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SERVICE MANUAL AIR

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2. 707 706 SVM 12085_051 114 indd 111 12 06 12 11 15 AM FILE NO SVM 12085 Location RAV Part No Description No SP804ATP E SP804ATJP E 3 43T60432 Sensor Ass y 06 3 43T63318 Holder Sensor TE 43T60433 Sensor Ass y 04 Holder Sensor TD SP804ATP E Lo 3 3 112 SVM 12085_051 114 indd 112 12 06 12 11 15 AM FILE NO SVM 12085 WARNINGS ON REFRIGERANT LEAKAGE Check of Concentration Limit The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out its concentration will not exceed a set limit The refrigerant R410A which is used in the air conditioner is safe without the toxicity or combustibility of ammonia and is not restricted by laws to be imposed which protect the ozone layer However since it contains more than air it poses the risk of suffocation if its concentration should rise excessively Suffocation from leakage of R410A is almost non existent If a conditioner system is to be installed in a small room select a suitable model and installation procedure so that if the refrigerant accidentally leaks out its concentration does not reach the limit and in the event of an emergency measures can be made before injury can occur In a room where the concentration
3. Current display The current value which flows in the outdoor unit is displayed Refer to Page 80 Compressor operation frequency display The operation frequency of the compressor is displayed Refer to Page 80 SVM 12085_051 114 indd 78 PMV opening display The opening of PMV Pulse Motor Valve is displayed 2i m Refer to Page 80 12 0642 11 15 AM 2 Error display The error which is generating at present and the latest error Latest error information including present can be confirmed by lighting LED D800 to D804 on the outdoor control P C board a When all DIP switch SW803 are OFF the status of error which is generating at present is displayed b 1 only of DIP switch SW803 is turned on the error which generated before Latest error information including present is displayed C If there is an error any of LED D800 to D804 goes on Display 1 d When pushing the pushdown button switch SW800 for approx 1 second the display is exchanged Display 2 e When pushing SW800 again or after 2 minutes the status returns to that of Display FILE NO SVM 12085 Legend Present error Latest error SW803 SW803 D800 Yellow
4. Pa peaj jenas D ger peol eseud N elg eseud ejBuis peo Ajddns 1 Logad A asn YSL E 204 Joyoedeo 1 1991 10126 emod ufi YL EL CLO 0 9 epoip 10128 10 pee YGZ ZO 104 V 12 06 12 11 06 SVM 12085 001 050 indd 45 FILE NO SVM 12085 RAV SP80 ATP MCC 1571 Fan motor output Compressor output terminals CN300 White CN202 CN201 CN200 Power circuit protective fuse F100 250V 3 15A plastic case 4 way valve connector CN701 White Electrolytic capacitors Case thermo connector CN609 Blue Compressor ON output connector CN704 Blue Heater output connector CN703 Gray Reactor connecting connectors Optional input connector CN610 Yellow Specific operation SW T SW801 SW804 P09 Black Display exchange SW sss SW800 Ah HPE Papa i 4 Power supply protective fuse ibas RE 2 ax Mira d ys F01 250V 25A Temp sensor connector TL CN604 White TD CN603 White TO CN602 Yellow TE CN601 White TS CN600 White Lead wire for grounding Power supply connecting lead wire P01 Red P02 White Power Alarm display LED D800 to 804 Yellow D805
5. Ud y LAESA 140d s89 g A m 12 06 12 11 06 AM SVM 12085_001 050 indd 18 RAV TWP30E2 RAV TWP50E2 Simultaneous Twin FILE NO SVM 12085 Inner diameter C Inner Inner diameter D diameter O D Model RBC Liquid side TWP30E2 Gas side Liquid side TWP50E2 Gas side SVM 12085_001 050 indd 19 19 12 06 12 11 06 FILE NO SVM 12085 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3 1 Indoor Unit Single type Combination of 1 indoor unit and 1 outdoor unit Indoor unit Distributor Strainer incorporated Strainer Air heat exchanger TCJ sensor Heating s Cooling Refrigerant pipe Refrigerant pipe I at liquid side at gas side Outer dia OB Outer dia To outdoor unit To outdoor unit Dimension table Outer diameter of refrigerant pipe Gas side OA Liquid side OB Indoor unit SM40 45 56 type 12 7 6 4 SM80 type 15 9 9 5 Twin type Combination of 2 indoor units and 1 outdoor unit Heating Cooling Indoor unit A Indoor unit B Distributor Distributor Strainer incorporated Strainer incorporated sensor TCJ sensor Strainer Strainer exchanger exchanger Air heat Air heat
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7. Check outdoor P C board Defect Replace D01 D02 003 004 Red Yellow Yellow Yellow e O e Discharge temp error Is there gas leak Is there refrigerant shortage NO y Is PMV under correct conditions YES Does an abnormal overload happen NO Is connection of CN601 correct 15 resistance value of TD sensor correct Repair defective position Recharge refrigerant Repair defective position Replace defective part Remove and improve the cause of overload Correct connector Sensor error Replace Check outdoor P C board Defect Replace D01 D02 D03 D04 Red Yellow Yellow Yellow Power supply error Voltage error Is AC mains voltage correct 198 to 264V Confirm power supply construction etc Check outdoor P C board Defect Replace D01 D02 D03 D04 Red Yellow Yellow Yellow e e or O Power supply error Voltage error Refer to columns H03 and P04 and then check power supply and voltage error LED display legend Go off O Go on Flash 5Hz SVM 12085_051 114 indd 60 60 12 06 12 11 15 APPLICATION CONTROL KIT LED display Y Is flow of refrigerant by PMV under correct conditions YES FILE NO SVM 12085 lt ln case of SP40 to SP56 gt Check Countermeasures Part wit
8. 26 SVM 12085_001 050 indd 26 12 06 12 11 06 FILE NO SVM 12085 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
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10. 0 5 to 1 0 Table 6 2 4 Flare and flare nut dimensions for R410A Outer diameter mm Thickness mm Dimension mm B 1 5102 0 Flare nut width mm Nominal diameter Table 6 2 5 Flare and flare nut dimensions for R22 Outer diameter mm Thickness mm Dimension mm B Flare nut width mm SVM 12085_001 050 indd 29 29 12 06 12 11 06 22 _ FILE NO SVM 12085 I Fig 6 2 2 Relations between flare nut and flare seal surface 2 Flare Connecting Procedures and Precautions a Make sure that the flare and union portions do not have any scar or dust etc b Correctly align the processed flare surface with the union axis c Tighten the flare with designated torque by means of a torque wrench The tightening torque for R410A is the same as that for conventional R22 Incidentally when the torque is weak the gas leakage may occur When it is strong the flare nut may crack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 6 2 6 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Table 6 2 6 Tightening torque of flare for RA10A
11. peioejep sem 1eeu jo ujoug uedo slu luoo 10418 Jo uoneue dx3 Joopu 5 1 Josuas 1oopul uonisod Buiusejj omy snoeuejnuigs snoeueynuls WIS ow aay Buyse eyeuJei y ITV 1009 5514 009 O uoneiedo 49019 10suos uoneoipui 53 12 06 12 11 15 SVM 12085_051 114 indd 53 Error mode detected by indoor unit Operation of diagnostic function Cause of operation No communication from remote controller including wireless and communication adapter Status of air conditioner Stop Automatic reset Condition Displayed when error is detected FILE NO SVM 12085 Judgment and measures Check cables of remote controller and communication adapters Remote controller LCD display Disconnection Central remote controller 97 check code The serial signal is not output from outdoor unit to indoor unit Miswiring of inter unit wire Defective serial sending circuit on outdoor P C board Defective serial receiving circuit on indoor PC board Stop Automatic reset Displayed when error is detected
12. Repair defectives position Recharge refrigerant Open service valve lully Correct defective position Replace defective part Check crushed or broken pipe Defect Correct and Replace SVM 12085_051 114 indd 66 lt Display 1 gt lt Display 2 gt Oeoeoe Unset model type Only when service P C board is used Cut jumper line according to the explanation sheet packaged with the service P C board 12 0642 11 15 AM FILE NO SVM 12085 lt ln case of SP80 gt Check Outdoor Check and troubleshooting code LED display Item without special mention Indicates part of outdoor unit There is a possibility that it is one of the following errors Confirm LED on outdoor board to judge which error it is Communication error between MCU Heat sing temp sensor TH error EEPROM error Unset model type Heat sink overheat error Gas leak detection 4 way valve inverse error lt Display 1 gt lt Display 2 gt Communication error between MCUs Check outdoor P C board Defect Replace lt Display 1 gt lt Display 2 gt Heat sink temp sensor TH error Refer to F13 column O00000 O 6 6 6 e 9 OO OOO O e e o 6 9 Display 1 Display 2 EEPROM error Refer to F31 column OOoeeoo 000000 Display 1 gt Display 2 gt Unset model type Refer L10 column e e O O e
13. eBjeuosiq pod eBueuosiq o dn Jo 06 10 006 005 10 OGL pod uonons 009 BOIS 10 eoeds Q eip g eip 104 s lou deys N L eip z 8ry slloq QL eip gelp 104 Buo 717 X L eip z 400pjno Burxij 104 0 9 elp 8 gt 9 eip epis pnb pod edid 6u no uuoo 4c V eip epis seo pod edid Bunoeuuo syoq Joyoue o eip g eip 404 deys N L eip z 961 801 009 92 2 5 82 TIS S gt s 58 5 o gt gg x oz eip z joy 17 12 06 12 11 06 SVM 12085_001 050 indd 17 FILE NO SVM 12085 2 2 RAV SP80 ATP uurgium SMOIA Z Buldid 10 inoyoouy
14. 1040 6005 29N p4eog 9 d a N3dHD NUD MOTI3A 73A NYO amg mg 3lIHM IHM yovga X18 20100 at e if E 01140 uone4edo y Oc AE 23 uo s 941 00 N9 seH HEH 0 12 06 12 11 06 24 SVM 12085_001 050 indd 24 4 2 RAV SP80 ATP Control P C Board FM REACTOR FILE NO SVM 12085 CN604 eh CPI MCC 1571 pers M Waaa MENS TL t DE eke teo oS cles oe NN NA SG wee oe TD e 5182 wH F Re ar eR Im E e pe ease TO f o SE ee ee S REACTOR C 1de1 lCN601 TE f 1651 WH PSS LZ s OEE C E pog zw ap 5 PMV To INDOOR UNIT POWER SUPPLY 220 240V 50Hz Symbol Parts name Symbol Parts name Field wiring Color Indication 4 BLK BLACK 49C Compressor case thermostat Pulse motor valve Protective earth BLU BLUE 4WV 4 way valve coil Pipe temp sensor discharge Terminal block GRY GRAY CM Compressor Heat exchange temp sensor 1 DRE RED RED FM Fan motor Heat exchange tem
15. Fan motor forced operation Drive the fan motor forcedly When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control No operation especially PMV full open operation Open PMV Pulse Motor Valve fully When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control PMV full close operation Close PMV Pulse Motor Valve fully When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control Note 1 Note 2 SVM 12085 051 114 indd 81 PMV middle opening operation Set PMV Pulse Motor Valve to middle opening 250 pulses When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control Indoor cooling test run demand Indoor heating test run demand Only when combining with the following indoor unit cooling heating operation can be performed from the outdoor unit Test run is available Indoor unit of 4 series and after 5 407 etc Test run is unavailable Indoor units other than the above mentioned indoor units or indoor units other than above mentioned indoor units are included in the twin connection The forced test run by this setting cannot be cleared on the indoor remote controller Be sure to clear the test run by operation of t
16. Display 1 Display 2 gt Other error Compressor disorder due to sudden change of load etc No code Although the display of outdoor LED outputs the unit automatically restarts and error is not determined LED display also may output due to wire coming off of compressor O 6 O O O 000000 SVM 12085_051 114 indd 72 12 06 12 11 15 FILE NO SVM 12085 8 2 5 Diagnostic Procedure for Each Check Code Outdoor Unit Temperature sensor Temperature Resistance value characteristic table TA TC TCJ TE TS TO sensors TD TL sensors Representative value Representative value Temperature Resistance value Temperature Resistance value Minimum value Standard value Maximum value Minimum value Standard value Maximum value TA TC TCJ TE TS TO sensors Resistance Temperature TD TL sensors Resistance 50 or lower Resistance 50 or higher 0 10 20 30 40 50 60 70 80 90 100 Temperature C As TH sensor Outdoor unit heat sink temp sensor is incorporated in the outdoor control P C board the resistance value cannot be measured Eric rom SVM 12085 051 114 indd 73 12 0642 11 15 AM FILE NO SVM 12085 8 3 Table Inspection of outdoor unit main parts mo rece Check
17. Confirmation of lamp display Trouble gt When 4 way air discharge cassette type gt wireless remote controller is connected Check defective position and parts 1 Outline of judgment The primary judgment to check where a trouble occurred in indoor unit or outdoor unit is performed with the following method Method to judge the erroneous position by flashing indication on the display part of indoor unit sensors of the receiving unit The indoor unit monitors operating status of the air conditioner and the blocked contents of self diagnosis are displayed restricted to the following cases if a protective circuit works 48 SVM 12085_001 050 indd 48 12 06 12 11 06 FILE NO SVM 12085 8 2 Troubleshooting 8 2 1 Outline of judgment The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method Method to judge the erroneous position by flashing indication on the display part of the indoor unit sensors of the receiving part The indoor unit monitors the operating status of the air conditioner and the blocked contents of self diagnosis are displayed restricted to the following cases if a protective circuit works Go off Go on Xx Flash 0 5 sec Lamp indication Check code Cause of trouble occurrence Operation Timer Ready 5 e e No indication at all Power supply OFF or miswiring between
18. Display 1 gt Display 2 gt OO eoo O e 6 o eo Heat sink temp sensor TH error Check outdoor P C board Defect Replac Display 1 gt Display 2 gt OO eoo O e 6 6 O6 9 Miswiring of heat exchanger sensor TE TS Is mounting status of TE and TS sensors correct YES Is connection of CN600 correct Is resistance value of TS sensor correct YES Is connection of CN601 correct Is resistance value of TE sensor correct YES Check outdoor P C board Defect Replace Correct sensor mounting Correct connector Sensor error Replace Correct connector Sensor error gt Replace SVM 12085 051 114 indd 64 Display 1 gt Display 2 gt 000000 EEPROM error Check outdoor P C board Defect Replace 12 0642 11 15 AM Outdoor LED display lt Display 1 gt lt Display 2 gt FILE NO SVM 12085 lt ln case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit Compressor break down Is AC mains voltage correct AC198 to 264V YES Is wire connection correct Compressor lead Board side Compressor side Reactor lead Power supply lead Does an abnormal overload happen NO Check outdoor P C board Defect Replace Correct power supply line Check wire connection and correct it Remove and improve the cause
19. Is there gas leak Is there refrigerant shortage NO Is PMV under correct conditions YES 15 service valve fully opened YES Is there crushed pipe NO Check temp sensor TD sensor CN603 TS sensor CN600 Check outdoor P C board Defect Replace Repair defective part Recharge refrigerant Correct defective part Replace defective part Open service valve fully Correct and replace piping Correct connector Sensor error Replace 12 0642 11 15 AM SVM 12085_051 114 indd 70 Outdoor LED display Display 1 gt lt Display 2 gt O ee FILE NO SVM 12085 lt ln case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit 4 way valve reversal error Temperature sensor check TE sensor CN601 TS sensor CN600 Indoor TC sensor Defect Correct and repair Replace coil of 4 way valve Does 4 way valve work correctly Check pipe temp etc in cooling heating operation Is the coil resistance value of 4 way valve between 1 3kQ and 1 6 Check operation of outdoor P C board See below Check outdoor P C board Defect replace Check 4 way valve Defect Replace Check method of outdoor P C board operation Self holding valve type 1 Set SW804 of Dip switch as the following figure and then push SW801 fo
20. O e O O Display 1 gt lt Display 2 gt Heat sink overheat error Refer to P07 column OO OOO O00000 lt Display 1 gt lt Display 2 gt Gas leak detection Refer to P15 column O e o 6 6 9 Display 1 Display 2 gt 4 way valve inverse error Refer to P19 column OO OOO O00000 267 SVM 12085_051 114 indd 67 12 06 12 11 15 Outdoor LED display lt Display 1 gt lt Display 2 gt FILE NO SVM 12085 lt ln case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp error Is there gas leak Repair defective position Is there refrigerant shortage Recharge refrigerant NO Repair defective position Is PMV under correct conditions Replace defective part YES Does an abnormal overload happen Hemove and improve the cause of overload NO Is connection of CN603 correct Correct connector Is resistance value of TD sensor correct Sensor error Replace Check outdoor P C board Defect Replace There is a possibility that it is one of the following errors Confirm LED on outdoor P C board to judge which error it is Power supply error Vdc High pressure protective operation Case thermostat operation Display 1 gt OOeoee lt Display 2 gt e e e Case thermostat operation Refer to H
21. Overload 30 Low load 15 This compressor has 4 motor value when compressor frequency Hz is measured by meter becomes 2 times of No of compressor revolutions rps RAV SP45 ATP Cooling Standard Pressure Pipe surface temperature C MPa kg cm g Discharge Suction Indoor heat exchanger Outdoor heat exchanger Pd Ps Pd Ps TD TS TC TE Compressor drive revolution frequency rps Indoor fan Indoor Outdoor temp conditions DB WB C Indoor 27 19 Outdoor Overload 32 24 Low load 18 15 5 Heating Standard 20 Overload 30 Low load 15 This compressor has 4 motor value when compressor frequency Hz is measured by meter becomes two times of No of compressor revolutions rps SVM 12085_001 050 indd 21 E 12 06 12 11 06 AM RAV SP56 ATP TS sensor Accumulator 1L Standard TD sensor gt Rotary compressor DA150A1F 21F Pressure E 4 way valve STF 0213Z Muffler 019 05 x 160L TO sensor 5 Heat exchanger FP1 3 flat fin 9 08 ripple 2 rows 20 stages Dis PMV FILE NO SVM 12085 Pulse Motor Valve CAM B30YGTF 2 sensor
22. A sensor trouble may cause a liquid back flow or abnormal overheat resulting in excessive shortening of the compressor life In a case of trouble on the compressor be sure to check there is no error in the resistance value or the refrigerating cycle of each sensor after repair and then start the operation 2 Discharge temperature release control 1 When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control this control lowers the operation frequency It subdivides the frequency control up to 0 6Hz to stabilize the cycle 2 When the discharge temperature detected an abnormal stop zone the compressor stops and then restarts after 2 minutes 30 seconds The error counting is cleared when the operation continued for A minutes If the error is detected by B times without clearing the error is determined and restarting is not performed The cause is considered as excessively little amount of refrigerant PMV error or clogging of the cycle 3 For displayed contents of error confirm on the check code list TD C Abnormal stop 117 111 NETT 107 109 105 106 102 103 Frequency slow up Up to command As command is 93 96 SP40 to a SP56 SP80 A 6 10 SP40 to SP56 in the parentheses B 8 4 _ 38 SVM 12085_001 050 indd 38 12 06 12 11 06 AM FILE NO SVM 12085 3 Outdoor fan control Revolution frequency allocation of fan taps
23. Dip switch setup lt Latest error display gt When turning on 1 only of SW803 the latest error Only 1 of SW803 is ON is displayed As the memory is stored it can be confirmed even if the power supply is turned off Cole once excluding outside temp sensor TO error LH When the work finished or the outdoor temp SES sensor TO error was found turn off all of SW803 Error display which occurs at present gt The error which occurs at present is displayed All SW803 are OFF Initial status C Cala Zm Display selection Display 1 lt gt Display 2 gt When an error happens some of yellow LED No error Error occurred Push SW800 D800 to D804 turn on Display 1 D800 Yellow f pushing the button switch SW800 for 1 second D801 under the above condition the yellow LED is D802 Yellow Yellow displayed with flashing lt Display 2 gt D803 Yellow When pushing SW800 for 1 second again the D804 Yellow status returns to lt Display 1 gt D805 The error contents can be confirmed by combining lt Display 1 gt and lt Display 2 gt Example of discharge temp sensor error Go off Go on Flash Outdoor Check and troubleshooting LED display Item without special mention Indicates part of outdoor unit Indoor Outdoor communication error Is setting of group address Check Item code 14 of rem
