Toshiba RAV-SM802KRT-E User Manual

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Page 1

FILE NO.SVM-05053-1

SERVICE MANUAL

HI WALL TYPE (INDOOR UNIT)

RAV-SM562KRT-E

RAV-SM802KRT-E

R410A

Rev. Mar, 2006

Page 2

CONTENTS

1. SPECIFICATIONS................................................................................................ 2

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) ................................................. 4

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ......................................... 5

4. WIRING DIAGRAM .............................................................................................. 6

5. SPECIFICATIONS OF ELECTRICAL PARTS ..................................................... 7

6. REFRIGERANT R410A ....................................................................................... 8

7. INDOOR UNIT CONTROL ................................................................................. 16

8. TROUBLESHOOTING ....................................................................................... 27

9. HOW TO REPLACEMENT OF SERVICE INDOOR P.C. BOARD....................... 50

10. SETUP AT LOCAL SITE AND O THERS ........................................................... 54

11. ADDRESS SETUP ............................................................................................. 71

12. EXPLODED VIEWS AND PARTS LIST.............................................................. 76

NOTE :

This Service Manual describes explanation for the Under Ceiling type indoor unit. For the combined outdoor unit, refer to the following Service Manual.

Outdoor unit Model name SVM to be referred RAV-SMXX0AT-E A03-007 RAV-SPXXXAT-E A03-014

RAV-SMXX1AT-E A05-001

– 1 –

Page 3

1-1. High-Wall Type (Indoor Unit)

1. SPECIFICATIONS

Model name

Standard capacity (Note 1) (kW)

Heating low temp. capacity (Note 1) (kW)

Energy consumption effect ratio (Cooling)

Power supply

Running current (A) Electrical characteristics

Appearance

Power consumption (kW)

(Low temp.) (kW)

Power factor (%)

Main unit

Ceiling Panel

(Sold separately)

Main unit Width (mm)

Model

Panel color

Height (mm)

RAV-SM562KRT-E RAV-SM802KRT-E

Cooling Heating Average Cooling Heating Average

5.1 5.6 6.7 8

(1.5 – 5.6) (1.5 – 6.3) (2.2 – 8.0) (2.2–9.0)

4.9 5.8

2.93 [D] 3.29 [C] 3.11 2.46 [E] 3.00 [D] 3.24

1 phase 230V (220 – 240V) 50Hz

8.33–7.63 8.138–7.46 13.15–12.05 12.91–11.84

1.74 1.7 2.72 2.67

1.95 2.21

95 95 94 94

Pure white

——

298

998

Outer dimension

Ceiling panel

(Sold separately)

Total weight

Heat exchanger

Soundproof/Heat-insulating material

Fan unit Standard air flow High (Mid./Low) (m³/h)

Air filter

Controller (Sold separately)

Connecting pipe

Main unit (kg)

Ceiling panel

Fan

Motor (W)

Gas side (mm)

Liquid side (mm)

Drain port (Nominal dia.)

Depth (mm)

Height (mm)

Width (mm)

Depth (mm)

221

——

Finned tubu

Inflammable polyethylene foam Foamed polyethylen

Turbo fan

840 1110

Attached main unit

Wired remote controller RBC-AMT21E

Ø12.7 (1/2”) Ø15.9 (5/8”)

Ø6.4 (1/4”) Ø9.5 (3/8”)

25 (Polyvinyl chloride tube)

Sound level High (Mid./Low) (Note 2) (dB•A)

45 41 36 45 41 36

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions speciied by JIS B 8616 based

on the reference piping. The reference piping consists of 3 m of main piping and 2 m of branch piping connected with 0 meter height.

Note 2 : The sound level is measured in an anechoic chamber in accordance with JIS B8616. Normally, the values measured in

the actual operating environment become larger than the indicated values due to the effects of external sound.

Note : Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB

Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB

– 2 –

Page 4

Operation characteristic curve

RAV-SM802KRT-E

Current (A)

0201540 60 70 80 100

RAV-SM562KRT-E

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

Compressor speed (rps)

Current (A)

020

RAV-SM802KRT-E

RAV-SM562KRT-E

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

40 60 80 90 100

Compressor speed (rps)

•Capacity variation ratioaccor ding to temperature <Cooling> <Heating>

105

100

120

110

100

Capacity ratio (%)

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

32 33 34 35 36 37 38 39 40 41 42 43

Capacity ratio (%)

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

Outsoor temp. (°C)

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

Outsoor temp. (°C)

– 3 –

Page 5

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

High-Wall Type RAV-SM562KRT-E/RAV-SM802KRT-E

Knock out system

Back body

Front panel

Grille inlet

298

Air inlet

Air outlet

998

220

Knock out system

Connection pipe (0.39 m)

(For SM802 : Flare ∅15.88) (For SM562 : Flare ∅12.7)

55 or more

Outline of indoor unit

298

Minimum distance

to ceiling

∅65



100

998

763.5

450

Installation Plate outline

Drain hose (0.54 m)

Connection pipe (0.49 m) (Flare ∅6.35)

100

Wireless remote control

(For stud bolt ∅6)

(For stud bolt ∅8 -∅10)

5555



∅6

160

– 4 –

Page 6

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Hi Wall type

RAV-SM562KRT-E/SM802KRT-E

Outer diameter of refrig erant pipeModel

RAV-SM 562KRT-E 802KRT-E

Gas side ØA Liquid side ØB

12.7 mm 6.4 mm

15.9 mm

9.5 mm

Indoor unit

TCJ

sensor

Air heat exchanger

TC sensor

Refrigerant pipe at gas side Outer dia. ØA

Pd PsPacked valve

Packed valve Outer dia. ØA

Refrigerant pipe at liquid side Outer dia. ØB

Outer dia. ØB

Outdoor unit

NOTE :

The refrigerating cycle differs according to the combined outdoor units. For the cycle diagram, cycle pressure, etc., refer to the following Service Manual.

RAV-SMXXX0AT-E : A03-007 RAV-SPXXXXAT-E : A03-014

RAV-SMXXX1AT-E : A05-001

– 5 –

Cooling Heating

Page 7

4-1. Hi Wall type (Indoor unit)

RAV-SM562KRT-E/SM802KRT-E

ＬＯＵＶＥＲＭＯＴＯＲ

BLK

ＣＮ２２

Ｆ３０１ＦＵＳＥ

Ｔ３．１５Ａ２５０Ｖ〜

１

３

５

ＣＮ６７（ＢＬＫ）

ＣＮ２１３（ＷＨＩ）

５８７６

６７８５

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

６７８５

５８７６

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

10 10

ＷＨＩ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵ 9

ＣＮ８０（ＧＲＮ）

１２３

ＣＮ８２（ＢＬＵ）

１

４２３

１

３２４

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

１

３２４

１

４２３

ＩＮＦＲＡＲＥＤＲＡＹＳＲＥＣＥＩＶＥ

ＡＮＤＩＮＤＩＣＡＴＩＯＮＰＡＲＴＳ

（ＭＣＣ−８１９）

ＰＮＬ/ＥＭＧ

4. WIRING DIAGRAM

ＴＥＲＭＩＮＡＬ

２１４５３

ＲＥＤ

ＢＬＫ

１

３４

１

ＣＮ６１（ＹＥＬ）

５３４６２１５３４６２

３４２

ＢＬＯＣＫ

ＢＬＵ

１１２

２

ＣＮ４０（ＢＬＵ）

ＰＯＷＥＲＳＵＰＰＬＹＣＩＲＣＵＩＴ

ＣＮ６０（ＷＨＩ）

２５４３１６

ＯＰＴＩＯＮ

FAN MOTOR

ＹＥＬ

ＷＨＩ

ＢＲＷ

ＲＥＤ

ＯＲＮ

ＢＬＵ

ＹＥＬ

ＰＮＫ

ＢＬＵ

１３２１２３

ＣＮ２１０（ＷＨＩ）

５５６６

４３

６５

４

５６

４

ＣＮ３３（ＷＨＩ）

（ＭＣＣ−１５１０）

ControlP.Cboard forindoorunit

ＣＮ８１（ＢＬＫ）

６３２１４５

４５１２３

１

ＢＵＳ

ＥＭＧ

１２

ＣＮ４４ (ＢＲＷ)

ＤＣ１５ＶＤＣ０Ｖ

ＤＣ１２ＶＤＣ７Ｖ

２１５４３

ＣＮ５０（ＷＨＩ）

３

ＣＮ４１

２１

（ＢＬＵ）

１

ＣＮ１００

２

（ＢＲＷ）

３１

ＣＮ１０１（ＢＬＵ）

１

ＣＮ１０３

２

（ＧＲＮ）

１

ＣＮ１０２

２

（ＹＥＬ）

１

ＣＮ１０４

２

（ＷＨＩ）

３２１

２１２

１２

ＢＬＫＢＬＫ

ＴＥＲＭＩＮＡＬＢＬＯＣＫ

ＢＡ

ＨＥＡＴＥＸＣＨＡＮＧＥＲＳＥＮＳＯＲ（ＴＣ）

ＨＥＡＴＥＸＣＨＡＮＧＥＲＳＥＮＳＯＲ（ＴＣＪ）

ＴＨＥＲＭＯＳＥＮＳＯＲ（ＴＡ）

WHI

BLK

ＣＮ１(WHI)



WIERDREMOTE CONTROLLER

NOTE

: Fan motor

: Indoor temp. sensor

: Temp. sensor

TCJ

: Louver motor

WHI BLK

RED

321

Serial

signal

Single phase 220V, 50Hz

– 6 –

Indoor unit earth screw

Outdoor unit earth screw

Color

Identification

BLACK

BLK

BLUE

BLU

RED

GRAY

GRY

PINK

PNK

GREEN

GRN

WHITE

WHI

BROWN

BRW

ORANGE

ORN

YELLOW

YEL

Page 8

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor Unit

High-Wall Type RAV-SM562KRT-E/RAV-SM802KRT-E

No.

Fan motor (for indoor)

Grille motor

Thermo. sensor (TA-sensor)

Heat exchanger sensor (TC-sensor)

Heat exchanger sensor (TCJ-sensor)

Parts name

Type

ICF340-30-X

MF-340-30-X

MP35EA12

268 mm Ø6 mm, 400 mm

Ø6 mm, 400 mm

Specifications

Output (Rated) 30 W, 220–240 V

10 kW at 25°C 10 kW at 25°C

– 7 –

Page 9

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 repairÕs 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 0.8 mm even when it is available on the market.

– 8 –

Page 10

Table 6-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter

1/4

3/8

1/2

5/8

(2) Joints

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

a) Flare Joints

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

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 6-2-3 to 62-6 below.

Outer diameter (mm)

6.35

9.52

12.70

15.88

R410A R22

0.80 0.80

1.00 1.00

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)

6-2-2. 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.

6.35

9.52

12.70

15.88

Minimum joint thickness

(mm)

0.50

0.60

0.70

0.80

(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.

– 9 –

Page 11

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.

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

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure "dimension A" by using a gauge for size adjustment.

ØD

Fig. 6-2-1 Flare processing dimensions

Nominal

diameter

1/4

3/8

1/2

5/8

Nominal

diameter

1/4

3/8

Outer

diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

1.0

Flare tool for

R410A clutch type

0 to 0.5

Table 6-2-4 Dimensions related to flare processing for R22

Outer

diameter

(mm)

6.35

9.52

Thickness

(mm)

0.8

Flare tool for

R22 clutch type

0 to 0.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

1.0 to 1.5 1.5 to 2.0

1.0 to 1.5 2.0 to 2.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

0.5 to 1.0 1.0 to 1.5

1/2

5/8

Nominal

diameter

1/4

3/8

1/2

5/8

12.70

15.88

Table 6-2-5 Flare and flare nut dimensions for R410A

Outer diameter

(mm)

6.35

9.52

12.70

15,88

0.8

1.0

Thickness

(mm)

0.8

1.0

0 to 0.5

0.5 to 1.0 1.5 to 2.0

Dimension (mm)

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

– 10 –

Flare nut

width (mm)

Page 12

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

Nominal Outer diameter Thickness

diameter (mm) (mm)

1/4 6.35 0.8

3/8 9.52 0.8

1/2 12.70 0.8

5/8 15.88 1.0

3/4 19.05 1.0

to 46

B A

Dimension (mm)

ABCD

9.0 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

to 45

Flare nut width

(mm)

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.

Table 6-2-7 Tightening torque of flare for R410A [Reference values]

Nominal Outer diameter Tightening torque

diameter (mm) N.m (kgf.cm)

1/4 6.35 14 to 18 (140 to 180)

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 6-2-7 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.

Tightening torque of torque

wrenches available on the market

N.m (kgf.cm)

16 (160), 18 (180)

3/8 9.52 33 to 42 (330 to 420)

1/2 12.70 50 to 62 (500 to 620)

5/8 15.88 63 to 77 (630 to 770)

– 11 –

42 (420)

55 (550)

65 (650)

Page 13

6-3. Tools

6-3-1. Required Tools

The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. 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

9

Charging cylinder

10

Usage

Pipe flaring

Flaring by conventional flare tool

Connection of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating

Refrigerant charge

Refrigerant charge Gas leakage check Refrigerant charge

air conditioner installation

Existence of Whether convennew equipment tional equipment for R410A can be used

Ye s

Ye s Ye s

(Note 2)

R410A

(Note 1)

X X

Conventional air

conditioner installation

Whether new equipment can be used with conventional refrigerant

(Note 1)

(Note 1) 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.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

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

(1) Vacuum pump

Use vacuum pump by

attaching vacuum pump adapter. (2) Torque wrench (3) Pipe cutter

(4) Reamer (5) Pipe bender (6) Level vial (7) Screwdriver (+, - ) (8) Spanner or Monkey wrench

(9) Hole core drill (Ø65) (10) Hexagon wrench

(Opposite side 4mm) (11) Tape measure (12) Metal saw

Also prepare the following equipments for other installation method and run check. (1) Clamp meter (2) Thermometer

(3) Insulation resistance tester (4) Electroscope

– 12 –

Page 14

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.

When the compound gauge's pointer has indicated

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

Connect the charge hose 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.

Never charge refrigerant exceeding the specified amount.

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

Do not carry out additional charging.

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.)

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

(INDOOR unit)

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

Electronic balance for refrigerant charging

Fig. 6-4-1 Configuration of refrigerant charging

(Liquid side)

(Gas side)

– 13 –

(OUTDOOR unit)

Opened

Closed

Service port

Page 15

Be sure to make setting so that liquid can be charged. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ] [ Cylinder without siphon ]

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

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

Electronic

balance

Siphon

Phosphor bronze brazing filler tends to react

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

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

6-5-2. Flux

(1) Reason why flux is necessary

1.By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

2.In the brazing process, it prevents the metal surface from being oxidized.

3.By reducing the brazing filler's surface tension, the brazing filler adheres better to the treated metal.

– 14 –

Page 16

(2) Characteristics required for flux

Nitrogen gas

cylinder

Pipe

Flow meter

Stop valve

From Nitrogen cylinder

Nitrogen gas

Rubber plug

Nitrogen gas

cylinder

Pipe

Flow meter

Stop valve

From Nitrogen cylinder

Nitrogen gas

Rubber plug

1.Activated temperature of flux coincides with the brazing temperature.

2.Due to a wide effective temperature range, flux is hard to carbonize.

3.It is easy to remove slag after brazing.

4.The corrosive action to the treated metal and brazing filler is minimum.

5.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 braz-

ing 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 (N2) flow.

Never use gas other than Nitrogen gas.

(1) Brazing method to prevent oxidation

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

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

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.

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

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.

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).

Remove the flux completely after brazing.

Copper - Copper

Copper - Iron

Piping

material

Iron - Iron

Used brazing

filler

Phosphor copper

Silver

Used

flux

Do not use

Paste flux

Vapor flux

Do not enter flux into the refrigeration cycle. When chlorine contained in the flux remains

within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine.

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

Remove the flux after brazing.

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

– 15 –

Page 17

7-1. Indoor Control Circuit

7. INDOOR UNIT CONTROL

Max. 8 units are connectable.*1

*1 When group and twin combination. main remote controller shal be connected follower indoor unit

*2 Weekly timer is not connectable to the sub remote controller.

Indoor unit

#1 Header unit

Indoor control P.C. board (MCC-1510)

Central control

remote controller

(Sold separatrly)

Reciver and Display P.C board

(MCC-819)

Reciver unit

Display LED

Main (Sub) master remote controller

(Wired)

Display

LCD

Display

LED

DC20V DC12V

DC5V

Buzzer

CPU

Remote

controller

communication

circuit

Central control

communication

circuit

Driver

Function setup

Key switch

CN2 CN1

DC5V

Power circuit

Sold separatrly Sold separatrly

Remote

controller

communication

circuit

CPU

Driver

H8/3039

Weekly timer

Display

LCD

Powe r

circuit

EEPROM

TA sensor

TC sensor

TCJ sensor

LCD

driver

CPU

DC5V

Secondary

battery

Follower unit

Same as

the left

Function setup

Key switch

Same as

the left

Louver

motor

Indoor

fan

motor

DC280V

Power circuit

DC15V

Outdoor unit

Fan motor

control

circuit

123

Outside output

Run

Warning

Ready

Thermo. ON

Cool Heat

Fan

synchronous

signal input

circuit

Serial send/

receive

circuit

Wireless

remote

signal

Setting (A/B)

123

Outdoor

unit

123

Outdoor

unit

– 16 –

Page 18

INDOOR UNIT CONTROL CIRCUIT (Continued)

7-2. Control Specifications

NO.

Control at power-on reset

Operation mode

switching

Item

Overview of specifications

(1) Identification of outdoor unit

Identifies outdoor unit at power-on reset, and switches control according to the identification result.

(2)

Setting of indoor unit fan speed and adjustment of air flow direction Switches indoor unit fan speed, setting of air flow direction adjustment, etc. based on EEPROM data.

(1) Switches operation mode according to mode select instruction

from remote controller.

R/C instructions

OFF

FAN

COOL

DRY HEAT AUTO

Turns OFF air conditioner “Fan only” operation Cooling operation Dehumidifying operation Heating operation

• Selects COOL or HEAT mode

Outline of control

automatically according to Ta, Ts, and To.

• The first operation is as follows according to Ta. (COOL thermo sensor continues OFF (FAN mode with set fan speed) within the range of Ts +α-1<Ta< Ts +α+1.)

COOL operation

FAN mode with set fan speed

( )

+1.0

Ts+

Remarks

The “PREPARING” lamp lights during initial setting (model recognition) after power-on reset. Fan speed, adjustment of air flow direction

Ta : Room temperature Ts : Set temperature To : Outside air temperature

Room temperature

control

-1.0

HEAT operation

• α is corrected according to outside air temperature.

Outside air temp. Corrected value (α)

No To 0 K

24°C -1 K

24>To

18°C 0 K

To<18°C +1 K

Abnormal To 0 K

(2) Operation instruction permission mode

HEAT and AUTO modes are not available for COOL only models. When instruction is issued from wireless remote controller in the HEAT or AUTO mode, it is indicated by a reception sound “pi, pi” and by alternate blinking of “TIMER” and “PREPARING” lamps. To cancel this alternate blinking, issue an instruction of mode other than HEAT or AUTO.

(1) Adjustment range Remote controller set temperature (°C)

COOL/DRY HEAT AUTO

Wired type 18 - 29 18 - 29 18 - 29

Wireless type 17 - 30 17 - 30 17 - 30

* When use of remote controller sensor is set (with DN32), even

when sensor value is within the above range in HEAT or AUTO mode, the thermo sensor turns OFF when Ta sensor value exceeds 35 °C.

k=deg

– 17 –

Page 19

NO.

Room temperature

control

Capacity auto

control

(GA control)

Item

Overview of specifications

(2) The set temperature for HEAT operation can be corrected by code

No. 06.

Set data 0246

Correction of set temp. +0°C +2°C +4°C +6°C

Factory setting

Set data 2

* When use of remote controller sensor is set (with DN32), no

correction is performed.

(1) Issues instruction of operating frequency to outdoor unit according

to the difference between Ta and Ts.

(2) COOL operation

Calculates room temp. difference between Ta and Ts as well as room temp. variation every 90 seconds to find correction value of specified operating frequency and to correct the current operating frequency. Ta(n)–Ts(n) : Room temp. difference n : Number of detection times Ta(n-1)–Ta(n) : Room temp. variation n–1 : Number of detection times

(90 seconds before)

(3) HEAT operation

Calculates room temp. difference between Ta and Ts as well as room temp. variation every 60 seconds to find correction value of specified operating frequency and to correct the current operating frequency. Ts(n)–Ts(n) : Room temp. difference n : Number of detection times Ta(n)–Ta(n_1) : Room temp. variation n–1 : Number of detection times

(60 seconds before)

(4) DRY operation

The frequency correction control is the same as that for COOL operation. However, the maximum frequency is limited to S6 or so.

Note) When LOW fan speed is set, the maximum frequency is

limited to SB or so.

Remarks

Heat intake temperature shift (When unit’s temperature sensor is used)

COOL/HEAT/

AUTO control

(1) Switching between COOL and HEAT is determined based on the

following control.

(˚C)

+1.5

Tsc

Tsh

COOL

(COOL ON)

(COOL OFF)

-1.5

After 10 minutes pass from thermo sensor OFF, operation mode changes from HEAT (thermo sensor OFF) to COOL if Ta exceeds Tsh +1.5.

( ) shows an example of

HEAT

COOL ON/OFF.

After 10 minutes pass from thermo sensor OFF, operation mode changes from COOL (thermo sensor OFF) to HEAT if Ta lowers below Tsc -1.5.

(2) The GA control after determination of operation mode follows the

description in No. 4.

(3) The room temperature control and temperature correction follow

the descriptions in No. 3 and No. 15.

Tsc : COOL set temp. Tshc : HEAT set temp. +

room temp. control/ correction

– 18 –

Page 20

INDOOR UNIT CONTROL CIRCUIT (Continued)

NO.

Fan speed control

Item

Overview of specifications

(1) A fan speed HH (quick high), H (high), L (low) or AUTO is selected

according to the instruction from remote controller for FAN mode operation.

(2) Fan speed is switched according to the difference between Ta and

Ts in the AUTO mode.

[Cooling]

Ta (˚C)

+3.0

+2.5

+2.0

+1.5

+1.0

+0.5

Tsc

-0.5

HH (HH)

H+(HH)

H(HH)

L+(H+)

L(H)

L(L+)

• The fan speed control is the same for temperature setting by remote controller or the unit.

• Once fan speed is changed, it remains unchanged for 3 minutes unless different fan speed is selected by instruction.

• At the beginning of cooling, a falling gradient (higher fan speed) is selected.

• When the temperature difference between Ta and Ts is on a threshold line, fan speed does not change.

• ( ): Auto cooling

Remarks

HH>H+>H> L+>L>UL

Wireless type allows HH, H+, H, L+, L, and AUTO.

H+

L+

[Heating]

Ta (˚C)

(-0.5)

(0)

(+0.5)

(+1.0)

(+1.5)

(+2.0)

-1.0

Tsh

+1.0

+2.0

+3.0

+4.0

L( L+)

L+(H)

H(H+)

H+ (HH)

HH (HH)

( ): Temperature setting by remote controller Other than ( ): Temperature setting by unit

• Once fan speed is changed, it remains unchanged for one minute unless different fan speed is selected by instruction.

• At the beginning of heating, a rising gradient (higher fan speed) is selected.

• When the temperature difference between Ta and Ts is on a threshold line, fan speed does not change.

• ( ): Auto heating

• Fan speed is switched to a higher level when Tc reaches 60 °C.

Tc : Indoor unit heat

exchange sensor temp.

– 19 –

Page 21

NO.

Fan speed control

Item

COOL

HH H+

L+

Overview of specifications

HEAT

AP40-56

1220

AP63

1180

H+

1140 1120 1060

L+

1060

990 940

500

1360 1300 1240 1200 1120 1120 1020

970 500

Remarks

AP71-80

1480 1340 1320 1300 1200 1200 1100 1040

500

Cool air prevention control

(3) When thermo sensor turns OFF during heating, the fan speed

mode becomes UL (weak).

(4) When Ta is 25 °C or above at the beginning of HEAT operation or

when canceling defrost mode, H or HH mode continues for one minute from the time when Tc enters zone E shown in the figure in No.7 below.

(5) The HH fan speed for auto cooling/heating is set to a speed higher

than that for normal cooling/heating. However, it varies depending on the temperature difference of Tc during auto heating.

(˚C)

HH+

(1) Performs indoor unit fan control in the HEAT mode according to

the Tc (or Tcj) sensor detect temperature. The maximum speed is limited as shown below.

Tc Tcj

(˚C)

OFF

Shifts Tc control value by +6 °C during defrosting. However, zone B is regarded as zone C after 6 minutes pass from the startup of compressor.

Zone E

Zone D

Zone C Zone B

Zone A

“HEAT PREPARING” indication

Fan speed select setting by remote controller takes precedence in zones D and E. “HEAT PREPARING” is indicated in zones A and B.

– 20 –

Page 22

INDOOR UNIT CONTROL CIRCUIT (Continued)

NO.

Freezing prevention control (low-temp. release)

High-temp. release control

Item

Overview of specifications

(1) Performs the following operation control in the COOL or DRY

mode according to the Tc (or Tcj) sensor detect temperature. When zone J in the figure below is detected for 6 minutes, the specified operating frequency is decreased from the actual operating frequency, and the specified operating frequency is changed every 30 seconds in zone J. Timer count stops and is maintained in zone K. Timer count is cleared to restore normal operation when zone I is detected. If the specified operating frequency becomes SO due to continuation of zone J, return temperature A is raised from 5 to 12 °C, and operation with L fan speed continues until zone I is detected.

Tc(˚C)

If 4-way valve cannot be switched during heating and the following conditions become true, freezing prevention control is performed. (However, zone J entering control temperature is changed from 2 to -5 °C.) [Conditions] The following A or B becomes true after 5 minutes pass from operation start.

A Tcn B Tcn<Tc(n–1)–1 and Tcn

Tc(n–1)–5

Ta<5°C

(1) Performs the following operation control in the HEAT mode

according to the Tc (or Tcj) sensor detect temperature.

•

When zone M is detected, the specified operating frequency is decreased from the actual operating frequency, and the specified operating frequency is changed every 30 seconds in zone M.

• The specified operating frequency is maintained in zone N.

• When zone L is detected, the specified operating frequency is returned by approx. 6 Hz every 60 seconds.

Factory setting

Control temp. (°C)

Tc Tcj

(˚C)

56 (54) 52 (52)

Remarks

Tcj : Indoor unit heat

exchange sensor temp.

Tcn :

Tc after 5 minutes from operation start

Tc (n-1):

Tc at operation start

This control is disabled for twin follower indoor units.

Note) At the beginning of operation or when Tc (or Tcj) lowers below

30 °C after operation start, values (54) and (52) in the table are used as control temperature.

10 Runs indoor unit fan in L (low) mode for about 30 seconds after HEAT

Residual heat removal

operation stops to remove residual heat.

– 21 –

Even when the thermo is set to OFF, the control is implemented in the same way.

Page 23

NO.

Item

Flap control

Overview of specifications

(1) During the first operation after power on, flap position is controlled

automatically according to operation mode (COOL/HEAT).

Cooling Heating

Remarks

Louver angle: 0 °C (full close)

Full close

45°

103°

(2) When louver position is controlled by remote controller, the unit’s

microcomputer memorizes the position for use in the next operation.

* The memorized louver position is cleared when power is turned

off, and returns to the state of (1) above.

(3) Flap position setting

• Flap position can be set within the range below.

COOL/DRY HEAT/FAN

• Flap position can be set collectively or individually in the group twin or triple operation mode. (Wireless remote controller allows individual setting only.)

(4) Swing setting

• Flap moves within the range below.

All operation modes

• Flap swing range can be set collectively or individually in the group twin or triple operation mode. (Setting by wireless remote controller is disabled when the main remote controller is used.)

(5) When air conditioner operation stops, flap closes automatically. It

keeps its position in the event of an alarm. (6) Flap tilts upward automatically during preparation for heating. (7) In the twin or triple operation mode selected by wireless remote

controller, swing setting interlocks with the header indoor unit. If

this setting is transmitted from a follower indoor unit, operation

does not change with a reception sound “pi, pi, pi” if operation

mode differs between header unit and follower unit.

0°

Alarm : A code number

(except F08 and L31) appears on the remote controller and the indoor unit stops.

– 22 –

Page 24

INDOOR UNIT CONTROL CIRCUIT (Continued)

NO.

Item

HA control

Overview of specifications

(1) When connected to a remote control system (tele-control or

remote on/off interface), operation ON/OFF can be controlled by

the HA signal input. (2) Outputs operation ON/OFF status to the HA output terminal. (3) HA signal input/output specifications conform to the JEMA

standard.

Remarks

A connector (separately available) is required when using the HA terminal CH61 for remote ON/OFF control.

When group operation is in use, connect the connector to either header or follower indoor unit.

Filter sign indication (unavailable for wireless type)

(1) Transmits filter replacement signal to remote controller for

indication on the LCD when accumulated operation hours of

indoor unit fan exceeds the specified time (150 hours).

(2) Clears accumulation timer upon receiving the filter reset signal

from remote controller. At this time, when the specified time has

already passed, the accumulated time is reset and the filter sign

disappears from the LCD.

“FILTER” lamp ON

– 23 –

Page 25

NO.

15 (1) Power-saving operation is available in the AUTO mode.

Item

Central control mode switching

Power-saving control

Maximum frequency limit control

(1) The scope of operation by remote controller on the indoor unit

side can be switched by the setting of remote controller. (2) Scope of operation by remote controller on the indoor unit side

[Individual] : All settings and ON/OFF operations are available.

[Central 1] : ON/OFF operations are disabled.

[Central 2] : ON/OFF operations, operation mode selection, and

[Central 3] : Operation mode selection and temperature setting

[Central 4] : Operation mode selection is disabled.

(2) The set temperature is corrected using various sensor data within

the range where comfort is maintained. (3) By using various sensor data including room temp. Ta, outside air

temp. To, fan speed, and indoor unit heat exchange sensor temp.

Tc, 20-minute data is averaged to calculate a set temperature

correction value. (4) The set temperature is corrected every 20 minutes with the

following shift range.

Cooling : +1.5 to -1.0K

Heating : -1.5 to +1.0K

(1) This control is performed when AUTO mode is selected. (2) COOL mode: When To is under 28 °C, the control is as follows.

Ta(˚C)

Tsc

Overview of specifications

temperature setting are disabled.

are disabled.

Normal control

Maximum frequency is limited to the rating of cooling.

Remarks

No indication “CENTRAL CONTROL”

lamp ON “CENTRAL CONTROL”

lamp ON

When wired remote controller is not used, operation range is the same as above though lamp indication remains unchanged.

If an unavailable operation mode is transmitted from wireless remote controller, it is indicated with a reception sound “pi, pi, pi, pi, pi”.

(3) HEAT mode: When To is over 15 °C, the control is as follows.

Ta(˚C)

Tsh

-3

-4

Normal control

Maximum frequency is limited to the rating of heating.

– 24 –

Page 26

INDOOR UNIT CONTROL CIRCUIT (Continued)

7-3. P. C. Board of Indoor Unit

MCC-1510

HA (T10)

CN61, DC12V

Option output

CN60, DC12V

CHK

CN71, DC5V

DISP

CN72, DC5V

External alarm input

CN80, DC12V

EXCT

CN73, DC5V

R/C power LED

D203

TA sensor

CN104, DC5V

Remote controller

CN41, DC20V

TC sensor TCJ sensor

CN101, DC5V CN102, DC5V D02

Microcomputer run LED

EEPROM

IC10 CN67, AC200V

Indoor unit - outdoor unit wire

Optional power supply

CN309, AC200V

Central control

CN40, DC

Terminating resistor provided/not provided

Remote controller A/B selection

SW01

FAN DRIVE

CN32, DC12V

Indication output/wireless receptionDC fan input/outputLouver

CN213, DC5VCN210CN33, DC12V

– 25 –

Page 27

7-4. Optional Onboard Connector Specifications

Description

Factory setting OFF: No terminating resistor ON for one unit when performing

central control by custom air conditioner only.

Factory setting OFF: Remote controller A

Specification

OFF: No terminating resistor

ON: Terminating resistor provided

OFF: R/C A, ON: R/C B

Bit 1

Pin No.

Connector No.

Bit 2

SW01

Single operation setting is performed with VENT button on the remote controller

(DN=31)

Factory setting: Interlocking with indoor unit operation ON/OFF

HA ON/OFF input (J01: input/no input=pulse (factory setting) / static input

changeover)

Enables/disables operation OFF by remote controller using the R/C prohibition

input.

ON during operation (answerback of HA)

DC12V

CN32

ON/OFF input

Output

CN61

OV (COM)

R/C prohibition input

Operation ON output

DEFABCDEFAB

ON during alarm

ON while outdoor unit is defrosting

DC12V (COM)

Alarm output

DC12V (COM)

Defrost output

CN60

ON when thermo sensor is ON (compressor ON)

ON in cooling mode (COOL/DRY/auto cooling)

ON in heating mode (HEAT/auto heating)

ON while indoor unit fan is ON

Factory setting: External alarm input setting (DN: 2A=2)

Indicates alarm code “L30” when an alarm continues for one minute and

performs forcible operation OFF.

(DN: 2A=1) Performs option alarm input control (indication of unit protection

attached externally).

* Remote control performs setting of option alarm input controller.

Used for checking indoor unit operation. (Outputs specified operations such as indoor

Thermo sensor ON output

COOL output

HEAT output

FAN output

DC12V (COM)

Filter/option/external alarm input

CN80

Check mode input

ABA

CN71

unit fan speed H, without communication with outdoor unit or remote controller.)

DISP mode enables communication only between indoor unit and remote

controller. (at power on)

Timer short-circuited (always)

Turns OFF indoor unit thermo sensor forcibly.

Display mode inputOVDemand input

CN72

CN73

Function

Terminating resistor

Remote controller A/B

Ventilation output

Option output

– 26 –

External

alarm input

CHK Operation

check

DISP DISP mode

EXCT Demand

Page 28

8. Troubleshooting

1. Guide to Troubleshooting

[Wired Remote Controller Type]

(1) Before starting troubleshooting

(a) Necessary tools/measuring equipment

• Phillips screwdrivers, flat-blade screwdrivers, wrenches, pliers, nipper, etc.

• Multimeter, thermometer, pressure gauge, etc.

(b) Precheck

A The following operations are normal.

1) Compressor does not work.

• Is 3-minute delay operation functioning? (for 3 minutes after compressor OFF)

• Is thermo sensor OFF?

• Is FAN mode or TIMER mode operation going?

• Is water overflow alarm detected?

• Is high outside air temperature operation control working during heating?

2) Indoor unit fan does not work.

• Is cool air prevention control working during heating?

3) Outdoor unit fan does not work or its fan speed changes.

• Is high-temp. release operation control working during heating?

• Is low outside air temperature operation control working during cooling?

• Is defrosting operation going?

4) Operation ON/OFF by remote controller is disabled.

• Is any remote controller or external control working?

• Is auto address setting in progress? (At t he first power on or when indoor unit address is changed, operation control is disabled for about 5 minutes after power on.)

B Are all cables/wiring set in the initial state? C Are indoor unit and remote controller connected correctly?

(2) Troubleshooting procedure

When an error occurs, check the unit in the following procedure.

Error Check indication of check code Check faulty location and parts

(Note) Other than the check items in the table, malfunction or wrong diagnosis of microcomputer

due to effect of power or external noise is considered. If there is any source of noise, shield the remote controller wiring.

→→

[Wireless Remote Controller Type]

(1) Before starting troubleshooting

(a) Necessary tools/measuring equipment

• Phillips screwdrivers, flat-blade screwdrivers, wrenches, pliers, nipper, etc.

• Multimeter, thermometer, pressure gauge, etc.

(b) Precheck

A The following operations are normal.

1) Compressor does not work.

• Is 3-minute delay operation functioning? (for 3 minutes after compressor OFF)

• Is thermo sensor OFF?

• Is FAN mode or TIMER mode operation going?

• Is high outside air temperature operation control working during heating?

2) Indoor unit fan does not work.

• Is cool air prevention control working during heating?

– 27 –

Page 29

3) Outdoor unit fan does not work or its fan speed changes.

• Is high-temp. release operation control working during heating?

• Is low outside air temperature operation control working during cooling?

• Is defrosting operation going?

4) Operation ON/OFF by remote controller is disabled.

• Is forcible operation OFF mode set?

• Is any remote controller or external control working?

• Is auto address setting in progress? (At the first power on or when indoor unit address is changed, operation control is disabled for about 5 minutes after power on.)

B Are all cables/wiring set in the initial state? C Are indoor unit and receiver unit connected correctly?

(2) Troubleshooting procedure

When an error occurs, check the unit in the following procedure.

Error Check indication of lamps Check faulty location and parts

→→

(Note) Other than the check items in the table, malfunction or wrong diagnosis of microcomputer

due to effect of power or external noise is considered. If there is any source of noise, shield the signal lines.

(a) Outline of judgment

The following describes the primary judgment of locating faulty unit (indoor unit or outdoor unit). (In the case of group control operation, the header unit also indicates errors of follower unit by lamp.)

Judging from lamp status of indoor unit

The indoor unit monitors the operating status of air conditioner. When the protection circuit is activated, the indoor unit indicates the following self-diagnosis contents.

: OFF : ON : Blinking (0.5 seconds interval)

Lamp indication

TIMER PREPARINGOPERATION

All OFF

TIMER PREPARINGOPERATION

Blinking

TIMER PREPARINGOPERATION

Check code

–

E01

E02

E03 E08 E09 E18

E04

Power OFF Poor connection/contact between receiver/indication unit and indoor unit control board

Reception error Transmission error Communication error

Duplication of indoor unit No. Duplication of remote controller header

Poor connection/contact between indoor units or indoor unit power OFF (Communication error between header and follower indoor units or between twin header and follower indoor units)

Wrong connection or poor contact between indoor unit and outdoor unit (Communication error between indoor and outdoor units)

Possible causes

Wired remote controller

Wrong connection or poor contact between wired remote controller and indoor unit

Invalid setting

Blinking

TIMER PREPARINGOPERATION

Alternate blinking

P12

Failure of indoor unit DC fan (Protection device of indoor unit is activated.)

– 28 –

Page 30

Troubleshooting (Continued)

Outline of judgment (Contenued)

Lamp indication Check code

TIMER PREPARINGOPERATION

Alternate blinking

TIMER PREPARINGOPERATION

Alternate blinking

TIMER PREPARINGOPERATION

Alternate blinking

TIMER PREPARINGOPERATION

P03 P04

P19 P22 P26 P29 P31

F01 F02 F10

F04 F06 F08

F29

Possible causes

Abnormal outdoor unit discharge temperature Outdoor u

nit high-pressure system error

(*) Protection device

of outdoor unit is activated.

Four-way valve system error (judged by indoor unit) Outdoor unit: Malfunction of fan

Outdoor unit: Inverter Idc activated Outdoor unit: Position detect error

Protection device of outdoor unit is activated.

Header and follower indoor units in the group are not running due to the following alarm. (Alarm code: E03, L03, L07, L08)

Heat exchange sensor (TCJ) error Heat exchange sensor (TC) error

Indoor unit sensor error

Room temperature sensor (TA) error

Discharge temperature sensor (TD) error Temperature sensor (TE, TS) error Outside air temperature sensor (TO) error

(*) Outdoor unit

sensor error

Failure of indoor unit EEPROM

Simultaneous blinking

TIMER PREPARINGOPERATION

Blinking

TIMER PREPARINGOPERATION

Simultaneous blinking

H01 H02 H03 H06

L03 L07 L08 L09

Compressor breakdown Compressor locking Current detect circuit error Outdoor unit low-pressure system error

Duplication of header indoor unit Group connection indoor unit for

→

individual indoor unit Group address not set No setting (indoor unit capacity)

(*) Outdoor unit

Auto address

*If group configuration

or address at power on is invalid, the unit enters address setting mode automatically.

TIMER PREPARINGOPERATION

L20 L29 L30

L31

Duplication of indoor unit collective address Other errors of outdoor unit (*) External interlock error Phase sequence error

Simultaneous blinking

(*) Check code detected by outdoor unit is a typical example. It varies with outdoor unit of combination.

For details, see the Service Guide of applicable outdoor unit.

compressor system error

Others

– 29 –

Page 31

Others (Excluding check code)

Lamp indication Check code

TIMER PREPARINGOPERATION

Simultaneous blinking

TIMER PREPARINGOPERATION

Alternate blinking

–

Trial operation in progress

Invalid setting (Auto cooling/heating setting for auto cooling/heating unavailable unit or heating setting for cool only unit)

Possible causes

Error mode detected by remote controller or central controller

Diagnosis function

Check code

indication

(remote controller disabled)

E01

E02

E09

L20

Central

controller

L20

–

Central

controller

(Transmission)

C05

(Reception)

C06

–

Central

controller

P30/b7

No check code can be indicated by wired remote controller. (Normal operation of air conditioner cannot be controlled by wired remote controller.) Check codes are indicated by the lamps for wireless models.

*3 This is an error related to communication of remote controller (A, B) or central control system (TCC-LINK U3, U4).

Remote controller indicates E01, E02, E03, E09, E18 or no code according to situation.

Possible causes

No communication with header indoor unit Remote controller is not connected correctly. Indoor unit is not powered on. Auto address setting is not completed.

No communication with header indoor unit Disconnection between remote controller and header indoor unit (detected by R/C)

Signal transmission error to indoor unit (detected by R/C)

Multiple remote controller headers (detected by R/C)

Duplication of indoor unit collective address during communication of central control system (detected by indoor unit/ central controller)

Failure of central control communication circuit (detected by central controller)

Failure of indoor unit group follower unit.

Air conditioner status

OFF

OFF (auto reset) *Operation

continues under central control

OFF (auto reset) *Operation

continues under central control

OFF (Follower R/C continues operation)

OFF (auto reset)

Operation continues (following R/C)

Continue/OFF (depending on situation)

Conditions

–

Indicated when an error is detected

Judgment and action

Failure of remote controller power supply or indoor unit EEPROM

1.Check remote controller wires.

2.Check remote controller.

3.Check indoor unit power wiring.

4.Check indoor unit P. C. board.

5.Check indoor unit EEPROM and insertion into socket.

Auto address repetition occurs.

...

Remote controller signal reception error

1.Check remote controller wires.

2.Check remote controller.

3.Check indoor unit power wiring.

4.Check indoor unit P. C. board. Remote controller transmission error

Check remote controller transmitter. ... Replace remote controller.

Check for multiple remote controller headers. ... One header only, others are

follower R/C.

1.Check central control network address setting.

1.Check communication line, wrong connection, and indoor unit power supply.

2.Check communication circuit (U3, U4, XY terminals).

3.Check central controller (including central control R/C).

4.Check terminating resistors (TCC-LINK).

Check the unit's check code with remote controller

– 30 –

Page 32

Troubleshooting (Continued)

Check Code Table (Indoor Unit)

Operation

continuation

A/C operation

Auto

reset

–

Operation

continuation

Auto

reset

–

A/C operation

–

A/C operation

Operation

Auto

continuation

reset

–

Description of failures

No signal from remote controller (no communication with central controller system)

When indoor unit – out door unit serial communication is abnormal

When same address as mine is detected

When communication between main motor microcomputers is abnormal

When communication between header and follower indoor units is disabled

When open-circuit or short-circuit of TCJ is detected

When open-circuit or short-circuit of TC is detected

Main faulty location

Indoor unit – R/C communication error

Indoor unit – out door unit serial communication error

Duplication of indoor unit address

Communication error between indoor unit MCUs

Communication error between header and follower indoor units

Indoor unit heat exchange sensor TCJ

Indoor unit heat exchange sensor TC

When open-circuit or short-circuit of TA is detected

Failure of EEPROM (Other errors are also detected in some cases.

Auto address repeated with no other errors.)

When multiple header units exist in the group

When there is at least one group connection indoor unit in individual indoor unit

When indoor group address is not set

Indoor unit room temp. sensor TA

Indoor unit other boards

Duplication of indoor group header unit setting

Group line in individual indoor unit

Indoor group address not set

Indoor unit capacity is not set.

Duplicated central control refrigerant line address is set.

Alarm stop by external alarm input (CN80)

When indoor unit AC fan alarm is detected (Fan motor thermal relay is activated.)

When float switch is turned on

When indoor unit DC fan alarm (overcurrent, locking, etc.) is detected

When an alarm is detected during heating due to temperature drop of

heat exchange sensor

Follower units in the group are disabled due to alarm (E03/L03/L07/L08) of header unit

Indoor unit capacity not set

Duplication of central control refrigerant line address

External alarm input into indoor unit (interlock)

Indoor unit AC fan

Indoor unit water overflow

Indoor unit DC fan

Four-way valve system

Other indoor unit errors

Description of failures

When signals cannot be received from indoor unit or when header R/C is

not set (including two R/Cs)

When signal transmission to indoor unit is disabled

When two remote controllers are set as header by double R/C control

(Header unit stops alarm, and follower continues operation.)

Main faulty location

No header R/C, R/C reception error

R/C transmission error

Duplication of header R/C

:When this alarm is detected before checking group configuration and address at power on, the unit enters auto address setting mode automatically.

Description of failures

When transmission of central control signals is disabled or when there

are multiple central controllers with same address (AI-NET)

Main faulty location

Central control system transmission error

When signal transmission to indoor unit is disabled

A device connected to general equipment control interface (for TCC-

LINK/AI-NET only) is abnormal.

Group follower unit is abnormal. (R/C indicates unit No. and details.)

Central control system reception error

General equipment control I/F total alarm

Group follower unit error

Lamp indication

ON, Blinking, OFF, Alternate: Two LEDs blink alternately, Simultaneous: Two LEDs blink simultaneously

Check code

(Detected by indoor unit)

Blinking

Block indication

OPERATION TIMER PREPARING

E03

E04

E08

and remote controller

TCC-LINK central control

E10

E18

Alternate

F01

Alternate

F02

Alternate

Simultaneous

F10

F29

Simultaneous

L03

L07

L08

Simultaneous

L09

L20

L30

Alternate

P01

Alternate

P10

P12

– 31 –

Alternate

P19

Alternate

Lamp indication

P31

Check code

(Detected by remote controller)

Blinking

Block indication

OPERATION TIMER PREPARING

E01

E02

Remote controller

E09

Blinking

Block indication

Lamp indication

OPERATION TIMER PREPARING

control

Check code

TCC-LINK central

(Detected by central controller)

–

(when R/C is used together)

No indication

C05

C06

C12

Depends on alarm No. above

P30

Note: Check code varies in some cases depending on the unit which detects errors even if its content is the same.

Check codes detected by R/C or central controller are not always related to air conditioner operation. This table does not include check codes detected by outdoor unit or thermal storage unit.

Page 33

Check Code Table (Outdoor Unit)

Operation

continuation

A/C operation

Auto

reset

Description of failures

Lamp indication

ON, Blinking, OFF, Alternate: Two LEDs blink alternately, Simultaneous: Two LEDs blink simultaneously

Typical error of thermal storage unit (Details are checked by R/C.)

When open-circuit or short-circuit of TD is detected

Main faulty location

Thermal storage unit error

Outdoor unit heat discharge sensor TD error

Blinking

Simultaneous

Alternate

Block indication

OPERATION TIMER PREPARING

When open-circuit or short-circuit of TE,TS is detected

When open-circuit or short-circuit of TO is detected

Short-circuit current Idc after direct current excitation is detected when

reaching minimum frequency in current release control.

When compressor locking is detected

Outdoor unit temp. sensor TE, TS error

Outdoor unit outside air temp. sensor TO error

Compressor breakdown

Compressor locking

Alternate

Other outdoor unit errors 1) MCU communication error between PDU and

CDB, 2) IGBT heatsink temp. detect error

When phase sequence of 3-phase current is abnormal (thermo sensor

OFF operation continued) or other errors

When discharge temperature release control detects an error

When abnormal current is detected by AC-CT or when phase loss is

detected

Ps pressure sensor error. Low-pressure protection circuit is activated.

Current detect circuit error

Low-pressure system error

Other outdoor unit errors

Phase sequence error or others

Simultaneous

When high-pressure switch or IOL is activated or when high-pressure

Abnormal outdoor unit discharge temperature

High-pressure system error

Alternate

release control by TE detects an error

When outdoor unit fan drive circuit error (overcurrent, locking, etc.) is

detected

When short-circuit prevention control for compressor drive circuit devices

(G,Tr, IGBT) is activated

When compressor motor position error is detected

Outdoor unit fan alarm

Inverter Idc activated

Position detect error

Alternate

C15

Check code

and remote controller

TCC-LINK central control

(Main errors detected by outdoor unit)

F04

F06

F08

H01

H02

H03

H06

L29

L31

P03

P04

– 32 –

P22

P26

P29

applicable outdoor unit.

Note: The above check codes are typical examples. They vary with outdoor unit (including thermal storage unit) of combination. For details, see the Service Guide of

Page 34

Troubleshooting (Continued)

Check Code Table

Failure mode detected by indoor unit

Check code

E03

E04

E08

L03

L07

L08 L09

L30

P12

P19

P31

F01

F02

F10

F29

E18

Diagnosis function

Possible causes

No signal reception from remote controller

Serial signal from outdoor unit does not reach indoor unit.

• Wrong wire connection

• Failure of outdoor unit serial transmitter

• Failure of indoor unit serial receiver

Duplication of indoor unit address

Duplication of header indoor unit

Group line in individual indoor unit

Indoor unit group address not set Indoor unit capacity not set

External interlock alarm input

Failure of indoor unit DC fan

Failure of 4-way valve system

• Indoor unit heat exchange temperature lowers after HEAT operation starts.

Indoor unit OFF during alarming to other indoor units

Improper mounting, disconnection or short-circuit of indoor unit heat exchange sensor TCJ

Improper mounting, disconnection or short-circuit of indoor unit heat exchange sensor TC

Improper mounting, disconnection or short-circuit of indoor unit room temp. sensor TA

Failure of indoor unit EEPROM

• EEPROM access error

Communication error between header and follower indoor units

Air conditioner status OFF

(auto reset)

OFF (auto reset)

OFF

OFF (auto reset)

OFF (follower units) (auto reset)

OFF (auto reset)

Indicated when an error is detected

Conditions

Judgment and action

1.Check remote controller wiring.

• No indication on remote controller LCD (disconnection)

•

Central controller [C06] check code

When outdoor unit does not work at all

• Check wires, correct wrong connection.

•

Check outdoor unit boards and wiring

2.When outdoor unit works normally Check boards (indoor unit receiver, outdoor unit transmitter)

1.Check remote controller connection (group/individual) change after power on.

* If group configuration or address is

not correct, the unit enters auto address setting mode automatically for address re-setting.

1.Set indoor unit capacity (DN=11)

1.Check external devices.

2.Check indoor unit boards.

1. Position detect error

2.Overcurrent protection circuit operation of indoor unit fan driver

3. Indoor unit fan lock

4. Check indoor unit boards.

1.Check 4-way valve.

2.Check 2-way valve/check valve.

Check indoor unit heat exchanger (TC/TCJ)

4.Check indoor unit boards.

1.Judging follower unit when header unit is E03, L03, L07 or L08

2.Check indoor unit boards.

1.Check TCJ.

2.Check indoor unit boards.

1.Check TC.

2.Check indoor unit boards.

1.Check TA.

2.Check indoor unit boards.

1.Check indoor unit EEPROM and insertion into socket.

2.Check indoor unit boards.

1.Check remote controller wiring.

2.Check indoor unit power wiring.

3.Check indoor unit boards.

– 33 –

Page 35

Failure mode detected by outdoor unit (Representative codes)

• The check code used varies depending on the combination with the outdoor unit.

Diagnosis function

Check code Possible causes

H01

H02

H03

H06*1

L29

L31*1

P03

P04

P22

P26

P29

F04

F06

F08

*1 ROA-P*** is not detected by 1HS models.

Fan continues rotating in a failure mode detected by outdoor unit because there is no communication between outdoor unit and follower indoor unit in twin group.

Compressor breakdown

• Compressor stops due to operating frequency decrease.

Compressor does not work.

• Overcurrent protection circuit is activated after a certain time from compressor startup.

Failure of current detect circuit

• Large AC current even during compressor OFF

• Phase loss in power supply

Low-pressure switch ON (applicable models) COOL : 30 seconds HEAT : 10 minutes

Other outdoor unit errors

• CDB-IPDU communication error (connector disconnection)

• Abnormal heatsink temperature (over specified value)

Phase detection protection circuit activated (normal models)

Abnormal discharge temperature (over specified value)

Failure of high-pressure protection circuit (Temperature over specified value detected by TE sensor) High-pressure switch (normal models)

Failure of outdoor unit DC fan

Inverter overcurrent protection circuit activated (short time) Main circuit short voltage operation

Failure of IPDU position detect circuit

Improper mounting, disconnection or short-circuit of outdoor unit temp. sensor TD

Improper mounting, disconnection or short-circuit of outdoor unit temp. sensor TE, TS

Improper mounting, disconnection or short-circuit of outdoor unit outside air temp. sensor TO

Air conditioner status OFF

OFF

Operation continued (compressor OFF)

OFF

Operation continued

Indicated when an error is detected

Conditions

Check power voltages (200±20 VAC).

2.Freezing cycle overload operation

Check current detect circuit on the AC side

1.Failure of compressor (lock, etc.) ... Replace the compressor.

Improper compressor wiring (phase loss)

3.Lost-phase operation of power supply (3-phase models)

Operation stops soon when restarted

1. ... Check IPDU.

Lost-phase operation of power supply Check 3-phase power voltages and wiring.

1.Check freezing cycle (gas leakage).

2.Check low-pressure switch circuit.

3.Check outdoor unit CDB board.

1.Check CDB/IPDU wiring.

2.Freezing cycle overload operation

1.Check phase sequence, reverse phase, and phase loss.

2.Check outdoor unit boards.

3.Check high-pressure switch.

Check high-pressure switch circuit wiring.

Check freezing cycle (gas leakage).

Failure of electronic expansion valve

3.Check piping sensor (Td).

1.Freezing cycle overload operation

2.Check outdoor unit TE sensor.

3.Check outdoor unit CDB board.

Check high-pressure switch and circuit.

1.Position detect error

2.Overcurrent protection circuit operation of outdoor unit fan driver

3.Outdoor unit fan lock

4.Check outdoor unit CDB board.

Operation stops soon when restarted. ... Compressor partial short-circuit

2.Check IPDU for improper wiring.

1.The circuit is activated even after compressor’s 3P connector is

disconnected. ...Replace IPDU.

1.Check TD.

2.Check outdoor unit CDB board.

1.Check TE, TS.

2.Check outdoor unit CDB board.

1.Check TO.

2.Check outdoor unit CDB board.

Judgment and action

– 34 –

Page 36

Troubleshooting (Continued)

Troubleshooting by Remote Controller Check Indication

Main Remote Controller (RBC-AMT31E)

(1) Checking

When an error occurs in the air conditioner, a check code and an indoor unit number appear on the LCD of remote controller. Check code is displayed only during operation. If indication disappears, check errors following

Check code

“Checking Error Log” below.

(2) Checking Error Log

When an error occurs in the air conditioner, error log can be checked following the steps below. Up to 4 errors are memorized. Error log can be checked in both operation ON and OFF states.

Step Operation

Press [SET] and [TEST] at the same time for 4 seconds or more. The LCD indication changes as shown below. Indication of “SERVICE CHECK” shows that the unit is in the error log mode.

• Code No. “01” (order of error log) is displayed.

• A check code is displayed.

• The address of faulty indoor unit is displayed in the UNIT No. area.

Faulty indoor unit No.

Each pressing of TEMP. ∆/∇ buttons displays stored error log sequentially. Check code “01” shows the latest error, and “04” shows the oldest.

Note

Do not press [CL] as this button clears entire error log of indoor unit.

After checking the error log, press [TEST] to return to the normal indication.

Numbers appearing on the LCD <Seven-segment display>

Hexadecimal number

– 35 –

Page 37

TCC-LINK Central Control Remote Controller (TCB-SC642TLE)

(1) Checking

Indication of unit number

UNIT No.

R.C. No.

Indication of alarm

CHECK

Alternate blinking

(2) Checking Error Log

When an error occurs in the air conditioner, error log can be checked following the steps below. Up to 4 errors are memorized. Error log can be checked in both operation ON and OFF states.

A Press [SET] and [TEST] at the same time for 4 seconds or more. B Indication of “SERVICE CHECK” and UNIT No. “01” appear. C When selecting a group number (blinking), a unit number and the latest error log, if any, are displayed

alternately. * Temperature setting is disabled at this time.

Indication of unit number

UNIT No.

Alternate blinking

R.C. No.

Indication of alarm

CHECK

D To check other errors, choose a code (01 to 04) with TEMP. ∆/∇ buttons. E To check error log of another group, choose a group number with

/ buttons.

Do not press [CL] as this button clears entire error log of the selected group.

F Press [TEST] to finish the service check.

– 36 –

Page 38

Troubleshooting (Continued)

3. Troubleshooting for Each Check Code

Check code

[E01]

(New code)

Are R/C wires

A/B correct?

Improper harness

connection from

I/U terminal block?

Group control

operation?

YES

Check code name

I/U - R/C communication error

(detected by R/C)

YES

Possible causes

AImproper R/C wire connection BFailure of I/U power supply CFailure of I/U board DInvalid R/C address setting EFailure of R/C board

Correct R/C wires.

Correct connector connection.

Check circuit wiring.

Are all indoor

units powered ON?

YES

Is R/C powered ON?A/B

terminals: Approx. 18VDC

YES

Is “no header”

set by double R/C?

YES

Check I/U power connection

(power off and on).

Check I/U boards.

→ Replace defective board.

Correct one header/one follower.

(R/C address connector)

Check R/C board.

→ Replace it if necessary.

– 37 –

Page 39

Check code

Check code name

Possible causes

[E02]

(New code)

R/C transmission error

Signal transmission to indoor unit is disabled.

* Not indicated on the central controller and outdoor unit 7-segment.

Com. cable between

R/C and I/U connected

properly?

YES

Failure of R/C

transmitter → Replace R/C.

Check code

[E03]

(New code)

Indoor unit (I/U) detects this error when it cannot receive signals from remote controller (R/C). Check communication wiring of R/C A and B. This code E03 is not displayed on the R/C because of communication error. This code is displayed on the TCC-LINK central controller.

Check code name

I/U - R/C communication error

(detected by I/U)

Possible causes

No communication from R/C and communication adapter.

Correct communication cable.

– 38 –

Page 40

Troubleshooting (Continued)

Check code

[E04]

(New code)

Does O/U work?

YES

Check code name

I/U - O/U communication error

(detected by I/U)

NO NO

Is group address set correctly?

Are 1/2/3 wires normal?

Are connectors from I/U and

O/U connected normally?

Is I/U switch SW02

setting correct? Bit 1, 2: OFF

AImproper connector connection between I/U and O/U BImproper wire connection between I/U and O/U CFailure of I/U or O/U board DCase thermo sensor ON EInvalid I/U board switch setting

YES

Possible causes

Check code “14”.

Correct wires.

Correct connector connection.

Correct switch setting on

MCC-1510 board.

Check I/U boards.

® Replace defective board.

Does voltage between

I/U terminal 2 and 3 fluctuate?

(0-140 VDC)

* Measure within

YES

Is 280VDC

applied across IPDU main

circuit capacitor?

YES

Is 280VDC supplied to

CDB? (CN03)

YES

Is 7VDC supplied

to CDB? Is CN06-CN800

connection normal?

YES

Is case thermo sensor

connected? (CN500)

YES

Is case thermo sensor working?

YES

Check and correct refrigerant volume.

20 seconds from power on.

Check MCC-1510 board.

→ Replace it if necessary.

Black

White

B A

Terminal block

Replace IPDU.

Correct connector connection.

Check MCC-1510 board.

→ Replace it if necessary.

Check CDB. → Replace it if

necessary.

– 39 –

Page 41

Check code

Check code name

Possible causes

[E09]

(New code)

Are 2 headers set by double R/C?

Check code

[E18]

(New code)

Are A/B wires

normal?

Improper harness

connection from I/U terminal

block?

Communication error between header

YES

Duplication of R/C header

YES

Check code name

and follower I/U

YES

R/C header setting is duplicated.

Correct one header/one follower.

(R/C address connector)

Check R/C board.

→ Replace it if necessary.

Possible causes

A Improper wire connection between I/U B Improper wire connection between I/U and O/U C Failure of I/U board D Invalid I/U board switch setting

Correct R/C wire connection.

Correct connector connection.

Check circuit wiring.

Is I/U switch SW02

setting correct?

Bit 1, 2: OFF

YES

Group control operation?

YES

Are all indoor

units powered ON?

YES

Twin or triple control?

YES

Improper signal

connection between I/U

and O/U?

YES

Correct switch setting on

MCC-1510 board.

Check I/U power connection

(power off and on).

Correct signal wire connection

between I/U and O/U.

Check MCC-1510 board.

→ Replace it if necessary.

– 40 –

Page 42

Troubleshooting (Continued)

Check code

[F01]

(New code)

Is TCJ connector

CN102 connected

normally?

YES

Is TCJ resistor

characteristic

normal?

* See I/U temp. sensor characteristics-2.

YES

Check I/U main board.

→ Replace it if necessary.

Check code name

I/U sensor TCJ error

Possible causes

I/U sensor TCJ error

Correct connector connection.

Replace sensor TCJ.

Check code

[F02]

(New code)

Is TC connector

CN101 connected

normally?

YES

Is TC resistor characteristic

normal?

* See I/U temp. sensor characteristics-2.

YES

Check I/U boards.

→ Replace defective board.

Check code name

I/U sensor TC error

Possible causes

Sensor TC open or short-circuit

Correct connector connection.

Replace sensor TC.

– 41 –

Page 43

Check code

Check code name

Possible causes

[F10]

(New code)

Is TA connector

CN104 connected

normally?

YES

Is TA resistor

characteristic

normal?

YES

Check MCC-1510 board.

Replace it if necessary.

Check code

I/U sensor TA error

Sensor TA open or short-circuit

* See I/U temp. sensor characteristics-1.

Check code name

Correct connector connection.

Replace sensor TA.

Possible causes

[F29]

Other indoor unit errors

Failure of I/U board

(New code)

This is an error of non-volatile EEPROM IC10 on the indoor unit board, which occurs during operation. Replace the service board.

* If EEPROM is not mounted at power on or if no data can be read/written from/in the EEPROM,

auto address mode is repeated. At this time, the AI-NET central controller indicates code “97”.

(About 3 minutes) (About 1 minutes)

(Power on)

“SETTING” appears on the R/C.

“SETTING” disappears.

(Repeated)

LED (D02) on the I/U board blinks for about 10 seconds (1Hz).

Reboot (reset)

– 42 –

Page 44

Troubleshooting (Continued)

Check code

[F31]

(New code)

Is O/U free from

power fluctuation?

YES

Check CDB board.

Check code name

O/U EEPROM error

AFailure of O/U power supply (voltage, noise, etc.) BFailure of O/U CDB board.

Check code

[E08][L03][L07][L08]

(New code/old code)

E08: I/U number duplicated L03: Multiple header I/U under group control L07: One or more group address “individual” under group control L08: I/U group address not set (99)

Possible causes

Check power voltage.

Improve power lines.

Check external noise.

When any of these codes is detected at power on, the unit enters auto address setting mode automatically. (No code is indicated.) However, if any of these codes is detected in the auto address setting mode, a check code is displayed in some cases.

Check code

[L09]

(New code)

Is indoor unit capacity set?

YES

Check code name

Indoor unit capacity not set

Possible causes

Set I/U capacity data. (DN=11)

Check MCC-1510 board. → Replace it if necessary.

– 43 –

Page 45

Check code

Check code name

Possible causes

[L20]

(New code)

Are U3/U4

communication

cables connected

normally?

When a unit

connected to U3/U4

is in a group, is it set

to header unit?

Check and correct I/U address,

central control address.

Duplication of central control address

YES

Central control address is duplicated.

Correct cable connection.

Set the connected unit to

header unit.

Check code

[L30]

(New code)

Is external device

connected to CN80?

YES

Is external device working normally?

YES

Check possible error

causes.

Check code name

I/U external interlock

Possible causes

When an external alarm is input

Check I/U boards.

→ Replace defective board.

Check external device.

→ Replace it if necessary.

– 44 –

Page 46

Troubleshooting (Continued)

Check code

[P12]

(New code)

Turn OFF the breaker.

Turn it ON 10 seconds

after.

Does fan stop with

operation OFF?

YES

Start cooling with LOW

fan speed.

Does fan rotate?

YES

Change fan speed to HH.

Does fan speed

increase?

YES

Fan motor is normal.

Check code name

Malfunction of I/U fan motor

Is min.1VDC present

between CN210 pin

E and C ?

YES

Is min. 280VDC present

between CN210 pin

A and C ?

YES

Is min. 15VDC present

between CN210 pin

D and C with

motor connected?

YES

Operate I/U (except

heating) by R/C. Is min.

1VDC present between

CN210 pin

?(Measure within

and

15 seconds.)

YES

Does cross flow fan

rotate normally by hand?

YES

Rotate the fan by hand with

operation OFF. Is 0 to

15VDC (rev return signal)

generated between CN210

and C ?

YES

A Failure of fan motor connector B Failure of fan motor C Failure of I/U board D Failure of cross flow fan shaft

Stop operation and turn OFF

breaker. Disconnect CN210,

turn ON breaker again, and

then stop operation using R/C.

Is min. 280VDC present

between CN210 pin

and C ?

YES

Stop operation and unplug

AC cord. Disconnect

CN210, plug in AC cable

again, and then stop operation using R/C.

Operate I/U (except heating) by R/C. Is min. 1VDC present between

CN210 pin

? (Measure within

15 seconds.)

YES

and

Possible causes

Replace I/U fan

motor.

Replace I/U MCC-

1510 board.

Repair cross flow

fan shaft.

– 45 –

Page 47

Check code

Check code name

Possible causes

[P12]

(New code)

Check the fan motor output DC voltage on the I/U board.

Check voltage on the motor connector CN210 pin C (GND,

black) and pin E (+V line, yellow) while fan is rotating.

1.0VDC or

Failure of I/U

MCC-1510 board

Malfunction of I/U fan motor

When AC cord is plugged in, I/U fan starts rotating.

higher

Below 1.0VDC

Failure of I/U fan

motor

A Failure of fan motor connector B Failure of fan motor C Failure of I/U board D Failure of cross flow fan shaft

Yello w

Black

P. C. board

(Blue)

(Yellow)

(White)

(Black)

(Red)

– 46 –

Page 48

Troubleshooting (Continued)

Check code

[P31]

(New code)

When header unit detects E03, L03, L07 or L08 during group operation, “P31” is indicated on follower units in the group and their operation stops. No code or alarm log is displayed on the R/C.

Check code name

Other I/U errors

(Group follower I/U error)

When an error occurs with other units in the group

Possible causes

– 47 –

Page 49

Check code

Check code name

Possible causes

[C05], [C06]

(Central controller)

Is I/U

powered ON?

YES

Is harness from I/U

terminal block

connected properly?

YES

Can I/U be

operated by R/C

individually?

YES

Are U3/U4 com. cables. normal?

YES

TCC-LINK central control

TCC-LINK central control communication error

communication error

* Check wrong connection, disconnection, and

shield wire’s contact with com. cable.

Power ON.

Correct connector connection.

Correct com. cable.

When a unit

connected to U3/U4

is in a group, is it

set to header

unit?

YES

Free from noise?

YES

Can other units

controlled by

central R/C? Is I/U

operating status

reflected?

YES

Is the code [C05]?

Is I/U onboard fuse

F03 normal?

YES

Set the connected unit to

header unit.

Remove noise source.

