error

Detection

Outdoor

Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor

Outdoor Outdoor Outdoor Outdoor

Outdoor

Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor Remote

controller

Remote

controller

Indoor

Indoor Indoor

Remote

controller

Indoor

Indoor Indoor Indoor Indoor Indoor

Outdoor

Explanation of error contents

Open/Short of discharge temp. sensor was detected. Open/Short of heat exchanger temp. sensor was detected.

Miswiring between TE sensor and TS sensor Open/Short of outside temp. sensor was detected. Open/Short of heat exchanger temp. sensor was detected. Open/Short of suction temp. sensor was detected. Open/Short of heat sink temp. sensor (Board installed) was detected. Misconnection of outdoor heat exchanger temp. sensor and suction temp. sensor was detected. Outdoor P.C. board part (EEPROM) error was detected. When reached min-Hz by current release control, short-circuited current (Idc) after

DC excitation was detected. Compressor lock was detected. Current detection circuit error Case thermostat operation was detected. When outdoor service P.C. board was used, model type select jumper setting was inappropriate.

1) Defective parts on outdoor P.C. board (MCU communication, EEPROM, TH sensor error)

2) When outdoor service P.C. board was used, model type selection was inappropriate.

3) Other error (Heat sink abnormal overheat, gas leak, 4-way valve inverse error) was detected. Error was detected by discharge temp. release control. When case thermostat worked or High-pressure SW worked error was detected

by high release control from indoor/outdoor heat exchanger temp. sensor. Power supply voltage error Power supply voltage error Abnormal overheat was detected by outdoor heat sink temp. sensor. Abnormal overheat of discharge temp. or suction temp. was detected. Error was detected by high release control from indoor/outdoor heat exchanger temp. sensor. Error (Over-current, lock, etc.) was detected on outdoor fan drive circuit. Short-circuited protective operation of compressor drive circuit element (G-Tr /IGBT) worked. Position detection error of compressor motor was detected. Signal was not received from indoor unit.

Main remote controller was not set. (including 2 remote controllers)

Signal cannot be sent to indoor unit.

No communication from remote controller and network adapter

Serial communication error between indoor and outdoor Same address as yours was detected. In 2-remote controller control, both were set as master.

(Indoor header unit stops warning and follower unit continues operation.) MCU communication error between main motor micro computer and micro computer

Regular communication was impossible between master and follower indoor units.

There are multiple header units in a group. When even one group connection indoor unit exists in individual indoor unit Indoor address group was unset. Capacity of indoor unit was unset.

In heating operation, error was detected by temp. down of indoor heat exchanger or temp. up ofTE, TS.

Automatic Operation

reset

continuation

×× ××

{{

×× ×× ×× ×× ××

×× ××

×× ×× ××

×× ××

×× ×× ×× ×× ×× ××

——

{ × { ×

{

××

{ { ×

×× ×× ×× ××

{ ×

Revised : Feb. 2010

– 51 –

{

: Go on,  : Flash, z : Go off

ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous 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

Representative defective position

Indoor unit Heat exchanger sensor (TCJ) error Indoor unit Heat exchanger sensor (TC) error Indoor unit Room temp. sensor (TA) error Indoor unit Other indoor P.C. board error Indoor unit Indoor fan error Indoor unit Overflow detection Indoor unit Indoor fan error Other indoor unit error

Detection

Indoor Indoor Indoor Indoor Indoor Indoor Indoor Indoor

Explanation of error contents

Open/Short of heat exchanger (TCJ) was detected. Open/Short of heat exchanger (TC) was detected. Open/Short of room temp. (TA) was detected. EEPROM error (Other error may be detected. If no error, automatic address is repeated. Indoor AC fan error was detected. (Fan thermal relay worked.) Float switch worked. Indoor fan error (Over-current / Lock, etc.) was detected. Other indoor under condition of warning in group. E03/L07/L03/L08 warning

Automatic Operation

reset

continuation

{ × { × { ×

×× ×× ×× ××

{ ×

– 52 –

Error mode detected by indoor unit

Check

code

E03

E04

E08

L03

L07

L08

L09

L30

P10

P12

P19

P31

F01

F02

F10

F29

E10

E18

Cause of operation

No communication from remote controller (including wireless) and communication adapter

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. board

Duplicated indoor unit address

Duplicated indoor header unit

There is group wire in individual indoor unit.

Unset indoor group address

Unset indoor capacity

Abnormal input of outside interlock

Float switch operation

• Float circuit, Disconnection, Coming-off, Float switch contact error

Indoor DC fan error

4-way valve system error

• After heating operation has started, indoor heat exchangers temp. is down.

Own unit stops while warning is output to other indoor units.

Coming-off, disconnection or short of indoor heat exchanger temp. sensor (TCJ)

Coming-off, disconnection or short of indoor heat exchanger temp. sensor (TC)

Coming-off, disconnection or short of indoor heat exchanger temp. sensor (TA)

Indoor EEPROM error

• EEPROM access error

Communication error between indoor MCU

• Communication error between fan driving MCU and main MCU

Regular communication error between indoor header and follower units and between main and sub units

Status of

air conditioner

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Follower unit)

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Condition

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Judgment and measures

1. Check wires of remote controller and communication adapters.

• Remote controller LCD display OFF (Disconnection)

1. Outdoor unit does not completely operate.

• Inter-unit wire check, correction of miswiring

• Check outdoor P.C. board. Correct wiring of P.C. board.

• Check case tharmostat operation. (SP180 only)

2. When outdoor unit normally operates Check P.C. board (Indoor receiving / Outdoor sending).

1. Check whether remote controller connection (Group/Individual) was changed or not after power supply turned on (Finish of group construction/Address check).

* If group construction and address are not normal when the

power has been turned on, the mode automatically shifts to address setup mode. (Resetting of address)

1. Set indoor capacity (DN=11)

1. Check outside devices.

2. Check indoor P.C. board.

1. Trouble of drain pump

2. Clogging of drain pump

3. Check float switch.

4. Check indoor P.C. board.

1. Position detection error

2. Over-current protective circuit of indoor fan driving unit operated.

3. Indoor fan locked.

4. Check indoor P.C. board.

1. Check 4-way valve.

2. Check 2-way valve and check valve.

3. Check indoor heat exchanger (TC/TCJ).

4. Check indoor P.C. board.

1. Judge follower unit while header unit is [E03], [L03], [L07] or [L08].

2. Check indoor P.C. board.

1. Check indoor heat exchanger temp. sensor (TCJ).

2. Check indoor P.C. board.

1. Check indoor heat exchanger temp. sensor (TC).

2. Check indoor P.C. board.

1. Check indoor heat exchanger temp. sensor (TA).

2. Check indoor P.C. board.

1. Check indoor EEPROM. (including socket insertion)

2. Check indoor P.C. board.

1. Check indoor P.C. board.

1. Check remote controller wiring.

2. Check indoor power supply wiring.

3. Check indoor P.C. board.

Operation of diagnostic function

Revised : Feb. 2010

– 53 –

Error mode detected by outdoor unit

Check code

Indoor unit

4-Way

Under

High

Ceiling

Wall

F04 F04

F06 F06

F07

F12

F15

F08 F08

L29 F13

F31

L10

L29

P07

P15

P19

H01 H01

H02 H02

H03 H03

Cause of operation

Disconnection, short of discharge temp. sensor (TD)

Disconnection, short of outdoor temp. sensor (TE)

Disconnection, short of outdoor temp. sensor (TL)

Disconnection, short of suction temp. sensor (TS)

Miss-mounting of outdoor temp. sensor (TE, TS)

Disconnection, short of outside temp. sensor (TO)

Disconnection, short of heat sink temp. sensor (TH)

Outdoor P.C. EEPROM error

Unset jumper of service P.C. board

Communication error between outdoor P.C. board MCU

Heat sink overheat error ∗ Heat sink temp. sensor detected

over specified temperature.

Detection of gas leak ∗ Discharge temp. sensor (TD),

Suction temp. sensor (TS) detected temperature over specified temp.

4-way valve inverse error ∗ After heating operation has started,

indoor heat exchanger temp. lowers under the specified temp.

∗ After heating operation has started,

outdoor heat exchanger / suction temp. rises over the specified temp.

Compressor break down ∗ Although operation has started,

operation frequency decreases and operation stops.

Compressor lock ∗ Over-current detection after

compressor start-up

Current detection circuit error

Status of

air conditioner

Stop

Continue

Stop

Condition

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Judgment and measures

1. Check discharge temp. sensor (TD).

2. Check outdoor P.C. board.

1. Check temp. sensor (TE).

2. Check outdoor P.C. board.

1. Check temp. sensor (TL).

2. Check outdoor P.C. board.

1. Check suction temp. sensor (TS).

2. Check outdoor P.C. board.

1. Check temp. sensor (TE, TS).

2. Check outdoor P.C. board.

1. Check outside temp. sensor (TO).

2. Check outdoor P.C. board.

1. Check outdoor P.C. board.

1. Outdoor service P.C. board Check model type setting jumper wire.

1. Check outdoor P.C. board.

1. Check screw tightening between PC. Board and heat sink and check radiator grease.

2. Check heat sink blast path.

1. Check gas leak, recharge

2. Check full open of service valve.

3. Check PMV (Pulse Motor Valve).

4. Check broken pipe.

5. Check discharge temp. sensor (TD), suction temp. sensor (TS).

1. Check operation of 4-way valve.

2. Check outdoor heat exchanger (TE), suction temp. sensor (TS).

3. Check indoor heat exchanger sensor (TC).

4. Check 4-way valve coil.

5. Check PMV (Pulse Motor Valve).

1. Check power supply voltage. (AC187, 253V)

2. Overload operation of refrigerating cycle.

3. Wiring error of compressor (Open phase)

1. Trouble of compressor (Lock, etc.): Replace compressor.

2. Wiring error of compressor (Open phase)

1. Check outdoor P.C. board. (AC current detection circuit)

Operation of diagnostic function

– 54 –

Operation of diagnostic function

Check code

Indoor unit

4-Way

Under

High

Ceiling

Wall

P03 P03

P04

H04

P04

P05

P20

P22 P22

P26 P26

P29 P29

Cause of operation

Discharge temp. error ∗ Discharge temp. (TD) over

specified value was detected.

Case thermostat operation ∗ Abnormal overheat of compressor

High-pressure SW error

Power supply voltage error

High pressure protective operation

• During cooling operation, outdoor temp. sensor (TL) detected temperature over specified temp.

• During heating operation, indoor temp. sensor (TC, TCJ) detected temperature over specified temp.

