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Toshiba RAV-SP804ATZ-E, RAV-SP804ATZG-E, RAV-SP804AT-E service manual Air-Conditioner

Models: RAV-SM564SDT-E RAV-SM454SDT-E RAV-SP404ATZ-E RAV-SP404ATZG-E RAV-SP404AT-E RAV-SP454ATZ-E RAV-SP454ATZG-E RAV-SP564AT-E RAV-SP454AT-E RAV-SP564ATZG-E RAV-SP564ATZ-E RAV-SP804AT-E RAV-SP804ATZ-E RAV-SP804ATZG-E

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FILE NO. A08-007

SERVICE MANUAL

AIR-CONDITIONER

INDOOR UNIT

RAV-SM404SDT-E RAV-SM454SDT-E RAV-SM564SDT-E

OUTDOOR UNIT

RAV-SP404AT-E RAV-SP404ATZ-E RAV-SP404ATZG-E

RAV-SP564AT-E RAV-SP564ATZ-E RAV-SP564ATZG-E

SPLIT TYPE

RAV-SP454AT-E RAV-SP454ATZ-E RAV-SP454ATZG-E

RAV-SP804AT-E RAV-SP804ATZ-E RAV-SP804ATZG-E

R410A

PRINTED IN JAPAN, Jan., 2009 ToMo

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Toshiba RAV-SP804ATZ-E, RAV-SP804ATZG-E, RAV-SP804AT-E, RAV-SP564ATZ-E, RAV-SP564ATZG-E service manual Air-Conditioner

Contents

AIR-CONDITIONER Contents Outdoor Controls Outdoor Print Circuit Board 10-1 Summary of Troubleshooting 10-211-1 Indoort Unit Slim Duct Type 107 14-1 Indoor Unit 142 14-2 Outdoor Unit 147 Explanation of illustrated marks Explanation of indicationsConfirmation of warning label on the main unit Indication Explanation Never recover the refrigerant into the outdoor unit ∗ For details, refer to the parts listCatch the inner wires Do not modify the products Before test run, install the front panel and cabinet For a check, turn off the power breakerCheck the following items after reinstallation Metal section Earth position Pipe Materials Safety Caution Concerned to New RefrigerantCopper pipe Piping Flare nut R410A Conventional air General tools Conventional tools can be usedUsed tool Usage Single type Way Air Discharge Cassette TypeIndoor unit Outdoor unit TCB-AX21E2 Concealed Duct Type Single type TCB-AX21E2, AX22CE2 Under Ceiling Type Single type High Wall Type Single type 404ATZZG-E 454ATZZG-E 564ATZZG-E 402MUT-E 452MUT-E 562MUT-E Outdoor unit Twin type 404SDT-E 454SDT-E 564SDT-E Outdoor unit Slim Duct Type Single type RAV-SM404SDT-E Model name Outdoor unit Super Digital Inverter404ATZZG-E 454ATZZG-E 564ATZZG-E 804ATZZG-E Cooling Heating Operation characteristic curve Super Digital InverterCurrent a Compressor speed rps Current a Cooling Heating SP45 Capacity variation ratio according to temperatureSP40 Ratio Capacity Refrigerant piping Air filterDrain-up port Hung-up plate RAV-SP404ATZZG-E, RAV-SP454ATZZG-E, RAV-SP564ATZZG-E Space required for service Name Power supply inlet hole Kockout hole Model RBC RAV-TWP30E2, RAV-TWP50E2 Simultaneous Twin Capillary tube specifications Dimension tableSingle type Combination of 1 indoor unit and 1 outdoor unit Twin type Combination of 2 indoor units and 1 outdoor unit Outer dia. ØA CAM-B30YGTF-2 PMV CAM-B30YGTF-2 RAV-SM404SDT-E, RAV-SM454SDT-E For Indoor Unit Control P.C. BoardMCC-1570 Slim Duct Type MCC-5009 Board Identification ColorMCC-1571 Parts name Type Specifications Specifications of Electrical Parts Piping Materials and Joints Used Safety During Installation/Servicing 1 Thicknesses of annealed copper pipes Thickness mm Processing of Piping MaterialsOuter diameter mm R410A R22 Minimum thicknesses of socket joints Flare and flare nut dimensions for R22 Flare and flare nut dimensions for R410AR410A R22 R410A, R22 Clutch type Wing nut type Diameter Wrenches available on the market Nm kgfm Refer to the 4. Tools Required Tools Flux Reason why flux is necessary Low temperature brazing fillerMaterials for Brazing Silver brazing filler Phosphor bronze brazing filler Types of flux Characteristics required for fluxPiping materials for brazing and used brazing filler/flux Brazing Branching Pipe for Simultaneous Operation System Basic Conditions Needed to Reuse the Existing PipeCuring of Pipes Restricted Items to Use the Existing Pipes Existing pipe no * Use a new pipes Handling of Existing Pipe SW802 When shipped from factory When using existing pipeReference outside diameter Wall thickness Connection of Wired Remote Controller Indoor Controller Block Diagram Indoor unit #1 Master Wireless remote controller kit Connection of Wireless Remote Controller Kit Max units Ts Setup temp Outline of specifications RemarksTa Room temp To Outside temp Setup data Setting at shipment+ temp. correction Room temp. control Cool Tc ≥ 60C, the air speed increases by 1 step Temperature Slim Duct Type Tcn When Q or R is established 5 minutes afterConditions Tc n Time Control temp. C Setup at shipment Command frequency Case of wired remote controllerAt shipment of Item code DN CC to Performed. Unit stops Frequency fixed Setup temperature is shifted every 20 minutes, Restriction ratio can be set by keeping Function Connector No Pin No Specifications Remarks Print Circuit Board IndoorMCC-1570 Outdoor Controls Discharge temperature release controlPMV Pulse Motor Valve control Case of RAV-SP56 and SP80 models Cooling fan control SP56 Outdoor fan controlSP80 Revolution frequency allocation of fan taps rpm Heating fan control Coil heating control SP80 SP56Short intermittent operation preventive control Current release control Current release value shift control Temperature range SP56 SP80 Start of heating operation Defrost control SP56 onlyNormal To Abnormal To Compressor protective control SP80 only SP80 only¡ Short circuit, × Open J805 J806 Case of RAV-SP40 and SP45 models Pulse Motor Valve PMV control Allocations of fan tap revolutions rpm Operation with WETE ˚C TD ˚C Temp. range 34.1Hz 34.1Hz ≤ 58.6Hz 58.6Hz ≤ f Min Max Maximum Temp. range 38.9Hz 38.9Hz ≤ f 67.6Hz 67.6Hz ≤ f Start of heating operation Defrost controlZone Circuit Board Outdoor PrintMCC-5009 Fan motor output Troubleshooting procedure Before troubleshootingWired remote controller type Trouble Confirmation of lamp display Wireless remote controller type Outline of judgment TroubleshootingLamp indication Check code Cause of trouble occurrence Case thermostat worked Lamp indication Check code Cause of trouble occurrence Others Other than Check Code Remote controller detected Check Code List IndoorIndoor unit detected Central control devices detected Way valve inverse error Check Code List Outdoor Open/Short of heat exchanger TCJ was detected Cause of operation Status Error mode detected by indoor unit Cause of operation Series Error mode detected by outdoor unit Operation of diagnostic function YES E09 error E10 error E04 error E08, L03, L07, L08 error E18 errorL09 error L30 error L20 errorP30 error Central controller F10 error P10 error CN333 CN334 P12 error F01 error F02 error C06 error TCC-LINK central controller F29 error E03 error Master indoor unitP31 error Follower indoor unit LED display legend l Go off, ¡ Go on, ¥ Flash 5Hz Case of SP40 to Discharge temp. error Power supply error, Current detection circuit errorPower supply error Voltage error L29 Position detection circuit error Outdoor fan system errorP22 P26 Error display, which occurs at present Latest error displayDisplay selection Only 1 of SW803 is on Display Heat exchanger temp. sensor TL error → Display Display 2 Heat exchanger temp. sensor TE errorCase of SP80 Is connection of CN603 correct? F13 Display Display 2 Heat sink temp. sensor TH error F12 Display 1 Display 2 Suction temp. sensor TS errorF31 Display Eeprom error H02 Display Compressor lock H03 Display 1 Display 2 Current detection circuit error L10 Display Check outdoor P.C. board Defect → Replace 100 101 P05 Display 1 Display 2 Power supply errorIs there refrigerant shortage? Recharge refrigerant Repair defective position Replace defective part P15 Display 1 Display 2 Gas leak detection 102 Exchange to cooling cycle Exchange to heating cycle 103 104 Single operation check for outdoor fan 105Outdoor fan single operation Display TA, TC, TCJ, TE, TS, to sensors Temperature Resistance value characteristic tableTD, TL sensors 106 107 Replacement procedures C. Board for indoor unit servicing replacement procedures Setting data read out from Eeprom108 Swing operation also starts if it has the louvers 109 Writing the setting data to Eeprom 110 Eeprom layout diagram 111 Setting data Code No. table exampleType Code No Indoor unit capacity Code No Practical operation Test Run Setup on Remote Controller Wired remote controller112 LED Display on P.C. Board D501 Red Function Selection SetupD403 Red D503 Yellow Main bus communication 114 ContentsFunction selection item No. DN list When connected 2 remote controllers operate an indoor unit Setup methodWhen connected 2 remote controllers operate the twin Operation Monitor Function of Remote Controller Switch Calling of sensor temperature displayProcedure 116 Contents Calling of error historyGroup control operation System example By feed unit Automatic address judgment Indoor unit power-ON sequenceInitial communication Usual regular communication TCC-LINK wiring connection Microprocessor block diagramTCC-LINK Adapter For TCC-LINK Central Control Function 119 C. board switch SW01 setup Wiring specificationsGround earth wire to 1 point at indoor unit side No. of wires Size Address setup External view of P.C. board assemblySetup from remote controller at indoor unit side 121 How to set contents of save operation When installing separately sold filters Changing of settings of for applicable controls123 When wireless remote controller is used Setup of external static pressureTo restore the factory settings Change on wired remote controller Change of lighting time of filter sign How to set up power saving modeTo secure better effect of heating 125 Operation method Refrigerant Recovery Control126 Function Set position Control contents Function Setting position Control contents127 Defrost control Specifications Operation contents ∗ All LED are colorless when it goes off128 Operation part Selection of LED display SW800, SW803 operation Switch Function / Contents Refer129 Display selection list Error contents Error display130 131 Operation when pushdown button switch SW801 is pushed Specific operation for maintenance check SW801, SW804132 Specific operation 133 SW804 Operation when pushdown button switch SW801 is pushed 134 Item code Data at shipment Setup data range Terminology System Configuration135 Single Twin 136 Automatic Address Example from Unset Address No miswiringHeader unit Follower unit Standard One outdoor unit Single Twin Triple 137Multiple groups operation 138 Wiring diagramSingle system 139 Address Setup Manual setting from remote controller 140 To know the position of indoor unit body by addressButton if the unit stops Unit No -1is displayed on LCD Part name Object Contents of check Contents of maintenance Maintenance/Check list141 142 No. Part name Procedure RemarksDetachment Attachment 143 No. Part name Procedure 144 Part name ProcedureCase of drain pump incorporated model Fan motor 1. Detachment 145 Drain pump, 1. Detachment 146 147 Part name Procedure RemarksDetachment Attachment 148 No. Part name Procedure 149 150 151 Procedure RemarksTighten the flange nut with torque 4.9Nm 50kgf/cm Part name 152 Pulse Motor Valve 153Fan guard With minus screwdriver along with 154 RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E 155 Exchange of 1. Control P.C. board 156 157 Remove the relay connector connected toExchange of 1. Reactor Electric parts Carry out works of 1 of 1 158 159 Part name ProcedureCompressor 1. Removal of broken compressor Control P.C. board 160 Compressor Using a burner, remove the dischargeCompressor lead Pipe and the suction pipe connected to Compressor to the bottom plate Compressor 2. Mounting of compressor 161 Vacuuming 162Refrigerant charging Forced full-opening method of PMV 163 164 RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E Location Description Model Name 165404SDT-E 454SDT-E 564SDT-E 404 403 405 402 Parts assembly166 167 RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E Location Description Model Name RAV-SP 168404ATZ-E 454ATZ-E 169 Inverter assemblyLocation Description Model Name 404ARZ-E 170 37,38 Location Description Model Name RAV-SP 171564ATZ-E 564AT-E 172 Inverter assembly 173 30, 31 804ATZ-E 174804AT-E 804ATZ-E 804ATZG-E 175Location Model Name RAV-SP Check of Concentration Limit Toshiba Carrier Corporation