Check central controller. → Replace it if necessary.

Confirm normal connection of

com. cable. Change connector

connection CN40 to CN44

(EMG) on I/U board.

YES

Check I/U boards. → Replace

defective board.

– 48 –

Page 50

Troubleshooting (Continued)

Relationship Between Temperature Sensor Resistance and Temperature

Characteristic-1

Sensor TA

Resistance

[k ]

10 20 30 40

Temperature

200

Resistance

[k ] [k ]

(10°C or lower)

Characteristic-3

[˚C]

Resistance

[k ]

-10

Characteristic-2

Sensor TC, TCJ

10 20 30 40

Temperature

Sensor TE, TO, TS

Resistance

(10°C or higher)

[˚C]

60 70

100

200

Resistance

[k ]

(50°C or lower)

100

Characteristic-4

10 20 30 40

Temperature

[˚C]

60 70-10

Sensor TD

Resistance

[k ]

(50°C or lower)

Temperature

100

[˚C]

– 49 –

Page 51

9. HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT

Requirements When Replacing Service Board of Indoor Unit

The non-volatile EEPROM (IC10) on the board of indoor unit stores important data such as model-specific type and capacity code (written during factory shipping) as well as system/indoor unit/group addresses set automatically/manually (written during installation). Therefore, observe the following procedure when replacing indoor unit service boards. After installation of indoor unit, check whether the settings are correct by checking indoor unit number and group header/ follower unit setting, and also check cycle through a trial operation.

[Replacement Procedures]

Case 1

When it is possible to power ON indoor unit before replacement and when wired R/C can read settings

Reading EEPROM Data *1 (see page 51)

Replacing Service Board and Power ON *2 (see page 51)

Writing Setting Data in EEPROM *3 (see page 52)

Power ON reset (for all indoor units connected to R/C in group control mode)

Case 2

When it is impossible to power ON indoor unit before replacement or when wired R/C is disabled due to failure of power supply circuit (board failure)

Replacing EEPROM (For layout of components and replacement, see page 49.)

Remove the EEPROM on the board, and replace it with the EEPROM on the service board.

Replacing Service Board and Power ON *2 (see page 51)

Reading EEPROM Data *1 (see page 51)

If data cannot be read, go to Case 3.

Replacing EEPROM (For layout of components and replacement, see page 49.)

Replace EEPROM again. (Mount the original EEPROM on the service board.)

Replacing Service Board and Power ON *2 (see page 51)

Writing Setting Data in EEPROM *3 (see page 52)

Power ON reset (for all indoor units connected to R/C in group control mode)

Case 3

When the EEPROM before replacement is defective, and the settings cannot be read

Replacing Service Board and Power ON *2 (see page 51)

Writing Setting Data in EEPROM (using customer information) *3 (see page 52)

Power ON reset (for all indoor units connected to R/C in group control mode)

– 50 –

Page 52

HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT (Continued)

*1 Reading EEPROM Data

(Read EEPROM data that was updated at site in addition to factory setting.)

1) Press

, , and on the R/C simultaneously for 4 seconds or more.

* In the group control mode, the header unit number is displayed first.

At this time, code (DN)

is displayed, and the fan of the selected indoor unit runs, its flap swings,

and the OPERATION, TIMER, and PREPARING lamps blink.

(see page 52)

2) Each pressing of

indicates indoor unit number in the group sequentially.

Specify indoor unit number whose board is to be replaced.

3) Each pressing of TEMP.

buttons increments or decrements DN.

4) Change DN from to first. (Setting of filter sign ON time) Write down the setting data displayed.

5) Change DN with TEMP.

buttons, and write down the setting data displayed.

6) Repeat step 5) in the same way, and write down the important setting data shown in the table (page 49). * DN =

7) After writing down setting data, press

to . DN does not always shift sequentially.

to return the operation mode to normal OFF.

(It takes about one minute until R/C operation is enabled.)

Essential DN codes

11 12 13 14

Description Indoor unit capacity Refrigerant line address Indoor unit address Group address

(1) Indoor unit capacity is necessary for fan speed setting. (2) If refrigerant line address, indoor unit address or group

address differs from that before replacement, the unit enters auto address setting mode, which requires manual re-setting for group operation including twin or triple operation.

*2 Replacing Service Board and Power ON

1) Replace the board with a service board. Reflect the jumper wire (cut) setting and switch setting on the board in the service board. For switch setting and component layout, see page 53.

2) Power ON the indoor unit in either way of the following according to system configuration. a) Single (individual) operation

Power ON the indoor unit with no operation.

i) Go to *3 when auto address setting mode ends (about 5 minutes).

(Refrigerant line address=1, indoor unit address=1, and group address=0 are set automatically.)

ii) Press

address setting mode, and then go to *3. (UNIT No.

, , and on the R/C simultaneously for 4 seconds or more (1) to cancel auto

is indicated.)

b) Group operation (including twin/triple/double twin)

Power ON the indoor unit whose service board is replaced in either way of the following.

i) Power ON the indoor unit only whose service board is replaced in the same way as a) i) and ii)

above. There must be remote controller connection. If not, operation *3 is disabled.

ii) Power ON multiple indoor units including the unit whose service board is replaced.

• Twin, triple, double twin: One system only

• Group control: All indoor units

Go to *3 when auto address setting mode ends (about 5 minutes).

* Header indoor unit may change depending on auto address setting. The refrigerant line address and

indoor unit address of the indoor unit whose service board is replaced are automatically set to an address that is not used in other units. It is recommended that you take a memo beforehand that to which refrigerant system the indoor unit belongs and that the indoor unit is header or follower unit in the group.

– 51 –

Page 53

*3 Writing Setting Data in EEPROM

(The data of the EEPROM on the service board is the factory setting data.)

1) Press * In the group control mode, the header unit number is displayed first.

(If auto address setting mode is canceled in 2-2) a) ii) above, UNIT No. At this time, code (DN) and the OPERATION, TIMER, and PREPARING lamps blink.

, , and on the R/C simultaneously for 4 seconds or more.

is displayed, and the fan of the selected indoor unit runs, its flap swings,

(see page 52)

is indicated.)

2) Each pressing of

indicates indoor unit number in the group sequentially. Specify indoor unit number whose board is replaced. (This operation is disabled if UNIT No. is

3) Each pressing of TEMP.

buttons increments or decrements DN.

4) Set the indoor unit capacity first. The factory setting data is written in the EEPROM. i) Change DN to ii) Set the indoor unit capacity with TIME

with TEMP. buttons.

buttons. 4 (for

example, “0012” for 80 class) ... See the table (page 53).

iii) Press iv) Press

Indication on the LCD shows normal operation. to return the operation mode to normal OFF.

(It takes about one minute until R/C operation is enabled.)

5) Write the data set after installation (such as address) in the EEPROM. Repeat steps 1) and 2) above.

6) Specify DN

with TEMP. buttons. (Setting of filter

sign ON time)

7) Check the displayed data comparing the content written down in *1 (page 49). i) If the data is incorrect, change it with TIME

data of the memo, and then press

Indication on the LCD shows

buttons to the

normal operation.

ii) No operation is required for the same data.

RBC-AMT21E

SETTING

8) Change DN with TEMP.

buttons. In the same way as above, check the displayed data comparing the content of the memo. If the data is incorrect, change it to the data of the memo.

9) Repeat steps 7) and 8) above.

10) When the setting is completed, press mode to normal OFF.

to return the operation

(It takes about one minute until R/C operation is enabled.)

* DN =

updated and restored with

to . DN does not always shift sequentially. Even if data is

button is pressed by mistake, the previous data can be

button unless DN is changed.

RBC-AMT31E

3 5

6 2

– 52 –

Page 54

HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT (Continued)

Example of Setting Contents to be Written Down (Code Table)

Filter sign ON time

01 02

Filter contamination level Central control address

03 06

HEAT intake temp. shift PREPARING indication selection

0C 0F

COOL only Type

10 11

Indoor unit capacity Refrigerant line address

12 13

Indoor unit address Group address

Temp. range at COOL/HEAT auto switching control Auto restart after power failure

Option/alarm input (CN80) selection Thermo output (T10-C) selection

HA terminal (T10-A) selection Ventilation fan (single operation)

31 32

Sensor selection Timer setting (wired R/C)

60 69

Flap setting for cooling Correction of feeling of strong heating

Item

Memo

Must be set to 0008

Factory setting 0001: 150 hours 0000: Average 0099: Not determined 0002: +2°C 0000: Normal 0000: Heat pump type air conditioner 0008: Wall type Depends on capacity type 0099: Not determined 0099: Not determined 0099: Not determined 0003: 3°C (Ts±1.5) 0000: Not provided 0002: External alarm input 0000: Thermo output ON 0000: Operation input 0000: Disabled 0000: Unit sensor 0000: Available 0000: Normal 0000: Not provided

Onboard Component Layout

<MCC-1510>

SW01

2 1

IC10

DIP switch setting

SW01

SW02

*1: Set to the state before replacement

Bit 1 Bit 2 Bit 1 Bit 2

Terminating resistor (for central control) Selection of R/C A or B Selection of custom or multiple Not used

Setting

SW02

1 2

J01

Indoor unit capacity Code “11”

Setting data

0000* 0006 0007

DIP switches (SW01, SW02)

0008 0009 0010 0011 0012

* Default value of EEPROM on the

EEPROM (IC10)

Mount EEPROM aligning its notch with the notch of IC socket.

IC socket Notch EEPROM

AIK-AP**1H

*1 OFF OFF

service board

Factory setting OFF (no resistor) OFF (A is selected) OFF (custom models) OFF

Model Invalid

40 type

45 50 56 63 71 80

Notch

– 53 –

Page 55

10. ON-SITE SETTING AND OTHERS

1. Indoor Unit

1.1 Trial Operation Setting by Remote Controller only.

The lamps on the unit blink during trial operation.

Press on the R/C for 4 seconds. When “TRIAL OPERATION” appears on the LCD, press .

• “TRIAL OPERATION” appears on the LCD during trial operation.

• Trial operation disables temperature control, but allows fan speed control.

• An instruction of fixed frequency is issued for cooling and heating of trial operation.

• Alarm detection is performed as usual. The trial operation mode must be used for its original purpose only, because it stresses the air conditioner.

Choose COOL or HEAT mode only for trial operation.

• (Note) Outdoor unit does not run about 3 minutes after power on or operation stop.

Repress after trial operation and confirm that “TRIAL OPERATION” disappears from the LCD. Wired remote controller has 60-minute timer reset function to prevent continuous trial operation.

Checking wiring and piping of indoor/outdoor units

1. Open the front panel of the indoor unit.

2. Press [TEMPORARY] button for 10 seconds. The unit enters forcible cooling mode with a sound

“pi”. COOL operation starts forcibly about 3 minutes later. Check whether cool air is discharged. If COOL operation does not start, recheck the wiring.

3. Repress [TEMPORARY] for about one second to stop trial operation. The vertical airflow flap

closes and the operation stops.

Checking signal transmission from R/C

1. Press [ON/OFF] on the R/C to check for normal operation using R/C.

• To enter AUTO mode, press [TEMPORARY] once

for about one second. For forcible cooling, press [TEMPORARY] for 10

seconds or more.

• COOL operation specified by R/C may not start

depending on temperature conditions. Use forcible cooling operation to check wiring and

piping of indoor/outdoor units.

[TEMPORARY] button

– 54 –

Page 56

ON-SITE SETTING AND OTHERS (Continued)

1.2 Forcible Defrost Setting by Remote Controller (wired R/C only)

Preliminary operation

Press , , and at the same time for 4 seconds or more in the OFF mode. In the group control mode, the header unit number is displayed first.

Each pressing of indicates indoor unit number in the group sequentially. Choose the main indoor unit (connected to the outdoor unit) for which forcible defrosting is to be performed. The fan and flap of the selected indoor unit start working.

Specify DN “8C” with buttons.

Set data 0001 with buttons. (Factory setting: 0000)

Press Indication on the LCD shows normal operation.

Press to return the operation mode to normal OFF.

Execution procedure

• Press

• Choose HEAT operation mode.

• After a while, a forcible defrosting signal is transmitted to the outdoor unit. Upon receiving the signal, the outdoor unit starts defrosting. It takes up to 12 minutes.

• On completion of defrosting, the indoor unit restart HEAT operation.

on the R/C.

To reexecute defrosting, repeat steps from step

above.

Once forcible defrosting is performed, the above setting for forcible defrosting is reset.

1.3 Indication of Onboard LEDs

1. D02 (red)

Lights up by the control of main microcomputer when the indoor unit is powered on. Blinks at intervals of one second (0.5-second on and off) when EEPROM is not mounted or write error occurs. Blinks at intervals of 10 seconds (5-second on and off) in the DISP mode. (CN72 short-circuited at power on) Blinks at intervals of 2 seconds (1-second on and off): Applicable unit in the EEPROM setting (address, function selection, etc.) mode

2. D203 (red)

Lights up by hardware control when power is supplied to remote controller.

– 55 –

Page 57

1.4 JRA Capacity Measurement Mode (wired R/C only)

Preliminary operation

Press , , and at the same time for 4 seconds or more in the OFF mode. In the group control mode, the header unit number is displayed first.

Each pressing of indicates indoor unit number in the group sequentially. Choose the main indoor unit (connected to the outdoor unit) for which this control is to be performed. The fan and flap of the selected indoor unit start working.

Specify DN “91” with buttons.

Set the following data with buttons. (Factory setting: 0000)

Data Rating Middle

Press Indication on the LCD shows normal operation.

Press to return the operation mode to normal OFF.

Execution procedure

• Press

0001 0002

Use this mode to measure JRA capacity. Use this mode under the conditions of JIS B8615-1 Perform the settings in the table by remote controller

Cooling rating

Heating rating Cooling middle Heating middle

on the R/C.

Operation

Cooling

Heating Auto Cooling Auto Cooling

Fan speed

Quick high Quick high

Auto Auto

Setting temp.

18°C 29°C 23°C 24°C

Flap position Horizontal angle Horizontal angle Horizontal angle Horizontal angle

To reexecute JRA capacity measurement, repeat steps from step Once this measurement is completed, the above setting is reset.

1.5 Function Select Setting (wired R/C only)

Perform the following steps in the operation OFF mode.

Press , , and at the same time for 4 seconds or more in the OFF mode. In the group control mode, the header unit number is displayed first.

Each pressing of indicates indoor unit number in the group sequentially. Choose the main indoor unit (connected to the outdoor unit) this function is to be performed. The fan and flap of the selected indoor unit start working.

Specify DN with buttons.

Operation procedure

Set the setting data with buttons.

above.

3 5

6 2

1 2 3 4 5 6

END

Press Indication on the LCD shows normal operation.

• To change the selected indoor unit, go to

• To change the item to be set, go to

Press to return the operation mode to normal OFF.

– 56 –

Page 58

ON-SITE SETTING AND OTHERS (Continued)

Function Select Code (DN) Table

Filter sign ON time

Filter contamination level

Central control address

HEAT intake temp. shift

PREPARING indication selection

COOL only

Type

Indoor unit capacity

Refrigerant line address

Indoor unit address

Group address

Temp. range at COOL/HEAT auto switching control

Auto restart after power failure

Option/alarm input (CN80) selection

Thermo output (T10-3) selection

HA terminal (T10-1) selection

Ventilation fan (single operation)

Sensor selection

Timer setting (wired R/C)

Flap setting for cooling

Correction of feeling of strong heating

Item

Description

0000: None 0001: 150H 0002: 2500H 0003: 5000H 0004: 10000H 0005: Clogging sensor used

0000: Average 0001: Heavy

(half of standard time)

0001: No. 1 - 0064: No. 64 0099: Not determined

0000: No shift 0001: +1 °C 0002: +2 °C - 0010: +10 °C

(Up to +6 recommended)

0000:

PREPARING indicated

0000: Heat pump 0001: COOL only

0000: (Ceiling panel 1) 0001 (ceiling panel 4) -

0000: Not determined 0001 - 0034

0001: No. 1 - 0030: No. 30 0001: No. 1 - 0064: No. 64 0000: Individual 0001: Group header

0002: Group follower 0000: 0deg - 0010: 10deg

(Switching at set temperature ±(data)/2) 0000: Not provided 0001: Provided 0000: Filter input 0001: Alarm input

External alarm input

0002: 0000:

I/U thermo sensor ON

0000: Normal (JEMA) 0001: Card input 0002: Fire alarm input

0000: Disabled 0001: Enabled 0000: Unit sensor TA 0001: R/C sensor 0000: Available 0001: Unavailable 0000: Normal 0001: Down allowed 0000: Not provided 0001: Provided

0001: No indication

(No “AUTO”, “HEAT” indication)

0037

0001: O/U compressor ON

output

Factory setting

0001: 150H

0000: Average

0099: Not determined

0002: +2 °C

0000: PREPARING

indicated

0000: Heat pump

0008: Wall type

Depends on capacity type

0099: Not determined 0099: Not determined 0099: Not determined

0033: 3deg (Ts ± 1.5)

0000: Not provided 0002: External alarm

input

0000: I/U thermo

sensor ON

0000: Normal

(HA terminal) 0000: Disabled 0000: Unit sensor 0000: Available 0000: Normal 0000: Not provided

– 57 –

Page 59

1.6 Wiring and Setting for Remote Controller

Double R/C control (when controlling by two remote controller switches)

This control is provided to control one or more indoor units by two remote controllers. Up to 2 remote controllers can be installed. No setting is required when using in combination with a wireless remote controller .

Controlling one indoor unit by 2 remote controllers

R/C switch

(header)

A B

Indoor unit

1 2 3

R/C switch

(follower)

OptionOption

R/C wiring (on-site arrangement)

R/C wiring terminals

1 2 3

Outdoor unit

Setting

This control is provided to control one or more indoor units by two remote controllers. Up to 2 remote controllers can be installed.

Remote controller (back, inside)

Setting to use a wired remote controller as follower R/C:

Change the setting of DIP switch on the back of R/C switch to “R/C follower” as shown in the figure.

R/C follower

R/C header

DIP switch

– 58 –

Page 60

ON-SITE SETTING AND OTHERS (Continued)

1.7 Monitoring Function of Remote Controller Switch

■■

■Calling indication of sensor temperature

■■

Calls the service monitor mode from the remote controller to monitor sensor temperatures of the remote controller, indoor units, and outdoor unit.

Press and on the R/C simultaneously for 4 seconds or more to call the service monitor mode. “Service monitor” lights up and the header indoor unit number is displayed first, and then temperature of code “

Choose a sensor number (code) you want to monitor with buttons.

The following table lists sensor numbers.

Code

Room temp. under control *1

00 01

Room temp. (R/C) Indoor unit intake temp.

02 03

Indoor unit coil temp. TCJ Indoor unit coil temp. TC

Indoor unit data

Indoor unit coil temp. TC1

Data

Code

Heat exchange temp. TE

Outside air temp. TO

Discharge temp. TD

Intake temp. TS

Outdoor unit data

–

Heatsink temp. THS

” is displayed.

Data

4 3

Operation procedure

1 2 3 4

Returns to normal indication.

*1 Header indoor unit only under group control

Choose an indoor unit you want to monitor with button to monitor sensor temperatures of indoor units and outdoor unit in the same control group.

Press to return to the normal indication.

– 59 –

Page 61

■■

■Calling error log

■■

Calls past errors.

Press and on the R/C simultaneously for 4 seconds or more to call the service check mode. “Service check” lights up and code is displayed first to display the latest error. The faulty indoor unit number and error content are displayed.

To monitor other errors, change error log number (code) with

buttons.

Code

(latest) → Code (oldest)

Note) Up to 4 errors are memorized in the error log.

Press to return to the normal indication.

Returns to normal indication.

Operation procedure

Do not press as this button clears entire error log of indoor unit.

1 2 3

– 60 –

Page 62

ON-SITE SETTING AND OTHERS (Continued)

Group control allows operation control of up to 8 indoor units using one remote controller. It includes twin, triple, and double twin controls with one outdoor unit. The indoor unit connected to outdoor unit controls room temperature according to the R/C setting.

O/U O/U

I/U I/U

1-1 2-1 3-1 3-2 4-1 7-1

R/C

Header

O/U O/U

I/U I/U

I/U

O/U

I/U

8 units maximum

(1) Scope of R/C indication

The indoor unit setting range (operation mode/fan speed/temperature) set in the header unit is reflected in the remote controller.

A Do not set a concealed duct high static pressure type (AID-P***1H) for header unit.

• If the type is set as header unit, settings are as follows. Operation mode: [Auto cooling/heating], [HEAT], [COOL] or [FAN] without [DRY]

Fan speed : [HH]

• In the DRY operation mode, FAN mode is not available for duct models.

B Do not set a “COOL only” model for header unit.

• [Auto cooling/heating] and [HEAT] operation modes are not available.

(2) HA

Both indoor and outdoor units are compatible with the remote control HA. Operation ON/OFF control for entire group is available.

A Multiple HA inputs in one group are not allowed.

(3) Address setting

If there is no serial data communication between indoor and outdoor units at power on, the indoor unit is regarded as twin follower unit. (Each time of power on)

... Recognition of twin header (main)/follower (sub) is carried out at each power on, and the result is

not stored in the non-volatile memory.

When performing auto address setting, power on the indoor units in a control group within 3 minutes.

... If powered on after 3 minutes when auto address judgment is completed, the unit is rebooted

and reenters auto address setting mode.

A Connect 3 wires between indoor and outdoor units properly. B Check refrigerant line address, indoor unit address, and group address of each unit.

Regarding twin, triple, and double twin, in particular, check for one refrigerant line address for all units.

C An indoor unit number (refrigerant line address/group address), once it is set, is retained in

principle unless it is not used for any other unit.

– 61 –

Page 63

Indoor Unit Power ON Sequence

Checking group

Power ON

Incorrect

configuration

Correct * Correct group configuration means

A No duplication of indoor unit address B No invalid indoor unit address C Individual units and header/follower units

are not mixed

D Only one individual unit E One header and one or more follower units

in a group

System start

• Indoor units that are not supplied with power are in waiting mode continuously. →System start resets the waiting mode.

• Rebooted if power is supplied halfway

3 minutes

passed

Auto address start

O/U model identification (10 seconds) (I/U) Twin header/follower unit identification (I/U)

Group configuration/flap information (R/C)

R/C operation enabled (50 seconds after power on)

Between indoor units (30-second cycle) (Header/follower)

Within same piping (30-second cycle) (Twin main/sub)

(Communication starts as soon as above status changes.)

<<Notes on trial operation>>

•

Check for normal connections of power cable, I/U-O/U serial wiring, and group wiring

•

Power ON all indoor units within 3 minutes

•

R/C operation available time (after power on)

When address is correct: Approx. 50 seconds

When auto address is used: Approx. 4-5 minutes

(Repeated)

(About one minute to end)

• The indoor unit powered on after auto address judgment under group control is rebooted (system reset), unless it does not receive data from the header unit or periodic communication within same piping within 120 seconds after power on. →The sequence restarts from auto address judgment (checking group configuration).

• If the previous address fixed and the header unit is powered on and is rebooted, the refrigerant line address of indoor units remains unchanged, but the header unit address may change.

– 62 –

Page 64

ON-SITE SETTING AND OTHERS (Continued)

3. Connections for Central Control

3.1 Connections for TCC-LINK Central Control

3.1.1 Functions

Connect an indoor unit to the TCC-LINK central controller.

3.1.2 Connection Diagram

Central controller

TCC-LINK

Number of units : 64 Communication length : 2km

CN41

Terminal block

(A/B)

Remote controller

Indoor unit

CN40

Terminal block

(U3/U4)

3.1.3 TCC-LINK Connections

How to make connections

The terminal block for TCC-LINK central control is located at the lower right of the indoor unit. For details, see the installation manual of applicable central control remote control system. When using the terminal block, detach the front panel following the description on how to replace main components in this manual.

Electric parts box

Terminal block

Cord clamp

Terminal block for central control wiring (lower right part without front panel)

– 63 –

Page 65

3.1.4 Wiring Specifications

Number of wires

Size

Up to 1000m: 1.25mm2 stranded wires Up to 2000m: 2.0mm2 stranded wires

Specification

MVVS

• A 2-wire non-polarity cable is used.

• The cable length depends on each central control system. When used in a system including multiple air conditioners, the length includes the length of all wires between indoor and outdoor units on the side of multiple air conditioners.

• Use 2-wire shield cable (MVVS) to protect from noise.

• Joint shield wire between indoor units by closed-end terminating, and leave its end open with insulation processing. Make one-point grounding at the indoor unit side. Set the terminating resistors.

(Central control for custom indoor units only)

A Joint shield wire between indoor units by closed-end terminating.

B Leave the end of the shield wire open with insulation processing.

123

C Make one-point grounding at the indoor unit side.

123

Note A

123

Central controller

U1 U2

Note B

Outdoor

unit

Indoor

unit

U3 U4

Header

123

R/C R/C R/C

U3 U4

123

(Group operation)

Follower

123

– 64 –

Page 66

ON-SITE SETTING AND OTHERS (Continued)

3.1.5 Setting Onboard Switches

Setting of terminating resistors is necessary for central control of custom indoor units only.

• Use SW01 to set terminating resistors.

• Set terminating resistors for the indoor unit only with the smallest refrigerant line address.

Central controller Central controller

U1U3U2

Refrigerant system 1 Refrigerant system 2 Refrigerant system 3

Outdoor unit

123

Indoor unit

U3 U4

123

R/C R/C R/C

Refrigerant line address

SW01 bit 1

Central controller: Up to 10 units

123

U3 U4

TCC-LINK adapter (option) Required for custom indoor units other than wall type

Header

123

R/C wiring

Group operation (up to 8 indoor units)

OFF

123

Follower

OFF

Remarks Bit 1 ON Factory setting Factory setting

– 65 –

Page 67

3.1.6 Onboard Switch Setting Procedure

1. Detach the front panel.

2. Remove the drain guide, ground line, sensor TCJ, sensor TC, and motor leads.

3. Remove the screws to detach the electric parts box.

Sensor TCJ insertion position (Insert the sensor drawn from above electric parts.)

Sensor TC insertion position (Insert the sensor drawn from under electric parts.)

Fan motor connector insertion position

Louver motor connector insertion position

Electric parts box screw

4. Detach the electric parts cover, and set SW01 bit 1 to ON.

Do not touch bit 2 as it is for other setting.

DB301

C302

L301

CN67

C301

CN102

CN101

CN22

CN40

L41

CN213

IC01

BZ01

MCC-1510

T301

SW01

L201

CN104

SW02

1 : ON

1 : OFF

2 : OFF2 : OFF

12ON12

After setting

Factory

setting

change

5. Install the removed parts by reversing steps 1 to 4.

(Insert the sensors and motor leads firmly into their correct positions.)

– 66 –

Page 68

ON-SITE SETTING AND OTHERS

3.1.7 Setting Addresses

Overview

To connect custom air conditioners to the TCC-LINK central control system for central control/monitoring, addresses of connected indoor units must be set in the following procedure.

Connections/wiring completed

System power ON

Auto address setting The system performs automatically after power on.

Manual setting/change of refrigerant line addresses

Is group control (including twin/triple/

double twin) going?

YES

Are all indoor units with central control

function header unit (group address=1)?

Re-set indoor units with central control function to header

unit, and other indoor units to follower unit.

* Refer to 11 ADDRESS SETTING.

Central control address number setting

* Refer to the manual of the central control system.

Change refrigerant line address. If auto address setting failed, set refrigerant line address manually.

* Refer to 11 ADDRESS SETTING.

YES

END

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Page 69

(1) Manual setting/change of indoor unit refrigerant line addresses

[In the case of 29 refrigerant systems or less (when multiple air conditioners are included, their number of refrigerant systems is also included)]

Refrigerant address “1” is assigned to all indoor units except for group control by the auto address setting after system power on. Therefore, change refrigerant line address of each refrigerant system using the wired remote controller.

Central

controller

Refrigerant

system 1

O/U O/U O/U O/U O/U

I/U I/U I/U I/U I/UI/U

R/C R/C R/C R/C

Refrigerant line address

Indoor unit address

Group address

Refrigerant line address

Indoor unit address

Group address

Refrigerant

system 2

Refrigerant

system 3

Refrigerant

system 4

Refrigerant

system 5

An example after auto address setting

After changing refrigerant line address manually

* For changing/setting refrigerant line addresses by wired remote controller, refer to 11 ADDRESS

SETTING.

* Refrigerant line address must be unique for each refrigerant system.

To perform central control in combination of multiple and custom air conditioners, set refrigerant line addresses different from those of multiple air conditioners.

– 68 –

Page 70

ON-SITE SETTING AND OTHERS

(2) Manual setting/change of indoor unit refrigerant line addresses

[In the case of 30 refrigerant systems or more (when multiple air conditioners are included, their number of refrigerant systems is also included)] Regarding refrigerant systems up to No. 29, manual setting/change is the same as that on the previous page.

• Refrigerant address “1” is assigned to all indoor units except for group control by the auto address setting after system power on. Therefore, change refrigerant line address of each refrigerant system using the wired remote controller.

• Also change indoor unit addresses so as to avoid duplication of indoor unit numbers.

Central

controller

Refrigerant

system 30

O/U O/U O/U O/U O/U

I/U I/U I/U I/U I/UI/U

R/C R/C R/C R/C

Refrigerant line address

Indoor unit address

Group address

Refrigerant line address

Indoor unit address

Group address

* For changing/setting refrigerant line addresses by wired remote controller, refer to

Refrigerant

system 31

Refrigerant

system 32

Refrigerant

system 33

Refrigerant

system 34

An example after auto address setting

After changing refrigerant line address manually

ADDRESS

SETTING.

* Change refrigerant line address of all indoor units connected directly to the central controller to

“30”. These indoor units are under twin or triple control, also change the refrigerant line address of follower indoor units to “30”.

* Change indoor unit addresses so that they are not duplicated.

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Page 71

3.1.8 Central Control Address Number Setting

To connect an indoor unit to the central control remote controller, an address number for central control must be set.

An address number for central control is indicated as the refrigerant line number of the remote controller.

1. Setting by Remote Controller on Indoor Unit Side

<Procedure> Perform the following steps in the operation OFF mode.

Press and on the R/C simultaneously for 4 seconds or more. When group control is going, UNIT No.

is displayed first, and all indoor units in the group are selected. At this time, the fans of all the selected indoor units start running. (Fig. 1) Maintain this state without pressing

. For individual remote controllers without group control, a refrigerant line address and an indoor unit address are indicated.

Specify code with buttons.

Choose setting data with buttons. Table 1 shows setting data.

Press Indication on the LCD shows normal operation.

• To change an item for setting, return to

(Fig. 1)

Tab l e 1

Setting data

0001 0002 0003

.....

0064 0099

Address No. for central control

1 2 3

.....

Not set (factory setting)

Press to return to the normal indication.

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Page 72

11. ADDRESS SETTING

1. Address Setting

Address Setting Procedure

When twin or triple operation is selected with one indoor unit and one outdoor unit or when one outdoor is connected to each indoor unit even with multiple refrigerant systems in group operation, auto address setting is completed during the power on process of outdoor unit. Remote controller operation is disabled during the auto address setting process (4 to 5 minutes).

O/U refrigerant line address/I/U address/group address setting

Connections/wiring completed

Do you set I/U address freely?

(manually)

Connect com. cable between R/C and I/U temporarily one to one.

Power ON outdoor unit.

One refrigerant system?

Power ON outdoor unit

(To auto address setting mode)

Auto address setting ends within 4 to 5 minutes.

Is group control going?

Multiple units for twin/triple operation?

Auto address setting first, then corrected?

Power ON outdoor unit.

(Corrected to an address/group

Set address for each I/U individually

END

manually after address setting)

• Unless the following addresses are stored in the EEPROM (IC10) on the indoor unit board, trial operation is disabled. (Undefined data is stored at factory shipping.)

Setting data range Refrigerant line address Indoor unit address

Group address

Code

12 13

Factory setting data

0099 0099

0099

0001 (unit No. 1) to 0030 (unit No. 30) 0001 (unit No. 1) to 0064 (unit No. 64)

Maximum I/U address in the same refrigerant system (double twin=4) 0000 : Individual (indoor units without group control)

0001 : Header (one indoor unit in the group) 0002 : Follower (indoor units in the group except header unit)

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Page 73

2. Address Setting and Group/Twin/Triple Control

Indoor unit No. : N-n=O/U refrigerant line address N (30 max.) -I/U address n (64 max.) Group address : 0=Individual (without group control)

1=Header unit under group control 2=Follower units under group control

Header indoor unit (=1) : A representative unit of multiple indoor units in group operation, which performs

communication between R/C and follower I/U. (* It does not mean an indoor unit that communicates with O/U.) Operation mode and setting temperature range (except flap air flow control) of header unit are reflected on the LCD of remote controller.

Follower indoor unit (=2) : Indoor units except header unit in group operation.

It does not control communication with remote controller in principle (except response to alarm/service data request).

Main unit : (Representative)

(Twin header)

Sub indoor unit : Indoor units except the main indoor unit in a twin, triple or double twin system. (Sub unit)

(Twin follower)

[1] System Configuration

a)Single b)Twin

In a minimal configuration of refrigerant cycle such as twin, triple or double twin, an indoor unit which communicates with O/U among those with same refrigerant line address. Communicates with sub indoor units and with O/U (instructions to compressor) on behalf of cycle control.

Communicates with the main indoor unit with the same refrigerant line address, and provides control in synchronization with the main indoor unit. It does not communicate with O/U (no detection of serial signal alarm).

Outdoor unit

Indoor unit

1:1

individual

R/C

(H/M)

1-2

H/M

1-1 F/S

1-4 F/S

c) Single group operation

2-1

F/M

1-1

F/M

• Each indoor unit controls outdoor unit individually.

4-1

H/M

3-1

F/M

8-1

F/M

d) Multiple single/twin/triple group operation (manual address setting)

2-1

F/M

1-1

F/M

1-2 F/S

1-3

F/S

3-3

H/M

3-4

F/S

3-2 F/S

1-3 F/S

3-1

F/S

H : Header indoor unit F : Follower indoor unit M: Main indoor unit S : Sub indoor unit

• Main indoor unit : Receives data (thermo status, etc.) from sub indoor units with same refrigerant line address, and controls O/U compressor referring to the self thermo status. Transmits this instruction to sub units.

• Sub indoor unit : Receives data from the main indoor unit with same refrigerant line address and serial interface with O/U, and performs thermo operation in synchronization with the main unit. Sends self thermo ON/OFF request to the main unit. (Example) 1-1 main unit communicates with 1-2 and 1-3 sub units without being

affected by indoor units with refrigerant line address 2 or 3.

– 72 –

Page 74

[2] Examples of Auto Address Setting from No Address Setting

1) Standard (one outdoor unit)

a) Single

1-1

individual

(H/M)

2) Group operation (multiple O/U = multiple indoor units with serial communication interface, no twin)

b) Twin

(1-1) (1-2)

1-2

H/M

*** Turn ON the power. Address setting is completed automatically. ***

1-1

F/S

2-1

F/M

1-1

F/M

3-1

H/M

*** Turn ON the power. Address setting is completed automatically. ***

3) Multiple group operation

A (single) B (triple) C (double)

2-1

F/M

1-1

F/M

2-1 F/S

3-3 H/S

8-1

F/M

8 indoor units maximum

3-1

F/M

Change sub unit addresses at the same time manually

2-2 F/S

*** Address change required ***

from remote controller.

1-2

F/S

3-2

F/S

2-1 1-1 1-2 1-3 3-1 3-2 3-3 3-4

– 73 –

H : Header indoor unit F : Follower indoor unit M: Main indoor unit S : Sub indoor unit

Page 75

3. Address Setting

When determining indoor unit addresses with wiring completed without piping construction

(Manual setting by remote controller)

Connect a remote controller to the indoor unit whose address you want to set one to one.

Turn ON the power.

Press , , and on the R/C simultaneously for 4 seconds or more.

Wiring example of 2 refrigerant systems (Solid line: wiring, broken line: refrigerant piping)

O/U

(Power cable only) (Power cable only)

I/U

I/U I/U I/U I/U

Refrigerant line

address

Indoor unit address

Group address

→ 1 → 1 → 1

O/U

Refrigerant line address

Indoor unit address

→

Set code with buttons.

Set a refrigerant line address with buttons.

Press Indication on the LCD shows normal operation.

→

Set code with buttons.

For systems like this example, connect a wired remote controller independently without connecting R/C wires, and then set these addresses.

Group address

Individual: 0000 Header unit: 0001 Follower unit: 0002

in case of group control

Group address

5 63

2 4

8 9

End

Operation procedure

1 2 3 4

8 9 10 11

5 6 7

End

Set indoor unit addresses with buttons.

Press Indication on the LCD shows normal operation.

→

Set code with buttons.

Set indoor unit addresses with buttons as follows: Individual=

, header unit= ,

follower unit=

Press Indication on the LCD shows normal operation.

Press . Indoor unit address setting is completed. The operation mode returns to normal OFF.

– 74 –

Page 76

ADDRESS SETTING (Continued)

■■

■Checking location of indoor unit number

■■

(1) To find the address of indoor unit whose location is clear

In case of independent operation (1:1 connection of wired R/C and I/U) Perform the procedure during operation of indoor unit.

When the indoor unit is not working, press on the R/C.

Press . UNIT No. seconds. The displayed number shows the refrigerant line address and indoor unit address. When other indoor units are connected to the same remote controller (group control), their unit numbers are displayed in order each time

appears on the LCD and disappears in several

is pressed.

2 1

Operation procedure

1 2

(2) To find the location of indoor unit from its address

When checking indoor unit number in the group. Perform the procedure while the indoor unit is not working. This procedure stops operation of all indoor units in the group.

<Procedure> Indoor unit numbers appear one by one and the fan and flap of the displayed unit run.

Press and on the R/C simultaneously for 4 seconds or more.

• UNIT No. appears.

• The fan and flap of all indoor units in the group run.

Each pressing of on the R/C displays unit numbers in the group sequentially.

• The header unit address appears first.

• The fan and flap of a selected indoor unit run.

Press to finish the procedure. Operation of all the indoor units in the group turns OFF.

End Operation procedure

1 2 3

End

– 75 –

Page 77

12. EXPLODED VIEWS AND PARTS LIST

High-Wall Type

RAV-SM562KRT-E/RAV-SM802KRT-E

202

203

201

227

229

230

221

217

208

228

213

222

219

210

220

215

232214

218

216

211

209

231

226

224

212

223

207

204

Location Part

No. No. No. No.

201 43T00409 FRONT PANEL ASSY 217 43T19322 FIX-P-SENSOR 202 43T09375 GRILLE ASSY 218 43T49323 SPRING 203 43T80306 204 43T80312 207 43T03010 BODY; RIGHT 221 43T49038 PLATE; EVA-SEAL 208 43T03011 BODY; LEFT 222 43T49037 HOLDER; PLATE EVA-SEAL 209 43T03012 HIDE; CLAW 223 43T79007 GUIDE DRAIN 210 43T09345 LOUVER-H 224 43T39016 FIX FOR MOTOR 211 43T70001 HOSE ASSY; DRAIN 226 43T21368 MOTOR FAN 212 43T21367 MOTOR;STEPPING 227 43T20315 FAN; CROSS FLOW 213 43T44373 REFRIGERATION ASSEMBLY 228 43T22307 M-B-BEARING

213 43T44374 REFRIGERATION ASSEMBLY 230 43T03336 BACK BODY ASSY 216 43T49021 PIPE; SHIELD 232 43T82306 PLATE; INSTALLATION

AIR FILTER (L) 219 43T49324 PLATE; EVA-SEAL AIR FILTER (R) 220 43T49039 HOLDER; PLATE EVA-SEAL

(FOR RAV-SM562KRT-E) 229 43T39015 BASE; BEARING (FOR RAV-SM802KRT-E) 231 43T07022 HOLDER; PIPE

Description

236

233

Location Part

234 43T69495 WIRELESS REMOCON

235 43T83003 HOLDER; REMOTE CONTROLLER

236 43T62029 COVER; TERMINAL

Description

234

235

– 76 –

Page 78

RAV-SM562KRT-E/RAV-SM802KRT-E

Location Part Location Part

No. No. No. No.

401 43T60047 TERMINAL 407 43T60361 FUSE 402 43160508 TERMINAL 408 43T09343 E-PARTS BASE 403 43T60321 TERMINAL 409 43T69536 PC BOARD 404 43T50308 SENSOR HEAT EXCHANGER 410 43T69500 DISPLAY UNIT 405 43T50306 TEMPERATURE SENSOR 411 43T09344 CORD CLAMP 406 43T69320 TEMPERATURE SENSOR

Description Description

– 77 –

Page 79

TOSHIBA CARRIER (THAILAND) CO.,LTD.

144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI,

AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

Toshiba RAV-SM802KRT-E User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual