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