24. Os D801 Yellow Le D802 Yellow Go off O Go on Flash Coa Cos D803 Yellow SL d 50 1 D804 Yellow O D805 Green Display 1 Initial display 000000 Display 2 51 800 operation 000000 Error contents Normal Wired remote controller Error code eeoeoo OOO OO Discharge temp sensor TD error F04 000000 Heat exchanger temp sensor TE error F06 Oo Heat exchanger temp sensor TL error F06 F07 e eoeo Outside temp sensor TO error F08 000000 Suction temp sensor TS error 206 F12 000000 Heat sink temp sensor TH error F13 L29 O Heat exchanger sensor TE TS miswiring F06 F15 O EEPROM error Compressor break down F31 L29 00000 Compressor lock 000000 Current detection circuit error 000000 Case thermostat operation Model unset L10 L29 O Communication error between MCU L29 O e eeeo Other error Compressor disorder etc Discharge temp error Error is not determined P03 oeoeeo Power supply error P04 POS e eeo Heat sink overheat error P07 L29 O Gas leak detection P15 L29 4 way valve reverse error P19 L29 High pressure pr
25. S1 31 40sues yun O OJOJOO e x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 19591 peioejep sem Josuas dwa eBieuosip jo uioug uedo U9 U09 10418 Jo uoreue dx3 Joopino uono l q om WIS Burusej Buluselj Jo 0D usel 009 01 10sues un uonisod Apeoy uoneoipul uoneoipur 42019 105 6 1511 2 49949 52 12 06 12 11 15 SVM 12085_051 114 indd 52 FILE NO SVM 12085 uo sieydepe ejdnjnuu eju L Jeydepe Omen ldillnui e19u Jo 5 depe uongeoiunuuuJoo ueis s O X O JejoJjuoo
26. Displayed when error is detected Check temp sensor TE Check outdoor PC board Disconnection or short circuit of outdoor temp sensor TL Stop Displayed when error is detected Check temp sensor TL Check outdoor P C board Disconnection or short circuit of suction temp sensor TS Stop Displayed when error is detected Check suction temp sensor TS Check outdoor P C board Miss mounting of outdoor temp sensor TE TS Stop Displayed when error is detected Check temp sensor TE TS Check outdoor P C board Disconnection or short circuit of outside temp sensor TO Continue Displayed when error is detected Check outside temp sensor TO Check outdoor P C board Disconnection or short circuit of heat sink temp sensor TH Stop Displayed when error is detected Check outdoor P C board Outdoor P C EEPROM error Stop Displayed when error is detected Check outdoor P C board Incorrect setting of service P C board Stop Displayed when error is detected Outdoor service P C board Check model type setting jumper wire Communication error between MCUs on outdoor P C board Stop Displayed when error is detected Check outdoor P C board Heat sink overheat error Heat sink temp sensor detected over the specified temperature Stop Displayed when error is detected
27. FILE NO SVM 12085 lt lnverter assembly gt 103 SVM 12085 051 114 indd 103 12 06 12 11 15 AM FILE NO SVM 12085 Location RAV Part No Description SP404ATP E SP454ATP E 1 No 08 43T60426 Fuse 6 3A 250VAC 43160422 Reactor CH 76 TM1 104 SVM 12085 051 114 indd 104 12 0642 11 15 AM FILE NO SVM 12085 11 2 SP564ATP E SP564ATJP E 5 K STA OA Z l Wr ARATE BEE ASA N 1 Y AS SN A lt Ker V7 2 Nz 105 SVM 12085 051 114 indd 105 12 06 12 11 15 AM FILE NO SVM 12085 SP564ATP E SP564ATJP E Location Part No Description z 1 43T42352 BASE PLATE ASSEMBLY 0 02 43T00605 FRONT PANEL CABINET ASSEMBLY 03 RIGHT PANEL CABINET ASSEMBLY 04 LEFT PANEL CABINET ASSEMBLY 05 PCAKED VALVE COVER ASSEMBLY UPPER CABINET ASSEMBLY 0 0 7 43T39348 MOTOR BASE 8 43T39347 MOTOR BASE 43T41451 COMPRESSOR DA150A1F 21F 010 43T48302 ACCUMLATOR ASSEMBLY 011 43T48303 ACCUMLATOR ASSEMBLY 012 VALVE 4WAY 013 COIL VALVE 4WAY 014 VALVE PULSE MODULATING 015 COIL PMV 016 VALVE PACKED 12 7 DIA 017 VALVE PACKED 6 35 DIA 018 CONDENSER ASSEMBLY 019 CONDENSER ASSEMBLY FAN MOTOR PROPELLER FAN FAN GUARD
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29. 4 Muffler 031 75 x 200L tributor Strainer 2 step muffler 025 x 2001 In cooling operation In heating operation R410A 1 4 kg Pipe surface temperature C Compressor MPa kg cm g Discharge Suction Indoor heat exchanger Outdoor heat exchanger drive revolution frequency Pd Ps Pd Ps TD TS TC TE rps Refrigerant pipe gt at liquid side 26 4 Packed valve Refrigerant pipe Ix at gas side 012 7 Packed valve Indoor fan Indoor Outdoor temp conditions DB WB C Indoor Outdoor 27 19 Cooling Overload 32 24 Low load 18 15 5 Standard 20 Heating Overload 30 Low load SVM 12085_001 050 indd 22 22 15 12 06 12 11 06 FILE NO SVM 12085 RAV SP80 ATP TS sensor PMV 9 TO sensor TL sensor Pulse Motor Valve CAM B30YGTF 2 4 way valve LI m Q2 x 83 6001 2 x 03 x 5501 Strainer Q2 x 83 x 450L STF 0218G i Muffler Heat exchanger 28 2 rows 34 stages 025 x L180 FP1 45 flat fin b TD A sensor ccumulator Sub ass y Refrigerant pipe gt lt at liquid side 29 5 Packed valve Accumulator 1 8L Rotary compressor 25 x 1210 DA220A2F 22
30. 43 43 Gas side mm Connecting pipe Liquid side mm Sound pressure level Cooling Heating dB A Sound power level Cooling Heating dB A Outside air temperature Cooling Outside air temperature Heating 15 to 15 15 to 20 14 SVM 12085 001 050 indd 14 12 0642 11 06 AM FILE NO SVM 12085 1 2 Operation Characteristic Curve RAV SP40 ATP SP45 ATP lt Cooling gt lt Heating gt 14 12 10 4 Conditions A Conditions Indoor DB27 C WB19 C 1 7 ofh 4 74 Indoor 20 1 2 Outdoor DB35 C 1 Outdoor DB7 C WB6 C Air flow High rs asi r Air flow High 1 Pipe length 7 5m Pipe length 7 5m 230V i r i 230V 0 i i 0 20 40 50 60 70 80 90 100 0 20 40 60 80 90100 120 RAV SP56 ATP lt Cooling gt lt Heating gt 16 RAV SM564BT CT KRT MUT 4 RAV SMS564BT KRT MUT RAV SM564SDT RAV SM564SDT 12 SM564UT Conditions Indoor DB20 C Outdoor 087 6 Outdoor DB35 C _ o Air flow High 2 i Air flow High Pipe length 7 5m Pipe length 7 5m 230V 230V j j 7 e 1 ee ee S 0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80 90 100110120 Compressor speed rps Compressor speed rps
31. Reference values Nominal Outer diameter diameter mm Tightening torque Nem kgfem 14 to 18 1 4 to 1 8 Tightening torque of torque wrenches available on the market Nem kgfem 16 1 6 18 1 8 33 to 42 3 3 to 4 2 42 4 2 50 to 62 5 0 to 6 2 55 5 5 SVM 12085_001 050 indd 30 63 to 77 6 3 to 7 7 30 65 6 5 12 06 12 11 06 FILE NO SVM 12085 6 3 Tools 6 3 1 Required Tools Refer to the 4 Tools Page 13 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 u When the compound gauge s pointer has indicated 0 1 Mpa 76 cmHg place the handle Low in the fully closed position and turn off the vacuum pump s power switch Connect the charge hose to packed valve service port at the outdoor unit s gas side tie chard h BU Keep the status as it is for 1 to 2 minutes and ensure Onnect me QENE vacuum purnp that the compound gauge s pointer does not return adapter TEA Set the refrigerant cylinder to the electronic balance ce fully both packed valves at liquid and gas connect the connecting hose to the cylinder and the SIGes connecting port of the electronic balance and charge liquid refrigerant P
32. Replace Check outdoor P C board Defect Replace Display 1 Display 2 gt e e O Heat exchanger temp sensor TL error Refer to F07 column lt Display 1 gt lt Display 2 gt Oeooee Suction temp sensor TS error Refer to F12 column Display 1 gt Display 2 gt O e o 6 Oo Miswiring of heat exchanger sensor TE TS Refer to F15 column SVM 12085 051 114 indd 63 Display 1 gt Display 2 gt O00000 Heat exchanger temp sensor TL error Is connection of CN604 correct Is resistance value of TL sensor correct Correct connector Sensor error Replace Check outdoor P C board Defect Replace 12 0642 11 15 AM Outdoor LED display Display 1 gt lt Display 2 gt FILE NO SVM 12085 lt ln case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit Outside temp sensor TO error Is connection of CN602 correct Is resistance value of TO sensor correct Check outdoor P C board Defect Replace Correct connector Sensor error Replace Display 1 gt Display 2 gt Oeooee Suction temp sensor TS error Is connection of CN600 correct Is resistance value of TS sensor correct Check outdoor P C board Defect Replace Correct connector Sensor error Replace
33. Torque at tightening time 1 47 x 0 1Nem Compressor lead U CN200 Red V CN201 White W CN202 Black Reactor lead Relay connector 2 positions Remove the power wire from the power supply terminal block Torque at tightening time 2 5 0 1Nem 4 Remove the earth wire from the control PC board Truss B tight screw O4 x 6 1 pc 5 Remove the fixing screws of the control PC board Screw with collar for fixing element x 16 7 pcs Pan S tight screw for fixing P C board 3 x 20 1 pc 6 Remove the control P C board Supporter 5 positions NOTE It is difficult to take out it because of radiator grease for heat sink 7 Mount a new control P C board NOTE Do not forget to attach the aluminum plate Q201 and the insulating sheet Q300 Applying a little of radiator grease at the rear surface of the insulating sheet in advance to adhere to the heat sink makes easy the work 93 FILE NO SVM 12085 Remarks Compressor lead Relay connector Control 2 positions P C board 1 at rear side Fan motor Bundling band Reactor lead PMV coil Indoor power supply Screw for fixing P C board Control P C board Insulating sheet Q300 Aluminum plate Q201 12 06 12 11 15 AM Part name Exchange of electric parts Continued SVM 12085_051 114 indd 94 Procedure 1 Reactor 1 Carry out works of 1 of and 3 2 Remove the relay connector connected to the con
34. dust the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with new refrigerant during installation work or service work If an incorrect work or incorrect service is performed there is a possibility to cause a serious accident Use the tools and materials exclusive to R410A to purpose a safe work 2 Cautions on Installation Service 1 Do not mix the other refrigerant or refrigerating oil For the tools exclusive to R410A shapes of all the joints including the service port differ from those of the former refrigerant in order to prevent mixture of them 2 As the use pressure of the new refrigerant is high use material thickness of the pipe and tools which are specified for R410A In the installation time use clean pipe materials and work with great attention so that water and others do not mix in because pipes are affected by impurities such as water oxide scales oil etc Use the clean pipes Be sure to brazing with flowing nitrogen gas Never use gas other than nitrogen gas For the earth protection use a vacuum pump for air purge R410A refrigerant is azeotropic mixture type refrigerant Therefore use liquid type to charge the refrigerant If using gas for charging composition of the refrigerant changes and then characteristics of the air conditioner change 3 lt E 3 Pipe Materials For the refrigerant pipes copper pipe and joints are main
35. removing connectors REQUIREMENT As each connector has a lock mechanism avoid to remove the connector by holding the lead wire but by holding the connector 86 FILE 5 12085 Remarks Inverter assembly Remove the connectors with locking function by pushing the part indicated by the arrow mark 12 07 12 11 00 AM Part name Control P C board assembly SVM 12085_051 114 indd 87 Procedure 1 Remove sub board base from inverter frame BT 2T 4 x 10 2 pcs Remove connector of control board frame side 2 Remove lead wire connector that connected from control board frame to other parts 1 Lead wire Connect with terminal block Black white orange single phase red white black orange three phase earthed lines black 1 pc 2 Connector CN605 Sub SW board black Warning 1 X Warning 1 Please remove housing part s lock before removing connectors 3 Remove inverter box metal plate 4 Remove control board frame from PC board base Remove while heat sink is still attached to control board frame Warning 2 Remove PC board base s hook 4 places hold heat sink pull up 5 Take off 2 screws that connect heat sink and control board frame 6 Install new control board frame Warning 3 When install new control board frame please correctly insert the board Make sure to install that heat sink touch m
36. rpm psa s wo Wo Wo I Wa S WA Wa SW 250 300 400 480 500 520 560 640 670 700 750 800 880 980 SP40to SP56 200 SP80 200 230 260 300 340 380 420 460 520 570 600 630 670 710 740 3 1 Cooling fan control lt SP40 to SP56 gt lt SP80 gt The outdoor fan is controlled by TE sensor TO The outdoor fan is controlled by TL sensor TO sensor and the operation frequency It is controlled sensor and the operation frequency by every 1 tap of DC fan control 15 taps The outdoor fan is controlled by every 1 tap of DC Only for 60 seconds after start up of operation it is fan control 15 taps fixed by the maximum fan tap corresponded to the 2 Only for 60 seconds after the operation has zone in the following table and then the fan is started the maximum fan tap corresponding to the controlled by temperature of TE sensor zone in the following table is fixed and then the fan 8 When temperature of TD sensor became high is controlled by temperature of TL sensor sufficiently it is controlled so that the fan revolution frequency will become higher ignoring TE sensor temperature 1 tap 20 sec Up to the maximum TL WF tap revolution frequency of each zone Operation with W1 in case of fan OFF 58 Revolution frequency hold 1 tap 20 sec Up to the maximum revolution frequency of eac
37. 1 Compressor does not operate 15 not 3 minutes delay 3 minutes after compressor OFF 15 not the outdoor unit in standby status though the remote controller reached the setup temperature Does not operate during fan operation 15 not an overflow error detected on the indoor unit 15 not outside high temperature operation controlled in heating operation 2 Indoor fan does not rotate Does not cool air discharge preventive control work in heating operation 3 Outdoor fan does not rotate or air volume changes Does not high temperature release operation control work in heating operation Does not outside low temperature operation control work in cooling operation 15 not defrost operation performed 4 ON OFF operation cannot be performed from remote controller 15 not forced operation performed 15 not the control operation performed from outside remote side 15 not automatic address being set up 15 not being carried out a test run by operation of the outdoor controller a Did you return the cabling to the initial positions b Are connecting cables between indoor unit and receiving unit correct 2 Troubleshooting procedure When the power is turned on at the first time or when indoor unit address setting is changed the operation cannot be performed for maximum approx 5 minutes after power ON When a trouble occurred check the parts along with the following procedure
38. 15 to 19 60 to 79 eeoeeo 10to 5 4 to 4 9 20 to 24 80 to 99 oeoceeo 5 to 1 5 to 5 9 25 to 29 100 to 119 eooeeo 0104 6 to 6 9 30 to 34 120 to 139 OOO O 5to 9 7 to 7 9 35 to 39 140 to 159 00000 10 14 8 to 8 9 40 to 44 160 to 179 15 to 19 9 to 9 9 45 to 49 180 to 199 201024 10 to 10 9 50 to 54 200 to 219 O00000 25 to 29 11 to 11 9 55 to 59 220 to 239 eeooeo 30 to 34 12 to 12 9 60 to 64 240 to 259 35 10 39 1310 13 9 65 10 69 260 10 279 eoooeo 40 to 44 14 to 14 9 70 to 74 280 to 299 45 10 49 15 10 15 9 75 10 79 300 10 319 00000 50 to 54 16 16 9 80 84 320 to 339 55 to 59 17 to 17 9 85 to 89 340 to 359 60 to 64 18 to 18 9 80 to 84 360 to 379 65 69 1910 19 9 95 0 99 380 to 399 eeoeoo 70 to 74 20 to 20 9 100to 104 400to 419 75 10 79 21t021 9 10510109 42010 439 eooeoo 80 to 84 221022 9 110to 114 440to 459 OOO OO 85 to 89 231023 9 115to119 46010 479 00000 90 94 24 to 24 9 120 124 480 to 499 95 to 99 251025 9 125to 129 eoeooo 100 to 104 261026 9 13010 134 OO OOO 105 to 109 271027 9 13510 139 eeoooo 110 to 114 281028 9 140to 144 O OOOO 115 10 119 29 to 29 9 14510 149 Over 120 30 to 30 9 150 10 154 Sensor error unconnected Over 31 Over 155 As TD TL and TH are sensors for high temperature there is error at normal temperature or b
39. 24 x 10 1 pc Remove the piping panel Rear Remove screws of the piping panel Rear and the bottom plate Hexagonal screw O4 x 10 2 pcs Remove the valve fixing plate Remove bolts of the valve Hexagonal screw 6 x 15 4 pcs Remove screws of the valve fixing plate and the partition plate ST1T 04 x 8 1 pc Remove screws of the valve fixing plate and the accumulator ST1T 04 x 8 1 pc Cut off the bundling band for the dis charge pipe and the suction pipe and then remove each sensor and coil lead of PMV 6 Remove the soundproof plate Upper side outer winding inner winding 7 Remove terminal cover from the compressor and then remove the compressor lead and also the compressor case thermo 8 Remove TD sensor fixed to the discharge pipe 9 Remove the compressor lead Leave the ferrite core attached to the electric parts box as it is Control P C board U CN200 Red V CN201 White W CN202 Black Tightening torque 1 47 x 0 1Nem 96 FILE NO SVM 12085 Remarks Bundling band for Neatiprooti Compressor Casejthermo 1 Pipe cover x bundling band Black pipe cover for heat proof bundling band for heat proof each sensor Mb TO TE TD TS sensors PMV coil lea 12 06 12 11 15 Part name Compressor Compressor lead Continued SVM 12085_051 114 indd 97 Procedure 10 Using a burner remove the discharge pipe and the suction pipe
40. 3 seconds or continued 7 C lt TE lt 12 C for 1 minute The defrost operation also finishes when it continued for 10 minutes even if TE sensor temperature was 7 C or lower 3 After defrost operation was reset the compressor stopped for approx 40 seconds and then the heating operation starts Start of heating operation TE C 0 10 15 39 45 55 min The minimum TE value and To value between 10 and 15 minutes after heating operation has started are stored in memory as and To0 respectively In normal To In abnormal To When status TE ToO gt 3 C When status TE0 TE gt 3 C continued for 20 seconds continued for 20 seconds When status TE ToO To gt 2 C When status TE gt 2 C continued for 20 seconds continued for 20 seconds When the status TE lt 25 C continued for 20 seconds When compressor operation status of TE lt 2 C is calculated as d minutes The time of above d can be changed by exchanging jumper J805 and J806 of the outdoor control P C board Setting at shipment 150 minutes 150 minutes Setting at shipment 90 minutes 60 minutes 30 minutes O Short circuit X Open 11 Compressor protective control lt SP80 only gt 1 This control purposes to raise the operation frequency until 45Hz for 2 minutes in order to protect the compressor Prevention of oil accumul
41. FIN GUARD REACTOR COMPRESSOR LEAD ASSEMBLY THERMOSTAT BIMETAL HOLDER THERMOSTAT HOLDER SENSOR HOLDER SENSOR HOLDER SENSOR HOLDER SENSOR CUSHION RUBBER BONNET 12 7 DIA BONNET 6 35 DIA NUT FLANGE WATERPROOF CAP DRAIN NIPPLE MARK TOSHIBA SOUNDPROOF COVER UP 43T04316 SOUNDPROOF COVER INSIDE 1 43T04317 SOUNDPROOF COVER OUTSIDE 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 0 106 SVM 12085_051 114 indd 106 12 06 12 11 15 AM FILE NO SVM 12085 lt lnverter assembly gt 107 SVM 12085_051 114 indd 107 12 06 12 11 15 AM FILE NO SVM 12085 Location RAV Part No Description SP564ATP E SP564ATJP E 1 No 08 43T60426 Fuse 6 3A 250VAC 43160422 Reactor CH 76 TM1 108 SVM 12085_051 114 indd 108 12 06 12 11 15 AM FILE NO SVM 12085 11 3 RAV SP804ATP E SP804ATJP E 109 SVM 12085_051 114 indd 109 12 06 12 11 15 AM FILE NO SVM 12085 RAV Description SP804ATJP E BASE PLATE ASSEMBLY 1 AIR OUTLET CABINET 1 FRONT PANEL CABINET ASSEMBLY 1 RIGHT PANEL CABINET ASSEMBLY 1 UPPER CABINET ASSEMBLY 1 FRONT PANEL PIPING CABINET 1 BACK PANEL PIPING CABINET 1 MOTOR BASE 1 MOTOR BASE GUARD FIN ASSEMBLY 1 COMPRESSOR DA220A2F 2
42. In the concurrent twin system when TOSHIBA specified branching pipe is used it can be reused Branching pipe model name RBC TWP30E 2 On the existing air conditioner for simultaneous operation system twin system there is a case of using branch pipe that has insufficient compressive strength In this case please change it to the branch pipe for R410A 6 6 4 Curing of Pipes When removing and opening the indoor unit or outdoor unit for a long time cure the pipes as follows Otherwise rust may generate when moisture foreign matter due to dewing enters in the pipes The rust cannot be removed by cleaning and a new piping work is necessary 1 month or more Pinching Outdoors Less than 1 month Pinching or taping Indoors Every time 34 SVM 12085_001 050 indd 34 12 06 12 11 06 AM FILE NO SVM 12085 6 6 5 Final Installation Checks Is there no scratch or dent on the existing pipes Existing pipe NO Use a new pipes Ls NO Is it possible to operate the existing air conditioner YES After the existing air conditioner operated in cooling mode for approx 30 minutes or longer recover the refrigerant For cooling the pipes and recovering of oil Refrigerant recovery Pump down method Nitrogen gas pressure 0 5 Mpa Remove the existing air conditioner from the piping and carry out flashing nitrogen pressure 0 5 Mpa to remove the remains inside o
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44. Outdoor unit does not completely operate Inter unit wire check correction of miswiring Check outdoor board Correct wiring of P C board When outdoor unit normally operates Check P C board Indoor receiving Outdoor sending Duplicated indoor unit address Duplicated indoor master unit There is group wire in individual indoor unit Unset indoor group address Displayed when error is detected Check whether remote controller connection Group Individual was changed or not after power supply turned on Finish of group construction Address check f group construction and address are not normal when the power has been turned on the mode automatically shifts to address setup mode Resetting of address Unset indoor capacity Displayed when error is detected Set indoor capacity DN 11 Abnormal input of outside interlock Displayed when error is detected Check outside devices Check indoor P C board Float switch operation Float circuit Disconnection Coming off Float switch contact error Displayed when error is detected Trouble of drain pump Clogging of drain pump Check float switch Check indoor P C board Indoor DC fan error Displayed when error is detected Position detection error Over current protective circuit of indoor fan driving unit operated Indoor fan locked Check indoor P C board 4 way valve sy
45. Short circuit Is resistance value of TL sensor correct Is there any defect such as loosening of nut in the outdoor fan Does the outdoor fan perform abnormal operation Open service valve fully and then perform test run Cooling season matching to the season Cooling operation Replace TL sensor YES Check outdoor fan Defect Replace retightening YES P22 error Check the same items as which interfere heat exchange Clogging of heat exchanger Eliminate interfering element Defect Correct defect Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Does indoor fan Are indoor fan motor operate correctly an connector correct Is there anything which interfere heat exchange of indoor unit Are resistance values of indoor TC and TCJ Replace sensors normal Repair defect sensor Check indoor P C board Defect Replace Choking up the filter Clogging of heat exchanger Short circuit Check overcharge of refrigerant clogging of cycle broken pipe abnormal overload etc Defect Correct defect Eliminate interfering element 12 06 12 11 15 AM FILE NO SVM 12085 lt ln case of SP80 gt Outdoor Check and troubleshooting LED display Item without special mention Indicates part of outdoor unit lt Display 1 gt
46. When all SW803 are OFF or when any of D800 to D804 goes on LED displays that the outdoor controller detects an error When status of SW803 is other than OFF various indications are displayed D800 to D804 Yellow LED Power ON display Green LED When the power of the outdoor unit is turned on LED goes on When SW801 and SW804 operate the specific operation LED flashes All LED are colorless when it goes off M H SW804 Specific operation switch SW801 Various operations during maintenance check operation ey OG S I 1 e SW800 LED display select switch I 1 SW803 H 4 Co 0 s r I D800 1 0801 D802 Yellow LED Error display various display D804 g c L9 D503 Green LED Serial signal Outdoor Indoor E a D502 Orange LED Serial signal Indoor gt Outdoor 11111 SW802 Selection of various initial settings 77 SVM 12085_051 114 indd 77 12 06 12 11 15 FILE NO SVM 12085 2 Selection of LED display SW800 SW803 operation 1 Display selection list The displayed contents of LED D800 to D804 on the outdoor control P C board can be exchanged by operation
47. been trained and is thus thoroughly acquainted with the knowledge related to this work The qualified service person who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work 12 06 12 11 06 AM FILE NO SVM 12085 Definition of Protective Gear When the air conditioner is to be transported installed maintained repaired or removed wear protective gloves and safety work clothing In addition to such normal protective gear wear the protective gear described below when undertaking the special work detailed in the table below Failure to wear the proper protective gear is dangerous because you will be more susceptible to injury burns electric shocks and other injuries Work undertaken Protective gear worn All types of work Protective gloves Safety working clothing Electrical related work Gloves to provide protection for electricians and from heat Insulating shoes Clothing to provide protection from electric shock Work done at heights 50 cm or more Helmets for use in industry Transportation of heavy objects Shoes with additional protective toe cap Repair of outdoor unit Gloves to provide protection for ele
48. communication wire miswiring Check communication U3 U4 terminals Check network adapter P C board Check central controller such as central control remote controller etc Check terminal resistance TCC LINK Central controller Indoor Gr sub unit error Detected by central controller side Continuation Stop According to each case Displayed when error is detected 2 The check code cannot be displayed by the wired remote controller Usual operation of air conditioner becomes unavailable For the wireless models an error is notified with indication lamp 3 This trouble is related to communication of remote controller B central system TCC LINK U4 and 201 E02 203 E09 or E18 is displayed or no check display on the remote controller according to the contents SVM 12085 051 114 indd 55 55 Check the check code of the corresponding unit from remote controller 12 06 12 11 15 AM Error mode detected by outdoor unit Operation of diagnostic function Check code Indoor unit after 4 series Cause of operation Disconnection short circuit of discharge temp sensor TD Status of air conditioner Stop Condition Displayed when error is detected FILE NO SVM 12085 Judgment and measures Check discharge temp sensor TD Check outdoor P C board Disconnection or short circuit of outdoor temp sensor TE Stop
49. lt Display 2 gt Fan system error Is AC mains voltage correct Check wiring construction 198 to 264V Ask repair of power supply Rotate shaft of the fan motor by hands during power OFF Can it rotate smoothly Is coil resistance of fan motor correct Between red and white lead wire 12 to 200 Between white and black lead wire 12 to 200 Between black and red lead wire 12 to 200 Check outdoor P C board Replace fan motor Defect Replace Single operation check for outdoor fan 1 Set Dip switch of SW804 as the following figure and then push SW801 for approx 1 second to check single operation of outdoor fan Use this method to check which fan upper or lower fan has a trouble When SW801 is pushed for 1 second again or 2 minutes passed the fan stops Outdoor fan single operation 2 After check turn off all Dip switch of SW804 Display 1 gt Display 2 gt Short circuit of compressor drive element Are connections of compressor lead and reactor correct Correct wiring Check referring to the Wiring diagram Does the same error occur in operation without compressor lead Replace outdoor P C board Check compressor Rear short etc Defect Replace e e O Display 1 gt Display 2 gt Position detection circuit error Check outdoor P C board Defect Replace
50. may exceed the limit create an opening with adjacent rooms or install mechanical ventilation combined with a gas leak detection device The concentration is as given below Total amount of refrigerant kg lt Concentration limit kg m Min volume of the indoor unit installed room m3 The concentration limit of which is used in air conditioners is 0 3kg m NOTE The minimum indoor floor area compared with the amount of refrigerant is roughly as follows When the ceiling is 2 7m high Range below the density limit of 0 3 kg m countermeasures not needed density limit of 0 3 kg m countermeasures 10 20 30 gt Total amount of refrigerant kg 113 SVM 12085_051 114 indd 113 12 06 12 11 15 AM TOSHIBA CARRIER THAILAND CO LTD 144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND SVM 12085 051 114 indd 114
51. not a trouble 5 Short intermittent operation preventive control 1 For 3 to 10 minutes after operation start in some cases the compressor does not stop to protect the compressor even if receiving the THERMO OFF signal from indoor However it is not abnormal status The operation continuance differs according to the operation status 2 When the operation stops by the remote controller the operation does not continue 6 Current release control No of revolutions of the compressor is controlled by AC current value detected by the outdoor board so that the input current of the inverter does not exceed the specified value Current A Frequency down Model 1 I1 value A Hold 0 Normal operation I1 value A 41 SVM 12085_001 050 indd 41 12 06 12 11 06 FILE NO SVM 12085 7 Current release value shift control 1 This control purposes to prevent troubles of Current release control value 11 the electronic parts such as the compressor A driving elements and the compressor during cooling operation Temperature range SP40 to SP56 2 The current release control value T1 is 50 C lt TO selected from the following table according to 45 lt TO lt 50 TO sensor value 39 lt TO lt 45 TO lt 39 TO error 8 Over current protective control 1 When the over current protective circuit detected an abnormal current s
52. of SW803 Switch Function Contents Error display Error generating at present Error generating at present is displayed This switch goes off when an error does not generate Refer to Page 79 Error display The latest error Latest error including present After error status was cleared the error which generated before can be confirmed by this setting Reconfirmation is available even if power supply was turned off once If an error generates at present the same contents as those of error which is generating at present are displayed Only error of TO sensor is not displayed by this setting Confirm it by setting of error which is generating at present Refer to Page 79 Temperature sensor display The detected value of temperature sensor is displayed Refer to Page 80
53. of compounds such as potassium fluoride potassium chloride and sodium fluoride to the borax boric acid compound 4 Piping materials for brazing and used brazing filler flux Piping material Used brazing filler Do not use Copper Copper Phosphor copper Silver Paste flux Copper Iron Iron Iron Silver Vapor flux 1 Do not enter flux into the refrigeration cycle 2 When chlorine contained in the flux remains within the pipe the lubricating oil deteriorates Therefore use a flux which does not contain chlorine 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the after brazing FILE NO SVM 12085 6 5 3 Brazing As brazing work requires sophisticated techniques experiences based upon a theoretical knowledge it must be performed by a person qualified In order to prevent the oxide film from occurring in the pipe interior during brazing it is effective to proceed with brazing while letting dry Nitrogen gas flow Never use gas other than Nitrogen gas 1 Brazing method to prevent oxidation 1 Attach a reducing valve and a flow meter to the Nitrogen gas cylinder 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 orde
54. off of the outdoor unit and result in injury When transporting the air conditioner wear shoes with additional protective toe caps When transporting the air conditioner do not take hold of the bands around the packing carton You may injure yourself if the bands should break When transporting the air conditioner use a forklift and when moving the air conditioner by hand move the unit with 4 people Do not customize the product Doing so may result in electric shock or other failure This air conditioner has passed the pressure test as specified in IEC 60335 2 40 Annex EE Before troubleshooting or repair work check the earth wire is connected to the earth terminals of the main unit otherwise an electric shock is caused when a leak occurs If the earth wire is not correctly connected contact an electric engineer for rework Check earth After completing the repair or relocation work check that the ground wires are connected properly wires Be sure to connect earth wire Grounding work Incomplete grounding causes an electric shock Do not connect ground wires to gas pipes water pipes and lightning rods or ground wires for telephone wires Do not modify the products Do not also disassemble or modify the parts It may cause a fire electric shock or injury Prohibition of y modification When any of the electrical parts are to be replaced ensure that the replacement parts satisfy the
55. other indoor unit in a group Check codes of E03 L03 L07 L08 1 These are representative examples and the check code differs according to the outdoor unit to be combined 49 SVM 12085_001 050 indd 49 12 06 12 11 06 Lamp indication Operation Timer Ready Alternate flash Check code FILE NO SVM 12085 Cause of trouble occurrence Heat exchanger sensor error Heat exchanger sensor TC error Heat exchanger sensor TA error Indoor unit sensor error Operation Timer Alternate flash Discharge temp sensor TD error Temp sensor TE error Temp sensor TL error Temp sensor TO error Temp sensor TS error Temp sensor TH error Temp sensor miswiring TE TS Sensor error of outdoor unit 1 Operation Timer o0 9 Xo Simultaneous flash Indoor EEPROM error Operation Timer Ready o o Xt Xt 4 Simultaneous flash Outdoor EEPROM error Operation Timer Ready Compressor break down Compressor lock Current detection circuit error Case thermostat worked Outdoor compressor system error 1 Operation Simultaneous flash Duplicated master indoor units There is indoor unit of group connection in individual indoor unit Unsetting of group address Missed setting Unset indoor capacity AUTO address f group construction and address are not norma
56. pcs Left side of front panel is inserted into side cabinet left Remove by pulling the upper part How to install 1 Insert front panel s hook into side cabinet left 2 Insert side cabinet left s hook into front cabinet s corner hole 3 Insert the removed screws to their positions 84 FILE SVM 12085 Remarks Motor base Front cabinet Front cabinet left side Corner hole Hook 45 45 Corner hole Hook 12 07 12 11 00 AM Part name Inverter assembly SVM 12085 051 114 indd 85 Procedure 1 Detachment 1 Perform work of item 1 of 2 Take off screws of the upper part of the front cabinet ST1T O4 x 8L 2 pcs f removing the inverter cover under this condition P C board can be checked f there is no space in the upper part of the upper cabinet perform work of 2 CAUTION Be careful to check the inverter because high voltage circuit is incorporated in it 3 Perform discharging by connecting polarities by discharging resistance approx 1000 40W or plug of soldering iron to terminals of the C14 printed as CAU TION HIGH VOLTAGE electrolytic capaci tor BOOUF of P C board WARNING The electrolytic capacitor may not normally discharge according to error contents and the voltage may remain Therefore be sure to discharge the capacitor WARNING For discharging never use a screw
57. 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 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 insta
58. when 2 minutes elapsed the operation returns to the normal control For RAV SP1104AT E to RAV SP1404AT E the part is not mounted so do not operate Heater output relay operation For check RY703 CN703 check Turn on relay for option heater 703 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control Outside output relay operation RY704 CN704 Turn on relay for outside output RY704 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control No operation especially SVM 12085 051 114 indd 82 Relay operation change for outside output CAUTION Do not use this setting 82 CAUTION Although these operations can be performed even during operation basically perform operation while the unit stops If performing this operation during driving the unit it is dangerous because the pressure may change suddenly 12 06 12 11 15 AM FILE NO SVM 12085 10 DETACHMENTS 10 1 RAV SP40 ATP SP45 ATP SP56 ATP Part name Procedure Remarks Common procedure CAUTION Never forget to put on the gloves at working time otherwise an injury will be caused by the parts etc 1 Detachment 1 Stop operation of the air conditioner and turn off the main switch of the breaker for a
59. work in cooling operation 15 not defrost operation performed 4 ON OFF operation cannot be performed from remote controller 15 not the control operation performed from outside remote side 15 not automatic address being set up When the power is turned on at the first time or when indoor unit address setting is changed the operation cannot be performed for maximum approx 5 minutes after power ON 15 not being carried out a test run by operation of the outdoor controller b Did you return the cabling to the initial positions c Are connecting cables of indoor unit and remote controller correct 2 Troubleshooting procedure When a trouble occurred check the parts along with the following procedure Trouble Confirmation of check code display Check defective position and parts NOTE For cause of a trouble power conditions or malfunction erroneous diagnosis of microcomputer due to outer noise is considered except the items to be checked If there is any noise source change the cables of the remote controller to shield cables 47 SVM 12085_001 050 indd 47 12 06 12 11 06 FILE NO SVM 12085 lt Wireless remote controller type gt 1 Before troubleshooting 1 Required tools instruments and screwdrivers spanners radio cutting pliers nippers etc Tester thermometer pressure gauge etc 2 Confirmation points before check a The following operations are normal
60. 001 050 indd 4 Indicates cautions Including danger warning The sentences or illustration near or in an illustrated mark describe the concrete cautious contents 12 0642 11 06 AM FILE NO SVM 12085 Warning Indications on the Air Conditioner Unit Confirmation of warning label on the main unit Confirm that labels are indicated on the specified positions If removing the label during parts replace stick it as the original Warning indication Description WARNING WARNING ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies Disconnect all remote electric before servicing power supplies before servicing WARNING WARNING Moving parts Do not operate unit with grille removed Stop the unit before the servicing Moving parts Do not operate unit with grille removed Stop the unit before the servicing High temperature parts High temperature parts You might get burned when removing You might get burned when removing this panel this panel CAUTION CAUTION Do not touch the aluminum fins of the unit Doing so may result in injury Do not touch the aluminum fins of the unit Doing so may result in injury FACTION CAUTION BURST HAZARD BURST HAZARD Open the service valves before the Open the service valves before the operation operation otherwise there might be the otherwise there might be the burst burst SVM 12085 001 050 indd 5 12 06
61. 04 column lt Display 1 gt OO OOO lt Display 2 gt O e e o e o Power supply error Refer to P05 column Display 1 OO OOO lt Display 2 gt High pressure protective operation Refer to P20 column SVM 12085 051 114 indd 68 Display 1 OO lt Display 2 gt O e e o e o Power supply error Is AC mains voltage correct Confirm power supply 198 to 264V construction etc Check outdoor P C board Defect Replace 12 0642 11 15 AM Outdoor LED display lt Display 1 gt lt Display 2 gt O e e o o 9 FILE NO SVM 12085 In case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit Heat sink overheat error Are the power devices on P C board screwed without looseness Rear sides of Q201 Q300 Q650 DB01 DB02 Are radiation grease properly applied 0201 0650 DBO1 2802 Apply radiation grease to objective parts Retightening of screws Be sure not to forget to attach insulating sheet between heat sink and Q300 Does something block the ventilation around the heat sink Does something block air flow from the fan Check outdoor P C board Defect Replace Remove blocking matter Correct short circuit SVM 12085 051 114 indd 69 Display 1 Display 2 gt e O Gas leak detection
62. 15 SVM 12085_001 050 indd 15 12 06 12 11 06 RAV SP80 ATP lt Cooling gt 13 12 11 Current A 0 10 20 lt Heating gt Current A Conditions Indoor DB27 C WB19 C Outdoor DB35 C Compressor speed rps Capacity variation ratio according to temperature RAV SP40 ATP SP45 ATP RAV SP56 ATP RAV SP80 ATP lt Cooling gt 105 100 Capacity ratio lt Heating gt 120 Capacity ratio Conditions Indoor DB27 C WB19 C 55 peer Indoor air flow High Pipe length 7 5 502 33 34 35 36 37 38 39 40 41 42 43 Outdoor temp 16 SVM 12085 001 050 indd 16 FILE NO SVM 12085 Conditions Indoor DB20 C Outdoor DB7 C WB6 C Compressor speed rps Conditions Indoor DB20 C Indoor air flow High Outdoor temp C Air flow High Air flow High Pipe length 7 5m Pipe length 7 5m 230V 230V 0 r uot pl i A s 40 50 60 70 80 0 10 20 30 40 50 60 70 80 90 100110 120 12 0642 11 06 AM FILE NO SVM 12085 2 CONSTRUCTION VIEWS EXTERNAL VIEWS SP56 ATP 2 1 RAV SP40 ATP SP45 lou jonpoud o lou edeus y x pep Joyoue 0 eip g eIp 404 uod lou wol t x etp z W efJeuosiq ft JO 006 yeg 6 y eip y ejou
63. 2L 1 ACCUMLATOR ASSEMBLY 1 ACCUMLATOR ASSEMBLY VALVE 4WAY 1 COIL VALVE AWAY 1 VALVE PULSE MODULATING 1 COIL PMV 1 VALVE BALL 15 88 DIA 1 VALVE PACKED 9 52 DIA 1 CONDENSER ASSEMBLY 1 5 I 4 3 CONDENSER ASSEMBLY Location Part No 001 43T42351 002 43T00606 003 43T00601 004 43T00607 005 43T00600 43T00608 007 43T00609 008 43T39342 43T39349 43T19346 43T41445 43T48301 43T48304 43T46383 43T63344 43T46382 43T46338 43T46381 43T46380 020 43743472 021 43743473 022 43747372 023 43747373 024 43721429 025 43720329 026 43719343 027 43722313 028 43719345 029 43771302 030 43760421 031 43754319 032 43750307 033 43719333 034 43749346 035 43747334 036 43747332 037 43739346 038 43779317 039 43779305 DRAIN NIPPLE 040 43T85529 MARK TOSHIBA 43704314 SOUNDPROOF COVER UP 43704312 SOUNDPROOF COVER INSIDE 43704313 SOUNDPROOF COVER OUTSIDE 110 1 1 010 1 011 012 013 014 015 016 017 018 019 1 STRAINER 25 4 DIA STRAINER 12 7 DIA FAN MOTOR PROPELLER FAN FAN GUARD BELLMOUTH FIN GUARD HANDLE COMPRESSOR LEAD ASSEMBLY THERMOSTAT BIMETAL HOLDER THERMOSTAT HOLDER SENSOR CUSHION RUBBER BONNET 15 88 DIA BONNET 9 52 DIA NUT FLANGE WATERPROOF CAP 2 3 5 SVM 12085 051 114 indd 110 12 0642 11 15 AM FILE NO SVM 12085 lt lnverter assembly gt 709 710 711
64. 42 11 06 AM FILE NO SVM 12085 Precaution for Safety The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual DANGER Before carrying out the installation maintenance repair or removal work be sure to set the circuit breaker to the OFF position Otherwise electric shocks may result Before opening the intake grille of the indoor unit or service panel or valve cover of the outdoor unit set the circuit breaker to the OFF position Failure to set the circuit breaker to the OFF position may result in electric shocks through contact with the interior parts Only a qualified installer 1 or qualified service person 1 is allowed to remove the intake grille of the indoor unit or service panel of the outdoor unit and do the work required Turn off Before starting to repair the outdoor unit fan or fan guard be absolutely sure to set the circuit breaker breaker to the OFF position and place a Work in progress sign on the circuit breaker before proceeding with the work When cleaning the filter or other parts of the indoor unit set the circuit breaker to OFF without fail and place a Work in progress sign near the circuit breaker before proceeding with the work When you access inside of the service panel to repair electric parts wait for about five minutes after turning off the breaker Do not start repairing immediately Otherwise you may get e
65. 9 Hole core drill Hexagon wrench Opposite side 4mm Tape measure Metal saw 10 11 12 Also prepare the following equipments for other installation method and run check 1 Clamp meter 2 Thermometer SVM 12085 001 050 indd 13 3 Insulation resistance tester Megger 4 Electroscope 13 12 06 12 11 06 1 SPECIFICATIONS 1 1 Outdoor Unit lt Super Digital Inverter gt Model name Outdoor unit RAV SP 404 454 FILE NO SVM 12085 564ATP 804ATP Power supply Power exclusive to outdoor is required 1 phase 220 240V 50Hz Compressor Motor Hermetic compressor Pole 4 4 Refrigerant charged 1 0 1 4 Refrigerant control Pulse motor valve Inter connecting pipe Outer dimension Standard length 7 5 7 5 7 5 7 5 Min length 5 5 5 5 Max total length 30 30 50 50 Additional refrigerant charge under long piping connector 20g m 21m to 30m 20g m 21m to 30m 40g m 21m to 50m 40g m 31m to 50m Height Outdoor lower m 30 30 30 30 difference Outdoor higher 30 30 550 30 550 30 780 780 290 290 Appearance Silky shade Muncel 1Y8 5 0 5 Total weight 40 44 Heat exchanger Finned tube Fan Propeller fan Fan unit Standard air flow high m3 min 40 40 Motor W
66. Check PMV Pulse Motor Valve Check clogging and short circuit of indoor outdoor heat exchanger Overcharge of refrigerant Recharge Outdoor fan system error Displayed when error is detected Check lock of fan motor Check power supply voltage AC198 to 264V Check outdoor P C board Short circuit error of compressor driving device Displayed when error is detected When performing operation while taking off compressor wire P26 error occurs Check control P C board When performing operation while taking off compressor wire an error does not occur Compressor rare short Position detection circuit error AP40 to AP56 is only SVM 12085 051 114 indd 57 Displayed when error is detected 57 Check control board 12 06 12 11 15 AM 8 2 3 Diagnostic Procedure for Each Check Code Outdoor Unit 1 This section describes the diagnostic method for each check code displayed on the wired remote controller 2 When APPLICATION CONTROL KIT TCB PCOS1E2 sold separately is connected the error contents can be judged by LED on the APPLICATION CONTROL KIT In this case turn off both bit 1 and 2 of DIP switch 01 on the All purpose control kit APPLICATION CONTROL KIT LED display FILE NO SVM 12085 lt ln case of SP40 to SP56 gt Check Countermeasures Part without special mention indicates a part of the outdoor unit Indoor Outdoor commu
67. Check screw tightening between PC Board and heat sink and check radiator grease Check heat sink cooling Detection of gas leak Discharge temp sensor TD Suction temp sensor TS detected temperature over the specified temp Displayed when error is detected Check gas leak Check whether the service valve is fully opened Check PMV Pulse Motor Valve Check broken pipe Check discharge temp sensor TD suction temp sensor TS 4 way valve inverse error After heating operation has started indoor heat exchanger temp lowers under the specified temp After heating operation has started outdoor heat exchanger suction temp rises over the specified temp Displayed when error is detected Check operation of 4 way valve Check outdoor heat exchanger TE suction temp sensor TS Check indoor heat exchanger sensor TC Check 4 way valve coil Check PMV Pulse Motor Valve Compressor break down Although operation has started operation frequency decreases and operation stops Displayed when error is detected Check power supply voltage AC198 to 264V Overload operation of refrigerating cycle Compressor lock Over current detection after compressor start up Displayed when error is detected Trouble of compressor Lock etc Replace compressor Wiring error of compressor Open circuit Current detection circuit erro
68. E Refrigerant pipe Refrigerant pipe at liquid side at gas side Outer dia Outer dia Refrigerant pipe Refrigerant pipe at liquid side at gas side Outer dia Outer dia OB Branch pipe Branch pipe asen Refrigerant pipe Refrigerant pipe at liquid side at liquid side Outer dia C Outer dia D To outdoor unit To outdoor unit Brenon pige neo amp C p 20 SVM 12085 001 050 indd 20 12 0642 11 06 AM 3 2 Outdoor Unit RAV SP40 ATP SP45 ATP Rotary compressor DA150A1F 20F RAV SP40 ATP Cooling Standard 4 way valve STF 0108Z gt Outer dia 2 step muffler Muffler 019 x L160 Pressure 019 05 x 200L Heat exchanger cked valve TO sensor 08 ripple 2 rows 1 FP1 3 flat fin 4 steps Pipe surface temperature C MPa kg cm g Discharge Suction Indoor heat exchanger Outdoor heat exchanger Pd Ps Pd Ps TD TS TC TE Compressor drive revolution frequency rps PMV Pulse Motor Valve Sa Distributor FILE NO SVM 12085 Packed valve Cooling Heating Indoor Outdoor temp conditions DB WB C Indoor 27 19 Outdoor Overload 32 24 Low load 18 15 5 Heating Standard 20
69. Green Initial set SW SW802 PMV connector CN710 White Inter unit wire connector CN04 White Indoor Outdoor communication signal LED D503 Green Outdoor Indoor D502 Orange Indoor Outdoor 4 way valve protective fuse Inter unit wire protective fuse F700 250V 3 15A plastic case F03 250V 104 46 SVM 12085 001 050 indd 46 12 06 12 11 06 FILE NO SVM 12085 8 TROUBLESHOOTING 8 1 Summary of Troubleshooting lt Wired remote controller type gt 1 Before troubleshooting 1 Required tools instruments and screwdrivers spanners radio cutting pliers nippers push pins for reset switch Tester thermometer pressure gauge etc 2 Confirmation points before check a The following operations are normal 1 Compressor does not operate 15 not 3 minutes delay 3 minutes after compressor OFF 15 not the outdoor unit in standby status though the remote controller reached the setup temperature Does not timer operate during fan operation 15 not an overflow error detected on the indoor unit 15 not outside high temperature operation controlled in heating operation 2 Indoor fan does not rotate Does not cool air discharge preventive control work in heating operation 3 Outdoor fan does not rotate or air volume changes Does not high temperature release operation control work in heating operation Does not outside low temperature operation control
70. Hexagonal screw O4 x 10 2 pcs FILE NO SVM 12085 Remarks Heat exchanger Discharge port cabinet Motor base Partition plate Fin guard Side cabinet 1 Carry out work of 1 of 1 2 Remove screws which fix the inverter assembly and the side cabinet ST1T 04 x 8 2 pcs 3 Remove screws of the side cabinet and the valve fixing plate ST1T O4 x 8 2 pcs 4 Remove screws of the side cabinet and the pipe panel Rear Hexagonal screw O4 x 10 2 pcs 5 Remove screws of the side cabinet and the bottom plate Hexagonal screw 24 x 10 1 pc 6 Remove screws of the side cabinet and the heat exchanger Hexagonal screw 24 x 10 3 pcs 7 Slide the side cabinet upward and then remove it Hook of inverter SVM 12085 051 114 indd 92 92 Inverter assembly Side cabinet Piping panel Rear 12 06 12 11 15 AM Part name Exchange of electric parts SVM 12085_051 114 indd 93 Procedure 1 Control P C board 1 Carry out work of 1 of 1 N WARNING Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused 2 Remove the connectors connected to the control P C board Indoor power supply temperature sensors PMV coil 4 way valve coil compressor case thermo fan motor Unlock the lock of the housing part and then remove the connectors 3 Remove the lead wires connected to the control P C board
71. L Refrigerant pipe gt lt at gas side 15 9 Strainer Ball valve In cooling operation lt In heating operation 2 1 kg lt ls D La ILLE exe Pressure Pipe surface temperature C Compressor Indoor Outdoor temp conditions MPa kg emeg Discharge Suction Indoor heat Outdoor heat drive revolution Indoor exchanger exchanger frequency fan DB WB C Pd Ps Pd Ps TD TS TC TE rps Indoor Outdoor Standard 27 19 Cooling Overload 32 24 Low load 7 18 15 5 Standard 4 20 Heating Overload 30 Low load 15 23 SVM 12085_001 050 indd 23 12 06 12 11 06 AM FILE NO SVM 12085 4 WIRING DIAGRAM 4 1 RAV SP40 ATP SP45 ATP SP56 ATP ZHOS lt 1070 000 ddng 49MOd ian o O S1 99N P4b0g ANS 440 20 9 jeulw4el 191 Josues edid 013015 91 Josues duei joopino Ol TAA NUYD YOLOVAY AWd Josues edid 31 Josues duoj edid ru 26 1030W es nd 3 7974 SOLER AN x 20040 VE 91 9574 704 65 m sg vane sz A09Z vaz 9514 104 Ze Lies igg yore 9 10889 Jduio N 109 Aem yl 1 15 1 9580 e D YOLOVaY S sjJed OqWAS E 5 79
72. TO G H FILE NO SVM 12085 SERVICE MANUAL AIR CONDITIONER SPLIT TYPE OUTDOOR UNIT SUPER DIGITAL INVERTER RAV SP404ATP E RAV SP454ATP E RAV SP564ATP E RAV SP564AT JP E RAV SP804ATP E RAV SP804AT JP E HFC FILE NO SVM 12085 Original instruction Adoption of New Refrigerant This Air Conditioner is a new type which adopts a new refrigerant HFC R410A instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer CONTENTS SAFETY CAUTION z essen 3 1 SPECIFICATIONS L z lt UWIIIAI I9IIAII 9ISWI AIIIABIAIII 14 1 1 Outdoor 14 1 2 Operation Characteristic Curve 15 2 CONSTRUCTION VIEWS EXTERNAL VIEWS 17 2 1 RAV SP40 ATP SP45 ATP lDt LRlR RI Lo 17 2 2 RAV SPBO ATP J GC SSkSsSsricrkssbts LL 18 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 20 31 Indoor Unit 72 Gz gcsascaauguakuwqs 20 3 2 Outdoor Unt 21 4 WIRING DIAGRAM Ll ssesssenemm 24 4 1 RAV SP40 ATP SP45 ATP SPBGSATP _ 24 4 2 RAV SP8BO ATPx LA RR N R e N N 25 5 SPECIFICATIONS OF ELECTRICAL PARTS 26 6 REFRIGERANT h 27 6 1 Safety During Installation Servicing e
73. a leak or fire is caused Cabling at user s side After the work has finished be sure to use an insulation tester set 500V Megger to check the resistance is 1 or more between the charge section and the non charge metal section Earth position Insulator check f the resistance value is low a disaster such as a leak or electric shock is caused at user s side When the refrigerant gas leaks during work execute ventilation If the refrigerant gas touches to a fire poisonous gas generates A case of leakage of the refrigerant and the closed room full with gas is dangerous because a shortage of oxygen occurs Be sure to execute ventilation If refrigerant gas has leaked during the installation work ventilate the room immediately If the leaked refrigerant gas comes in contact with fire noxious gas may be generated Ventilation After the installation work confirm that refrigerant gas does not leak If refrigerant gas leaks into the room and flows near a fire source such as a cooking range noxious gas may be generated When the refrigerant gas leaks find up the leaked position and repair it surely If the leaked position cannot be found up and the repair work is interrupted pump down and tighten the service valve otherwise the refrigerant gas may leak into the room The poisonous gas generates when gas touches to fire such as fan heater stove or cocking stove though the refrigerant gas itself is innocuous
74. an the following thickness Reference outside diameter Wall thickness mm mm Never use any pipe with a wall thickness less than these thicknesses due to insufficient pressure capacity 8G SVM 12085_001 050 indd 36 12 06 12 11 06 AM FILE NO SVM 12085 6 7 Replenishing refrigerant In order to assure the reliability of the appliance the amount of refrigerant to be replenished shall be subject to the following restrictions Follow the margin of excess replenished refrigerant which is equivalent to the current R22 Otherwise abnormally high pressure may be generated in the refrigeration cycle which may result in failure explosion of the product or personal injury Possible gas leakage Recharging refrigerant is allowed only if it is confirmed that the amount of leakage e g slow leakage upon installation is within the additional margin specified below The amount of leakage is not certain if the product does not function properly e g insufficient cooling heating performance In such case recover the refrigerant and replenish the refrigerant Restrictions for the amount of additional charging a The amount of refrigerant additionally charged shall not exceed 10 of that specified If the situation is not solved with such amount recover the refrigerant completely and charge the specified amount b In case of slow leakage upon installation and the pipe connection length of not over 15m furth
75. andard amount is charged and an abnormal high pressure is applied to the inside of the refrigerating cycle resulted in cause of breakage or injury Therefore if the refrigerant gas leaks recover the refrigerant in the air conditioner execute vacuuming and then newly recharge the specified amount of liquid refrigerant In this time never charge the refrigerant over the specified amount Refrigerant When recharging the refrigerant in the refrigerating cycle do not mix the refrigerant or air other than R410A into the specified refrigerant If air or others is mixed with the refrigerant abnormal high pressure generates in the refrigerating cycle resulted in cause of injury due to breakage After the installation work confirm that refrigerant gas does not leak If refrigerant gas leaks into the room and flows near a fire source such as a cooking range noxious gas may be generated Never recover the refrigerant into the outdoor unit When the equipment is moved or repaired be sure to recover the refrigerant with recovering device The refrigerant cannot be recovered in the outdoor unit otherwise a serious accident such as breakage or injury is caused After repair work surely assemble the disassembled parts and connect and lead the removed wires as before Perform the work so that the cabinet or panel does not catch the inner wires Assembly incorrect assembly or incorrect wire connection was done a disaster such as
76. ation in the refrigerating cycle when the status that the operation frequency is 45Hz or less has continued for 10 hours was calculated The operation frequency follows the normal indoor command after controlling 2 Although the compressor may stop by THERMO OFF control when the room temperature varies and then attains the set temperature by this control it is not abnormal 3 During this control works if stopping the operation by the remote controller the operation does not continue 44 SVM 12085 001 050 indd 44 12 0642 11 06 AM FILE NO SVM 12085 it Board 7 2 Outdoor Print RAV SP40 ATP SP45 ATP SP56 ATP dL ALO 21 e ug 0029 eui 1eduunf youms pOIN J0joeuuoo MS qns J010euuoo ANd d9 10 1891 S02O 01 9020 908 208 01 008 S09NO 002 0 dwog d9 ALO 134 GOED 010060 oulleu 529 Jojoeuuoo 1J0sues qL efueuosiq LO9NO 00SNO euuM pee duuoo J0j9euuoo 1osues 61 uonons 509 0 10sues 31 einye1eduue 009NO E J0j9euuoo S NN 908NO 410 08UUOD JOSUaS OL ejnjejeduue JOOPINO cO9NO 32778 i 28 uej 008NO AJLA em p LOZNO
77. ba Carrier Corporation He or she has been trained to install repair maintain relocate and remove the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations The qualified service person who is allowed to do the electrical work involved in installation repair relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work The qualified service person who is allowed to do the refrigerant handling and piping work involved in installation repair relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have
78. connected to the compressor N WARNING In case of removing the piping by broiling the welded part with a burner if the piping includes oil it may burst into flames at the moment when wax melted so take sufficient care N CAUTION Note so that the flame does not catch the 4 way valve and An operation may become an error 11 Pull off the discharge pipe and the suction pipe of the refrigerating cycle upward 12 Remove the compressor bolts which fix the compressor to the bottom plate 3 pcs 13 Pull out the compressor toward you N CAUTION The weight of the compressor is 15kg or more so handle it by 2 workers 2072 FILE SVM 12085 Remarks Remove Remove Discharge pipe Suction pipe Compressor bolt 3 pcs 12 06 12 11 15 AM Part name Compressor Compressor lead Continued SVM 12085_051 114 indd 98 Procedure 2 Mounting of compressor 1 Mount the compressor in the reverse procedure of removal NOTES After exchange of the compressor be sure to exchange the compressor lead Repair part code of compressor lead 43160591 In this time wrap the ferrite core with the compressor lead wire by 4 times Using bundling band on the market bind the compressor lead As the compressor lead is long be sure that the compressor lead does not contact with the discharge pipe Fix the removed each sensor and PMV coi
79. ctricians and from heat The important contents concerned to the safety are described on the product itself and on this Service Manual Please read this Service Manual after understanding the described items thoroughly in the following contents Indications lllustrated marks and keep them Explanation of indications Indication Explanation DANGER Indicates contents assumed that an imminent danger causing a death or serious injury of the repair engineers and the third parties when an incorrect work has been executed WARNING Indicates possibilities assumed that a danger causing a death or serious injury of the repair engineers the third parties and the users due to troubles of the product after work when an incorrect work has been executed N CAUTION Indicates contents assumed that an injury or property damage may be caused on the repair engineers the third parties and the users due to troubles of the product after work when an incorrect work has been executed Property damage Enlarged damage concerned to property furniture and domestic animal pet Explanation of illustrated marks Explanation Indicates prohibited items Forbidden items to do The sentences near an illustrated mark describe the concrete prohibited contents Indicates mandatory items Compulsory items to do The sentences near an illustrated mark describe the concrete mandatory contents SVM 12085
80. driver and others for short circuiting between and electrodes As the electrolytic capacitor is one with a large capacity it is very dangerous because a large electric spark will occur 4 Perform 1 012 5 Take off screw between side cabinet right and inverter box wiring gate side ST1T O4 x 8 2 pcs 6 Take off screw between partition plate and inverter box ST1T O4 x 8 1 pc 7 Remove each lead wire type from holder of inverter upper part 8 Pull upper part of inverter Here please cut bundling band that tie each lead wire type 9 Remove connector of each lead wire type 85 FILE SVM 12085 Remarks Screws Front panel Inverter cover Plug of soldering iron 4 Discharging osition Discharging eriod 12 07 12 11 14 AM Part name Inverter assembly SVM 12085 051 114 indd 86 Procedure Connector Connection to compressor 3P Relay connector white X Warning 1 Reactor 2 Relay white CN300 Outdoor fan 3P white Warning 1 CN701 4 directional valve yellow X Warning 1 CN700 PMV coil 6P white X Warning 1 CN601 TD sensor white CN603 TS sensor white X Warning 1 CN600 sensor 2 white X Warning 1 CN602 TO sensor 2P white CN500 Case thermo 2P Blue X Warning 1 Warning 1 Please remove housing part s lock before
81. e compressor still operating will cause air etc to be sucked in raising the pressure inside the refrigeration cycle to an abnormally high level and possibly resulting in reputing injury etc When the service panel of the outdoor unit is to be opened in order for the compressor or the area around this part to be repaired immediately after the air conditioner has been shut down set the circuit breaker to the OFF position and then wait at least 10 minutes before opening the service panel If you fail to heed this warning you will run the risk of burning yourself because the compressor pipes and other parts will be very hot to the touch In addition before proceeding with the repair o work wear the heat resistant gloves When the service panel of the outdoor unit is to be opened in order for the fan motor reactor Cooling check inverter or the areas around these parts to be repaired immediately after the air conditioner has been shut down set the circuit breaker to the OFF position and then wait at least 10 minutes before opening the service panel If you fail to heed this warning you will run the risk of burning yourself because the fan motor reactor inverter heat sink and other parts will be very hot to the touch In addition before proceeding with the repair work wear the heat resistant gloves Only a qualified installer 1 or qualified service person 1 is allowed to install the air conditioner If the air conditio
82. e oil when the existing air conditioner was removed after refrigerant had been recovered In this case if the oil is judged as clearly different compared with normal oil The refrigerator oil is copper rust green There is possibility that moisture is mixed with the oil and rust generates inside of the pipe There is discolored oil a large quantity of the remains or bad smell A large quantity of sparkle remained wear out powder is observed in the refrigerator oil 7 The air conditioner which compressor was ex changed due to a faulty compressor When the discolored oil a large quantity of the remains mixture of foreign matter or a large quantity of sparkle remained wear out powder is observed the cause of trouble will occur 8 Installation and removal of the air conditioner are repeated with temporary installation by lease and etc 9 In case that type of the refrigerator oil of the existing air conditioner is other than the following oil Mineral oil Suniso Freol S MS Synthetic oil alkyl benzene HAB Barrel freeze ester series PVE only of ether series e Winding insulation of the compressor may become inferior NOTE The above descriptions are results of confirmation by our company and they are views on our air conditioners but they do not guarantee the use of the existing pipes of the air conditioner that adopted R410A in other companies 6 6 3 Branching Pipe for Simultaneous Operation System
83. eating is lowered In this case the Max capacity decreases Max frequency of compressor Max frequency change RAV SP80 Model COOL HEAT Standard status 72 0 99 6 When J807 is cut 72 0 79 2 When using the air conditioner as a cooling only conditioner cut the jumper line An air conditioner can be changed to cooling only conditioner by OF of DN code on the remote controller Cooling only setup 76 SVM 12085_051 114 indd 76 12 06 12 11 15 AM FILE NO SVM 12085 9 3 Service Support Function LED Display Switch Operation lt SP80 only gt 1 Outline A various setup and operation check can be performed by DIP switches at 3 positions SW802 SW803 SW804 and the pushdown button switches SW800 SW801 at 2 positions Operation part Part No Specifications Operation contents Pushdown button switch Exchanges the displayed contents of LED D800 to D804 on the outdoor DIP switch control P C board Pushdown button switch Performs the specific operation to check maintenance DIP switch DIP switch Performs various initial settings Refer to 9 2 Display part Part No Specifications Operation contents Indoor Outdoor communication Serial communication signal display Orange LED Receive signal from indoor signal Indoor Outdoor communication Serial communication signal display Green LED Send signal from outdoor signal Error display
84. echnical or operational modifications are introduced without the manufacturer s consent Disposal How to dispose of air conditioners with a rating of 12 kW and below in accordance with the 2002 96 EC Directive WEEE Waste Electrical and Electronic Equipment is provided in the Installation Manual supplied with your product For disposal of the product above 12 kW in rating you should use a registered company in accordance with any national or EU legislation lt Model names with a rating of 12 kW and below outdoor units gt SDI series RAV SP404ATP E RAV SP454ATP E RAV SP564ATP E RAV SP564ATJP E RAV SP804ATP E RAV SP804ATJP E 10 SVM 12085_001 050 indd 10 12 06 12 11 06 Specifications Model Sound power level dBA Cooling Heating FILE NO SVM 12085 Weight kg RAV SP404ATP E 40 RAV SP454ATP E 40 RAV SP564ATP E 44 RAV SP564ATJP E 44 RAV SP804ATP E 66 RAV SP804ATJP E Under 70 dBA SVM 12085_001 050 indd 11 ia 66 12 06 12 11 06 AM FILE NO SVM 12085 New Refrigerant R410A This air conditioner adopts a new HFC type refrigerant R410A which does not deplete the ozone layer 1 Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1 6 times of that of the former refrigerant R22 Accompanied with change of refrigerant the refrigerating oil has been also changed Therefore be sure that water
85. ed individual since a fire electric shocks injury water leakage noise and or vibration may result When carrying out the pump down work shut down the compressor before disconnecting the refrigerant pipe Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air etc to be sucked in raising the pressure inside the refrigeration cycle to an abnormally high level and possibly resulting in reputing injury etc 1 Refer to the Definition of Qualified Installer or Qualified Service Person Declaration of Conformity Manufacturer TOSHIBA CARRIER THAILAND CO LTD 144 9 Moo 5 Bangkadi Industrial Park Tivanon Road Amphur Muang Pathumthani 12000 Thailand Authorized Nick Ball Representative TCF holder Toshiba EMEA Engineering Director Toshiba Carrier UK Ltd Porsham Close Belliver Industrial Estate PLYMOUTH Devon PL6 7DB United Kingdom Hereby declares that the machinery described below Generic Denomination Air Conditioner Model type RAV SP404ATP E RAV SP454ATP E RAV SP564ATP E RAV SP564ATJP E RAV SP804ATP E RAV SP804ATJP E Commercial name Super Digital Inverter Series Air Conditioner Complies with the provisions of the Machinery Directive Directive 2006 42 EC and the regulations transposing into national law Complies with the provisions of the following harmonized standard EN 378 2 2008 A2 2012 Note This declaration becomes invalid if t
86. ee 27 6 2 Refrigerant Piping Installation 27 31 6 4 Recharging of Refrigerant 1 22255 31 6 5 Brazing of Pipes 0 Rseestieiiesiro eui 32 6 6 Instructions for Re use Piping of R22 or R407C Ta 34 6 7 Replenishing refrigerant 2 425 4 Lem 37 7 OUTDOOR CONTROL CIRCUIT ll LLlLL LGI k aaa e 38 7 1 Outdoor Controls sC b pt 38 7 2 Outdoor Print Circuit Board 45 8 TROUBLESHOOTING J 47 8 1 Summary of Troubleshooting eeseseeee 47 8 2 Troubleshooting OQ 49 8 3 Table Inspection of outdoor unit main parts 2222 74 9 OTHERS 75 9 1 Refrigerant Recovery Control gt gt 75 9 2 Various Setting on Outdoor Unit 76 Existing piping Power save Cooling only etc 9 3 Service Support Function LED Display Switch Operation 77 10 44 83 10 1 5 40 SPAB ATP SP56 ATP 83 10 2 RAV SP80 ATP _ 0 S N SN R R QN N N NaN R aQ 91 11 EXPLODED VIEWS AND PARTSLIST 4 101 11 1 RAV SP404ATP E SPABAATP E enses 101 11 2 8P564ATP E SP564ATJP E 105 11 3 RAV SP804ATP E SP804ATJP E 109 Dc SVM 12085 001 050 indd 2 12 0642 11 06 AM FILE NO SVM 12085 SAFETY CAUTION Please read carefully through these ins
87. elow position For current value the current for the outdoor unit only is displayed 80 SVM 12085_051 114 indd 80 12 06 12 11 15 4 Specific operation for maintenance check SW801 SW804 The following specific operations for the maintenance check are performed by operation of SW801 or SW804 a Select DIP switch SW804 See table below b Push the pushdown button switch SW801 for approx 1 second c The following functions start While each function starts LED D805 Green flashes d When pushing the pushdown button switch SW801 again for approx 1 second when selecting lt Specific operation gt FILE NO SVM 12085 DIP switch SW804 or when the specified time of each function elapsed each function stops and LED D805 Green returns to the continuous lighting SW804 Operation when pushdown button switch SW801 is pushed Refrigerant recovery operation The outdoor unit performs cooling operation The indoor unit does not work by this operation alone Therefore operate the fan beforehand Refer 9 1 Refrigerant Recovery Control Indoor cooling test run demand The cooling test run is performed Note 1 Indoor heating test run demand The heating test run is performed Note 1
88. emoving the oxide film and any foreign 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 SVM 12085_001 050 indd 32 matter on the metal surface it assists the flow of brazing filler In the brazing process it prevents the metal surface from being oxidized By reducing the brazing filler s surface tension the brazing filler adheres better to the treated metal 12 0642 11 06 AM Characteristics required for flux Activated temperature of flux coincides with the brazing temperature Due to a wide effective temperature range flux is hard to carbonize t is easy to remove slag after brazing The corrosive action to the treated metal and brazing filler is minimum t 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 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
89. er tighten the flare nut or take other effective measures Do not recharge the refrigerant Cautions for recharging with refrigerant a Use a scale with an accuracy of at least 10g to recharge the refrigerant Do not use a bathroom scale b If the refrigerant leaks identify the source and make sure to repair it The refrigerant gas is not hazardous but if it touches a heat source e g fan heater stove a poisonous gas may be generated c Use liquid refrigerant for replenishment Replenish the refrigerant carefully and slowly _37 SVM 12085_001 050 indd 37 12 06 12 11 06 AM FILE NO SVM 12085 7 OUTDOOR CONTROL CIRCUIT 7 1 Outdoor Controls 1 PMV Pulse Motor Valve control 1 PMV is controlled between SP40 to SP56 20 to 500 SP80 30 to 500 pulsed during operation 2 In cooling operation PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming SP40 to SP56 2 to 5K SP80 1 to 4K as the target value 3 In heating operation PMV is usually controlled with the temperature difference between TS sensor and TE sensor aiming SP40 to SP56 2 to 4K SP80 2 to 4K as the target value 4 When the cycle excessively heated in both cooling and heating operation PMV is controlled by TD sensor The target value is 101 C for both cooling and heating operations in SP40 to SP56 and 91 C for cooling operation and 96 C for heating operation respectively in SP80 REQUIREMENT
90. erator oil to the flare surface Trial run _ 35 SVM 12085_001 050 indd 35 12 06 12 11 06 AM FILE NO SVM 12085 6 6 6 Handling of Existing Pipe RAV SP804ATP When using the existing pipe carefully check it for e To use an existing 19 1 mm pipe set bit 3 of the following SW802 switch for existing pipe on the P C board Wall thickness within the specified range of the outdoor unit to ON Scratches and dents Water oil dirt or dust in the pipe Flare looseness and leakage from welds Deterioration of copper pipe and heat insulator SW802 In this case the heating performance may be reduced depending on the outside air temperature and room temperature Cautions for using existing pipe When shipped from factory When using existing pipe Do not reuse the flare to prevent gas leak Replace it with the supplied flare nut and then process it to a flare Blow nitrogen gas or use an appropriate means to keep the inside of the pipe clean If discolored oil or much residue is discharged wash the pipe Check welds if any on the pipe for gas leak When the pipe corresponds to any of the follow ing do not use it Install a new pipe instead The pipe has been open disconnected from indoor unit or outdoor unit for a long period The pipe has been connected to an outdoor unit that does not use refrigerant R22 R410A or R407C The existing pipe must have a wall thickness equal to or larger th
91. eset If center exists operation continues Displayed when error is detected Receiving error from remote controller 1 Check remote controller inter unit wiring 2 Check remote controller 3 Check indoor power wiring 4 Check indoor P C board Signal send error to indoor unit Detected by remote controller side Stop Automatic reset If center exists operation continues Displayed when error is detected Sending error of remote controller 1 Check sending circuit inside of remote controller Replace remote controller There are multiple main remote controllers Detected by remote controller side Stop Sub unit continues operation Displayed when error is detected In 2 remote controllers including wireless there are multiple main units Check that there are 1 main remote controller and other sub remote controllers Central controller Duplicated indoor central addresses on communication of central control system Detected by indoor central controller side Stop Automatic reset Displayed when error is detected Check setting of central control system network address Network adapter SW01 Check network adapter P C board Central controller Send C05 Receive Communication circuit error of central control system Detected by central controller side Continues By remote controller Displayed when error is detected Check
92. etal plate m FILE NO SVM 12085 Remarks Sub board base Power line Remove earth screw Inverter box eq metal plate Control board frame PC board base Control board frame PC board base z Hook 4 places Inverter box metal plate Heat sink 12 07 12 11 00 AM Part name Rear cabinet Procedure 1 Perform works of items 1 of and 2 2 Take off fixed screws for the bottom plate ST1T O4 x 8L 2 pcs 3 Take off fixed screw for the valve mounting plate ST1T O4 x 8L 3 pcs FILE NO SVM 12085 Remarks Rear cabinet Fan motor SVM 12085 051 114 indd 88 1 Perform works of items 1 of 1 and 2 2 Take off the flange nut fixing the fan motor and the propeller Turning it clockwise the flange nut can be loosened To tighten the flange nut turn counterclockwise 3 Remove the propeller fan 4 Disconnect the connector for fan motor from the inverter 5 Take off the fixing screws 3 pcs holding by hands so that the fan motor does not fall NOTE Tighten the flange nut with torque 4 9Nm 50kgf cm 88 Flange nut Loosen the nut by turning clockwise 12 06 12 11 15 Part name Compressor Procedure 1 Perform works of items 1 of 0 and 2 2 Discharge refrigerant gas 3 Remove the partition plate ST1T 04 x 8L 3 pcs 4 Remove the terminal covers of t
93. f smoke or abnormal sound If check is not executed a fire or an electric shock is caused Before test run install the front panel and cabinet G Check the following matters before a test run after repairing piping Connect the pipes surely and there is no leak of refrigerant The valve is opened Do not Running the compressor under condition that the valve closes causes an abnormal high operate the pressure resulted in damage of the parts of the compressor and etc and moreover if there is unit with the leak of refrigerant at connecting section of pipes the air is suctioned and causes further valve closed abnormal high pressure resulted in burst or injury Only a qualified installer 1 or qualified service person 1 is allowed to relocate the air conditioner It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire electric shocks injury water leakage noise and or vibration may result Check the following items after reinstallation 1 The earth wire is correctly connected 2 The power cord is not caught in the product 3 There is no inclination or unsteadiness and the installation is stable Check after If check is not executed a fire an electric shock or an injury is caused reinstallation When carrying out the pump down work shut down the compressor before disconnecting the refrigerant pipe Disconnecting the refrigerant pipe with the service valve left open and th
94. f the pipe Note In case of twin also be sure to flash the branching pipe If there is discharge of remains it is judged that there is a large quantity of remains Was not largely discolored oil or a large quantity of remains discharged When a oil delenorales the colonel the Gleanithe pipes Gr Use The n w pipes oil changes to muddy and black color If you are in trouble of pipe cleaning please contact us Connect the indoor outdoor units to the existing pipe Use a flare nut attached to the main unit for the indoor outdoor units Do not use the flare nut of the existing pipe Re machine the flare machining size to size for In case that the gas pipe 019 mm is used for the outdoor unit of SP80 3 HP or higher machining size due to pipe compression Gas pipe size of our R410A model is 015 9 mm 1 Flare nut width H Turn the existing pipe switch on the cycle control board of the outdoor unit to ON side At shipment from factory OFF for existing pipe Refer to the table below Be sure to set the contents For R410A 17 in the table below in order to restrict the refrigerating cycle pressure of the equipment in the pipe standard For R22 Same as above mm Existing pipe SW Bit 3 of SW802 ON 9 1 For R22 Airtight test Vacuum dry Refrigerant charge Becomes large little for R410A Gas leak check Do not apply the refrig
95. g SVM 12085 001 050 indd 27 12 0642 11 06 AM FILE NO SVM 12085 Table 6 2 1 Thicknesses of annealed copper pipes Thickness mm Nominal diameter Outer diameter mm 1 Joints For copper pipes flare joints or socket joints are used Prior to use be sure to remove all contaminants a Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm In such a case socket joints can be used Sizes of flare pipe ends flare joint ends and flare nuts are as shown in Tables 6 2 3 to 6 2 5 below b Socket Joints Socket joints are such that they are brazed for connections and used mainly for thick pipings whose diameter is larger than 20 mm Thicknesses of socket joints are as shown in Table 6 2 2 Nominal diameter Table 6 2 2 Minimum thicknesses of socket joints Reference outer diameter of copper pipe jointed mm Minimum joint thickness 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
96. g operation defrost operation is performed when TE sensor satisfies any condition in zone to D zone 2 During defrosting operation it finishes if TE sensor continued 12 C or continued 5 C lt TE lt 12 C for 80 seconds The defrost operation also finishes when it continued for 15 minutes even if TE sensor temperature was 5 C or lower 3 After defrost operation was reset the compressor stopped for approx 40 seconds and then the heating operation starts Start of heating operation TE C 0 10 15 29 35 91 min A zone i Done The minimum TE value and To value between 10 and 15 minutes after heating operation has started are stored in memory as and ToO respectively In normal To In abnormal To When status TE ToO gt 3 C When status TE 2 3 continued for 20 seconds continued for 20 seconds When status TE ToO To gt 2 5 C When status TE 2 2 5 C continued for 20 seconds continued for 20 seconds When the status lt 26 C continued for 20 seconds When the status TE lt 10 continued for 20 seconds 43 SVM 12085 001 050 indd 43 12 0642 11 06 AM FILE NO SVM 12085 lt SP80 only gt 1 In heating operation defrost operation is performed when TE sensor satisfies any condition in zone to D zone 2 During defrosting operation it finishes if TE sensor continued 12 C or higher for
97. h zone 1 tap 20 sec Down to the minimum revolution frequency of each zone 38 gt TD C 35 Revolution frequency hold 1 tap 20 sec Down to the minimum revolution frequency of each zone Operation with WF 85 2191 eee Operation with the maximum tap of each zone 75 65 m ss Normal fan control by TE sensor lt SP40 to SP56 gt lt SP80 gt 20 Hz 20Hz 45Hz 20 Hz 20Hz 45Hz Temp range orlower to45Hz orhigher Temp range orlower to45Hz orhigher Min Max Min Max Min Max Min Max Min Max Min Max 38 C lt TO 38 C lt TO 28 C lt TO lt 38 C 29 C lt TO lt 38 C 15 lt TO lt 28 15 lt TO lt 29 5 5 C lt TO lt 15 5 C lt TO lt 15 C 0 C lt TO lt 5 5 C 0 C lt TO lt 5 C 5 C lt TO lt 0 C 4 C lt TO lt 0 C TO lt 5 G TO lt 4 TO error TO error 39 SVM 12085_001 050 indd 39 12 06 12 11 06 FILE NO SVM 12085 3 2 Heating fan control The outdoor fan is controlled by TE sensor TO sensor and the operation frequency Control from minimum W1 to maximum according to the following table For 3 minutes after the operation has started the maximum fan tap corresponding to the zone in the following table is fixed and
98. he compressor and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal 5 Take off the soundproof plate 6 Remove pipes connected to the compressor with a burner CAUTION Pay attention to that flame does not involve 4 way valve or PMV If doing So a malfunction may be caused 7 Take off the fixing screws of the bottom plate and heat exchanger ST1T O4 x 8L 8 Take off the fixing screws of the valve clamping plate to the bottom plate ST1T O4 x 8L 2 pcs 9 Pull upward he refrigerating cycle 10 Take off nut fixing the compressor to the bottom place CAUTION When reconnecting the lead wires to the compressor terminals after replacement of the compressor be sure to caulk the Faston terminal without loosening Remove Discharge pipe FILE NO SVM 12085 Remarks Partition plate Se Screws 2 pcs Compressor bolt 3 pcs Reactor SVM 12085 051 114 indd 89 1 Perform works of item 1 of Q and 3 2 Remove partition plate ST1T O4 x 8L 3 pcs 3 Take off screw attached to reactor ST1T O4 x 8L 5 pcs 89 12 06 12 11 15 Part name Pulse Motor Valve PMV coil Procedure 1 Detachment 1 Perform works of items 1 and 2 2 Release the coil from the concavity by turning it and remove coil from the Attachment 1 Put the coil deep into the bottom posi tion 2 Fix t
99. he coil firmly by turning it to the concavity FILE NO SVM 12085 Remarks PMV coil Fan guard SVM 12085 051 114 indd 90 Detachment 1 Perform works of items 1 of D 2 Remove the front cabinet and put it down so that fan guard side directs downward CAUTION Perform works on a corrugated cardboard cloth etc to prevent flaw on the product 3 Remove the hooking claws by pushing with minus screwdriver along with the arrow mark in the right figure and remove the fan guard 2 Attachment 1 Insert claws of the fan guard in the hole of the front cabinet Push the hooking claws 10 positions with hands and then fix the claws CAUTION All the attaching works have completed Check that all the hooking claws are fixed to the specified positions 90 Minus screwdriver Hooking claw Front cabinet Front cabinet Fan guard 12 06 12 11 15 AM 10 2 RAV SP80 ATP Part name Common procedure SVM 12085_051 114 indd 91 Procedure CAUTION Be sure to put on the gloves at working time otherwise an injury may be caused by a part etc Detachment 1 Stop operation of the air conditioner and then turn off switch of the breaker 2 Remove the front panel Hexagonal screw O4 x 10 2 pcs After removing screws remove the front panel while pulling it downward 3 Remove the power wire and indoor outdoor connecting wire from the c
100. he outdoor unit Push SW801 again for 1 second add NOTE Although these operations can be performed even during operation basically perform operation while the unit stops If performing this operation during driving the unit it is dangerous because the pressure may change suddenly 12 0642 11 15 AM FILE NO SVM 12085 SW804 Operation when pushdown button switch SW801 is pushed 4 way valve relay operation For RY700 CN70 check Turn on 4 way valve power relay RY700 When pushing SW801 again or when 2 minutes elapsed the operation returns to the normal control NOTE In case of model adopting the self hold valve RAV SP1104AT E RAV SP1404AT E the coil develops fever Therefore do not perform this operation as coil is connected Self hold valve suction operation Exchange to heating cycle For RY700 RY701 RY705 CN701 check Turn on relay RY700 RY701 RY705 CN701 between D and Voltage Approx 198 to 380V This function works for 10 seconds and then is OFF Self hold valve separation operation Exchange to cooling cycle Turn on relay RY700 CN701 between 1 and 4 Voltage Approx 198 to 380V This function works for 10 seconds and then is OFF SV valve relay operation For RY702 CN702 check Turn on SV valve relay RY702 When pushing SW801 again or
101. hout special mention indicates a part of the outdoor unit 4 reversal error Does 4 way valve work correctly Check pipe temperature etc during cooling heating operation 15 coil of 4 way valve electrified during heating mode NO Check outdoor P C board Defect Replace NO Check 4 way valve Defect Replace Check PMV Defect Replace Check temperature sensors TE sensor CN600 TS sensor CN603 Indoor TC sensor Defective Correct or replace n case of SP40 to 56 the coil of 4 way valve is electrified during cooling cycling In cooling operation P19 error may be displayed when the refrigerant pressure rises high abnormally In this case remove the cause of pressure rising and then diagnose it again D01 D02 D03 D04 Red Yellow Yellow Yellow O O O e Outdoor fan system error Is connection of connector CN300 correct Correct connection of connector Fan motor exchange 18 to 300 Check outdoor P C board Defective Replace After pulling out the connector of the fan motor CN300 rotate its shaft by hands Can it rotate smoothly Is the fan motor coil resistance within the range described below Between red and white lead Between white and black lead 18 to 300 Between black and red lead 18 to 300 D01 D02 D03 D04 Red Yellow Yellow Yellow e After disconnection of the compre
102. ing procedure Compressor Measure the resistance value of each winding by using the tester Model DA150A1F 20F Position Resistance value Red White White Black Black Red Under 20 C Compressor Measure the resistance value of each winding by using the tester Model DA150A1F 21F Red Position Resistance value Red White White Black White Black Black Red Compressor Measure the resistance value of each winding by using the tester Model DA220A2F 22L Under 20 C Position Resistance value Red Red White White Black White Black Black Red Under 20 C Fan motor Measure the resistance value of each winding by using the tester Model ICF 140 43 4R Position Resistance value Red Red White White Black 21 00 1 05 White Black Black Red Under 20 G Fan motor Measure the resistance value of each winding by using the tester Model ICF 280 A60 1 Position Resistance value Red Red White White Black 32 6 3 3 0 White Black Black Red Under 20 C 74 SVM 12085_051 114 indd 74 12 06 12 11 15 FILE NO SVM 12085 9 OTHERS 9 1 Refrigerant Recovery Control The ozone destruction coefficient of HFC refrigerant is 0 and the discharge regulation is set as anathermal effect gas To this model a switch which can perform
103. ir conditioner 2 Remove the valve cover ST1T O4 x 8L 3 pcs After removing screw remove the valve cover pulling it downward 3 Remove wiring cover 2 04 x 101 1 pc and then remove connecting cable 4 Remove the upper cabinet 5 04 x 8L 5 pcs After taking off screws remove the upper cabinet pulling it upward 2 Attachment 1 Attach the waterproof cover CAUTION Be sure to attach a waterproof cover If it is not attached there is a possibility that E zz Water proof water enters inside of the outdoor unit cover 2 Attach the upper cabinet ST1T O4 x 8L 5 pcs Hook the rear side of the upper cabinet to claw of the rear cabinet and then put it on the front cabinet 3 Perform cabling of connecting cables and fix with cord clamp BT2T O4 x 12L 3 pcs 4 Attach the wiring cover PT2T x 10L 1 pc 5 Attach the valve cover 5 04 x 8L 3 pcs Front cabinet 82 SVM 12085_051 114 indd 83 12 06 12 11 15 Part name Front cabinet SVM 12085_051 114 indd 84 Procedure 1 How to remove 1 Perform 1 of D 2 Remove the screw between front cabinet and side cabinet right ST1T O 4 x 8 1 pc 3 Remove the screw between front cabinet and inverter ST1T 24 x 8 2 pcs 4 Remove the screw between front cabinet and bottom slab ST1T 4 x 8 3 pcs 5 Remove the screw between front cabinet and motor base ST1T x 8 2
104. l lead wire to the discharge pipe and the suction pipe with the bundling band via the pipe cover In this time take note that each sensor and PMV coil lead wire do not come to contact with the discharge pipe and the reactor For fixing to the discharge pipe use the black heat proof pipe cover and the bundling band for heat proof which is sold on the market As shown in the right figure mount the soundproof plate inner winding outer winding by inserting between the compres sor and the piping and between piping and the partition plate Put the compressor lead wire and the compressor case thermo between inner winding and outer winding of the soundproof as if dropping them in Pipe cover bundling band TS sensor FILE NO SVM 12085 Remarks Wind the ferrite core with the compressor lead wire jjwirelby 4 times Y A S VA i Ferrite core Compressor lead 2 standard o comenso leadiwire PS Using the bundling band on the market fix the bundle at 2 positions Pass the soundproof plate outer winding through between the suction pipe and the accumulator Pass the Soundproof p plate inner winding throu through discharge pipeWsuc tionfpipe and then put it on the other side at this position Put the soundproof plate outer winding on the other side at this position Do not make clearance between the soundproof plate upper and the soundproof plate o
105. l when power supply turned on automatically goes to address setup mode Operation Timer 0 Simultaneous flash Ready Unset model type Service board Duplicated indoor central addresses Other error of outdoor unit Outside interlock error 1 These are representative examples and the check code differs according to the outdoor unit to be combined SVM 12085_001 050 indd 50 50 12 06 12 11 06 FILE NO SVM 12085 8 2 2 Others Other than Check Code Lamp indication Operation Timer Ready 92 455 Simultaneous flash Check code Cause of trouble occurrence During test run Operation Timer Ready O xe eet Alternate flash SVM 12085 051 114 indd 51 Disagreement of cool heat Automatic cool heat setting to automatic cool heat prohibited model or setting of heating to cooling only model 51 12 06 12 11 15 FILE NO SVM 12085 apow dnl s ssejppe OLNY sylus y sem Ajddns Y29949 dno46 sem siu uayM lt gt SL 30 dn Jo 1 1 umop dwa Aq sew 1048 Buneeu ul Joopino Joopu JOJJ0 AJLA eM p 10119 episino Aq dois jewuouqy Joo
106. lace the handle of the gauge manifold Low in the For refrigerant charging see the figure below fully opened position and turn on the vacuum pump s power switch Then evacuating the refrigerant in the cycle 1 Never charge refrigerant exceeding the specified amount 2 If the specified amount of refrigerant cannot be charged charge refrigerant bit by bit in COOL mode 3 Do not carry out additional charging When additional charging is carried out if refrigerant leaks the refrigerant composition changes in the refrigeration cycle that is characteristics of the air conditioner changes refrigerant exceeding the specified amount is charged and working pressure in the refrigeration cycle becomes abnormally high pressure and may cause a rupture or personal injury INDOOR unit Liquid side OUTDOOR unit Opened Gas side Refrigerant cylinder With siphon pipe Check valve Closed O Open Close valve for charging Service port Electronic balance for refrigerant charging Fig 6 4 1 Configuration of refrigerant charging 31 SVM 12085_001 050 indd 31 12 06 12 11 06 AM FILE NO SVM 12085 1 Be sure to make setting so that liquid can be charged 2 When using a cylinder equipped with a siphon liquid can be charged without turning it upside down It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of
107. le supporting the fan motor so that it does not fall Cautions when assembling the fan motor Tighten the flange nut with 4 95Nem 50kgf cm Adjust length on the fan motor lead fixing rubber so that the fan motor lead does not slacken in order not to put the fan motor lead into contact with the propeller fan Attach the fan motor lead fixing rubber to the partition plate so that projection directs to the refrigerating cycle side Be sure that the rector body does not come to contact with the fan motor lead Be sure to bind the removed bundling band with the bundling band on the market N CAUTION Use the metal band of the motor base to fix the fan motor lead on the motor base so that the fan motor lead does not come to contact with the propeller fan 05 FILE SVM 12085 Remarks Propeller fan Loosened by turning clockwise S agami Propeller fan Fan motor lead fixing rubber Projection Refrigerating cycle side Fan motor 12 06 12 11 15 AM Part name Compressor Compressor lead SVM 12085_051 114 indd 96 Procedure 1 Removal of broken compressor 1 Recover the refrigerant gas 2 Carry out works of 1 of Q 3 Remove the piping panel Front Remove screws of the piping panel Front and the bottom plate Hexagonal screw O4 x 10 2 pcs Remove screws of the piping panel Front and the piping panel Rear Hexagonal screw
108. lectric shock by touching terminals of high voltage capacitors Natural discharge of the capacitor takes about five minutes Electric shock Before operating the air conditioner after having completed the work check that the electrical parts box hazard cover of the indoor unit and service panel or valve cover of the outdoor unit are closed and set the circuit breaker to the ON position You may receive an electric shock etc if the power is turned on without first conducting these checks Even if the circuit breaker has been set to the OFF position before the service panel is removed and the electrical parts are repaired you will still risk receiving an electric shock For this reason short circuit the high voltage capacitor terminals to discharge the voltage before Execute proceeding with the repair work discharge For details on the short circuiting procedure refer to the Service Manual between You may receive an electric shock if the voltage stored in the capacitors has not been sufficiently terminals discharged Place a Work in progress sign near the circuit breaker while the installation maintenance repair or removal work is being carried out There is a danger of electric shocks if the circuit breaker is set to ON by mistake When checking the electric parts removing the cover of the electric parts box of Indoor Unit and or front panel of Outdoor Unit inevitably to determine the failure put a sign Do not enter ar
109. llation may cause refrigeration trouble water leakage electric shock fire etc 8 Unauthorized modifications to the air conditioner may be dangerous If a breakdown occurs please call a qualified air conditioner technician or electrician Improper repair may result in water leakage electric shock and fire etc 6 2 Refrigerant Piping Installation 6 2 1 Piping Materials and Joints Used For the refrigerant piping installation copper pipes and joints are mainly used Copper pipes and joints suitable for the refrigerant must be chosen and installed Furthermore it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants 1 Copper Pipes It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg 10 m Do not use copper pipes having a collapsed deformed or discolored portion especially on the interior surface Otherwise the expansion valve or capillary tube may become blocked with contaminants As an air conditioner using R410A incurs pres sure higher than when using R22 it is necessary to choose adequate materials Thicknesses of copper pipes used with R410A are as shown in Table 6 2 1 Never use copper pipes thinner than 0 8mm even when it is avail able on the market NOTE Refer to the 6 6 Instructions for Re use Piping of R22 or R407C c
110. lothing during installation servicing and removal SVM 12085 001 050 indd 6 12 0642 11 06 AM FILE NO SVM 12085 WARNING ating that meets the specifications in the Installation Manual and the stipulations in the local regulations and laws Use of wiring which does not meet the specifications may give rise to electric shocks electrical leakage smoking and or a fire The appliance shall be installed in accordance with national wiring regulations Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire Only a qualified installer 1 or qualified service person 1 is allowed to undertake work at heights using a stand of 50 cm or more When working at heights use a ladder which complies with the ISO 14122 standard and follow the procedure in the ladder s instructions Also wear a helmet for use in industry as protective gear to undertake the work When working at heights put a sign in place so that no one will approach the work location before proceeding with the work Parts and other objects may fall from above possibly injuring a person below Do not touch the aluminum fin of the outdoor unit You may injure yourself if you do so If the fin must be touched for some reason first put on protective gloves and safety work clothing and then proceed Do not climb onto or place objects on top of the outdoor unit You may fall or the objects may fall
111. low 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 1 Used tool Flare tool Pipe flaring FILE NO SVM 12085 Conventional air conditioner installation R410A air conditioner installation Whether conventional equipment can be used Existence of new equipment for R410A Whether conventional equipment can be used Copper pipe gauge for adjusting projection margin Flaring by conventional flare tool Torque wrench Tightening of flare nut Gauge manifold Charge hose Evacuating refrigerant charge run check etc Vacuum pump adapter Vacuum evacuating Electronic balance for refrigerant charging Refrigerant charge Leakage detector Gas leakage check Note When flaring is carried out for R410A using the conventional flare tools adjustment of projection margin is necessary For this adjustment a copper pipe gauge etc are necessary General tools Conventional tools can be used In addition to the above exclusive tools the following equipments which serve also for R22 are necessary as the general tools Vacuum pump Use vacuum pump by attaching vacuum pump adapter Torque wrench Pipe cutter Reamer Pipe bender Level vial 7 Screwdriver 8 Spanner or Monkey wrench
112. ly used It is necessary to select the most appropriate pipes to conform to the standard Use clean material in which impurities adhere inside of pipe or joint to a minimum 1 Copper pipe lt Piping gt The pipe thickness flare finishing size flare nut and others differ according to a refrigerant type When using a long copper pipe for R410A it is recommended to select Copper or copper base pipe without seam and one with bonded oil amount 40mg 10m or less Also do not use crushed deformed discolored especially inside pipes Impurities cause clogging of expansion valves and capillary tubes lt Flare nut gt Use the flare nuts which are attached to the air conditioner unit 2 Joint The flare joint and socket joint are used for joints of the copper pipe The joints are rarely used for installation of the air conditioner However clear impurities when using them 12 SVM 12085_001 050 indd 12 12 06 12 11 06 4 Tools Required Tools for R410A Mixing of different types of oil may cause 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 be
113. n error between fan driving MCU and main MCU Stop Automatic reset Displayed when error is detected Check indoor P C board Regular communication error between indoor aster and follower units and between main and sub units SVM 12085 051 114 indd 54 Stop Automatic reset Displayed when error is detected 54 Check remote controller wiring Check indoor power supply wiring Check indoor P C board 12 06 12 11 15 AM FILE NO SVM 12085 Error mode detected by remote controller or central controller TCC LINK Operation of diagnostic function Check code Not displayed at all Operation on remote controller is impossible Cause of operation No communication with master indoor unit Remote controller wiring is not correct Power of indoor unit is not turned on Automatic address cannot be completed Status of air conditioner Condition Judgment and measures Power supply error of remote controller Indoor EEPROM error 1 Check remote controller inter unit wiring Check remote controller Check indoor power wiring Check indoor board Check indoor EEPROM including socket insertion Automatic address repeating phenom enon generates No communication with master indoor unit Disconnection of inter unit wire between remote controller and master indoor unit Detected by remote controller side Stop Automatic r
114. ner is installed by an unqualified individual a fire electric shocks injury water leakage noise and or vibration may result Before starting to install the air conditioner read carefully through the Installation Manual and follow its instructions to install the air conditioner combustible gas o Do not install the air conditioner in a location that may be subject to a risk of expire to a If a combustible gas leaks and becomes concentrated around the unit a fire may occur Installation Install a circuit breaker that meets the specifications in the installation manual and the stipulations in the local regulations and laws Install the circuit breaker where it can be easily accessed by the agent Do not place any combustion appliance in a place where it is directly exposed to the wind of air conditioner otherwise it may cause imperfect combustion SVM 12085 001 050 indd 9 12 0642 11 06 AM FILE NO SVM 12085 Explanations given to user f you have discovered that the fan grille is damaged do not approach the outdoor unit but set the circuit breaker to the OFF position and contact a qualified service person to have the repairs done Do not set the circuit breaker to the ON position until the repairs are completed Relocation Only a qualified installer 1 or qualified service person 1 is allowed to relocate the air conditioner It is dangerous for the air conditioner to be relocated by an unqualifi
115. ng connection correct Compressor lead Check and P C board side Compressor side correct connection of wires Reactor cord Power supply lead prora Is there stagnation Compressor lock conditions of refrigerant Replace YES TE TS sensor Does PMV operate correctly Check PMV Defective Replace YES Check outdoor P C board Defect Replace LED display legend 6 Go off Go on Flash 5Hz 59 SVM 12085_051 114 indd 59 12 06 12 11 15 APPLICATION CONTROL KIT LED display D01 D02 D03 D04 Red Yellow Yellow Yellow e e FILE NO SVM 12085 lt ln case of SP40 to SP56 gt Check Countermeasures Part without special mention indicates a part of the outdoor unit Power supply error Current detection circuit error Are connections of wires correct Between power cable and terminal block Between outdoor P C board and terminal block Correct wires Check outdoor P C board Defect Replace D01 D02 D03 D04 Red Yellow Yellow Yellow or e Power supply error Current detection circuit error Is AC mains voltage correct No 198 to 264V YES Is compressor under correct conditions Correct power supply line Compressor trouble Rare short check Defective Replace
116. nication error Is setting of group address NO on the remote controller correct YES Are inner wiring of the indoor unit and inter unit wires 1 2 3 correct 15 wiring of the outdoor terminal block correct Is connection of case thermo CN500 correct Does the case thermo operate Is the compressor abnormally heated Check item code 14 Correct wiring and inter unit wires Correct wiring of terminal block Correct connection of connector Check and correct charged refrigerant amount Check outdoor P C board Defect Replace D01 D02 D03 D04 Red Yellow Yellow Yellow O e e Discharge temp sensor TD error Is connection of CN601 correct Is resistance value of TD sensor correct YES Correct connector Sensor error Replace Check outdoor P C board Defect Replace There is a possibility that any of the following items is not correct Checking LED on the APPLICATION CONTROL KIT enables you to judge what is incorrect D01 Red O D02 D03 D04 Yellow Yellow Yellow Heat exchanger temp sensor TE error Is connection of CN600 correct 15 resistance value of TE sensor correct YES Correct connector Sensor error Replace Check outdoor P C board Defect Replace D01 Red D02 D03 D04 Yellow Yellow Yellow e e Suction tem
117. nt close valve at gas side 5 Push the button switch SW801 again for approx 1 second The outdoor unit stops 6 Stop the indoor unit and then turn off the power supply 75 SVM 12085_051 114 indd 75 12 06 12 11 15 FILE NO SVM 12085 9 2 Various Setting on Outdoor Unit Existing piping Power save Cooling only etc The following settings are available by DIP switch setup and jumper line setup lt SP40 to SP56 gt Function Setting position Control contents Existing piping setup Turn off the switches 019 1 existing pipes cannot be used When using the power saving function turn on switches The control to lower the compressor frequency approx 1096 is performed by indoor heat exchanger temp in heating operation Power save setup Existing pipe setting Cooling only Power saving setting setup Cooling only setting When using the outdoor unit as a cooling only machine turn on switches OF of DN cord on the remote controller also can be used for changing the machine to the cooling only model lt SP80 gt Function Set position Control contents Turn the switch to ON when mounting a duct to the discharge port of the outdoor unit Add 3 taps to the upper limit value of the outdoor fan tap The operation is performed with High static Max Upper fan 890
118. ntilation carbon monoxide poisoning may be caused 3 Do not bring inflammables close to the refrigerant cycle otherwise fire of the welder may catch the inflammables SVM 12085 001 050 indd 7 12 06 12 11 06 AM FILE NO SVM 12085 The refrigerant used by this air conditioner is the R410A Check the used refrigerant name and use tools and materials of the parts which match with it For the products which use R410A refrigerant the refrigerant name is indicated at a position on the outdoor unit where is easy to see To prevent miss charging the route of the service port is changed from one of the former R22 Do not use any refrigerant different from the one specified for complement or replacement Otherwise abnormally high pressure may be generated in the refrigeration cycle which may result in a failure or explosion of the product or an injury to your body For an air conditioner which uses R410A never use other refrigerant than R410A For an air conditioner which uses other refrigerant R22 etc never use R410A If different types of refrigerant are mixed abnormal high pressure generates in the refrigerating cycle and an injury due to breakage may be caused Do not charge refrigerant additionally If charging refrigerant additionally when refrigerant gas leaks the refrigerant composition in the refrigerating cycle changes resulted in change of air conditioner characteristics or refrigerant over the specified st
119. o When installing equipment which includes a large amount of charged refrigerant such as a multi air Sa asa in a sub room it is necessary that the density does not the limit even if the refrigerant eaks Compulsion If the refrigerant leaks and exceeds the limit density an accident of shortage of oxygen is caused Tighten the flare nut with a torque wrench in the specified manner Excessive tighten of the flare nut may cause a crack in the flare nut after a long period which may result in refrigerant leakage Nitrogen gas must be used for the airtight test The charge hose must be connected in such a way that it is not slack For the installation moving reinstallation work follow to the Installation Manual If an incorrect installation is done a trouble of the refrigerating cycle water leak electric shock or fire is caused SVM 12085 001 050 indd 8 12 06 12 11 06 AM FILE NO SVM 12085 Once the repair work has been completed check for refrigerant leaks and check the insulation resistance and water drainage Then perform a trial run to check that the air conditioner is running properly After repair work has finished check there is no trouble If check is not executed a fire electric shock or injury may be caused For a check turn off the power breaker Check after repair After repair work installation of front panel and cabinet has finished execute a test run to check there is no generation o
120. of overload lt Display 1 gt lt Display 2 gt Compressor lock Is AC mains voltage correct AC198 to 264V YES Is wire connection correct Compressor lead Board side Compressor side Reactor lead Power supply lead 15 compressor under correct conditions NO NO Is there refrigerant stagnation YES Does PMV correctly operate YES Check outdoor P C board Defect Replace Correct power supply line Check wire connection and correct it Check outdoor P C board Defect Replace Compressor lock Replace Check TE TS sensors and PMV Defect Replace SVM 12085_051 114 indd 65 lt Display 1 gt lt Display 2 gt Current detection circuit error Check outdoor P C board Defect Replace 12 06 12 11 15 AM Outdoor LED display Display 1 gt lt Display 2 gt FILE NO SVM 12085 lt ln case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit Case thermostat operation Are CN609 connection and case thermostat correct YES Short each pins of CN609 Can compressor operate YES Is there gas leak Is there refrigerant shortage NO 15 service fully opened YES Is PMV under correct conditions YES Correct connector Case thermostat error Replace Check outdoor P C board Defect Replace
121. ord clamp and the terminals 4 Remove the top plate Hexagonal screw O4 x 10 5 pcs Attachment 1 Attach the top plate Hexagonal screw 04 x 10 5 pcs In this time insert the fin guard of rear side between the top plate and the heat exchanger Rear side 2 Connect the power supply wire and the indoor outdoor connecting wire to the terminal and fix it with cord clamp CAUTION Using bundling band on the market be sure to fix the power wire and indoor outdoor connecting wire along the crossover pipe so that they do not come to contact with the compressor valve at gas side pipe at gas side and discharge pipe 3 Attach the front panel Hexagonal screw O4 x 10 2 pcs 91 FILE SVM 12085 Remarks Front panel Top plate Insert the fin guard of rear side between the top plate and the heat exchanger at rear side 12 06 12 11 15 AM Part name Discharge port cabinet Procedure 1 Detachment 1 Carry out work of 1 of T 2 Remove screws for the discharge port cabinet and the partition plate ST1T x 8 3 pcs 3 Remove screws for the discharge port cabinet and the bottom plate Hexagonal screw O4 x 10 2 pcs 4 Remove screws of the discharge port cabinet and the motor base ST1T O4 x 8 2 pcs 5 Remove screws of the discharge port cabinet and the heat exchanger ST1T 04 x 8 1 pc 6 Remove screws of the discharge port cabinet and the fin guard
122. ote controller correct YES Are inner wiring of indoor unit and Correct wiring inter unit wires 1 2 3 correct and inter unit cable Are CN04 connection and wiring Correct wiring of connectors of terminal blocks 1 2 3 correct and terminal blocks After turning off the power supply Check indoor P C board turn on it again Does D502 Orange LED flash Defect Replace Check outdoor P C board Defect Replace _ 62 SVM 12085_051 114 indd 62 12 06 12 11 15 AM Outdoor LED display lt Display 1 gt lt Display 2 gt FILE NO SVM 12085 lt ln case of SP80 gt Check and troubleshooting Item without special mention Indicates part of outdoor unit Discharge temp sensor TD error Is connection of CN603 correct Is resistance value of TD sensor correct Correct connector Sensor error Replace Check outdoor P C board Defect Replace There is a possibility that it is one of the following errors Confirm LED on outdoor P C board to judge which error it is Heat exchanger temp sensor TE error Heat exchanger temp sensor TL error Suction temp sensor TS error Miswiring of heat exchanger sensor TE TS Display 1 Display 2 gt O00000 Heat exchanger temp sensor TE error Is connection of CN601 correct Is resistance value of TE sensor correct Correct connector Sensor error
123. otective operation P04 P20 eooeoo Fan system error P22 000000 Driving element short circuit P26 O Position detection circuit error P29 As the error code displayed on the wired remote controller may differ according to type of indoor model multiple codes are described 79 SVM 12085_051 114 indd 79 12 06 12 11 15 FILE NO SVM 12085 3 Sensor current compressor operation frequency PMV opening display The values detected by the controller such as temperature sensor or current value are simply confirmed Legend D800 Yellow D803 Yellow D801 Yellow D804 Yellow Go off O Goon D802 Yellow D805 Green Temperature sensor C Compressor PMV Current operation SW803 SW803 SW803 SW803 A frequency Pu sey rpm Li L z LH 6 LED display 000000 Below 25 0 to 0 9 0 to 4 010 19 090000 25 to 21 1 to 1 9 5to9 20 to 39 20 to 16 2 to 2 9 10 to 14 40 to 59 15 to 11 3 to 3 9
124. ound the site before the work Failure to do this may result in third person getting electric shock o If in the course of carrying out repairs it becomes absolutely necessary to check out the electrical 2 Prohibition parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies wear insulated heat resistant gloves insulated boots and insulated work overalls and take care to avoid touching any live parts Stay on You may receive an electric shock if you fail to heed this warning Only qualified service person 1 is protection allowed to do this kind of work WARNING Before starting to repair the air conditioner read carefully through the Service Manual and repair the air conditioner by following its instructions Only qualified service person 1 is allowed to repair the air conditioner o Repair of the air conditioner by unqualified person may give rise to a fire electric shocks injury water leaks and or other problems Only a qualified installer 1 or qualified service person 1 is allowed to carry out the electrical work of the air conditioner Under no circumstances must this work be done by an unqualified individual since failure to carry out the work properly may result in electric shocks and or electrical leaks General Wear protective gloves and safety work c
125. p sensor TS error Refer to column of 212 LED display legend 6 Go off Go on Flash 5Hz SVM 12085 051 114 indd 58 58 12 0642 11 15 AM FILE NO SVM 12085 lt ln case of SP40 to SP56 gt APPLICATION CONTROL KIT Check Countermeasures LED display Part without special mention indicates a part of the outdoor unit D01 D02 D03 D04 Outside temp sensor TO error Red Yellow Yellow Yellow e O e e Is connection of CN602 correct Correct connector Is resistance value of TO sensor correct Sensor error Replace YES Check outdoor P C board Defect Replace D01 D02 D03 D04 Suction temp sensor TS error Red Yellow Yellow Yellow Is connection of CN603 correct Correct connector Is resistance value of TS sensor correct Sensor error Replace YES Check outdoor P C board Defect Replace D01 D02 D03 D04 Compressor breakdown Red Yellow Yellow Yellow i e e voltage coriect Correct power supply line YES Is wiring connection correct Compressor lead Check and correct P C board side Compressor side wiring connection Reactor cord Power supply lead Remove and Does abnormal overload happen improve the cause of overload NO D01 D02 D03 D04 Compressor lock Check outdoor P C board Defect Replace Red Yellow Yellow Yellow e o o Is AC mains voltage correct 198 to 264V Correct power supply line YES Is wiri
126. p sensor 2 Man Mei F01 Fuse 25A 250V Outside temp sensor Connector for main power supply cum P C board E Fuse T10A 250V ipe temp sensor suction for indoor unit REACTOR Reactor Terminal block power supply Terminal block to indoor unit SVM 12085 001 050 indd 25 _ 25 12 06 12 11 06 AM FILE NO SVM 12085 5 SPECIFICATIONS OF ELECTRICAL PARTS RAV SP40 ATP SP45 ATP SP56 ATP 40 45 DA150A1F 20F 4 way valve coil STF H01AJ1872A1 6 7 Fuse Switching power Proto 5 5 3 Fuse Inverter input Current protect ___ ACMOV 79 outdoortemp sensor To sensor 10 Heat exchanger sensor Te senso okaze 711 Suction temp sensor Ts sensor 12 Dischargetemp sensor Tdsenso _ SOK ALAS CS 12AL O Compressor thermo Protection CS 12AL OFF 125 4 C ON 90 5 C RAV SP80 ATP Pa Comes __ j ewawmecd SIEHMAPIMA OOOO O O 4 C Pera wectn ____ mew S8mHi88A C boa 9 Fuse Mounted on board EE Outdoor temp sensor To sensor Fe Heat exchanger sensor Te sensor Fe 10 at 25 C 10 kO at 25 C Discharge temp sensor Td sensor 50 kO at 25 C Heat exchanger temp sensor TI sensor 50 kO at 25 C 4
127. per pipe remove the coil from PMV main body 2 Attachment 1 Match the spring to the copper pipe and fix it 99 coil 12 06 12 11 15 Part name Fan guard SVM 12085_051 114 indd 100 Procedure 3 Detachment 1 Carry out works of 1 of 1 and 2 CAUTION To prevent scratching on the product handle the product on a cardboard or cloth 2 Remove the discharge port cabinet and then put on it so that the fan guard side directs downward 3 Remove the hooking claws 8 positions of the fan guard 2 Attachment 1 Push the hooking claws 8 positions with hands from the front side to fix the claws CAUTION Check that all the hooking claws are fixed at the specified positions 100 FILE 5 12085 Remarks Bell mouth Discharge port cabinet Fan guard Hooking claw 12 06 12 11 15 AM 11 EXPLODED VIEWS AND PARTS LIST 11 1 RAV SP404ATP E SP454ATP E SVM 12085_051 114 indd 101 FILE NO SVM 12085 2 2 2 9 AN Qu M E 0210221023 08 101 12 06 12 11 15 AM FILE NO SVM 12085 Part No Description No SP404ATP E SP454ATP E 43T63323 HOLDER SENSOR 1 0 102 SVM 12085_051 114 indd 102 12 06 12 11 15 AM
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129. r AP40 to AP56 is only SVM 12085 051 114 indd 56 Displayed when error is detected 56 Check outdoor board current detection circuit 12 06 12 11 15 AM Operation of diagnostic function Check code Indoor unit Cause of operation Discharge temp error Discharge temp TD detected temperature over the specified temp Status of air conditioner Condition Displayed when error is detected FILE NO SVM 12085 Judgment and measures 1 Check refrigerating cycle Gas leak Trouble of electronic expansion valve Check discharge temp sensor TD Case thermostat operation Abnormal overheat of compressor Displayed when error is detected Check case thermostat and connector Check gas leak recharge Check whether the service valve is fully opened Check PMV Pulse Motor Valve Check broken pipe Power supply voltage error Displayed when error is detected Check power supply voltage AC198 to 264V High pressure protective operation During cooling operation outdoor temp sensor TL detected temperature over specified temp During heating operation indoor temp sensor TC TCJ detected temperature over specified temp Displayed when error is detected Check outdoor heat exchanger sensor TL Check indoor heat exchanger sensor TC TCJ Check full open of service valve Check indoor outdoor fan
130. r approx 1 second to check exchange operation to cooling cycle heating cycle Power is turned on for approx 10 seconds n case of operating with the coil of 4 way valve connected to CN701 take interval over 1 minute before re operation otherwise it may cause overheat of the coil 2 After check turn off all the Dip switch SW804 Exchange to cooling cycle Exchange to heating cycle SW804 SW801 701 N SW804 SW801 CN701 N h SL ais M N DC200V or more O O O N 7 DC200V more Note Check by tester Analog tester Good if over DC200V Digital tester Good if the maximum voltage is over DC200V though the varied voltage may be displayed In cooling operation P19 error may happen when the refrigerant pressure rose abnormally In this case remove the cause of pressure rising and then diagnose the error again 12 0642 11 15 AM SVM 12085_051 114 indd 71 Outdoor LED display Display 1 gt lt Display 2 gt FILE 5 12085 lt ln case of SP80 Check and troubleshooting Item without special mention Indicates part of outdoor unit High pressure protective operation 15 service valve NO fully opened YES Reset the power supply Heating season Heating operation YES Is there anything of outdoor unit
131. r 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 m Hr or 0 02 MPa 0 2kgf cm by means of the reducing valve After performing the steps above keep the 2 3 4 lt 5 6 lt Nitrogen gas flowing until the pipe cools down to a certain extent temperature at which pipes are touchable with hands 7 Remove the flux completely after brazing Flow meter Stop valve Nitrogen gas cylinder From Nitrogen cylinder gas Rubber plug Nitrogen Fig 6 5 1 Prevention of oxidation during brazing 33 SVM 12085_001 050 indd 33 12 06 12 11 06 AM FILE NO SVM 12085 6 6 Instructions for Re use Piping of R22 or R407C Instruction of Works The existing R22 and R407C piping can be reused for our digital inverter R410A products installations NOTE Confirmation of existence of scratch or dent of the former pipes to be applied and also confirmation of reliability of the pipe strength are conventionally referred to the local site If the definite conditions can be cleared it is possible to update the existing R22 and R407C pipes to those for R410A models 6 6 1 Basic Conditions Needed to Reuse the Existing Pipe Check and observe three conditions of the refrigerant piping works 1 Dry There is no moisture in
132. receiving unit and indoor unit Receiving error Sending error Receiving unit ecelvingu Miswiring or wire connection error between receiving unit and indoor unit Communication stop Operation Timer D 3 Duplicated indoor unit No o Duplicated master units of remote controller Setup error Communication error between CPUS on indoor unit P C board Wire connection error between indoor units Indoor power OFF Communication stop between indoor master and follower or between main and sub indoor twin Operation Timer D g eS Miswiring between indoor unit and outdoor unit or connection erorr e o Communication stop between indoor outdoor units Operation Timer eS O Overflow was detected e O Indoor DC fan error Protective device of indoor unit worked ise Alternate flash outdoor unit worked Outdoor unit discharge temp error Protective device of Outdoor high pressure system error Power supply voltage error Heat sink overheat error Outdoor unit error Gas leak detection error Operation Timer Ready 4 way valve system error Indoor outdoor unit judged Outdoor unit high pressure protection Alternate flash Outdoor fan system error Short circuit error of compressor driving device Position detection circuit error Protective device of outdoor unit worked Stopped because of error of
133. 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 Gauge manifold OUTDOOR unit Refrigerant cylinder 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 jueJeBujeH Electronic Cylinder without siphon Gauge manifold OUTDOOR unit balance Siphon 6 5 Brazing of Pipes 1 Phosphor bronze brazing filler tends to react 6 5 1 Materials for Brazing with sulfur and produce a fragile compound 1 Silver brazing filler water solution which may cause a gas MAP leakage Therefore use any other type of Silver brazing filler is an alloy mainly composed brazing filler at a hot spring resort etc and of silver and copper coat the surface with a paint It is used to join iron copper or copper alloy and 2 When performing brazing again at time of is relatively expensive though it excels in solder servicing use the same type of brazing filler ability 2 Phosphor bronze brazing filler ee 6 5 2 Flux Phosphor bronze brazing filler is generally used to join copper or copper alloy 1 Reason why flux is necessary 3 Low temperature brazing filler By r
134. rpm Lower fan 910 rpm WF pressure setup 225 In this case the upper limit value of static pressure for duct is 5Pa or less on 25 degrees and please use straight duct In this case the outdoor noise level may increase High static pressure setup Existing piping setup Turn the switch to ON when 19 1 is used for the existing pipe ini In this case the heating capacity may lower according to outside temp and piping setup Snow proof fan control indoor temp in fecta 9 3 z Existing Power save setup Turn the switch to ON when using the power save function The control to lower the compressor frequency Approx 10 is performed by indoor heat exchanger temp in heating operation Power save setup all are OFF at shipment When snow enters from clearance of the fan guard or heat exchanger into blast path and it is accumulated the control to prevent generation of motor lock is validated When outside temp is below 0 C though the compressor stops the outdoor fan operates with W5 Snow proof fan control The defrost interval is cut to shorten it than the standard status Defrost time change J805 J806 For contents of control and cutting method refer to Section 9 1 10 Defrost control When it is needed to lower the maximum value of the compressor frequency cut the jumper line Max frequency at cooling h
135. s relating to electrical work on the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work The qualified installer who is allowed to do the refrigerant handling and piping work involved in installation relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work The qualified installer who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work Qualified service person 1 SVM 12085_001 050 indd 3 The qualified service person is a person who installs repairs maintains relocates and removes the air conditioners made by Toshi
136. side of the pipes 2 Clean There is no dust inside of the pipes 3 Tight There is no refrigerant leak 6 6 2 Restricted Items to Use the Existing Pipes In the following cases the existing pipes cannot be reused as they are Clean the existing pipes or exchange them with new pipes 1 When a scratch or dent is heavy be sure to use the new pipes for the works 2 When the thickness of the existing pipe is thinner than the specified Pipe diameter and thickness be sure to use the new pipes for the works The operating pressure of R410A is high 1 6 times of R22 and R407C If there is a scratch or dent on the pipe or thinner pipe is used the pressure strength is poor and may cause break age of the pipe at the worst Pipe diameter and thickness mm R410A Thickness R22 1 0 1 0 R407C n case that the pipe diameter is 012 7 mm or less and the thickness is less than 0 7 mm be sure to use the new pipes for works 3 The pipes are left as coming out or gas leaks Poor refrigerant There is possibility that rain water or air including moisture enters in the pipe 4 Refrigerant recovery is impossible Refrigerant recovery by the pump down operation on the existing air conditioner There is possibility that a large quantity of poor oil or moisture remains inside of the pipe 5 Adryer on the market is attached to the existing pipes There is possibility that copper green rust generated 6 Check th
137. specifications given in the Service Manual or use the parts contained on the parts list in the Service Manual Use specified Use of any parts which do not satisfy the required specifications may give rise to electric shocks smoking parts and or a fire If in the course of carrying out repairs it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies place Keep out signs around the work site Do not bring before proceeding child close to ird indivi p TE the equipment Third party individuals may enter the work site and receive electric shocks if this warning is not heeded Connect the cut off lead wires with crimp contact etc put the closed end side upward and then apply a Insulating water cut method otherwise a leak or production of fire is caused at the users side measures When performing repairs using a gas burner replace the refrigerant with nitrogen gas because the oil that coats the pipes may otherwise burn When repairing the refrigerating cycle take the following measures 1 Be attentive to fire around the cycle When using a gas stove etc be sure to put out fire before work otherwise the oil mixed with refrigerant gas may catch fire 2 Do not use a welder in the closed room When using it without ve
138. ssor leads from P C board the air conditioner operates in heating mode Does the fan motor run Short circuit of compressor driving device Is AC mains voltage correct 198 to 264V ES Is there any problem on connection of compressor lead or reactor Check connection referring to the wiring diagram Correct power line Correct wiring Replace outdoor P C board Check compressor Rare short etc Defective Replace D01 D02 D03 D04 Red Yellow Yellow Yellow Position detection circuit error e e Check outdoor P C board Defective Replace LED display legend Go off O Go on Flash 5Hz 61 SVM 12085_051 114 indd 61 12 06 12 11 15 FILE NO SVM 12085 lt ln case of SP80 gt 8 2 4 Diagnostic Procedure for Each Check Code Outdoor Unit 1 This section describes the diagnostic method for each check code displayed on the wired remote controller 2 In some cases a check code indicates multiple symptoms In this case confirm LED display on the outdoor P C board to narrow the contents to be confirmed 3 The check code on the remote controller is displayed only when the same error occurred continuously by multiple times while LED of the outdoor P C board displays even an error which occurred once Therefore the display on the remote controller may differ from that of LED How to check LED display on outdoor P C board
139. stem error After heating operation has started indoor heat exchangers temp is down Stop Automatic reset Displayed when error is detected Check 4 way valve Check 2 way valve and check valve Check indoor heat exchanger Check indoor P C board Own unit stops while warning is output to other indoor units Stop Follower unit Automatic reset Displayed when error is detected Judge follower unit while master unit is 203 L03 L07 or L08 Check indoor P C board Coming off disconnection or short of indoor heat exchanger temp sensor TCJ Stop Automatic reset Displayed when error is detected Check indoor heat exchanger temp sensor TCJ Check indoor P C board Coming off disconnection or short of indoor heat exchanger temp sensor TO Stop Automatic reset Displayed when error is detected Check indoor heat exchanger temp sensor TC Check indoor P C board Coming off disconnection or short of indoor heat exchanger temp sensor TA Stop Automatic reset Displayed when error is detected Check indoor heat exchanger temp sensor TA Check indoor P C board Indoor EEPROM error EEPROM access error Stop Automatic reset Displayed when error is detected Check indoor EEPROM including socket insertion Check indoor P C board Communication error between indoor MCU Communicatio
140. the refrigerant recovery pump down by the outdoor unit is mounted so that it is easy to react against the environment at reinstalling or rejection time Operation method lt SP40 to SP56 gt 1 See the mode of the indoor unit to fan mode 2 Push the refrigerant recovery switch SW802 of the outdoor unit for approx 2 seconds The cooling operation starts This operation finishes after 10 minutes 3 After operation for 3 minutes or more close the valve at liquid side 4 After recovering refrigerant close the valve at gas side 5 When keeping pushed the refrigerant recovery SW again for approx 2 seconds the outdoor unit stops 6 Stop the indoor unit and then turn off the power supply Refrigerant recovery SW Exchange SW802 to Cooling only Power saving Existing piping NOTE The electric portion of the refrigerant recovery SW on the sub board W804 All OFF As initial status is electrified therefore be careful to an electric shock SW801 Push for 1 second e 0805 Green LED m lt 5 80 gt 1 Set the mode of the indoor unit to fan mode 2 Set all DIP switch SW804 to OFF Initial status and then push the button switch SW801 for approx 1 second The cooling operation starts During this time D805 Green LED flashes This operation finishes by 10 minutes 3 After operation for 3 minutes or more close valve at liquid side 4 After recovery of refrigera
141. then the fan is controlled by temperature of TE sensor When TE gt 24 C continues for 5 minutes the TE C compressor stops It is the same status as the normal THERMO 2 a Rown to W1 OFF without error display op timer coun E The compressor restarts after approx 2 minutes 2 taps 20 sec Down to W1 30 seconds and this intermittent operation is not abnormal 1 tap 20 sec Down to W1 In case that the status in item 3 generates frequently stain on filter of the suction part of Revolution frequency hold the indoor unit is considered Clean the filter and then restart the operation 1 tap 20 sec Up to the maximum tap of each zone lt SP40 to SP56 gt lt SP80 gt 20 Hz 20Hz 45Hz 20 Hz 20Hz 45Hz Temp range orlower to45Hz or higher Temp range or lower to 45Hz or higher Max Max Max Max Max Max 10 C lt TO 10 C lt TO 5 5 C lt TO lt 10 C 5 C lt TO lt 10 C 5 C lt TO lt 5 5 C 3 C lt TO lt 5 C TO lt 5 C 10 C lt TO lt 3 C TO error TO 10 C TO error 4 Coil heating control 1 This control function heats the compressor by turning on the stopped compressor instead of a case heater It purposes to prevent stagnation of the refrigerant inside of the compressor 2 As usual turn on power of the compressor for the specified time before a test run after installation other
142. top the compressor 2 The compressor restarts after 2 minutes 30 seconds as setting 1 as an error count 3 When the error count 8 was found determine an error and restart operation is not performed 4 For the error display contents confirm on the check code list 9 High pressure release control lt SP80 only gt 1 The operation frequency is controlled to restrain abnormal rising of high pressure by TL sensor in cooling operation and TC sensor in heating operation 2 When TL sensor in cooling operation or TC sensor in heating operation detects abnormal temperature of the stop zone stop the compressor and the error count becomes 1 3 When the compressor stopped with 2 the operation restarts from the point of the normal operation zone e point or lower where it returned after 2 minutes 30 seconds 4 The error count when the compressor stopped with 2 is cleared after the operation continued for 10 minutes Ifthe error count becomes 10 without clearing the error is determined and reactivation is not performed 5 For the error display contents confirm on the check code list HEAT TC COOL TL 4 stop Frequency normal down Frequency slow down d Frequency hold Frequency slow up Up to command As command is 42 SVM 12085_001 050 indd 42 12 06 12 11 06 FILE NO SVM 12085 10 Defrost control lt SP40 to SP56 only gt 1 In heatin
143. trol P C board 3 Cut off the bundling band binding the compressor lead and the relay connector 4 Remove each reactor Truss B tight screw O4 x 6 2 pcs each 5 Attach a new reactor NOTE Be sure to bind the removed bundling band with the bundling band on the market Be careful that the fan motor lead does not come to contact with the reactor body 94 FILE NO SVM 12085 Remarks Reactor relay connector Connected to lead wire White at P C board side Reactor relay connector Connected to lead wire Charcoal gray at P C board side Fan motor lead Bundling band Compressor lead reactor lead Upper reactor Connected to reactor relay connector Connected to lead wire White at P C board side uw Bundling band Lower reactor Connected to reactor relay connector Connected to lead wire Charcoal gray at P C board side 12 06 12 11 15 AM Part name Fan motor SVM 12085_051 114 indd 95 Procedure 1 Carry out works of 1 of 1 and 2 2 Remove the flange nut fixing the fan motor and the propeller fan The flange nut is loosened by turning clockwise To tighten it turn it counterclockwise 3 Remove the propeller fan 4 Remove the connector for fan motor from the inverter 5 Remove the fan motor lead from the fan motor lead fixing rubber of the penetrated part of the partition plate 6 Remove the fixing screws 4 pcs each whi
144. tructions that contain important information which complies with the Machinery Directive Directive 2006 42 EC and ensure that you understand them Generic Denomination Air Conditioner Definition of Qualified Installer or Qualified Service Person The air conditioner must be installed maintained repaired and removed by a qualified installer or qualified service person When any of these jobs is to be done ask a qualified installer or qualified service person to do them for you Aqualified installer or qualified service person is an agent who has the qualifications and knowledge described in the table below Qualifications and knowledge which the agent must have Qualified installer 1 The qualified installer is a person who installs maintains relocates and removes the air conditioners made by Toshiba Carrier Corporation He or she has been trained to install maintain relocate and remove the air conditioners made by Toshiba Carrier Corporation or alternatively he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations The qualified installer who is allowed to do the electrical work involved in installation relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations and he or she is a person who has been trained in matter
145. uter winding Black heat proof pipe cover and heat proof bundling band each sensor TL TO TE TD TS sensor PMV coil lea wire Set each sensor so that it does not _ come to contact with the discharge pipe Suction pipe PMV coil lead Pipe cover bundling band each sensor art TO TE TS sensor PMV coil lea 98 12 06 12 11 15 Part name Compressor Compressor lead Continued Procedure 3 Vacuuming 1 Connect the vacuum pump to the charge port of the gas pipe valve and then drive the vacuum pump 2 Carry out vacuuming until the vacuum low pressure gauge indicates 1 mmHg NOTE Before vacuuming open PMV fully If PMV is closed vacuuming may be impossible between the liquid pipe valve and PMV of the outdoor unit Forced full opening method of PMV Turn on the leakage breaker Turn on 1 and 3 of DIP SW804 on the control P C board of the outdoor unit Keep pushing SW801 on the control P C board of the outdoor unit for 1 second or more After pushing SW801 for 1 second or more turn off the leakage breaker within 2 minutes 4 Refrigerant charging 1 Add the quantity of refrigerant specified by the pipe length into the charge port of the valve FILE NO SVM 12085 Remarks PMV coil SVM 12085 051 114 indd 99 1 Detachment 1 Carry out works of 1 of 1 and 3 2 While pulling the coil upward and removing the spring which pinches the cop
146. wise a trouble of the compressor may be caused As same as a test run it is recommended to turn on power of the compressor beforehand when starting operation after power of the compressor has been interrupted and left as it is for a long time 3 SP80 judgment for electricity is performed by TD and TO sensors If TO sensor is defective a backup control is automatically performed by TE sensor For a case of defective TO sensor judge it with outdoor LED display Using TD sensor and TE sensor SP40 to SP56 judges the power on 4 For every model the power is turned off when TD is 30 C or more ds SVM 12085 001 050 indd 40 12 0642 11 06 AM lt SP40 to SP56 gt Normal time No power Continuous power ON Output 10W or equivalent Continuous power ON Output 20W or equivalent 5 Normal time FILE NO SVM 12085 E EE kas In defective sensor TE 18 C 20 C No power No power 15 C 18 C Intermittent power ON Intermittent power ON 10 C 10 minutes ON 12 C 10 minutes ON 0 5 minutes OFF 5 minutes OFF Output 40W or equivalent Output 40W or equivalent BC sa Fees 10C Pasa e ese Continuous power ON Continuous power ON Output 40W or equivalent Output 40W or equivalent REQUIREMENT While heating the coil the power sound may be heard However it is
147. with an airtight cap or any other cover 1 Flare Processing Procedures and Precautions a Cutting the Pipe By means of a pipe cutter slowly cut the pipe so that it is not deformed b Removing Burrs and Chips If the flared section has chips or burrs refrigerant leakage may occur Carefully remove all burrs and clean the cut surface before installation SVM 12085 001 050 indd 28 28 12 06 12 11 06 c Insertion of Flare Nut d Flare Processing Make certain that a clamp bar and copper pipe have been cleaned By means of the clamp bar perform the flare processing correctly Use either a flare tool for R410A or conventional flare tool Flare processing dimensions differ according to the type of flare tool When using a conventional flare tool be sure to secure dimension A by using a gauge for size adjustment Nominal diameter FILE NO SVM 12085 Fig 6 2 1 Flare processing dimensions Table 6 2 3 Dimensions related to flare processing for R410A R22 Outer diameter mm Thickness mm A mm Flare tool for R410A R22 clutch type Conventional flare tool R410A Conventional flare tool R22 Clutch type Wing nut type 1 0 to 1 5 1 5 to 2 0 Clutch type Wing nut type 0 5 to 1 0 1 0 to 1 5 1 0 to 1 5 1 5 to 2 0 0 5 to 1 0 1 0 to 1 5 1 0 to 1 5 2 0 to 2 5 0 5 to 1 0 1 5 to 2 0 Nominal diameter 1 0 to 1 5 2 0 to 2 5

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