Toshiba RAV-SM1403AT-E1 User Manual

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Page 1

FILE NO. A11-016

SERVICE MANUAL

(SPLIT TYPE)

OUTDOOR UNIT

< DIGITAL INVERTER>

RAV-SM1103AT-E1 RAV-SM1403AT-E1

R410A

PRINTED IN JAPAN, Jan., 2012 ToMo

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CONTENTS

Precaution for Safety ............................................................................................................ 6

New Refrigerant (R410A) .................................................................................................... 11

1. SPECIFICATIONS ........................................................................................................ 13

1-1. Outdoor Unit ............................................................................................................................... 13

1-2. Characteristic Curve ................................................................................................................. 14

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS).......................................................... 15

3. REFRIGERATING CYCLE DIAGRAM ......................................................................... 17

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

5. SPECIFICATIONS OF ELECTRICAL PARTS .............................................................. 20

6. REFRIGERANT R410A ................................................................................................ 21

6-1. Safety During Installation/Servicing ........................................................................................21

6-2. Refrigerant Piping Installation ............................................................................................... 21

6-3. Tools ............................................................................................................................................ 25

6-4. Recharging of Refrigerant ........................................................................................................ 25

6-5. Brazing of Pipes ......................................................................................................................... 26

6-6. Instructions for Re-use Piping of R22 or R407C .................................................................... 28

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS .............................. 31

7-1. Outdoor Unit Control ................................................................................................................. 31

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

8. TROUBLESHOOTING .................................................................................................. 37

8-1. Summary of Troubleshooting ................................................................................................... 37

8-2. Troubleshooting ......................................................................................................................... 39

9. SETUP AT LOCAL SITE AND OTHERS...................................................................... 63

9-1. Calling of Error History ............................................................................................................. 63

9-2. Group Control Operation .......................................................................................................... 63

9-3. Outdoor Unit ............................................................................................................................... 65

9-4. Applicable Control of Outdoor Unit ......................................................................................... 72

10. ADDRESS SETUP ....................................................................................................... 73

10-1. Address Setup Procedure ......................................................................................................... 73

10-2. Address Setup & Group Control ..............................................................................................74

10-3. Remote Controller Wiring.......................................................................................................... 77

10-4. Address Setup (Manual setting from remote controller) ....................................................... 77

10-5. Confirmation of Indoor Unit No. Position ................................................................................ 78

11. REPLACEMENT OF THE SERVICE P.C. BOARD MCC-1630 ..................................... 80

12. HOW TO EXCHANGE COMPRESSOR........................................................................ 81

12-1. Exchanging Procedure of Compressor (Outline) ................................................................... 81

12-2. Exchange of Compressor ......................................................................................................... 81

13. DETACHMENTS ........................................................................................................... 82

14. EXPLODED VIEWS AND PARTS LIST........................................................................ 90

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Original instruction

Please read carefully through these instructions that contain important information which complies with the “Machinery” Directive (Directive 2006/42/EC), and ensure that you understand them.

Generic Denomination: Air Conditioner

Definition of Qualified Installer or Qualified Service Person

The air conditioner must be installed, maintained, repaired and removed by a qualified installer or qualified service person.

When any of these jobs is to be done, ask a qualified installer or qualified service person to do them for you.

A qualified installer or qualified service person is an agent who has the qualifications and knowledge described in the table below.

Agent

Qualified installer (∗1)

Qualified service person (∗1)

Qualifications and knowledge which the agent must have

• The qualified installer is a person who installs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Corporation.

He or she has been trained to install, maintain, relocate and remove the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations.

• The qualified installer who is allowed to do the electrical work involved in installation, relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.

• The qualified installer who is allowed to do the refrigerant handling and piping work involved in installation, relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.

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

• The qualified service person is a person who installs, repairs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Corporation. He or she has been trained to install, repair, maintain, relocate and remove the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations.

• The qualified service person who is allowed to do the electrical work involved in installation, repair, relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.

• The qualified service person who is allowed to do the refrigerant handling and piping work involved in installation, repair, relocation and removal has the qualifications pertaining to this refrigerant handling

she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.

• The qualified service person who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.

and piping work as stipulated by the local laws and regulations, and he or

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Definition of Protective Gear

When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’ work clothing.

In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below.

Failure to wear the proper protective gear is dangerous because you will be more susceptible to injury, burns, electric shocks and other injuries.

Work undertaken

All types of work

Electrical-related work

Work done at heights (50 cm or more)

Transportation of heavy objects

Repair of outdoor unit

Protective gloves “Safety” working clothing

Gloves to provide protection for electricians and from heat Insulating shoes Clothing to provide protection from electric shock

Helmets for use in industry

Shoes with additional protective toe cap

Gloves to provide protection for electricians and from heat

Protective gear worn

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]

Indication

Explanation

DANGER

WARNING

CAUTION

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.

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

[Explanation of illustrated marks]

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.

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Warning Indications on the Air Conditioner Unit

[Confirmation of warning label on the main unit]

Confirm that labels are indicated on the specified positions

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

Warning indication

WARNING

ELECTRICAL SHOCK HAZARD

Disconnect all remote electric power supplies before servicing.

WARNING

Moving parts. Do not operate unit with grille removed. Stop the unit before the servicing.

Description

WARNING

ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies

before servicing.

WARNING

Moving parts. Do not operate unit with grille removed. Stop the unit before the servicing.

CAUTION

High temperature parts. You might get burned when removing

this panel.

CAUTION

Do not touch the aluminum fins of the unit. Doing so may result in injury.

CAUTION

BURST HAZARD

Open the service valves before the operation, otherwise there might be the burst.

CAUTION

High temperature parts. You might get burned when removing this panel.

CAUTION

Do not touch the aluminum fins of the unit. Doing so may result in injury.

CAUTION

BURST HAZARD

Open the service valves before the operation, otherwise there might be the burst.

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Precaution for Safety

The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual.

DANGER

Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position. Otherwise, electric shocks may result.

Before opening the intake grille of the indoor unit or service panel of the outdoor unit, set the circuit breaker to the OFF position. Failure to set the circuit breaker to the OFF position may result in electric shocks through contact with the interior parts. Only a qualified installer (*1) or qualified service person (*1) is allowed to remove the intake grille of the indoor unit or service panel of the outdoor unit and do the work required.

Turn off

breaker.

Electric shock

hazard

Before starting to repair the outdoor unit fan or fan guard, be absolutely sure to set the circuit breaker to the OFF position, and place a “Work in progress” sign on the circuit breaker before proceeding with the work.

When cleaning the filter or other parts of the indoor unit, set the circuit breaker to OFF without fail, and place a “Work in progress” sign near the circuit breaker before proceeding with the work.

When you access inside of the service panel to repair electric parts, wait for about five minutes after turning off the breaker. Do not start repairing immediately. Otherwise you may get electric shock by touching terminals of high-voltage capacitors. Natural discharge of the capacitor takes about five minutes.

Before operating the air conditioner after having completed the work, check that the electrical parts box cover of the indoor unit and service panel of the outdoor unit are closed, and set the circuit breaker to the ON position. You may receive an electric shock etc. if the power is turned on without first conducting these checks.

Execute

discharge

between

terminals.

Prohibition

Stay on

protection

WARNING

General

Even if the circuit breaker has been set to the OFF position before the service panel is removed and the electrical parts are repaired, you will still risk receiving an electric shock. For this reason, short-circuit the high-voltage capacitor terminals to discharge the voltage before proceeding with the repair work. For details on the short-circuiting procedure, refer to the Service Manual. You may receive an electric shock if the voltage stored in the capacitors has not been sufficiently discharged.

Place a “Work in progress” sign near the circuit breaker while the installation, maintenance, repair or removal work is being carried out. There is a danger of electric shocks if the circuit breaker is set to ON by mistake.

When checking the electric parts, removing the cover of the electric parts box of Indoor Unit and/or front panel of Outdoor Unit inevitably to determine the failure, put a sign “Do not enter” around the site before the work. Failure to do this may result in third person getting electric shock.

If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, wear insulated heat-resistant gloves, insulated boots and insulated work overalls, and take care to avoid touching any live parts. You may receive an electric shock if you fail to heed this warning. Only qualified service person (*1) is allowed to do this kind of work.

Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions.

Only qualified service person (*1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.

Only a qualified installer (*1) or qualified service person (*1) is allowed to carry out the electrical work of the air conditioner. Under no circumstances must this work be done by an unqualified individual since failure to carry out the work properly may result in electric shocks and/or electrical leaks.

Wear protective gloves and safety work clothing during installation, servicing and removal.

Use wiring that meets the specifications in the Installation Manual and the stipulations in the local regulations and laws. Use of wiring which does not meet the specifications may give rise to electric shocks, electrical leakage, smoking and/or a fire.

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WARNING

General

Check earth

wires.

The appliance shall be installed in accordance with national wiring regulations. Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire.

Only a qualified installer (*1) or qualified service person (*1) is allowed to undertake work at heights using a stand of 50 cm or more or to remove the intake grille of the indoor unit to undertake work.

When working at heights, use a ladder which complies with the ISO 14122 standard, and follow the procedure in the ladder’s instructions. Also wear a helmet for use in industry as protective gear to undertake the work.

When working at heights, put a sign in place so that no-one will approach the work location, before proceeding with the work. Parts and other objects may fall from above, possibly injuring a person below.

Do not touch the aluminum fin of the outdoor unit. You may injure yourself if you do so. If the fin must be touched for some reason, first put on protective gloves and safety work clothing, and then proceed.

Use forklift to carry in the air conditioner units and use winch or hoist at installation of them.

Do not climb onto or place objects on top of the outdoor unit. You may fall or the objects may fall off of the outdoor unit and result in injury.

When transporting the air conditioner, wear shoes with additional protective toe caps.

When transporting the air conditioner, do not take hold of the bands around the packing carton. You may injure yourself if the bands should break.

When transporting the air conditioner, use a forklift and when moving the air conditioner by hand,move the unit with 4 people.

Do not customize the product. Doing so may result in electric shock or other failure.

This air conditioner has passed the pressure test as specified in IEC 60335-2-40 Annex EE.

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.

After completing the repair or relocation work, check that the ground wires are connected properly.

Be sure to connect earth wire. (Grounding work) Incomplete grounding causes an electric shock. Do not connect ground wires to gas pipes, water pipes, and lightning rods or ground wires for telephone wires.

Prohibition of modification.

Use specified

parts.

Do not bring a

child close to

the equipment.

Insulating measures

No fire

Do not modify the products.Do not also disassemble or modify the parts. It may cause a fire, electric shock or injury.

When any of the electrical parts are to be replaced, ensure that the replacement parts satisfy the specifications given in the Service Manual (or use the parts contained on the parts list in the Service Manual). Use of any parts which do not satisfy the required specifications may give rise to electric shocks, smoking and/or a fire.

If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, place "Keep out" signs around the work site before proceeding. Third-party individuals may enter the work site and receive electric shocks if this warning is not heeded.

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 performing repairs using a gas burner, replace the refrigerant with nitrogen gas because the oil that coats the pipes may otherwise burn. 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.

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Refrigerant

The refrigerant used by this air conditioner is the R410A.

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.

Do not use any refrigerant different from the one specified for complement or replacement. Otherwise, abnormally high pressure may be generated in the refrigeration cycle, which may result in a failure or explosion of the product or an injury to your body.

For an air conditioner which uses R410A, never use other refrigerant than R410A. For an air conditioner which uses other refrigerant (R22, etc.), never use R410A. If different types of refrigerant are mixed, abnormal high pressure generates in the 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.

Assembly/

Cabling

Insulator check

Ventilation

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.

After the work has finished, be sure to use an insulation tester set (500V Megger) to check the resistance is 1MΩ 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.

If refrigerant gas has leaked during the installation work, ventilate the room immediately. If the leaked refrigerant gas comes in contact with fire, noxious gas may be generated.

After the installation or servicing work, confirm that refrigerant gas does not leak. If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may be generated.

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.

Compulsion

Tighten the flare nut with a torque wrench in the specified manner. Excessive tighten of the flare nut may cause a crack in the flare nut after a long period, which may result in refrigerant leakage.

Nitrogen gas must be used for the airtight test.

The charge hose must be connected in such a way that it is not slack.

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.

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Check after

repair

Do not

operate the unit

with the valve

closed.

Check after

reinstallation

Cooling check

Installation

Once the repair work has been completed, check for refrigerant leaks, and check the insulation resistance and water drainage. Then perform a trial run to check that the air conditioner is running properly.

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 matters before a test run after repairing piping.

• Connect the pipes surely and there is no leak of refrigerant.

• The valve is opened. Running the compressor under condition that the valve closes causes an abnormal high pressure resulted in damage of the parts of the compressor and etc. and moreover if there is leak of refrigerant at connecting section of pipes, the air is suctioned and causes further abnormal high pressure resulted in burst or injury.

Only a qualified installer (*1) or qualified service person (*1) is allowed to relocate the air conditioner. It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire, electric shocks, injury, water leakage, noise and/or vibration may result.

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.

When carrying out the pump-down work shut down the compressor before disconnecting the refrigerant pipe. Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly resulting in reputing, injury, etc.

When the service panel of the outdoor unit is to be opened in order for the compressor or the area around this part to be repaired immediately after the air conditioner has been shut down, set the circuit breaker to the OFF position, and then wait at least 10 minutes before opening the service panel. If you fail to heed this warning, you will run the risk of burning yourself because the compressor pipes and other parts will be very hot to the touch. In addition, before proceeding with the repair work, wear the heat-resistant gloves.

When the service panel of the outdoor unit is to be opened in order for the fan motor, reactor, inverter or the areas around these parts to be repaired immediately after the air conditioner has been shut down, set the circuit breaker to the OFF position, and then wait at least 10 minutes before opening the service panel. If you fail to heed this warning, you will run the risk of burning yourself because the fan motor, reactor, inverter heat sink and other parts will be very hot to the touch. In addition, before proceeding with the repair work, wear the heat-resistant gloves.

Only a qualified installer (*1) or qualified service person (*1) is allowed to install the air conditioner. If the air conditioner is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result.

Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner.

Do not install the air conditioner in a location that may be subject to a risk of expire to a combustible gas. If a combustible gas leaks and becomes concentrated around the unit, a fire may occur.

Install the indoor unit at least 2.5 m above the floor level since otherwise the users may injure themselves or receive electric shocks if they poke their fingers or other objects into the indoor unit while the air conditioner is running.

Install a circuit breaker that meets the specifications in the installation manual and the stipulations in the local regulations and laws.

Install the circuit breaker where it can be easily accessed by the agent.

Do not place any combustion appliance in a place where it is directly exposed to the wind of air conditioner, otherwise it may cause imperfect combustion.

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Explanations given to user

• If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person to have the repairs done.

Do not set the circuit breaker to the ON position until the repairs are completed.

Relocation

• Only a qualified installer (∗1) or qualified service person (∗1) is allowed to relocate the air conditioner. It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire, electric shocks, injury, water leakage, noise and/or vibration may result.

• When carrying out the pump-down work shut down the compressor before disconnecting the refrigerant pipe. Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly resulting in reputing, injury, etc.

(∗1) Refer to the “Definition of Qualified Installer or Qualified Service Person.”

Declaration of Conformity

Manufacturer: Toshiba Carrier Corporation

336 Tadehara, Fuji-shi, Shizuoka-ken 416-8521 JAPAN Authorized Nick Ball Representative/TCF holder: Toshiba EMEA Engineering Director

Toshiba Carrier UK Ltd.

Porsham Close, Belliver Industrial Estate,

PLYMOUTH, Devon, PL6 7DB.

United Kingdom Hereby declares that the machinery described below: Generic Denomination: Air Conditioner Model/type: RAV-SM1103AT-E1 RAV-SM1403AT-E1 Commercial name: Digital Inverter Series Air Conditioner Complies with the provisions of the “Machinery” Directive (Directive 2006/42/EC) and the regulations transposing

into national law. Complies with the provisions of the following harmonized standard:

EN 378-2: 2008 + A1:2009 Note: This declaration becomes invalid if technical or operational modifications are introduced without the

manufacturer’s consent.

Disposal

How to dispose of air conditioners with a rating of 12 kW and below in accordance with the 2002/96/EC Directive WEEE (Waste Electrical and Electronic Equipment) is provided in the Installation Manual supplied with your product. For disposal of the product above 12 kW in rating you should use a registered company in accordance with any national or EU legislation.

DI series

RAV-SM563AT-E RAV-SM803AT-E RAV-SM1103AT-E, RAV-SM1103AT-E1

SDI series

RAV-SP404AT-E RAV-SP404ATZ-E RAV-SP404ATZG-E RAV-SP454AT-E RAV-SP454ATZ-E RAV-SP454ATZG-E RAV-SP564AT-E RAV-SP564ATZ-E RAV-SP564ATZG-E RAV-SP804AT-E RAV-SP804ATZ-E RAV-SP804ATZG-E RAV-SP1104AT-E RAV-SP1104ATZ-E RAV-SP1104ATZG-E RAV-SP1104AT8-E RAV-SP1104AT8Z-E RAV-SP1104AT8ZG-E RAV-SP1104AT8-TR RAV-SP1104AT8Z-TR RAV-SP1104AT8ZG-TR

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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 40mg/10m 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.

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Page 12

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

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

air conditioner installation

Existence of

new equipment

for R410A

Ye s ∗ (Note)

Ye s N o

Ye s Ye s

Ye s N o

R410A

Whether conventional

equipment can be used

Conventional air

conditioner installation

Whether

conventional equipment

can be used

Ye s

∗ (Note)

Ye s

(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. 7) Screwdriver (+, –)

2) Torque wrench 8) Spanner or Monkey wrench

3) Pipe cutter 9) Hole core drill

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

5) Pipe bender 11) Tape measure

6) Level vial 12) Metal saw

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

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

2) Thermometer 4) Electroscope

– 12 –

Page 13

1-1. Outdoor Unit

1. SPECIFICATIONS

Model name Outdoor unit RAV-

Power supply

Type

Compressor Motor (kW)

Pole

Refrigerant charged (kg)

Refrigerant control

Standard length (m)

Min. length (m)

Inter connecting pipe

Max. total length (m)

Additional refrigerant charge under long piping connector

Height difference

Outdoor lower (m)

Outdoor higher (m)

SM1103AT-E1

1 phase 230V (220 – 240V) 50Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

2.5 3.0

2.8 2.8

Pulse motor valve

7.5 7.5

5.0

50 50

40g/m 40g/m

(31m to 50m) (31m to 50m)

30 30

SM1403AT-E1

5.0

Height (mm)

Outer dimension

Appearance

Total weight (kg)

Heat exchanger

Fan unit Standard air flow (m³/h.)

Connecting pipe

Sound pressure level Cooling/Heating (dB

Sound power level Cooling/Heating (dB

Outside air temperature, Cooling (˚C)

Width (mm)

Depth (mm)

Fan

Motor (W)

Gas side (mm)

Liquid side (mm)

•

795 795

900 900

320 320

Silky shade (Muncel 1Y 8.5/0.5)

76 76

Finned tube

Propeller fan

75 75

100 100

15.9 15.9

9.5 9.5

53 / 54 54 / 54

70 / 71 70 / 71

43 to – 15

Outside air temperature, Heating (˚C)

15 to – 15

– 13 –

Page 14

RAV-SM1403AT-E

RAV-SM1103AT-E

1-2. Operation Characteristic Curve

• Operation Characteristic Curve <Digital Inverter>

RAV-SM1103AT-E1,RAV-SM1403AT-E1

22 22

RAV-SM1103AT-E1

RAV-SM1403AT-E1

Current (A)

0204060

• Conditions Indoor : DB27˚C/WB19˚C Outdoor : DB35˚C Air flow : High Pipe length : 7.5m 230V

80 100 120

Compressor speed (rps)

• Capacity variation ratio according to temperature

RAV-SM1403AT-E1

Current (A)

0 204060

RAV-SM1103AT-E1

• Conditions Indoor : DB20˚C Outdoor : DB7˚C/WB6˚C Air flow : High Pipe length : 7.5m 230V

80 100 120

Compressor speed (rps)

RAV-SM1103AT-E1,RAVSM1403AT-E1

105

100

Capacity ratio (%)

32 33 34 35 36 37 38 39

• Conditions Indoor : DB27˚C/WB19˚C Indoor air flow : High Pipe length : 7.5m

41 42 43

120

110

100

Capacity ratio (%)

-14-12-10-8-6-4-20246810

• Conditions Indoor : DB20˚C Indoor air flow : High Pipe length : 7.5m

Outdoor temp. (˚C)

– 14 –

Page 15

2 . CONSTRUCTION VIEWS (EXTERNAL VIEWS)

RAV-SM1103AT-E1, RAV-SM1403AT-E1

Knockout (For draining)

Suction port

365 17.517.5

(Long hole pitch

for anchor bolt)

565 101

Drain hole (Ø20 × 88 Burring hole)

29 90 191 20

Suction port

Knockout (For draining)

6026

Discharge port

600150

900

314

Drain hole (Ø25 Burring hole)

Part B

Part A

Handles (Both sides)

Refrigerant pipe connecting port Flare at liquid side : Ø9.5

Refrigerant pipe connecting port Flare at gas side : Ø15.9

Installation bolt hole (Ø12 × 17 U-shape holes)

17.5

4040

Details of B part

Details of A part

17.5

Installation bolt hole (Ø12 × 17 U-shape holes)

Discharge guide mounting hole (4-Ø4 Embossing)

60 90

161

32028

400

6760

264

154

300

264

307

2760

Knockout for lower piping

86 7

Z views

Space required for service

795

165

60 80

25 50

2-Ø12 × 17 U-shape holes (For Ø8–Ø10 Anchor bolt)

150 or more

365

500 or more

Suction port

150

or more

Discharge port

600

150 or more

Discharge port

(Minimum distance up to wall)

2-Ø12 × 17 long hole (For Ø8–Ø10 Anchor bolt)

– 15 –

Page 16

RBC-TWP30E2, RBC-TWP50E2 (Simultaneous Twin)

Inner diameter Ø C

Inner

diameter Ø D

TWP30E2

TWP50E2

Model (RBC-)

Liquid side

Gas side

Liquid side

Gas side

Inner

diameter Ø D

ABCD

36 14 Ø9.5 Ø6.4

43 23 Ø15.9 Ø12.7

34 14 Ø9.5 Ø9.5

44 21 Ø15.9 Ø15.9

– 16 –

Page 17

3 . REFRIGERATING CYCLE DIAGRAM

RAV-SM1103AT-E1, RAV-SM1403AT-E1

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

15.9mm 9.5mm

Height difference (m)

Outdoor unit

at upper side

30 30

Outdoor unit at lower side

TS sensor

Pressure

TD sensor

Height difference

switch

Strainer

Refrigerant pipe at gas side Ø15.9

Ball valve Outer dia. ØA

Strainer

TO sensor

TL sensor

Indoor unit

TCJ sensor

Air heat exchanger

Section shape

of heat insulator

Outdoor unit

Distributor (Strainer incorporated)

TC sensor

Refrigerant pipe at liquid side Ø9.5

Min. 5m

Packed valve Outer dia. ØB

PMV (Pulse Motor Valve) (UKV-25D22)

Max. 50m

Accumulator

(2500cc)

(DA422A3F-12M)

Rotary

compressor

Muffler

4-way valve

(STF-H0218)

Ø25 × L210

Ø25 × L180

Heat exchanger Outer side Ø8, 2 rows, 20 steps FP1.3 flat fin Inner side Ø9.52 row, 30 steps FP1.5 flat fin

Strainer

TE sensor

Distributor

R410A 2.8kg

Cooling Heating

– 17 –

Page 18

RAV-SM1103AT-E1

Standard

Pressure

(MPa) (kg/cm

Pd Ps Pd Ps TD TS TC

3.44 0.92 35.1 9.4 82 8 10 56 39 47 HIGH

Pipe surface temp.

Comp.

TE Hz Fan In Out

27/19

Temp

35/–

Cooling

Heating

Overload

Low load

Standard

Overload

Low load

RAV-SM1403AT-E1

Standard

Cooling

Heating

Overload

Low load

Standard

Overload

3.73 1.18 38.1 12.0 82 15 17 59 48 42 HIGH 32/24 43/–

1.49

2.80

3.43 1.08 35.0 11.0 82 14 55 12 13 24 LOW 30/– 24/18

2.20 0.25 22.4 2.6 76 -19 36 -16 -16 55 HIGH 15/–

3.52 0.85 35.9 8.7 87 8 9 57 39 54 HIGH 27/19 35/–

3.78

1.51 0.71

2.88

3.41

0.70 15.2 7.1 39 8 3 23 22 30 LOW 18/15.5 –5/–

0.61

(MPa) (kg/cm

Pd Ps Pd Ps TD TS TC

1.12

0.60

1.08

28.6 6.2 80 0 46 7 1 48 HIGH 20/– 7/6

Pressure

38.6

15.4

29.4

34.8

11.4

7.2 40 7 3 23 23

6.1

11.0 81

84 15 17 59 47 45 HIGH 32/24 43/–

Pipe surface temp.

Comp.

TE Hz Fan In Out

LOW

161

HIGH

LOW

Temp

18/15.5

20/–

30/–

–10/(70%)

–5/–

7/6

24/18

Low load

4 poles are provided to this compressor.

2.35 0.24

24.0

2.4

-19

-16

-16 73 HIGH 15/–

The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.

–10/(70%)

– 18 –

Page 19

4. WIRING DIAGRAM

– 19 –

Page 20

5. SPECIFICATIONS OF ELECTRIC PARTS

Part name Type Specifications

Compressor

Outdoor fan motor

Reactor

4-way valve coil

High-pressure SW

PMV coil

P.C. board

Fuse

Surge absorber

Rectifier

Electrolytic condenser

DA422A3F-12M

WDF-340-A100-1

CH62-2Z-T

STF-H01AJ1949A1

ACB-4UB83W

UKV-A039

MCC-1630

GDT 250V25A

50T (P) 063HF

SCT3.15A

DA38-362MT or DA38-302MT

D25XB60

LLQ2G761KHUATF or ECST401LIN761KA58

Output 100W

6mH, 18.5A

AC230V

OFF: 4.15MPa

DC12V

1Ø AC220V/230V/240V±10%, 50/60HZ

AC250V, 25A

AC250V, 6.3A

AC250V, 3.15A

Discharge voltage 3600V Discharge voltage 3000V

DC600V, 25A

DC400V, 760μF

Power relay

Relay

Switching transformer

Fuse

DW12D1

G5NB or DQ12D1 or RPG-12

SWT-91

50T100H

AC250V, 20A x 2

AC250V, 3A AC250V, 5A AC250V, 3A

Input: DC240 to 390V Output: DC7V, DC13V, DC17V

AC250V, 10A

– 20 –

Page 21

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 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 0.8mm even when it is available on the market.

NOTE

Refer to the “6-6. Instructions for Re-use Piping of R22 or R407C”.

– 21 –

Page 22

Table 6-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter

1/4

3/8

1/2

5/8

Outer diameter (mm)

6.4

9.5

12.7

15.9

R410A R22

0.80 0.80

1.00 1.00

1. Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a) Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.

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 20 mm. Thicknesses of socket joints are as shown in Table 6-2-2.

Table 6-2-2 Minimum thicknesses of socket joints

Nominal diameter

1/4

3/8

1/2

5/8

Reference outer diameter of

copper pipe jointed (mm)

6.4

9.5

12.7

15.9

Minimum joint thickness

(mm)

0.50

0.60

0.70

0.80

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.

– 22 –

Page 23

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.

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

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

Flare tool for

R410A, R22 clutch type

Conventional flare tool

Clutch type Wing nut type

ØD

Fig. 6-2-1 Flare processing dimensions

A (mm)

Conventional flare tool

(R410A)

Clutch type Wing nut type

(R22)

1/4

3/8

1/2

5/8

3/4

Nominal

diameter

1/4

3/8

1/2

5/8

3/4

6.4

9.5

12.7

15.9

19.1

Outer diameter

(mm)

6.4

9.5

12.7

15.9

19.1

0.8

1.0

1.2

0 to 0.5

1.0 to 1.5 1.5 to 2.0

1.0 to 1.5 2.0 to 2.5

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

Thickness

(mm)

0.8

1.0

1.2

ABCD

9.1 9.2 6.5 13

13.2 13.5 9.7 20

16.6 16.0 12.9 23

19.7 19.0 16.0 25

24.0 — 19.2 28

Dimension (mm)

0.5 to 1.0 1.0 to 1.5

0.5 to 1.0 1.5 to 2.0

——

Flare nut width

(mm)

Nominal

diameter

1/4

3/8

1/2

5/8

3/4

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

Outer diameter

(mm)

6.4

9.5

12.7

15.9

19.1

Thickness

(mm)

0.8

1.0

Dimension (mm)

ABCD

9.1 9.2 6.5 13

13.0 13.5 9.7 20

16.2 16.0 12.9 20

19.4 19.0 16.0 23

23.3 24.0 19.2 34

– 23 –

Flare nut width

(mm)

Page 24

45˚to 46˚

43˚to 45˚

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]

Nominal

diameter

1/4

3/8

1/2

5/8

3/4

Outer diameter

(mm)

6.4

9.5

12.7

15.9

19.1

Tightening torque

N•m (kgf•m)

14 to 18 (1.4 to 1.8)

33 to 42 (3.3 to 4.2)

50 to 62 (5.0 to 6.2)

63 to 77 (6.3 to 7.7)

100 to 120 (10.0 to 12.0)

Tightening torque of torque

wrenches available on the market

N•m (kgf•m)

16 (1.6), 18 (1.8)

42 (4.2)

55 (5.5)

65 (6.5)

——

– 24 –

Page 25

6-3. Tools

6-3-1. Required Tools

Refer to the “4. Tools”

6-4. Recharging of Refrigerant

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

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

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

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 –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

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

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

(For refrigerant charging, see the figure below.)

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 refrigera-

tion 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.

(INDOOR unit)

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

(Liquid side)

(Gas side)

(OUTDOOR unit)

Opened

Closed

Service port

Electronic balance for refrigerant charging

Fig. 6-4-1 Configuration of refrigerant charging

– 25 –

Page 26

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.

[ Cylinder with siphon ] [ Cylinder without siphon ]

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Gauge manifold

OUTDOOR unit

Electronic

balance

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.

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.

Fig. 6-4-2

1) Phosphor bronze brazing filler tends to react with

2) When performing brazing again at time of

6-5-2. Flux

1. Reason why flux is necessary

Electronic

balance

Siphon

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.

servicing, use the same type of brazing filler.

• 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.

– 26 –

Page 27

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 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

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 0.02 MPa (0.2kgf/cm²) 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.

Piping material

Copper - Copper

Copper - Iron

Iron - Iron

Used brazing filler

Phosphor copper

Silver

Used flux

Do not use

Paste flux

Vapor 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.

Flow meter

Stop valve

Nitrogen gas

cylinder

From Nitrogen cylinder

Pipe

Rubber plug

Fig. 6-5-1

Prevention of oxidation during brazing

Nitrogen gas

– 27 –

Page 28

6-6. Instructions for Re-use Piping of R22 or R407C

Instruction of Works: The existing R22 and R407C piping can be reused for our digital inverter R410A products installations.

NOTE)

Confirmation of existence of scratch or dent of the former pipes to be applied and also confirmation of reliability of the pipe strength are conventionally referred to the local site.

If the definite conditions can be cleared, it is possible to update the existing R22 and R407C pipes to those for R410A models.

6-6-1. Basic Conditions Needed to Reuse the

Existing Pipe

Check and observe three conditions of the refrigerant piping works.

1. Dry (There is no moisture inside of the pipes.)

2. Clean (There is no dust inside of the pipes.)

3. Tight (There is no refrigerant leak.)

6-6-2. Restricted Items to Use the Existing Pipes

In the following cases, the existing pipes cannot be reused as they are. Clean the existing pipes or exchange them with new pipes.

1. When a scratch or dent is heavy, be sure to use the new pipes for the works.

2. When the thickness of the existing pipe is thinner than the specified “Pipe diameter and thickness” be sure to use the new pipes for the works.

• The operating pressure of R410A is high

(1.6 times of R22 and R407C). If there is a scratch or dent on the pipe or thinner pipe is used, the pressure strength is poor and may cause breakage of the pipe at the worst.

∗ Pipe diameter and thickness (mm)

Pipe outer diameter

R410A

Thickness

R22

(R407C)

Ø6.4 Ø9.5 Ø12.7 Ø15.9 Ø19.0

0.8 0.8 0.8 1.0 1.0

• In case that the pipe diameter is Ø12.7 mm or

less and the thickness is less than 0.7 mm, be sure to use the new pipes for works.

3. The pipes are left as coming out or gas leaks. (Poor refrigerant)

• There is possibility that rain water or air including

moisture enters in the pipe.

4. Refrigerant recovery is impossible. (Refrigerant recovery by the pump-down operation on the existing air conditioner)

• There is possibility that a large quantity of poor oil

or moisture remains inside of the pipe.

5. A dryer on the market is attached to the existing pipes.

• There is possibility that copper green rust

generated.

6. Check the oil when the existing air conditioner was removed after refrigerant had been recovered. In this case, if the oil is judged as clearly different compared with normal oil

• The refrigerator oil is copper rust green :

There is possibility that moisture is mixed with the oil and rust generates inside of the pipe.

• There is discolored oil, a large quantity of the

remains, or bad smell.

• A large quantity of sparkle remained wear-out

powder is observed in the refrigerator oil.

7. The air conditioner which compressor was exchanged due to a faulty compressor. When the discolored oil, a large quantity of the remains, mixture of foreign matter, or a large quantity of sparkle remained wear-out powder is observed, the cause of trouble will occur.

8. Installation and removal of the air conditioner are repeated with temporary installation by lease and etc.

9. In case that type of the refrigerator oil of the existing air conditioner is other than the following oil (Mineral oil), Suniso, Freol-S, MS (Synthetic oil), alkyl benzene (HAB, Barrel-freeze), ester series, PVE only of ether series.

• Winding-insulation of the compressor may

become inferior.

NOTE)

The above descriptions are results of confirmation by our company and they are views on our air conditioners, but they do not guarantee the use of the existing pipes of the air conditioner that adopted R410A in other companies.

6-6-3. Branching Pipe for Simultaneous

Operation System

• In the concurrent twin system, when TOSHIBA-

specified branching pipe is used, it can be reused. Branching pipe model name: RBC-TWP30E2, RBC-TWP50E2 On the existing air conditioner for simultaneous operation system (twin system), there is a case of using branch pipe that has insufficient compressive strength. In this case please change it to the branch pipe for R410A.

6-6-4. Curing of Pipes

When removing and opening the indoor unit or outdoor unit for a long time, cure the pipes as follows:

• Otherwise rust may generate when moisture or

foreign matter due to dewing enters in the pipes.

• The rust cannot be removed by cleaning, and a new

piping work is necessary.

Place position

Outdoors

Indoors

Term

1 month or more

Less than 1 month

Every time

Curing manner

Pinching

Pinching or taping

– 28 –

Page 29

6-6-5. Final Installation Checks

Is there no scratch or dent on the existing pipes?

Is it possible to operate the existing air conditioner?

YES

∗ After the existing air conditioner operated in cooling mode for approx. 30 minutes or longer*, recover the refrigerant.

∗ For cooling the pipes and recovering of oil

• Refrigerant recovery: Pump down method

∗ Remove the existing air conditioner from the piping and carry out flashing (nitrogen pressure 0.5 Mpa) to remove the remains inside of the pipe.

Note] In case of twin, also be sure to flash the branching pipe.

Was not largely discolored oil or

a large quantity of remains discharged?

(When the oil deteriorates, the color of the

oil changes to muddy and black color.)

YES

Existing pipe: NO * Use a new pipes.

Nitrogen gas pressure 0.5 Mpa

(If there is discharge of remains, it is judged that there is a large quantity of remains.)

Clean the pipes or use the new pipes.

If you are in trouble of pipe cleaning, please contact us.

 Connect the indoor/outdoor units to the existing pipe.

• Use a flare nut attached to the main unit for the indoor/outdoor units. (Do not use the flare nut of the existing pipe.)

• Re-machine the flare machining size to size for R410A.

∗ In case that a gas pipe Ø19 mm or bigger is used for the outdoor unit of SM80 (3 HP) : (Our R410A model 3 to 6 HP gas pipe size is Ø15.9 mm)

See page 9-3-2.

∗ (Airtight test), Vacuum dry, Refrigerant charge, Gas leak check

Trial run

Piping necessary to change the flare nut/ machining size due to pipe compression.

1) Flare nut width: H

Copper pipe outer dia.

For R410A

For R22

Ø6.4

Same as above

Ø9.5

Ø12.7

2) Flare machining size: A

Copper pipe outer dia.

For R410A

For R22

Becomes large a little for R410A

Ø6.4

9.1

Ø9.5

13.2

Ø12.7

16.6

Ø15.9

2724

Ø15.9

19.7

(mm)

Ø19.1

Same

as above

(mm)

Ø19.1

24.0

23.319.416.213.09.0

– 29 –

Do not apply the refrigerator oil to the flare surface.

Page 30

6-6-6. Handling of Existing Pipe

When using the existing pipe, carefully check it for the following:

• Wall thickness (within the specified range)

• Scratches and dents

• Water, oil, dirt, or dust in the pipe

• Flare looseness and leakage from welds

• Deterioration of copper pipe and heat insulator

Cautions for using existing pipe

• Do not reuse the flare to prevent gas leak.

Replace it with the supplied flare nut and then process it to a flare.

• Blow nitrogen gas or use an appropriate means to keep the inside of the pipe clean.

If discolored oil or much residue is discharged, wash the pipe.

• Check welds, if any, on the pipe for gas leak.

When the pipe corresponds to any of the following, do not use it. Install a new pipe instead.

• The pipe has been open (disconnected from indoor unit or outdoor unit) for a long period.

• The pipe has been connected to an outdoor unit that does not use refrigerant R22, R410A or R407C.

• The existing pipe must have a wall thickness equal to or larger than the following thickness.

Reference outside diameter

(mm)

Ø9.5

Ø15.9

Ø19.1

Wall thickness

(mm)

0.8

1.0

• Never use any pipe with a wall thickness less than these thicknesses due to insufficient pressure capacity.

– 30 –

Page 31

7.CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS

7-1. Outdoor unit control

7-1-1. Prim circuit board (MCC-1630)

Case thermo

connector

Temp. sensor

connector

TD: CN601 (White)

TO: CN602 (Yellow)

Service switch

SW800

SW801

TE: CN603 (White)

TS: CN604 (White)

TL: CN605 (White)

Optional P.C. board

Connection connector

CN806

PMVconnector

CN701 (White)

CN500 (Blue)

4-way valve connector

CN700 (Yellow)

Indoor unit

connecting lead wire

P24 (Gray)

P23 (White)

P22 (Red)

Power supply

connecting lead wire

P21 (White)

P20 (Red)

Inter-unit wire

protective fuse

F22 (250V, 10A)

Varistor

protection fuse

F23 (250V, 6.3A)

Power protection fuse

F20 (250V, 25A)

Power error

display LED

D800 to 804 (Yellow)

D805 (Green)

Jumper wire

J800 to J804, J806

High-pressure

SW connector

CN501 (Green)

Lead wire for grounding

P25 (Black)

Reactor lead wire (Gray)

P28, P29

P26, P27

Power supply circuit

protection fuse

F03 (250V, 3.15A,

Plastic case)

Compressor

output lead

P03, P04, P05

Fan motor

output

CN300

(White)

Electrolyte capacitor Reactor lead wire (White)

– 31 –

Page 32

7-1-2. Outline of Main Controls

1. Pulse Modulating Valve (PMV) control

1) For PMV with 50 to 500 pulses during operation, respectively.

2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.

3) In heating operation, PMV is controlled with the temperature difference between TS sensor and TE sensor.

4) For the temperature difference in items 2) and 3), 1 to 5K is aimed as the target in both cooling and heating operations.

5) When the cycle excessively rose in both cooling and heating operations, PMV is controlled by TD sensor. The aimed value is usually 92°C for SM110, SM140 in 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 an 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.

TD [˚C]

111

109

106

103

Abnormal stop

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up

(Up to command)

As command is

– 32 –

Page 33

3. Current release control

The output frequency and the output voltage are controlled by AC current value detected by T20 on the outdoor P.C. board so that input current of the inverter does not exceed the specified value.

Current [A]

I1 – 0.5

Frequency down

Hold

Normal operation

Hold

Objective model

I1 value [A]

SM110 SM140

COOL HEAT COOL HEAT

20.4 21.2 21.2 21.2

4. Outdoor fan control

Allocations of fan tap revolutions [rpm]

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

SM110 250 280 320 360 410 460 520 580 640 700 760 880 880 900 930

SM140 250 280 320 360 410 460 520 580 640 700 760 880 880 900 970

4-1. Cooling fan control

1) An outdoor fan is controlled by TL sensor, TO sensor and operation frequency. An outdoor fan is controlled at 1-tap interval of DC fan control.

2) At the start time, the fan is fixed for 60 seconds only with the maximum fan tap corresponded to the zone in the following table but it is controlled with TL sensor temperature after then.

58˚C

55˚C

1 tap / 20 sec (Up to the maximum

rotational frequency of each zone)

38˚C

Rotational frequency hold

35˚C

– 1 tap / 20 sec (Up to the minimum rotational frequency of each zone)

WF tap

Temp. range

˚C ≤ TO

˚C ≤ TO < 38˚C

˚C ≤ TO < 29˚C

˚C ≤ TO < 15˚C

˚C ≤ TO < 5˚C

– 4

˚C ≤ TO < 0˚C

TO < – 4

TO error

SM110

SM140 Under 34.2 Hz

˚C

Under 30.0 Hz

MIN.

W6 WB W8

W5 WA W7 WD W9

W3 W7 W5 W9 W7 WB

W2 W5 W4 W7 W6 W9

W1 W3 W3 W5 W4 W7

W1 W2 W2 W4 W3 W5

OFF OFF OFF OFF OFF OFF

OFF WB OFF OFF

Over 30.0,

under 43.8 Hz

Over 34.2,

under 52.2 Hz

MAX. MIN. MAX. MIN. MAX.

SM110:WD SM140:WF

SM110:WD

SM140:WF

Over 43.8 Hz

Over 52.2 Hz

SM110:WD

SM140:WF

SM110:WD SM140:WF

– 33 –

Page 34

4-2. Heating fan control

1) An outdoor fan is controlled by TE sensor, TO sensor and operation frequency. (It is controlled with W1 for minimum and the maximum is controlled according to the following table.)

2) At the start time, the fan is fixed for 3 minutes only with the maximum fan tap corresponded to the zone in the following table but it is controlled with TE sensor temperature after then.

3) When a status TE

24°C continues for 5 minutes, the operation stops. In this case, no error display

≥

appears and the status is same as the normal thermo-OFF. The can restarts after approx. 2 minutes 30 seconds and this continuous operation is not an error.

4) When the above status as 3) occurs frequently, it is considered that filter of the suction part of the indoor unit is dirty. Clean the filter and restart the operation.

Over 31.2,

under 47.4 Hz

Over 36.0,

under 55.8 Hz

Over 47.4 Hz

Over 55.8 Hz

– 2 tap / 20 seconds (up to W1)

Stop timer count

24˚C

– 2 tap / 20 seconds (up to W1)

21˚C

– 1 tap / 20 seconds (up to W1)

18˚C

Rotational frequency hold

15˚C

1 tap / 20 seconds

(up to Max. tap of each zone)

Temp. range

˚C ≤ TO

˚C ≤ TO < 10˚C

– 3

˚C ≤ TO < 5˚C

– 10

˚C ≤ TO < – 3˚C

TO < – 10

SM110

Under 31.2 Hz

SM140 Under 36.0 Hz

MAX. MAX. MAX.

W7 W8 W9

W9 WB WF

WF WF WF

˚C

WF WF WF

TO error WF WF WF

5. 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 30°C or more.

(Normal time) (In defective TO sensor)

No power

Intermittent power-ON 10 minutes: ON / 5 minutes: OFF Output [24W or equivalent]

Continuous power-ON Output [24W or equivalent]

• Power-ON condition TD < 30˚C

2˚C

1˚C

0˚C

–

1˚C

• Power-ON condition TD<30˚C

0˚C

–

1˚C

–

2˚C

–

3˚C

REQUIREMENT

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

– 34 –

No power

Intermittent power-ON 10 minutes: ON / 5 minutes: OFF Output [24W or equivalent]

Continuous power-ON Output [24W or equivalent]

Page 35

6. 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.

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

Current release control value (

Temperature range

47°C ≤ TO

44°C ≤ TO < 47°C

39°C ≤ TO < 44°C

TO error

I1) [A]

SM110 SM140

15.0 15.5

16.8 17.4

17.7 18.3

15.0 15.5

TO sensor value.

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 release control

1) The operation frequency is controlled to restrain abnormal rising of high pressure by TL sensor in cooling operation and TC sensor in heating operation.

2) When TL sensor in cooling operation or TC sensor in heating operation detects abnormal temperature of the stop zone, stop the compressor and the error count becomes +1.

3) When the compressor stopped with 2), the operation restarts from the point of the normal operation zone (e point or lower) where it returned after 2 minutes 30 seconds.

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.

HEAT TC / COOL TL

[˚C]

Abnormal stop

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up (Up to command)

As command is

HEAT COOL

TC TL

62°C 63°C

57°C 62°C

55°C 60°C

53°C 58°C

49°C 54°C

10. Defrost control

In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition

in A zone to D zone.

The defrost operation is immediately finished if TE sensor temperature has become 12°C or more, or it

also is finished when condition of 7°C < TE < 12°C has continued for 1 minute. The defrost operation is also finished when defrost operation has continued for 10 minutes even if TE sensor temperature has become 7°C or lower.

After defrost operation has finished, the compressor and the outdoor fan start heating operation after

stopped for approx. 40 seconds.

– 35 –

Page 36

Start of heating operation

A zone

B zone

C zone

D zone

0 10 15 c b a d [min.]

TE [˚C]

– 5

– 10 – 13

B zone

– 18

C zone

* From 10 minutes to 15 minutes after a heating operation started, the minimum value of TE is stored in

memory as TEO and the minimum temperature of TO as ToO.

A zone

D zone

At error TOAt normal TO

A zone

B zone

C zone When status of [TE ≤ – 18˚C] continued for 20 seconds

D zone When compressor operation status with TE ≤ – 13˚C are added by d times

a 55

b 39

c 29

d 90

When status of [(TEO – TE) – (ToO – TO) ≥ 3

continued for 20 seconds

When status of [(TEO – TE) – (ToO – TO) ≥ 2˚C]

continued for 20 seconds

SM110, SM140

When status of [(TEO – TE) ≥ 3˚C]

continued for 20 seconds

When status of [(TEO – TE) ≥ 2

continued for 20 seconds

11. High-pressure switch

1) When the high-pressure switch operates, the operation of the compressor is terminated.

2) The compressor restarts after 5 minutes using [1] as an error count. After restart, the error count is cleared when operation continues for 10 minutes or more.

3) An error is confirmed with the error count [10].

4) For the indicated contents of error, confirm using the check code table.

12 Control of compressor case thermo

1) The compressor stops when the case thermo of the compressor operated.

2) When the case thermo operated for approx. 80 seconds, E04 error code (same as serial error) is displayed on the wired remote controller. → Refer to the Check Code.

3) When the case thermo is reset, the operation restarts.

– 36 –

Page 37

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 the control operation performed from outside/remote side?

• Is not automatic address being set up? (When the power is turned on at the first time or when indoor unit address setting is changed, the 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 controller?

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 position and 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.

– 37 –

Page 38

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?

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

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

2. Troubleshooting procedure

(When the power is turned on at the first time or when 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.

Confirmation of lamp display

Trouble

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.

→→

(EX : When 4-way air discharge cassette type wireless remote controller is connected)

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.

Check defective position and parts.

– 38 –

Page 39

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.)

Lamp indication

Operation

No indication at all

Operation

Flash

Operation

Timer Ready

Flash

Timer Ready

Alternate flash

Check code

—

E01

E02

E03

E08

E09

E10

E18

E04

P01

P10

P12

Cause of tr oub le occurrence

Power supply OFF or miswiring between receiving unit and indoor unit

Receiving error

Sending error

Communication stop

Duplicated indoor unit No.

Duplicated header units of remote controller

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

Wire connection error between indoor units, Indoor power OFF (Communication stop between indoor master and follower or between main and sub indoor twin)

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

Outdoor unit case thermostat work on

Overflow was detected. Indoor DC fan error

⎫

Receiving unit

⎬ ⎭

⎫ ⎬

⎫

Miswiring or wire connection error

⎬

between receiving unit and indoor unit

⎭

Setup error

................

Protective device of indoor unit worked.

Comp. overheating Outdoor wiring error

⎭

P03

P04

P05

P07

Operation

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

Timer Ready

Alternate flash

P15

P19

P20

P22

P26

P29

P31

Outdoor unit discharge temp. error Case thermostat work on, Power error, High pressure protection

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 fan error

Outdoor unit: Inverter Idc operation

Outdoor unit: Position detection error

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

⎫ ⎬ ⎭

⎫

Protective device of

⎬

outdoor unit worked.

⎭

Protective device of outdoor unit worked.

– 39 –

Page 40

Lamp indication

Operation

Alternate flash

Timer Ready

Check code

F01

F02

P10

Cause of trouble occurrence

Heat exchanger sensor (TCJ) error

Heat exchanger sensor (TC) error Indoor unit sensor error

Heat exchanger sensor (TA) error

⎫ ⎪ ⎬ ⎪ ⎭

Operation

Timer Ready

Alternate flash

Operation

Timer Ready

Simultaneous flash

Operation

Timer Ready

Simultaneous flash

Operation

Timer Ready

Flash

Operation

Timer Ready

Simultaneous flash

F04

F06

F07

F08

F12

F13

F15

F29

F31

H01

H02

H03

L03

L07

L08

L09

Discharge temp. sensor (TD) error

Temp. sensor (TE) error

Temp. sensor (TL) error

Temp. sensor (TO) error Sensor error of outdoor unit ∗1

Temp. sensor (TS) error

Temp. sensor (TH) error

Temp. Sensor miswiring (TE, TS)

⎫ ⎪ ⎪ ⎪ ⎪ ⎪ ⎬ ⎪ ⎪ ⎪ ⎪ ⎪ ⎭

Indoor EEPROM error

Outdoor EEPROM error

Compressor break down Outdoor compressor system error ∗1

Compressor lock

⎫ ⎬ ⎭

Current detection circuit error } Power supply, outdoor P.C. board error

Duplicated header indoor units

There is indoor unit of group connection in individual indoor unit.

Unsetting of group address

Missed setting (Unset indoor capacity)

⎫ ⎪ ⎬

→ AUTO address

⎪

* If group construction and

⎭

address are not normal power supply turned on, automatically goes to address setup mode.

Operation

Simultaneous flash

Timer Ready

L10

L20

L30

Unset model type (Service board)

Duplicated indoor central addresses

Outside interlock error

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

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

Lamp indication

Operation

Simultaneous flash

Operation

Timer Ready

Alternate flash

Check code

—

Cause of trouble occurrence

During test run

Disagreement of cool/heat (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model)

– 40 –

Page 41

SET

CLSAS

ON / OFF

UNIT

LOUVER

8-2-3. Monitor Function of Remote Controller Switch



 Calling of sensor temperature display



Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller.

1 Push

TES

+ CL buttons simultaneously for 4 seconds to

call the service monitor mode.

The service monitor goes on, the master indoor unit No. is displayed at first and then the temperature of CODE No. displayed.

2 Push temperature set

the CODE No. of data to be monitored.

The CODE No. list is shown below.

CODE No.

02 03

∗ 07

Indoor unit data

∗ F2

∗ F8

Room temperature (Remote controller)

Indoor suction temperature (TA) Indoor heat exchanger (Coil)

temperature (TCJ) Indoor heat exchanger (Coil)

temperature (TC) Indoor fan revolution frequency Indoor fan calculated operation time Filter sign time Indoor discharge temperature*1 (4-way only)

Data name

TEMP.

buttons and then change

Unit

°C

°C °C

°C

rpm

×100h

×1h

°C

• The CODE No. with ∗ marks in the above table are displayed only

on the indoor units of 4 series models and after. (4 series indoor units mean RAV-SM1404UT-E for example.).

• The indoor discharge temperature of CODE No. [F8] is the estimated value from TC or TCJ sensor.

Use this value to check discharge temperature at test run.

(A discharge temperature sensor is not provided to this model.)

• The data value of each item is not the real time, but value delayed by a few seconds to ten-odd seconds.

0000

CODE No.

Outdoor heat exchanger (Coil) temperature (TE)

Outside temperature (TO)

Compressor discharge temperature (TD)

Compressor suction temperature (TS)

Heat sink temperature (TH)

Operation current (× 1/10)

∗ 6D

∗ 70

Outdoor unit data

∗ 72 ∗ 73

Outdoor heat exchanger (Coil) temperature (TL) Compressor operation frequency Outdoor fan revolution frequency (Lower) Outdoor fan revolution frequency (Upper)

Compressor calculated operation time

<RBC-AMT32E>

TIMER SE

TESTRESE

WING/FI

MOD

241 3

1 2 3 4

Returned to usual display

Data name

Unit

°C °C °C °C °C

°C

rps rpm rpm

×100h

3 Push

Each data of the indoor unit and its outdoor units can be monitored.

NIT LOUVE

button to select the indoor unit to be monitored.

Pushing

TES

button returns the status to the usual display.

– 41 –

Page 42

– 42 –

8-2-4. Check Code List (Outdoor)

Central

control

indication

1d 18 A2 43 18 IC

1d 17

AF 1C AE 22 1A 14 16

−

97,99

96 99 99 46 66

Remote controller indication

F04

F06

F08 F07 F12 F13 F15 F31

H01

H02 H03

L10

P03

P04

P05 P07 P15 P20 P22 P26 P29

E01

E02

E03

E04

E08

E09

E10

E18

L03 L07 L08 L09 L30

P19

Sensor lamp part

Block indication

Operation

Timer Ready Flash

  

    



 











   

     





    

  



































 





   

















 





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.



ALT

ALT ALT ALT ALT ALT SIM

SIM

ALT

ALT ALT ALT ALT ALT ALT ALT

SIM SIM SIM SIM SIM

ALT

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

Representative defective position

Outdoor unit Discharge temp. sensor (TD) error

Outdoor unit Temp. sensor (TE, TS, TL) 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 Setting error of service P.C. board type

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, Case thermostat operation of the outdoor unit occurred

Duplicated indoor addresses

Duplicated main remote controllers

Communication error between CPU Regular communication error between master and

follower indoor units Duplicated indoor master units There is group cable in individual indoor unit. Unset indoor group address Unset indoor capacity Outside error input to indoor unit (Interlock)

4-way valve inverse error



  

Detection

Outdoor

Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor

Outdoor

Outdoor Outdoor

Outdoor

Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor Remote

controller

Remote

controller

Indoor

Remote

controller

Indoor

Indoor Indoor Indoor Indoor Indoor Indoor

Outdoor

: Go on,  : Flash,  : Go off



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

When outdoor service P.C. board was used, model type select jumper setting was inappropriate.

Error was detected by discharge temp. release control. When case thermostat 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, Case thermostat operation occurred

Same address as yours was detected. In 2-remote controller control, both were set as master.

(Indoor master unit stops warning and follower unit continues operation.) MCU communication error between main motor and micro computer Regular communication was impossible between master and follower indoor units.

Communication between twin master (Main unit) and follower (sub unit) was impossible. There are multiple master 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. Abnormal stop by CN80 outside error input

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

Automatic Operation

reset

continuation

×× ××



×× ×× ×× ×× ××

×× ××

×× ×× ××

×× ×× ×× ×× ×× ××

——



× ×

××



×× ×× ×× ×× ××



Page 43

– 43 –

ash

door u

door f

door

rNetw

door

ed.

)

ed.

03/L07/L03/L08

)

eset

entra

ntr

indicati

Remot

ntrll

F F F1 F2 P P1

Block indicati

ReadyFl

By unit with warning N

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

Representative defective positio

Indoor unit Heat Indoor unit Heat exchanger sensor (TC) erro

nit In Indoor unit Ovrflow detecti Indoor unit Indoor fn erro

ther indoor unit erro

Error in indoor grou

LAN system commnication erro

LAN system commnication err

There are multiple communication adapter

n err

Detecti

Indoo Indoo Indoo In In Indoo Indoo Indoo

k adapte

Net

Netwadapter

Netwadapte

Explanation of errr content

Open/Sho

In Float

Sub remote controller error in a grou

Duplicated indoor address of central control system communicatio

There are multiple communication adapters on remote controller communication lin

t of heat

ACn error w detect

itchw

ommunication error of central control system signa

on the remote controll

(Fn thermal rel

detect

with unit N

woed.

warnin

: Go on, : Flash, : Go o

tomaticOperatio

ed.

ntinuati

Page 44

Error mode detected by indoor unit

door u

)

een

sub u

)

ces

door f

)

ser

)

door

board.

Operation of diagnostic functio

Cause of operati

ir condition

tatus o

onditi

udgment and measure

No communication from remo

controller (including wireless) an

ommunication adapte

The serial signal is not output fro

nit to in

Defective serial sending circuit o

Defective serial receiving circuit o

indoor P.C. boar

Case thermostat operatio * Abnormal overheat of compresso

Duplicated indoor unit addres

Duplicated indoor master un

There is group wire in individual indoo

nit

Unset indoor group addre

Unset indoor capacit

Abnormal input of outside interl

Float switch operatio

Float circuit, Disconnection

Coming-off, Float switch contact erro

Sto

utomatic reset

nit

Sto

utomatic reset

Sto

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Displ wh

rror is detect

Remote controller LCD display OFF (Disconnection Central remote controller [97] check cod

Inter-unit wire check, correction of miswirin Check outdoor P.C. board. Correct wiring of P.C. board

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

1. Check case thermostat and connector

2. Check gas leak, rechar

3. Check full open of service valve

4. Check PMV (Pulse Motor Valve

5. Check broken pipe

1. Check whether remote controller connection (Group/Individual was changed or not after power supply turned o (Finish of group construction/Address check) * If group construction and address are not normal when th power has been turned on, the mode automatically shifts t address setup mode. (Resetting of address

Set indoor capacity (CODE NoDN) = 11

heck outside devi heck indoor

1. Trouble of drain pum

2. Clogging of drain pum . Check float switch

4. Check indoor P.C. board

boar

Indoor DC fn err

ayvae system err

After heating operation has started indoor heat exchangers temp. i

own

Own unit stops while waing is outpu to other indoor unit

Coming-off, disconnection or short o

indoor heat exchanger temp. senso (TCJ

Coming-off, disconnection or short o

indoor heat exchanger temp. senso

Coming-off, disconnection or short o

indoor heat exchanger temp. senso

Indoor EEPRM err

M access erro

ommunication error between indoo

ommunication error between fa

driving MCU and main MC

Regular commnication error betw indoor aster and fwer units an

tween main and

osition detection erro

Sto

utomatic reset

Sto

lloer unit

utomatic reset

Sto

utomatic reset

Sto

utomatic reset

Sto

utomatic reset

Sto

utomatic reset

Sto

utomatic reset

Sto

nit

utomatic reset

Display wh

rror is detect

Displ wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Display wh

rror is detect

Displ wh

rror is detect

er-current protectiv circuit of in

. 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

udgefollower unit while header unit is [E03], [L03], [L07] or [L08

heck indoor

heck indoor heat exchanger tem sensor (TCJ heck indoor

heck indoor heat exchanger tem sensor (TC hec indoor

heck indoor heat exchanger tem heck indoor

heck indoor EEPRM. (including socket in heck in

hec indoor

1. Check remote controller wirin

2. Check indoor power supply wirin . Check indoor P.C. board

boar

n driving unit operated

tion

– 44 –

Page 45

Error mode detected by outdoor unit

The indoor unit check code has been ramified from 4 series and after.

The ramified check code is displayed only when combined with 4-series indoor unit.

(Ex. Combination of RAV-SM1404UT-E with RAV-SM1403AT-E1)

When the indoor unit is 3 series and before, the conventional check code is displayed.

(Ex. Combination of RAV-SM1402CT-E and RAV-SM1403AT-E1)

Operation of diagnostic function

Check code

Indoor unit

before after

3 series 4 series

F04 F04

F06

F07

F06

F12

F15

F08 F08

F13

F31

L10

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

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

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 (IC200 is incorporated in TH sensor.)

1. Check outdoor P.C. board.

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

L29

H01 H01

H02 H02

P07

P15

P19

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

Stop

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

1. Check screw tightening between P.C. 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. (AC198 to 264V)

2. Overload operation of refrigerating cycle

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

2. Wiring error of compressor (Open phase)

– 45 –

Page 46

Check code

Indoor unit

before after

3 series 4 series

H03

P03 P03

P04

P22 P22

P26 P26

P29 P29

H03

P04

P05

P20

Operation of diagnostic function

Cause of operation

Current detection circuit error

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

specified value was detected.

High pressure SW system 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 outdoor P.C. board. (AC current detection circuit)

1. Check refrigerating cycle (Gas leak)

2. Trouble of electronic expansion valve

3. Check discharge temp. sensor (TD).

1. Check service valves are fully opened. (Gas side, Liquid side)

2. Check of outdoor fan operation.

3. Check motor error of outdoor fan.

4. Check clogging of outdoor PMV.

5. Check clogging of heat exchanger in indoor/outdoor units.

6. Short-circuit status of suction/discharge air in outdoor unit.

7. Check outdoor P.C. board error.

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

9. Check PMV opening status in indoor unit.

1. Check power supply voltage. AC198 to 264V

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 264V

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.

– 46 –

Page 47

Error mode detected by remote controller or central controller (TCC-LINK)

Operation of diagnostic function

Check code

Not displayed at all (Operation on remote controller is impossible.)

Cause of operation

No communication with master indoor unit

• Remote controller wiring is not correct.

• Power of indoor unit is not turned on.

• Automatic address cannot be completed.

Status of

air conditioner

Stop

Condition

—

Power supply error of remote controller, Indoor EEPROM error

1. Check remote controller inter-unit wiring.

2. Check remote controller.

3. Check indoor power wiring.

4. Chec k indoor P.C. board.

5. Check indoor EEPROM. (including socket insertion)

→ Automatic address repeating phenom-

enon generates.

Judgment and measures

E01

∗2

E02

E09

L20

Central controller

L20

—

∗3

Central controller

(Send)

C05

(Receive)

C06

—

Central controller

P30

No communication with master indoor unit

• Disconnection of inter-unit wire between remote controller and master indoor unit (Detected by remote controller side)

Signal send error to indoor unit (Detected by remote controller side)

There are multiple main remote controllers. (Detected by remote controller side)

Duplicated indoor central addresses on communication of central control system (Detected by indoor/central controller side)

Communication circuit error of central control system (Detected by central controller side)

Indoor Gr sub unit error (Detected by central controller side)

Stop

(Automatic reset)

∗ If center exists,

operation continues.

Stop

(Automatic reset)

∗ If center exists,

operation continues.

Stop

(Sub unit

continues operation.)

Stop

(Automatic reset)

Continues

(By remote controller)

Continuation/Stop

(According

to each case)

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

Receiving error from remote controller

1. Check remote controller inter-unit wiring.

2. Check remote controller.

3. Check indoor power wiring.

4. Chec k indoor P.C. board.

Sending error of remote controller

1. Check sending circuit inside of remote controller.

→ Replace remote controller.

1. In 2-remote controllers (including wireless), there are multiple main units.

Check that there are 1 main remote controller and other sub remote controllers.

1. Check setting of central control system network address. (Network adapter SW01)

2. Check networ k adapter P.C. board.

1. Check communication wire / miswiring

2. Check communication (U3, U4 terminals)

3. Check networ k adapter P.C. board.

4. Check central controller (such as central control remote controller, etc.)

5. Check terminal resistance. (TCC-LINK)

Check the check code of the corresponding unit from remote controller.

∗2 The check code cannot be displayed by the wired remote controller.

(Usual operation of air conditioner becomes unavailable.) For the wireless models, an error is notified with indication lamp.

∗3 This trouble is related to communication of remote controller (A, B), central system (TCC-LINK U3, U4),

and [E01], [E02], [E03], [E09] or [E18] is displayed or no check display on the remote controller according to the contents.

– 47 –

Page 48

Contents Error Display

∗ When fixations of the errors were overlapped, the latest error is displayed.

∗ When D800 to D804 are slowly flashing or D805 is flashing, push and hold SW800 and SW801 simulta-

neously for 5 seconds or more. The error display changes to the error which is generated.

Check code LED display

No.

TD sensor error

TE sensor error

TL sensor error

TO sensor error

TS sensor error

TH sensor error

Heat exchanger sensor (TE, TS)

misconnection

EEPROM error

Compressor breakdown

Compressor lock

Model unset

Discharge temp. error

High-pressure SW error

Current detection circuit error

Power supply error

Heat sink overheat error

Gas leak detection

4-way valve reversal error

High-pressure protective

operation

Fan system error

Driving element short circuit

Position detection circuit error

Others (No fixation)

Item

Wired remote controller

series

F04

F06

F08

F06

L29

F06

L29

H01

H02

L29

P03

P04

H03

P04

L29

P04

P22

P26

P29

—

Indoor unit

after 4

series

F04

F06

F07

F08

F12

F13

F15

F31

H01

H02

L10

P03

P04

H03

P05

P07

P15

P19

P20

P22

P26

P29

—

Indoor unit

before 3

D800

(Yellow)

D801

(Yellow)

D802

(Yellow)

D803

(Yellow)

D804

(Yellow)

D805

(Green)

: ON

: OFF

: Rapid flash (5 times /sec.)

* The LEDs and switches are located at the top right of the P.C. board of the outdoor unit as shown in the figure on the right.

Service switches s cover SW800, SW801

– 48 –

Electric parts cover

Inspection window through which to check the LED displays

D800 D801 D802 D803 D804 D805

(yellow) (yellow) (yellow) (yellow) (yellow) (green)

Page 49

8-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit)

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

2) 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 wired 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 wired remote controller may differ from that of LED.

LED display on outdoor P.C. board

Operation method of the service SW

[Display of error which is generating]

• When even one of D800 to D804 rapid flashing, it indicates that an error occurred. When D800 to D801 indicate slow flashing or when D805 flashes, push and hold SW800 and SW801 for 5 seconds or more simultaneously. The error display exchanges to display of the error under occurrence at present.

Display of the latest error

• The latest error is displayed by the following action. As the memory is kept, it is confirmed even after the power supply was turned off once. (Except outside air temp. sensor (TO) error)

1) Check D800 to D804 are turned off (or rapid flashing) and D805 is turned on. When D800 to D804 are slowly flashing or D805 flashes, push and hold SW800 and SW801 for 5 seconds or more simultaneously. D800 to D804 will be turned off (or rapid flashing) and D805 flashes.

2) Push and hold SW800 for 5 seconds or more. D804 changes to slow flashing.

3) Push SW800 several times and change LED display (D800 to D804) to [Display of latest error (Including the present error)].

4) Push SW801. The latest error is displayed.

5) When finishing the work, be sure to execute item 1) to return LED to the initial status (Display of error under occurrence).

(No error) (Error occurred)

D800 (Yellow)

D801 (Yellow)

D802 (Yellow)

D803 (Yellow)

D804(Yellow)

D805 (Green)

: ON, { : OFF,  :Rapid flashing (5 times /second)

D800 (Yellow)

D801 (Yellow)

D802 (Yellow)

D803 (Yellow)

D804(Yellow)

D805 (Green)

: ON, { : OFF,  :Rapid flashing (5 times / second)

z zz zz zz zz

{{

(Example of discharge temp. sensor error)

Display of latest error

(Including the present error)



{

z z z z



– 49 –

Page 50

Check

code

Outdoor

LED display

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

Check and troubleshooting

—

[Indoor/Outdoor communication error]

Is setting of group address

of remote controller correct?

YES

Are inner wiring and indoor/outdoor

control wires (1, 2, 3) normal?

YES

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

YES

[Case thermostat operation]

Check CODE No. [14].

Correct wiring indoor/outdoor

control wires

Correct wiring of connectors

and terminal blocks.

Check outdoor P.C. board .

Defect → Replace

[E04]

Are CN500 connection

and case thermostat normal?

YES

Is cooling/heating operation available

when short-circuiting case thermostat?

YES

Is there no gas leak?

Is it not refrigerant shortage?

YES

Is valve fully opened?

YES

Is PMV normal?

YES

Correct connector.

Case thermostat error → Replace

Check outdoor P.C. board .

Defect → Replace

Repair defectives position.

Recharge refrigerant.

Open valve fully.

Correct defective position.

Replace defective part.

Check crushed or broken pipe. Defect → Correct and Replace

– 50 –

Page 51

Check

code

Outdoor

LED display

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

Check and troubleshooting

[F04]

[F06]



z z z z

{



z z z

{

[Discharge temp. sensor (TD) error]

Is CN601 connection normal?

Is resistance value of TD sensor normal?

YES

• 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, TL)

Heat exchanger temp. sensor (TE) error]

Is CN603 connection normal?

Is resistance value of TE sensor normal?

YES

Check outdoor P.C. board .

Check outdoor P.C. board.

Correct connector.

Sensor error → Replace

Defect → Replace

Correct connector.

Sensor error → Replace

Defect → Replace

[F07]

 

z z z

{



z z

{

  

z z

{

 

z z z

{

[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]

Is CN605 connection normal?

Is resistance value of TL sensor normal?

YES

Correct connector.

Sensor error → Replace

– 51 –

Check outdoor P.C. board.

Defect → Replace

Page 52

Check

code

Outdoor

LED display

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

Check and troubleshooting

[F08]

[F12]

[F13]

z z



z z

{



z z

{

 

z z

{

[Outside air temp. sensor (TO) error]

Is CN602 connection normal?

Is resistance value of TO sensor normal?

YES

[Suction temp. sensor (TS) error]

Is CN604 connection normal?

Is resistance value of TS sensor normal?

YES

[Heat sink temp. sensor (TH) error]

Check outdoor P.C. board.

Defect → Replace

Check outdoor P.C. board.

Correct connector.

Sensor error → Replace

Defect → Replace

Correct connector.

Sensor error → Replace

Defect → Replace

[F15]

  

z z

{

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

Is mounting status of

TE and TS sensors normal?

YES

Is CN604 connection normal?

Is resistance value of TS sensor normal?

YES

Is CN603 connection normal?

Is resistance value of TE sensor normal?

YES

Correct sensor mounting.

Correct connector.

Sensor error → Replace

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

– 52 –

Page 53

Check

code

Outdoor

LED display

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

Check and troubleshooting

[F31]

[EEPROM error]



Check outdoor P.C. board.

Defect → Replace

{

[H01] [Compressor break down]

 



{

Is power supply voltage normal?

AC198 to 264V

YES

Is wire connection normal?

Compressor lead

(P.C. board side, Compressor side),

Reactor lead, Power supply lead

YES

Is it not abnormal overload?

YES

Correct power supply line.

Check wire connection

and correct it.

Correct and clear the cause.

[H02] [Compressor lock]

z z

 

{

Is power supply voltage normal?

AC198 to 264V

YES

Is wire connection normal?

Compressor lead

(P.C. board side, Compressor side),

Reactor lead, Power supply lead

YES

Is compressor normal?

Is there no refrigerant stagnation?

YES

Does PMV normally operate?

YES

Check outdoor P.C. board.

Defect → Replace

Correct power supply line.

Check wire connection

and correct it.

Check outdoor P.C. board.

Defect → Replace

Compressor lock → Replace

Check TE, TS sensors and PMV.

Defect → Replace

– 53 –

Check outdoor P.C. board.

Defect → Replace

Page 54

Check

code

Outdoor

LED display

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

Check and troubleshooting

[H03]



[Current detection circuit error]

 

Check outdoor P.C. board.

Defect → Replace

{

[L10] [Unset model type] : Only when service P.C. board is used

z z z z



{



z z z z

{

Cut jumper line according

to the explanation sheet packaged

with the service P.C. board.

[Discharge temp. error][P03]

Is there no gas leak?

Is refrigerant charge amount adequate?

YES

Is PMV normal?

Repair defective position.

Recharge refrigerant.

Repair defective position.

Replace defective part.

YES

Is it not abnormal overload?

Is CN601 connection normal?

Is resistance value of TD sensor normal?

YES

Correct and clear the cause.

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

– 54 –

Page 55

Check

code

Outdoor

LED display

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

<DCheck and troubleshooting

[P04]

∗ 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. (1) high-pressure SW system error, (2) power supply error (Vdc), (3) high-pressure protective operation.

 

z z



{

[High pressure SW system error]

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

Doesn’t high pressure switch

high pressure switch normal?

Is service valve fully opened?

Reset the power supply and

then do a test operation according

operate?

YES

Are parts of

YES

to the season.

B Cooling operation.

Does cooling outdoor fan

normally operate?

YES YES

Is circuit wiring normal?

B ← Cooling operation C ← Heating operation

Parts check

Defective → Replace

Open service valve fully.

Is there no fan breakage

or coming-off?

Check outdoor PC board

Defective → Replace

Wiring check,

Correct.

YES

Is there any element

which blocks heat exchanger

of the outdoor unit?

Clogging of heat exchanger



Short circuit



Heating operation

Does the heating indoor fan

normally operate?

YES

Is there any element which

blocks indoor heat exchanger?

Filter clogging



Clogging of heat exchanger



Short circuit



Repair defective position.

Connection of connectors,

outdoor P.C. board,

Fan motor, Wiring.

YES

NO NO

YES

blocking element

Are connections of

connectors,capacitors

and fan motor normal?

Elimination of

YES

Elimination of

blocking element

Overcharge of refrigerant/

Clogging/Pipe breakage/

Abnormal overload

defective position.

Repair

Clogging by refrigerant

overcharge/Pipe breakage/

Abnormal overload

Check indoor P.C. board

Defective → Replace

– 55 –

Are characteristics

of TC and TCJ sensor

resistance value normal?

YES

TC or TCJ sensor.

Replace

Page 56

Check

code

LED display

Outdoor

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

Check and troubleshooting

[P04]



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



{



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

z z

 

{

[P05]



[Power supply error (Voltage error)]



{

[P07] [Heat sink overheat error]

 



{

Is there no down or up

of power supply voltage?

(AC198 to 264V)

Is there no loosening of

screws of motor drive element of

outdoor P.C. board IC200?

Did not forget to apply radiation grease

to rear side of IC200?

Is not the ventilation flue

of the heat sink blocked?

Is not the fan blocked?

(Short-circuit, etc.)

YES

Confirm electric construction, etc.

Check outdoor P.C. board.

Defect → Replace

YES

Apply radiation grease

to objective part.

Retightening of screws.

Remove blocking matter.

Correct short-circuit.

Check outdoor P.C. board.

Defect → Replace

[P15] [Gas leak detection]

  



{

Is refrigerant charge amount adequate?

Is there no gas leak?

YES

Is PMV normal?

YES

Is valve fully opened?

YES

Is there no crushed pipe?

Check temp. sensor.

TD sensor CN601, TS sensor CN604

– 56 –

YES

Error

Repair defective position.

Recharge refrigerant.

Correct defective position.

Replace defective part.

Open valve fully.

Correct and replace piping.

Correct connector.

Sensor error → Replace

Check outdoor P.C. board.

Defect → Replace

Page 57

Check

code

Outdoor

LED display

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

Check and troubleshooting

[P19]

z z z

 

{

[4-way valve reversal error]

Is operation of 4-way valve

(Check pipe temp. and etc. in

cooling/heating operation.)

Are temperature sensor normal?

normal?

YES

TE sensor: CN603 TS sensor: CN604

YES

Is refrigerant flow by

PMV normal?

YES

Is power supply to 4-way

valve coil normal?

Replace TE sensor. Replace TS sensor.

Check and

replace of PMV

Replace coil

of 4-way valve.

YES

Is power supply to

4-way valve coil in heating?

YES

Check outdoor

P.C. board.

Check outdoor P.C. board.

Defect → Replace

Error

Are TC sensor and TCJ

sensor normal?

YES

Replace TC sensor

Replace TCJ sensor

Check indoor P.C. board.

Defect → Replace

Check 4-way valve.

Defective → Replace

– 57 –

Page 58

Check

code

Outdoor

LED display

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

Check and troubleshooting

[P20]



z z

 

{

[High pressure protective operation]

Is valve fully opened?

YES

Reset the power supply

and then perform test run

matching to the season.

Heating season Heating operation

Is there no problem

on outdoor TL sensor?

(Measurement of resistance value)

YES

Is there no crack or

loosening of outdoor fan?

YES

Does not the outdoor fan

perform abnormal operation?

YES

Open valve fully.

Cooling season Cooling operation

Replace sensor.

Check outdoor fan.

Defect → Replace, retightening

Check the same items as

[P22] error.

which interfere heat exchange

• Clogging of heat exchanger

• Short circuit

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

Does indoor fan

normally operate?

YES

Is there no element which

interfere heat exchange of indoor unit?

• Clogging of filter

• Clogging of heat exchanger

• Short circuit

Is there no element

of outdoor unit?

Are indoor fan motor

and connector normal?

YES

Are resistance values of indoor TC and TCJ

sensors normal?

YES

Eliminate interfering element.

Repair defective position.

Check indoor P.C. board.

Defect → Replace

Eliminate interfering element.

Replace

sensor.

– 58 –

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

Page 59

Check

code

Outdoor

LED display

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

Check and troubleshooting

[P22]



 

{

[Fan system error]

Is there no problem on power supply voltage?

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

Single operation check for outdoor fan

(AC 198 to 264V)

YES

Replace fan motor.

Check wiring construction.

Ask repair of power supply.

YES

Check outdoor P.C. board.

Defect → Replace

A single operation of the outdoor fan can be confirmed by handling the

service switch SW800, SW801. Use this method to check whether there is trouble or not on the fan.

[Method]

(1) Check D800 to D804 are turned off (or rapid flashing) and D805 is

turned on. When D800 to D801 flash slowly or D805 flashes, push and hold SW800 and SW801 for 5 seconds or more simultaneously. In the result, D800 to D804 are turned off (or rapid flashing) and D805 changes from flashing to lighting.

(2) Push and hold SW800 for 5 seconds or more. D804 changes to

slow flashing.

(3) Push SW800 and stop it at LED display of the following “Outdoor fan

single operation”.

Outdoor fan single operation

: OFF

: ON,

D800 D801 D802 D803

Rapid flashing

D804

(4) Push SW801 and then stop it at the position where D805 flashes

rapidly.

(5) Push and hold SW801 for 5 seconds or more. In the result, D804

changes to slow flashing, D805 changes to lighting and the fan rotates.

(6) The fan stops when pushing long SW800 and SW801 for 5 seconds

or more simultaneously or when 2 minutes passed.

* If an unknown point generated on the way of the operation, push and

hold SW800 and SW801 for 5 seconds or more simultaneously. You can return to the item (1).

– 59 –

Page 60

Check

code

Outdoor

LED display

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

Check and troubleshooting

[P26]

[P29]

 

{

z z

  

{

[Short-circuit of compressor drive element]

Is there no problem on connection

of compressor lead or reactor?

(Check referring to Wiring diagram.)

YES

The same error does not occur in

operation without compressor lead.

YES

[Position detection circuit error]

Check outdoor P.C. board.

Defect → Replace

Check compressor. (Rear short, etc.)

Correct wiring.

Replace outdoor P.C. board.

Defect → Replace

—

No code



  

{

[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.

∗ A code may not appear when an open phase shortage, coming-out of wires or

power relay trouble occurred.

– 60 –

Page 61

Temperature sensor Temperature – Resistance value characteristic table

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

Representative value

Temperature

(°C)

100

(Minimum value) (Standard value) (Maximum value)

32.33 33.80 35.30

19.63 20.35 21.09

12.23 12.59 12.95

9.75 10.00 10.25

7.764 7.990 8.218

5.013 5.192 5.375

3.312 3.451 3.594

2.236 2.343 2.454

1.540 1.623 1.709

1.082 1.146 1.213

0.7740 0.8237 0.8761

0.5634 0.6023 0.6434

Resistance value (k

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

ΩΩ

Ω)

ΩΩ

TD, TL sensors

Representative value

Temperature

(°C)

100

(Minimum value) (Standard value) (Maximum value)

150.5 161.3 172.7

92.76 99.05 105.6

58.61 62.36 66.26

47.01 49.93 52.97

37.93 40.22 42.59

25.12 26.55 28.03

17.00 17.92 18.86

11.74 12.34 12.95

8.269 8.668 9.074

5.925 6.195 6.470

4.321 4.507 4.696

3.205 3.336 3.468

Resistance value (k

ΩΩ

Ω)

ΩΩ

Resistance (kΩ)

Output voltage (V)

10 20 30 40 50 60 70 80 90 100

Temperature (˚C)

TD, TL sensors

200

150

100

Resistance (kΩ) (50˚C or higher)

Resistance (kΩ) (50˚C or lower)

10 20 30 40 50 60 70 80 90 100

Temperature (˚C)

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

resistance value cannot be measured.

– 61 –

Page 62

Table Inspection of outdoor unit main parts

No.

Compressor

Parts name

(Model : DA422A3F-12M)

Outdoor fan motor (Model : WDF-340-A100-1)

4-way valve coil (Cooling/heating switching) (Model : STF-H)

Checking procedure

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

Red

Position

Resistance value

Red – White

White Blac

White – Black

0.476 Ω

Black – Red

Under 20°C

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

Red

Position

Resistance value

Red – White

White Blac

White – Black

17.3 ± 1.7 Ω

Black – Red

Under 20°C

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

Resistance value

Connector : White

1215.3 ± 121.5 Ω

Under 20°C

– 62 –

Page 63

9. SETUP AT LOCAL SITE AND OTHERS

LOUVER

9-1. Calling of Error History

The error contents in the past can be called.

SET

1 Push

4 seconds or more to call the service check mode.

Service Check goes on, the CODE No. then the content of the latest alarm is displayed. The number and error contents of the indoor unit in which an error occurred are displayed.

TES

buttons simultaneously for

0101

is displayed, and

0101

2 In order to monitor another error history, push the set

temperature history No. (CODE No.).

TES

0101

CODE No.

NOTE : 4 error histories are stored in memory.

3 Pushing

/ buttons to change the error

(Latest) → CODE No.

0404

(Old)

button returns the display to usual display.

TIMER SE

TESTRESE

231

WING/FI

N / OFF

MOD

REQUIREMENT

Do not push CL button, otherwise all the error histories of the

1 2 3

indoor unit are deleted.

Returned to usual display

9-2. Group Control Operation

In a group control, operation of maximum 8 indoor units can be controlled by a remote controller. The indoor unit connected with outdoor unit (Individual/Master of twin) controls room temperature according to setting on the remote controller.

OUT

1-1

Remote controller

OUT

Master 2-1

OUT

3-1

OUT

4-1

OUT

7-1 Max. 8 units

1. Display range on remote controller The setup range (Operation mode/Air volume select/Setup temp) of the indoor unit which was set to the master unit is reflected on the remote controller.

2. Address setup Turn on power of the indoor unit to be controlled in a group within 3 minutes after setting of automatic address. If power of the indoor unit is not turned on within 3 minutes (completion of automatic address setting), the system is rebooted and the automatic address setting will be judged again.

1) Connect 3 In/Out cables surely.

2) Check line address/indoor address/group address of the unit one by one.

3) The unit No. (line/indoor gout address) which have been set once keep the present status as a rule if the

unit No. is not duplicated with one of another unit.

– 63 –

Page 64



 Indoor unit power-ON sequence



Power ON

Gr construction check

System start

Not normal NO

Normal ∗ Gr normal

1) There is no duplicated indoor unit address.

2) There is no invalid indoor unit address.

3) Individual unit and master/follower units are not intermingled.

4) Only a unit for individual.

5) A master indoor unit and 1 or more follower indoor units for Gr.

• The unit without power feed waits entirely → Waiting status is released by system start

• Reboot when power is fed on the way

3 minutes elapse

YES

Automatic address starts.

(Approx. 1 minute up to finish)

Outdoor model distinction (10 seconds) (Indoor unit) Twin Master/follower distinction (Indoor unit) Gr construction, louver information (Remote controller)

Remote controller operation is available.

(Approx. 50 seconds after power-ON)

• Power supply/Indoor/Outdoor serial and Gr wiring: OK

• Powers of all indoor units are turned on within 3 minutes.

• Reception time for remote controller operation (After power supply was turned on)

1) When address is OK : Approx. 50 seconds

2) In AUTO address : Approx. 4 to 5 minutes

Regular communication between indoor units (Every 30 seconds) (Master/Follower) Regular communication on the identical pipe (every 30 seconds) (Twin Master/Follower)

(When the above status changes, immediately communicates.)

(Repetition)

• In a group operation, if the indoor unit which was fed power after judgment of automatic address cannot

receive regular communication from the master unit and regular communication on identical pipe within 120 seconds after power was turned on, it reboots (system reset).

→ The operation starts from judgment of automatic address (Gr construction check) again.

(If the address of the master unit was determined in the previous time, the power fed to the master unit and reboot works, the master unit may change though the indoor unit line address is not changed.)

– 64 –

Page 65

9-3. Outdoor Unit

Various displays and various operations are enabled by push buttons (service) switches and LED on the outdoor control P.C. board.

Service switch (SW800, SW801) operations

LED display

• 4 patterns are provided for LED display.

: ON, : OFF,

• In the initial status of LED display, D805 is ON as the right

figure.

When the initial status does not appear (in case of flashing of D805), LED display can be returned to the initial status by pushing and holding the service switches SW800 and SW801 for 5 seconds or more simultaneously.

9-3-1. Refrigerant recovery control

HFC refrigerant is “Ozone layer destructive coefficient = 0”. However the discharge regulation is established for HFC refrigerant as it is greenhouse gas.

For this Model, a switch is mounted for refrigerant recovery operation (pump down) by the outdoor unit so that this Model can easily react to the environment when it will be reinstalled or scrapped.

: Rapid flashing (5 times/second),

: Slow flashing (Once/second)

LED display: Initial status

D800 D801 D802 D803 D804 D805

LED

(Yellow) OFF or rapid flashing (Yellow) OFF or rapid flashing (Yellow) OFF or rapid flashing (Yellow) OFF or rapid flashing (Yellow) OFF or rapid flashing (Green) ON

[Operating method]

1) Set fan operation to the indoor unit.

2) Check LED display is the initial status. If it is not so, set the initial status.

3) Push and hold SW800 for 5 seconds or more and then check D804 flashes slowly.

4) Push SW800 several times and then stop it at the point where LED display (D800 to D804) is indicated as the following table.

D800 D801 D802 D803 D804

: ON, : OFF,

: Rapid flashing (5 times/second)

5) Push SW801 so that D805 flashes rapidly.

6) Push and hold SW801 for 5 seconds or more. The forced cooling operation star ts if D804 flashes slowly and D805 is turned on. (Max. 10 minutes)

7) After operation for 3 minutes or more, close the valve at liquid side.

8) After recovery of refrigerant, close the valve at gas side.

9) Push and hold SW800 and SW801 for 5 seconds or more simultaneously. The LED returns to the initial status, the cooling operation stops and the indoor fan operation stops.

10)Turn off the power supply.

* If an unknown point generated on the way of the operation, push and hold SW800 and SW801 for 5 seconds

or more simultaneously. You can return to the item 2).

– 65 –

Page 66

9-3-2. Various settings on outdoor unit (Existing piping, power save, cooling-only, etc.)

(1) Service switch setting

Various settings are available by setting service switches.

[Operating method]

1) Check LED display is the initial status. If it is not so, set the initial status.

2) Push and hold SW800 for 5 seconds or more and then check D804 flashes slowly.

3) Push SW800 several times and then stop it at the LED display of function item to be set up.

Function LED display Control contents

Existing pipes setting

Power save setting

Snow-break fan control

Max. frequency change

D800 D801 D802 D803 D804

When the existing piping uses Ø19.1 pipe, this function is validated. In this case, the heating capacity may drop due to outside temp. and indoor temp. in heating time.

This function validates the power save function. This function lowers the compressor frequency. In this case, the Max. capacity drops (Approx. –10%)

This function validates the control to prevent occurrence of motor lock by the accumulated snow entered from clearance of the fan guard or heat exchanger into blast route. Even when the compressor stops, the outdoor fan is operated with W3 when the outside temperature is under 7˚C.

This function is validated if the max. value of compressor frequency is required to lower. It lowers the max. frequency in cooling/heating time. In this case, the max. capacity lowers.

Max. compressor frequency (rps)

Model

Standard status When setting is valid

SM110 SM140

Cool Heat Cool Heat

54.0

54.6 65.4 73.2

48.6 48.6 65.4 65.4

: ON, : OFF,

: Rapid flashing (5 times/second)

4) Push SW801 so that D805 will flash rapidly.

5) Push and hold SW801 for 5 seconds or more. D804 changes to slow flashing, D805 changes to lighting and then various settings are validated.

6) When you want to continue the settings, moreover repeat items from 3) to 5).

7) To invalidate various settings, execute items 1) to 3), push SW801 and then turn off D805.

8) Push and hold SW801 for 5 seconds or more. D804 changes to slow flashing, D805 is turned off and then various settings are invalidated.

* If an unknown point generated on the way of the operation, push and hold SW800 and SW801 for 5 seconds

or more simultaneously. You can return to the item (1).

Confirmation method of various settings

You can confirm that various settings are validated.

1) Check LED displays are in the initial status. If it are not so, return them to the initial status.

2) Push and hold SW800 for 5 seconds or more. D804 changes to slow flashing.

3) Push SW800 several times and then stop it at the point where LED display (D800 to D804) to be checked. If the setting became valid, D804 and D805 flash rapidly. (When the setup was invalid, D804 flashes rapidly and D805 goes off.)

4) Push SW800 and SW801 for 5 seconds or more simultaneously to return LED display to the initial status.

– 66 –

Page 67

In the case to return the setting to one at shipment from factory

When to return the setting to one at shipment from the factory due to reinstallation and so on, the setting can be returned in the following procedure.

1) Check LED display is the initial status. If it is not the initial status, return the setting to the initial status.

2) Push and hold SW800 for 5 seconds or more and then check D804 flashes slowly.

3) Push SW800 several times to make LED display status to “LED display to return the setting at shipment from the factory” in the right table.

4) Push and hold SW801 for 5 seconds or more and then check D804 flashes slowly.

5) Push and hold SW800 and SW801 simultaneously to return the LED display to the initial status.

LED display to return the setting at

shipment from the factory

D800 D801 D802 D803 D804 D805

: ON, : OFF, : Rapid flashing (5 times/second)

(2) Cooling-only setting

By changing setting of the jumper line, the setting can be changed to a cooling-only air conditioner.

Function

Cooling-only

setting

Setting

position

J804 When using the machine as a ooling-only

air conditioner, cut the left jumper line. (There is another method to change the machine to a cooling-only air conditioner; that is to use DN code "0F" of the remote controller.)

Control contents

D800 (Yellow LED) D801 (Yellow LED) D802 (Yellow LED) D803 (Yellow LED) D804 (Yellow LED) D805 (Green LED)

SW800 SW801

J806

J800

J801

J802

J803

J804

– 67 –

Page 68

9-3-3. Service support function (LED display, service switch operating method)

1. LED display switching

1-1. Display switching list

The displayed contents of LED D800 to D805 on the outdoor P.C. board can be switched by handling the service switches SW800 and SW801.

[Operating method]

1) Check LED display is the initial status. If it is not so, set the initial status.

2) Push SW800 several times and then stop it at the point where LED display to be indicated.

LED display Control contents

D800 D801 D802 D803 D804 D805

Error display (Error which is occurring at present) The error which is occurring at present is displayed. LED goes off while an error does not occur.

Error display (The latest error: The latest error including this moment) After error status was eliminated, if you want to check the error which occurred before, call this setting and check it. (Even after turning off the power supply once, you can recheck it.) * In the case that an error occurred at present, the same contents as that at present is displayed. * TO sensor error only is not displayed in this setting. (Check setting which is occurring at present.)

Discharge temperature sensor (TD) display Detected value of the discharge temperature (TD) is displayed.

Outdoor heat exchanger temperature sensor (TE) display Detected value of the outdoor heat exchanger temperature sensor (TE) is displayed.

Liquid temperature sensor (TL) display The detected value of the liquid temperature sensor (TL) is displayed.

Suction temperature sensor (TS) display Detected value of the suction temperature sensor (TS) is displayed.

Outside temperature sensor (TO) display Detected value of the outside temperature sensor (TO) is displayed.

Heat sink temperature sensor (TH) display Detected value of the heat sink temperature sensor (TH) is displayed.

Current display The current value which flows to the outdoor unit is displayed.

Compressor operation frequency display The operation frequency of the compressor is displayed.

PMV opening display The opening of PMV (Electronic expansion valve) is displayed.

Indoor suction temperature sensor (TA) display The detected value of the indoor suction temperature sensor (TA) is displayed.

Indoor heat exchanger temperature sensor (TC) display The detected value of the indoor heat exchanger temperature sensor (TC) is displayed.

Indoor heat exchanger temperature (TCJ) display The detected value of the indoor heat exchanger temperature sensor (TCJ) is displayed.

(Refer to A)

(Refer to B)

(Refer to C)

: ON, : OFF,

: Rapid flashing (5 times/second)

3) Pushing SW901 changes item to one to be displayed.

4) To see other display contents, repeat items 1) to 3).

5) To finish LED display, be sure to execute item 1) to return LED to the initial status (error display of current occurrence) and then finish LED display.

– 68 –

Page 69

1-2. Error display

The error which is occurring at present and the latest error (the latest error data including one which is occurring now) can be confirmed by lighting LED D800 to D805 on the outdoor control P.C. board.

A. Error display which occurs at present

LED display

D800 D801 D802 D803 D804 D805

: ON, : OFF,

: Rapid flashing (5 times/second)

Error name

Normal Discharge temp. sensor (TD) error Heat exchanger temp. sensor (TE) error Liquid 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) misconnection EEPROM error Compressor breakdown Compressor lock Model unset Discharge temp. error High-pressure SW error Current detection circuit error Power supply error Heat sink overheat error Gas leak detection 4-way valve reversal error High pressure protective operation Fan system error Driving element short circuit Position detection circuit error Others (No determination)

Wired remote controller

error code

Indoor units

before 3 series

F04 F06 F06 F08 F06 L29 F06 L29

H01 H02

L29 P03 P04

H03

P04 L29 L29 L29 P04 P22 P26 P29 L31

Indoor units

after 4 series

F04 F06 F07 F08 F12 F13 F15 F31

H01 H02

L10

P03 P04 H03 P05 P07 P15 P19 P20 P22 P26 P29

L31

B. Error display of the latest (including error which occurs at present) error

LED display

D800 D801 D802 D803 D804 D805

Normal Discharge temp. sensor (TD) error Heat exchanger temp. sensor (TE) error Liquid temp. sensor (TL) error Suction temp. sensor (TS) error Heat sink temp. sensor (TH) error Heat exchanger sensor (TE, TS) misconnection EEPROM error Compressor breakdown Compressor lock Model unset Discharge temp. error High-pressure SW error Current detection circuit error Power supply error Heat sink overheat error Gas leak detection 4-way valve reversal error High pressure protective operation Fan system error Driving element short circuit Position detection circuit error Others (No determination)

Error name

: ON, : OFF,

: Rapid flashing (5 times/second),

– 69 –

: Slow flashing (Once/second)

Page 70

C. Sensor, current, compressor operation frequency, PMV opening display

The values, such as the temperature sensor or the current value, which the controller detects are easily confirmed.

* Temperature sensor: TD, TE, TL, TS, TO, TH, TA, TC, TCJ

LED display

D800 D801 D802 D803 D804 D805

: ON, : OFF,

: Slow flashing (Once/second)

Temp. sensor

(

– 25 or less

– 25 ~

– 20 ~ – 15 ~ – 10 ~

– 5 ~

0 ~

5 ~ 10 ~ 15 ~ 20 ~ 25 ~ 30 ~ 35 ~ 40 ~ 45 ~ 50 ~ 55 ~ 60 ~ 65 ~ 70 ~ 75 ~ 80 ~ 85 ~ 90 ~ 95 ~

100 ~ 105 ~ 110 ~ 115 ~

120 or more

Sensor error

Current

(A)

0 ~

1 ~ 2 ~ 3 ~ 4 ~ 5 ~ 6 ~ 7 ~ 8 ~

9 ~ 10 ~ 11 ~ 12 ~ 13 ~ 14 ~ 15 ~ 16 ~ 17 ~ 18 ~ 19 ~ 20 ~ 21 ~ 22 ~ 23 ~ 24 ~ 25 ~ 26 ~ 27 ~

28 ~

29 ~ 30 ~

31 or more

Compressor

frequency (rps)

0 ~

5 ~ 10 ~ 15 ~ 20 ~ 25 ~ 30 ~ 35 ~ 40 ~ 45 ~ 50 ~ 55 ~ 60 ~ 65 ~ 70 ~ 75 ~ 80 ~ 85 ~ 90 ~ 95 ~

100 ~ 105 ~ 110 ~ 115 ~ 120 ~ 125 ~ 130 ~ 135 ~ 140 ~ 145 ~ 150 ~

155 or more

PMV opening

(pls)

0 ~ 19

20 ~ 39 40 ~ 59 60 ~ 79 80 ~ 99

100 ~ 119 120 ~ 139 140 ~ 159 160 ~ 179 180 ~ 199 200 ~ 219 220 ~ 239 240 ~ 259 260 ~ 279 280 ~ 299 300 ~ 319 320 ~ 339

340 ~359 360 ~ 379 380 ~ 399 400 ~ 419

420 ~439 440 ~ 459 460 ~ 479 480 ~ 499

500

– – – – – –

– 70 –

Page 71

2. Special operation for maintenance check (SW800 and SW801 operations)

D800 D801 D802 D803 D804

LED displaySpecial operation

Refrigerant recovery operation

Control contents

The outdoor unit performs cooling operation. As the indoor unit does not operate by this operation only, carry out the fan operation beforehand. (Refer to 9-3-1.)

D800 D801 D802 D803 D804

PMV full open operation

Open PMV (Electronic expansion valve) fully. Execute the following item 6) or the control returns to normal operation after 2 minutes. (Refer Note 1)

D800 D801 D802 D803 D804

PMV full close operation

Close PMV (Electronic expansion valve) completely. Execute the following item 6) or the control returns to normal operation after 2 minutes. (Refer Note 1)

D800 D801 D802 D803 D804

PMV middle opening operation

Open PMV (Electronic expansion valve) to middle position (250 pulses). Execute the following item 6) or the control returns to normal operation after 2 minutes. (Refer Note 1)

D800 D801 D802 D803 D804

Indoor heating trial operation command

Carry out a trial heating operation. The operation returns to the normal control by executing the following item 6). (Refer Note 2)

D800 D801 D802 D803 D804

Indoor cooling trial operation command

Carry out a trial cooling operation. The operation returns to the normal control by executing the following item 6). (Refer Note 2)

D800 D801 D802 D803 D804

Fan motor forced operation

Operate the fan motor forcedly. Execute the following item 6) or the control returns to normal operation after 2 minutes. (Refer Note 1)

D800 D801 D802 D803 D804

4-way valve relay operation

Turn on 4-way valve power relay (CN700) Execute the following item 6) or the control returns to normal operation after 2 minutes. (Refer Note 1)

The following special operations for maintenance check can be performed by handling the service switches SW800 and SW801.

[Operating method]

1) Check LED display is the initial status. If it is not so, set the initial status.

2) Push and hold SW800 for 5 seconds or more and then check D804 flashes slowly.

3) Push SW800 and then stop it at the LED display of the function item to be set.

(Note 1) Although these special operations are available even operating time, basically carry out these

(Note 2) Indoor trial cooling operation request / Indoor trial heating operation request

4) Push SW801 and then stop it at point where D805 becomes rapid flashing.

5) Push and hold SW801 for 5 seconds or more. D804 changes to slow flashing, D805 changes lighting and then the special operation becomes valid.

6) To invalidate various settings, push and hold SW800 and SW801 for 5 seconds or more simultaneously. D800 to D804 go off (or rapid flashing), D805 goes on (Initial status: Display of error which is occurring at present), and then the special operation becomes invalid (normal control).

* If an unknown point generated on the way of the operation, push and hold SW800 and SW801 for 5 seconds

or more simultaneously. You can return to the item 1).

: ON, : OFF,

: Rapid flashing (5 times/second)

operations while the machine stops. If carrying out these operations, the pressure may change suddenly and a danger may grow.

Cooling/heating trial operations are available from the outdoor unit only in combination with the following indoor units.

Trial operation is available: Indoor units after 4 series (RAV-SM

Trial operation is unavailable: Indoor units except the above units or in case that the indoor units except the above units are included at twin connection.

Note) The forced trial operation in this setting cannot be cleared by the indoor remote controller.

Be sure to clear it by operation of the outdoor unit (6 below).

– 71 –

****4*

T-E)

Page 72

9-4. Applicable Control of Outdoor unit

The following controls are enabled by connecting the part “Application control kit” (TCB-PCOS1E2) sold separately.

(1) Power peak cut control

* The capacity of the outdoor unit is saved by the Demand signal from outside and corresponds to the

temporary peak cut.

* The capacity save is switched to 3 stages, 75%, 50% and operation stop.

(2) Night operation (Sound reduction) * Input a timer on the market (Arranged at site). The capacity is lowered regardless of load and the operation

noise is reduced until 45dB. However the normal control is carried out if the outside temperature (TO sensor value) is 40°C or more.

(3) Compressor operation output

* When the compressor drives, turn on the contact output of no voltage.

– 72 –

Page 73

10. ADDRESS SETUP

10-1. Address Setup Procedure

When an outdoor unit and an indoor unit are connected, or when an outdoor unit is connected to each indoor unit respectively in the group operation even if multiple refrigerant lines are provided, the automatic address setup completes with power-ON of the outdoor unit. The operation of the remote controller is not accepted while automatic address works. (Approx. 4 to 5 minutes)

Setup of line address of outdoor unit, indoor unit address, and group address

Completion of cabling work

Do you arbitrarily set the

indoor unit address?

YES

Connect one remote controller with one indoor unit (1 : 1) tentatively with communication cable.

Turn on power of outdoor unit.

Set to all indoor units one by one.

(MANUAL)

Is group control performed?

YES

Do you change setting after

automatic setting at the first time?

YES

Turn on power of outdoor unit.

After completion of address setup, change is to arbitral

( )

address/group manually.

(To AUTO address mode)

Setup of automatic address finishes within

( )

4 to 5 minutes.

Is refrigerant line 1 line?

Turn on power of outdoor unit.

YES

END

• When the following addresses are not stored in the neutral memory (IC503) on the indoor P.C. board, a test

run operation cannot be performed. (Unfixed data at shipment from factory)

Line address

Indoor unit address

Group address

Item code

Data at shipment

0099

Setup data range

0001 (No. 1 unit) to 0064 (No. 64 unit)

0001 (No. 1 unit) to 0064 (No. 64 unit) Max. value of indoor units in the identical refrigerant line

0000 : Individual (Indoor units which are not controlled in a group) 0001 : Master unit (1 indoor unit in group control) 0002 : Sub unit (Indoor units other than master unit in group control)

– 73 –

Page 74

10-2. Address Setup & Group Control

Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control)

1 = Master unit in group control 2 = Sub unit in group control

Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/from

the remote controllers and sub indoor units. (∗ It has no relation with an indoor unit which communicates serially with the outdoor units.)

The operation mode and setup temperature range are displayed on the remote controller LCD. (Except air direction adjustment of louver)

Sub unit (= 2) : Indoor units other than master unit in group operation

Basically, sub units do not send/receive signals to/from the remote controllers. (Except errors and response to demand of service data)

Header unit (Representative unit) (Master Twin)

: This unit communicates with the indoor unit (follower) which serial-communicates with the

outdoor units and sends/receives signal (Command from compressor) to/from the outdoor units as the representative of the cycle control in the indoor units of the identical line address within the minimum unit which configures one of the refrigerating cycles of Twin.

Follower unit (Subordinate unit) (Sub Twin)

: Indoor units excluding the header unit in Twin

This unit communicates with (Header) indoor unit in the identical line address and performs control synchronized with (Header) indoor unit.

This unit does not perform the signal send/receive operation with the outdoor units. : No judgment for serial signal error.

10-2-1. System Configuration

1. Single

Outdoor

Indoor (Master/Header)

Remote controller

3. Single group operation

2-1

Sub/Header

1-1

Individual

1-1

Sub/Header

4-1

Master/Header

2. Twin

Sub/Header

Master/Header

3-1

1-1

1-2

Sub/Follower

8-1

Sub/Header

– 74 –

Page 75

10-2-2. Automatic Address Example from Unset Address (No miswiring)

1. Standard (One outdoor unit)

1) Single

1-1

Individual

(Master/Sub)

2) Group operation (Twin, Triple operation)

(Multiple outdoor units = Miltiple indoor units only with serial communication)

2-1

Sub/Header

1-1

Sub/Header

1-2

Sub/Follower

3-1

Master/Header

3-2

Sub/Follower

Only turning on source power supply (Automatic completion)

3-3

Sub/Follower

• Header unit: The header unit receives the indoor unit data (thermo status) of the follower (Without identical line address & indoor/outdoor serial) and then finally controls the outdoor compressor matching with its own thermo status.

The header unit sends this command information to the follower unit.

• Follower unit: The follower unit receives the indoor unit data from the header (With identical line address & indoor/outdoor serial) and then performs the thermo operation synchronized with the header unit.

The follower unit sends own thermo ON/OFF demand to the header unit.

(Example)

No. 1-1 header unit sends/receives signal to/from No. 1-2 and No. 1-3 follower units. (It is not influenced by the line 2 or 3 address indoor unit.)

– 75 –

Page 76

10-2-3. Automatic Address Example from Unset Address (No miswiring)

1. Standard (One outdoor unit)

1) Single 2) Twin

(1-1) (1-2)

1-1

Individual

(Master/Header)

1-2

Master/Header

Only turning on source power supply (Automatic completion)

2. Group operation (Multiple outdoor units = Multiple indoor units with serial communication only, without twin)

1-1

Sub/Follower

2-1

Sub/Header

Only turning on source power supply (Automatic completion)

3. Multiple groups operation

Single Twin

2-1

Sub/Header

1-1

Sub/Header

1-1

Sub/Header

3-1

Master/Header

2-3

Master/Follower

8-1

Sub/Header

(Max. : 8 units)

2-1

1-1 1-2

Change is necessary

Manually change addresses of the multiple follower units simultaneously from the remote controller.

– 76 –

Page 77

10-3. Remote Controller Wiring

• Strip off approx. 9 mm the wire to be connected.

• For single system, use non polarity, 2 core wire is

used for wiring of the remote controller. (0.5 mm² to 2.0 mm² wires)

• For the synchronous twin, triple system, use

2-conre shield wire (Vinyl cord for microphone 0.5 to 2.0 mm²) to conform to the EMC standard.

Single system

Remote controller

Remote controller wiring

A B

Indoor side

Indoor/Outdoor connecting wires

Outdoor side

223

L N

Power supply

Wiring diagram

Terminal block for remote controller wiring of indoor unit

A B

Remote controller wire (Procured locally)

∗ For details of wiring/installation of the remote

controller, refer to the Installation Manual enclosed with the remote controller.

Terminal block

Remote controller

unit

Simultaneous twin system

Remote controller

Remote controller wiring

A B

Indoor side

Indoor/Outdoor connecting wires

Outdoor side

223

L N

Power supply

10-4. Address Setup (Manual setting from remote controller)

In case that addresses of the indoor units will be determined prior to piping work after cabling work

• Set an indoor unit per a remote controller.

• Turn on power supply.

Line address → 1

Indoor unit address → 1

Group address → 1

(Example of 2-lines cabling) (Real line: Cabling, Broken line: Refrigerant pipe)

Outdoor

1 23

1 2 3

Indoor

A B

Remote controller

For the above example, perform setting by connecting singly the wired remote controller without remote controller inter-unit cable.

Group address Individual : 0000 Master unit : 0001 Sub unit : 0002

1 2 3

Indoor

A B

1 2 2

Outdoor

1 2 3

Indoor

A B

2 1 2

In case of group control

1 2 3

Indoor

A B

2 2 2

– 77 –

Page 78

1 Push

2 (

3 Using timer time / buttons, set the line address. 4 Push 5 (

6 Using timer time / buttons, set 1 to the line address. 7 Push 8 (

9 Using timer time / buttons, set 10 Push 11 Push

SET

+ CL +

for 4 seconds or more.

←←

← Line address)

←←

Using the temperature setup

1212

to the CODE No.

set

1212

SET

button. (OK when display goes on.)

←←

← Indoor unit address)

←←

Using the temperature setup

SET

button. (OK when display goes on.)

←←

← Group address)

←←

Using the temperature setup

SET

TES

Setup completes. (The status returns to the usual stop status.)

TES

buttons simultaneously

/ buttons,

/ buttons, set

00000000

0000

to Individual,

00000000

button. (OK when display goes on.) button.

1313

to the CODE No.

1313

1414

to the CODE No.

1414

00010001

0001

00010001

to Master unit, and

00020002

0002

to sub unit.

00020002

10-5. Confirmation of Indoor Unit No. Position

1. To know the indoor unit addresses though position of the indoor unit body is recognized

• In case of individual operation (Wired remote controller : indoor unit = 1 : 1)

(Follow to the procedure during operation)

1 Push 2 Push

Unit No. (It disappears after several seconds.)

The displayed unit No. indicate line address and indoor unit address.

(When other indoor units are connected to the identical remote controller (Group control unit), other unit numbers are also displayed every pushing

NIT LOUVE

ON / OFF

NIT LOUVE

button.

button if the unit stops.

button.

1-11-1

1-1

is displayed on LCD.

1-11-1

– 78 –

Page 79

2. To know the position of indoor unit body by address

• To confirm the unit No. in the group control

(Follow to the procedure during operation) (in this procedure, the indoor units in group control stop.)

The indoor unit numbers in the group control are successively displayed, and fan, louver, and drain pump of the corresponding indoor unit are turned on. (Follow to the procedure during operation)

1 Push

VENT

and

TES

buttons simultaneously for

4 seconds or more.

• Unit No. is displayed.

• Fans and louvers of all the indoor units in the group control operate.

2 Every pushing

NIT LOUVE

button, the unit numbers

in the group control are successively displayed.

• The unit No. displayed at the first time indicates the master unit address.

• Fan and louver of the selected indoor unit only operate.

3 Push

TES

button to finish the procedure.

All the indoor units in the group control stop.

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.

If an indoor unit operates for approx. 8 hours or more per day, usually it is necessary to clean the indoor/ outdoor units once three months at least.

These cleaning and maintenance should be carried out by a qualified dealer. 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.

Part name

Heat exchanger

Fan motor

Filter

Fan

Suction/ Discharge grille

Drain pan

Face panel, Louver

External appearance

Object

Indoor Outdoor

{{ {{

{

—

{{

{

—

{

Contents of check

• Blocking with dust, damage check

• Audibility for sound

• Visual check for dirt and breakage

• Visual check for swing and balance

• Check adhesion of dust and external appearance.

• Visual check for dirt and scratch

• Check blocking by dust and dirt of drain water.

• Check dirt and scratch.

• Check rust and pealing of insulator

• Check pealing and floating of coating film

Contents of maintenance

• Clean it when blocking is found.

• When abnormal sound is heard

• Clean with water if dirty

• Replace if any breakage

• Replace fan when swinging or balance is remarkably poor.

• If a large dust adheres, clean it with brush or water.

• Repair or replace it if deformation or damage is found.