Outdoor fan system error

Short-circuit error of compressor driving element

Position detection circuit error

Status of

air conditioner

Stop

Condition

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Displayed when

error is detected

Judgment and measures

1. Check refrigerating cycle (Gas leak)

2. Trouble of electronic expansion valve

3. Check discharge temp. sensor (TD).

1. Check case thermostat and connector.

2. Check gas leak, recharge

3. Check full open of service valve.

4. Check PMV (Pulse Motor Valve).

5. Check broken pipe.

• Check full-open of service valve.

• Check outdoor fan error.

• Check outdoor fan motor error.

• Check clogging of outdoor PMV.

• Check loading of indoor/outdoor heat exchangers.

• Short-circuit of outdoor discharge/suction air

• Check outdoor P.C. board (I/F) error.

• Check error of fan system (air volume drop) at indoor side.

• Check miswiring of communication line between indoor and outdoor.

• Check overcharge of refrigerant.

1. Check power supply voltage. AC198 to 253V

1. Check outdoor heat exchanger sensor (TL).

2. Check indoor heat exchanger sensor (TC, TCJ).

3. Check full open of service valve.

4. Check indoor/outdoor fan.

5. Check PMV (Pulse Motor Valve).

6. Check clogging and short circuit of indoor/outdoor heat

exchanger.

7. Overcharge of refrigerant. Recharge

1. Check lock of fan motor.

2. Check power supply voltage. AC198 to 253V

3. Check outdoor P.C. board.

1. When performing operation while taking-off compressor

wire, P26 error occurs. Check control P.C. board.

2. When performing operation while taking-off compressor

wire, an error does not occur. (Compressor rare short)

1. Check control P.C. board.

– 55 –

8-2-4. Diagnostic Procedure for Each Check Code (Outdoor Unit)

RAV-SP180AT2-UL

1) This section describes the diagnostic method for each check code displayed on the wired remote controller.

2) When “APPLICATION CONTROL KIT” (TCB-PCOS1UL) 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.

Is setting of group address

on the remote controller correct?

Check outdoor P.C. board.

Defect → Replace

Are inner wiring of the indoor unit

and inter-unit wires (1, 2, 3) correct?

Is wiring of the

outdoor terminal block correct?

Correct wiring

and inter-unit wires.

Check CODE No. [14].

Is connection of

case thermo (CN500) correct?

Correct wiring

of terminal block.

Does the case thermo operate?

Is the compressor abnormally heated?

Correct connection

of connector.

Check and correct charged

refrigerant amount.

YES

Is connection of CN601 correct?

Is resistance value of TD sensor correct?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Is connection of CN600 correct?

Is resistance value of TE sensor correct?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

CODE

No.

[E04]

[F04]

[F06]

APPLICATION CONTROL KIT

LED display

—

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{{

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{

zzz

Check / Countermeasures

(Part without special mention indicates a part of the outdoor unit.)

[Indoor / Outdoor communication error]

[Discharge temp. sensor (TD) error]

∗ There is a possibility that any of the following items is not correct.

Checking LED on the APPLICATION CONTROL KIT enables you to judge what is incorrect.

[Heat exchanger temp. sensor (TE) error]

[Suction temp. sensor (TS) error]

→→

→ Refer to column of [F12].D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{

LED display legend: z Go off, { Go on,  Flash (5Hz)

– 56 –

Is connection of CN602 correct?

Is resistance value of TO sensor correct?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Is connection of CN603 correct?

Is resistance value of TS sensor correct?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Correct power supply line.

Does abnormal overload happen?

Is AC mains voltage correct?

208/230V ± 10V

Remove and

improve the cause of overload.

Check outdoor P.C. board.

Defect → Replace

Check and correct wiring connection.

Is wiring connection correct?

Compressor lead

(P.C. board side, Compressor side)

Reactor cord, Power supply lead

YES

Compressor lock

→ Replace

Correct power supply line.

Does PMV operate correctly?

Check outdoor P.C. board.

Defect → Replace

Is AC mains voltage correct?

208/230V ± 10V

Is there stagnation

of refrigerant?

Is compressor

under correct

conditions?

Check and

correct connection of wires.

TE, TS sensor,

Check PMV.

Defective → Replace

Is wiring connection correct?

Compressor lead

(P.C. board side, Compressor side)

Reactor cord, Power supply lead

YES

NONO

CODE

No.

[F08]

[F12]

[H01]

[H02]

APPLICATION CONTROL KIT

LED display

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)



D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)



Check / Countermeasures

(Part without special mention indicates a part of the outdoor unit.)

[Outside temp. sensor (TO) error]

[Suction temp. sensor (TS) error]

[Compressor breakdown]

[Compressor lock]

LED display legend: z Go off, { Go on,  Flash (5Hz)

– 57 –

Correct wires

Check outdoor P.C. board.

Defect → Replace

Are connections of wires correct?

Between power cable and terminal block

Between outdoor P.C. board and terminal block

YES

Is compressor under correct conditions?

Is AC mains voltage correct?

208/230V ± 10V

Correct

power supply line.

Compressor trouble

Rare short check

Defective → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Is PMV under correct conditions?

Is connection of CN601 correct?

Is resistance value of TD sensor correct?

Is there gas leak?

Is there refrigerant shortage?

Repair defective position.

Recharge refrigerant.

Repair defective position.

Replace defective part.

Does an abnormal overload happen?

Remove and improve

the cause of overload.

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Is AC mains voltage correct?

208/230V ± 10V

Confirm power supply

construction, etc.

Check outdoor P.C. board.

Defect → Replace

YES

CODE

No.

[H03]

[L29]

[P03]

[P04]

APPLICATION CONTROL KIT

LED display

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)



D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{



D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{{

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{

Check / Countermeasures

(Part without special mention indicates a part of the outdoor unit.)

[Power supply error, Current detection circuit error]

[Discharge temp. error]

[Power supply error (Voltage error)]

LED display legend: z Go off, { Go on,  Flash (5Hz)

– 58 –

CODE

No.

[P04]

APPLICATION CONTROL KIT

LED display

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{

Check / Countermeasures

(Part without special mention indicates a part of the outdoor unit.)

[High-pressure SW error]

1. High-pressure SW error

2. Service valve closed.

3. Indoor/Outdoor fan error

4. Clogging of indoor/outdoor PMV

5. Loading of indoor/outdoor heat exchangers or short-circuit

6. Overcharge of refrigerant

Cooling operation → B Heating operation → C

Cooling operation

Heating operation

Doesn’t high-pressure SW operate?

Are parts of high-pressure SW normal?

Does outdoor fan normally operate?

Does the indoor fan normally operate?

Are service valves fully opened?

Reset the power supply and perform a test run appropriate to the season

Is the circuit wiring normal?

Open service valve fully.

Take measures

for defective position.

Check parts.

Defective → Replace

Isn’t there fan crack

or getting-out of fan?

Are connector connection,

capacitor and fans of the

fan motor normal?

Are resistance value

characteristics of the sensors

(TC, TCJ) normal?

Overcharge of refrigerant

Clogging / Pipe breakage /

Abnormal overload

Overcharge of refrigerant

Clogging / Pipe breakage /

Abnormal overload

Check P.C. board.

Defective → Replace

Check and repair wiring.

Connector connection / Fan IPDU / Fan motor / Wiring

Is there any element to disturb heat exchange of indoor unit?



Clogging of filter



Loading of heat exchanger



Short-circuit

Is there any element to disturb

heat exchange of outdoor unit?



Loading of heat exchanger



Short-circuit

Eliminate disturbing element.

Replace TC or TCJ sensor.

Repair defective position.

Check indoor P.C. board.

Defective → Replace

YES

[P05] D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)



{

[Power supply error (Voltage error)]

→ Refer to columns [H03] and [P04] and then check power supply and

voltage erro

LED display legend: z Go off, { Go on,  Flash (5Hz)

– 59 –

Is flow of refrigerant by

PMV under correct conditions?

Is coil of 4-way valve

electrified during heating mode?

Does 4-way valve work correctly?

(Check pipe temperature, etc.

during cooling/heating operation.)

Check temperature sensors.

TE sensor CN600, TS sensor CN603

Indoor TC sensor

Defective → Correct or replace

Check outdoor P.C. board.

Defect → Replace

Check 4-way valve.

Defect → Replace

Check PMV.

Defect → Replace

YES

Is connection of connector

CN300 correct?

Correct connection of connector.

Fan motor

exchange

Check outdoor P.C. board.

Defective → Replace

YES

After pulling out the connector

of the fan motor CN300, rotate its shaft by hands.

Can it rotate smoothly?

Is the fan motor coil resistance within the range described below?

Between red and white lead : 18 to 30Ω Between white and black lead : 18 to 30Ω Between black and red lead : 18 to 30Ω

Is AC mains voltage correct?

208/230V ± 10V

After disconnection of the compressor leads from

P.C. board, the air conditioner operates in heating mode.

Does the fan motor run?

Is there any problem on connection

of compressor lead or reactor?

(Check connection referring to the wiring diagram.)

Replace

outdoor P.C. board.

Check compressor. (Rare short, etc.)

Defective → Replace

Correct power line.

Correct wiring.

YES

Check outdoor P.C. board.

Defective → Replace

CODE

No.

[P19]

[P22]

[P26]

[P29]

APPLICATION CONTROL KIT

LED display

—

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{{{

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)



zzz

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)



Check / Countermeasures

(Part without special mention indicates a part of the outdoor unit.)

[4-way reversal error]

∗ In case of RAV-SP180AT2-UL, the coil of 4-way valve is electrified during cooling cycling. ∗ In cooling operation, [P19] error may be displayed when the refrigerant pressure rises high abnormally.

In this case, remove the cause of pressure rising and then diagnose it again.

[Outdoor fan system error]

[Short-circuit of compressor driving device]

[Position detection circuit error]

LED display legend: z Go off, { Go on,  Flash (5Hz)

– 60 –

Dip switch setup

• When turning on 1) only of SW803, the latest error is displayed. As the memory is stored, it can be confirmed even if the power supply is turned off once. (excluding outside temp. sensor (TO) error)

• When the work finished or the outdoor temp. sensor (TO) error was found, turn off all of SW803. (The error which occurs at present is displayed.)

Check CODE No. [14].

Correct wiring of connectors

and terminal blocks.

Check indoor P.C. board.

Defect → Replace

Check outdoor P.C. board.

Defect → Replace

Correct wiring

and inter-unit wires.

Is setting of group address

of remote controller correct?

Are inner wiring and

inter-unit wires (1, 2, 3) normal?

Are CN04 connection and

wiring of terminal blocks (1, 2, 3) normal?

Does D502 (Orange LED) flash after

power supply is turned on again?

YES

CODE

No.

[E04]

Outdoor

LED display

—

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Indoor/Outdoor communication error]

Display selection

• When even a LED of D800 to D804 (Yellow) goes on, error occurrence is indicated. <Display 1>

• If pushing the button switch SW800 for 1 second under the above condition, the yellow LED is displayed with flashing. <Display 2>

• When pushing SW800 for 1 second again, the status returns to <Display 1>.

• The error contents can be confirmed by combining

<Display 1> and <Display 2>.

(No error) (Error occurred) (Push SW800)

D800 (Yellow)

{

D801 (Yellow)

{

D802 (Yellow)



D803 (Yellow)

zzz

D804 (Yellow)

{

D805 (Green)

{{{

(Example of discharge temp. sensor error)

: Go off, { : Go on,  : Flash

Only 1) of SW803 is ON.

All SW803 are OFF. (Initial status)

1234

RAV-SP240AT2-UL, RAV-SP300AT2-UL, SP360AT2-UL, SP420AT2-UL

1) This section describes the diagnostic method for each check code displayed on the 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. board displays even an error which occurred once. Therefore the display on the remote controller may differ from that of LED.

LED display on outdoor P.C. board

– 61 –

Is CN603 connection normal?

Is resistance value of TD sensor normal?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Is CN601 connection normal?

Is resistance value of TE sensor normal?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

Is CN604 connection normal?

Is resistance value of TL sensor normal?

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

YES

CODE

No.

[F04]

[F06]

[F07]

Outdoor

LED display

{



{

{{

{

{ 



{

{{

{  { 



{

{{

{



{

{{

{  { 



{

{{

{  { 



{

{{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Discharge temp. sensor (TD) error]

• There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C. board to judge which error it is. Heat exchanger temp. sensor (TE) error, Heat exchanger temp. sensor (TL) error,

Suction temp. sensor (TS) error, Miswiring of heat exchanger sensor (TE, TS)

Heat exchanger temp. sensor (TE) error]

[Heat exchanger temp. sensor (TL) error] → Refer to [F07] column.

[Suction temp. sensor (TS) error] → Refer to [F12] column.

[Miswiring of heat exchanger sensor (TE, TS)] → Refer to [F15] column.

[Heat exchanger temp. sensor (TL) error]

– 62 –

Correct connector.

Sensor error → Replace

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

Correct connector.

Sensor error → Replace

Correct connector.

Sensor error → Replace

Correct sensor mounting.

Check outdoor P.C. board.

Defect → Replace

Check outdoor P.C. board.

Defect → Replac

Check outdoor P.C. board.

Defect → Replace

Check outdoor P.C. board.

Defect → Replace

Is mounting status of

TE and TS sensors normal?

Is CN600 connection normal?

Is resistance value of TS sensor normal?

Is CN602 connection normal?

Is resistance value of TO sensor normal?

Is CN600 connection normal?

Is resistance value of TS sensor normal?

Is CN601 connection normal?

Is resistance value of TE sensor normal?

YES

CODE

No.

[F08]

[F12]

[F13]

[F15]

[F31]

Outdoor

LED display

{

z zz z



{

{{

{

z z



{

{{

{  {

z z



{

{{

{  { 



{

{{

{  { 



{  {{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Outside air temp. sensor (TO) error]

[Suction temp. sensor (TS) error]

[Heat sink temp. sensor (TH) error]

[Miswiring of heat exchanger sensor (TE, TS)]

[EEPROM error]

– 63 –

Correct and clear the cause.

Check wire connection

and correct it.

Correct power supply line.

Check outdoor P.C. board.

Defect → Replace

Check wire connection

and correct it.

Correct power supply line.

Is compressor normal?

Is there no refrigerant stagnation?

Does PMV normally operate?

Is it not abnormal overload?

Is power supply voltage normal?

208/230V ± 10V

Is power supply voltage normal?

208/230V ± 10V

Is wire connection normal?

Compressor lead

(Board side, Compressor side),

Reactor lead, Power supply lead

Is wire connection normal?

Compressor lead

(Board side, Compressor side),

Reactor lead, Power supply lead

Compressor lock → Replace

Check outdoor P.C. board.

Defect → Replace

Check TE, TS sensors and PMV.

Defect → Replace

Check outdoor P.C. board.

Defect → Replace

Check outdoor P.C. board.

Defect → Replace

YES

CODE

No.

[H01]

[H02]

[H03]

Outdoor

LED display



{

z zz

{

{{

zz z



{

z zz

{

{{



{

z zz

{

{{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Compressor break down]

[Compressor lock]

[Current detection circuit error]

– 64 –

Check crushed or broken pipe. Defect → Correct and Replace

Correct defective position.

Replace defective part.

Open valve fully.

Repair defectives position.

Recharge refrigerant.

Check outdoor P.C. board.

Defect → Replace

Correct connector.

Case thermostat error → Replace

Cut jumper line according

to the explanation sheet packaged

with the service P.C. board.

Is valve fully opened?

Is PMV normal?

Is there no gas leak?

Is it not refrigerant shortage?

Are CN609 connection

and case thermostat normal?

Is cooling/heating operation

available when short-circuiting

case thermostat?

YES

CODE

No.

[H04]

[L10]

Outdoor

LED display

zz zz

{

z z



{

{{

{  {

z z



{

{{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Case thermostat operation]

[Unset model type]: Only when service P.C. board is used



{

{ 



{  {{

{  {  { 

{

{{

[Communication error between MCU]

[Heat sink temp. sensor (TH) error] → Refer to [F13] column.

∗ 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. sensor (TH) error, EEPROM error,

Unset model type, Heat sink overheat error, Gas leak detection, 4-way valve inverse error

[L29]

Check outdoor P.C. board.

Defect → Replace

– 65 –

CODE

No.

[L29]

(Continued)

Outdoor

LED display

{  { 



{  {{

{  {

z z



{

{{

{  {  { 

{

{{

{  {  { 



{

{{

{  {  {

z zz

{  {{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[EEPROM error] → Refer to [F31] column.

[Unset model type] → Refer to [L10] column.

[Heat sink overheat error] → Refer to [P07] column.

[Gas leak detection] → Refer to [P15] column.

[4-way valve inverse error] → Refer to [P19] column.

Check outdoor P.C. board.

Defect → Replace

Correct connector.

Sensor error → Replace

Correct and clear the cause.

Repair defective position.

Replace defective part.

Repair defective position.

Recharge refrigerant.

Is it not abnormal overload?

Is PMV normal?

Is CN603 connection normal?

Is resistance value of TD sensor normal?

Is there no gas leak?

Is refrigerant charge amount adequate?

YES

{  {  {

z zz

{

{{

[Discharge temp. error][P03]

– 66 –

CODE

No.

[P04]

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. Power supply error (Vdc), High pressure protective operation, Case thermostat operation

zz zz

{ 

{

{{

{

{ 

{

{{

[Case thermostat operation] → Refer to [H04] column.

[High-pressure SW error]

1. High-pressure SW error

2. Service valve closed.

3. Indoor/Outdoor fan error

4. Clogging of outdoor PMV

5. Loading of indoor/outdoor heat exchangers or short-circuit

6. Overcharge of refrigerant

Cooling operation → B Heating operation → C

Cooling operation

Heating operation

Doesn’t high-pressure SW operate?

Are parts of high-pressure SW normal?

Does outdoor fan normally operate?

Does the indoor fan normally operate?

Are service valves fully opened?

Reset the power supply and perform a test run appropriate to the season

Is the circuit wiring normal?

Open service valve fully.

Take measures

for defective position.

Check parts.

Defective → Replace

Isn’t there fan crack

or getting-out of fan?

Are connector connection,

capacitor and fans of the

fan motor normal?

Are resistance value

characteristics of the sensors

(TC, TCJ) normal?

Overcharge of refrigerant

Clogging / Pipe breakage /

Abnormal overload

Overcharge of refrigerant

Clogging / Pipe breakage /

Abnormal overload

Check P.C. board.

Defective → Replace

Check and repair wiring.

Connector connection / Fan IPDU / Fan motor / Wiring

Is there any element to disturb

heat exchange of indoor unit?



Clogging of filter



Loading of heat exchanger



Short-circuit

Is there any element to disturb

heat exchange of outdoor unit?



Loading of heat exchanger



Short-circuit

Eliminate disturbing element.

Replace TC or TCJ sensor.

Repair defective position.

Check indoor P.C. board.

Defective → Replace

YES

Revised : Feb. 2010

– 67 –

CODE

No.

[P04]

(Continued)

[P05]

Outdoor

LED display

{  {

{ 

{

{{

{

{ 

{  {{

{  {

{ 

{

{{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Power supply error (Vdc)] → Refer to [P05] column.

[High pressure protective operation] → Refer to [P20] column.

[Power supply error (Voltage error)]

Confirm electric construction, etc.

Check outdoor P.C. board.

Defect → Replace

Is there no down or up

of power supply voltage?

208/230V ± 10V

YES

– 68 –

Is there no loosening of

screws of motor drive element of

outdoor P.C. board Q200, Q300, Q400

and rectifier DB01, DB02, DB03?

Did not forget to apply

radiation grease to rear side of

Q200, DB01, DB02 or DB03?

Check outdoor P.C. board.

Defect → Replace

Remove blocking matter.

Correct short-circuit.

Open valve fully.

Correct and replace piping.

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

Correct defective position.

Replace defective part.

Repair defective position.

Recharge refrigerant.

Is there no crushed pipe?

Is valve fully opened?

Is PMV normal?

Is there no gas leak?

Is refrigerant charge amount adequate?

Check temp. sensor.

TD sensor CN603 TS sensor CN600

Is not the ventilation flue

of the heat sink blocked?

Is not the fan blocked?

(Short-circuit, etc.)

Apply radiation grease to objective part.

Retightening of screws.

(Be sure not to forget to attach insulating sheet

between heat sink and Q300, Q400.)

Error

YES

CODE

No.

[P07]

[P15]

Outdoor

LED display

{  {  { 

{

{{

{  {  { 



{

{{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Heat sink overheat error]

[Gas leak detection]

– 69 –

1234

SW804 SW801 CN701

Push

DC200V or more

SW804 SW801 CN701

Push

DC200V or more

Check outdoor P.C. board.

Defect → replace

Replace coil of 4-way valve.

