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