FILE NO.
CONTENTS ORIGINAL INSTRUCTION ..................................................................................................... 3 WARNING INDICATIONS ON THE AIR CONDITIONER UNIT .............................................. 5 PRECAUTION FOR SAFETY ................................................................................................. 6 NEW REFRIGERANT (R410A) ............................................................................................ 11 1. SPECIFICATIONS .....................
Original instruction Please read carefully through these instructions that contain important information which complies with the “Machinery” Directive (Directive 2006/42/EC), and ensure that you understand them. Some of the details provided in these instructions differ from the service manual, and the instructions provided here take precedence.
Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’ work clothing. In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below. Failure to wear the proper protective gear is dangerous because you will be more susceptible to injury, burns, electric shocks and other injuries.
Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positions If removing the label during parts replace, stick it as the original. Description Warning indication WARNING WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing. WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing. WARNING Moving parts.
Precaution for Safety WARNING Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions. Only qualified service person (∗1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.
Execute discharge between terminals. Prohibition Stay on protection Even if the circuit breaker has been set to the OFF position before the service panel is removed and the electrical parts are repaired, you will still risk receiving an electric shock. For this reason, short-circuit the high-voltage capacitor terminals to discharge the voltage before proceeding with the repair work. For details on the short-circuiting procedure, refer to the Service Manual.
Refrigerant Assembly/ Cabling Insulator check Ventilation The refrigerant used by this air conditioner is the R410A. Check the used refrigerant name and use tools and materials of the parts which match with it. For the products which use R410A refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see. To prevent miss-charging, the route of the service port is changed from one of the former R22.
Once the repair work has been completed, check for refrigerant leaks, and check the insulation resistance and water drainage. Then perform a trial run to check that the air conditioner is running properly. Check after repair Do not operate the unit with the valve closed. After repair work has finished, check there is no trouble. If check is not executed, a fire, electric shock or injury may be caused. For a check, turn off the power breaker.
Explanations given to user • If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person to have the repairs done. Do not set the circuit breaker to the ON position until the repairs are completed. Relocation • Only a qualified installer (∗1) or qualified service person (∗1) is allowed to relocate the air conditioner.
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.
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. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Air Discharge Cassette Type Model Indoor unit RAV-SM Outdoor unit RAV-SP 1104AT8-E 1404AT8-E 1604AT8-E 1104AT8-TR 1404AT8-TR 1604AT8-TR 1104UT-E 1404UT-E 1604UT-E 1104UT-E 1404UT-E 1604UT-E 1104AT7 1404AT7 1604AT7 Cooling capacity (kW) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) Heating capacity (kW) 11.2 (2.4-15.6) 14.0 (2.4-18.0) 16.0 (2.4-19.0) 11.2 (2.4-15.6) 14.
Model Indoor unit 1 RAV-SM 564UT-E 804UT-E 804UT-E 564UT-E 804UT-E Indoor unit 2 RAV-SM 564UT-E 804UT-E 804UT-E 564UT-E 804UT-E 804UT-E 804UT-E Outdoor unit RAV-SP 1104AT8-E 1404AT8-E 1604AT8-E 1104AT8-TR 1404AT8-TR 1604AT8-TR 1104AT7 1404AT7 1604AT7 Cooling capacity (kW) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) Heating capacity (kW) 11.2 (2.4-15.6) 14.0 (2.4-18.0) 16.0 (2.4-19.0) 11.2 (2.4-15.6) 14.0 (2.
Model Indoor unit 1 RAV-SM 564UT-E 564UT-E Indoor unit 2 RAV-SM 564UT-E 564UT-E Indoor unit 3 RAV-SM 564UT-E 564UT-E RAV-SP 1604AT8-E 1604AT8-TR 1604AT7 14.0 (2.6-16.0) Outdoor unit Cooling capacity (kW) 14.0 (2.6-16.0) Heating capacity (kW) 16.0 (2.4-19.0) 16.0 (2.4-19.0) 3 phase 4wired (3N-4pole) 380V – 415V, 50Hz 3 phase 4wired (3N-4pole) 380V, 60Hz Power supply Running current (A) Power consumption Cooling Power factor 7.55 - 6.91 7.55 (kW) 4.49 4.
1-1-2. Concealed Duct Type Indoor unit Model Outdoor unit RAV-SM 1102BT-E 1402BT-E 1102BT-E 1402BT-E RAV-SP 1104AT8-E 1104AT8-TR 1404AT8-E 1404AT8-TR 1104AT7 1404AT7 Cooling capacity (kW) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 10.0 (2.6-12.0) 12.5 (2.6-14.0) Heating capacity (kW) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz Power supply Running current (A) Power consumption Cooling Power factor 5.51 - 5.05 6.
Model Indoor unit 1 RAV-SM 562BT-E 802BT-E 802BT-E 562BT-E 802BT-E Indoor unit 2 RAV-SM 562BT-E 802BT-E 802BT-E 562BT-E 802BT-E 802BT-E Outdoor unit RAV-SP 1104AT7 1404AT7 1604AT7 1104AT8-E 1404AT8-E 1604AT8-E 1104AT8-TR 1404AT8-TR 1604AT8-TR 802BT-E Cooling capacity (kW) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) Heating capacity (kW) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 16.0 (2.4-19.0) 11.2 (2.4-14.0) 14.0 (2.
Model Indoor unit 1 RAV-SM 562BT-E Indoor unit 2 RAV-SM 562BT-E 562BT-E 562BT-E Indoor unit 3 RAV-SM 562BT-E 562BT-E Outdoor unit RAV-SP 1604AT8-E 1604AT8-TR 1604AT7 14.0 (2.6-16.0) Cooling capacity (kW) 14.0 (2.6-16.0) Heating capacity (kW) 16.0 (2.4-19.0) 16.0 (2.4-19.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 8.61 - 7.88 8.61 (kW) 5.12 5.
1-1-3. Under Ceiling Type Indoor unit Model Outdoor unit RAV-SM 1102CT-E 1402CT-E 1102CT-E 1402CT-E RAV-SP 1104AT8-E 1104AT8-TR 1404AT8-E 1404AT8-TR 1104AT7 1404AT7 Cooling capacity (kW) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 10.0 (2.6-12.0) 12.5 (2.6-14.0) Heating capacity (kW) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz Power supply Running current (A) Power consumption Cooling Power factor EER 5.23 - 4.
Model Indoor unit 1 RAV-SM 562CT-E 802CT-E 802CT-E 562CT-E 802CT-E Indoor unit 2 RAV-SM 562CT-E 802CT-E 802CT-E 562CT-E 802CT-E 802CT-E Outdoor unit RAV-SP 1104AT7 1404AT7 1604AT7 1104AT8-E 1404AT8-E 1604AT8-E 1104AT8-TR 1404AT8-TR 1604AT8-TR 802CT-E Cooling capacity (kW) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) 10.0 (2.6-12.0) 12.5 (2.6-14.0) 14.0 (2.6-16.0) Heating capacity (kW) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 16.0 (2.4-19.0) 11.2 (2.4-14.0) 14.0 (2.
Model Indoor unit 1 RAV-SM 562CT-E Indoor unit 2 RAV-SM 562CT-E 562CT-E 562CT-E Indoor unit 3 RAV-SM 562CT-E 562CT-E Outdoor unit RAV-SP 1604AT8-E 1604AT8-TR 1604AT7 14.0 (2.6-16.0) Cooling capacity (kW) 14.0 (2.6-16.0) Heating capacity (kW) 16.0 (2.4-19.0) 16.0 (2.4-19.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 8.39 - 7.68 8.39 (kW) 4.99 4.
1-1-4. High Wall Type Model Indoor unit 1 RAV-SM 562KRT-E 802KRT-E 802KRT-E 562KRT-E 802KRT-E 802KRT-E Indoor unit 2 RAV-SM 562KRT-E 802KRT-E 802KRT-E 562KRT-E 802KRT-E 802KRT-E Outdoor unit RAV-SP 1104AT8-E 1404AT8-E 1604AT8-E 1104AT8-TR 1404AT8-TR 1604AT8-TR 1104AT7 1404AT7 1604AT7 Cooling capacity (kW) 10.0 (2.6-12.0) 12.3 (2.6-13.5) 14.0 (2.6-16.0) 10.0 (2.6-12.0) 12.3 (2.6-13.5) 14.0 (2.6-16.0) Heating capacity (kW) 11.2 (2.4-14.0) 14.0 (2.4-18.0) 16.0 (2.
Model Indoor unit 1 RAV-SM 562KRT-E Indoor unit 2 RAV-SM 562KRT-E 562KRT-E 562KRT-E Indoor unit 3 RAV-SM 562KRT-E 562KRT-E Outdoor unit RAV-SP 1604AT8-E 1604AT8-TR 1604AT7 14.0 (2.6-16.0) Cooling capacity (kW) 14.0 (2.6-16.0) Heating capacity (kW) 16.0 (2.4-19.0) 16.0 (2.4-19.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 8.57 - 7.85 8.57 (kW) 5.10 5.
1-1-5. Compact 4-Way Cassette (600 × 600) Type Model Indoor unit 1 RAV-SM 562MUT-E 562MUT-E Indoor unit 2 RAV-SM 562MUT-E 562MUT-E RAV-SP 1104AT8-E 1104AT8-TR 1104AT7 10.0 (2.6-12.0) Outdoor unit Cooling capacity (kW) 10.0 (2.6-12.0) Heating capacity (kW) 11.2 (2.4-14.0) 11.2 (2.4-14.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 5.23 - 4.79 5.23 (kW) 2.79 2.
Model Indoor unit 1 RAV-SM 562MUT-E Indoor unit 2 RAV-SM 562MUT-E 562MUT-E 562MUT-E Indoor unit 3 RAV-SM 562MUT-E 562MUT-E Outdoor unit RAV-SP 1604AT8-E 1604AT8-TR 1604AT7 14.0 (2.6-16.0) Cooling capacity (kW) 14.0 (2.6-16.0) Heating capacity (kW) 16.0 (2.4-19.0) 16.0 (2.4-19.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 8.39 - 7.68 8.39 (kW) 4.99 4.
1-1-6. Slim Duct Type Model Indoor unit 1 RAV-SM 564SDT-E 564SDT-E Indoor unit 2 RAV-SM 564SDT-E 564SDT-E RAV-SP 1104AT8-E 1104AT8-TR 1104AT7 10.0 (2.6-12.0) Outdoor unit Cooling capacity (kW) 10.0 (2.6-12.0) Heating capacity (kW) 11.2 (2.4-14.0) 11.2 (2.4-14.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 5.23 - 4.79 5.23 (kW) 2.79 2.79 (%) 81 81 3.58 3.
Model Indoor unit 1 RAV-SM 564SDT-E 564SDT-E Indoor unit 2 RAV-SM 564SDT-E 564SDT-E Indoor unit 3 RAV-SM 564SDT-E 564SDT-E RAV-SP 1604AT8-E 1604AT8-TR 1604AT7 14.0 (2.6-16.0) Outdoor unit Cooling capacity (kW) 14.0 (2.6-16.0) Heating capacity (kW) 16.0 (2.4-19.0) 16.0 (2.4-19.0) 3 phase 4wired (3N-4pole) 380V - 415V 50Hz 3 phase 4wired (3N-4pole) 380V 60Hz Power supply Running current (A) Power consumption Cooling Power factor 8.39 - 7.68 8.39 (kW) 4.99 4.
1-1-7. High Static Duct Type Model Indoor unit RAV-SM 1403DT-A 1603DT-A Outdoor unit RAV-SP 1404AT8-E 1604AT8-E Cooling capacity (kW) 13.0 (3.3-14.1) 14.3 (3.3-16.0) Heating capacity (kW) 14.0 (4.2-18.0) 16.0 (4.2-19.0) Power supply 3 phase 4wired (3N-4pole) 415V 50Hz Running current Power consumption Cooling Power factor (A) 6.89 7.71 (kW) 4.32 5.01 (%) 87 90 3.01 2.
1-2. Outdoor Unit Model Outdoor unit RAV-SP RAV-SP 1104AT8-E 1404AT8-E 1604AT8-E 1104AT8-TR 1404AT8-TR 1604AT8-TR 3 phase 4wired (3N-4pole) 380V – 415V 50Hz (Power exclusive to outdoor required.) Power supply Type Compressor Motor (kW) Refirigerant charged 3 phase 4wired (3N-4pole) 380V 60Hz (Power exclusive to outdoor required.) (kg) 3.75 3.75 3.75 3.75 3.75 4 4 4 4 4 4 3.1 3.1 3.1 3.1 3.1 3.1 Pulse motor valve Standard length (m) 7.5 7.5 7.5 7.5 7.5 7.
1-3. Operation Characteristic Curve • Operation characteristic curve, 50Hz RAV-SP1104AT8 (Z) (ZG)-E, -TR RAV-SP1404AT8 (Z) (ZG)-E, -TR RAV-SP1604AT8 (Z) (ZG)-E, -TR 10 15 9 14 SP160 13 8 12 11 7 Current (A) Current (A) 10 6 SP140 5 4 SP110 SP110 9 8 7 6 5 3 4 • Conditions Indoor : DB27˚C/WB19˚C Outdoor : DB35˚C Air flow : High Pipe length : 7.
• Capacity variation ratio according to temperature RAV-SP1104AT8 (Z) (ZG)-E, -TR RAV-SP1404AT8 (Z) (ZG)-E, -TR RAV-SP1604AT8 (Z) (ZG)-E, -TR RAV-SP1104AT7 (Z) (ZG) RAV-SP1404AT7 (Z) (ZG) RAV-SP1604AT7 (Z) (ZG) 105 120 100 110 95 100 90 Capacity ratio (%) Capacity ratio (%) 90 85 80 75 70 65 60 55 80 70 60 50 40 30 20 • Conditions Indoor : DB27˚C/WB19˚C Indoor air flow : High Pipe length : 7.5m 10 50 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Outdoor temp.
7 Z views 83 74 17.5 365 17.5 327 518 178 550 178 900 600 80 Z 135 18 Details of A legs 1 2 1 2 18 30 Refrigerant pipe connecting port (Ø15.9 flare at gas side) 151 80 400 320 Details of B legs 12 Mounting bolt hole (Ø12 × 17 long hole) Refrigerant pipe connecting port (Ø9.
RBC-TWP30E2, RBC-TWP50E2 (Simultaneous Twin) B Inner diameter Ø C Inner diameter Ø D Inner diameter Ø D A A B C D Liquid side 36 14 Ø9.5 Ø6.4 Gas side 43 23 Ø15.9 Ø12.7 Liquid side 34 14 Ø9.5 Ø9.5 Gas side 44 21 Ø15.9 Ø15.
RBC-TRP100E (Simultaneous Triple) Header assembly 300 80 Inner diameter Ø15.9 80 100 Inner diameter Ø25.4 100 1 pc. Branch pipe assembly 100 80 80 Inner diameter Ø9.52 100 Inner diameter Ø12.7 35 1 pc. Insulator Gas side socket Liquid side socket Ø15.9 Ø12.7 9 26 24 8 12 46 10 28 Ø9.5 Ø6.4 Ø15.9 Ø25.4 Ø9.5 Ø12.7 (External diameter) (External diameter) (External diameter) (External diameter) 3 pcs. 1 pc. 3 pcs. – 34 – 1 pc.
3. OUTDOOR UNIT REFRIGERATING CYCLE DIAGRAM TO sensor TS sensor PMV TL sensor Pressure switch Strainer P TE sensor Check joint Capillary Ø4 ×Ø3 (6 pcs.) Cooling: High pressure Heating: Low pressure Heat exchanger Ø8, 2 rows, 52 stages FP1.45, flat fin TD sensor Distributor Refrigerant pipe at liquid side Ø9.5 Packed valve In cooling operation In heating operation Refrigerant pipe at gas side Ø15.
4. WIRING DIAGRAM 4-1.
5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit No. Parts name Type Specifications — 1 Compressor DA422A3F-27M 2 Outdoor fan motor ICF-280-A100-1 DC 280 V, 100 W 3 4-way valve coil STF-01AJ502E1 AC 220 – 240 V, 50/60 Hz 4 PMV coil 5 High pressure switch 6 Reactor CH-78 4.2 mH, 16 A 7 Reactor CH-68 18 mH, 5 A 8 Reactor CH-56 5.8 mH, 18.5 A 9 P.C. board (Compressor drive) MCC-1596 — 10 P.C. board (Fan motor drive) MCC-1597 — 11 P.C.
6. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer. The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant (R22).
Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A R22 1/4 6.4 0.80 0.80 3/8 9.5 0.80 0.80 1/2 12.7 0.80 0.80 5/8 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. In such a case, socket joints can be used.
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. Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment. ØD A Fig.
6˚ to 4 45˚ A B C 43˚ D to 4 5˚ Fig. 6-2-2 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. The tightening torque for R410A is the same as that for conventional R22.
6-3. Tools 6-3-1. Required Tools Refer to the “4. Tools” 6-4. 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. When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.
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.
2. Characteristics required for flux 6-5-3. Brazing • Activated temperature of flux coincides with the brazing temperature. • Due to a wide effective temperature range, flux is hard to carbonize. • It is easy to remove slag after brazing. • The corrosive action to the treated metal and brazing filler is minimum. • It excels in coating performance and is harmless to the human body.
6-6. Instructions for Re-use Piping of R22 or R407C Instruction of Works: The existing R22 and R407C piping can be reused for our digital inverter R410A products installations. NOTE) Confirmation of existence of scratch or dent of the former pipes to be applied and also confirmation of reliability of the pipe strength are conventionally referred to the local site. If the definite conditions can be cleared, it is possible to update the existing R22 and R407C pipes to those for R410A models. 6-6-1.
6-6-5. Final Installation Checks Is there no scratch or dent on the existing pipes? Existing pipe: NO * Use a new pipes. NO Is it possible to operate the existing air conditioner? YES ∗ After the existing air conditioner operated in cooling mode for approx. 30 minutes or longer*, recover the refrigerant. ∗ For cooling the pipes and recovering of oil • Refrigerant recovery: Pump down method Nitrogen gas pressure 0.
6-6-6. Handling of Existing Pipe 6-6-7. Recovery Method of Refrigerant When using the existing pipe, carefully check it for the following: • Wall thickness (within the specified range) • Scratches and dents • Water, oil, dirt, or dust in the pipe • Flare looseness and leakage from welds • Deterioration of copper pipe and heat insulator • Use the refrigerant recovery switch SW801 on the P.C. board of the outdoor unit to recover refrigerant when the indoor unit or outdoor unit is moved.
7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1596 (Compressor IPDU) CN851 (Red) CN101 (White) Connector for MCC-1597 (CN505) Connector for MCC-1597 (CN502) CN13 (Black) Terminal for power relay F02 Electric circuit protective fuse (500V, 31.5A) CN12 (White) Terminal for MCC-1600 (CN17) F01 Electric circuit protective fuse (500V, 31.
7-1-2.
7-1-3. Print Circuit Board, MCC-1599 (Interface (CDB)) CN708 (Blue) Connector for power relay coil CN608 (White) Connector for MCC-1600 (CN50) CN02 (Red) Connector for MCC-1600 (CN10 and CN19) CN802 (White) Connector for MCC-1597 (CN504) F01 CN700 (Yellow) 4-way valve connector Power supply protective fuse (250V, 3.15A) Temp.
7-1-4. Print Circuit Board, MCC-1600 (Noise Filter) CN05 (Red) Power supply terminal (L1) CN10 (Red) Terminal for MCC-1599 (CN02) and Terminal for PTC thermistor CN16 (Red) Terminal for power relay F01 Varistor protective fuse (250V, 6.3A) CN06 (White) Power supply terminal (L2) CN17 (White) Terminal for F02 Varistor protective fuse MCC-1596 (CN02) (250V, 6.
7-2. Outline of Main Controls 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between 30 and 500 pulses during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming 1 to 4K as the target value. 3) In heating operation, PMV is usually controlled with the temperature difference between TS sensor and TE sensor aiming –1 to 4K as the target value.
3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] SP110 to SP160 W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE Up 200 240 240 260 320 380 480 500 530 610 640 660 720 780 Down — — 200 280 360 400 500 520 550 630 660 700 740 820 3-1) Cooling fan control The outdoor fan is controlled by TL sensor, TO sensor and the operation frequency. The outdoor fan is controlled by every 1 tap of DC fan control (14 taps).
4. Coil heating control 1) This control function heats the compressor by turning on the stopped compressor instead of a case heater. It purposes to prevent stagnation of the refrigerant inside of the compressor. 2) As usual, turn on power of the compressor for the specified time before a test run after installation; otherwise a trouble of the compressor may be caused.
7. Current release value shift control Current release control value (I1) [A] 1) This control purposes to prevent troubles of the electronic parts such as the compressor driving elements and the compressor during cooling operation. 2) The current release control value (11) is selected from the following table according to TO sensor value. Temperature range SP110 SP140 SP160 47°C ≤ To 7.5 7.5 7.5 39°C ≤ To < 47°C 7.5 8.7 9.6 To < 39°C 9.6 9.6 9.6 To < –5°C 7.5 8.7 9.6 TO error 7.5 7.
10. Defrost control 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 ≤ TE < 12°C for 1 minute. The defrost operation also finishes when it continued for 10 minutes even if TE sensor temperature was 7°C or lower. 3) After defrost operation was reset, the compressor stopped for approx.
8. TROUBLESHOOTING 8-1. Summary of Troubleshooting 1. Before troubleshooting 1) Required tools/instruments • + and – 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. 1. Compressor does not operate.
1. Before troubleshooting 1) Required tools/instruments • + and – 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.
8-2. Troubleshooting 8-2-1. 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.
Lamp indication Operation Timer Ready Alternate flash Operation Timer Ready Alternate flash Operation Timer Check code Cause of trouble occurrence F01 Heat exchanger sensor (TCJ) error F02 Heat exchanger sensor (TC) error P10 Heat exchanger sensor (TA) error F04 Discharge temp. sensor (TD) error F06 Temp. sensor (TE) error F07 Temp. sensor (TL) error F08 Temp. sensor (TO) error F12 Temp. sensor (TS) error F13 Temp. sensor (TH) error F15 Temp.
8-2-2.
8-2-3. Monitor Function of Remote Controller Switch n Calling of sensor temperature display Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. 1 2 TEST CL Push + buttons simultaneously for 4 seconds to call the service monitor mode. The service monitor goes on, the master indoor unit No. is displayed at first and then the temperature of CODE No. is displayed. TEMP.
– 63 – P19 L03 L07 L08 L09 L30 E18 E10 E09 E04 E08 ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ l ¡ ¥ E03 l ¥ E02 E01 P05 P07 P15 P20 P22 P26 P29 ¥ ¥ ¥ ¥ ¥ ¥ l l l l ¥ l l l ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ l l l l l l l l l l l l l l l l l l l l l ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ P03 P04 ¥ ¥ l l l l ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¡ ¥ ¥ l l l l ¥ ¥ ¥ ¥ ¥ ¥ ¥ ² ALT SIM SIM SIM SIM SIM ALT ALT ALT ALT ALT ALT ALT ALT ALT SIM SIM ALT ALT ALT ALT ALT SIM ALT Sensor lamp part Block indication Operation Timer Rea
– 64 – — L20 ¥ — ¡ ¥ — — l By unit with warning No. l l l l l l l SIM ALT Sensor lamp part Block indication Operation Timer Ready Flash ALT ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ SIM ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ ALT ¥ ¥ — F01 F02 F10 F29 P01 P10 P12 P31 Remote controller indication There are multiple communication adapters.
Error mode detected by indoor unit Operation of diagnostic function Check code Cause of operation E03 No communication from remote controller (including wireless) and communication adapter E04 The serial signal is not output from outdoor unit to indoor unit. • Miswiring of inter-unit wire • Defective serial sending circuit on outdoor P.C. board • Defective serial receiving circuit on indoor P.C.
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-SM1404UT-E with RAV-SP1404AT8-E) When the indoor unit is 3 series and before, the conventional check code is displayed. (Ex. Combination of RAV-SM1402CT-E and RAV-SP1404AT8-E: Outdoor unit only is 4 series.
Operation of diagnostic function Check code Indoor unit before 3 series Cause of operation after 4 series Status of air conditioner Condition H03 Current detection circuit error Stop Displayed when error is detected P05 Open phase of 3-phase power supply Stop Displayed when error is detected Stop Displayed when error is detected H03 Discharge temp. error P03 P03 ∗ Discharge temp. (TD) over specified value was detected. Judgment and measures 1. Check outdoor P.C. board (MCC-1596).
Error mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Check code Cause of operation Status of air conditioner Judgment and measures Condition Power supply error of remote controller, Indoor EEPROM error 1. Check remote controller inter-unit wiring. 2. Check remote controller. 3. Check indoor power wiring. 4. Check indoor P.C. board. 5. Check indoor EEPROM. (including socket insertion) → Automatic address repeating phenomenon generates.
8-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board to narrow the contents to be confirmed. 3) The check code on the remote controller is displayed only when the same error occurred continuously by multiple times while LED of the outdoor P.C.
Check code Outdoor LED display [F04] ¡ ¡ l l ¡ ¡ ¡ l l ¥ l l [Discharge temp. sensor (TD) error] NO Is CN603 connection normal? Is resistance value of TD sensor normal? Correct connector. Sensor error → Replace YES Check outdoor P.C. board (MCC-1599). Defect → Replace • There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C. board to judge which error it is. Heat exchanger temp. sensor (TE) error, Heat exchanger temp.
Check code Outdoor LED display [F08] ¡ ¡ l l ¡ ¡ ¡ l ¥ l l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Outside air temp. sensor (TO) error] Is CN602 connection normal? Is resistance value of TO sensor normal? NO Correct connector. Sensor error → Replace YES Check outdoor P.C. board (MCC-1599). Defect → Replace [F12] ¡ ¡ l l ¡ ¡ ¡ l ¥ ¥ l l [Suction temp.
Check code Outdoor LED display [F31] ¡ ¡ l l ¡ ¡ [H01] ¡ ¥ ¥ ¥ ¥ ¥ ¡ ¡ l ¡ l l ¡ l l l l ¥ Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [EEPROM error] Check outdoor P.C. board (MCC-1599). Defect → Replace [Compressor break down] Is power supply voltage normal? AC342 to 457V NO Correct power supply line.
Check code Outdoor LED display [H03] ¡ ¡ l ¡ l l ¡ l l l [H04] ¡ ¡ ¡ ¡ ¡ ¡ ¥ [Power supply error (Vdc)] → Refer to [P05] column. l ¥ ¡ ¡ ¡ ¡ ¥ l l Check outdoor P.C. board (MCC-1596). Defect → Replace l l l [Current detection circuit error] ¥ ¥ l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.
Check code Outdoor LED display Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) ∗ There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C. board to judge which error it is. Communication error between MCU, Heat sing temp.
Check code Outdoor LED display [P03] ¡ ¡ ¡ ¡ ¡ ¡ ¥ ¥ l l l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Discharge temp. error] Is there no gas leak? Is refrigerant charge amount adequate? NO Repair defective position. Recharge refrigerant. NO Repair defective position. Replace defective part. YES Is PMV normal? YES YES Is it not abnormal overload? Correct and clear the cause.
Check code Outdoor LED display Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [P04] C Heating operation Does the heating indoor fan normally operate? NO Are connections of connectors,capacitors and fan motor normal? YES NO YES Is there any element which blocks indoor heat exchanger? Filter clogging Clogging of heat exchanger Short circuit YES Elimination of blocking element Repair defective position.
Check code Outdoor LED display [P05] ¡ ¡ ¡ ¡ ¡ ¡ ¥ l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Power supply error (Voltage error)] l l Is there no open phase of the power supply? l Is there no down or up of power supply voltage? (AC342 to 457V) ¥ YES Correct wiring. NO YES Confirm electric construction, etc. NO [P07] ¡ ¡ ¡ ¡ ¡ ¡ ¥ ¥ ¥ l l l Check outdoor P.C. board (MCC-1600).
Check code Outdoor LED display [P20] ¡ ¡ ¡ ¥ ¡ ¡ ¡ ¥ l l l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [High pressure protective operation] NO Is valve fully opened? Open valve fully. YES Reset the power supply and then perform test run matching to the season.
Check code Outdoor LED display [P22] ¡ ¡ ¡ ¥ ¡ ¡ ¡ ¥ ¥ l l l Check and troubleshooting (Item without special mention Indicates part of outdoor unit.) [Fan system error] NO Is there no problem on power supply voltage? (342 to 457V) Check wiring construction. Ask repair of power supply.
Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Ω) Resistance value (kΩ Temperature (°C) (Minimum value) (Standard value) (Maximum value) Ω) Resistance value (kΩ Temperature (°C) (Minimum value) (Standard value) (Maximum value) 0 32.33 33.80 35.30 0 10 19.63 20.35 21.09 10 150.5 92.76 161.3 99.05 172.7 20 12.23 12.59 12.95 20 58.61 62.36 66.26 25 9.75 10.00 10.
Table Inspection of outdoor unit main parts No. 1 Parts name Compressor (Model : DA422A3F-27M) Checking procedure Measure the resistance value of each winding by using the tester. Red Resistance value Position Red – White White Black White – Black 0.79 ± 0.04 Ω Black – Red Under 20°C 2 Outdoor fan motor (Model : ICF-280-A100-1) Measure the resistance value of each winding by using the tester. Red Position Resistance value Red – White White Black White – Black 14.8 ± 1.
9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Error History The error contents in the past can be called. 1 2 3 SET TEST Push + buttons simultaneously for 4 seconds or more to call the service check mode. Service Check goes on, the CODE No. 01 is displayed, and then the content of the latest alarm is displayed. The number and error contents of the indoor unit in which an error occurred are displayed. TEMP.
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 Not normal NO 3 minutes elapse Gr construction check YES Normal ∗ Gr normal 1) There is no duplicated indoor unit address. 2) There is no invalid indoor unit address. 3) Individual unit and master/follower units are not intermingled. 4) Only a unit for individual.
9-3. Outdoor Unit 9-3-1. 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. Function Control contents Set position Turn the switch to ON when mounting a duct to the discharge port of the outdoor unit. Add 3 taps to the upper limit value of the outdoor fan tap. High static pressure setup The operation is performed with (Max: Upper fan: 890 rpm / Lower fan: 910 rpm (WF)).
9-3-2. Service Support Function (LED Display, Switch Operation) 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. Specifications SW800 Pushdown button switch SW803 DIP switch SW801 Pushdown button switch SW804 DIP switch SW802 DIP switch Operation contents Exchanges the displayed contents of LED (D800 to D804) on the outdoor control P.C.
9-3-3. Others 1. 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 SW803 ON 1 2 3 SW803 TD SW803 2 3 4 TS SW803 1 2 3 4 3 4 1 TA SW803 3 4 1 2 3 4 2 3 4 2 3 ON 2 3 3 Current display The current value which flows in the outdoor unit is displayed.
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> only of DIP switch SW803 is turned on, the error which generated before (Latest error information including present) is displayed.a) c) If there is an error, any of LED D800 to D804 goes on.
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.
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. While each function starts, LED D805 (Green) flashes. d) When pushing the pushdown button switch SW801 again for approx.
SW804 SW804 ON 1 2 3 4 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). When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control. [CAUTION] SW804 ON 1 2 3 4 SW804 ON 1 2 3 4 ON 2 3 4 Forced stop command The indoor unit connected to the system is forcedly stopped.
10. ADDRESS SETUP 10-1. 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. The operation of the remote controller is not accepted while automatic address works. (Approx.
10-2. Address Setup & Group Control 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. (* It has no relation with an indoor unit which communicates serially with the outdoor units.
10-2-2. Automatic Address Example from Unset Address (No miswiring) 1.
10-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple (SP160 only) (1-1) 1-2 Master/Header 1-1 Individual (1-1) (1-2) 1-2 Sub/Header 1-1 Sub/Follower (1-2) (1-3) 1-3 Master/Follower 1-1 Sub/Follower (Master/Header) Only turning on source power supply (Automatic completion) 2.
10-3. 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-conre shield wire (Vinyl cord for microphone 0.5 to 2.0 mm²) to conform to the EMC standard.
10-4. Address Setup (Manual setting from remote controller) In case that addresses of the indoor units will be determined prior to piping work after cabling work • Set an indoor unit per a remote controller. • Turn on power supply. (Example of 2-lines cabling) (Real line: Cabling, Broken line: Refrigerant pipe) Outdoor Outdoor 1 2 3 1 2 3 1 2 3 1 2 3 2 3 4 5 6 7 8 SET CL Indoor Indoor A B A B A B A B 1 2 2 2 1 2 2 2 2 A B TEST Push + + buttons simultaneously for 4 seconds or more.
10-5. 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) 1 2 Push ON / OFF button if the unit stops. UNIT LOUVER Push button. Unit No. 1-1 is displayed on LCD. (It disappears after several seconds.) The displayed unit No. indicate line address and indoor unit address.
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. Check periodically signs of rust or scratches, etc. on coating of the outdoor units.
11. REPLACEMENT OF THE SERVICE P.C. BOARD (4316V417) MCC-1599 1. Setting the jumper wires and DIP switches Function Part name Jumper wire DIP switch Setting J800 to J803 Model switching Cut these jumper wires according to the following table. J804 to J811 Settings Set these jumper wires to the settings of the P.C. board before replacement SW802 Settings Set SW802 to the setting of the P.C. board before replacement SW803 LED indication switching Set SW803 to all OFF.
12. HOW TO EXCHANGE COMPRESSOR 12-1. Exchanging Procedure of Compressor (Outline) START Has refrigerant recovery work been done? NO Open PMV forcedly and then recover refrigerant using a refrigerant recovery unit. YES Turn off the leakage breaker. Remove the defective compressor. Mount a service compressor. Never recover the refrigerant to the outdoor unit. For the refrigerant recovery work during reinstallation of repair work, be sure to use the refrigerant recovery unit.
– 101 – ADOPTION OF NEW REFRIGERANT 13. INSTALLATION MANUAL 1.35 1.35 RAV-SP1604AT8(Z)(ZG)-E EN-i 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 i PRECAUTIONS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ACCESSORY PARTS AND REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION OF NEW REFRIGERANT AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION CONDITIONS . . . . . . .
– 102 – EN-2 Work done at heights (50 cm or more) Transportation of heavy objects Repair of outdoor unit Electrical-related work Work undertaken All types of work 2 Gloves to provide protection for electricians and from heat Shoes with additional protective toe cap Protective gloves “Safety” working clothing Gloves to provide protection for electricians and from heat Insulating shoes Clothing to provide protection from electric shock Helmets for use in industry Protective gear worn When the air co
– 103 – EN-4 1 Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner. Only a qualified installer(*1) or qualified service person(*1) is allowed to install the air conditioner. If the air conditioner is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result.
– 104 – EN-6 Upon completion of the installation work, tell the user where the circuit breaker is located. If the user does not know where the circuit breaker is, he or she will not be able to turn it off in the event that trouble has occurred in the air conditioner. If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person to have the repairs done.
– 105 – EN-8 1 1 5 1 1 1 Drain nipple Waterproof rubber cap Protective bush Guard material for passage part Clamp filter Q’ty Outdoor unit installation manual Part name Accessory Parts 8 Shape For conforming to EMC standards (Used for power wire) For protecting passage part (pipe cover) For protecting wires (pipe cover) Hand this directly to the customer. (For other languages that do not appear in this Installation Manual, please refer to the enclosed CD-R.
– 106 – EN-10 10 Flare nuts and flare machining • The flare nuts and flare machining are different from those for the conventional refrigerant. Use the flare nuts supplied with the air conditioner or those for R410A. • Before performing flare machining, carefully read “REFRIGERANT PIPING”. When using general copper pipes • Use general copper pipes with a wall thickness of 0.8 mm for Ø6.4 mm, Ø9.5 mm, and Ø12.7 mm, and with a wall thickness of 1.0 mm for Ø15.9 mm.
EN-12 12 1. Install the outdoor unit in a location where the discharge air is not blocked. 2. When an outdoor unit is installed in a location that is always exposed to strong winds like a coast or on the high stories of a building, secure normal fan operation by using a duct or wind shield. 3. When installing the outdoor unit in a location that is constantly exposed to strong winds such as on the upper stairs or rooftop of a building, apply the windproofing measures referred to in the following examples.
– 108 – 300 or more 1,500 or more 2,000 or more EN-14 • 200 or more Drain nipple mounting hole 150 Drain hole Drain hole 525 600 150 14 Before installation, check the strength and horizontalness of the base so that abnormal sounds do not emanate. According to the following base diagram, fix the base firmly with the anchor bolts. (Anchor bolt, nut: M10 x 4 pairs) 400 365 • Installation of Outdoor Unit 1,000 or more Standard installation Open above and to the right and left of the unit.
– 109 – Pipe insulating material (polyethylene foam, 10 mm thick) Putty, PVC tape A B C One each 1 One each Q’ty EN-16 A 19.7 13.2 A +0 –0.4 1.0 to 1.5 Conventional tool used In case of flaring for R410A with the conventional flare tool, pull the tool out approx. 0.5 mm more than that for R22 to adjust it to the specified flare size. The copper pipe gauge is useful for adjusting the projection margin size. 1.0 mm * 9.5 15.9 Thickness Outer diam. of copper pipe Ø15.9 mm 16 0 to 0.
EN-18 Ø15.9 Ø15.9 SP140, SP160 SP160 only Indoor Unit Ø9.5 Ø9.5 Ø9.5 Liquid side 2 18 1 3 Distributor Indoor Unit Indoor Unit Ø9.5 Ø6.4 Ø15.9 Ø12.7 Out Ø6.4 10 or less 10 or less 10 or less Number of bent portions 0.5 0.5 0.5 Indoo d r Unit U it 2 1 4 Distributor Indoor Unit 3 Indoorr Unit Figure off Simultaneous triple Liquid side 30 30 30 Ø12.
– 111 – Movable part of valve (Stem) Opened fully While the valve is fully opened, after the screwdriver has reached the stopper, do not apply torque exceeding 5 N•m. Applying excessive torque may damage the valve. Main stopper Stopper pin Handle position Flare nut Using a minus screwdriver, turn it counterclockwise by 90° until it hits the stopper. (Full open) Valve unit EN-20 Charge port Valve size 20 to 25 N•m (2.0 to 2.5 kgf•m) Ø15.9 mm 20 14 to 18 N•m (1.4 to 1.
– 112 – EN-22 * * 3 3 Power supply L1 L2 L3 N 2 2 1 1 B A 1 2 B Indoor power inter-unit wiring Indoor side Remote controller inter-unit wiring 3 1 A Indoor power inter-unit wiring Indoor side Remote controller inter-unit wiring Outdoor side Indoor/Outdoor connecting wires Indoor side Remote controller wiring Remote controller 3 3 2 B 3 Power supply L1 L2 L3 N 2 2 1 1 B A Simultaneous twin system Outdoor side Indoor/Outdoor connecting wires Indoor side Remote co
– 113 – After the refrigerant pipe, inter-unit wires, and drain pipe have been connected, cover them with finishing tape and clamp them to the wall with off-the-shelf support brackets or their equivalent. Keep the power wires and indoor/outdoor connecting wires off the valve on the gas side or pipes that have no heat insulator. FINISHING Turn on the leakage breaker at least 12 hours before starting a test run to protect the compressor during startup.
– 114 – Check that DIP switch SW803 is set to OFF. Jot down the states of LED800 to LED804. (Display mode 1) Press SW800 for at least 1 second. The LED status changes to display mode 2. Check the code whose display mode 1 equals the LED states jotted down and display mode 2 equals the current flashing status of LED800 to LED804 from the following table to identify the cause. EN-26 1. 2. 3. 4. 26 Set bit 1 of DIP switch SW803 to ON. Jot down the states of LED800 to LED804.
– 115 – R22 (R407C) R410A 0.8 Ø6.4 0.8 0.8 1.0 1.0 Ø9.5 Ø12.7 Ø15.9 Ø19.0 EN-28 28 • In case the pipe diameter is Ø12.7 mm or less and the thickness is less than 0.7 mm, be sure to use new pipes for the refrigerant piping works. 3. When the outdoor unit was left with the pipes disconnected, or the gas leaked from the pipes and the pipes were not repaired and refilled. • There is the possibility of rain water or air, including moisture, entering the pipe. 4.
– 116 – R410A 1 975 EN-30 30 1. Paste the enclosed refrigerant label adjacent to the charging and/or recovering location. 2. Clearly write the charged refrigerant quantity on the refrigerant label using indelible ink. Then, place the included transparent protective sheet over the label to prevent the writing from rubbing off. 3. Prevent emission of the contained fluorinated greenhouse gas.
– 117 – Nick Ball Toshiba EMEA Engineering Director Toshiba Carrier UK Ltd. Porsham Close, Belliver Industrial Estate, PLYMOUTH, Devon, PL6 7DB.
14. DETACHMENTS 14-1. Outdoor Unit RAV-SP1104AT8 (7), RAV-SP1404AT8 (7), RAV-SP1604AT8 (7) series No. 1 Part name Procedure Common procedure Remarks WARNING Stop operation of the air conditioner and turn off breaker switch. CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc. 1. Detachment 1) Remove the service panel. (Hexagonal screws Ø4 × 10, 2 pcs.) • Remove the screws and then pull service panel downward to remove.
No. Part name 2 Discharge port cabinet Procedure Remarks 1. Detachment 1) Carry out the operation in 1. of Q above. 2) Remove the screws fixing the inverter assembly, the discharge port cabinet and the partition board. (ST1T Ø4 × 8, 4 pcs.) 3) Remove the screws for the discharge port cabinet and the bottom plate. (Hexagonal screw Ø4 × 10, 2 pcs.) 4) Remove screw for the discharge port cabinet and heat exchanger. (ST1T Ø4 × 8, 1 pc.) 5) Remove screw for the discharge port cabinet and the motor base.
No. Part name 3 Side cabinet Procedure Remarks 1. Detachment 1) Carry out the operation in 1. of Q above. 2) Remove the screws fixing the inverter assembly and the side cabinet. (ST1T Ø4 × 10, 3 pcs.) 3) Remove the screws for the side cabinet and the valve fixing plate. (ST1T Ø4 × 10, 2 pcs.) 4) Remove screw for the side cabinet and piping panel (rear). (Hexagonal screw Ø4 × 10, 2 pcs.) 5) Remove screw for the side cabinet and the bottom plate. (Hexagonal screw Ø4 × 10, 1 pc.
No. Part name 4 Inverter assembly Remarks Procedure 1. Detachment 1) Carry out the operation in 1. of Q, 1. of S above. 2) Remove the connectors connected to the Fan IPDU board, the connector connected to other components from the control board (Interface board). CN600 : TS sensor (3P: White, tube: Gray) CN601 : TE sensor (2P: White, tube: Blue) CN602 : TO sensor (2P: Yellow, tube: Black) CN603 : TD sensor (3P: White, tube: Red) CN604 : TL sensor (2P: White, tube: White) CN609 : Case thermo.
No. 5 Part name Interface board (Control board) MCC-1599 Procedure Remarks 1. Detachment 1) Carry out the operation in 1. of Q, and 1. of S above. 2) Remove lead wires and connectors to other components from the interface board (control board).
No. Part name 6 Fan-IPDU board MCC-1597 Remarks Procedure 1. Detachment FAN-IPDU board 1) Carry out the operation in 1. of Q, and 1. of S above. 2) Remove lead wires and connectors to other components from the Fan-IPDU board.
No. Part name 7 Noise filter board MCC-1600 Procedure 1. Detachment 1) Perform the operation in 1. of Q,1. of T, 1.-2 of U and 1.-2 of V. 2) Remove the screws (3 positions) fixing the inverter assembly (front). Then slide the inverter assembly (front) upwardly and remove. 3) Remove the lead wires connector to other components from the noise filter board.
No. Part name 8 Compressor IPDU board MCC-1596 Procedure Remarks 1. Detachment 1) Carry out the operation in 1. of Q, 1. of T, 1. of U, 1. of V and 1. of W. 2) Remove the screw (4 positions) fixing the inverter assembly (IPDU). 3) Remove the lead wire and connector to other components from the compressor IPDU board.
No Part name 9. Fan motor Part name Procedure 1) Carry out works of item 1 of Q and work of R. 2) Remove the flange nut fixing the fan motor and the propeller fan. • The flange nut is loosened by turning it clockwise. (When tightening it, turn it counterclockwise.) 3) Remove the propeller fan. 4) Remove the connector for the fan motor from the inverter. (Remove the ferrite core of the lower fan motor because it is used.
Part name 10 Compressor Compressor lead Remarks Procedure 1. Removal of defective compressor Piping panel (Front) 1) Recover the refrigerant gas. 2) Carry out work of item 1 of Q, 1 of S and 1 of W. 3) Remove the piping panel (Front). Remove the piping panel (Front) and screws of the bottom plate. (Hexagonal screw Ø4 × 10, 2 pcs.) Remove screw of the piping panel (Front) and the piping panel (Rear). (Hexagonal screw Ø4 × 10, 1 pc.) 4) Remove the piping panel (Rear).
No. Part name 10 Compressor Compressor lead (Continued) Procedure Remarks 2. Mounting of compressor 1) Mount the compressor in the reverse procedure for removal. Wrap the ferrite core with the compressor lead wire for 1 time. Compressor lead NOTE Ferrite core 0 o5 0t • After replacement of the compressor, be sure to replace the compressor lead. (Repair part code of compressor lead: 43160612) In this time, wrap the ferrite core with the compressor lead wire by 1 time.
No. 11 Part name PMV coil Procedure Remarks 1. Detachment Concave part 1) Carry out work of item 1 of Q. 2) Turn the coil while pulling upward and then remove the coil from the PMV main unit. PMV main unit 2. Attachment 1) Surely match the positioning projection of the coil with the concave part of PMV main unit and then fix it. Positioning projection 12 Fan guard 1. Detachment 1) Carry out works of item 1 of Q and 1 of R.
15.
Location No. Model name Part No.
Inverter Assembly RAV-SP1104AT8-E, RAV-SP1104AT8Z-E, RAV-SP1104AT8ZG-E RAV-SP1104AT8-TR, RAV-SP1104AT8Z-TR, RAV-SP1104AT8ZG-TR RAV-SP1104AT7, RAV-SP1104AT7Z, RAV-SP1104AT7ZG 702 705 714 718, 719 711 718, 719 704 712 720 717 721 710 708 720 713 720 709 715 TE TS TO TD TL 701 – 132 – 706 707
Model name Location No. Part No.
Outdoor Unit RAV-SP1404AT8-E, RAV-SP1404AT8Z-E, RAV-SP1404AT8ZG-E RAV-SP1404AT8-TR, RAV-SP1404AT8Z-TR, RAV-SP1404AT8ZG-TR RAV-SP1404AT7, RAV-SP1404AT7Z, RAV-SP1404AT7ZG 41, 42, 43 16 48 21 38, 39, 40 1 2 25 23 18 20 32, 33 8 29, 30 44, 45 22 17 47 46 37 27 34 31, 36 3, 28 24 4, 10 26 19 7, 9, 35 6 5, 11, 12 15 13 – 134 – 14
Location No. Model name Part No.
Inverter Unit RAV-SP1404AT8-E, RAV-SP1404AT8Z-E, RAV-SP1404AT8ZG-E RAV-SP1404AT8-TR, RAV-SP1404AT8Z-TR, RAV-SP1404AT8ZG-TR RAV-SP1404AT7, RAV-SP1404AT7Z, RAV-SP1404AT7ZG 702 705 714 718, 719 711 718, 719 704 712 720 717 721 710 708 720 713 720 709 715 TE TS TO TD TL 701 – 136 – 706 707
Model name Location No. Part No.
Outdoor Unit RAV-SP1604AT8-E, RAV-SP1604AT8Z-E, RAV-SP1604AT8ZG-E RAV-SP1604AT8-TR, RAV-SP1604AT8Z-TR, RAV-SP1604AT8ZG-TR RAV-SP1604AT7, RAV-SP1604AT7Z, RAV-SP1604AT7ZG 41, 42, 43 16 48 21 38, 39, 40 1 2 25 23 18 20 32, 33 8 29, 30 44, 45 22 17 47 46 37 27 34 31, 36 3, 28 24 4, 10 26 19 7, 9, 35 6 5, 11, 12 15 13 – 138 – 14
Location No. Model name Part No.
Inverter Unit RAV-SP1604AT8-E, RAV-SP1604AT8Z-E, RAV-SP1604AT8ZG-E} RAV-SP1604AT8-TR, RAV-SP1604AT8Z-TR, RAV-SP1604AT8ZG-TR RAV-SP1604AT7, RAV-SP1604AT7Z, RAV-SP1604AT7ZG 702 705 714 718, 719 711 718, 719 704 712 720 717 721 710 708 720 713 720 709 715 TE TS TO TD TL 701 – 140 – 706 707
Model name Location No. Part No.
WARNINGS ON REFRIGERANT LEAKAGE Check of Concentration Limit The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its concentration will not exceed a set limit. The refrigerant R410A which is used in the air conditioner is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws to be imposed which protect the ozone layer.
TOSHIBA CARRIER CORPORATION 23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN Copyright © 1999 to 2010 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.