Temperature sensor check

TE sensor CN601 TS sensor CN600

Indoor TC sensor

Defect → Correct and repair

Is the coil

resistance value of 4-way valve

between 1.3 and 1.6kΩ?

Check operation of outdoor P.C. board.

(See below.)

Is operation of

4-way valve normal?

(Check pipe temp., etc. in

cooling/heating operation.)

Check 4-way valve.

Defect → Replace

YES

Error

CODE

No.

[P19]

Outdoor

LED display

{  {  {

z zz

{  {{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[4-way valve inverse error]

Check method of outdoor P.C. board operation (Self-hold valve type)

1) Set SW804 of Dip switch as the following figure and then push SW801 for approx. 1 second to check exchange operation to cooling cycle/heating cycle.

• Power is turned on for approx. 10 seconds.

• When checking again, check operation 1 minute or more after the first check because exothermic of part (Coil, resistance R700) is large. (There is no problem when coil is not connected.)

2) After check, turn off all the Dip switch SW804.

Exchange to cooling cycle

Exchange to heating cycle

Note) Check by tester

Analog tester : Good if over DC200V Digital tester : Good if Max. value is over DC200V though the varied

value may be displayed.

– 70 –

Reset the power supply

and then perform test run

matching to the season.

Open valve fully.

Check outdoor fan.

Defect → Replace, retightening

Replace

sensor.

Check indoor P.C. board.

Defect → Replace

Repair defective position.

Is valve fully opened?

Is there no crack or

loosening of outdoor fan?

Does not the outdoor fan

perform abnormal operation?

Does indoor fan

normally operate?

Are indoor fan motor

and connector normal?

Is there no problem

on outdoor TL sensor?

(Measurement of resistance value)

Are resistance values of indoor TC and TCJ

sensors normal?

Replace sensor.

Check the same items as

[P22] error.

Check overcharge of refrigerant, clogging of cycle, broken pipe, abnormal overload, etc. Defect → Correct defective position.

Eliminate interfering element.

Heating season Heating operation

Cooling season Cooling operation

Is there no element

which interfere heat exchange

of outdoor unit?

• Clogging of heat exchanger

• Short circuit

Is there no element which

interfere heat exchange of indoor unit?

• Clogging of filter

• Clogging of heat exchanger

• Short circuit

YES

CODE

No.

[P20]

Outdoor

LED display

{

{ 

{  {{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[High pressure protective operation]

– 71 –

Correct wiring.

Replace outdoor P.C. board.

Check outdoor P.C. board.

Defect → Replace

The same error does not occur in

operation without compressor lead.

Check compressor. (Rear short, etc.)

Defect → Replace

Is there no problem on connection

of compressor lead or reactor?

(Check referring to Wiring diagram.)

YES

Check outdoor P.C. board.

Defect → Replace

Replace fan motor.

Check wiring construction.

Ask repair of power supply.

YES

Is there no problem on power supply voltage?

208/230V ± 10V

Does the fan rotate without trouble when rotating

shaft of fan motor with hands during power-OFF?

Is there no problem on coil resistance of fan motor?

Between red and white lead wire : 12 to 20Ω Between white and black lead wire : 12 to 20Ω Between black and red lead wire : 12 to 20Ω

YES

CODE

No.

[P22]

[P26]

[P29]

—

No code

Outdoor

LED display

{

{  { 

{  {{

{

{  {



{  {{

{  {

{ 



{  {{



{  { 



{  {{

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Fan system error]

Single operation check for outdoor fan

1) Set SW804 of Dip switch as the following figure and then push SW801 for approx. 1 second to check single operation of outdoor fan. Use this method to check which fan, upper or lower fan, has a trouble.

• When pushing SW801 for 1 second again or 2 minutes passed, the fan stops.

2) After check, turn off all Dip switch SW804.

[Short-circuit of compressor drive element]

1234

SW804 SW801

Push

Outdoor fan single operation

[Position detection circuit error]

[Other error] Compressor disorder due to sudden change of load, etc.

∗ Although the display of outdoor LED outputs, the unit automatically restarts

and error is not determined.

∗ LED display also may output due to negative phase of compressor or wire

coming-off.

– 72 –

Resistance (kΩ)

(122˚F (50˚C) or lower)

Resistance (kΩ)

(122˚F (50˚C) or higher)

(0) 32

100

150

200

(10)50(20)68(30)86(40)

104

(50)

122

(60) 140

(70) 158

(80)

176

(90)

194

(100)

212

Temperature ˚F (˚C)

Resistance (kΩ)

(0) 32

(10)50(20)68(30)86(40)

104

(50)

122

(60) 140

(70) 158

(80)

176

(90)

194

(100)

212

Temperature ˚F (˚C)

Temperature sensor Temperature – Resistance value characteristic table

TA, TC, TCJ, TE, TS, TO sensors

Representative value

TD, TL sensors

Representative value

TA, TC, TCJ, TE, TS, TO sensors

TD, TL sensors

∗ As TH sensor (Outdoor unit heat sink temp. sensor) is incorporated in the outdoor control P.C. board, the resistance

value cannot be measured.

Temperature

°F (°C)

32 ( 0)

50 ( 10)

68 ( 20)

77 ( 25)

86 ( 30)

104 ( 40)

122 ( 50)

140 ( 60)

158 ( 70)

176 ( 80)

194 ( 90)

212 (100)

Resistance value (k

ΩΩ

Ω)

(Minimum (Standard (Maximum

value) value) value)

32.33 33.80 35.30

19.63 20.35 21.09

12.23 12.59 12.95

9.75 10.00 10.25

7.764 7.990 8.218

5.013 5.192 5.375

3.312 3.451 3.594

2.236 2.343 2.454

1.540 1.623 1.709

1.082 1.146 1.213

0.7740 0.8237 0.8761

0.5634 0.6023 0.6434

Temperature

°F (°C

32 ( 0)

50 ( 10)

68 ( 20)

77 ( 25)

86 ( 30)

104 ( 40)

122 ( 50)

140 ( 60)

158 ( 70)

176 ( 80)

194 ( 90)

212 (100)

Resistance value (k

ΩΩ

Ω)

(Minimum (Standard (Maximum

value) value) value)

150.5 161.3 172.7

92.76 99.05 105.6

58.61 62.36 66.26

47.01 49.93 52.97

37.93 40.22 42.59

25.12 26.55 28.03

17.00 17.92 18.86

11.74 12.34 12.95

8.269 8.668 9.074

5.925 6.195 6.470

4.321 4.507 4.696

3.205 3.336 3.468

– 73 –

8-2-5. Outdoor Unit

Red

White Blac

Red

White Blac

Red

White Blac

No.

Part name

Compressor (Model :DA111A1FD-21F)

Compressor (Model :DA220A2-22L)

Compressor (Model :DA422A3F-25M)

Checking procedure

Measure the resistance value of each winding by using the tester.

Revised : Feb. 2010

Position

Red – White

White – Black

Black – Red

Resistance value

1.07 Ω

Under 20°C

Position

Red – White

White – Black

Black – Red

Resistance value

0.606 Ω

Under 20°C

Position

Red – White

White – Black

Black – Red

Resistance value

0.264 Ω

Under 20°C

– 74 –

9. REPLACEMENT OF SERVICE P.C. BOARD

9-1. Outdoor Unit

1. Setting the jumper wires and DIP switches

Model switching (J800 to J803)

Since this service P.C. board is available for several models, cut the jumper wires according to the following table. If they are not cut correctly, an error code “L10” or “L29” appears on the remote controller and the operation of the air

conditioner is disabled.

2. Installing the P.C. board

1) Apply thermal grease to the back (heat sink contacting side) of devices Q200, Q650, DB01, and DB02. ( Q300 and Q400 are not necessary to be applied thermal grease.)

2) Reuse the insulating sheet. When a small amount of thermal grease is applied to the back of the insulating sheet, it adheres temporarily to the heat sink, which makes it easy to attach the insulating sheet.

3) Insert the P.C. board, align the holes of the insulating sheets, semiconductor devices, and heat sinks, and then secure them with screws.

4) Connect the lead wires according to the wiring diagram sticked on the backside of the pannel .

J800 to J803

Apply thermal grease to the back (heat sink contacting side) of Q200, Q650, DB01, and DB02.

Reuse the insulating sheet. Applying thermal grease to the back of the insulating sheet makes it easy to attach the insulating sheet.

Model name

Factory setting (default)

RAV-SP300AT2-UL

RAV-SP360AT2-UL

RAV-SP420AT2-UL

J 800 J 801 J 802 J 803

{{{{

{ × { ×

××{ ×

{{××

Part name

J800 to J803

Jumper wire

J804 to J810

SW802

DIP switch SW803

SW804

Function

Model switching

Settings

LED indication switching

Special operations for service

Setting

Cut these jumper wires according to the following table.

Set these jumper wires to the settings of the P.C. board before replacement.

Set SW802 to the setting of the P.C. board before replacement.

Set SW803 to all OFF.

Set SW804 to all OFF.

{{

{

: Connected, × : Cut

– 75 –

10. SETUP AT LOCAL SITE AND OTHERS

10-1. Outdoor Unit

10-1-1. Various Setting on Outdoor Unit (Power save, Cooling-only, etc.)

The following settings are available by DIP switch setup and jumper line setup.

<RAV-SP180AT2-UL>

Power saving setting

Cooling only setting

SW802

321

Function

Power save setup

Cooling-only setup

Set position Control contents

When using the power saving function, turn on switches. The maximum operating current of the COOL/HEAT operation can

be limited by dropping the current release point of the outdoor unit.

When using the outdoor unit as a cooling-only machine, turn on switches. (“OF” of DN cord on the remote controller also can be used for changing the machine to the cooling-only model.)

<RAV-SP240, SP300, SP360, SP420AT2-UL>

Function

High static pressure setup

Power save setup

Snow-proof fan control

Defrost time change

Max. frequency change

Cooling-only setup

Set position

J805, J806

J807

J808

Control contents

Turn the switch to ON when mounting a duct to the discharge port of the outdoor unit.

Add 3 taps to the upper limit value of the outdoor fan tap. The operation is performed with

(Max: Upper fan: 890 rpm / Lower fan: 910 rpm (WF)). In this case, the upper limit value of static pressure for duct is 5Pa

or less on 77°F (25°C) degrees and please use straight duct. In this case, the outdoor noise level may increase.

Turn the switch to ON when using the power save function. The control to lower the compressor frequency (Approx. –10%) is

performed by indoor heat exchanger temp. in heating operation.

When snow enters from clearance of the fan guard or heat exchanger into blast path and it is accumulated, the control to prevent generation of motor lock is validated.

When outside temp. is below 32°F (0°C) though the compressor stops, the outdoor fan operates with W5.

The defrost interval is cut to shorten it than the standard status. For contents of control and cutting method, refer to

10. Defrost control (See to Page 43).

When it is needed to lower the maximum value of the compressor frequency, cut the jumper line. Max. frequency at cooling/heating is lowered.

In this case the Max. capacity decreases.

Max. frequency of compressor

When using the air conditioner as a cooling-only conditioner, cut the jumper line. (An air conditioner can be changed to cooling-only conditioner by “0F” of DN code on the remote controller.)

4321

High static pressure setup

Power save setup

Snow-proof fan control

SW802

∗ all are OFF at shipment.

RAV-

Model

Standard status

When J807 is cut

SP240

COOL HEAT

72.0 99.6

72.0 79.2

SP300

COOL HEAT

53.4 71.4

53.4 64.2

SP360, SP420

COOL HEAT

64.2 90.6

64.2 72.0

Revised : Feb. 2010

– 76 –

Display part

∗ All LED are colorless when it goes off.

1234

D800 D801 D802 D803 D804 D805

D503 (Green LED) : Serial signal (Outdoor → Indoor) D502 (Orange LED) : Serial signal (Indoor → Outdoor)

SW802 : Selection of various initial settings

LED display select switch

SW800 SW803

Error display / various display

D800 (Yellow LED) D801 (Yellow LED) D802 (Yellow LED) D803 (Yellow LED) D804 (Yellow LED) D805 (Green LED) : Display while power is ON

Specific operation switch (Various operations during maintenance check operation)

SW804 SW801

10-1-2. 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.

D502

D503

D800

D804

D805

Specifications

Orange LED

Green LED

Yellow LED

Green LED

Operation contents

Indoor/Outdoor communication (Serial communication) signal display (Receive signal from indoor signal)

Indoor/Outdoor communication (Serial communication) signal display (Send signal from outdoor signal)

Error display

When all SW803 are OFF, or when any of D800 to D804 goes on, LED displays that the outdoor controller detects an error.

When status of SW803 is other than OFF, various indications are displayed.

Power-ON display

When the power of the outdoor unit is turned on, LED goes on.

When SW801 and SW804 operate the specific operation, LED flashes.

Specifications

Pushdown button switch

DIP switch

Pushdown button switch

DIP switch

Operation contents

Exchanges the displayed contents of LED (D800 to D804) on the outdoor control P.C. board.

Performs the specific operation to check maintenance.

Performs various initial settings. (Refer to 10-1-2.)

Part No.

SW800

SW803

SW801

SW804

SW802

– 77 –

SW803

TCJ

SW803

2341

SW803

2341

SW803

2341

SW803

2341

SW803

2341

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

Refer to

Page 78.

Error display (The latest error: Latest error including present)

After error status was cleared, the error which generated before can be confirmed by this setting. (Reconfirmation is available even if power supply was turned off once.)

• If an error generates at present, the same contents as those of error which is generating at present are displayed.

• Only error of TO sensor is not displayed by this setting. (Confirm it by setting of error which is generating at present.)

Temperature sensor display

The detected value of temperature sensor is displayed.

Current display

The current value which flows in the outdoor unit is displayed.

Compressor operation frequency display

The operation frequency of the compressor is displayed.

PMV opening display

The opening of PMV (Pulse Motor Valve) is displayed.

Refer to

Page 78.

Refer to

Page 79.

10-1-3. Others

<RAV-SP240, SP300, SP360, SP420AT2-UL>

1. 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.

Refer to

Page 77.

Refer to

Page 79.

Refer to

Page 79.

– 78 –

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. (Display 1) d) When pushing the pushdown button switch SW800 for approx. 1 second, the display is exchanged.

(Display 2) e) When pushing SW800 again or after 2 minutes, the status returns to that of Display 1.

(Legend)

D800 (Yellow)

D801 (Yellow)



D802 (Yellow)

D803 (Yellow)

D804 (Yellow)

{

D805 (Green)

: Go off, { : Go on,  : Flash

Present error

SW803

2341

Latest error

SW803

2341

∗ As the error code displayed on the wired remote controller may differ according to type of indoor model, multiple

codes are described.

Display 1)

(Initial display)

zzzzz

{

{{

zz{z

{{

{{z{{

{{{z{{

Display 2)

(SW800 operation)

zzzzz

{

zzzz

{



{



{

zzzz

{

z{ zz{ z{ { 

zzzz

{

zzzz

{



zzz

{

zzzz

{

zzz

{ z{ { 

zzz

{

zzzz

{ z

{ 

{ z{ 

{

zzz

{

z{

zz

{

z{

Error contents

Normal

Discharge temp. sensor (TD) error

Heat exchanger temp. sensor (TE) error

Heat exchanger temp. sensor (TL) error

Outside temp. sensor (TO) error

Suction temp. sensor (TS) error

Heat sink temp. sensor (TH) error

Heat exchanger sensor (TE, TS) miswiring

EEPROM error

Compressor break down

Compressor lock

Current detection circuit error

Case thermostat operation

Model unset

Communication error between MCU

Other error (Compressor disorder, etc.)

Discharge temp. error

High-pressure SW error

Power supply error

Heat sink overheat error

Gas leak detection

4-way valve reverse error

High pressure protective operation

Fan system error

Driving element short-circuit

Position detection circuit erro

Wired remote controller

Error code

—

F04

F06

F06, F07

F08

F06, F12

F13, L29

F06, F15

F31, L29

H01

H02

H03

H04

L10, L29

L29

Error is not determined.

P03

P04

P05

P07, L29

P15, L29

P19, L29

P04, P20

P22

P26

P29

– 79 –

SW803

2341

SW803 SW803 SW803

2341

SW803

2341

SW803

2341

SW803

2341

SW803

2341

SW803

2341

TCJ

SW803

2341

SW803

2341

SW803

2341

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.

(Legend)

D800 (Yellow)

D803 (Yellow)

D801 (Yellow)

D804 (Yellow)

D802 (Yellow)

{

D805 (Green)

: Go off, { : Go on

∗ As TD, TL and TH are sensors for high temperature, there is error at normal temperature or below position. ∗ For current value, the current for the outdoor unit only is displayed.

Item

setup

LED display

zzzzz

{

zzzz

{

z{zzz

{

{{

zzz

{

zz{zz

{

{z{zz{

{{

{

{{{

{

zzz{z

{

zz{z

{

z{z{z

{

{{z{z{

{{z{

{z{{z{

{{{z{

{{{{z{

zzzz

{{

{

zzz

{{

z{zz

{{

{{zz{{

zz{z

{{

{z{z{{

{{z{{

{{{z{{

zzz

{{{

{

{{{

z{z

{{{

{{z{{{

{{{{

{z{{{{

{{{{{

{{{{{{

Temperature sensor °F (°C)

Below –13 (–25) –13 (–25) to –5.8 (–21) –4 (–20) to 3.2 (–16) 5 (–15) to 12.2 (–11) 14 (–10) to 23 ( – 5) 23 ( –5) to 30.2 ( –1) 32 ( 0) to 39.2 ( 4) 41 ( 5) to 48.2 ( 9) 50 ( 10) to 57.2 ( 14) 59 ( 15) to 66.2 ( 19) 68 ( 20) to 75.2 ( 24) 77 ( 25) to 84.2 ( 29) 86 ( 30) to 93.2 ( 34) 95 ( 35) to 102.2 ( 39) 104 ( 40) to 111.2 ( 44) 113 ( 45) to 120.2 ( 49) 122 ( 50) to 129.2 ( 54) 131 ( 55) to 138.2 ( 59) 140 ( 60) to 147.2 ( 64) 149 ( 65) to 156.2 ( 69) 158 ( 70) to 165.2 ( 74) 167 ( 75) to 174.2 ( 79) 176 ( 80) to 183.2 ( 84) 185 ( 85) to 192.2 ( 89) 194 ( 90) to 201.2 ( 94) 203 ( 95) to 210.2 ( 99) 212 (100) to 219.2 (104) 221 (105) to 228.2 (109) 230 (110) to 237.2 (114) 239 (115) to 246.2 (119) Over 248 (120)

Sensor error, unconnected

Current

(A)

0 to 0.9 1 to 1.9 2 to 2.9 3 to 3.9 4 to 4.9 5 to 5.9 6 to 6.9 7 to 7.9 8 to 8.9

9 to 9.9 10 to 10.9 11 to 11.9 12 to 12.9 13 to 13.9 14 to 14.9 15 to 15.9 16 to 16.9 17 to 17.9 18 to 18.9 19 to 19.9 20 to 20.9 21 to 21.9 22 to 22.9 23 to 23.9 24 to 24.9 25 to 25.9 26 to 26.9 27 to 27.9 28 to 28.9 29 to 29.9 30 to 30.9

Over 31

Compressor

operation

frequency

(rpm)

0 to 4

5 to 9 10 to 14 15 to 19 20 to 24 25 to 29 30 to 34 35 to 39 40 to 44 45 to 49 50 to 54 55 to 59 60 to 64 65 to 69 70 to 74 75 to 79 80 to 84 85 to 89 80 to 84 95 to 99

100 to 104 105 to 109 110 to 114 115 to 119 120 to 124 125 to 129 130 to 134 135 to 139 140 to 144 145 to 149 150 to 154

Over 155

PMV

opening

(Pulse)

0 to 19 20 to 39 40 to 59 60 to 79

80 to 99 100 to 119 120 to 139 140 to 159 160 to 179 180 to 199 200 to 219 220 to 239 240 to 259 260 to 279 280 to 299 300 to 319 320 to 339 340 to 359 360 to 379 380 to 399 400 to 419 420 to 439 440 to 459 460 to 479 480 to 499

500

— — — — — —

– 80 –

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. 1 second, when selecting DIP

switch SW804 or when the specified time of each function elapsed, each function stops and LED D805 (Green) returns to the continuous lighting.

Note 1) Indoor cooling test run demand / Indoor heating test run demand

Only when combining with the following indoor unit, cooling/heating operation can be performed from the outdoor unit. Test run is available: Indoor unit (4-Way, Under ceiling, High wall)

Test run is unavailable: Indoor units other than the above-mentioned indoor units.

Note 2) The forced test run by this setting cannot be cleared on the indoor remote controller.

Be sure to clear the test run by operation of the outdoor unit. (Push SW801 again for 1 second.)

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804 Operation when pushdown button switch SW801 is pushed

Refrigerant recovery operation

The outdoor unit performs cooling operation. The indoor unit does not work by this operation alone. Therefore operate the fan beforehand.

Indoor cooling test run demand

The cooling test run is performed. (→ Note 1)

Indoor heating test run demand

The heating test run is performed. (→ Note 1)

Fan motor forced operation

Drive the fan motor forcedly. When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

(No operation especially)

PMV full open operation

Open PMV (Pulse Motor Valve) fully. When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

PMV full close operation

Close PMV (Pulse Motor Valve) fully. When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

PMV middle opening operation

Set PMV (Pulse Motor Valve) to middle opening (250 pulses). When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

[NOTE]

Although these operations can be performed even during operation, basically perform operation while the unit stops.

If performing this operation during driving the unit, it is dangerous because the pressure may change suddenly.

– 81 –

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

SW804

2341

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.

[NOTE]

In case of these models adopting the self hold valve, the coil develops fever. Therefore do not perform this operation as coil is connected.

Self-hold valve suction operation (Exchange to heating cycle)

(For RY700 RY701, RY705, CN701 check) Turn on relay RY700, RY701, RY705. (CN701 between

and f : Voltage=Approx. +198 to 380V)

This function works for 10 seconds and then is OFF.

Self-hold valve separation operation (Exchange to cooling cycle)

Turn on relay RY700. (CN701 between 1) and 4): Voltage=Approx. –198 to 380V) This function works for 10 seconds and then is OFF.

SV valve relay operation (For RY702, CN702 check)

Turn on SV valve relay (RY702). When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

* For these models, the part is not mounted, so do not operate.

Heater output relay operation (For check RY703, CN703 check)

Turn on relay for option heater (RY703). When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

Outside output relay operation (RY704, CN704)

Turn on relay for outside output (RY704). When pushing SW801 again or when 2 minutes elapsed, the

operation returns to the normal control.

(No operation especially)

Relay operation change for outside output

[CAUTION]

Do not use this setting.

[CAUTION]

Although these operations can be performed even during operation, basically perform operation while the unit stops.

If performing this operation during driving the unit, it is dangerous because the pressure may change suddenly.

– 82 –

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.

Repair the defective position or apply the rust resisting paint if necessary.

Although the customer has to pay the charge for the maintenance, the life of the unit can be prolonged.

Failure to clean the indoor/outdoor units regularly will cause shortage of capacity, freezing, water leakage or trouble on the compressor.

Periodic Maintenance - periodic maintenance is recommended to ensure proper operation of the unit.

Recommended maintenance intervals may vary depending on the installation environment, e.g. dusty zones, etc.

Refer to table below.

Periodic Maintenance

INDOOR UNIT

Clean Air Filter

∗1

Clean Drain Pan

Clean indoor heat exchanger

∗2

Clean fan

∗2

Change Remote Control Batteries

INDOOR UNIT

Clean Outdoor Coil from Outside

Clean Outdoor Coil from Inside

∗2

Blow Air Over Electric Parts

∗2

Check Electric Connection Tightening

∗2

Clean Fan Wheel

∗2

Check Fan Tightening

∗2

Clean Drain Pans

∗2

EVERY MONTH EVERY 4 MONTHS EVERY YEAR

∗1: Increase frequency in dusty zones. ∗2: Maintenance to be carried out by qualified service personal Refer to the Installation Manual.

– 83 –

No.cPart name

Common procedure

Procedure

CAUTION

Never forget to put on the gloves at working time, otherwise an injury will be caused by the parts, etc.

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. (M4, 8 mm, 3 pcs.)

• After removing screw, remove the valve

cover pulling it downward.

3) Remove connecting cable.

4) Remove the conduit mounting plate by taking off 2 screws. (M4, 8 mm, 2 pcs.)

5) Remove the upper cabinet. (M4, 8 mm, 5 pcs.)

• After taking off screws, remove the upper

cabinet pulling it upward.

6) Remove the waterproof cover.

2. Attachment

1) Attach the waterproof cover.

CAUTION

Be sure to attach a waterproof cover. If it is not attached, there is a possibility that water enters inside of the outdoor unit.

2) Attach the upper cabinet. (M4, 8 mm, 5 pcs.)

3) Attach the conduit mounting plate. (M4, 8 mm, 2 pcs.)

4) Perform cabling of connecting cables.

5) Attach the valve cover. (M4, 8 mm, 3 pcs.)

• Insert the upper part of the upper cabinet,

set hooking claw of the valve cover to the slit (at three positions) of the main body, and then attach it pushing upward.

Remarks

11. DETACHMENTS

11-1. Outdoor Unit

11-1-1. RAV-SP180AT2-UL

Valve cover

Upper cabinet

Waterproof cover

Connecting cover

Conduit mounting plate

Valve cover

Upper cabinet

Waterproof cover

Connecting cover

Conduit mounting plate

– 84 –

No.dPart name

Front cabinet

Procedure

1. Detachment

1) Perform work of Detachment 1 of c .

2) Remove screws (M4, 8 mm, 2 pcs.) of the front cabinet and the inverter cover.

3) Take off screws of the front cabinet and the bottom plate. (M4, 8 mm, 3 pcs.)

4) Take off screws of the front cabinet and the motor support. (M4, 8 mm, 2 pcs.)

5) Take off screws of the front cabinet and side cabinet (Right). (M4, 8 mm, 1 pc.)

• The left side of the front side if made to insert to

the rear cabinet, so remove it pulling upward.

2. Attachment

1) Insert hook at the left side of the front side into the rear cabinet.

2) Hook the lower part at the right side of the front to concavity of the bottom plate. Insert the hook of the rear cabinet into the slit of the front cabinet.

3) Attach the removed screws to the original positions.

Remarks

1) Perform works of Detachment 1 of c and d.

2) Take off screw of the side cabinet (Right) and the heat exchanger. (M4, 8 mm, 1 pc.)

3) Take off fixed screws between the main unit and the inverter box. (Wiring port side) (M4, 8 mm, 2 pcs.)

4) Take off screws of the side cabinet (Right) and the bottom plate. (M4, 8 mm, 2 pcs.)

5) Take off screw of the side cabinet (Right) and the valve fixed plate. (M4, 8 mm, 1 pc.)

Side cabinet (Right)

Motor support

Inverter cover

Front

cabinet

Motor support

Inverter cover

Front cabinet

Side cabinet

(Right side)

Screw

Side cabinet (Right side)

Screw

Slit

Claw

Slit

Claw

Front cabinet

Slit

Front cabinet

Heat exchanger

Screw

Inverter box

Side cabinet

(Right side)

Valve fixed plate

Side cabinet

(Right side)

Heat exchanger

Screw

Inverter box

Side cabinet (Right side)

Valve fixed plate

Side cabinet (Right side)

– 85 –

No.fPart name

Inverter assembly

Procedure

1. Turn off the power supply.

1) Perform work of Detachment 1 of c .

2) Take off screws, which fix the upper part of the front cabinet and the inverter cover. (M4, 8 mm, 2 pcs.)

• If removing the inverter cover under the above

condition, P.C. board can be checked.

ELECTRIC SHOCK

The control circuits (including each sensor circuit and 5V, 12V of PMV circuit, etc.) of this control P.C. board are high-voltage circuits.

Before work, be sure to turn off the power supply. Take sufficient care to an electric shock on the

control circuits and the conductive parts of their parts.

3) Using the discharging resistor (100Ω/40W or equivalent) or plug of the soldering iron, electrify continuously between

and – poles of the electrolytic capacitor of 3 phases: C10, 11 and single phase: C12, 13, 14 (“CAUTION HIGH VOLTAGE” is printed) on P.C. board, and then discharge power.

For the products that the rear side are coated, perform normal discharge.

NOTES:

According to the trouble condition, the electrolytic capacitor may not normally discharge and the voltage may remain.

Therefore be sure to discharge the capacitor. As the electrolytic capacitor is one with a large capacity,

never use a screwdriver and others for short-circuiting between

and – electrodes for discharging; otherwise it is very dangerous because a large electric spark will generate.

4) Perform works Detachment 1 of

and e .

5) Take off fixing screw between the partition plate and the inverter box. (M4, 8 mm, 1 pc.)

6) Remove various lead wires from the holder at upper part of the inverter box.

7) Pull the inverter box upward. In this time, cut the bundling bands which bind

each lead wire.

8) Remove connectors of various lead wires.

NOTE:

When removing the connectors, do not hold lead wires by hands, but hold the connectors.

Remarks

Screws

Front

cabinet

Inverter cover

Plug of soldering iron

Discharging position

(Discharging period

10 seconds or more)

Screws

Front cabinet

Inverter cover

Plug of soldering iron

Discharging position (Discharging period 10 seconds or more)

Fixed screw

Partition plate

Inverter assembly

Remove the connectors

with locking function by

pushing the part indicated

by the arrow mark.

Fixed screw

Partition plate

Inverter assembly

Remove the connectors with locking function by pushing the part indicated by the arrow mark.

– 86 –

No.gPart name

Control P.C. board assembly

Procedure

1) Remove the sub-board base from the inverter

assembly. (M4, 8 mm, 2 pcs.)

• Remove connector at the control P.C. board assembly side.

2) Remove the lead wires and connectors that are connected from the control P.C. board assembly to the other parts.

1. Lead wires:

Connected to the power supply terminal block; 3 pcs.

Black, White, Orange (Single phase), Red, White, Black, Orange (3 phases)

Earth wire (Black); 1 pc

2. Connector

Connected to compressor; (3P: Relay connector White)

Reactor (2P: Relay connector White) ∗ (NOTE 1)

CN300; Outdoor fan (3P: White) ∗ (NOTE 1) CN701; 4-way valve (3P: Yellow) ∗ (NOTE 1) CN700; PMV coil (6P: White) CN601; TD sensor (3P: White) CN603; TS sensor (3P: White) ∗ (NOTE 1) CN600; TE sensor (2P: White) ∗ (NOTE 1) CN602; TO sensor 2P: White) CN500; Case thermo + Pressure SW (2P: Blue)

∗ (NOTE 1) CN605; Sub SW P.C. base (3P: Black)

NOTE 1):

Unlock the lock of the housing part and then remove the connector.

3) Remove the inverter box (Sheet metal).

4) Remove the control P.C. board assembly from

P.C. board base. (For the heat sink and the control P.C. board assembly, remove them as they are screwed.)

NOTE 2):

Take off claws (4 positions) of P.C. board base, hold the heat sink and then remove it upward.

5) Take off 2 screws that fix the heat sink and the

control P.C. board assembly.

6) Mount a new control P.C. board assembly.

NOTE 3):

Mount a new control P.C. board assembly while it is correctly inserted in the P.C. board-receiving groove.

Mount it so that the heat sink surely contact with the sheet metal.

Remarks

Power supply cable

Earth screw

Power supply cable

Earth screw

Inverter box

(Sheet metal)

Control P.C.

board assembly

P.C. board base

Inverter box (Sheet metal)

Control P.C. board assembly

P.C. board base

Control P.C.

board assembly

Hooking claws (4 positions)

Heat sink

Hooking claws (4 positions)

Heat sink

P.C. board

base

Control P.C. board assembly

P.C. board base

– 87 –

Flange nut

Loosen the nut by

turning clockwise

Flange nut

Loosen the nut by turning clockwise

Propeller fan

Fan motor

Partition plate

Compressor lead

Case thermo

Compressor lead

Case thermo

Valve

support board

Fusible plug

Pressure

switch

Compressor bolt

(3 pcs.)

Remove

(Suction pipe)

Remove

(Discharge pipe)

Valve support board

Fusible plug

Pressure switch

Compressor bolt (3 pcs.)

Remove (Suction pipe)

Remove (Discharge pipe)

No.hPart name

Fan motor

Procedure

1) Perform works of Detachment 1 of c and d .

2) Take off the flange nut fixing the fan motor and the propeller.

• Turning it clockwise, the flange nut can be loosened. (To tighten the flange nut, turn counterclockwise.)

3) Remove the propeller fan.

4) Disconnect the connector for fan motor from the inverter.

5) Take off the fixing screws (2 pcs.) holding by hands so that the fan motor does not fall.

NOTE:

Tighten the flange nut with torque 4.9Nm (50kgf/cm).

Remarks

1) Perform works of Detachment 1 of c , d , e and f .

2) Discharge refrigerant gas.

3) Remove the partition plate. (M4, 8 mm, 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.

CAUTION

Pay attention to that flame does not involve 4-way valve, PMV, pressure SW, or fusible plug. (If doing so, a malfunction may be caused.)

7) Remove the side cabinet (Left). (M4, 8 mm, 3 pcs.)

8) Take off the fixing screws of the bottom plate and heat exchanger. (M4, 8 mm)

9) Take off the fixing screws of the valve clamping plate to the bottom plate. (M4, 8 mm, 1 pc.)

10) Pull upward he refrigerating cycle.

11) Take off nut fixing the compressor to the bottom place.

CAUTION

When reconnecting the lead wires to the compressor terminals after replacement of the compressor, be sure to caulk the Faston terminal without loosening.

Compressor

– 88 –

Reactors

Partition

plate

Reactor

support board

PMV coil

Reactors

Partition plate

Reactor support board

No.

Part name

Reactor

Procedure

1) Perform works of Detachment 1 of c , d ,

and f .

2) Take off the fixing screw for the reactor. (M4, 8 mm)

Remarks

1. Detachment

1) Perform works of Detachment c and d .

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.

1. Detachment

1) Perform works of Detachment 1 of

and d .

2) Remove the front cabinet, and put it

down so that fan guard side directs downward.

CAUTION

Perform works on a corrugated cardboard, cloth, etc. to prevent flaw on the product.

3) Remove the fan guard stopper.

(4 positions)

2. Attachment

1) Insert the fan guard stopper and then fix

the fan guard. (4 positions)

CAUTION

All the attaching works have completed. Check that all the hooking claws and the

fan guard stopper are fixed to the specified positions.

Pulse Motor Valve (PMV) coil

Fan guard

Front cabinet

Fan guard stopper

Front cabinet

Fan guard

Front cabinet

Fan guard

Fan guard stopper

Front cabinet

– 89 –

No.cPart name

Common procedure

Procedure

CAUTION

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 M4, 10 mm, 2 pcs.)

∗ After removing screws, remove the front

panel while pulling it downward.

3) Remove the power wire and indoor/outdoor connecting wire from the cord clamp and the terminals.

4) Remove the top plate. (Hexagonal screw M4, 10 mm, 5 pcs.)

2. Attachment

1) Attach the top plate. (Hexagonal screw M4, 10 mm, 5 pcs.)

In this time, insert the fin guard of rear side between the top plate and the heat exchanger (Rear side).

2) Connect the power supply wire and the indoor/outdoor connecting wire to the terminal and fix it with cord clamp.

CAUTION

Using bundling band on the market, be sure to fix the power wire and indoor/outdoor connecting wire along the crossover pipe so that they do not come to contact with the compressor, valve at gas side, pipe at gas side and discharge pipe.

3) Attach the front panel. (Hexagonal screw M4, 10 mm, 2 pcs.)

Remarks

11-1-2. RAV-SP240AT2-UL

Front panel

Top plate

Insert the fin guard of rear side between the top plate and the heat exchanger (at rear side).

– 90 –

Motor base

Heat exchanger Partition plate

Inverter protective cover

Inverter assembly

Side

cabinet

Inverter assembly

Side cabinet

Fin guard

Discharge port cabinet

No.dPart name

Discharge port cabinet

Procedure

1. Detachment

1) Perform work of Detachment 1 of c .

2) Remove screws for the discharge port cabinet and the partition plate. (M4, 8 mm, 3 pcs.)

3) Remove screws for the discharge port cabinet and the bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

4) Remove screws of the discharge port cabinet and the motor base. (M4, 8 mm, 2 pcs.)

5) Remove screws of the discharge port cabinet and the heat exchanger. (M4, 8 mm, 1 pc.)

6) Remove screws of the discharge port cabinet and the fin guard. (Hexagonal screw M4, 10 mm, 2 pcs.)

Remarks

1) Perform work of Detachment 1 of c .

2) Remove screws which fix the inverter assembly and the side cabinet. (M4, 8 mm, 2 pcs.)

3) Remove screws of the side cabinet and the valve fixing plate. (M4, 8 mm, 2 pcs.)

4) Remove screws of the side cabinet and the pipe panel (Rear). (Hexagonal screw M4, 10 mm, 2 pcs.)

5) Remove screws of the side cabinet and the bottom plate. (Hexagonal screw M4, 10 mm, 1 pc.)

6) Remove screws of the side cabinet and the heat exchanger. (Hexagonal screw M4, 10 mm, 3 pcs.)

7) Slide the side cabinet upward and then remove it. (Hook of inverter)

Side cabinet

Inverter protective cover

1) Perform work of Detachment 1 of c .

2) Take off screw which fixes the inverter assembly and the inverter protective cover. (M4, 8 mm, 1 pc.)

– 91 –

No.gPart name

Exchange of electric parts

Procedure

1. Control P.C. board

1) Perform work of Detachment 1 of c and f .

WARNING

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. (Indoor power supply, temperature sensors, PMV coil, 4-way valve coil, compressor case thermo, fan motor, reactor, pressure switch.)

∗ Unlock the lock of the housing part and then

remove the connectors.

3) Remove the lead wires connected to the control P.C. board. (Torque at tightening time: 1.47 ± 0.1N•m)

Compressor lead

U: CN200 Red V: CN201 White W: CN202 Black

Reactor lead

Relay connector: 2 positions

Remove the power wire from the power supply terminal block. (Torque at tightening time: 2.5 ± 0.1N•m)

4) Remove the earth wire from the control P.C. board. (Truss B tight screw M4, 6 mm, 1 pc.)

5) Remove the fixing screws of the control P.C. board. (Screw with collar for fixing element M3, 16 mm, 7 pcs. Pan S tight screw for fixing P.C. board M3, 20 mm, 1 pc.)

6) Remove the control P.C. board. (Supporter: 5 positions)

NOTE:

It is difficult to take out it because of radiator grease for heat sink.

7) Mount a new control P.C. board.

NOTE:

Do not forget to attach the aluminum plate (Q201) and the insulating sheet (Q300). (Applying a little of radiator grease at the rear surface of the insulating sheet in advance to adhere to the heat sink makes easy the work.)

Remarks

Control P.C. board

Insulating sheet

(Q300)

Aluminum plate

(Q201)

Radiator grease

Control P.C. board

Insulating sheet (Q300)

Aluminum plate (Q201)

Radiator grease

PMV coil

Indoor power supply

4-way valve coil

Pressure switch

Compressor lead

Fan motor

Bundling band

(Reactor lead)

Power supply terminal block

Screw for fixing P.C. board

Power supply terminal block

Screw for fixing P.C. board

Screw for fixing element (7 positions)

Compressor case thermo.

PMV coil

Senser

Indoor power supply

4-way valve coil

Ground screw

Inter unit

cable

Senser

Ground screw

Inter unit cable

Bundling band (Reactor lead)

Relay

connector

Relay connector

– 92 –

No.gPart name

Exchange of electric parts (Continued)

Procedure

1. Reactor

1) Perform work of Detachment 1 of c ,

and f .

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 M4, 6 mm, 2 pcs. each)

5) Attach a new reactor.

NOTE:

Be sure to bind the removed bundling band with the bundling band on the market.

Be careful that the fan motor lead does not come to contact with the reactor body.

Remarks

Reactor relay connector (Connected to lead wire (White) at P.C. board side)

Reactor relay connector (Connected to lead wire (Charcoal gray) at P.C. board side)

Bundling band (Compressor lead, reactor lead)

Fan motor lead

Upper reactor Connected to reactor relay connector (Connected to lead wire (White) at P.C. board side)

Bundling band

Lower reactor Connected to reactor relay connector (Connected to lead wire (Charcoal gray) at P.C. board side

)

– 93 –

No.hPart name

Fan motor

Procedure

1) Perform work of Detachment 1 of c , d , e and

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. each) while supporting the fan motor so that it does not fall.

[ Cautions when assembling the fan motor

∗ Tighten the flange nut with 4.95N•m

(50kgf.cm).

∗ Adjust length on the fan motor lead fixing

rubber so that the fan motor lead does not slacken in order not to put the fan motor lead into contact with the propeller fan.

Attach the fan motor lead fixing rubber to the partition plate so that projection directs to the refrigerating cycle side.

∗ Be sure that the rector body does not come to

contact with the fan motor lead.

∗ Be sure to bind the removed bundling band

with the bundling band on the market.

CAUTION

Use the metal band of the motor base to fix the fan motor lead on the motor base so that the fan motor lead does not come to contact with the propeller fan.

Remarks

Propeller fan

Propeller fan Loosened by

turning clockwise

Fan motor

Propeller fan

Fan motor

Flange nut

Fan motor

Fan motor lead fixing rubber

Projection/Refrigerating cycle side

Fan motor connector

– 94 –

No.iPart name

Compressor Compressor lead

Procedure

1. Removal of broken compressor

1) Recover the refrigerant gas.

2) Perform work of Detachment 1 of

, d , e and f .

3) Remove the wiring guide (vertical). Take off screw of the wiring guide (vertical) and

volve fixing plate. (M4, 8 mm, 1 pc.) Take off screw of the wiring guide (vertical) and

piping panel (Front). (M4, 8 mm, 1 pc.)

4) Remove the wiring division panel. Take off screw of the wiring division panel and the

inverter assembly. (M4, 8 mm, 1 pc.) Take off screw of the wiring division panel and the

valve fixing plate. (M4, 8 mm, 1 pc.)

5) Remove the piping panel (Front). Remove screws of the piping panel (Front) and the

bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.) Remove screws of the piping panel (Front) and the

piping panel (Rear). (Hexagonal screw M4, 10 mm, 1 pc.)

6) Remove the piping panel (Rear). Remove screws of the piping panel (Rear) and the

bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

7) Remove the valve fixing plate. Remove bolts of the valve.

(Hexagonal screw M6, 15 mm, 4 pcs.) Remove screws of the valve fixing plate and the

partition plate. (M4, 8 mm, 1 pc.) Remove screws of the valve fixing plate and the

accumulator. (M4, 8 mm, 1 pc.) Cut off the bundling band for the discharge pipe and

the suction pipe and then remove each sensor and coil lead of PMV.

8) Remove the sound insulating plate. (Upper side, outer winding, inner winding)

9) Remove terminal cover from the compressor and then remove the compressor lead and also the compressor case thermo.

10) Remove TD sensor fixed to the discharge pipe.

11) Remove the compressor lead.

(Leave the ferrite core attached to the electric parts box as it is.)

Control P.C. board

U : CN200 Red V : CN201 White W : CN202 Black

(Tightening torque: 1.47 ± 0.1 N•m)

Remarks

Bundling band

for heat proof

TD sensor

Compressor lead

Pipe cover

Compressor

case thermo

Piping panel (Rear)

Piping panel (Front)

Bundling band for heat proof

TD sensor Compressor lead

Pipe cover

Compressor case thermo

Piping panel (Rear)

Wiring

guide

Valve fixing plate

Wiring guide

Valve fixing plate

Piping panel (Front)

Compressor lead

Control P.C. board

Ferrite core

Compressor lead

Control P.C. board

Ferrite core

Pipe cover, bundling ban

TS sensor

Black pipe cover for heat proof, bundling band for heat proof, each sensor (TL, TO, TE, TD, TS sensors) PMV coil lead

Pipe cover,

bundling band,

each sensor

(TL, TO, TE, TD,

TS sensors)

PMV coil lead

Discharge pip

eDischarge pipe

Suction

pipe

Accumulator

Pipe cover, bundling band, each sensor (TL, TO, TE, TD, TS sensors) PMV coil lead

Discharge pip

Suction pipe

Accumulator

– 95 –

No.iPart name

Compressor Compressor lead (Continued)

Procedure

12) Using a burner, remove the discharge

pipe and the suction pipe connected to the compressor.

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 frame does not catch the 4-way valve, PMV and pressure switch. (An operation may become an error.)

13) Pull off the discharge pipe and the

suction pipe of the refrigerating cycle upward.

14) Remove the compressor bolts which fix

the compressor to the bottom plate. (3 pcs.)

15) Pull out the compressor toward you.

CAUTIONX

The weight of the compressor is 15kg or more, so handle it by 2 workers.

Remarks

Remove (Discharge pipe)

Remove (Suction pipe)

Com

ressor bolt (3 pcs.

)

– 96 –

No.iPart name

Compressor Compressor lead (Continued)

Procedure

2. Mounting of compressor

1) Mount the compressor in the reverse procedure of removal.

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.

Using bundling band on the market, bind the compressor lead. As the compressor lead is long, be sure that the compressor lead does not contact with the discharge pipe.

∗ Fix the removed each sensor and PMV coil

lead wire to the discharge pipe and the suction pipe with the bundling band via the pipe cover.

In this time, take note that each sensor and PMV coil lead wire do not come to contact with the discharge pipe and the reactor. (For fixing to the discharge pipe, use the black heat-proof pipe cover and the bundling band for heat-proof which is sold on the market.)

∗ As shown in the right figure, mount the

sound-insulation plate (inner side, outer side) by inserting between the compressor and the piping, and between piping and the partition plate.

∗ Put the compressor lead wire and the

compressor case thermo between inner side and outer side of the sound-insulation as if dropping them in.

Remarks

Compressor lead

Pass the soundproof plate (outer winding)

through between the suction pipe and

the accumulator.

Do not make clearance between the sound-insulation plate (upper) and the sound-insulation plate (outer side).

Put the sound

-insulation

plate (outer side)

on the other side at this position.

Sound-insulation plate

(upper)

Sound-insulation

plate (outer side)

Sound-insulation plate (upper)

Sound-insulation plate (outer side)

Accumulator

Using the bundling band on the market, fix the bundle at 2 positions.

Wind the ferrite core

with the compressor

lead wire by 4 times.

0 to 2

0 to 2”

(0 to 50mm)

(Positioning standard of

compressor lead wire)

0 to 2” (0 to 50mm) (Positioning standard of compressor lead wire)

Ferrite core

Wind the ferrite core with the compressor lead wire by 4 times.

Suction pipe

Pass the sound-insulation plate (outer side) through between the suction pipe and the accumulator.

Accumulator

Discharge pipe

Suction pipe

Pass the sound-insulation

plate (inner side) through

between compressor and

discharge pipe, suction pipe

and then put it on the other

side at this position.

Pass the sound-insulation plate (inner side) through between compressor and discharge pipe, suction pipe and then put it on the other side at this position.

Pipe cover, bundling band, each sensor (TL, TO, TE, TS sensor) PMV coil lead

Pipe cover, bundling band, TS sensor

Discharge pipe

Suction pipe

PMV coil lead

Set each sensor so that it does not come to contact with the discharge pipe.

– 97 –

SW804 SW801

PMV coil

Spring PMV main body

No.iPart name

Compressor Compressor lead (Continued)

Procedure

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

∗ Turn on the leakage breaker. ∗ Turn on 1 and 3 of DIP SW804 on the control

P.C. board of the outdoor unit.

∗ Keep pushing SW801 on the control P.C. board

of the outdoor unit for 1 second or more.

∗ After pushing SW801 for 1 second or more,

turn off the leakage breaker within 2 minutes.

4. Refrigerant charging

1) Add the quantity of refrigerant specified by the pipe length into the charge port of the valve.

Remarks

1. Detachment

1) Perform work of Detachment c and e.

2) While pulling the coil upward and removing the spring which pinches the copper pipe, remove the coil from PMV main body.

2. Attachment

1) Match the spring to the copper pipe and fix it.

PMV coil

– 98 –

No.kPart name

Fan guard

Procedure

3. Detachment

1) Perform work of Detachment c and d.

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 fan guard stopper. (8 positions)

2. Attachment

1) Insert the fan guard stopper to fix the fan guard. (8positions)

CAUTIONX

Check that entire fan guard stoppers are fixed at the specified positions.

Remarks

Bell mouth

Fan guard

stopper

Discharge port cabinet

Fan guard

Hooking claw

Bell mouth

Fan guard stopper

Discharge port cabinet

Fan guard

Hooking claw

– 99 –

No.cPart name

Common procedure

Procedure

XCAUTIONX

Never forget to put on the gloves at working time; otherwise an injury will be caused by the parts, 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 M4, 10 mm, 2 pcs.)

• Remove the screws and then remove

the front panel by pulling it downward.

3) Remove the power supply wire and the indoor/outdoor connecting wire from the cord clamp and the terminal.

4) Remove the top plate. (Hexagonal screw M4, 10 mm, 5 pcs.)

2. Attachment

1) Attach the top plate. (Hexagonal screw M4, 10 mm, 5 pcs.)

2) Connect the power supply wire and the indoor/outdoor connecting wire to the terminal and then fix them with the cord clamp.

XREQUIREMENTX

For the power supply wire and the indoor/ outdoor connecting wire, be sure fix them using the bundling band on the market along the crossover pipe so that they do not come to contact with the compressor, valve at gas side, pipe at gas side and discharge pipe.

3) Attach the front panel. (Hexagonal screw M4, 10 mm, 2 pcs.)

Remarks

11-1-3. RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Top plate

Front panel

– 100 –

Valve fixing plate

Inverter assembly

Side cabinet

Valve fixing plate

Inverter assembly Side cabinet

Fin guard

Inverter protective cover

Partition boardMotor base

Heat exchanger Discharge

port cabinet

No.

Part name

Discharge port cabinet

Side cabinet

Procedure

1. Detachment

1) Perform work of Detachment 1 of c .

2) Remove screws for the discharge port cabinet and the partition board. (M4, 8 mm, 4 pcs.)

3) Remove screws for the discharge port cabinet and the bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

4) Remove screws for the discharge cabinet and the motor base. (M4, 8 mm, 2 pcs.)

5) Remove screw for the discharge cabinet and the heat exchanger. (M4, 8 mm, 1 pc.)

6) Remove screws for the discharge port cabinet and the fin guard. (Hexagonal screw M4, 10 mm, 2 pcs.)

1) Perform work of Detachment 1 of c .

2) Remove the screws which fix the inverter assembly and the side cabinet. (M4, 8 mm, 2 pcs.)

3) Take off screws that fix the wiring division panel and the side cabinet.

4) Remove the screws for the side cabinet and the valve fixing plate. (M4, 8 mm, 2 pcs.)

6) Remove screws for the side cabinet and the piping panel (Rear). (Hexagonal screw M4, 10 mm, 2 pcs.)

6) Remove screw for the side cabinet and the bottom plate. (Hexagonal screw M4, 10 mm, 1 pc.)

7) Remove screws for the side cabinet and the fin guard (Heat exchanger). (Hexagonal screw M4, 10 mm, 5 pcs.)

Remarks

Inverter protective cover

1) Perform work of Detachment 1 of c .

2) Take off screw which fixes the inverter assembly and the inverter protective cover. (M4, 8 mm, 1 pc.)

Toshiba Carrier RAV-SP180AT2-UL, Carrier RAV-SP300AT2-UL, Carrier RAV-SP240AT2-UL, Carrier RAV-SP360AT2-UL, Carrier RAV-SP420AT2-UL Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual