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Toshiba RAV-SM560AT-E Air Conditioner User Manual

1. 633 Knock out system 200 Min 1093 Grille air inlet Back body 1015 742 450 20 220 Installation plate Mount plate 330 Hack Kini im I I Bi iti M10 Suspention bolt PS ace 19 all ce OD D 1 0 Wf 633 460 165 160 Wireless remote control 70 Min 7 7 UNDER CEILING amp CONSOLE INSTALLATION Knock out system 2 2 Outdoor Unit RAV SM560AT E Drain hole 225 Drain hole 2 220 x 88 long hole 83 600 97 A legs N g d 115 3 125 I
2. N alo 22 lz 30 ore co 99 quc X 4 Ps 75 HE pu 55 8 ae os Pane E B legs 780 pun 115 3 Discharge guide mounting hole 216 49 5 147 9 4 4 embossing SE Y by EH JE s EE s s WM SS 1 et Y 9 25 220 4 200 Fan center dividing Protective net mounting hole 2 04 embossing 43 707 130 Protective net mounting hole 4 04 embossing St wo N lt Refrigerant pipe connecting 012 7 flare at gas side Refrigerant pipe connecting port 6 4 flare at liquid side Space required for service 2 011 x 14 U shape holes 600 For 208 010 anchor bolt o f Suction port Ns ay 300 AER SL 10 150 Product _ amp omoe Minimum derma ling c niue i BONE Titanes up to wall 11 x 14 U shape hole ___ 600 x X Details of A legs Details of B legs 500 X 2 011 x 14 long hole por For 8 10 anchor bolt 2 3 Outdoor Unit RAV SM800AT E Knockout For draining Drain hole 2
3. a ot o Compressor thermo Protection US 622 ON 90 5 C OFF 125 4 C 5 3 Outdoor Unit RAV SM800AT E Parts name Specifications Fan motor ICF 140 63 1 Output Rated 63 W 220 240 V Compressor DA220A2F 20L 3 phase 4P 1600 W Reactor CH 47 Outdoor temp sensor To sensor 10 at 25 C Heat exchanger sensor Te sensor 10 at 25 C Suction temp sensor Ts sensor 10 kQ at 25 C Discharge temp sensor Td sensor 50 kQ at 25 C Fuse Switching power Protect T3 15 AC 250 V 0 N AJ 0 Fuse Inverter input Current protect 25 250 4 valve solenoid coil DKV M0ZS743B0 oa Compressor thermo Protection US 622 ON 90 5 C OFF 125 4 C 12 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 Confor
4. 48 Table 10 2 2 Operation of diagnostic function from outside devices Check Unit Judgement and action Block code Symptom status Condition MODE Tes The serial signal is not output Operation Displayed when 1 Outdoor unit does not completely TIMER lamp pre from outdoor unit to indoor unit continues error is detected operate 5Hz flash Miscabling of inter unit cables e Inter unit cable check correction of Defective serial sending circuit miscabling on outdoor P C board Outdoor P C board check P C board Defective serial receiving circuit cables check on outdoor P C board e Compressor case thermo check Compressor case thermo 2 In normal operation operation When outdoor sending serial LED Green flashes the receiving serial LED Orange also flashes Indoor P C board Main P C board check When the receiving serial LED Orange does not flash Outdoor P C board check F1 BUS communication circuit error Operation Displayed when 1 Communication line check miscabling BUS communication was continues error is detected check interrupted over the specified According Power supply check for central control time to remote Central control remote control etc control of and indoor unit indoor 2 Communication check XY terminal unit 3 Indoor P C board check 4 Central control check Communication P C board
5. lt Primary check gt 1 Is the preset temperature higher than the room temperature in cooling operation 2 Is the crossover cable connected properly lt Inspection procedure gt Cooling only model Turn on power supply Does OPERATION lamp blink Refer to 9 6 1 Power can not be turned on Thermo sensor or heat exchanger sensor is defective Is resistance value of thermo sensor TA and heat exchanger sensor TC normal YES Microcontroller is defective Miniature relay RY04 is defective Does miniature relay RYO4 switch on and off due to temperature changes Replace thermo sensor or heat exchanger sensor Is it possible to detect AC 220 240 V between and on the terminal block Replace P C board Rewire or replace Are all of compressor defective cords cords normal YES Is compressor motor winding normal Check winding resistor YES Is capacitor for compressor normal YES Is overload relay normal YES Does compressor start YES Replace compressor Compressor is defective Capacitor is defective Replace capacitor Overload relay is defective Replace overload relay NH Compressor is defective Replace compressor Does compressor stop after a while YES Is gas quantity normal Check gas pressure YES Compressor is defective YES Gas sh
6. Replace Check electron expansion valve Replace YES Check IPDU and CDB Defect Replace error Is protective control such as NO Are connections of discharge temprelease control normal cable connector normal YES YES For RAV SM560AT E check control P C board Defect Replace Correct the cabling and connection of connector Check parts Defect Replace Check and correct the charged NO Is charged refrigerant amount normal YES refrigerant amount YES Is not abnormal overload NO Improve and delete the cause Replace TD sensor Are characteristics of NO TD sensor resistance value normal Refer to Characteristics 4 YES Check CDB For RAV SM560AT E check control P C board 1F error NO Defect Replace Is power voltage normal YES YES Improve power line Is not abnormal overload NO NO Is the circuit detected by Improve and delete the cause current sensor normal YES Check and correct circuit cables Check IPDU For RAV SM560AT E check control P C board 54 Defect Replace 21 error Is high voltage protective operation by TE sensor normal Is connection of cabling Correct connection of connector normal cabling connector YES Check TE sensor
7. Packed 12 7 43047667 Nut Flange HKU R410A H4 43020329 Fan Propeller PJ421 43147196 Bonnet 1 4 IN 6 4 CU 4302C033 Motor Fan ICF 140 43 1 43055521 Reactor CH 57 43146128 Condenser Ass y 43063321 Holder Sensor 4 8 9 52 43041609 Compressor DA130A1F 23F 43063322 Holder Sensor 6 11 4 12 7 43050407 Thermostat Bimetal 43063325 Holder Sensor 6 6 35 8 43063317 Holder Thermostat 43063332 Holder Sensor 43097206 Bolt Compressor M6 43089160 Cap Waterproof 43049749 Rubber Cushion 43032441 Nipple Drain 43046363 Valve 4 WAY VT7101D 12 4 Outdoor Unit RAV SM800AT E 35 Location Description Location No p No 43191634 Cabinet Air Outled 43097204 Nut 43191636 Cabinet Front Ass y 43046344 Valve 4 WAY CHV 0213 43191635 Cabinet Side Ass y 43046348 Coil Solenoid VHV 01A150A1 43191637 Panel Upper 43046385 Valve Pulse Modulating 43005489 Guard Fin SKV 18D26 43191630 Guard Fan PP K 43046386 Coil PMV DKV MO25743BO 43122065 Bell Mouth Plastic 43048066 Accumulator Ass y 43047667 Nut Flange 43146584 Valve Packed 9 52DIA HKT9 52 43120123 Fan Propeller PJ491 AS G 43047401 Bonnet 3 8 IN 9 52 CU 43121693 Motor Fan ICF 140 63 1 43146613 Valve Ball B5 8F 4314G117 Condenser Ass y 43195029 Bonnet 43191515 Panel Front Piping 43148169 Strainer 43191605 Panel Back Piping 43148176 Stra
8. three seconds The unit beeps three times The lamp changes from and continues to operate orange to green If the unit is not required to operate at this time push TEMPORARY button once more or use the remote control to turn it off Motions The unit is in operation The orange lamp is on Y The unit stops operating The orange lamp is turned off T After approx three seconds The unit beeps three times If the unit is required to operate at this time push TEMPORARY button once more or use the remote control to turn it on e While this function is being set if the unit is in 8 10 Filter Check Lamp operation the orange lamp is on When the elapsed time reaches 1000 hours the filter 8 9 3 Power failure during timer operation check lamp indicates After cleaning the filters turn off the filter check lamp When the unit is in Timer operation if it is turned off because of power failure the timer operation is 8 10 1 How to turn off filter check lamp cancelled Therefore set the timer operation again 1 Press FILTER button on the remote control 2 Push TEMPORARY button on the indoor unit Note If TEMPORARY button is pushed while the filter check lamp is not indicating the indoor unit will start the Automatic Operation 26 9 INSTALLATION PROCEDURE Remark per EMC Directive 89 336 EEC To prevent flicker impressions during the start of the compressor technical process following in
9. 1 Red lead 2 White lead Between 2 White lead and Black lead Between 3 Black lead and D Red lead of motor winding of connector CN301 The status that there is 5k to 20kQ resistance values between Yellow lead and 4 Pink lead of motor position detection of connector CN300 CN302 is normal YES e For RAV SM560AT E CN300 changes to CN301 and CN301 to CN300 respectively Normal fan motor Defective fan motor CDB error NOTE However GND circuit error inside of the motor is rarely detected even if the above check is carried out When the circuit does not become normal even if P C board has been replaced replace outdoor fan motor RAV SM560AT E RAV SM800AT E Objective P C board Control P C board CDB PC board Fan motor winding CN300 CN301 Motor position detection CN301 51 CN300 14 error NO Improve the power supply line Is power voltage normal YES Are connections of cabling connector normal YES For RAV SM560AT E check RY01 on the control P C board Does RYO1 relay of YES IPDU operate NO Single phase type is not provided to RAV SM560AT E YES Y Is not AC fuse fused NO NO Check and correct circuit cables Correct connection of connector Check and correct reactor connection Is not 14 errors output when
10. 10L pcs 72 Part name Discharge port cabinet Procedure 1 Detachment 1 Perform work of item 1 of CD 2 Take off screws ST1T 04 x 10L pcs of discharge port cabinet for the partition plate 3 Take off screws ST1T 04 x 10L 2 pcs of discharge port cabinet for the bottom plate 4 Take off screw ST1T 04 101 1 pc of discharge port cabinet for the heat ex changer 5 Take off screws ST1T 04 x 10L 2 pcs of discharge port cabinet for the fin guard 2 Attachment 1 Put the upper left side of the discharge port cabinet on the end plate of the heat exchanger and then fix it with screw ST1T 04 x 101 1 pc 2 Attach the removed screws to the original positions Remarks Side cabinet Hm Fin guard Discharge port End plate of the heat exchanger Side cabinet 1 Perform work of item 1 of CD 2 Remove screw fixing the inverter and the side cabinet ST1T 4 x 10 1 pc 3 Remove screws of the side cabinet and the valve support plate ST1T 04 x 10 2 pcs 4 Remove screw of the side cabinet and the cabling panel Rear ST1T O4 x 10 1 pc 5 Remove screw of the side cabinet and the bottom plate ST1T 24 x 10 1 pc 6 Remove screw of the side cabinet and the fin guard Heat exchanger ST1T O4 x 10 2 pcs 73 Valve support plate Side cabinet Inverter Valve support Cabling panel plate Rear Part name Inverter ass
11. FD Error in 4 way valve system Operation Displayed when 1 Check 4 way valve Indoor heat exchanger continues error is detected 2 Check 2 way valve and non return SEDE temperature rise after start of valve cooling operation 3 Check indoor heat exchanger sensor e Indoor heat exchanger TC temperature fall after start of 4 Check indoor P C board heating operation Main P C board mm Error in other cycles Operation Displayed when 1 Compressor case thermo operation Lt Ct Indoor heat exchanger temp continues error is detected 2 Coming off of detection part of indoor 73421 TC does not vary after start of heat exchanger sensor cooling heating operation 3 Check indoor heat exchanger sensor TC 4 Check indoor P C board Main P C board MODE lamp IF Coming off disconnection or Operation Displayed when 1 Check indoor temp sensor TA 5Hz flash pu short of indoor temp sensor TA continues error is detected 2 Check indoor P C board CI Z Main P C board Coming off disconnection or Operation Displayed when 1 Check indoor temp sensor TC Lir short of indoor temp sensor TC continues error is detected 2 Check indoor P C board EN Main P C board FL Coming off disconnection or Operation Displayed when 1 Check indoor temp sensor Lir Short of indoor temp sensor continues error is detected 2 Check indoor P C board Main P C 73 TCJ board MODE lamp
12. R410A 1 5 Refrigerant control Pulse motor valve Standard length 20 without additional charge Max total length 30 50 Over 20m Add 20g m Max 200g Add 40g m 12000 Outdoor lower Height difference Outdoor higher Height Outer dimension Width Depth Total weight Heat exchanger Finned tube Fan Propeller fan Fan unit Standard air flow High Motor 43 63 Connecting Gas side 12 7 1 2 015 9 5 8 pipe Liquid side 26 4 1 4 29 5 3 8 Protection device Discharge temp sensor Over current sensor Compressor thermo Sound level Note 2 Note 1 The sound level is measured in an anechoic chamber in accordance with JIS B8616 Normally the values measured in High Mid Low Cooling Heating the actual operating environment become larger than the indicated values due to the effects of external sound Note 2 Rated conditions Cooling Indoor air temperature 27 C DB 19 C WB Outdoor air temperature 35 C DB Heating Indoor air temperature 20 C DB Outdoor air temperature 7 C DB 6 C WB 2 1 Indoor Unit For stud bolt 8 G10 For stud bolt 86 2 CONSTRUCTION VIEWS Front panel 208
13. an operation is performed by removing 3P connector of compressor YES Replace IPDU Replace control P C board of RAV SM560AT E NO Replace IPDU NO Is compressor normal Replace control P C board of RAV SM560AT E Check IPDU Check rare short of compressor trouble Defect Replace Defect Replace 16 error Are connections of NO Check and correct circuit cabling cable connector normal such as cabling to compressor YES NO YES Is not earthed NO Compressor error Replace Is not winding shorted Is resistance between windings 0 6 to 1 2 Q Compre or ert r gt Replace NO Is not winding opened NO Compressor error Replace Check IPDU P C board Defect Replace 52 18 error Are connections of TE TS sensor connectors of CDB CN604 CN605 normal YES Are characteristics of TE TS sensor resistance values normal YES Check CDB Defect Replace 19 error Is connection of TD sensor connector NO of CDB CN600 normal YES NO Correct connection of connector gt For RAV SM560AT E 600 sensor and CN603 TS sensor NO Refer to Characteristics 3 For RAV SM560AT E replace the gt Replace TE and TS sensors contr
14. direction slit or cover 2 Pipes and the Drain hose should be fixed together by the Drain band with two screws Cut Fig 9 5 15 34 9 5 5 Console Installation e Select the terminal of Selector SW from C position to F position lt N ATA Fig 9 5 18 lt Cutting hole and mounting the Installation plate gt e When installing the rear piping determine the pipe hole position drill the pipe hole 80 mm at a slight downward slant to the outdoor side For mounting of the Installation plate 1 use the Paper pattern which is inside the package box cover 1093 375 mm 742 or more 160 390 mm or more Rear piping hole 280 Fig 9 5 19 emp x O x Anchor bolt N Projection 15 mm or less Mo Mounting screw 04 x 25 2 Clip anchor local parts Fig 9 5 20 CAUTION Failure to firmly install the unit may result in personal injury and property damage if the unit falls e In case of block brick concrete or similar type walls make 5 mm dia holes in the wall e Insert clip anchors for appropriate Mounting screws NOTE e Secure four corners and lower parts of the Installation plate 1 with 6 to 8 mounting screws to instal
15. is used for nominal diameters 1 4 and 3 8 Flare tool clutch type By increasing the clamp bar s receiving hole strength of spring in the tool has been improved Gauge for projection adjustment Used when flare is made with using conventional flare tool Vacuum pump adapter Connected to the conventional vacuum pump It is necessary to use an adapter to prevent vacuum pump oil from flowing back to the charge hose The charge hose connecting part has two ports one for conventional refrigerant 7 16 UNF 20 threads per inch and one for R410A If the vacuum pump oil mineral mixes with R410A a sludge may occur and damage the equipment Gas leakage detector Exclusive for HFC refrigerant e Incidentally the refrigerant cylinder comes with the refrigerant designation R410A and protector coating in the U S s ARI specified rose color ARI color code PMS 507 e Also the charge port and packing for refrigerant cylinder require 1 2 UNF 20 threads per inch corresponding to the charge hose s port size 44 9 11 ENVIRONMENT 9 11 1 Environmental Issues lt Product maintenance gt 1 To minimize the chances of environmental damage and to ensure the efficient operation of the unit it is recommended to have the air conditioner periodically checked and serviced by a qualified engineer lt Product disposal gt 1 Please dispose of the air conditioner unit in an environmentally responsible mann
16. normal Overload relay is defective YES Does compressor start YES Does compressor stop after a while YES Is gas quantity normal Check gas pressure YES Compressor is defective YES Replace P C board Replace capacitor Replace overload relay Compressor is defective Replace compressor Gas shortage Gas leak Supply gas 59 11 1 Indoor Unit Part name Air Inlet grille 11 DETACHMENTS Procedures lt How to remove the Air inlet grille gt 1 Stop the operation of the Air conditioner and turn off its main power supply 2 Open the Air inlet grille with both hands 3 Unfasten 3 screws about two to three rounds for fixing the Panel arms 4 Move the Air inlet grille toward 5 Remove the Grille stopper from the axis of the Front panel After that remove the Air inlet grille 6 Remove the Panel arms from the Front panel lt How to install the Air inlet grille gt 1 Insert three Panel arms on the Air inlet grille and fix each securely by screws 2 Set the Air inlet grille arm to the axis of the Front panel 3 Insert the Grille stopper to the correct position and fix it securely with screws 4 Push the Air inlet grille to the correct position Remarks Air inlet grille Panel arm Grille stopper Air inlet grille Panel arm Part name Front panel Procedures lt How to remove the Front panel gt 1 Remove the Ai
17. outdoor unit 2 Attach the upper cabinet ST1T O4 x 101 2 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 ST1T O4 x 10L 3 pcs 4 Attach the wiring cover ST1T O4 x 10L 2 pcs 5 Attach the valve cover ST1T 04 x 101 1 pc Insert the upper part of the upper cabinet set hooking claw of the valve cover to the slit at three positions of the main body and then attach it pushing upward 65 Remarks 2 Wiring Upper cabinet Water proof cover Cord clamp Part name Procedure Remarks Front cabinet 1 Detachment 1 Perform work of item 1 of 2 Remove screws ST1T 4 x 10L 2 pcs of the front cabinet and the inverter cover 3 Take off screws of the front cabinet and the bottom plate ST1T O4 x 10L 3 pcs 4 Take off screws of the front cabinet and the motor support ST1T O4 x 10L 2 pcs The left side of the front side if made to Front cabinet For single phase type models insert to the rear cabinet so remove it also take off this screw pulling upward Front cabinet Left side Attachment Insert hook at the left side of the front side into the rear cabinet Hook the lower part at the right side of the front to concavity of the bottom plate Insert the hook of the rear cabinet into the slit of the front cabinet
18. pipe Remove Suction pipe Screws 2 pcs Compressor bolt 3 pcs Reactor 1 Perform works of item 1 of and 2 First take off two screws ST1T 4 x 10L of the reactor fixed to the reactor support 3 Remove the reactor support from the partition plate ST1T O4 x 10L 4 pcs 4 Take off two screws ST1T 24 x 101 directly attached to the partition plate 70 Partition plate Reactor Reactor support board Part name Pulse Modulating Valve PMV coil Procedure 1 Detachment 1 Perform works of items Q 2 Release the coil from the concavity by turning it and remove coil from the PMV 2 Attachment 1 Put the coil deep into the bottom position 2 Fix the coil firmly by turning it to the concavity Remarks PMV body Positioning extrusion P i i PMV coil Concavity Fan guard 1 Detachment 1 Perform works of items 1 of 2 2 Remove the front cabinet and put it down so that fan guard side directs downward CAUTION Perform works on a corrugated card board 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 at
19. put the Drain hose into water 3 Do not form the Drain hose into a wave shape 4 Do not put the Drain hose end in the drainage ditch 2 Open the louver manually and put some water into it Then check the flow of water from the Drain hose Fig 9 6 2 3 When connecting the Extension drain hose insulate the connecting part of Extension drain hose with the Pipe shield Pipe shield B la Inside the room E Extension drain hose 1 Drain hose Fig 9 6 3 CAUTION Arrange the drain pipe for proper drainage from the unit Improper drainage can result in dew dropping Provide by customer 36 9 7 REFRIGERANT PIPING 9 7 1 Refrigerant Piping 1 If the outdoor units are to be mounted on a wall make sure that the platform supporting is sufficiently strong The platform should be designed and manufactured to maintain its strength over a long period of time and sufficient consideration should be given to ensuring that the outdoor unit will not fall 2 Use copper pipe with 0 8 mm or more thickness 3 Flare nut and flare works are also different from those of the conventional refrigerant Take out the flare nut attached to the main unit of the air conditioner and use it CAUTION IMPORTANT 4 POINTS FOR PIPING WORK 1 Take away dust and moisture from the inside of the connecting pipes 2 Tight connection between pipes and unit 3 E
20. terminals after replacement of the compressor be sure to caulk the Faston terminal without loosening JE Remarks Partition plate support Compressor lead wire Case thermo Discharge pipe I Compressor c BE 3 pcs Part name Procedure Remarks Reactor 1 Perform works of items 1 of and 2 Take off screws fixing the reactor 24 x 10L 2 pcs per one reactor An outdoor unit has two reactors on the partition plate Pulse Modulating 1 Detachment Valve PMV coil 1 Perform works of items 1 of and T PMV body Positioning extrusion 2 Remove the coil from PMV body while pulling it upward a M 2 Attachment 1 Match the positioning extrusion of the coil surely to the concavity of PMV body to fix it PMV coil Concavity 78 Part name Fan guard Procedure 1 Detachment 1 Perform works of items 1 of and 2 Remove the air flow cabinet and put it down so that the fan guard side directs downward Perform work on a corrugated card board cloth etc to prevent flaw to the product Take off screws fixing the bell mouth ST1Tf4 x 101 2 pcs Remove the bell mouth Remove the hooking claws by pushing with minus screwdriver along with the arrow mark as shown in right figure Attachment Insert claw of the fan guard in hole of the discharge panel Push the hooking claws 5 positions with hands and fi
21. unit blinks 2 Check the indoor P C board Disconnection or short circuit when error is defected indoor heat exchanger Operation The lamp on the 1 Check the indoor heat exchanger J IJ I sensor TC is defective continues indoor unit blinks sensor TC ties Disconnection or short circuit when error is 2 Check the indoor P C board defected The indoor fan motor or its circuit All off The lamp on the 1 Check the connector circuit of the I is defective indoor unit blinks indoor fan motor CN10 when error is 2 Check the indoor fan motor defected 3 Check the indoor P C board 11 The part other than the above Operation The lamp on the 1 Check the indoor P C board we parts on the indoor P C board is continues indoor unit blinks EEPROM and peripheral circuits defective when error is EEPROM access error defected IOL operation All off The lamp on the Overload operation of refrigerating cycle J indoor unit blinks when error is defected The block is 11 The variation of TC 5 minutes Operation The lamp on the 1 Check whether or not the TC sensor unidentifi I after starting the compressor continues indoor unit blinks comes off able is 2K or less when error is 2 Check whether or not it is possible to defected operate the compressor and the outdoor fan motor 3 Check gas leak Cable Fill The serial signals can not be Operation The lamp on the 1 In the case of the outdoor
22. 0 x 88 burring hole Drain hole 25 burring hole 29 90 191 20 Suction u 17 5 21 Z Part B i Knockout gt For draining 365 Long hole pitch for anchor bol 40 39 47 26 60 Dou 150 300 900 17 5 21 Handles Both sides Y h Z Z q s N 20 1 622244 SSS TE SS N SSS SS SSNNS 5555 2 22 SS Ss 565 2 r 22 4 E pas 1 7 WSS 9 9 9 RS SII Z SS Z SS Z 55 2 S Discharge guide mounting hole 4 04 embossing 28 320 Space required for service 2 012 x 17 U shape holes For 08 010 anchor bolt 500 or more Pi edge Installation bolt hole 12 x 17 U shape holes 17 5 mlj lt Details of B part Details of A part 1 r Installation bolt hole 812 x 17 U shape holes 17 5 Refrigerant pipe connecting port 9 5 flare at liquid side Refrigerant pipe connecting port 015 9 flare at gas side Knockout for lower pi
23. 3 1 Fig 8 3 2 and Table 8 3 1 2 STOP Air conditioner stops FAN Fan operation COOL Cooling operation lt COOL gt 3 2 5 D 2 41 5 g E 1 8 c 0 5 0 temp 05 NOTE DRY Dry operation 1 The values marked with 1 are calculated and HEAT Heating operation controlled by the difference in motor speed between M and L AUTO Automatic operation 2 Automatic Operation e The air conditioner selects and operates in one of the operating modes of cooling heating or fan only depending on the room temperature f the AUTO mode is uncomfortable you can select the desired conditions manually Fig 8 3 1 Table 8 2 2 Room temperature in operation Operating condition The set temperature 1 C or higher Cooling Performs the cooling operation at a temperature 1 C in case that the room is hot operation higher than the setting The set temperature 1 C to 1 C Fan only Performs the fan only operation low speed while operation monitoring the room temperature When the room temperature changes the air conditioner will select the cooling or heating mode The set temperature 1 C or lower Heating Performs the heating operation at a temperature 1 in case that the room is cold operation lower than the setting 22 lt HEAT gt C Preset gt 0 temp 0 5 1 1 5 2 5 0 5 5
24. Attach the removed screws to the original positions Cord clamp Front cabinet Concavity at bottom plate 66 Part name Inverter assembly Procedure 1 Detachment 1 Perform work of item 1 of 2 Take off screws of the upper part of the front cabinet If removing the inverter cover under this condition P C board can be checked f there is no space in the upper part of the upper cabinet perform work of 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 100Q 40W or plug of soldering iron to 2 terminals of the C14 printed as CAUTION HIGH VOLTAGE electrolytic capacitor 500UF of P C board The electrolytic capacitor may not nor mally discharge according to error con tents and the voltage may remain There fore be sure to discharge the capacitor For discharging never use a screwdriver and others for short circuiting between electrodes As the electrolytic capacitor is one with a large capacity it is very dangerous because a large electric spark will occur 4 Take off screws ST1T 24 x 101 2 pcs fixing the main body and the inverter box 5 Remove various lead wires from the holder at upper part of the inverter box and wiring holder at right side of the terminal block 6 Remove the lead wire from the b
25. C BOARD 4WAY VALVE COIL FO4 a Am 3 15A oN 9C13 YEL VRHCI len BLU Converter module POWE H ba P10 RED 313 CNO6 TEH ORN PNK 4 PC BOARD 11 REACTOR 1 1359 212 LIII KA P12 REACTOR Post P15 BRN 4 SUB N PC BOARD MCC 1398 ABSORBER I CN01 CN02 CN03 REACTOR EMEN LU C eee eran RED WHI BLK 7 7 RED 1 0060106 TERMINAL OF COMPRESSOR TO POWER BLACK C INDOOR SUPPLY WHITE S The sign in UNIT 220 240 is displayed 50Hz in the terminal RED R cover SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS Diagnosis result TERMINAL BLOCK There is no supply voltage AC220 to 240V between D O gt Connecting cable check There is no voltage DC15 25V 2 FUSE 25A fuse F01 blown 15A fuse 02 blown Converter module DBO1 and electrolytic 3 15A fuse F04 blown capacitor C10 to C13 check IGBT T5A fuse F300 blown SUB PC board gt module Q200 check Fan motor check T3 15A fuse 01 blown SUB PC board SUB PC board check Color Identification BLACK WHI WHITE BLUE BRN BROWN RED RED ORN ORANGE ELECTROLYTIC CAPACITOR VOLTAGE
26. C10 C11 C12 C13 DC320V not available between 25A fuse F01 check Oterminal of electrolytic capacitor PC board and coverter module DB01 check INVERTER OUTPUT 09 CN10 CN11 Please confirm within six minutes after instructing in the drive Voltage between each line of inverterside IGBT module and conector pins are not equal PC board check GRY GRAY YEL YELLOW PNK PINK PUR PURPLE GREEN 5 SPECIFICATION OF ELECTRICAL PARTS 5 1 Indoor Unit Parts name Specifications Fan motor for indoor AFP 220 50 4A Output Rated 50 W 220 240 V Grille motor MP35EA12 DC 12V Thermo sensor TA sensor 550 mm 10 at 25 C Heat exchanger sensor TC sensor 26 mm 500 mm 10 kQ at 25 C Heat exchanger sensor TCJ sensor 26 mm 500 mm 10 kQ at 25 C 5 2 Outdoor Unit RAV SM560AT E Parts name Specifications Fan motor ICF 140 43 1 Output Rated 40 W Compressor DA130A1F 23F phase 4 1100 W Reactor CH 57 1 10 mH 16A Outdoor temp sensor To sensor 10 kQ at 25 C Heat exchanger sensor Te sensor 10 at 25 C Suction temp sensor Ts sensor 10 at 25 C Discharge temp sensor Td sensor 50 at 25 C Fuse Switching power Protect T3 15 A AC 250 V COIN OD oa BR oO N gt Fuse Inverter input Current protect 25 A 250 4 way valve solenoid coil STF 0108G
27. Defect Replace Does cooling outdoor fan normally operate YES Is connection of Correct connection of connector normal connector YES Replace fan motor Is fan motor normal YES NO Does electron control valve normally operate Do not TD and TO sensors off come off the detection part NO Are characteristics of R eplace TD TO TD TO TC sensor resistance values normal YES Check TE TC TS sensors Replace electron expansion valve Refer to Characteristics 3 and 4 Check CDB Defect Replace For RAV SM560AT E check control P C board Check charged refrigerant amount Check liquid gas valves Check abnormal overload 55 Relational graph of temperature sensor resistance value and temperature 20 40 Caracteristics 1 30 Caracteristics 2 Resistance Resistance kQ 10 20 10 0 10 20 30 40 50 10 0 10 20 40 50 60 70 Temperature C Temperature C 200 20 TE TO TS sensor Caracteristics 3 Resistance Resistance kQ 10 C or lower 10 C or higher 100 10 10 0 10 20 30 40 50 60 70 Temperature C TD sensor 200 Caracteristics 4 20 Resistance Resistance 50 C or lower 50 C or higher 100 10 50 100 Temperature C 56 10 4 Compressor does not operate
28. Error in indoor fan system All stop Displayed when 1 Check indoor fan motor connector 5Hz flash I Revolutions frequency error of fan error is detected circuit CN210 2 Check indoor fan 3 Check indoor P C board Main P C board Error in indoor unit or other Operation Displayed when 1 Check indoor P C board 7 positions continues error is detected EEPROM and peripheral circuits 1 EEPROM access error Main P C board LT Outside error input Operation Displayed when 1 Check outside devices Du Detected by input voltage level continues error is detected 2 Check indoor P C board from outside devices Main P C board LT Outside interlock input All stop Displayed when I 1 Detected by input voltage level error is detected No display the setting at shipment 49 Table 10 2 3 Operation of diagnostic function Judgement and action Check code Symptom Unit status Condition i Inverter over current protective circuit All stop Displayed when 1 Inverter immediately stops even if restarted 11 operates error is detected Compressor rare short For a short time 2 Check IPDU Cabling error Error on current detection circuit All stop Displayed when 1 Compressor immediately stops even if restarted tt Current value is high at AC side even error is detected Check IPDU while compressor stops 2 Phase missing operation of pow
29. H FAN AUTO Room temp Preset temp NOTE 1 2 The values marked with 1 and 2 are calculated and controlled by the difference in motor speed between M and L Fig 8 3 2 Table 8 3 1 RAV SM560XT E RAV SM800XT E MODEL Motor speed Air flow level Motor speed Air flow level rpm m h rpm m h Cooling HIGH 1060 800 1190 900 and MED 950 690 1010 750 Fanonly LOW 800 580 850 650 HIGH 1120 830 1300 980 Heating MED 970 730 1070 800 LOW 820 600 860 650 LOW LOW MED 2 MED MEDHHIGH 8 4 Cool air discharge preventive control In heating operation the indoor heat exchanger restricts revolving speed of the fan motor to prevent a cold draft The upper limit of the revolving speed is shown in Fig 8 4 1 and Table 8 4 1 Up to setting NOTES 1 The fan stops for 2 minutes after thermostat OFF 2 Ais 24 C when the preset temperature is 24 C or more and A is the preset temperature when it is under 24 C 3 SUL means Super Ultra Low 4 Calculated from difference in motor speed between SUL and HIGH Fig 8 4 1 Cold draft preventing control 5 and 6 Table 8 4 1 5 6 Starting period Stabilized period Up until 12 minutes passed after starting the unit From 12 to 25 minutes passed after starting the unit and room temperature is 3 C lower than preset temperature e From 12 to 25 minutes passed after sta
30. SM560AT E 15 9 mm diam Nominal diam 5 8 thick 1 0 mm RAV SM800XT E RAV SM800AT E Thermal insulation for drain pipe 10 mm or more foam polyethylene Drain pipe Outer 26 mm diam Tapes Power supply cord 2 5 mm HO7RN F or 245IEC66 or 3 5 mm AWG 12 Grounding cable 2 0 mm diam or more 30 Purifying filter AHJWN I9III uA 9 4 SELECTION OF INSTALLATION PLACE A WARNING e Install the air conditioner where there is sufficient strength to withstand the weight of the unit If the strength is not sufficient the unit may fall down resulting in injury CAUTION Upon approval of the customer install the air conditioner in a place that satisfies the following conditions e Place where the unit can be installed horizontally e Place where a sufficient servicing space can be ensured for safe maintenance and check e Place where drained water will not cause any problem Avoid installing in the following places e Place exposed to air with high salt content seaside area or place exposed to large quantities of sulfide gas hot spring Should the unit be used in these places special protective measures are needed e Place exposed to oil vapor oil smoke or corrosive gas e Place where organic solvent is used nearby e Place close to a machine generating high frequency e Place where noise of the outdoor unit is easy to transmit When installing the air conditioner o
31. TE BLU BLUE BRW BROWN RED RED ORN ORANGE Diagnosis result GRY GRAY YEL YELLOW TERMINAL BLOCK PNK PINK PUR PURPLE There is no supply voltage 220 to 240V between O Q D There is no voltage DC15 to 25V 2 3 FUSE T25A 250V to fuse F01 blown Power supply and connecting gt cable check GREEN NOTE Compressor Pulse modulating valve Fan motor Heat exchanger Temp Sensor Converter module DB01 and electrolytic capacitor C12 to C14 check IGBT module Q200 check Fan motor check T3 15A 250V to fuse 04 blown gt ELECTROLYTIC CAPACITOR VOLTAGE C12 C13 C14 DC320V not available between T25A fuse F01 check terminal of electrolytic capacitor board and converter module DB01 check INVERTER OUTPUT Inverter and compressor connector out of position Please confirm within six minutes after instructing in the drive Voltage between each line of inverter side ____y IGBT module and conector pins are not equal P C board check Discharge Temp Sensor Outdoor Temp Sensor Suction Temp Sensor Insulated Gate Bipolar Transistor Converter module Curreut Transformer Fan motor driver module 4 3 Outdoor Unit RAV SM800AT E WHI THERMOSTAT Compressor FOR BLK CN11 CT COMPRESSOR POWER SUPPLY CIRCUIT 4 ORNS FOR P
32. TO e B A FILE NO SVM 03021 SERVICE MANUAL AIR CONDITIONER UNDER CEILING CONSOLE TYPE RAV SM560XT E RAV SM560AT E RAV SM800XT E RAV SM800AT E Sep 2003 CONTENTS 1 SPECIFICATIONS 1 2 CONSTRUCTION VIEWS XR now uu uuu uu 4 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRANM 7 4 WIRING DIAGRAM uU Cod cU USE CU Ux CU V dE aD NE VY dH QS donde EIE 9 5 SPECIFICATION OF ELECTRICAL PARTS l u 12 6 REFRIGERANT R410A 13 7 CONTROL BLOCK DIAGRAN l aea ks dua dd aeg rcx EE u Ru E ex E cu E 21 8 OPERATION DESCRIPTION LE CE ran GE EK Un mu ur 22 9 INSTALLATION PROCEDURE U u u u uu uuu aar Ca uuu 27 10 TROUBLESHOOTING CHART 46 5 60 12 EXPLODED VIEWS AND PARTS LIST l l u u 80 1 SPECIFICATIONS 1 1 Indoor Unit Model name RAV SM560XT E RAV SM800XT E Coolin
33. al fittings and then move the indoor unit backward 4 Secure it with the M10 Nuts 4 pcs 5 Attach the Side covers to the unit D Installation plate Suspension bosco SAX Y Side s Suspension bolt e 1 25 2985 Fig 9 5 9 lt Condition for Installation gt e The unit must not decline more than 15 mm in either axis T 15mm Fig 9 5 10 lt Piping and Drain Hose Installation gt e The piping direction can be 4 ways as illustrated e The Drain hose is only one way Upper piping Rear piping Drain hose Fig 9 5 11 33 e How to install the Drain hose e Other direction piping 1 Remove the two screws and the Drain band 1 Cut the slit of connecting only upper direction 2 Cut a slit for the drain hose hole Hum Slit for upper piping J Slit for drain hose hole Drain band amp Fig 9 5 16 Screws Fig 9 5 12 2 Connect the Flexible pipe to the large pipe Gas side 3 Place the Drain hose on the U shape space and secure it with the Drain band and two screws um Big pipe Flexible pipe Fig 9 5 17 Fig 9 5 13 e Rear side piping with Drain hose Recommended direction Ceiling 4 Z 175 mm Rear piping hole 280 lt 140 Ceiling Z Fig 9 5 14 1 Cut or remove the determined
34. ct the wires between the units correctly Errors made in the connections can result in the unit malfunctioning 2 Connect the control wires between the outdoor unit and indoor unit as shown in the figure below 9 9 4 Wiring Connections Terminal cover Screws A PL v J Cord clamp 9 a gt P Els o Earth terminal 2 a3 Fd H Is AM H Fig 9 9 3 1 Remove the Terminal cover and the Cord clamp 2 Insert the connecting cable into the pipe hole on the wall 3 Insert the connecting cable fully into the terminal block and secure it tightly with the screw Tightening Torque 1 2 Nem 0 12 kgf m 4 Fix the connecting cable by the Cord clamp with two screws 5 Fix the Terminal cover 42 9 10 FINAL INSTALLATION CHECKS 9 10 1 Precautions Ensure that the electrical cable used for power supply and control of the system is unable to come into contact with either service valves or piping work which are not insulated 9 10 2 Electrical wiring When installation is complete check that all power supply and interconnecting wiring has been appropriately protected 9 10 3 Refrigerant piping When refrigerant and drain piping have been completed Ensure that all pipework is fully insulated and apply finishing tape to seal the insulation 9 10 4 Check and Te
35. e e In N zone the commanded frequency is held e When L zone is detected the commanded frequency is returned to the original value by approx 6Hz every 60 seconds Tc C 55A 52 48 B 8 7 Louver control 1 Vertical air flow louver Position of veritcal air flow louver is automatically controlled according to the operation mode Besides position of vertical air flow louver can be arbitrarily set by pressing FIX button The louver position which is set by FIX button is stored in the microcomputer and the louver is automatically set at the stored position for the next operation 2 Swing If SWING button is pressed when the indoor unit is in operation the vertical air flow louver starts swinging When SWING button is pressed it stops swinging 8 8 Filter sign display 1 The operation time of the indoor fan is calculated the filter lamp Orange on the display part of the main unit goes on when the specified time 240H has passed When a wired remote controller is connected the filter reset signal is sent to the remote controller and also it is displayed on LCD of the wired remote control 2 When the filter reset signal has been received from the wired remote control after FILTER lamp has gone on or when the filter check button Temporary button is pushed time of the calculation timer is cleared In this case the measurement time is reset if the specified time has passed and displa
36. e installation fuse 25A D type must be used for the power supply line of this conditioner WARNING e Ask an authorized dealer or qualified installation professional to install maintain the air conditioner Inappropriate installation may result in water leakage electric shock or fire e Turn off the main power supply switch or breaker before attempting any electrical work Make sure all power switches are off Failure to do so may cause electric shock e Connect the connecting cable correctly If the connecting cable is connected in a wrong way electric parts may be damaged e When moving the air conditioner for the installation into another place be very careful not to enter any gaseous matter other than the specified refrigerant into the refrigeration cycle If air or any other gas is mixed in the refrigerant the gas pressure in the refrigeration cycle becomes abnormally high and it may resultingly causes pipe burst and injuries on persons e Do not modify this unit by removing any of the safety guards or by by passing any of the safety interlock switches e Exposure of unit to water or other moisture before installation may cause a short circuit of electrical parts Do not store it in a wet basement or expose to rain or water _ 28 e After unpacking the unit examine it carefully if there are possible damage e Do not install in a place that might increase the vibration of the unit e To avoid personal injury with s
37. e the TA sensor wire 6 Remove the Drain hose Continue Louver motor Electrical wire LED base E x Shaft of Horizontal lover Drain hose TA sensor Part name Procedures Remarks Drain pan 7 Remove 7 screws and remove the Drain assembly pan assembly Drain Pan Electrical parts lt How to remove the Electrical parts assembly gt assembly 1 Remove the Air inlet grille the Front panel Refrigeration and the Drain pan assembly 2 9 Connecting Sensor assembly 2 Remove the Terminal cover cable Cord clamp Earth wire 3 Unfasten the screw of Cord clamp and 3 1 im disconnect the connecting cable 0 4 Remove the Connector cover and disconnect the Fan motor cords 5 Remove the TC sensor TCJ sensor and earth wire from Refrigeration assembly 6 Remove the Electrical parts assembly NOTE When install the electrical parts assembly fix the screw after the Back body is fixed Electrical parts assembly Fan motor cords Refrigeration lt How to remove the Refrigeration assembly gt assembly 1 Remove the Air inlet grille the Front panel and the Drain pan assembly 2 Stop the gas at the Outdoor unit 3 Remove 2 pipes from the Refrigeration TCJ sensor assembly Earth wire TC sensor 4 Remove the TC sensor TCJ sensor Pipe holder from holder 5 Remove the pipe holder 6 Remove the earth wire Continue Part name Ref
38. e wrench gauge manifold valve 4 Operate the vacuum pump to start for evacuating Valve handling precautions Cap tightening torque Perform evacuating for about 35 minutes if the s i M m 15 a piping length is total 30 meters for model SM560 valve size 295 32 10 3e ie eee and 50 meters for model 5 800 1 33 to 42 Nem 3 3 to 4 2 assuming a pump capacity of 27 liters per minute 15 9 20 to 25 Nem 2 0 to 2 5 kgfem Then confirm that the compound pressure gauge Charge port 14 to 18 Nem 1 4 to 1 8 kgfem reading is 101 kPa 76 cmHg 5 Close the low pressure side valve handle of gauge 9 8 2 Additional refrigerant manifold 6 Open fully the valve stem of the packed valves 1 The amount of refrigerant put into the outdoor unit both sides of Gas and Liquid at the factory is sufficient to fill up to 20 m of refrigerant piping work 2 If the length of the refrigerant piping work is 20 m or less addition of refrigerant at the installation site is unnecessary 3 If the length of the piping work exceeds 20 m extra refrigerant must be added Refer to the outdoor installation manual for details of the extra amounts 4 Overcharge or undercharge of refrigerant in the outdoor unit may cause malfunction of the compressor 7 Remove the charging hose from the service port 8 Securely tighten the caps on the packed valves Add Only R410A Refrigerant to The
39. eck the outdoor heat exchanger I 7l sensor is defective indoor unit blinks sensor TD Disconnection or short circuit when error is 2 Check the outdoor P C board defected 71 Other parts 71 The reply serial signal has been Operation The amp on the 1 Repeatedly turn the indoor unit on and L4 including gree transmitted when starting the continues indoor unit blinks off with the interval of approx 10 to 40 Sie compressor unit but stops being transmitted when error is minutes The check code is not shortly after defected And it indicated during operation And supply 1 Compressor thermo operation returns to the gas Check gas leak e Gas shortage normal condition 2 The indoor unit operates normally e Gas leak when recovering during the check 2 Instantaneous power failure from errors If the reply serial signal continues to be transmitted between and of the indoor terminal block replace the outdoor P C board If the signal stops between them replace the indoor P C board 117 The discharge temperature is All off The lamp on the 1 Check the heat exchanger sensor TD we over 120 C indoor unit blinks 2 Gas purging ont when error is defected 1 The IOL operation is defective All off The lamp on the When turning on the unit the normal Dui LI indoor unit blinks phase RST is detected but T R waveform when error is detected has not been detected for 120 seconds or more
40. embly Procedure 1 Perform works of items of 1 to 5 of 2 Take off screw ST1T 04 x 10L 1 pc of the upper left part of the inverter cover 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 works of items 6 to 7 of 1 and remove the partition fixing plate ST1T 4 x 10L 1 pc CAUTION Be careful to check the inverter because high voltage circuit is incorporated in it 3 Perform discharging by connecting the discharging resistance approx 100Q 40W or plug of soldering iron to G terminals of the C10 too 13 printed as CAUTION HIGH VOLTAGE electrolytic capacitor 760uF of P C board WARNING The electrolytic capacitor may not nor mally discharge according to error con tents and the voltage may remain There fore be sure to discharge the capacitor WARNING For discharging never use a screwdriver and others for short circuiting between 4 and electrodes As the electrolytic capacitor is one with a large capacity it is very dangerous because a large electric spark will occur 4 Remove various lead wires from the holder at upper part of the inverter box 5 Remove the hook for the partition plate lower left side 6 Remove the hook for the side cabinet lower left side and the screw and lift up the inverter assembly upward ST1T 204 x 10L 1 pc In this time cu
41. eneration of sludge clogging of capillary etc Accordingly the tools to be used are classified into the following three types 1 Tools exclusive for R410A Those which cannot be used for conventional refrigerant R22 2 Tools exclusive for R410A but can be also used for conventional refrigerant R22 3 Tools commonly used for R410A and for conventional refrigerant R22 The table below shows the tools exclusive for R410A and their interchangeability Tools exclusive for R410A The following tools for R410A are required Tools whose specifications are changed for R410A and their interchangeability R410A air conditioner Conventional air installation conditioner installation Used tool Existence of Whether Whether new equipment new equipment conventional can be used with for R410A equipment can conventional refrigerant be used Flare tool Pipe flaring Copper pipe gauge Flaring by for adjusting projection conventional flare margin tool Connection of flare nut Gauge manifold Evacuating refrigerant charge Charge hose run check etc Torque wrench Vacuum pump adapter Vacuum evacuating Electronic balance for Refrigerant charge refrigerant charging 9 Refrigerant cylinder Refrigerant charge Leakage detector Gas leakage check 4 Charging cylinder Refrigerant charge Note 1 When flaring is carried out for R410A us
42. ent sensor Go off e O Serial communication error by thermo operation of Comp case O Goon 9 10 8 Installation Servicing Tools lt Changes in the product and components gt In the case of an air conditioner using R410A in order to prevent any other refrigerant from being charged accidentally the service port diameter of the outdoor unit control valve 3 way valve has been changed 1 2 UNF 20 threads per inch e order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of opposite side of flare nuts has been changed for copper pipes with nominal dimensions 1 2 and 5 8 New tools for R410A New tools for R410A Applicable to R22 model Changes Gauge manifold As pressure is high it is impossible to measure by means of conventional gauge In order to prevent any other refrigerant from being charged each port diameter is changed Charge hose In order to increase pressure resisting strength hose materials and port size are changed to 1 2 UNF 20 threads per inch When purchasing a charge hose be sure to check the port size Electronic balance As pressure is hight and gasification speed is fast it is difficult to read the for refrigerant charging indicated value by means of charging cylinder as air bubbles occur Torque wrench nominal diam 1 2 5 8 The size of opposite sides of flare nuts have been increased Incidentally a common wrench
43. er Recycling is the preferred disposal method 2 When disposing of an air conditioner system contact either the manufacture your local environmental control authority or a local waste disposal company for advice 3 Ensure all packing material is either recycled or disposed of in accordance with local regulations 4 The refrigerant gas within the unit should only be removed by an authorized company A WARNING Discharge of refrigerant to atmosphere is illegal and may lead to prosecution 45 10 TROUBLESHOOTING 10 1 Summary of Troubleshooting 10 1 1 Before troubleshooting 1 Required tools instruments and screwdrivers spanners radio cutting pliers nippers etc e Tester thermometer pressure gauge etc 2 Confirmation points before check D The following operations are normal a Compressor does not operate 5 not 3 minutes delay minutes after compressor OFF e Does not thermostat turn off e Does not timer operate during fan operation 5 not outside high temperature operation controlled in heating operation b Indoor fan does not rotate e Does not cool air discharge preventive control work in heating operation c Outdoor fan does not rotate or air volume changes e Does not high temperature release opera tion control work in heating operation e Does not outside low temperature opera tion control work in cooling operation e Is not defrost operation performed d ON OFF operation can
44. er supply e Phase of power supply is missed e Check power voltage of R S T Coming off disconnection or short of All stop Displayed when 1 Check outdoor temp sensor TE TS 1171 outdoor temp sensor error is detected 2 Check CDB IT Coming off disconnection or short of All stop Displayed when 1 Check outdoor temp sensor TD I 7l outdoor temp sensor error is detected 2 Check CDB Compressor drive output error All stop Displayed when 1 Abnormal overload operation of refrigerating 1 thermistor temp error error is detected cycle E IPDU heat sink temp is high 2 Loosening of screws and contact error of IPDU Communication error between IPDU and heat sink e Connector coming off between and 3 Cooling error of heat sink IPDU 4 Check cabling of CDB and IPDU Compressor does not rotate Over current All stop Displayed when 1 Compressor error Compressor lock etc wo protective circuit works when constant time error is detected Replace compressor passed after activation of compressor 2 Cabling trouble of compressor Phase missing Discharge temp error All stop Displayed when 1 Check refrigerating cycle Gas leak we e Discharge temp over specified value was error is detected 2 Error of electron control valve detected 3 Check pipe sensor TD Compressor breakdown All stop Displayed when 1 Check power voltage AC200V 20V uw e Operation frequency lowered and stops e
45. ersonal injury may be caused 5 After completion of installation work check to make sure that there is no refrigeration gas leakage If the refrigerant gas leaks into the room coming into contact with fire in the fan driven heater space heater etc a poisonous gas may occur 6 When an air conditioning system charged with a large volume of refrigerant is installed in a small room it is necessary to exercise care so that even when refrigerant leaks its concentration does not exceed the marginal level If the refrigerant gas leakage occurs and its concentration exceeds the marginal level an oxygen starvation accident may result 7 Be sure to carry out installation or removal according to the installation manual Improper installation may cause refrigeration trouble water leakage electric shock fire etc 8 Unauthorized modifications to the air conditioner may be dangerous If a breakdown occurs please call a qualified air conditioner technician or electrician Improper 5 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 suit able 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 Co
46. ew Set D T Fan Motor Drain Pan Assy Drain Hose Assy Louver Motor Assy Horizontal Louver Refrigeration Assy 212 7 SM560XT E Refrigeration Assy 215 9 SM800XT E 43703303 43709314 43749303 43719304 43719305 43719306 43719307 43719308 43782302 43760314 43762303 43783003 43769309 43785399 43749304 43749310 43780003 43700365 Description Back Body Assy Vertical Louver Pipe Holder Cover Body L Cover Body R Cover Body LD Bush Body R Bush Body D Installation Plate Terminal Cover Connector Cover Remote control Holder Wireless Remote control Owner s Manual Flexible pipe 212 7 Assy SM560XT E Flexible pipe 215 9 Assy SM800XT E Filter Frame Grille Stopper Assy 12 3 Outdoor Unit RAV SM560AT E 29 POS T K y gt IA lis ye IAN 6 JIET NS MS A 1 Wah NS 2 N Location Description Location Description No P No P 43105037 Cabinet Front PCM 43146617 Solenoid Coil LB64045 43100239 Cabinet Back PCM 43046385 Valve Pulse Modulating 43042468 Base Ass y SKV 18D26 43005508 Cabinet UP PCM 43046394 Coil PMV DKV MOZS744BO 43119460 Guard Fan 43046392 Valve Packed 6 35 AO 43119448 Cover Packed Valve 43147195 Bonnet 1 2 IN 43062230 Cover Wiring Ass y 43046393 Valve
47. 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 Nominal diameter Outer diameter mm When it is strong the flare nut may crack and may be made non removable When choosing the tightening torque comply with values Note designated by manufacturers Table 6 2 7 shows reference values When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Tightening torque N m kgf cm 14 to 18 140 to 180 Table 6 2 7 Tightening torque of flare for R410A Reference values Tightening torque of torque wrenches available on the market N m kgf m 16 160 18 180 33 to 42 330 to 420 42 420 55 550 50 to 62 500 to 620 63 to 77 630 to 770 16 65 650 6 3 Tools 6 3 1 Required tools The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to prevent mixing of other refrigerant To reinforce the pressure resisting strength flare processing dimensions and opposite side dimension of flare nut For 12 70 copper pipe of the refrigerant piping are lengthened The used refrigerating oil is changed and mixing of oil may cause a trouble such as g
48. g Heating Average Cooling Heating Average Standard capacity Note 1 5 0 5 6 6 7 8 0 1 5 5 6 1 5 6 3 2 2 8 0 2 2 9 0 Heating low temp capacity Note 1 kW 4 9 5 8 Energy consumption effect ratio Cooling 2 67 D 3 29 C 2 98 2 46 E 3 00 D Power supply 1 phase 220 240V 50Hz Running current 8 95 8 20 8 13 7 46 13 15 12 06 12 91 11 84 Power consumption 1 87 1 7 2 72 2 67 Electrical characteristics Low temp Power factor 94 Main unit Pure white Appearance Ceiling panel Model Sold separately Panel color m Height Main unit Width Outer Depth dimension Height cS Ceiling panel Sold separately Width Depth Main unit 23 Total weight Ceiling panel Do Heat exchanger Finned tube Fan Multi blade fan Fan unit Standard air flow High Mid Low 3 800 680 580 900 750 550 Motor W 50 Air filter Washable filter Controller Sold separately Wireless remote control 12 7 1 2 215 9 5 8 6 4 1 4 9 5 3 8 Gas side mm Dimensions pipe Liquid side mm Drain port Nominal dia Sound level High Mid Low Note 2 dBeA 25 Polyvinyl chloride tube 39 46 Note 1 The cooling capacities and electrical characteristics are measured under the conditions specified by JIS B 8616 based on the reference pi
49. g of the housing 3 Remove the control P C board assembly from board base Remove the heat sink and the inverter control P C board assembly as they are screwed Note 2 Remove the heat sink upward by taking off two claws of P C base and holding the heat sink 4 Take off three screws fixing the heat sink to the control P C board assembly 5 Mount a new control P C board assembly Note 3 When mounting a new board check that it is correctly set in the groove of the base holder of P C board base 75 Remarks Inverter box Metal sheet Cycle control P C board assembly Inverter control P C board assembly Cycle control board assembly Inverter control P C board assembly Es a Inverter EIN control ys P C board assembly Groove for P C boaed Inverter box Heat sink Metal sheet Part name Fan motor Procedure 1 Perform works of items 1 to 5 7 of 2 Remove the flange nut fixing the fan motor and the propeller fan Loosen the flange nut by turning clock wise To tighten the flange nut turn it counterclockwise 3 Remove the propeller fan 4 Remove the lead wire from the hook fixing the fan motor lead wires on the motor base Three positions 5 Disconnect the connector for fan motor from the inverter 6 Take off the fixing screws 4 pcs while holding by hands so that the fan motor does not fall NOTE Tighten
50. ge is useful for adjusting projection margin size p Fig 9 7 2 37 lt Tightening connection gt 9 7 3 Pipe Shield for Flare Nut Connection Align the centers of the connecting pipes and tighten Joints in liquid and gas pipes of the indoor unit should the flare nut as far as possible with your fingers Then be insulated with an attached Pipe shield 49 tighten the nut with a spanner and torque wrench as shown in the figure lt How io install the pipe shield gt CAUTION 1 Cut the Pipe shield 49 to appropriate length 2 Set the Pipe shield 49 3 In case of a ceiling installation orient the slit at the top of the pipe 4 Fix the Pipe shield 13 with vinyl tape Slit e Do not apply excess torque Otherwise the nut may crack depending on the conditions Unit Nem Outer diam of copper pipe Tightening torque 6 35 mm diam 14 to 18 1 4 to 1 8 kgf m Vinyl tape 9 52 mm diam 33 to 42 3 3 to 4 2 kgf m 12 7 mm diam 50 to 62 5 0 to 6 2 15 9 mm diam 63 to 77 6 3 to 7 7 kgf m 9 Pipe shield Fig 9 7 5 Tightening torque of flare pipe connections Pressure of R410A becomes higher than that of R22 Approx 1 6 times Therefore using a torque wrench tighten firmly the flare pipe connecting sections which connect the indoor and outdoor units up to the specified tightening torque Incorrect connections may cause not only a gas leakage but also a trouble of the refr
51. h a tip of pencil to set the remote control to the service mode 00 is indicated on the display of the remote control e The timer lamp on the indoor unit blinks continuously 5 times per 1 sec Press TIMER A button If there is no fault with a code the indoor unit will beep once Pi and the display of the remote control will change as follows a Check the unit with all 35 check codes 00 to 22 as shown in Table 10 2 1 e Press TIMER Y button to change the check code backwards If there is a fault the indoor unit will beep for 10 seconds Pi Pi Pi Note the check code on the display of the remote control e 2 digits alphanumeric will be indicated on the display All lamps on the indoor unit will blink 5 times per 1 sec Press CLR button After service finish for clear service code in memory is indicated on the display of the remote control Press START STOP button to release the service mode e The display of the remote control returns to as it was before service mode was engaged Table 10 2 1 Operation of diagnostic function Check Check Unit 2 Judgement and action code ree code Symptom status Condition Viri Indoor Vir The indoor thermo sensor TA is Operation The lamp on the 1 Check the indoor thermo sensor TA L 1L 4 P C board Lik defective continues indoor
52. harp edges be careful when handling parts e Perform installation work properly according to the Installation Manual Inappropriate installation may result in water leakage electric shock or fire e When the air conditioner is installed in a small room provide appropriate measures to ensure that the concentration of refrigerant leakage occur in the room does not exceed the critical level e Install the air conditioner securely in a location where the base can sustain the weight adequately e Perform the specified installation work to guard against an earthquake If the air conditioner is not installed appropriately accidents may occur due to the falling unit 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 generate e 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 might generate e Electrical work must be performed by a qualified electrician in accordance with the Installation Manual Make sure the air conditioner uses an exclusive power supply An insufficient power supply capacity or inappropriate installation may cause fire e Use the specified cables for wiring connect the terminals securely fix To prevent external forces applied to the terminals from affecting the terminals e Be s
53. igeration cycle or compressor damage Flare at indoor unit side Flare at outdoor unit side Fig 9 7 3 Half union Flare nut Externally Internally threaded side threaded side Use a wrench to secure Use a torque wrench to tighten Fig 9 7 4 38 9 8 EVACUATING AIR PURGE NOTE Evacuate the air in the connecting pipe and in the Use the vacuum pump vacuum pump adapters and indoor unit using vacuum pump gauge manifold referring to the manuals attached to Do not use the refrigerant in the outdoor unit each tool before using them For details see the manual of vacuum pump For the vacuum pump check oil is filled up to the specified line of the oil gauge 9 8 1 Use a vacuum pump e While the air is purged check again that the connecting port of charge hose which has a projection to push the valve core is firmly connected to the charge port Be sure to use a vacuum pump with counter flow prevention function so that inside oil of the pump does not flow backward into pipe of the air conditioner when the pump stops 1 Connect the charge hose from the manifold valve to the service port of the gas side packed valve e Open the valve stem or the handle until it strikes 2 Connect the charge hose to the port of vacuum the stopper It is unnecessary to apply further pump force 3 Open fully the low pressure side handle of the e Securely tighten the cap with a torqu
54. iner 43119390 Hanger 43058266 Reactor CH 47 Z K 43041772 Compressor Ass y 43063321 Holder Sensor 4 8 9 52 43050407 Thermostat Bimetal 43063322 Holder Sensor 6 11 4 12 7 43063317 Holder Thermostat 43063325 Holder Sensor 6 6 35 8 43005482 Base Ass y 43063332 Holder Sensor 43049739 Cushion Rubber 43032441 Nipple Drain Description 12 5 Outdoor Unit Inverter Assy RAV SM560AT E 702 TE Sensor TS Sensor c TO Sensor TD Sensor 703 No o 70 F4 a N 1 143050334 Sensor TD F4 TD Sensor 704 43160469 Terminal Block 6P AC250V 20 702 43050382 Sensor F6 TC Sensor 705 4316 182 P C Board Ass y MCC 813 703 43062228 Base P C Board ABS 12 6 Outdoor Unit Inverter Assy RAV SM800AT E INVERTER COVER TO Sensor TE Sensor TS Sensor TD Sensor Location Description Description No p No 701 43050334 Sensor TD F4 TD Sensor 706 43162042 Base Board ABS 702 143050382 Sensor TC TC Sensor 707 4316 183 P C Board Ass y MCC 1398 704 43160469 Terminal Block 6P AC250V 20 708 4316V184 PC Board Ass y IPDU MCC 1359 85 TOSHIBA CARRIER THAILAND CO LTD 144 9 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAM BOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND
55. ing the conventional flare tools adjustment of projection margin is necessary For this adjustment a copper pipe gauge etc are necessary Note 2 Charging cylinder for R410A is being currently developed General tools Conventional tools can be used In addition to the above exclusive tools the following equipments which serve also for R22 are necessary as the general tools 1 Vacuum pump 4 Reamer Hole core drill 265 Use vacuum pump by 5 Pipe bender 10 Hexagon wrench attaching vacuum pump adapter 6 Level vial Opposite side 4 mm 2 Torque wrench 7 Screwdriver 11 Tape measure 3 Pipe cutter 8 Spanner of Monkey wrench 12 Metal saw Also prepare the following equipments for other installation method and run check 1 Clamp meter 3 Insulation resistance tester 2 Thermometer 4 Electroscope 17 6 4 Recharging of Refrigerant When it is necessary to recharge refrigerant charge the specified amount of new refrigerant according to the following steps Recover the refrigerant and check no refrigerant remains in the equipment Connect the charge hose to packed valve service port at the outdoor unit s gas side Connect the charge hose of the vacuum pump adapter When the compound gauge s pointer has indi cated 0 1 Mpa 76 cmHg place the handle Low in the fully closed position and turn off the vacuum pump s power switch Keep the stat
56. intain the unit to the customer e Turn off the main power supply switch or breaker before the unit maintenance e Ask the customer to keep the Installation Manual together with the Owner s Manual CAUTION New Refrigerant Air Conditioner Installation e This air conditioner adopts the new HFC refrigerant R410A which does not destroy ozone layer The characteristics of R410A refrigerant are easy to absorb water oxidizing membrane or oil and its pressure is approx 1 6 times higher than that of refrigerant R22 Accompanied with the new refrigerant refrigerating oil has also been changed Therefore during installation work be sure that water dust former refrigerant or refrigerating oil does not enter the refrigerating cycle To prevent charging an incorrect refrigerant and refrigerating oil the sizes of connecting sections of charging port of the main unit and installation tools are charged from those for the conventional refrigerant Accordingly the exclusive tools are required for the new refrigerant R410A For connecting pipes use new and clean piping designed for R410A and please care so that water or dust does not enter Moreover do not use the existing piping because there are problems with pressure resistance force and impurity in it CAUTION To Disconnect the Appliance from Main Power Supply This appliance must be connected to the main power supply by means of a switch with a contact separation of at least 3 mm Th
57. is generally used to 6 5 2 Flux join copper or copper alloy 3 Low temperature brazing filler Low temperature brazing filler is generally called solder and is an alloy of tin and lead Since it is weak in adhesive strength do not use it for refrigerant pipes 19 1 Reason why flux is necessary e By removing the oxide film and any foreign matter on the metal surface it assists the flow of brazing filler e In the brazing process it prevents the metal surface from being oxidized e By reducing the brazing filler s surface tension the brazing filler adheres better to the treated metal 2 3 4 Characteristics required for flux e Activated temperature of flux coincides with the brazing temperature e Due to a wide effective temperature range flux is hard to carbonize lt is easy to remove slag after brazing e The corrosive action to the treated metal and brazing filler is minimum e lt 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 e 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 a
58. is in operation Operation Motions Push TEMPORARY button for more The unit is in operation The green lamp is on than three seconds i The unit stops operating The green lamp is turned off After approx three seconds The unit beeps three times Q Ace If the unit is required to operate at this time push TEMPORARY E button once more or use the remote control to turn it on e While this function is being set if the unit is in e While the filter check lamp is on the operation the orange lamp is on TEMPORARY button has the function of filter e This function can not be set if the timer operation reset button has been selected e When the unit is turned on by this function the louver will not swing even though it was swinging automatically before shutting down 25 8 9 2 How to cancel auto restart function To cancel auto restart function proceed as follows Repeat the setting prodedure the unit receives the signal and beeps three times The unit will be required to be turned on with the remote control after the main power supply is turned off When the unit is on standby Not operating Operation Push TEMPORARY button for more than three seconds Push TEMPORARY button for more than three seconds Motions The unit is on standby Y The unit starts to operate The orange lamp is on After approx
59. l it 35 lt Install the indoor unit gt e Install the Installation plate at the wall according to the Paper pattern e Hang the indoor unit on the hooks of the Installation plate 1 e Fix the lower portion of the indoor unit with Mounting screws 4 2 places Mounting screw Mounting screw Fig 9 5 21 lt Condition for installation gt The unit must not decline more than 15 mm in either axis 15mm Fig 9 5 22 lt Piping and Drain Hose Installation gt e The piping direction can be the following 3 ways with the Drain hose e Each piping direction should be connected with the Flexible pipe 5 Side piping Bottom piping Fig 9 5 22 Cut or remove the Le determined direction b slit or cover 343 a Slit for upper NA 2l ipin 2 piping Cover for side piping is Cover for rear upper piping Fig 9 5 23 9 6 DRAIN PIPING WORK 9 6 1 Drainage 1 Run the Drain hose sloping downward NOTE e The hole should be made at a slight downward slant on the outdoor side Under Ceiling Installation Console Installation 50 50 Fig 9 6 1 NOTICE In case of upward drainage from the unit Under Ceiling Installation it is necessary to use the Drain pump kit of optional part CAUTION 1 Do not raise the Drain hose 2 Do not
60. lange 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 69 Flange nut Loosen the nut by turning clockwise Propeller fan Part name Compressor Procedure 1 Perform works of items 1 of and 2 Discharge refrigerant gas 3 Remove the partition plate ST1T O4 x 10L 2 pcs 4 Remove the noise insulator 5 Remove the terminal covers of the compressor and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal 6 Remove pipes connected to the compressor with a burner CAUTION Pay attention to that flame does not involve 4 way valve 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 10L 2 pcs 8 Take off the fixing screws of the valve clamping plate to the bottom plate 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 Remarks Partition plate Remove Discharge
61. ming 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 exclu sive 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 air conditioner which is designed to operate with R410A If other refrigerant than R410A is mixed pressure in the refrigeration cycle becomes abnormally high and it may cause personal injury etc by a rupture 2 Confirm the used refrigerant name and use tools and materials exclusive for the refrigerant R410A The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air condi tioner using R410A as refrigerant To prevent mischarging the diameter of the service port differs from that of R22 3 If a refrigeration gas leakage occurs during installation servicing be sure to ventilate fully If the refrigerant gas comes into contact with fire a poisonous gas may occur 4 When installing or removing an air conditioner do not allow air or moisture to remain in the refrigeration cycle Otherwise pressure in the refrigeration cycle may become abnormally high so that a rupture of p
62. move the heat sink and the control board assembly as they are screwed NOTES 1 CN300 CN301 and CN701 etc at the control board assembly side are connec tors with locking function Therefore remove the connector while pushing the part indicated by an arrow mark Remove 4 hooking claws of P C board base and remove upward the heat sink with hands Take off 3 screws fixing the heat sink and main control board assembly side and replace the board with a new one NOTE When mounting a new board check that the board is correctly set in the groove of the base holder of P C board base Attach the P C board so that the heat sink comes securely contact with the metal sheet 68 Remarks 4 Take off SN earth screws Power line Inverter box Metal sheet Control P C board assembly P C board base Hooking claws 4 positions P C board base Heat sink Inverter box Metal sheet Part name Rear cabinet Procedure 1 Perform works of items 1 of and 2 Take off fixed screws for the bottom plate ST1T 4 x 10L 3 pcs 3 Take off fixed screws for the heat ex changer ST1T 4 x 10L 2 pcs 4 Take off fixed screw for the valve mounting plate ST1T 4 x 10L 1 pc Remarks Rear cabinet Fan motor 1 Perform works of items 1 of O and Q 2 Take off the flange nut fixing the fan motor and the propeller Turning it clockwise the f
63. n the boundary with the neighbor pay due attention to the level of noise e Place with poor ventilation e Where the ceiling height is more than 3 m e Where the floor wall ceiling structure is unable to support the weight of the unit 9 5 INSTALLATION OF INDOOR UNIT A WARNING e Install the air conditioner certainly at a place to sufficiently withstand the weight If the strength is insufficient the unit may fall down resulting in human injury e Perform a specified installation work to guard against an earthquake An incomplete installation can cause accidents by the units falling and dropping Locate the unit so as to provide uniform circulation of chilled air Avoid locating the unit as shown in the bad marked figures below Good location Bad location Bad location Evenly hot or cooled Shaded area well hot or cooled Shaded area well hot or cooled c If a good location is not possible use a fan to circulate the air evenly throughout the room 31 9 5 1 Installation Place e A place which provides the spaces around the indoor unit as shown in the above diagram e A place where there is no obstacle near the air inlet and outlet e A place that allows easy installation of the piping to the outdoor unit e A place which allows the Front panel to be opened CAUTION e Direct sunlight or fluorescent light to the indoor unit s wireless receiver should be avoided e The mic
64. not be performed from remote control 15 not forced operation performed e s not the control operation performed from outside remote side 2 Did you return the cabling to the initial positions 3 Are connecting cables between indoor unit and receiving unit correct 10 1 2 Troubleshooting procedure When a trouble occurred check the parts along with the following procedure Trouble gt Confirmation of check code by service mode Check defective position and parts NOTE For cause of a trouble power conditions or malfunc tion 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 signal line to shield cables 10 1 3 Outline of Judgment A primary judgment to detect cause of error exists on the indoor unit or outdoor unit is performed in the following procedure lt Judgment by flashing display on the indoor unit display part gt The indoor unit monitors operating status of the air conditioner and if a protective circuit works contents of the self diagnosis are displayed with a block restricted to the following cases on the indoor unit display part Sensor Table 10 1 1 Remote control code Block display Operation lamp display flashes 1 2 Contents of self diagnosis Check code Power failure In power ON Operation lamp display flashes 5Hz Indoo
65. o the name plate BLU BLUE block Chack the fluctuate voltage between 2 DC15 to 60V BLK BLACK Fuse Check to see if the fuse blows out Check the varistor R22 R21 GRY GRAY 6 3A PNK PINK Check the voltage at the No 8 pin on CN13 tor of the infrared recei Ab pid ias eck the voltage at the No 8 pin on connector of the infrared receiver 5 tt DG Sv Check the transformer and the power supply circuit of the rated voltage DDNSTEE 1 GREENG YELLOW fr DC 12V Check the voltage at the brown lead of the louver motor GRN GREEN Check the transformer and the power supply circuit of the rated voltage PUR PURPLE 4 2 Outdoor Unit RAV SM560AT E eo gt REACTOR IGBT MODULE MODULE BLU L fleur paw i UUUDPS0p PTS IN QUT N _ __ 29 BOARD MCC 813 31271 aes i COMPRESSOR H COIL FOR Poe BLK 4 WAY VALVE SURGE T ABSORBER BLK 00 VARISTOR N ORNI PMV FUSE Da T25A rd PULSE 250V MODULATING VALVE posppo x TERMINAL OF COMPRESSOR m BLACK C WHITE S feet a AGAR ASRS RED R ED a om FAN MOTOR The sign in is displayed in the terminalcover UNIT 220 to 240 50Hz Color Identification SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS BLK BLACK WHI WHI
66. ol B C board Correct connection of connector For RAV SM560AT E CN601 on control P C board Are characteristics of TD sensor resistance value normal YES Check control P C board Defect Replace 1C error Except RAV SM560AT E NO Refer to Characteristics 4 gt Replace TD sensors Correct connection of connector Was the error just after power ON determined NO Are connections of NO CDB CN800 and CDB IPDU CN06 connectors normal YES Are cabling connector normal Check cabling between IPDU and CDB and connector IPDU P C board error Defect Replace YES Is there no abnormal overload NO NO Improve and eliminate the cause Is IPDU P C board come to closely contact with heat sink YES Correct mounting IPDU P C board error 53 Defect Replace 1D error NO Is power voltage normal YES Improve power line NO Check and correct circuit cabling such as cabling to compressor phase missing and connector Are connections of cable connector normal YES Is there no slackened refrigerant Compressor lock Replace Is compressor normal YES YES Does electron expansion NO valve normally operate Check TE and TS sensors
67. ond fan DB WB C rps Pd Ps TD TS TC TE Indoor Outdoor Standard 3 1 0 9 85 13 10 47 74 HIGH 27 19 35 Cooling Overload 3 8 1 0 96 13 12 60 71 HIGH 32 24 43 Low load 0 9 0 5 25 7 10 5 28 LOW 18 15 5 5 Standard 2 8 0 6 87 3 46 1 87 HIGH 20 7 6 Heating Overload 3 3 1 1 78 22 55 16 55 LOW 30 24 18 Low load 1 7 0 2 110 20 26 22 110 HIGH 0 20 70 4 poles are provided to this compressor The compressor frequency Hz measured with a clamp meter is 2 times of revolutions rps of the compressor 7 3 2 RAV SM800XT E RAV SM800AT E U U 77 771 Air heat exchanger TC sensor Outer diameter of refrigerant pipe Gas side ZA Liquid side B S ek e I I 9 5mm 15 9 mm 1 Refrigerant pipe Refrigerant pipe 1 at liquid side at gas side Outer dia Outer dia ZA 1 Max 50m Pd Packed valve Packed valve Ps lt 4 Outer dia B Outer dia 4 lt Outdoor unit Modulating PMV TS sensor J Strainer SKV 18D26 TO sensor E33 11 TD sensor T Strainer valve TE 02137 sensor fie fi Mutter eh 1500cc 925 x L210 Heat exchanger 8 33 1530 25 x L160 1 row 30 stages FP1 3 flat fin i Rotary compressor DA220A2F 20L Prt 1 50 f Cooling Enzo Heating Pressure Pi
68. ons Nominal diameter Table 6 2 3 Dimensions related to flare processing for R410A Outer diameter mm Thickness mm Flare tool for R410A clutch type Conventional flare tool Clutch type 1 0 to 1 5 Wing nut type 1 5 to 2 0 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 2 0 to 2 5 Nominal diameter 1 0 to 1 5 Table 6 2 4 Dimensions related to flare processing for R22 Outer diameter mm Thickness mm A mm 2 0 to 2 5 Flare tool for R22 clutch type Conventional flare tool Clutch type 0 5 to 1 0 Wing nut type 1 0 to 1 5 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 5 to 2 0 Nominal diameter 0 5 to 1 0 Table 6 2 5 Flare and flare nut dimensions for R410A Outer diameter mm Thickness mm Dimension mm B 1 5 to 2 0 Flare nut width mm Nominal diameter Table 6 2 6 Flare and flare nut dimensions for R22 Outer diameter mm Thickness mm Dimension mm B Flare nut width mm 15 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 9 459 Fig 6 2 2 Relations between flare nut and flare seal surface the union axis c Tighten the
69. ortage Gas leak Supply gas Replace P C board 57 lt Inspection procedure gt Cooling and heating model Turn on power supply Does OPERATION lamp blink YES Is it possible to start unit by remote control YES Is it possible to detect DC 15 60 V between and on terminal block Is crossover cable normal YES Is it possible to detect AC 12 V on secondary side CNO6 of transformer YES Is it possible to detect NO DC 5 V at Q60 and 12 V at Q50 YES All lamps on NO indoor unit normal YES Are TD and TE sensors normal TD 17 9 at 50 C TE 10 kQ at 25 C YES Is it possible to detect NO 220 240 V at CN11 YES Does MG switch operate Next Page _ 58 Refer to item Power can not be turned Refer to 9 9 Troubleshooting for Remote Control Check TA and TC sensors or refer to 01 04 Table 9 4 1 Connect crossover cable properly Replace outdoor transformer Replace outdoor P C board Refer to item 9 8 3 How to check outdoor P C board Replace sensors Replace outdoor P C board Replace MG switch I Rewire or replace Are all of compressor cords normal defective cords YES Is compressor motor winding normal Check winding resistor Compressor is defective Replace compressor YES Is capacitor for compressor normal Capacitor is defective YES Is overload relay
70. pe surface temperature C Compressor Indoor Outdoor Indoor heat Outdoor heat revolutions temp conditions MPa Discharge Suction exchanger exchanger Per second DB WB C rps Pd Ps TD TS TC TE Indoor Outdoor Standard 3 3 0 9 89 8 40 64 27 19 35 Cooling Overload 37 1 1 87 14 45 32 24 43 Low load 1 0 0 8 22 1 24 18 15 5 5 Standard 3 3 93 54 70 20 7 6 Heating Overload 3 1 75 52 24 30 24 18 Lowload 2 0 90 25 90 0 20 70 4 poles are provided to this compressor The compressor frequency Hz measured with a clamp meter is 2 times of revolutions rps of the compressor 8 4 WIRING DIAGRAM 4 1 Indoor Unit EXCHANGER SWITCH PCB MCC 1428B SES FOR FLOAT SWITCH OPTION When you use float Switch you should cut J401 THERMO SENSOR HEAT EXCHANGER INFRARED RAYS RECEIVE AND INDICATION PARTS 00 SS FAN MOTOR LOUVER MOTOR INDOOR l UNIT OUTDOOR UNIT SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS Color Identification Check items Diagnosis result BRW BROWN OPERATION Check to see if OPERATION indicator goes on and off when the main switch RED RED indicator or breaker is turned on WHI WHITE YEL YELLOW Check the power supply voltage between T Refer t
71. phon liquid can be charged without turning it upside down It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant Accordingly when charging refrigerant from the refrigerant cylinder to the equipment charge it turning the cylinder upside down if cylinder is not equipped with siphon Cylinder with siphon 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 Cylinder without siphon Gauge manifold OUTDOOR unit Fig 6 4 2 6 5 Brazing of Pipes 6 5 1 Materials for brazing 1 Silver brazing filler Silver brazing filler is an alloy mainly composed of silver and copper It is used to join iron copper or copper alloy and is relatively expensive though it excels in solderability 2 Phosphor bronze brazing filler 1 Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution which may cause a gas leakage Therefore use any other type of brazing filler at a hot spring resort etc and coat the surface with a paint 2 When performing brazing again at time of servicing use the same type of brazing filler Phosphor bronze brazing filler
72. ping Z views 600 p 3l Suction port 150 22 ps Ee more nimum Heet gr distance up to wall 2 012 x 17 long hole 28 010 anchor bolt 3 SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3 1 RAV SM560XT E RAV SM560AT E Air heat exchanger TC sensor L Outer diameter of refrigerant pipe Gas side 2 Liquid side 2 6 4 mm 12 7mm _ Refrigerant pipe Refrigerant pipe I at liquid side at gas side Outer dia ZB Outer dia Packed valve lt i gt 7 eo NUT Sepa Ce a tare SUR eee nt Outer dia ZB Outdoor unit Outer dia ZA TS sensor SKV 18D26 TO sensor TD sensor 4 way valve VT7101D Muffler Heat exchanger 019 x L160 8 multiple thread ripple 1 row 22 stages Distributor Rotary compressor FP1 3 flat fin DA130A1F 23F R410A 0 9 kg o a UU ce we we a a a oe ee v a Cooling Heating Pressure Pipe surface temperature C Compressor Indoor Outdoor Indoor heat Outdoor heat revolutions Indoor temp conditions MPa Discharge Suction exchanger exchanger per sec
73. ping length 7 5 m with 0 meter height Note 2 The sound level is measured in an anechoic chamber in accordance with JIS B8616 Normally the values measured in the actual operating environment become larger than the indicated values due to the effects of external sound Note Rated conditions Cooling Indoor air temperature 27 C DB 19 C WB Outdoor air temperature 35 C DB Heating Indoor air temperature 20 C DB Outdoor air temperature 7 C DB 6 C WB Operation characteristic curve lt Cooling gt lt Heating gt V lu uuno 80 90 100 Indoor DB20 C Outdoor DB7 C WB6 C 60 Air flow High Pipe length 7 5m 230V 7 c 9 1520 40 0 100 60 70 80 Compressor speed rps Pipe length 7 5m 230V Compressor speed rps Capacity variation ratio according to temperature Cooling Heating oles Aoedey x oz m ax 0 oo Pipe length 7 5m 0 2 4 6 8 10 2 Outsoor temp C 35 36 37 38 39 40 41 42 43 Outsoor temp 34 1 2 Outdoor Unit Model name RAV SM560AT E RAV SM800AT E Appearance Silky shade Muncel 1Y8 5 0 5 Power supply 1 phase 230V 220 240V 50Hz Power exclusive to outdoor is required Type Hermetic compressor Compressor Motor Pole 4 poles Refrigerant charged R410A 0 9
74. piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas 4 When the Nitrogen gas is flowing be sure to keep the piping end open 5 Adjust the flow rate of Nitrogen gas so that it is lower than 0 05 m Hr or 0 02 Mpa 0 2 kgf cm by means of the reducing valve 6 After performing the steps above keep the Nitrogen gas flowing until the pipe cools down to a certain extent temperature at which pipes are touchable with hands 7 Remove the flux completely after brazing Flow meter Stop valve Nitrogen gas cylinder From Nitrogen cylinder Pipe lt 5 Nitrogen gas Rubber plug Fig 6 5 1 Prevention of oxidation during brazing 20 7 CONTROL BLOCK DIAGRAM Indoor Unit Control Panel M C U 8 MHz Heat Exchanger Sensor H Heat Exchanger Sensor TC Temperature Sensor Infrared Rays Signal Receiver h 1 Initializing Circuit Infrared R Clock Frequence Oscillator Circuit Power Supply Remote Circuit Noise Filter 7 x Functions e Louver Control e 3 minute Delay at Restart for Compressor e Motor Revolution Control e Processing Temperature Processing e Timer e Drain Pump ON OFF e Serial Signal Communication Hi POWER Display FILTER Sign Display PRE DEF Sign Di
75. pper pipes It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg 10 m Do not use copper pipes having a collapsed deformed or discolored portion especially on the interior surface Otherwise the expansion valve or capillary tube may become blocked with contaminants As an air conditioner using R410A incurs pressure higher than when using R22 it is necessary to choose adequate materials Thicknesses of copper pipes used with R410A are as shown in Table 6 2 1 Never use copper pipes thinner than 0 8 mm even when it is available on the market 13 Table 6 2 1 Thicknesses of annealed copper pipes Thickness mm Nominal diameter Outer diameter mm R410A 2 Joints For copper pipes flare joints or socket joints are used Prior to use be sure to remove all contaminants a Flare joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm In such a case socket joints can be used Sizes of flare pipe ends flare joint ends and flare nuts are as shown in Tables 6 2 3 to 6 2 6 below b Socket joints Socket joints are such that they are brazed for connections and used mainly for thick pipings whose diameter is larger than 20 mm Thicknesses of socket joints are as shown in Table 6 2 2 Table 6 2 2 Minimum thicknesses of
76. r P C board 0b to 0F 11 12 b5 b6 Operation timer lamp displays flash 5Hz Inter unit cables transmission system 04 Operation defrost lamp displays flash 5Hz Outdoor P C board 14 to 19 1 1C Operation timer defrost lamp displays flash BHz Cycle system etc id 1E 1F 21 1b 8b 46 10 2 Self Diagnosis by Remote Control Check Code 1 If the lamps are indicated as shown 00 to 03 in Table 10 1 1 exchanger the self diagnosis by the remote control When the remote control is set to the service mode the indoor controller diagnoses the operation condition and indicate the information of the self diagnosis on the display of the remote control with the check codes If a fault is detected all lamps on the indoor unit will blink at 5 Hz and it will beep for 10 seconds Pi Pi Pi The timer lamp usually blinks 5 Hz during the self diagnosis 2 10 2 1 How to use remote control in service mode RESET CLOCK CHECK AAUTOA xx 5 xx 77 DB won CHK ENON H a cama Y E A PRESET Cc Cc START STOP Auro O RESET CLOCK CHECK e Alphanumeric characters are used for the check code 5 is 5 B is 6 4 is A is is d is D rim 47 1 Press CHECK button wit
77. r inlet grille 2 In case of the Drain hose is installed through the Front panel Remove the Drain band from the Front panel Cut away the Opening base for piping from Front panel and keep parts 3 Open 3 Cap screws and remove the screws 4 Remove 5 screws fixing the Front panel 5 Remove the hooks of the Panel LED nearly side from the Drain pan Continue Remarks Drain band Screws Drain panel Part name Front panel Procedures 6 Remove both side hooks and remove the Front panel by turn to air inlet part direction lt How to install the Front panel gt 1 In case of the Drain hose installation through the Front panel install the opening base for piping in the Back body by a screw M4 x 12 Prepare it by yourself 2 Fit the Front panel in the Drain pan Then fix it in the Drain pan with 2 hooks in the center of the air outlet 3 Fix 5 hooks around the Front panel with conformation the Guide rib is inserting into the Back body 4 Fix 8 screws and close 3 Cap screws 5 Install the Drain band into the Front panel 6 Check the gap between the Front panel and the Back body Remarks Guide rib Drain pan assembly lt How to remove the Drain pan gt 1 Remove the Air inlet grille and the Front panel CD 2 Remove the Louver motor from the Drain pan 3 Remove the shaft of Horizontal louver 4 Remove the LED base and Electrical wire 5 Remov
78. re be sure to use a double spanner to loosen or tighten the flare nut of the valve at gas side If using a single spanner the nut cannot be tightened with necessary tightening torque SM800 type valve at gas side Cover Piping valve Handle Loosened Closed completely Opened fully Tightened Fig 9 8 6 Flare nut Fig 9 8 2 40 Compound pressure gauge Pressure gauge 101 kPa CY cmHg Ss Manifold valve Handle Lo Handle Hi Keep fully closed Charge hose p tury For R410A only Charge hose Service port Valve For R410A only core Setting pin Vacuum pump adapter for counter flow prevention For R410A only Packed valve at gas side Fig 9 8 7 lt For RAV SM560AT E model gt Compound pressure gauge Pressure gauge 101 kPa 76 cmHg p Handle Lo Manifold valve Handle Hi Keep fully closed Charge hose For R410A only Charge hose For R410A only Vacuum pump adapter for x counter flow prevention For R410A only Vacuum pump Packed valve Gas side Service port Valve core Setting pin Fig 9 8 8 Flare nut Valve unit Stopper Charge cap Charge port Valve rod Fig 9 8 9 41 9 9 ELECTRICAL WORK For the air conditioner that has no power cord NOTE For selection and connection method of the power supply cords refer to the details in the Installation Manual of the outdoor unit CAUTION e f incorrect incomple
79. re this type It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride potassium chloride and sodium fluoride to the borax boric acid compound Piping materials for brazing and used brazing filler flux Piping Used brazing Used material filler flux Copper Copper Phosphor copper Do not use Copper Iron Silver Paste flux Iron Iron Silver Vapor flux Do not enter flux into the refrigeration cycle When chlorine contained in the flux remains within the pipe the lubricating oil deteriorates Therefore use a flux which does not contain chloring 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 6 5 3 Brazing As brazing work requires sophisticated techniques experiences based upon a theoretical knowledge it must be performed by a person qualified In order to prevent the oxide film from occurring in the pipe interior during brazing it is effective to proceed with brazing while letting dry Nitrogen gas N flow Never use gas other than Nitrogen gas 1 Brazing method to prevent oxidation D Attach a reducing valve and a flow meter to the Nitrogen gas cylinder 2 Use a copper pipe to direct the piping material and attach a flow meter to the cylinder 3 Apply a seal into the clearance between the
80. rigeration assembly Procedures 7 Remove 2 screws and remove the refrigeration assembly with pushing it to right hand Remarks 2 Screws Multiblade fan and Fan motor lt How to remove the Multiblade fan and Fan motor gt 1 Remove the Air inlet grille and the Front panel 4 2 2 Disconnect 2 connectors 3 Remove the Fan covers 4 Remove the Motor band with holding the Fan motor and then remove the Fan motor with the Multi blade fans 5 Unfasten the Set screw and remove the Multi blade fans 64 Motor band Motor 2 Connectors Multi blade fan 11 2 Outdoor Unit RAV SM560AT E Part name Common procedure Procedure CAUTION Never forget to put on the gloves at working time otherwise an injury will be caused by the parts etc 1 Detachment 1 Stop operation of the air conditioner and turn off the main switch of the breaker for air conditioner 2 Remove the valve cover ST1T 04 x 101 1 pc After removing screw remove the valve cover pulling it downward 3 Remove wiring cover ST1T 4 x 10L 2 pcs and then remove connecting cable 4 Remove the upper cabinet ST1T O4 x 10L 2 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 water enters inside of the
81. roprocessor in the indoor unit should not be too close to RF noise sources For details see the owner s manual lt Remote controller gt e A place where there are no obstacles such as a curtain that may block the signal from the indoor unit e Do not install the remote controller in a place exposed to direct sunlight or close to a heating source such as a stove e Keep the remote controller at least 1 m apart from the nearest TV set or stereo equipment This is necessary to prevent image disturbances or noise interference e The location of the remote controller should be determined as shown below lt Remote controller usage gt e Under Ceiling Installation Ceiling Wall P Remote controller Reception range Reception Remote range controller Fig 9 5 1 e Console Installation 7m f Remote controller E Wall Reception 5 range 2 Reception N Remote range controller CNNNNNNNSNNNNNNNNN Floor Axial distance Fig 9 5 2 NOTICE The Paper pattern is inside the package box cover Do not bend and dispose of it before installing 9 5 2 Before Installation lt Remove the Air inlet grille gt 1 Open the Air inlet grille by both hands 2 Loosen three screws for fixing the Panel arm Do not remove the screws at this time Panel arm 3 First move the Air inlet grille up
82. rror is detected 2 Overload operation of refrigerating cycle though operation had started 3 Check current detection circuit at AC side High voltage protection error by TE sensor All stop Displayed when 1 Overload operation of refrigerating cycle J TE temp over specified value was error is detected 2 Check outdoor temp sensor TE detected DC outdoor fan motor error All stop Displayed when 1 Position detection error own IDC operation or lock was detected by error is detected 2 Over current protection circuit operation of DC outdoor fan driving outdoor fan drive unit Check e Refer to Judgment of outdoor fan Ir Error on IPDU position detection circuit All stop Displayed when 1 Position detection circuit operates even if driving we error is detected by removing 3P connector of compressor e Replace IPDU n Coming off disconnection or short of Operation Displayed when 1 Check outdoor temp sensor TO wo outdoor temp sensor continues error is detected 2 Check P C board 50 10 3 Troubleshooting for Each Check Code 1A error Are connections of CN301 and CN300 of CDB correct YES Does the fan rotate without trouble when handling the fan with hands under condition of removing CN301 and CN300 from CDB The status that the resistance values between leads below are 50 to 80 Q for 40 W motor ICF 140 43 and 25 to 55 Q for 60 W motor ICF 140 63 1 is normal Between
83. rting the unit and room temperature is between preset temperature and 3 C lower than preset temperature 25 minutes or more passed after starting the unit Manual L H Room temperature lt Preset temperature 4 C Room temperature 2 Preset temperature 3 5 C 23 8 5 Freeze preventive control Low temperature release The cooling operation including Dry operation is performed as follows based on the detected temperature of Tc sensor or Tcj sensor When J zone is detected for T1 minutes Following figure the commanded frequency is decreased from the real operation frequency After then the commanded frequency changes every 2 minutes while operation is performed in J zone T1 Normal 1 minute In K zone time counting is interrupted and the operation is held When I zone is detected the timer is cleared and the operation returns to the normal operation Fig 8 5 1 In heating operation the freeze preventive control works if 4 way valve is not exchanged and the condition is satisfied Remarks Tcj Indoor heat exchanger sensor temperature 8 6 High temp release control The heating operation is performed as follows based on the detected temperature of Tc sensor e When M zone is detected the commanded frequency is decreased from the real operation frequency After then the commanded frequency changes every 30 seconds while operation is performed in M zon
84. se Units 39 9 8 3 Heat insulation 1 Provide heat insulation on the refrigerant piping on both the liquid side and gas side separately and ensure that all joints in the insulation are completely sealed without gap 2 Since the temperature of the piping on the gas side increases during heating operations the heat insulating material used must be able to withstand temperatures of more than 120 C 3 Use the pipe insulation supplied in the accessory pack to insulate the piping connecting section on Cover Do not put the spanner or torque wrench etc on the cover The valve may be broken the indoor unit side Fig 9 8 3 9 8 1 Packed valve Manding precautions e On the contrary use a single spanner to loosen or e Open the valve stem all the way out do not try to tighten the flare nut of the valve at liquid side open it beyond the stopper valve unit e Securely tighten the valve stem cap in torque as follows Gas side 12 7 mm diam 50 to 62 Nem 5 0 to 6 2 kgf m Handle Pull out the handle and using cutting pliers etc turn it counterclockwise by 90 Open fully Liquid side 9 52 mm diam 33 to 42 Nem 3 3 to 4 2 kgf m Liquid side 6 35 mm diam 14 to 18 Nem 1 4 to 1 8 kgf m Service port 14 to 18 Nem 1 4 to 1 8 kgf m Hexagonal wrench is required Charge port Fig 9 8 1 For RAV SM800AT E model gt e As shown in the figu
85. socket joints Nominal diameter Reference outer diameter of copper pipe jointed mm Minimum joint thickness mm 6 2 1 Processing of piping materials When performing the refrigerant piping installation care should be taken to ensure that water or dust does not enter the pipe interior that no other oil other than lubricating oils used in the installed air conditioner is used and that refrigerant does not leak When using lubricating oils in the piping processing use such lubricating oils whose water content has been removed When stored be sure to seal the container with an airtight cap or any other cover 1 Flare Processing procedures and precautions a Cutting the pipe By means of a pipe cutter slowly cut the pipe so that it is not deformed b Removing burrs and chips If the flared section has chips or burrs refrigerant leakage may occur Carefully remove all burrs and clean the cut surface before installation c Insertion of flare nut 14 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 conven tional flare tool Flare processing dimensions differ according to the type of flare tool When using a conven tional flare tool be sure to secure dimension A by using a gauge for size adjustment Fig 6 2 1 Flare processing dimensi
86. splay B TIMER Display OPERATION Display Indoor Fan Motor Serial Signal Transmitter Receiver Y Louver ON OFF Signal Y Louver Driver Louver Motor witc dp vii MB Drain Pump From Outdoor Unit REMOTE CONTROL Operation START STOP Operation Mode Selection AUTO COOL DRY HEAT FAN ONLY Temperature Setting Fan Speed Selection j ON TIMER Setting I OFF TIMER Setting B Louver Auto Swing Louver Direction Setting fi Filter Reset Serial Signal Communication Infrared Rays Remote Control 8 OPERATION DESCRIPTION 8 1 When power supply is reset 1 Distinction of outdoor units When the power supply is reset the outdoors are distinguished and control is exchanged according to the distinguished result Setting of the indoor fan speed Based on EEPROM data rspeed of the indoor fan is selected 2 Remarks Air speed 8 2 Operation mode selection 1 Based on the operation mode selecting command from the remote control the operation mode is selected Table 8 2 1 Remote control Outline of control command 8 3 Air volume control 1 Operation with HIGH H MED M LOW L or AUTO mode is performed by the command from the remote control When FAN button is set to AUTO the indoor fan motor operates as shown in Fig 8
87. st Operation e Pressure of R410A is approx 1 6 times of that of R22 If installation work is incompletely finished a gas leakage may occur at the cases such as pressure rise during operation Therefore be sure to test the piping connections for leakage e Check the flare nut connections valve stem cap connections and service port cap fittings for gas leak with a leak detector or soap water Piping cover A Cord clamp Indoor Outdoor L Flare nut connecting c connections cables Indoor unit Power cable 8 Valve cover Fig 9 10 1 9 10 5 Test Operation To switch the TEST RUN COOL mode press TEMPORARY button for 10 sec The beeper will make a short beep Hi POWER FILTER TEMPORARY button Fig 9 10 2 9 10 6 Auto Restart Setting This product is designed so that after a power failure it can restart automatically in the same operating mode as before the power failure Information The product was shipped with Auto Restart function in the off position Turn it on as required lt How to set the Auto Restart gt e Press and hold the TEMPORARY button for about 3 seconds After 3 seconds the electronic beeper makes three short beeps to tell you the Auto Restart has been selected e To cancel the Auto Restart follow the steps described in the section Auto Restart Function of the Owner s Manual 43 9 10 7 Usef
88. stallation conditions do apply The power connection for the air conditioner has to be done at the main power distribution This distribution has to be of an impedance Normally the required impedance is reached at a 32A fusing point Air conditioner fuse has to be 16A No other equipment should be connected to this power line For detailed installation acceptance please contact your power supplier whether its restriction does apply for products like washing machines air conditioners or electrical ovens For power details of the air conditioner refer to the rating plate of the product Pipe shield Console Installation Mounting Air filter 70 mm or more 14 Wireless remote controller e With the remote controller cover open load the batteries supplied correctly observing their polarity remote controller Insulate the refrigerant pipes separately with insulation not together Batteries ai A Min 6 mm thick heat resisting polyethylene foam 27 9 2 PRECAUTIONS FOR SAFETY e Ensure that all Local National and International regulations are satisfied e Read this PRECAUTIONS FOR SAFETY carefully before Installation e The precautions described below include the important items regarding safety Observe them without fail e After the installation work perform a trial operation to check for any problem Follow the Owner s Manual to explain how to use and ma
89. t off the band bundling each lead wire 7 Disconnect connectors of various lead wires REQUIREMENT As each connector has a lock mechanism avoid to remove the connector by holding the lead wire but by holding the connector 74 Remarks Screw Inverter assembly UB Inverter cover 0 Inverter assembly gt Plug of soldering iron i Left time 10 sec or more Inverter assembly Hook for the side cabinet lower left side Remove the connectors with locking function by pushing the part indicated by the arrow mark Part name Control P C board assembly Procedure 1 Remove the inverter box from P C board base 2 Disconnect lead wires and connectors con nected from the control board assembly to other parts 1 Lead wires With the power terminal block 2 pcs Single phase Red White With the compressor 3 pcs Red White Black Connectors CN301 Outdoor fan 3P White Note 1 CN300 Position detection 5P White CN700 4 way valve 3P Yellow Note 1 CN702 PMV coil 6P White CN600 TD sensor 3P White CN605 TS sensor 3P White Note 1 CN604 TE sensor 2P White Note 1 CN601 sensor 2P White CN02 Indoor Outdoor connecting terminal block 2P Black CN500 Case thermo 2P White Note 1 CN14 CN15 Reactor 3P Relay connector Blue Note 1 Note 1 Remove the connector while releasing lockin
90. taching works have completed Check that all the hooking claws are fixed to the specified positions 71 Minus screwdriver Hooking claw Front cabinet Front cabinet Fan guard 11 3 Outdoor Unit RAV SM800AT E 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 also turn off switch of the breaker 2 Remove the front panel ST1T O4 x 101 pcs After taking off screws remove the front panel by pulling it downward 3 Disconnect the connecting cables and power cord from the terminals and cord clamp Upper plate 4 Remove the upper cabinet of cabinet ST1T 24 x 10L 6 pcs 2 Attachment 1 Attach the waterproof cover Water proof Be sure to attach a waterproof cover If it is not attached there is a possibility that water enters inside of the outdoor unit 2 Attach the upper cabinet ST1T 04 x 10L 6 pcs 3 Connect the connecting cable and power cord at the terminal and fix them with cord clamp CAUTION Using bundling band sold at a market be sure to fix the power cables and indoor outdoor connecting cables along the inter unit cable so that they do not come to contact with the compressor valves and cables at gas side and the discharge pipe 4 Attach the front cabinet ST1T O4 x
91. te wiring is carried out it may cause an electrical fire or smoke e Prepare the power supply for exclusive use with the air conditioner e Be sure to use the cord clamps specified posi tions with attached to the product e Do not damage or scratch the conductive core and inner insulator of power and inter connecting cables when peeling them e Be sure to comply with local cords on running the wire from outdoor unit to indoor unit size of wire and wiring method etc e Use the power cord and Inter connecting cable with specified thickness specified type and protective devices specified 9 9 1 How to wire 1 Connect the connecting cable to the terminal as identified with their respective matched numbers on the terminal block of indoor and outdoor unit HO7RN F or 245IEC66 1 5 mm or more 2 Insulate the unsheathed redundant cords conductors with electrical insulation tape Process them so that they do not touch any electrical or metal parts 3 For inter unit wiring do not use a cut wire jointed to another on the way 9 9 2 Stripping length of connecting cable DOOF lt 10 10 gt Earth line Fig 9 9 1 NOTE Use stranded wire only e Wire type More than 1 5 mm H07RN F or 2451 66 or 1 3 mm AWG 16 NOTE Connect the earth line to the metallic part mark located at the side of 3P terminal 9 9 3 Wiring between units 1 Conne
92. the flange nut with torque 9 8Nm 100kgf cm 76 Remarks Loosen by turning clockwise Propeller fan E Motor base Fixing claws for fan motor lead wires 3 positions Part name Compressor Procedure 1 Perform works of items and 2 Evacuate refrigerant gas 3 Disconnect the connector for fan motor from the inverter 4 Take off screws fixing the motor base to the bottom plate ST1T 24 x 101 2 pcs 5 Remove the motor base together with the fan motor and the propeller fan 6 Take off screws fixing the partition plate to the valve support plate ST1T 04 x 101 2 pcs 7 Remove the valve support plate M6 x 4 pcs 8 Take off screws of the partition plate and the bottom plate ST1T 24 x 101 2 pcs 9 Take off screws of the partition plate and the heat exchanger ST1T 24 x 10L 2 pcs 10 Remove the noise insulator 11 Remove the terminal covers of the com pressor and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal 12 Remove pipes connected to the compres sor with a burner CAUTION Pay attention to that flame does not involve 4 way valve or PMV If doing so a malfunc tion may be caused 13 Pull the refrigerating cycle upward 14 Take off nut fixing the compressor on the bottom plate 3 pcs 15 Pull the compressor toward you CAUTION When reconnecting the lead wires to the compressor
93. ul Functions SM800AT E only lt Self Diagnosis by LED Indication gt In addition to the code checking by remote controller of the indoor unit troubles of the outdoor unit can be diagnosed by LED indications on the cycle control P C board of the outdoor unit Utilize them for various checks For the check by remote controller of the indoor unit refer to the installation Manual of the indoor unit Before a check confirm each bit of the DIP switch is set to OFF position LED indication and code checking Cycle control P C board DIP switch SW800 LED indication D800 D801 D802 D803 O Heat exchanger sensor TE error Suction sensor TS error O Discharge sensor TD error O High pressure protection error Outdoor temperature sensor TO error O O O DC outside fan error O Communication error between IPDU s EED indication O O Discharge temp error D800 Red EEPROM error Communication error between IPDU D801 Yellow G Tr short circuit protection Oo 9 Detect circuit error t Yellow o Current sensor error 0803 vell Comp lock error 16100 9 9 Comp break down TET s O Rapid flash o e o o Phase missing detection Detection of coming off of CT curr
94. undled part at left side of the terminal block 7 Pull the inverter box upward 8 Disconnect connectors of various lead wires REQUIREMENT As each connector has a lock mechanism avoid to remove the connector by holding the lead wire but by holding the connector 67 Remarks Screws Inverter cover 25 n clamp Screws Plug of soldering iron Discharging position Discharging eriod 10 seconds or more zi 2 Inverter assembly Remove the connectors with locking function by pushing the part indicated by the arrow mark Part name Control P C board assembly Procedure 1 Disconnect lead wires and connectors connected from the control P C board assembly to other parts 1 Lead wires Connection with the power terminal block 3 wires Black White Orange Earth wire 1 wire Black 2 Connectors Connection with compressor Remove 3P connector Connection with reactor Remove the relay connectors from P07 08 2P White and P12 13 2P Yellow CN300 Outdoor fan 3P White CN301 Position detection BP White CN701 4 way valve Yellow CN600 TE sensor 2P White CN601 TD sensor White CN603 TS sensor 3P White CN602 TO sensor 3P White CN500 Case thermo 2P White CN703 PMV 6P White 2 Remove the inverter box Metal plate 3 Remove the control board assembly from P C board base Re
95. unit not JI connection LI 7I transmitted and received between continues indoor unit blinks operating at all a indoor and outdoor units when error is e Check the crossover cable and e The crossover wire is defected connect it properly connected wrongly Check the outdoor P C board The serial signal transmitting 2 In the case of the outdoor unit operating circuit on the outdoor P C board normally is defective e Check whether or not both of serial e The serial signal receiving LED Green and serial LED Orange circuit on the indoor P C board is blinking is defective If the serial LED Green is not blinking check the outdoor P C board If the serial LED Orange is not blinking check the indoor P C board The operation command signals Operation The lamp on the If the operation command signals continue 11 I are not transmitted from the continues indoor unit blinks to be transmitted between and of the e indoor unit to the outdoor unit when error is indoor terminal block replace the outdoor defected And it P C board returns to the normal condition when recovering from errors F1 Outdoor ITT The outdoor thermo sensor TE All off The lamp on the 1 Check the outdoor thermo sensor TE LUT P C board Uri is defective indoor unit blinks 2 Check the outdoor P C board as m Disconnection or short circuit when error is defected The outdoor heat exchanger TD All off The lamp on the 1 Ch
96. ure to provide grounding Do not connect ground wires to gas pipes water pipes lightning rods or ground wires for telephone cables e Conform to the regulations of the local electric company when wiring the power supply Inappropriate grounding may cause electric shock e Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas If a combustible gas leaks and stays around the unit a fire may occur 29 9 3 Accessory parts and Parts to be procured locally 9 3 1 Accessory parts Part name Part name Shape Installation plate Installation Manual Filter frame Owner s Manual Battery Mounting screw 04 x 257 Remote controller holder Flexible pipe Pan head wood screw 3 1 x 16 Drain nipple Packaged with the outdoor unit Pipe shield Zeolite filter 9 3 2 Parts to be procured locally Connecting pipe Liquid side 6 35 mm diam Nominal diam 1 4 thick 0 8 mm RAV SM560XT E RAV SM560AT E 9 52 mm diam Nominal diam 3 8 thick 0 8 mm RAV SM800XT E RAV SM800AT E Wireless remote controller Connecting cable HO7RN F or 2451EC66 1 5 mm or more Thermal insulation for refrigerant pipe 10 mm or more thermal insulating foam polyethylene Connecting pipe Gas side 12 7 mm diam Nominal diam 1 2 thick 0 8 mm RAV SM560XT E RAV
97. us as it is for 1 to 2 minutes and ensure that the compound gauge s pointer does not return Set the refrigerant cylinder to the electronic balance connect the connecting hose to the cylinder and the connecting port of the electronic balance and charge liquid refrigerant Open fully both packed valves at liquid and gas sides Place the handle of the gauge manifold Low in For refrigerant charging see the figure below the fully opened position and turn on the vacuum pump s power switch Then evacuating the refrigerant in the cycle D 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 OUTDOOR unit Refrigerant cylinder With siphon pipe Service port Electronic balance for refrigerant charging Fig 6 4 1 Configuration of refrigerant charging 18 D Be sure to make setting so that liquid can be charged 2 When using a cylinder equipped with a si
98. vacuate the air in the connecting pipes using VACUUM PUMP 4 Check the gas leakage Connected points 9 7 2 Permissible Piping Length and Head The maximum piping length from the outdoor to indoor unit The maximum height difference outdoor indoor unit 30 m Without charge 20 m 50 m Without charge 20 m Outdoor unit is above Outdoor unit is below RAV SM560AT E 5 800 30m 15m lt Flaring gt Insert a flare nut into the pipe and flare the pipe As the flaring sizes of R410A differ from those of refrigerant R22 the flare tools newly manufactured for R410A are recommended B However the conventional tools can be used by adjusting projection margin of Z the copper pipe 2 lt gt Fig 9 7 1 e Projection margin in flaring B Unit mm Rigid Clutch type Imperial Wing nut type Outer diam R410A tool used Conventional tools used Outer diam of copper pipe R410A R22 of copper pipe R410A R22 R410A R22 6 35 9 52 1 5 to 2 0 1 0 to 1 5 6 35 9 52 0to 0 5 Same as left 1 0 to 1 5 0 5 to 1 0 12 7 15 9 2 0 to 2 5 1 5 to 2 0 12 7 15 9 0 to 0 5 Same as left 1 0 to 1 5 0 5 to 1 0 In the case of the flaring for R410A with the conventional flare tool pull out it approx 0 5 mm e Flaring dia meter size A Unit mm Outer diam of copper pipe more than that for R22 to adjust to the specified flare size The copper pipe gau
99. ward then turn it backwards 4 Remove the Grille stopper from the axis of the Front panel After that remove the Air inlet grille 5 Remove the Panel arms from the Front panel Grille stopper Fig 9 5 4 9 5 3 After Installation lt Install the Air inlet grille gt 1 Insert the three Panel Arms on the Air inlet grille and fix each securely by screws CAUTION e The screws that fixed with Panel Arms must not be loose 2 Set the Air inlet grille arm to the axis of the Front panel 3 Insert the Grille stopper to the correct position and fix it securely with screws 4 Push the Air inlet grille to the correct position Axis of the Front panel Air inlet grille arm Fig 9 5 6 9 5 4 Under Ceiling Installation For the installation of the indoor unit use the Paper pattern which is inside the package box cover lt Install the Suspension bolts gt e Install the Suspension bolts so that it can support the indoor unit 1093 LA 240 mm or more x 5 235 mm or more Fig 9 5 7 e Adjust distance to ceiling before installation 25 30 mm Nut M10 40 45 mm Suspension bolt M10 Washer Spring washer lt lnstall the indoor unit gt 1 Remove the Side covers and the Installation plate 2 Insert the Suspension bolts into the metal fittings of the indoor unit 3 Set to nuts spring washers and washers on both sides of the met
100. x the claws After all the attachment works are completed check that all the hooking claws are fixed to the specified posi tions 2 Mount the bell mouth by hooking three claws at upper side of the bell mouth in the slits on the discharge cabinet 3 After attachment fix the bell mouth with screws ST1Tf4 x 101 2 pcs 79 Remarks Discharge A port cabinet Bell mouth Remove Discharge port cabinet Fan guard Hooking claw Discharge port cabinet Claw 3 positions Location No 43 69348 43 69349 43 50004 43 60002 43 62003 43 69315 12 EXPLODED VIEWS AND PARTS LIST 12 1 Indoor Unit E Parts Assy 408 Location D NS escription No PC Board RAV SM560XT E PC Board RAV SM800XT E Temperature sensor Terminal Block 3P Cord clamp Display unit 43T50302 43T69348 43T69349 43 08349 43 50306 401 409 Description Temperature sensor PC Board RAV SM560XT E PC Board RAV SM800XT E Switch cover Temperature Sensor Sensor 12 2 Indoor Unit 43 09312 43 00357 43 00358 43 01004 43 79303 43 80302 43 00359 43 00360 43 20303 43 20304 43 20305 43 19309 43 21325 43 72301 43 79304 43 19303 43 09313 43 44331 43 44332 Description Air Inlet Grille Panel Arm Assy Front Panel Assy Mark Drain Band Air Filter Cap Screw C Cap Screw LR Fan Cover Motor Band Assy Multiblade Fan Scr
101. y on LCD and the display on the main unit disappear Remarks FILTER goes on 24 8 9 Auto Restart Function 8 9 1 How to set auto restart function The indoor unit is equipped with an automatic To set the auto restart function proceed as follows restarting function which allows the unit to restart The power supply to the unit must be on the function operating with the set operating conditions in the event will not set if the power is off of power supply being accidentally shut down The Push the TEMPORARY button located in the center operation will resume without warning three minutes of the front panel continuously for three seconds after power is restored The unit receives the signal and beeps three times This function is not set to work when shipped from the The unit then restarts operating automatically in the factory Therefore it is necessary to set it to work event of power supply being accidentally shut down When the unit is on standby Not operating Operation Motions Push TEMPORARY button for more The unit is on standby than three seconds The unit starts to operate The green lamp is on T After approx three seconds The unit beeps three times The lamp changes from RQ A and continues to operate green to orange ibd If the unit is not required to operate at this time push TEMPORARY button once more or use the remote control to turn it off When the unit

Toshiba RAV-SM560AT-E Air Conditioner User Manual

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