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Toshiba RAV-SM404SDT-E Service Manual

Split type air-conditioner
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See also: Service Manual , Owner's Manual

SERVICE MANUAL

AIR-CONDITIONER
INDOOR UNIT
<DIGITAL INVERTER>
RAV-SM404SDT-E
RAV-SM454SDT-E
RAV-SM564SDT-E
OUTDOOR UNIT
<SUPER DIGITAL INVERTER>
RAV-SP404AT-E
RAV-SP404ATZ-E
RAV-SP404ATZG-E RAV-SP454ATZG-E
RAV-SP564AT-E
RAV-SP564ATZ-E
RAV-SP564ATZG-E RAV-SP804ATZG-E
R410A
SPLIT TYPE
RAV-SP454AT-E
RAV-SP454ATZ-E
RAV-SP804AT-E
RAV-SP804ATZ-E
PRINTED IN JAPAN, Jan., 2009 ToMo
FILE NO. A08-007

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  • Page 1: Service Manual

    FILE NO. A08-007 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE INDOOR UNIT <DIGITAL INVERTER> RAV-SM404SDT-E RAV-SM454SDT-E RAV-SM564SDT-E OUTDOOR UNIT <SUPER DIGITAL INVERTER> RAV-SP404AT-E RAV-SP454AT-E RAV-SP404ATZ-E RAV-SP454ATZ-E RAV-SP404ATZG-E RAV-SP454ATZG-E RAV-SP564AT-E RAV-SP804AT-E RAV-SP564ATZ-E RAV-SP804ATZ-E RAV-SP564ATZG-E RAV-SP804ATZG-E R410A PRINTED IN JAPAN, Jan., 2009 ToMo...

  • Page 2: Table Of Contents

    Adoption of New Refrigerant This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer. WARNING Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have a service person do it.
  • Page 3 7. REFRIGERANT R410A ................33 7-1. Safety During Installation/Servicing ............... 33 7-2. Refrigerant Piping Installation ............... 33 7-3. Tools ........................37 7-4. Recharging of Refrigerant................37 7-5. Brazing of Pipes....................38 7-6. Instructions for Re-use Piping of R22 or R407C ..........40 8.

  • Page 4: Safety Caution

    SAFETY CAUTION The important contents concerned to the safety are described on the product itself and on this Service Manual. Please read this Service Manual after understanding the described items thoroughly in the following contents (Indications/Illustrated marks), and keep them. [Explanation of indications] Indication Explanation...
  • Page 5 WARNING Before troubleshooting or repair work, check the earth wire is connected to the earth terminals of the main unit, otherwise an electric shock is caused when a leak occurs. If the earth wire is not correctly connected, contact an electric engineer for rework. Check earth wires.
  • Page 6 WARNING After the work has finished, be sure to use an insulation tester set (500V Megger) to check the resistance is 2MΩ or more between the charge section and the non-charge metal section (Earth position). If the resistance value is low, a disaster such as a leak or electric shock is caused at user’s Insulator check side.
  • Page 7 • New Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer. 1. Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of refrigerant, the refrigerating oil has been also changed.
  • Page 8 4. Tools 1. Required Tools for R410A Mixing of different types of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types. 1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) 2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22) 3) Tools commonly used for R410A and for conventional refrigerant (R22) The table below shows the tools exclusive for R410A and their interchangeability.

  • Page 9: Specifications

    1. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Air Discharge Cassette Type <Single type> Indoor unit RAV-SM564UT-E RAV-SM804UT-E Model Outdoor unit RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Power supply 1 phase 230V (220 – 240V) 50Hz Running current 6.82 – 6.25 8.72 –...

  • Page 10: Concealed Duct Type

    1-1-2. Concealed Duct Type <Single type> Indoor unit RAV-SM562BT-E RAV-SM802BT-E Model Outdoor unit RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Power supply 1 phase 230V (220 – 240V) 50Hz Running current 7.24 – 6.63 10.36 – 9.49 Power consumption (kW) 1.56 2.21...

  • Page 11: Under Ceiling Type

    1-1-3. Under Ceiling Type <Single type> Indoor unit RAV-SM562CT-E RAV-SM802CT-E Model Outdoor unit RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Power supply 1 phase 230V (220 – 240V) 50Hz Running current 7.24 – 6.63 10.36 – 9.49 Power consumption (kW) 1.56 2.21...

  • Page 12: High Wall Type

    1-1-4. High Wall Type <Single type> Indoor unit RAV-SM562KRT-E RAV-SM802KRT-E Model Outdoor unit RAV-SP564AT(Z)(ZG)-E RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Power supply 1 phase 230V (220 – 240V) 50Hz Running current 7.24 – 6.63 11.25 – 10.31 Power consumption (kW) 1.56 2.40...
  • Page 13 1-1-5. Compact 4-Way Air Discharge Cassette Type (600 × 600) <Single type> Indoor unit RAV-SM 402MUT-E 452MUT-E 562MUT-E Model Outdoor unit RAV-SP 404AT(Z)(ZG)-E 454AT(Z)(ZG)-E 564AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Power supply 1 phase 230V (220 – 240V) 50Hz Running current 5.05 –...
  • Page 14 <Twin type> Indoor unit 1 RAV-SM402MUT-E Model Indoor unit 2 RAV-SM402MUT-E Outdoor unit RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current 10.36 – 9.49 Power consumption (kW) 2.21 Cooling Power factor 3.21...
  • Page 15 1-1-6. Slim Duct Type <Single type> Indoor unit RAV-SM 404SDT-E 454SDT-E 564SDT-E Model Outdoor unit RAV-SP 404AT(Z)(ZG)-E 454AT(Z)(ZG)-E 564AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Power supply 1 phase 230V (220 – 240V) 50Hz Running current 5.20 – 4.77 5.87 – 5.38 7.24 –...
  • Page 16 <Twin type> Indoor unit 1 RAV-SM404SDT-E Model Indoor unit 2 RAV-SM404SDT-E Outdoor unit RAV-SP804AT(Z)(ZG)-E Cooling capacity (kW) Heating capacity (kW) Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current 10.36 – 9.49 Power consumption (kW) 2.21...

  • Page 17: Outdoor Unit

    1-2. Outdoor Unit <Super Digital Inverter> Model name Outdoor unit RAV-SP 404AT(Z)(ZG)-E 454AT(Z)(ZG)-E 564AT(Z)(ZG)-E 804AT(Z)(ZG)-E 1 phase 230V (220 – 240V) 50Hz Power supply (Power exclusive to outdoor is required.) Type Hermetic compressor Compressor Motor (kW) Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Standard length...

  • Page 18: Operation Characteristic Curve

    1-3. Operation Characteristic Curve • Operation characteristic curve <Super Digital Inverter> RAV-SP564AT-E, RAV-SP564ATZ-E, RAV-SP564ATZG-E <Cooling> <Heating> RAV-SM562BT, CT, KRT, MUT-E, RAV-SM562BT, CT, KRT, MUT-E, RAV-SM562BT, CT, KRT, MUT-E, RAV-SM562BT, CT, KRT, MUT-E, RAV-SM564SDT-E RAV-SM564SDT-E RAV-SM564SDT-E RAV-SM564SDT-E RAV-SM564UT-E RAV-SM564UT-E RAV-SM564UT-E RAV-SM564UT-E •...
  • Page 19 RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E <Cooling> <Heating> SP45 SP45 SP45 SP45 SP40 SP40 SP40 SP40 • Conditions • Conditions Indoor : DB27˚C/WB19˚C Indoor : DB20˚C Outdoor : DB35˚C Outdoor : DB7˚C/WB6˚C Air flow : High Air flow : High Pipe length : 7.5m Pipe length : 7.5m 230V...

  • Page 20: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Indoor Unit RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E 803 (inside) Refrigerant piping Air filter Fresh air inlet Drain-up port (knock-out hole) Hung-up plate – 20 –...

  • Page 21: Outdoor Unit

    2-2. Outdoor Unit RAV-SP404AT(Z)(ZG)-E, RAV-SP454AT(Z)(ZG)-E, RAV-SP564AT(Z)(ZG)-E Drain hole Drain hole (Ø25) (2-Ø20 × 88 long hole) 2-Ø11-14 U-shape hole A legs (For Ø8-Ø10 anchor bolts) Connecting pipe port (Gas flare side: Ø12.7) Connecting pipe port (Liquid flare side: Ø6.4) 8-Ø6 hole (For fixing outdoor unit) B legs 2-Ø11 ×...
  • Page 22 Name Note Drain hole (Ø25 burring hole) Refrigerant piping hole —— Indoor/Outdoor unit B legs Air inlet connecting wire inlet hole port Power supply inlet hole Ø38 Kockout hole Air inlet port Mounting bolt hole (Ø12 × 17 long hole) Air outlet port Mounting bolt hole...
  • Page 23 RAV-TWP30E2, RAV-TWP50E2 (Simultaneous Twin) Inner diameter Ø C Inner Inner diameter Ø D diameter Ø D Model (RBC-) Liquid side Ø9.5 Ø6.4 TWP30E2 Gas side Ø15.9 Ø12.7 Liquid side Ø9.5 Ø9.5 TWP50E2 Gas side Ø15.9 Ø15.9 – 23 –...

  • Page 24: Systematic Refrigerating Cycle Diagram

    3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3-1. Indoor Unit • Single type (Combination of 1 indoor unit and 1 outdoor unit) (Indoor unit) Distributor (Strainer incorporated) TCJ sensor Strainer Air heat exchanger TC sensor Heating Cooling Refrigerant pipe Refrigerant pipe at liquid side at gas side (Outer dia : ØB) (Outer dia : ØA)

  • Page 25: Outdoor Unit

    3-2. Outdoor Unit RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E Packed valve Packed valve Outer dia. ØA Outer dia. ØB TS sensor (Pulse Motor Valve) (CAM-B30YGTF-2) TO sensor 2-step muffler Ø19.05 × 200L TD sensor Strainer 4-way valve (STF-0108Z) sensor Heat exchanger Muffler Ø8 ripple, 2 rows, Ø19 ×...
  • Page 26 RAV-SP564AT-E, RAV-SP564ATZ-E, RAV-SP564ATZG-E TO sensor (Pulse Motor Valve) (CAM-B30YGTF-2) sensor sensor TE sensor Muffler 4-way valve Ø31.75 × 200L (STF-0213Z) Muffler Heat exchanger Ø19.05 × 160L Ø8 ripple, 2 rows, 20 stages FP1.3, flat fin Strainer Distributor Accumulator Refrigerant pipe (1L) at liquid side Ø6.4 Rotary compressor...
  • Page 27 RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E TS sensor TO sensor TL sensor (Pulse Motor Valve) (CAM-B30YGTF-2) Ø2 × Ø3 × 600L sensor Ø2 × Ø3 × 550L Accumulator Strainer Sub-ass’y Ø2 × Ø3 × 450L TE sensor 4-way valve (STF-0218G) Ø2 × Ø3 ×...

  • Page 28: Fan Characteristics

    4. FAN CHARACTERISTICS 4-1. Slim Duct (Filter Attached) RAV-SM404SDT-E, RAV-SM454SDT-E Standard air volume : 690m³/h High (50Pa) Upper limit of external static pressure(50Pa) High Lower limit of (35Pa) external static Upper limit of pressure (50Pa) external static pressure(35Pa) Lower limit of...

  • Page 29: Wiring Diagram

    5. WIRING DIAGRAM 5-1. Indoor Unit 5-1-1. Slim Duct Type RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E CN333 (WHI) 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 CN510 CN504 CN34 (WHI)

  • Page 30: Outdoor Unit

    CN500 Compressor CN300 Q200~205 Q300~305 P.C. Board IGBT MOS-FET (MCC-5009) R221 R321 Fan motor R220 R320 CN700 R219 R319 Pulse motor valve CAUTION : HIGH VOLTAGE Varistor Fuse T3.15A The high voltage circuit is AC250V incorporated. DB01 CN603 Be careful to do the check service, as the electric shock may be Surge (Suction pipe...
  • Page 31 RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E <MCC-1571> Reactor Reactor (RED) (WHI) (BLK) (GRY) (GRY) (WHI) (WHI) P04 P05 P06 P07 CN200 CN201 CN202 CN300 (WHI) SW804 SW801 SW800 CN609 (BLU) CN610 (YEL) Control P.C. Board MCC-1571 SW803 CN604 (WHI) CN603 (WHI) Fuse, F01 T25A, 250V~ CN602 (BLK)

  • Page 32: Specifications Of Electrical Parts

    6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E Parts name Type Specifications Fan motor SWF-280-60-3 — Drain pump motor MDP-1401 — Float switch FS-0218-102 — TA sensor Lead wire length : 328mm 10 kΩ at 25°C TC sensor Ø6 size lead wire length : 1200 mm Vinyl tube (Black)

  • Page 33: Refrigerant R410A

    7. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC 6. When an air conditioning system charged with a (R410A) which does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, The working pressure of the new refrigerant R410A even when refrigerant leaks, its concentration is 1.6 times higher than conventional refrigerant...
  • Page 34 Table 7-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 1. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm.
  • Page 35 c) Insertion of Flare Nut d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool. ØD Flare processing dimensions differ according to the type of flare tool.
  • Page 36 Fig. 7-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench.

  • Page 37: Tools

    7-3. Tools 7-3-1. Required Tools Refer to the “4. Tools” (Page 8) 7-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment.

  • Page 38: Brazing Of Pipes

    1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.
  • Page 39 2. Characteristics required for flux 7-5-3. Brazing • Activated temperature of flux coincides with As brazing work requires sophisticated techniques, the brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is hard to carbonize.

  • Page 40: Instructions For Re-Use Piping Of R22 Or R407C

    Operation System • In the concurrent twin system, when TOSHIBA- ∗ Pipe diameter and thickness (mm) specified branching pipe is used, it can be reused.

  • Page 41: Final Installation Checks

    7-6-5. Final Installation Checks Is there no scratch or dent on the existing pipes? Existing pipe: NO * Use a new pipes. Is it possible to operate the existing air conditioner? ∗ After the existing air conditioner operated in cooling mode for approx.
  • Page 42 7-6-6. Handling of Existing Pipe RAV-SP804AT-E • To use an existing Ø19.1 mm pipe, set bit 3 of When using the existing pipe, carefully check it for SW802 (switch for existing pipe) on the P.C. board the following: of the outdoor unit to ON. •...

  • Page 43: Indoor Control Circuit (Slim Duct Type)

    8. INDOOR CONTROL CIRCUIT (Slim Duct Type) 8-1. Indoor Controller Block Diagram 8-1-1. Connection of Wired Remote Controller Wired remote controller (Max. 2 units) Weekly timer Display LCD Function setup Display LCD LCD driver Display LED Key switch Function setup Key switch DC5V Remote controller...
  • Page 44 8-1-2. Connection of Wireless Remote Controller Kit Indoor unit #1 (Master) Wireless remote controller kit Receiver P.C. board (MCC-1504) Display LED Receive circuit Function setup SW Grille up/down SW Buzzer DC5V Power Remote controller Temporary circuit communication circuit operation SW (Follower) (Follower) Indoor control P.C.
  • Page 45 8-1-3. Connection of Both Wired Remote Controller and Wireless Remote Controller Kit Indoor unit #1 (Master) Master wired remote controller Wireless remote controller kit (Max. 2 units) Weekly timer Receiver P.C. board Display LED Display Function Display (MCC-1504) setup driver Receive Function setup SW Display...

  • Page 46: Indoor Controls (Slim Duct Type)

    8-2. Indoor Controls (Slim Duct Type) Item Outline of specifications Remarks When power 1) Distinction of outdoor unit supply is reset When the power supply is reset, the outdoors are distin- guished and the control is selected according to the distinguished result.
  • Page 47 Item Outline of specifications Remarks Room temp. 2) Using the Item code 06, the setup temperature in heating Shift of suction control operation can be corrected. temperature in heating (Continued) operation Setup data Setup temp. correction +0°C +2°C +4°C +6°C Setting at shipment Setup data Automatic...
  • Page 48 Item Outline of specifications Remarks Air speed selection 1) Operation with (HH), (H), (L) or [AUTO] mode is carried HH > H+ > H > L+ > out by the command from the remote controller. L > UL 2) When the air speed mode [AUTO] is selected, the air speed varies by the difference between Ta and Ts.
  • Page 49 Item Outline of specifications Remarks Air speed Slim Duct Type selection Selection of high static Standard Type 1 Type 3 Type 6 Item code (Continued): pressure type [5d] In case of Item code: Slim Duct Type SW501 (1)/(2) OFF/OFF ON/OFF OFF/ON ON/ON [5d] or selection of high...
  • Page 50 Item Outline of specifications Remarks Cool air discharge 1) In heating operation, the indoor fan is controlled In D and E zones, the preventive control based on the detected temperature of Tc sensor or priority is given to air Tcj sensor. As shown below, the upper limit of the volume selection setup revolution frequency is restricted.
  • Page 51 Item Outline of specifications Remarks High-temp. 1) The heating operation is performed as follows based on the release control detected temperature of Tc sensor or Tcj sensor. • When [M] zone is detected, the commanded frequency is However this control is decreased from the real operation frequency.
  • Page 52 Item Outline of specifications Remarks HA control 1) This control is connected to TV control or remote start/ In the group stop I/F, etc, and start/stop are available by HA signal operation, use this input from the remote position. control by connecting to either 2) This control outputs start/stop status to HA output master or follower...
  • Page 53 Item Outline of specifications Remarks Central control mode 1) Setting at the centerl controller side enables to select the selection contents which can be operated on the remote controller at indoor unit side. 2) Setup contents • 64 line central controller (TCB-SC642TLE2) Display at remote [Individual]: Operated on the remote controller controller side...
  • Page 54 Item Outline of specifications Remarks DC motor 1) When the fan operation has started, positioning of the stator and the rotor are performed. (Moves slightly with tap sound) 2) The motor operates according to the command from the indoor controller. Notes) •...

  • Page 55: Optional Connector Specifications Of Indoor P.c. Board

    Function Connector No. Pin No. Specifications Remarks Humidifier output is ON when heating operation is performed, when thermostat is on, when the fan is on. DC12V ∗ The setting of Humidifier provided + Drain pump ON is performed by short-circuit of CN70 or from the Humidifier output (∗) CN66 Output (Open collector)

  • Page 56: Indoor Print Circuit Board

    Serial send LED Sub bus communication LED Micro computer operation LED D15 (Green) D504 (Green) D501 (Red) Optional power supply Serial receive LED DC fan return HA (T10) High ceiling select switch CN309 (Yellow), AC230V D14 (Orange) CN334 (White) CN61 (Yellow), DC12V SW501 DC fan output Remote controller...

  • Page 57: Outdoor Control Circuit

    9. OUTDOOR CONTROL CIRCUIT 9-1. Outdoor Controls <In case of RAV-SP56 and SP80 models> 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between (SP56: 20 to 500, SP80: 30 to 500) pulsed during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming (SP56: 2 to 5K, SP80: 1 to 4K) as the target value.

  • Page 58: Outdoor Fan Control

    3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] SP56 SP80 3-1) Cooling fan control <SP56> <SP80>   The outdoor fan is controlled by TE sensor, TO The outdoor fan is controlled by TL sensor, TO sensor and the operation frequency. It is controlled sensor and the operation frequency.
  • Page 59 3-2) Heating fan control  The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (Control from minimum W1 to maximum (according to the following table)) ‚ For 3 minutes after the operation has started, the maximum fan tap corresponding to the zone in the following table is fixed and then the fan is controlled by temperature of TE sensor.

  • Page 60: Current Release Control

    <SP56> • Power-ON condition TD < 30˚C TE [˚C] (Normal time) No power REQUIREMENT –1 Continuous power-ON In some cases, the sound of power-ON may be –6 Output [10W or equivalent] heard. It is not abnormal. –7 Continuous power-ON Output [20W or equivalent] <SP80>...
  • Page 61 7. Current release value shift control 1) This control purposes to prevent troubles of Current release control value (11) the electronic parts such as the compressor driving elements and the compressor during cooling operation. Temperature range SP56 SP80 50°C ≤ TO 2) The current release control value (11) is 7.80 selected from the following table according to...

  • Page 62: Defrost Control

    10. Defrost control <SP56 only> 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 12°C or continued 5°C £ TE < 12°C for 80 seconds.
  • Page 63 <SP80 only> 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 12°C or higher for 3 seconds or continued 7°C ≤...
  • Page 64 <In case of RAV-SP40 and SP45 models> 1. Pulse Motor Valve (PMV) control 1) For PMV with 50 to 500 pulses during operation, respectively. 2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor. 3) In heating operation, PMV is controlled with the temperature difference between TS sensor and TE sensor.
  • Page 65 4. Outdoor fan control Allocations of fan tap revolutions [rpm] SP40, SP45 1) Cooling fan control  The outdoor fan is controlled by TE, TD, and TO sensors and also revolution frequency of the operation. The outdoor is controlled by every 1 tap of DC fan control (15 taps). ‚...
  • Page 66 2) Heating fan control  The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (From Min. W1 to Max. are controlled according to the following table.) ‚ During 3 minutes after start-up, the fan is fixed with the maximum fan tap corresponding to zone in the following table.
  • Page 67 6. Defrost control  In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition in A zone to C zone. ‚ The defrost operation is immediately finished if TE sensor temperature has become 12°C or more, or it also is finished when condition of 5°C <...

  • Page 68: Outdoor Print Circuit Board

    F01, 02, 25A fuse Lead wire for grounding DB02: (Black) High power factor diode Q404: High power factor circuit IGBT C12, 13, 14 C12, 13, 14 electrolytic capacitor electrolytic capacitor F03: 3.15A fuse F03: 3.15A fuse DB01: DB01: Single-phase rectifier diode Single-phase rectifier diode L-phase power supply lead (Black)
  • Page 69 RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E <MCC-1571> Fan motor output Compressor output terminals CN300 (White) CN202 CN201 CN200 Power circuit protective fuse 4-way valve connector F100 (250V, 3.15A plastic case) CN701 (White) Electrolytic capacitors Case thermo connector CN609 (Blue) Compressor ON output connector CN704 (Blue) Heater output connector CN703 (Gray)

  • Page 70: Troubleshooting

    10. TROUBLESHOOTING 10-1. Summary of Troubleshooting <Wired remote controller type> 1. Before troubleshooting 1) Required tools/instruments – • screwdrivers, spanners, radio cutting pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal.
  • Page 71 <Wireless remote controller type> 1. Before troubleshooting 1) Required tools/instruments – • screwdrivers, spanners, radio cutting pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1. Compressor does not operate. •...

  • Page 72: Troubleshooting

    10-2. Troubleshooting 10-2-1. Outline of judgment The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method. Method to judge the erroneous position by flashing indication on the display part of the indoor unit (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
  • Page 73 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready  Heat exchanger sensor (TCJ) error   Heat exchanger sensor (TC) error Indoor unit sensor error  Heat exchanger sensor (TA) error  Alternate flash Discharge temp. sensor (TD) error ...
  • Page 74 10-2-2. Others (Other than Check Code) Lamp indication Check code Cause of trouble occurrence Operation Timer Ready — During test run Simultaneous flash Operation Timer Ready Disagreement of cool/heat — (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model) Alternate flash –...
  • Page 75 10-2-3. Check Code List (Indoor) ¡ ¥ : Go on, : Flash, : Go off ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED (Indoor unit detected) Check code indication Sensor lamp indication Air conditioner operation Block indication...
  • Page 76 Check Code List (Outdoor) ¡ ¥ : Go on, : Flash, : Go off ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED Sensor lamp part Remote Automatic Operation controller Block indication Representative defective position...
  • Page 77 ¡ ¥ : Go on, : Flash, : Go off ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED Sensor lamp part Remote Automatic Operation controller Block indication Representative defective position Detection Explanation of error contents reset...

  • Page 78: Error Mode Detected By Indoor Unit

    Error mode detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of Cause of operation Condition code air conditioner 1. Check cables of remote controller and communication adapters. No communication from remote Stop Displayed when controller (including wireless) and •...

  • Page 79: Error Mode Detected By Remote Controller Or Central Controller (Tcc-Link)

    Error mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner Power supply error of remote controller, Indoor EEPROM error 1. Check remote controller inter-unit wiring. No communication with master indoor unit 2.

  • Page 80: Error Mode Detected By Outdoor Unit

    Error mode detected by outdoor unit The check code has been ramified from “4 series” and after. The ramified check code is displayed only when both the indoor unit and the outdoor unit are “4 series” and after. (Ex. Combination of RAV-SM804UT-E with RAV-SP804AT-E) When the indoor unit is 3 series and before, the conventional check code is displayed.
  • Page 81 Operation of diagnostic function Check code Judgment and measures Indoor unit Status of Cause of operation Condition air conditioner before after 3 series 4 series 1. Check refrigerating cycle (Gas leak) Discharge temp. error Displayed when ∗ Discharge temp. (TD) detected Stop 2.
  • Page 82 10-2-4. Diagnostic Procedure for Each Check Code (Indoor Unit) Check code [E01 error] Correct inter-unit cable Is inter-unit cable of A and B normal? of remote controller Is there no disconnection or Correct connection of connector. contact error of connector on harness Check circuit wiring.
  • Page 83 [E04 error] Is group address setup of Does outdoor operate? Check Item code [14]. remote controller correct? Are wiring in indoor unit and Correct wiring and 1, 2, 3 inter-unit cables correct? inter-unit cables. Correct wiring of connector Are wirings of terminal blocks and terminal blocks.
  • Page 84 [E18 error] Is inter-unit cable Correct inter-unit cable of A and B normal? of remote controller. Is there no disconnection or contact error of connector Correct connection of connector. on harness from terminal block Check circuit wiring. of indoor unit? Is group control operation? Check power connection status of indoor unit...
  • Page 85 [L20 error] Are wiring connections to communication lines Correct wiring connection. U3 and U4 normal? Is not the multiple same central Correct central control system address. control system addresses connected? Check central controller (including network adapter) and indoor P.C. board (MCC-1570). Defect →...
  • Page 86 [P10 error] Is connection of float switch connector Correct connection (Indoor control board CN34) of connector. normal? Does float switch work? Is circuit wiring normal? Check and correct wiring and wire circuit. Does drain pump work? Are connector pins 1 and 2 Is power of at drain pump unit side shorted drain pump turned on? ∗...
  • Page 87 [P12 error] Turn off the power. Is there no connection error or disconnection on connectors CN333 Correct connection and CN334 of indoor unit P.C. board of connector. (MCC-1570)? CN333 Remove connectors CN333 and CN334 of indoor unit P.C. board (MCC-1570). CN334 Does the fan rotate without trouble Replace indoor fan motor.
  • Page 88 [F02 error] Is connection of TC sensor connector Correct connection of connector. (CN101 on Indoor P.C. board) correct? Are characteristics of Replace TC sensor. TC sensor resistance value normal? ∗ Refer to Characteristics-2. Check indoor P.C. board (MCC-1570). Defect → Replace [F01 error] Is connection of TCJ sensor connector Correct connection of connector.
  • Page 89 [C06 error] (TCC-LINK central controller) Are U3 and U4 communication lines normal? Correct communication line. ∗1 Correct connection of connector. Is connection of connector normal? ∗1 TCC-LINK central: CN51 of TCC-LINK adapter P.C. board (MCC-1440) and CN050 of indoor P.C. board Check connection of A and B terminal blocks.
  • Page 90 [E03 error] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receive a signal from the remote controller (also central controller). Check A and B remote controllers and communication lines of the central control system U3 and U4. As communication is impossible, this check code [E03] is not displayed on the remote controller and the central controller.
  • Page 91 <In case of SP40 to 56> 10-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) When “APPLICATION CONTROL KIT” (TCB-PCOS1E2) sold separately is connected, the error contents can be judged by LED on the APPLICATION CONTROL KIT.
  • Page 92 <In case of SP40 to 56> Check APPLICATION CONTROL KIT Check / Countermeasures code LED display (Part without special mention indicates a part of the outdoor unit.) [F08] [Outside temp. sensor (TO) error] (Red) (Yellow) (Yellow) (Yellow) ¡ Is connection of CN602 correct? Correct connector.
  • Page 93 <In case of SP40 to 56> Check APPLICATION CONTROL KIT Check / Countermeasures code LED display (Part without special mention indicates a part of the outdoor unit.) [H03] [Power supply error, Current detection circuit error] (Red) (Yellow) (Yellow) (Yellow) ¥ ¥...
  • Page 94 <In case of SP40 to 56> Check APPLICATION CONTROL KIT Check / Countermeasures code LED display (Part without special mention indicates a part of the outdoor unit.) [P19] — [4-way reversal error] Does 4-way valve work correctly? (Check pipe temperature, etc. during cooling/heating operation.) Is coil of 4-way valve electrified during heating mode?
  • Page 95 <In case of SP80> 10-2-6. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C.
  • Page 96 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] <Display 1> <Display 2> [Discharge temp. sensor (TD) error] ¡ ¡ Is connection of CN603 correct? Correct connector. ¥...
  • Page 97 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F08] <Display 1> <Display 2> [Outside temp. sensor (TO) error] ¡ ¡ Is connection of CN602 correct? Correct connector. Sensor error →...
  • Page 98 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H01] <Display 1> <Display 2> [Compressor break down] ¥ Is AC mains voltage correct? ¡ Correct power supply line. AC198 to 264V ¡...
  • Page 99 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H04] <Display 1> <Display 2> [Case thermostat operation] ¥ ¡ Are CN609 connection and Correct connector. Case thermostat error → Replace case thermostat correct? ¡...
  • Page 100 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) ∗ There is a possibility that it is one of the following errors. [L29] Confirm LED on outdoor P .C. board to judge which error it is. Communication error between MCU, Heat sing temp.
  • Page 101 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P03] <Display 1> <Display 2> [Discharge temp. error] ¥ ¡ ¥ ¡ ¡ Repair defective position. Is there gas leak? Is there refrigerant shortage? Recharge refrigerant.
  • Page 102 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P07] <Display 1> <Display 2> [Heat sink overheat error] ¥ ¡ ¥ ¡ Are the power devices on ¥ ¡...
  • Page 103 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P19] <Display 1> <Display 2> [4-way valve reversal error] ¥ ¡ ¥ ¡ ¡ Temperature sensor check Does 4-way valve TE sensor CN601 work correctly? TS sensor CN600...
  • Page 104 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] <Display 1> <Display 2> [High pressure protective operation] ¡ ¡ Is service valve ¥ ¡ Open service valve fully. fully opened? ¥...
  • Page 105 <In case of SP80> Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] <Display 1> <Display 2> [Fan system error] ¡ ¥ ¡ Is AC mains voltage correct? Check wiring construction. ¥...

  • Page 106: Temperature Sensor

    10-2-7. Diagnostic Procedure for Each Check Code (Outdoor Unit) Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (kΩ Ω Ω Ω Ω ) Resistance value (kΩ Ω Ω Ω Ω ) Temperature Temperature (°C)

  • Page 107: Replacement Of Service P.c. Board

    11. REPLACEMENT OF SERVICE P.C. BOARD 11-1. Indoort Unit (Slim Duct Type) <Note: when replacing the P.C. board for indoor unit servicing> The nonvolatile memory (hereafter called EEPROM, IC503) on the indoor unit P .C. board before replacement includes the model specific type information and capacity codes as the factory-set value and the important setting data which have been automatically or manually set when the indoor unit is installed, such as system/ indoor/group addresses, high ceiling select setting, etc.
  • Page 108 [1] Setting data read out from EEPROM The setting data modified on the site, other than factory-set value, stored in the EEPROM shall be read out. TEST Step 1 Push button on the remote controller simultaneously for more than 4 seconds. ∗...
  • Page 109 [3] Writing the setting data to EEPROM The settings stored in the EEPROM of the P .C. board for indoor unit servicing are the factory-set values. TEST Step 1 Push buttons on the remote controller simultaneously for more than 4 seconds. ∗...
  • Page 110 Step 4 Write the on-site setting data to the EEPROM, such as address setting, etc. Perform the steps 1 and 2 above again. Step 5 Change the CODE No. (DN) to “ ” by pushing buttons for the temperature setting. (this is the setting for the filter sign lighting time.) Step 6 Check the setting data displayed at this time with the setting data put down in [1].
  • Page 111 Table 1. Setting data (CODE No. table (example)) Item Setting data Factory-set value Filter sign lighting time Depending on Type Filter pollution leve 0000: standard Central control address 0099: Not determined 0002: +2°C Heating suction temperature shift (flooring installation type: 0) Cooling only 0000: Heat pump Type...

  • Page 112: Setup At Local Site And Others

    12. SETUP AT LOCAL SITE AND OTHERS 12-1. Indoor Unit (Slim Duct Type) 12-1-1. Test Run Setup on Remote Controller <Wired remote controller> TEST 1. When pushing button on the remote controller for 4 seconds or more, “TEST” is displayed on LC display. ON / OFF Then push button.
  • Page 113 12-1-3. LED Display on P.C. Board 1. D501 (Red) • It goes on (Goes on by operation of the main microcomputer) at the same time when the power supply is turned on. • It flashes with 1-second interval (every 0.5 second): When there is no EEPROM or writing-in operation fails. •...
  • Page 114 Function selection item No. (DN) list Item Contents At shipment from factory 0000: None 0001: 150H Filter sign lighting time 0002: 2500H 0003: 5000H According to type 0004: 10000H 0005: Clogging sensor used 0000: Standard Filter stain level 0000: Standard 0001: Heavy stain (Half of standard time) 0001: No.1 unit 0064: No.64 unit...
  • Page 115 12-1-5. Wiring and Setting of Remote Controller Control 2-remote controller control <Wired remote controller> (Controlled by 2 remote controllers) How to set wired remote controller This control is to operate 1 or multiple indoor units as sub remote controller are operated by 2 remote controllers. Change DIP switch inside of the rear side of the (Max.
  • Page 116 12-1-6. Monitor Function of Remote Controller Switch n Calling of sensor temperature display <Contents> Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. <Procedure> TEST Push buttons simultaneously for 4 seconds to call the service monitor mode.

  • Page 117: Calling Of Error History

    n Calling of error history <Contents> The error contents in the past can be called. <Procedure> TEST Push buttons simultaneously for 4 seconds or more to call the service check mode. TEMP. ON / OFF Service Check goes on, the item code 01 is displayed, and TIMER SET MODE then the content of the latest alarm is displayed.
  • Page 118 n Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way <By feed unit> <Automatic address judgment> Not normal Gr construction check 3 minutes elapse Normal...

  • Page 119: Setup At Local Site / Others

    12-2. Setup at Local Site / Others Model name: TCB-PCNT30TLE2 12-2-1. TCC-LINK Adapter (For TCC-LINK Central Control) 1. Function This model is an optional P .C. board to connect the indoor unit to TCC-LINK (Central controller). 2. Microprocessor block diagram Indoor unit Central controller TCC-LINK adapter P.C.

  • Page 120: Wiring Specifications

    4. Wiring specifications No. of wires Size • Use 2-core with no polar wire. Up to 1000m: twisted wire 1.25mm • Match the length of wire to wire length of the central Up to 2000m: twisted wire 2.0mm control system. If mixed in the system, the wire length is lengthened with all indoor/outdoor inter-unit wire length at side.

  • Page 121: How To Set Up Central Control Address Number

    6. External view of P.C. board assembly Terminator (SW01) 7. Address setup In addition to set up the central control address, it is necessary to change the indoor unit number. (Line/Indoor/Group address). For details, refer to TCC-LINK Adapter Installation Manual. 12-3.
  • Page 122 2. How to confirm the central control address (New function for AMT32E remote controller) <Procedure> It can be confirmed even during operation or stopping. UNIT LOUVER Push button for 4 seconds or more. ò In the frame at left side of the remote controller screen, the lighting set contents are displayed.
  • Page 123 4. When installing separately sold filters REQUIREMENT • When you use this air conditioner for the first time, it takes approx. 5 minutes until the remote controller becomes available after power-on. This is normal. <When power is turned on for the first time after installation> Approx.
  • Page 124 n Setup of external static pressure When wireless remote controller is used Change the external static pressure setting with the Be sure to set up a tap change based upon the DIP switch on the receiver section P .C. board. resistance (external static pressure) of the duct to be connected.
  • Page 125 n Change of lighting time of filter sign n How to set up power saving mode SAVE According to the installation condition, the lighting 1. Push button for at least four seconds time of the filter sign (Notification of filter clean- when the air conditioner is not working.

  • Page 126: Outdoor Unit

    12-4. Outdoor Unit 12-4-1. Refrigerant Recovery Control The “ozone destruction coefficient” of HFC refrigerant is 0 and the discharge regulation is set as anathermal effect gas. To this model, a switch which can perform the refrigerant recovery (pump down) by the outdoor unit is mounted so that it is easy to react against the environment at reinstalling or rejection time.
  • Page 127 12-4-2. Various Setting on Outdoor Unit (Existing piping, Power save, Cooling-only, etc.) The following settings are available by DIP switch setup and jumper line setup. <SP56> Function Setting position Control contents Existing piping SW801 Turn off the switches. (Ø19.1 existing pipes cannot be used.) setup When using the power saving function, turn on switches.
  • Page 128 12-4-3. Service Support Function (LED Display, Switch Operation) <SP80 only> 1. Outline A various setup and operation check can be performed by DIP switches at 3 positions (SW802, SW803, SW804) and the pushdown button switches (SW800, SW801) at 2 positions. Operation part Part No.
  • Page 129 2. Selection of LED display (SW800, SW803 operation) 1) Display selection list The displayed contents of LED D800 to D804 on the outdoor control P .C. board can be exchanged by operation of SW803. Switch Function / Contents Refer Error display (Error generating at present) Refer to SW803 Page 130.
  • Page 130 2) Error display The error which is generating at present and the latest error (Latest error information including present) can be confirmed by lighting LED D800 toD804 on the outdoor control P .C. board. a) When all DIP switch SW803 are OFF, the status of error which is generating at present is displayed. b) <1>...
  • Page 131 3) Sensor, current, compressor operation frequency, PMV opening display The values detected by the controller, such as temperature sensor or current value are simply confirmed. (Legend) D800 (Yellow) D803 (Yellow) ¡ : Go off, : Go on D801 (Yellow) D804 (Yellow) ¡...
  • Page 132 4) Specific operation for maintenance check (SW801, SW804) The following specific operations for the maintenance check are performed by operation of SW801 or SW804. a) Select DIP switch SW804. (See table below) b) Push the pushdown button switch SW801 for approx. 1 second. c) The following functions start.
  • Page 133 SW804 Operation when pushdown button switch SW801 is pushed 4-way valve relay operation (For RY700, CN70 check) Turn on 4-way valve power relay (RY700). SW804 When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control. [NOTE] In case of model adopting the self hold valve (RAV-SP1104AT-E, RAV-SP1404AT-E), the coil develops fever.

  • Page 134: Address Setup

    13. ADDRESS SETUP 13-1. Address Setup Procedure When an outdoor unit and an indoor unit are connected, or when an outdoor unit is connected to each indoor unit respectively in the group operation even if multiple refrigerant lines are provided, the automatic address setup completes with power-ON of the outdoor unit.

  • Page 135: Address Setup & Group Control

    13-2. Address Setup & Group Control <Terminology> Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/from the remote controllers and sub indoor units.
  • Page 136 13-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single (Master/Sub) Individual 2) Group operation (Twin, Triple operation) (Multiple outdoor units = Miltiple indoor units only with serial communication) Sub/Header Sub/Header Sub/Follower Master/Header Sub/Follower Sub/Follower Only turning on source power supply (Automatic completion) •...
  • Page 137 13-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple (1-1) (1-2) (1-1) (1-2) (1-3) Individual Master/Header Sub/Follower Sub/Header Master/Follower Sub/Follower (Master/Header) Only turning on source power supply (Automatic completion) 2.

  • Page 138: Remote Controller Wiring

    13-3. Remote Controller Wiring • Strip off approx. 9 mm the wire to be connected. • For single system, use non polarity, 2 core wire is used for wiring of the remote controller. (0.5 mm² to 2.0 mm² wires) • For the synchronous twin, triple system, use 2-core shield wire (Vinyl cord for microphone 0.5 to 2.0 mm²) to conform to the EMC standard.

  • Page 139: Address Setup (Manual Setting From Remote Controller)

    13-4. Address Setup (Manual setting from remote controller) In case that addresses of the indoor units will be (Example of 2-lines cabling) determined prior to piping work after cabling work (Real line: Cabling, Broken line: Refrigerant pipe) • Set an indoor unit per a remote controller. Outdoor Outdoor 1 2 3...

  • Page 140: Confirmation Of Indoor Unit No. Position

    13-5. Confirmation of Indoor Unit No. Position 1. To know the indoor unit addresses though position of the indoor unit body is recognized • In case of individual operation (Wired remote controller : indoor unit = 1 : 1) (Follow to the procedure during operation) <Procedure>...
  • Page 141 <Maintenance/Check list> Aiming in environmental preservation, it is strictly recommended to clean and maintain the indoor/outdoor units of the operating air conditioning system regularly to secure effective operation of the air conditioner. It is also recommended to maintain the units once a year regularly when operating the air conditioner for a long time.

  • Page 142: Detachments

    14. DETACHMENTS 14-1. Indoor Unit 14-1-1. Slim Duct Type RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E Part name Procedure Remarks REQUIREMENT Be sure to put on gloves at working; otherwise an injury may be caused by parts, etc. • Before replacement of the parts, be sure to stop operation of the air conditioner and turn off switch of the breaker.
  • Page 143 Part name Procedure Remarks 1. Detachment E-cover 1) Perform work 1. of 2 . 2) Take off screws fixing E-cover, and then remove hooks of the hooking part by lifting up. (Ø4 × 10, 2 pcs) 2. Attachment 1) Hang on E-cover to hooks of the hooking part E-cover E-cover E-cover...
  • Page 144 Part name Procedure Remarks 1. Detachment P .C. board assembly P.C. board assembly 1) Perform works 1. of 2 , 1. of 3 , and 1. of 4 . 2) Disconnect connectors which are connected from P.C. board assembly to other parts. NOTE) Unlock the lock of the housing to disconnect the connectors.
  • Page 145 Part name Procedure Remarks 1. Detachment Fan motor 1) Perform works 1. of 2 , 1. of 3 , and 1. of 6 . 2) Remove lead wires which are connected to the following connectors of P .C. board assembly. NOTE) Unlock locks of the housing, and then remove the connectors.
  • Page 146 Part name Procedure Remarks 1. Detachment Drain pump, Float switch, 1) Perform works in procedures 1. of 2 , 1. of 3 , Drain hose Drain hose 1. of 8 . Hose band 2) Disconnect lead wires which are connected to Drain pump the following connectors of P .C.

  • Page 147: Outdoor Unit

    14-2. Outdoor Unit 14-2-1. RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E Part name Procedure Remarks Common procedure CAUTION Valve cover Never forget to put on the gloves at working time, otherwise an injury will be caused by the parts, etc. 1. Detachment 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner.
  • Page 148 Part name Procedure Remarks 1. Detachment Front cabinet Motor support 1) Perform work of item 1 of 2) Remove screws (ST1T Ø4 × 8L, 2 pcs.) of the front cabinet and the inverter cover. 3) Take off screws of the front cabinet and the bottom plate.
  • Page 149 Part name Procedure Remarks 1. Detachment Inverter Screws assembly 1) Perform work of item 1 of 2) Take off screws of the upper part of the front cabinet. • If removing the inverter cover under this Front cabinet condition, P .C. board can be checked. •...
  • Page 150 Part name Procedure Remarks Control P .C. 1) Disconnect lead wires and connectors board assembly connected from the control P .C. board assembly to other parts. 1. Lead wires Take off • Connection with the power terminal earth screws. block: 3 wires (Black, White, Orange) •...
  • Page 151 Part name Procedure Remarks Rear cabinet 1) Perform works of items 1 of 1 and 2 , 3 . 2) Take off fixed screws for the bottom plate. (ST1T Ø4 × 8L, 3 pcs.) 3) Take off fixed screws for the heat exchanger. (ST1T Ø4 ×...
  • Page 152 Part name Procedure Remarks Compressor 1) Perform works of items 1 of 1 and 2 , Partition plate 2) Discharge refrigerant gas. 3) Remove the partition plate. (ST1T Ø4 × 8L, 3 pcs.) 4) Remove the noise-insulator. 5) Remove the terminal covers of the compressor, and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal.
  • Page 153 Part name Procedure Remarks 1. Detachment Pulse Motor Valve (PMV) coil 1) Perform works of items 2) Release the coil from the concavity by turning it, and remove coil from the PMV. 2. Attachment 1) Put the coil deep into the bottom posi- tion.
  • Page 154 14-2-2. RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E Part name Procedure Remarks Common procedure CAUTION Front panel Be sure to put on the gloves at working time; otherwise an injury may be caused by a part, etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker.
  • Page 155 Part name Procedure Remarks 1. Detachment Discharge port cabinet Heat exchanger Discharge port cabinet 1) Carry out work of 1 of Motor base Partition plate 2) Remove screws for the discharge port cabinet and the partition plate. (ST1T Ø4 × 8, 3 pcs.) 3) Remove screws for the discharge port cabinet and the bottom plate.
  • Page 156 Part name Procedure Remarks 1. Control P.C. board Exchange of Compressor lead electric parts 1) Carry out work of 1 of Relay connector: 2 positions Control (1 at rear side) P.C. board WARNING Fan motor Bundling band (Reactor lead) Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused.
  • Page 157 Part name Procedure Remarks 1. Reactor Exchange of Reactor relay connector electric parts 1) Carry out works of 1 of (Connected to lead wire (Continued) (White) at P.C. board side) 2) Remove the relay connector connected to the control P .C. board. 3) Cut off the bundling band binding the compressor lead and the relay connector.
  • Page 158 Part name Procedure Remarks Fan motor 1) Carry out works of 1 of 1 and 2 . Propeller fan Loosened by 2) Remove the flange nut fixing the fan motor and the turning clockwise propeller fan. ∗ The flange nut is loosened by turning clockwise. (To tighten it, turn it counterclockwise.) 3) Remove the propeller fan.
  • Page 159 Part name Procedure Remarks 1. Removal of broken compressor Compressor Compressor lead Piping panel (Rear) Piping panel (Rear) Piping panel (Rear) 1) Recover the refrigerant gas. 2) Carry out works of 1 of 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and the bottom plate.
  • Page 160 Part name Procedure Remarks Compressor 10) Using a burner, remove the discharge Remove Remove Compressor lead pipe and the suction pipe connected to (Discharge pipe) (Suction pipe) (Continued) the compressor. WARNING In case of removing the piping by broiling the welded part with a burner, if the piping includes oil, it may burst into flames at the moment when wax melted, so take sufficient care.
  • Page 161 Part name Procedure Remarks 2. Mounting of compressor Compressor Compressor lead Wind the ferrite core Wind the ferrite core Wind the ferrite core Compressor lead 1) Mount the compressor in the reverse with the compressor with the compressor with the compressor (Continued) procedure of removal.
  • Page 162 Part name Procedure Remarks 3. Vacuuming Compressor Compressor lead 1) Connect the vacuum pump to the charge (Continued) port of the gas pipe valve and then drive the vacuum pump. 2) Carry out vacuuming until the vacuum low pressure gauge indicates 1 (mmHg). NOTE: Before vacuuming, open PMV fully.
  • Page 163 Part name Procedure Remarks 3. Detachment Fan guard Bell mouth Discharge port cabinet 1) Carry out works of 1 of CAUTION To prevent scratching on the product, handle the product on a cardboard or cloth. 2) Remove the discharge port cabinet and then put on it so that the fan guard side directs downward.

  • Page 164: Exploded Views And Parts List

    15. EXPLODED VIEWS AND PARTS LIST 15-1. Indoor Unit 15-1-1. RAV-SM404SDT-E, RAV-SM454SDT-E, RAV-SM564SDT-E 206, 209 213, 218, 224 225, 226, 231 TEST SETTING – 164 –...
  • Page 165 Model Name RAV-SM Location Part No. Description 404SDT-E 454SDT-E 564SDT-E 4312C040 Motor, Fan 43120227 Fan, Multi blade 43170244 Hose, Drain 4314J402 Refrigeration Cycle Ass’y 43122084 Case, Fan, Lower 43122085 Case, Fan, Upper 43100319 Plate, Inlet-B 43172183 Pan Ass’y, Drain 43149351 Socket 43179129 Cap, Drain...
  • Page 166 <E-parts assembly> Model Name RAV-SM Location Part No. Description 404SDT-E 454SDT-E 564SDT-E 43050425 Sensor Ass’y, Service TC (F6) 43050426 Sensor, Service 43160565 Terminal, Block, 3P , AC250V, 20A 43160568 Terminal, 2P , AC30V/DC42V, 1A 4316V368 P.C. Board Ass’y, 220–240V, MCC-1570 –...

  • Page 167: Outdoor Unit

    15-2. Outdoor Unit 15-2-1. RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E 16, 17 18, 19 12, 14 10, 26, 32 13, 15 – 167 –...
  • Page 168 Model Name RAV-SP Location Part No. Description 404AT-E 404ATZ-E 404ATZG-E 454AT-E 454ATZ-E 454ATZG-E 43105042 Cabinet, Front, RoHs 43105041 Cabinet, Upper 43005698 Cabinet, Side, Right, RoHs 43005672 Cabinet, Side, Left 4301V035 Guard, Fan 4301V053 Guard, Fin 43100346 Base Ass’y, RoHs 43119471 Caver, Valve, Packed 43162055 Caver, Wiring Ass’y, RoHs Compressor, DA150A1F-20, 43041786...
  • Page 169 <Inverter assembly> Model Name RAV-SP Location Part No. Description 404AT-E 404ARZ-E 404ATZG-E 454AT-E 454ATZ-E 454ATZG-E 43050422 Sensor, TE 43050423 Sensor, TS 43050427 Sensor, TO 43050430 Sensor, TD 43062228 Base, P .C.board 43160566 Terminal, Block 6P , 20A 4316V293 P .C. Board Ass’y, SW, MCC-1530 4316V367 P .C.board Ass’y, MCC-5009 43160571 Fuse, Holder, 250V, 15A 43160590 Fuse, AC250V, 6.3A...
  • Page 170 15-2-2. RAV-SP564AT-E, RAV-SP564ATZ-E, RAV-SP564ATZG-E 12, 13, 14 19, 20 39, 40 21, 22 15, 18 16, 17 10, 30, 36 37, 38 41, 42 26, 27 – 170 –...
  • Page 171 Model Name RAV-SP Location Part No. Description 564AT-E 564ATZ-E 564ATZG-E 43105042 Cabinet, Front 43105041 Cabinet, Upper 43005698 Cabinet, Side, Right 43005672 Cabinet, Side, Left 4301V088 Guard, Fan 4301V053 Guard, Fin 43100346 Base Ass’y 43119471 Cover, Valve, Packed 43162055 Cover, Wiring Ass’y 43041644 Compressor, DA150A1F-21F 4314Q064...
  • Page 172 <Inverter assembly> %& %" Model Name RAV-SP Location Part No. Description 564AT-E 564ATZ-E 564ATZG-E 43050422 Sensor, TE 43050423 Sensor, TS 43050427 Sensor, TO 43050430 Sensor, TD 43062228 Base, P .C.board 43160566 Terminal block, 6P , 20A 4316V293 P.C. board Ass’y, SW, MCC-1530 4316V384 P.C.
  • Page 173 15-2-3. RAV-SP804AT-E, RAV-SP804ATZ-E, RAV-SP804ATZG-E 30, 31, 32 7, 38 28, 29 4, 26 9, 10, 36 6, 27 8, 39, 40 25, 37 – 173 –...
  • Page 174 Model Name RAV-SP Location Part No. Description 804AT-E 804ATZ-E 804ATZG-E 43019904 Holder, Sensor 43032441 Nipple, Drain 43041798 Compressor, DA220A2F-22L 43046493 Coil, PMV, CAM-MD12TF-15 43046451 Valve, 4-Way, STF-0218G 43047246 Bonnet, 3/8 IN 43047669 Nut, Flange 43049739 Cushion, Rubber 43050407 Thermostat, Bimetal 43063317 Holder, Thermostat 43100437...
  • Page 175 <Inverter assembly> 709, 710 1 2 3 Model Name RAV-SP Location Part No. Description 804AT-E 804ATZ-E 804ATZG-E 43050425 Sensor Ass’y, Ø6 43063325 Holder, Sensor (TE) 43150319 Sensor Ass’y, Ø4 43155188 Reactor, CH-56-2Z-T 43160565 Terminal block, 3P , 20A 43160581 Termonal,3P , 60A 43160589 Fuse, 10A, 250V AC 43163055...
  • Page 176 WARNINGS ON REFRIGERANT LEAKAGE Important Check of Concentration Limit The room in which the air conditioner is to be installed requires a design that in the event of NOTE 2 : refrigerant gas leaking out, its concentration will The standards for minimum room volume are as follows. not exceed a set limit.
  • Page 177 TOSHIBA CARRIER CORPORATION 23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN Copyright © 2008 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.

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