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