SERVICE MANUAL
OUTDOOR UNIT
DIGITAL INVERTER
AIR-CONDITIONER
CONTENTS
REPLACEMENT OF
Explanation
SAFETY CAUTION
Indication
Mark
– 5 –
– 6 –
2.Cautions on Installation/Service
• New Refrigerant R410A
1. Safety Caution Concerned to New Refrigerant
3.Pipe Materials
4.Tools
General tools Conventional tools can be used
Simultaneous double twin
RAV-SM2244ATseries Simultaneous twin
Simultaneous triple
<RAV-SM2804ATseries> Simultaneous twin
Branch kit
– 10 –
RAV-SM2244ATseries
RAV-SM2804ATseries
1-1-1. 4-WayCassette Type
1. SPECIFICATIONS
1-1.Indoor Unit
<Twin type>
– 12 –
1-1-2.Duct Type <Twin type>
– 13 –
1-1-3.Ceiling Type <Twin type>
– 14 –
1-1-4. 4-WayCassette Type <Triple type>
– 15 –
1-1-5.Duct Type <Triple type>
– 16 –
1-1-6.Ceiling Type <Triple type>
– 17 –
1-1-7.High Wall Type Triple type
– 18 –
1-1-8. 4-WayCassette Type Double twin type
RAV-SM562MUT-E
– 19 –
Indoor unit
RAV-SM562MUT-E
– 20 –
1-1-10.Slim Duct Type <Double twin type>
– 21 –
1-1-11.Duct Type <Double twin type>
1-1-12.Ceiling Type <Double twin type>
– 23 –
1-1-12.High Wall Type Double twin type
1-2.Outdoor Unit
– 24 –
Cooling
RAV-SM2244AT8Z ZG -E, RAV-SM2804AT8Z ZG -E
RAV-SM2244AT7Z ZG, RAV-SM2804AT7Z ZG
<Heating>
RAV-SM2244AT7Z ZG, RAV-SM2804AT7Z ZG
– 26 –
RAV-SM2244AT8Z ZG -E, RAV-SM2804AT8Z ZG -E
<Cooling>
2. CONSTRUCTION VIEWS EXTERNAL VIEWS
2-1.Outdoor Unit
Branch pipe
– 28 –
RBC-DTWP101ESimultaneous Double Twin
<Joint pipe>
RBC-TRP100ESimultaneous Triple
<Gas side>
<Liquid side>
Gas side socket
<Branch pipe>
– 30 –
RBC-TWP101ESimultaneous Twin
<Joint pipe>
RAV-SM2244AT8Z ZG -E, RAV-SM2804AT8Z ZG -E
3. OUTDOOR UNIT REFRIGERANTING CYCLE DIAGRAM
– 31 –
RAV-SM2244AT7Z ZG, RAV-SM2804AT7Z ZG
RAV-SM2804series
Systematic diagram of refrigerating cycle
RAV-SM2244series
4. WIRING DIAGRAM
4-1.Outdoor Unit
RAV-SM2244AT8Z ZG -E, RAV-SM2804AT8Z ZG -E
5. SPECIFICATIONS OF ELECTRICAL PARTS
5-1.Outdoor Unit
RAV-SM2244AT7Z ZG, RAV-SM2804AT7Z ZG
6. REFRIGERANT R410A
6-1.Safety During Installation/Servicing
6-2.Refrigerant Piping Installation
6-2-1.Piping Materials and Joints Used
6-2-2.Processing of Piping Materials
1.Flare Processing Procedures and Precautions
1.Joints
Table 6-2-1Thicknesses of annealed copper pipes
Flare and flare nut dimensions for R22
Fig. 6-2-1Flare processing dimensions
Flare and flare nut dimensions for R410A
Table
Outer diameter
2.Flare Connecting Procedures and Precautions
Nominal
Tightening torque
6-4.Recharging of Refrigerant
Fig. 6-4-1Configuration of refrigerant charging
6-3.Tools
6-3-1.Required Tools
6-5-1.Materials for Brazing
3.Low temperature brazing filler
6-5-2.Flux 1.Reason why flux is necessary
1.Silver brazing filler
6-5-3.Brazing
2.Characteristics required for flux
3.Types of flux
Never use gas other than Nitrogen gas
Instruction of Works
6-6-2.Restricted Items to Use the Existing Pipes
6-6-4.Curing of Pipes
If the definite conditions can be cleared
6-6-5.Final Installation Checks
– 43 –
6-6-6.Handling of Existing Pipe
Cautions for using existing pipe
6-6-7.Recovering Refrigerant
– 44 –
7-1.Outdoor Unit Control
– 45 –
7-1-2.Print Circuit Board, MCC-1597Fan Motor IPDU
– 46 –
7-1-3.Print Circuit Board, MCC-1599Interface CDB
– 47 –
7-1-4.Print Circuit Board, MCC-1600Noise Filter
– 48 –
1.PMV Pulse Motor Valve control
2.Discharge temperature release control
7-2.Outline of Main Controls
3-1.Cooling fan control
3.Outdoor fan revolution number control
– 50 –
3-2Heating fan control
6.Electrical current release control
4.Defrost control
5.Short interrupted operation preventive control
9.Over-currentprotective control
7.Heat sink temperature detection control
8.Electrical current release value shift control
11.High-pressurerelease control
– 53 –
13.Oil recovery control
12.SV2 valve control
14.Coil heating control
– 54 –
1. Before troubleshooting
8. TROUBLESHOOTING
8-1.Summary of Troubleshooting
2. Troubleshooting procedure
<Wireless remote controller type>
1. Before troubleshooting
2.Troubleshooting procedure
– 56 –
8-2.Troubleshooting
8-2-1.Outline of judgment
Check code
– 58 –
Lamp indication
Cause of trouble occurrence
8-2-2.Others Other than Check Code
– 59 –
Page
Page
– 62 –
Judgment and measures
Error mode detected by indoor unit
Operation of diagnostic function
Cause of operation
Error mode detected by outdoor unit
– 64 –
Judgment and measures
Operation of diagnostic function
Check code
Indoor unit
– 66 –
<Error display, which occurs at present>
Dip switch setup
<Latest error display>
LED display on outdoor P.C. board
Page
– 69 –
– 70 –
– 71 –
– 72 –
¡l l l
– 74 –
– 75 –
– 76 –
Check
Check and troubleshooting
– 77 –
Outdoor
– 78 –
TD, TL sensors
Temperature sensor
TA, TC, TCJ, TE, TS, TO sensors
TA, TC, TCJ, TE, TS, TO sensors
4 seconds or more to call the service check mode
<Contents>
Procedure
REQUIREMENT
nIndoor unit power-ONsequence
9-3.Outdoor Unit
– 82 –
Operation part
D805 D804 D803 D802 D801 D800
1.Outline
Display part
– 84 –
9-3-3.Others
1.Selection of LED display SW800, SW803 operation
1Display selection list
lllll¡
lllll¡
SW804
– 87 –
<Specific operation>
– 88 –
SW804
10. ADDRESS SETUP
10-1.Address Setup Procedure
<Terminology>
10-2.Address Setup & Group Control
10-2-1.System Configuration
– 91 –
Example
– 92 –
Change is necessary
Simultaneous twin system
10-3.Remote Controller Wiring
Wiring diagram
Simultaneous triple and double twin system
1 2 3 4 5 6 7 8 9 10 11 END
2, 5,
3, 6, 9 4, 7,
10-5.Confirmation of Indoor Unit No. Position
1 2 END
1 2 3 END
<Maintenance/Check list>
– 96 –
Contents
1 ACCESSORY PARTS
– 98 –
2 SAFETY PRECAUTIONS
3 INSTALLATION OF NEW REFRIGERANT AIR CONDITIONER
Digital Inverter
Before installation
4 INSTALLATION CONDITIONS
Required Tools/Equipment and Precautions for Use
Electrical wiring
Digital Inverter
Installation Location
Necessary Space for Installation Unit: mm
Digital Inverter
Serial installation in front and rear
Installation of Outdoor Unit
Optional Installation Parts Locally procured
Knockout procedure
Branch pipe installation
Connecting the Gas Side Pipe
Tightening of Connecting Part
Branch Pipe
Airtight Test
6 AIR PURGING
Refrigerant Pipe Length
Air Purge
Insulating the Pipes
How to Open the Valve
Refrigerant replenishing procedure
Replenishing Refrigerant
Digital Inverter How to wire
Wiring between Indoor Unit and
Power and Wiring Specifications
Wiring diagram
9 FINISHING
11 ANNUAL MAINTENANCE
Stripping length power cord and connecting wire
10 TEST RUN
Cautions for using existing pipe
14 TROUBLESHOOTING
Recovering Refrigerant
13 FUNCTIONS TO BE IMPLEMENTED LOCALLY
D805
15 APPENDIX
Digital Inverter
D804
Digital Inverter
Existing pipe SW
Page
13-2.Exchange of Compressor
13. HOW TO EXCHANGE COMPRESSOR
13-1.Exchanging Procedure of Compressor Outline
2.Attachment
RAV-SM224, RAV-SM280series
1.Detachment
1. Detachment
1. Detachment
Procedure
– 113 –
2. Attachment
– 114 –
2. Attachment
2. Attachment
– 115 –
1. Detachment
Attachment
– 116 –
Detachment
2. Attachment
– 117 –
1. Detachment
– 118 –
Procedure
of Inverter Assembly front
1. Detachment
2. Attachment
– 119 –
9Compressor 1. Detachment
2. Attachment
– 120 –
10Fan motor 1. Detachment
No. Part name
Procedure
– 121 –
<Compressor terminal>
4.Refrigerant charge
11Compressor 2. Attachment
3.Vacuuming
12Pulse motor 1. Detachment
2. Attachment
123
13Fan guard 1. Detachment
15. EXPLODED VIEWS AND PARTS LIST
15-1.Outdoor Unit
– 125 –
15-2.Inverter Assembly
– 127 –
15-3.Outdoor Unit
– 129 –
15-4.Inverter Assembly
Model name
– 131 –
Location
RAV-SM
WARNINGS ON REFRIGERANT LEAKAGE
Check of Concentration Limit
TOSHIBA CARRIER CORPORATION