• Clean drain pan, Inclination check

• Cleaning/Coating with repair painting

• Coating with repair painting

– 79 –

Page 80

Model name J 806 J 800 J 801 J 802 J 803 J 804



11. REPLACEMENT OF THE SERVICE P.C. BOARD MCC-1630

1. Removing the P.C. board

(1) Turn off the power supply of the outdoor unit and allow at least 3 minute for the capacitor to discharge.

Confirm that the light of the LED (D800 to D805) fades away.

(2) Remove all the connectors and fast-on terminals connected to the P.C.board.

(Remove the connectors and fast-on terminals by pulling the connector body. Do not pull the wire).

(3) Remove all the screws which secures the P.C.board.

(These screws are to be reused after procedure.)

(4) Remove the P.C.board from the BOX.

2. Setting the jumper wires

Modelswitching (J800 to J804, J806)

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 E04”h appears on the remote controller and the operation of the air conditioner is disabled.

Factory setting (default) - - - - - - RAV-SM1103AT-E1 - Cut - - - RAV-SM1403AT-E1 - - Cut - - -

J806

J800

3. Installing the P.C. board

(1) Apply thermal grease to the back (heat sink contacting side) of devices IC200 and IC300.

(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) Reuse the sub heat sink. Applying thermal grease to the surface and the back of the sub heat sink.

(4) Insert the P.C. board, align the holes of the insulating sheets, semiconductor devices, and heat sinks,

and then secure them with screws.

Tighten the screw (A) at the end. (5) Connect the lead wires according to the wiring diagram sticked on the backside of the panel .

screw (A)

J801

J802

J803

J804

Apply thermal grease to the back (heat sink contacting side) of IC200 and IC300.

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

– 80 –

Reuse the sub heat sink. Applying thermal grease to the surface and the back of the sub heat sink.

Page 81

12. HOW TO EXCHANGE COMPRESSOR

12-1. Exchanging Procedure of Compressor (Outline)

START

Has refrigerant recovery work been done?

YES

Turn off the leakage breaker.

Remove the defective compressor.

Mount a service compressor.

Leakage check

Vacuuming

Charge the refrigerant.

END

Open PMV forcedly and then recover refrigerant using a refrigerant recovery unit.

Never recover the refrigerant to the outdoor unit. For the refrigerant recovery work during reinstallation

of repair work, be sure to use the refrigerant recovery unit. Recovery of refrigerant to the outdoor unit is unavailable;

otherwise a serious accident such as explosion or injury may be caused.

12-2. Exchange of Compressor

For exchange of compressors, refer to (11) Compressor in Section 13. Detachments.

– 81 –

Page 82

RAV-SM1103AT-E1, RAV-SM1403AT-E1

13. DETACHMENTS

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 also turn off switch of the breaker.

2) Remove the front cabinet. (M4 (Hexagon) x 10, 3 pcs.)

• After taking off screws, remove the front

cabinet by pulling it downward.

3) Remove the cover of the terminal block. (M4 x 8, 2 pcs.)

4) Disconnect the connecting cables and power cord from the terminals and cord clamp.

5) Remove the roof plate. (M4 (Hexagon) x 10, 6 pcs.)

Front cabinet

Screw

Remarks

Screw

2. Attachment

1) Attach the roof plate. (M4 (Hexagon) x 10, 6 pcs.)

2) Connect the connecting cable and power cord at the terminal and fix them with cord clamp.

3) Attach the cover of the terminal block. (M4 x 8, 2 pcs.)

CAUTION

Using bundling band sold at a market, be sure to fix the power cables and indoor/outdoor connecting cables along the inter-unit cable so that they do not come to contact with the compressor, valves and cables at gas side, and the discharge pipe.

4) Attach the front cabinet. (M4 (Hexagon) x 10, 3 pcs.)

Cover of the terminal block

Roof plate

– 82 –

Page 83

No.

Part name

Discharge port cabinet

Procedure

1. Detachment

1) Perform work of item 1 of c.

2) Remove screws (M4 x 8, 3 pcs.) of discharge port cabinet for partition plate.

3) Remove screws (M4 (Hexagon) x 10, 2 pcs.) of discharge port cabinet for the bottom plate.

4) Remove screw (M4 x 8, 1 pc.) of discharge port cabinet for the end plate of the heat exchanger.

5) Remove the screws (M4 x 8, 2pcs) of discharge port cabinet and motor base.

6) Remove screws (M4 (Hexagon) x 10, 2 pcs.) of discharge port cabinet for the fin guard.

2. Attachment

1) Put the upper left side of the discharge port cabinet on the end plate of the heat exchanger, and then fix it with screw.

(M4 x 8, 1 pc.)

2) Attach the removed screws to the original positions.

Remarks

Fin guard

Bottom plate

Side cabinet

1) Perform work of item 1 of c.

2) Remove screws fixing the inverter and the side cabinet. (M4 x 8, 2 pcs.)

3) Remove screws of the side cabinet and the valve support plate. (M4 x 8, 2 pcs.)

4) Remove screw of the side cabinet and the piping panel (Rear). (M4 (Hexagon) x 10, 1 pc.)

5) Remove screw of the side cabinet and the bottom plate. (M4 (Hexagon) x 10, 1 pc.)

6) Remove screw of the side cabinet and the fin guard (Heat exchanger). (M4 (Hexagon) x 10, 2 pcs.)

End plate of the heat exchanger

Valve support plate

Inverter assembly

Discharge port cabinet

Side cabinet

– 83 –

Valve support plate

Piping panel (Rear)

Page 84

No. Part name Procedure Remarks

Inverter assembly

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

2) Remove the front cover. (M4 x 8, 3 pcs.)

3) Remove the inverter fixing plate. (M4 x 8, 3 pcs.)

4) Remove connectors connected to other parts from P.C. board.

CN601: TD sensor (3P, White) CN602: TO sensor (2P, Yellow) CN603: TE sensor (2P, White) CN604: TS sensor (3P, White) CN605: TL sensor (2P, White) CN300: Outdoor fan (3P, White) CN500: Case thermo (2P, Blue) CN700: 4-way valve coil (3P, Yellow) CN701: PMV coil (6P, White) CN501: High-pressure SW (3P, Green)

* Unlock the locks of the housing part and

then remove the connectors.

5) Remove the compressor lead connectors.

6) Remove the relay connector of the reactor lead attached to the partition plate side.

7) Cut bunding band which fixed the various lead wires to the inverter assembly.

8) Pull up upward the hook for the partition plate (Back left) so as to remove it.

Inverter assembly

Front cover

Inverter fixing plate

Inverter assembly

* Caution for attachment of the inverter

assembly

When attaching the inverter assembly to the partition plate surely attach the hook for the partition plate (Back left).

Reactor (Partition plate side)

Relay connector

Complessor lead connector

Wire clamp

There is a hook for the partition board at the rear side.

Case thermo lead

4way valve

PMV

– 84 –

Page 85

No. Part name Procedure Remarks

Outdoor unit

control P.C. board

1) Perform works of 1 of c, 2) of f.

2) Remove the guide. (M4 x 8, 1 pc.)

3) Remove connectors and lead wires which are connected to the other parts from the cycle P.C. board.

1. Connectors (On P.C. board)

CN601: TD sensor (3P, White) CN602: TO sensor (2P, Yellow) CN603: TE sensor (2P, White) CN604: TS sensor (3P, White) CN605: TL sensor (2P, White) CN300: Outdoor fan (3P, White) CN500: Case thermo (2P, Blue) CN700: 4-way valve (3P, Yellow) CN701: PMV coil (6P, White) CN501: High-pressure SW (3P, Green)

2. Connectors (Relay connection)

Reactor lead wire (White) Reactor lead wire (Gray) Compressor lead wire (Red, White, Black)

* Unlock the locks of the housing part and

then remove the connectors.

4) Remove the Faston terminal (White (3)) on the indoor/outdoor connection terminal block.

5) Remove the earth wire (Black) which is fixed to the terminal fixed plate with screw (1 pc.).

6) Remove the power supply connection lead wire from the power supply terminal block. (L (Red), N (White)

7) Remove screws (4 pcs.) which fixed the heat sink and IPM and screws (3 pcs.) which fixed the heat sink and rectifier.

8) Remove screws which fixed P.C. board and remove board fixed claws (2 positions) to remove P.C. board.

9) Attach a new P.C. board.

Guide

Indoor/outdoor connection terminal block

To remove the guide, pull it toward arrow direction so that the force is not applied to this switch.

Earth wire

Guide fixing screw

Power supply terminal block

– 85 –

Page 86

No.hPart name

Flange nut

Loosened by turning clockwise

Fan motor

Procedure

Remarks

Fan motor

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

2) Remove the flange nut fixing the fan motor and the propeller fan.

• Loosen the flange nut by turning clock-

wise. (To tighten the flange nut, turn it counterclockwise.)

3) Remove the propeller fan.

4) Remove the lead wire from the hook fixing the fan motor lead wires on the motor base. (Three positions)

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

6) Remove the fixing screws (4 pcs.) while holding by hands so that the fan motor does not fall.

*(Note)

• Tighten the flange nut with torque 4.9N•m (50kgf/cm).

• Be careful that the reactor does not come to contact with the fan motor lead at the rear side of the inverter assembly.

CAUTION

Using a bundling band on the market, be sure to fix the fan motor lead wire to the motor base so that it does not come to contact with the propeller fan.

Flange nut

Motor base

Loosened by

turning clockwise

Fan motor

Fix with bundling band

– 86 –

Page 87

No.iPart name

Piping panel (Front)

Case thermo

Remove (Discharge pipe)

Procedure

Remarks

Compressor

1) Evacuate refrigerant gas.

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

3) Remove screws which fixes the piping panel (Front) and the bottom plate.

(M4 (Hexagon) x 10, 2 pcs.)

4) Remove screw of the piping panel (Front) and the piping panel (Rear).

(M4 (Hexagon) x 10, 1 pc.)

5) Remove screws fixing the partition plate to the valve support plate.(M4 x 8, 2 pcs.)

6) Remove the valve support plate. (M6 x 4 pcs.)

7) Remove screws of the partition plate and the bottom plate. (M4 x 8, 1 pc.)

8) Remove screws of the partition plate and the heat exchanger (M4 x 8, 2 pcs.)

9) Remove the noise-insulator.

10) Remove the terminal covers of the com-

pressor, and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal.

11) Remove pipes connected to the compres-

sor with a burner.

Screw

Partition plate

Piping panel (Front)

Partition plate

Valve support plate

CAUTION

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

12) Pull the refrigerating cycle upward.

13) Remove bolt fixing the compressor on the

bottom plate. (3 pcs.)

14) Pull the compressor toward you.

CAUTION

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

Valve support plate

Sensor pipe cover

Case thermo

Valve

Valve support plate

Compressor lead wire

Case thermo

Remove (Suction pipe)

– 87 –

Remove (Discharge pipe)

Compressor bolt (3 pcs.)

Page 88

No. Part name Procedure Remarks

Dent part

Pulse Modulating

Valve (PMV) coil

1. Detachment

1) Perform works of items 1 of c and e.

Positioning projection

PMV main unit

2) Remove the coil from PMV body while pulling it upward.

2. Attachment

1) Match the positioning extrusion of the coil surely to the concavity of PMV body to fix it.

PMV coil

Dent part

Reactor

1. Detachment

1) Perform works of items of 1 of c and 3) of

2) Remove the reactor lead wire from the cord clamp which fixes lead wires.

3) Remove screw which fixes the reactor. Partition plate side: M4 x 8, 1 pc. Inverter rear side: M4 x 8, 2 pcs.

4) Pull off the reactor upward to remove the reactor.

CAUTION

As the reactor body becomes high temperature in this Model, the lead wires are fixed with the cord clamp so that the reactor lead does not come to contact with the main body. When replacing the reactor or returning the inverter assembly to the original position after removing it, be sure to fix the lead wires with the cord clamp so that the main body does not come to contact to the lead.

Screw

Cord clamp

Do not pull the lead wire strongly too much.

Cord clamp Screw

Bind the lead wires with bundling band.

– 88 –

Page 89

No.

Part name

Procedure

Remarks

Fan guard

1. Detachment

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

2) Remove the discharge port cabinet, and put it down so that the fan guard side directs downward.

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

3) Remove screws fixing the bell mouth. (M4 x 8, 2 pcs.)

4) Remove the bell mouth.

5) Remove the hooking claws by pushing with minus screwdriver along with the arrow mark as shown in right figure.

2. Attachment

1) Insert claw of the fan guard in hole of discharge port cabinet. Push the hooking claws (5 positions) with hands and fix the claws.

After all the attachment works are completed, check that all the hooking claws are fixed to the specified positions.

Minus screwdriver

Discharge port cabinet

Bell mouth

Remove two screws

Bell mouth

Discharge port cabinet

Fan guard

2) Mount the bell mouth by hooking three claws at upper side of the bell mouth in the slits on the discharge port cabinet.

3) After attachment, fix the bell mouth with screws. (M4 x 8, 2 pcs.)

Hooking claw

Discharge port cabinet

Slit (3 positions)

Bell mouth

– 89 –

Claw (3 positions)

Page 90

14. EXPLODED VIEWS AND PARTS LIST

– 90 –

Page 91

Location

No.

1 43005727 CABINET, AIR, OUTLET

Part No. Description

Model Name RAV-

SM1103AT-E1 SM1403AT-E1

2 43100350 CABINET, FRONT, ASSY, ROHS

3 43100349 CABINET, SIDE, ASSY, ROHS

4 4310A009 PLATE, ROOF

5 4301V071 GUARD, FIN

6 43191651 GUARD, FAN

7 43122065 BELL MOUTH

8 43F47669 NUT, FLANGE

9 43120224 FAN, PROPELLER, PE492

10 4312C090 MOTOR, FAN, WDF-340-A100-1

11 4314G308 CONDENSOR ASSY

12 43100347 PANEL, FRONT, PIPING, ROHS

13 43100345 PANEL, BACK, PIPING, ROHS

14 43119390 HANGER

15 43141519 COMPRESSOR, DA422A3F-12M

16 43F50407 THERMOSTAT,BIMETAL

17 43F63317 HOLDER,THERMOSTAT

18 43160625 LEAD ASSY, COMPRESSOR

19 43100343 BASE ASS'Y, ROHS

20 43197183 BOLT, COMPRESSOR

21 43149324 RUBBER, CUSHION

22 43F46500 VALVE, 4WAY, STF-H0218

23 43146749 COIL, SOLENOID, STF-H01AJ1949A1

24 43146634 VALVE, PULSE, MODULATING

25 43046494 COIL, PMV, ASSY

26 43148170 ACCUMULATOR ASS'Y

27 43146686 VALVE, PACKED, 9.52

28 43146724 VALVE, BALL, SBV-JA5GTC-1, ROHS

29 43F47401 BONNET, 3/8 IN

30 43194029 BONNET, 5/8 IN

31 43151301 SWITCH, PRESSURE

32 43158231 REACTOR

33 43F19904 HOLDER, SENSOR (TS)

34 43F63188 HOLDER, TC SENSOR

35 43063332 HOLDER, SENSOR

36 4314Q068 STRAINER, ROHS

37 4314Q033 STRAINER, ROHS

38 43F89160 CAP, WATERPROOF

39 43F32441 NIPPLE, DRAIN

– 91 –

Page 92

Inverter assembly

Location

No.

701 43150351 SENSOR, TD

702 43150350 SENSOR ASSY

703 43150353 SENSOR

704 43150352 SENSOR

705 43150355 SENSOR

706 43F63338 HOLDER, ASSY (SENSOR)

707 4316V496 PC BOARD ASSY, MCC-1630

708 43160589 FUSE

709 43F63248 SUPPORTER, ASSY

710 43160567 TERMINAL BLOCK, 3P, 30A

711 43160565 TERMINAL BLOCK, 3P, 20A

712 43163059 SPACER, BUSH

713 43163066 SPACER, COLLAR

714 43163060 SPACER, COLLAR

Part No. Description

Model Name RAV-

SM1103AT-E1 SM1403AT-E1

– 92 –

Page 93

TOSHIBA CTOSHIBA C

TOSHIBA C

TOSHIBA CTOSHIBA C

23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN

ARRIER CORPORAARRIER CORPORA

ARRIER CORPORA

ARRIER CORPORAARRIER CORPORA

TIONTION

TION

TIONTION

Toshiba RAV-SM1403AT-E1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual