FILE NO. A07-009 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE OUTDOOR UNIT RAV-SM1603AT-E RAV-SM1603ATZ-E RAV-SM1603ATZG-E INDOOR UNIT RAV-SM1403DT-A RAV-SM1603DT-A ∗ Refer to the Service Manual with File No. A06-010 for Model RAV-SM1403AT-E, and refer to the Service Manual with File No. A07-003 for Model RAV-SP1403AT-E, respectively.
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. Do not attempt it yourself. The cleaning diagram for the air filter is there for the service person, and not for the customer. CONTENTS SAFETY CAUTION .....
6. REFRIGERANT R410A ............................................................................ 35 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. Safety During Installation/Servicing ............................................................... 35 Refrigerant Piping Installation ....................................................................... 35 Tools ..................................................................................................................
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.
WARNING Check earth wires. 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. Do not modify the products. Do not also disassemble or modify the parts. It may cause a fire, electric shock or injury. Prohibition of modification. Use specified parts. Do not bring a child close to the equipment.
WARNING Insulator check Ventilation After the work has finished, be sure to use an insulation tester set (500V Megger) to Ω or more between the charge section and the non-charge check the resistance is 2MΩ metal section (Earth position). If the resistance value is low, a disaster such as a leak or electric shock is caused at user’s side. When the refrigerant gas leaks during work, execute ventilation. If the refrigerant gas touches to a fire, poisonous gas generates.
• 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. High Static Duct Type Indoor unit RAV- SM1403DT-A SM1403DT-A Outdoor unit RAV- SM1403AT-E SP1404AT-E SM1603AT(Z)(ZG)-E Cooling capacity (kW) 12.5 13.0 14.3 Heating capacity (kW) 14.0 14.0 16.0 Model Power supply 1 phase 240V, 50Hz Running current (A) 21.3 18.5 21.97 (kW) 4.95 4.32 5.01 (%) 96.8 97.3 95 EER 2.53 3.01 2.
1-1-2. 4-way Air Discharge Cassette Type Indoor unit RAV- SM1604UT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.49 (%) 95 EER Electrical characteristics 3.12 Energy efficiency class ∗ (B) Energy rating ∗∗ — Running current (A) Power consumption Heating Power factor 4.43 (%) 95 3.
Indoor unit 1 RAV- SM804UT-E Indoor unit 2 RAV- SM804UT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.49 (%) 95 EER 3.12 Energy efficiency class ∗ Electrical characteristics (B) Running current (A) Power consumption Heating Power factor 4.43 (%) 95 3.
Indoor unit 1 RAV- SM564UT-E Indoor unit 2 RAV- SM564UT-E Indoor unit 3 RAV- SM564UT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.49 (%) 95 EER 3.12 Energy efficiency class ∗ Electrical characteristics (B) Running current (A) Power consumption Heating Power factor 4.43 (%) 95 3.
1-1-3. Concealed Duct Type Indoor unit 1 RAV- SM802BT-E Indoor unit 2 RAV- SM802BT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 5.12 (%) 95 EER 2.73 Energy efficiency class ∗ Electrical characteristics — Running current (A) Power consumption Heating Power factor 4.69 (%) 95 3.
Indoor unit 1 RAV- SM562BT-E Indoor unit 2 RAV- SM562BT-E Indoor unit 3 RAV- SM562BT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 5.12 (%) 95 EER 2.73 Energy efficiency class ∗ Electrical characteristics — Running current (A) Power consumption Heating Power factor 4.69 (%) 95 3.
1-1-4. Under Ceiling Type Indoor unit 1 RAV- SM802CT-E Indoor unit 2 RAV- SM802CT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.99 (%) 95 EER 2.81 Energy efficiency class ∗ Electrical characteristics — Running current (A) Power consumption Heating Power factor 4.69 (%) 95 3.
Indoor unit 1 RAV- SM562CT-E Indoor unit 2 RAV- SM562CT-E Indoor unit 3 RAV- SM562CT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.99 (%) 95 EER 2.81 Energy efficiency class ∗ Electrical characteristics — Running current (A) Power consumption Heating Power factor 4.69 (%) 95 3.
1-1-5. High Wall Type Indoor unit 1 RAV- SM802KRT-E Indoor unit 2 RAV- SM802KRT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 5.10 (%) 95 EER 2.75 Energy efficiency class ∗ Electrical characteristics — Running current (A) Power consumption Heating Power factor 4.98 (%) 95 3.
Indoor unit 1 RAV- SM562KRT-E Indoor unit 2 RAV- SM562KRT-E Indoor unit 3 RAV- SM562KRT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 5.10 (%) 95 EER 2.75 Energy efficiency class ∗ Electrical characteristics — Running current (A) Power consumption Heating Power factor 4.98 (%) 95 3.
1-1-6. Compact 4-way Cassette (600 × 600) Type Indoor unit 1 RAV- SM562MUT-E Indoor unit 2 RAV- SM562MUT-E Indoor unit 3 RAV- SM562MUT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Model Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.99 (%) 95 EER 2.
1-1-7. Slim Duct Type Model Indoor unit 1 RAV- SM564SDT-E Indoor unit 2 RAV- SM564SDT-E Indoor unit 3 RAV- SM564SDT-E Outdoor unit RAV- SM1603AT(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit Power supply 1 phase 230V (220 – 240V) 50Hz Running current (A) Power consumption Cooling Power factor (kW) 4.99 (%) 95 EER 2.
1-2. Outdoor Unit Model name RAV-SM1603AT(Z)(ZG)-E Power supply 1 phase 230V (220 – 240V) 50Hz Type Compressor Hermetic compressor Motor (kW) Pole 4 Refrigerant charged (kg) Refrigerant control Inter connecting pipe Standard length (m) 7.5 Min. length (m) 5 Max.
1-3. Operation Characteristic Curve • Operation characteristic curve RAV-SM1603AT-E, RAV-SM1603ATZ-E, RAV-SM1603ATZG-E 25 23.7 28.2 26 22 26 24 20 24 22 18 20 16 18 14 16 22 20 Current (A) Current (A) 30 28.2 14 12 12 10 10 • Conditions Indoor : DB27°C/WB19°C Outdoor : DB35°C Air flow : High Pipe length : 7.
2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Indoor Unit RAV-SM1403DT-A, RAV-SM1603DT-A 200 or more Service work space 704 664 (52) Air flow Hung-up plate 12 30 50 (915) 965 (Bolt pitch) (50) 100 or more Drain trap (900) 1050 Air flow 950 (Bolt pitch) 200 1300 or more Check port 400 × 800 600 (35) (52) Plug (Port for check and clean) (36) (53) (72) (50) (95) 50 or more Drain pipe (50) 32 52 Refrigerant piping (5/8” (Ø15.88)) Refrigerant piping (3/8” (Ø9.
1 —— 2 Power supply inlet hole A legs Mounting bolt hole (Ø12 × 17 U-shape hole) 39 Details of A legs 96 600 Ø38 Kockout hole 40 40 74 Air outlet 70 383 port 17.5 Note 48 54 12 75 150 Name Refrigerant piping hole Indoor/Outdoor unit connecting wire inlet hole Mounting bolt hole (Ø12 × 17 long hole) 34 170 118 Drain hole (Ø25) B legs 46 128 17.
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 Branch pipe assembly 35 80 80 Inner diameter Ø9.52 100 Inner diameter Ø12.7 100 Insulator Gas side socket Liquid side socket Ø15.9 Ø12.7 9 26 24 6 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. – 26 – 1 pc.
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3-1.
• Single type (Combination of one indoor unit and one outdoor unit) Distributor (Strainer incorporated) Indoor unit TCJ sensor Air heat exchanger TC sensor Refrigerant pipe at liquid side Outer diameter Ø9.5 Refrigerant pipe at gas side Outer diameter Ø15.
3-2. Outdoor Unit RAV-SM1603AT-E, RAV-SM1603ATZ-E, RAV-SM1603ATZG-E TO sensor TS sensor PMV Strainer 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.
• Single type • Twin type Power supply 220-240V Single phase 50Hz Power supply 220-240V Single phase 50Hz Outdoor unit Outdoor unit L N L N 1 2 3 1 2 3 Indoor A B unit 1 2 3 1 2 3 Indoor unit No.1 (Master) A B Earth screw 1 2 3 Indoor unit No.2 (Sub) A B A B Wired remote controller A B Wired remote controller • Triple type Power supply 220-240V Single phase 50Hz Outdoor unit L N 1 2 3 1 2 3 Indoor unit No.
4-2. Outdoor Unit RAV-SM1603AT-E, RAV-SM1603ATZ-E, RAV-SM1603ATZG-E CN06 WHI CN08 WHI WHI 1 2 3 4 5 7 7 RED WHI RED CAPA T02 CT RED 5 5 Noise Filter P.C. Board MCC-1551 3 3 WHI CN04 WHI CN01 CN03 CN02 P01 IPDU P.C.
4-3. Fan Characteristics Current value as a criterion, adjust the air volume value to become within the range of the chart below. Static pressure (Pa) (unit) 30 40 m³/h Hi 100 200 225 250 3,480 3,300 2,500 2,330 2,100 l/s 966 916 694 647 583 CMM 58.0 55.0 41.6 38.8 35.0 2,670 2,500 2,100 1,900 m³/h Med 2,700 l/s 750 742 694 583 527 CMM 45.0 44.5 41.6 35.0 31.
5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Indoor Unit RAV-SM1403DT-A, RAV-SM1603DT-A No. Parts name Type Specifications 1 Fan motor SWF-240-600-4A Output (Rated) 600 W 2 TA sensor Lead wire length : 1200mm 10 kΩ at 25°C 3 TC sensor Ø6 size lead wire length : 1200mm Vinyl tube (Black) 10 kΩ at 25°C 4 TCJ sensor Ø6 size lead wire length : 1200mm Vinyl tube (Red) 10 kΩ at 25°C 5-2. Outdoor Unit RAV-SM1603AT-E, RAV-SM1603ATZ-E, RAV-SM1603ATZG-E No.
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˚ B A 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” (Page 8) 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 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 Cautions for using existing pipe • Do not reuse the flare to prevent gas leak. Replace it with the supplied flare nut and then process it to a flare.
6-6-7. Recovery Method of Refrigerant RAV-SP1404AT(Z)(ZG)-E RAV-SM1603AT(Z)(ZG)-E • 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. • Use the refrigerant recovery switch SW802 on the P.C. board of the outdoor unit to recover refrigerant when the indoor unit or outdoor unit is moved. Procedure 1. Turn on the power of the air conditioner. 2.
6-7. Tolerance of Pipe Length and Pipe Head n Twin system Total length (L + a or L + b) 50 m Branch pipe length (a, b) 15 m Maximum difference between indoor units (b – a, or a - b) 10 m Between indoor units ( ∆ h) 0.
n Triple system Total length (L + a, L +b, L+c) 50 m Branch pipe length (a, b, c) 15 m Maximum difference between indoor units (|a – b|, |b – c|, |c – d|) 10 m Between indoor units ( ∆ h) 0.
6-8. Additional Refrigerant Amount n Twin system Do not remove the refrigerant even if the additional refrigerant amount becomes minus result as a result of calculations by the following formula and operate the air conditioner as it is.
n Triple system Do not remove the refrigerant even if the additional refrigerant amount becomes minus result as a result of calculations by the following formula and operate the air conditioner as it is.
6-9. Piping Materials and Sizes n Twin system Use copper tube of Copper and copper alloy seamless pipes and tubes, with 40mg/10m or less in the amount of oil stuck on inner walls of pipe and 0.8mm in pipe wall thickness for diameters for diameters 6.4, 9.5 and12.7mm and 1.0mm, for diameter 15.9mm. Never use pipes of thin wall thickness such as 0.7mm. In parentheres ( ) are wall thickness Main pipe Ø15.9 (1.0) Branch pipe Ø12.7 (0.8) Main pipe Ø9.5 (0.8) Branch pipe Ø6.4 (0.
6-10. Branch Pipe n Twin system Now the refrigerant pipe is installed using branch pipes supplied as accessories. • Bend and adjust the refrigerant piping so that the branch pipes and pipe after branching become horizontal. • Fix the branch pipes onto a wall in a ceiling or onto a column. • Provide a straight pipe longer than 500mm in length as the main piping of the branches. OK OK 500mm or more Horizontal Horizontal NO GOOG NO GOOG Inclination Inclination 6-11.
7. INDOOR CONTROL CIRCUIT 7-1. Indoor Controller Block Diagram RAV-SM1403DT-A, RAV-SM1603DT-A 7-1-1. Connection of Main (Sub) Remote Controller Main (Sub) Master remote controller (Max. 2 units) Display part LCD Function setup Display part LCD CPU Display part LED Power supply circuit A CN2 CPU Key switch *3 Power supply circuit DC5V Secondary battery B #2 A Network adapter (Option) X Y Function setup CN1 Remote controller communication circuit Network adapter P.C.
7-2. Control Specifications No. Item Outline of specifications 1 When power supply is reset 1) Distinction of outdoor unit When the power supply is reset, the outdoors are distinguished and the control is selected according to the distinguished result. 2 Operation mode selection 1) Based on the operation mode selecting command from the remote controller, the operation mode is selected. Remote controller command STOP Control outline Air conditioner stops.
No. 3 Item Room temp. control Remarks Outline of specifications 1) Adjustment range: Remote controller setup temperature (°C) COOL HEAT AUTO Wired type 18 to 29 18 to 29 18 to 29 Wireless type 18 to 30 16 to 30 17 to 27 2) Using the Item code 06, the setup temperature in heating operation can be corrected. Setup data 0 2 4 6 Setup temp.
No. Item Outline of specifications 6 Air speed selection 1) Operation [HH], [L] or [AUTO] is performed by command from the remote controller. 2) The air speed is varied with difference between Ta and Ts while the air speed is set to [AUTO]. Remarks HH > L > UL Ta (˚C) Normal cooling Cooling in Cooling/Heating [AUTO] HH (High wind) HH (High wind) HH (High wind) HH (High wind) HH (High wind) HH (High wind) L (Low wind) HH (High wind) L L (Low wind) +1.5 +1.0 +0.5 Tsc –0.
Remarks No. Item Outline of specifications 8 Freeze preventive control (Low temperature release) 1) The cooling operation (including Dry operation) is performed as follows based on the detected temperature of Tc sensor or Tcj sensor. When [J] zone is detected for 6 minutes (Following figure), the commanded frequency is decreased from the real operation frequency. After then the commanded frequency changes every 30 seconds while operation is performed in [J] zone.
No. 9 Item High-temp. release control Outline of specifications Remarks 1) The heating operation is performed as follows based on the detected temperature of Tc sensor or Tcj sensor. • When [M] zone is detected, the commanded frequency is decreased from the real operation frequency. After then the commanded frequency changes every 30 seconds while operation is performed in [M] zone. • In [N] zone, the commanded frequency is held.
No. Item Outline of specifications 13 Filter sign display (Except wireless type) ∗ It is provided on the separately sold type TCB-AX21E2. 1) The operation time of the indoor fan is calculated, the filter reset signal is sent to the remote controller when the specified time (2500H) has passed, and it is displayed on LCD. 2) When the filter reset signal has been received from the remote controller, time of the calculation timer is cleared.
7-3. Optional Connector Specifications of Indoor P.C. Board Function Ventilation output Connector No. Pin No.
EEPROM Indoor/Outdoor communication (Also used for communication of the central control system) Power transformer (Primary side) (AC240V) Remote controller power supply LED – 60 – Optional output Drain pump output Remote controller inter-unit wire Optional power supply EXCT AC fan output TA sensor Outside error input TCI sensor TC2 sensor Filter/Option error input DISP CHK Used for servicing TCJ sensor Float SW ∗ Short plug is inserted ∗1 No function 7-4.
7-5. Outdoor Print Circuit Board RAV-SM1603AT-E, RAV-SM1603ATZ-E, RAV-SM1603ATZG-E Inverter P.C.
Noise filter P.C.
EEPROM-IC IC801 Model selection jumpers (Available only service P.C. board) J800 to J803 Dip switch for service SW801 P.M.V. CN702 Case thermo.
8. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 8-1. Outdoor Controls 8-1-1. Outline of Main Controls 1. Pulse Motor Valve (PMV) control 1) 2) 3) 4) For PMV with 45 to 500 pulses during operation, respectively. In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor. In heating operation, PMV is controlled with the temperature difference between TS sensor and TE sensor.
4. Outdoor fan control Allocations of fan tap revolutions [rpm] SM160 W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF High 250 260 260 320 380 480 500 530 610 640 660 720 720 720 780 Low — — 240 300 400 500 520 550 630 660 700 740 740 740 820 1) Cooling fan control Q 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).
2) Heating fan control Q 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.) R During 3 minutes after start-up, the fan is fixed with the maximum fan tap corresponding to TE [˚C] zone in the following table. After then the fan is –2 tap/20 seconds controlled by temperature of TE sensor. STOP timer count 24 S If status, TE > 24°C continues for 5 minutes, the operation stops.
6. Short intermittent operation preventive control 1) For 3 to 10 minutes after operation start, in some cases, the compressor does not stop to protect the compressor even if receiving the thermostat-OFF signal from indoor. However it is not abnormal status. (The operation continuance differs according to the operation status.) 2) When the operation stops by the remote controller, the operation does not continue. 7.
10. Defrost control Q In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition R S in A zone to D 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 7°C < TE < 12°C has continued for 1 minute. The defrost operation is also finished when defrost operation has continued for 10 minutes even if TE sensor temperature has become 7°C or lower.
9. INDOOR UNIT TROUBLESHOOTING 9-1. 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.
9-2. Troubleshooting 9-2-1.
Error mode detected by indoor unit Operation of diagnostic function Check code E03 Cause of operation No communication from remote controller (including wireless) and communication adapter Status of air conditioner Judgment and measures Condition 1. Check cables of remote controller and communication adapters. Stop Displayed when (Automatic reset) error is detected • Central remote controller [97] check code The serial signal is not output from outdoor unit to indoor unit.
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. Not displayed at all (Operation on remote controller is impossible.) No communication with master indoor unit 2. Check remote controller. • Remote controller wiring is not correct.
9-2-2. Diagnostic Procedure for Each Check Code (Indoor Unit) Check code [E01 error] Is inter-unit cable of A and B normal? NO Correct inter-unit cable of remote controller YES Correct connection of connector. Check circuit wiring. NO Check power connection of indoor unit. (Turn on power again.) NO Check indoor P.C. board (MCC-1403). Defect → Replace YES Correct a master unit/a follower unit.
[E04 error] NO Does outdoor operate? Is group address setup of remote controller correct? YES NO Check Item code [14]. YES Are wiring in indoor unit and 1, 2, 3 inter-unit cables correct? NO Correct wiring and inter-unit cables. NO Correct wiring of connector and terminal blocks. NO Check indoor P.C. board. Defect → Replace YES Are wirings of terminal blocks (1, 2, 3) wired to CN04 normal? YES Does D502 (Orange LED) flash after power supply turned on again? YES Check indoor P.C. board.
[E18 error] Is inter-unit cable of A and B normal? NO Correct inter-unit cable of remote controller. YES Correct connection of connector. Check circuit wiring. NO Check power connection status of indoor unit (Connect again).
[L20 error] Are wiring connections to communication lines U3 and U4 normal? NO Correct wiring connection. YES Is not the multiple same central control system addresses connected? YES Correct central control system address. NO Check central controller (including network adapter) and indoor P.C. board (MCC-1403). Defect → Replace [L30 error] Are outside devices of connector CN80 connected? NO Check indoor P.C. board (MCC-1403). Defect → Replace NO Check outside devices.
[P10 error] Is connection of float switch connector (Indoor control board CN34) normal? NO Correct connection of connector. YES YES NO Does float switch work? Is circuit wiring normal? YES NO Check and correct wiring and wire circuit. NO Does drain pump work? YES Is power of drain pump turned on? ∗ NO YES Are connector pins 1 and 2 at drain pump unit side shorted (Resistance value 0)? NO YES Replace drain pump and indoor P.C. board (MCC-1403). Check the drain pipe, etc. Check indoor P.C.
[P19 error] Temperature sensor check TE sensor CN601 TS sensor CN600 Indoor TC sensor Defect → Correct and repair YES Is operation of 4-way valve normal? (Check pipe temp., etc. in cooling/heating operation.) NO NO Is the coil resistance value of 4-way valve between 1.3 and 1.6kΩ? Replace coil of 4-way valve. YES Error Check operation of outdoor P.C. board. (See below.) Check outdoor P.C. board. Defect → replace OK Check 4-way valve. Defect → Replace Check method of outdoor P.C.
[F02 error] Is connection of TC sensor connector (CN101 on Indoor P.C. board) correct? NO Correct connection of connector. YES Are characteristics of TC sensor resistance value normal? YES NO Replace TC sensor. ∗ Refer to TC sensor (Temperature-Resistance value characteristic table) Check indoor P.C. board (MCC-1403). Defect → Replace [F01 error] Is connection of TCJ sensor connector (CN102 on Indoor P.C. board) correct? NO Correct connection of connector.
[C06 error] (TCC-LINK central controller) NO Are U3 and U4 communication lines normal? Correct communication line. YES NO ∗1 Correct connection of connector. Is connection of connector normal? YES ∗1 TCC-LINK central: CN51 of TCC-LINK adapter P.C. board (MCC-1440) and CN050 of indoor P.C. board NO Are A and B communication lines normal? Check connection of A and B terminal blocks. Correct communication line of remote controller.
[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. [E01] is displayed on the remote controller and [C06 error] is displayed on the central controller.
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.
10. OUTDOOR UNIT TROUBLESHOOTING 10-1. 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.
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.
Lamp indication Operation Timer Ready F01 F02 Alternate flash Operation Timer F10 Ready F04 F06 Alternate flash Operation Timer Cause of trouble occurrence Check code F08 Heat exchanger sensor (TCJ) error Heat exchanger sensor (TC) error Heat exchanger sensor (TA) error Indoor unit sensor error Discharge temp. sensor (TD) error Temp. sensor (TE, TS) error Temp.
10-2-2. Others (Other than Check Code) Lamp indication Operation Timer Check code Cause of trouble occurrence Ready — During test run — Disagreement of cool/heat (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model) Simultaneous flash Operation Timer Ready Alternate flash New Check Code 1.
10-2-3. Check Code List (Outdoor) ALT (Alternate): Alternate flashing when there are two flashing LED Remote controller indication ¡ : Go on, ¥ : Flash, l : Go off SIM (Simultaneous): Simultaneous flashing when there are two flashing LED Sensor lamp part Block indication Explanation of error contents Detection Automatic reset Operation continuation Ready Flash F04 ¥ ¥ ¡ ALT Outdoor unit Discharge temp. sensor (TD) error Outdoor Open/Short of discharge temp. sensor was detected.
ALT (Alternate): Alternate flashing when there are two flashing LED Remote controller indication F01 F02 F10 F29 P01 P10 P12 P31 — Sensor lamp part — Representative defective position Detection ALT Indoor unit Heat exchanger sensor (TCJ) error Indoor Open/Short of heat exchanger (TCJ) was detected. ALT Indoor unit Heat exchanger sensor (TC) error Indoor Open/Short of heat exchanger (TC) was detected.
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 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.
Error mode detected by outdoor unit Operation of diagnostic function Check code Cause of operation Indoor unit Judgment anAd measures Status of air conditioner Condition F04 Disconnection, short of discharge temp. sensor (TD) Stop Displayed when error is detected 1. Check discharge temp. sensor (TD). 2. Check outdoor P.C. board. F06 Disconnection, short of outdoor temp. sensor (TE, TS) Stop Displayed when error is detected 1. Check temp. sensor (TE, TS). 2. Check outdoor P.C. board (CDB, IPDU).
10-2-4. Distinction of error mode by LED indication of outdoor unit On the Type AP112, AP140 and AP160, a Dip switch (SW801) and LED are provided on the P.C. board of the outdoor unit. Exchanging this Dip switch enables users to know the status of the outdoor unit in that time. Lighting status of LED enables users to know the distinction stage before trouble of the outdoor unit will be determined and displayed on the remote controller.
You can perform fault diagnosis of the outdoor unit with the LEDs on the P.C. board of the outdoor unit in addition to check codes displayed on the wired remote controller of the indoor unit. Use the LEDs and check codes for various checks. Details of check codes displayed on the wired remote controller of the indoor unit are described in the Installation Manual of the indoor unit. LED indication and code checking Cycle control P.C.
10-2-5. Diagnostic Procedure for Each Check Code (Indoor Unit) Check code [E01 error] Is inter-unit cable of A and B normal? NO Correct inter-unit cable of remote controller YES Correct connection of connector. Check circuit wiring. NO Check power connection of indoor unit. (Turn on power again.) NO Check indoor P.C. board (MCC-1570). Defect → Replace YES Correct a master unit/a sub unit.
[E04 error] NO Does outdoor unit operate? YES NO Check item code [14]. Is setup of group address correct? YES NO Are 1, 2, 3 inter-unit cables normal? Correct inter-unit cable. YES Are connections from connectors of inter-terminal blocks (1, 2, 3) of indoor/outdoor units normal? NO Correct connection of connector. YES Does voltage between 2 and 3 of inter-terminal blocks (1, 2, 3) of indoor unit vary?∗ NO Check indoor P.C. board.
[E10 error] YES Check power supply voltage. Correct lines. Check and eliminate noise, etc. Is there no disorder of power supply? NO Check indoor control P.C. board. Defect → Replace [E18 error] Is inter-unit cable of A and B normal? NO Correct inter-unit cable of remote controller. YES Correct connection of connector. Check circuit wiring. NO Check power connection status of indoor unit (Connect again).
[L09 error] Is not yet capacity setting of indoor unit set up? YES Set capacity data of indoor unit. (Setup item code (DN)=11) NO Check indoor P.C. board. Defect → Replace [L20 error] Are wiring connections to communication lines X and Y normal? NO Correct wiring connection. YES Is the central controller [98] displayed? NO Check indoor P.C. board.
[b7 error] (Central controller) NO Is group operation carried out? YES Is there check code on the follower unit of main/sub remote controllers? NO Check indoor P.C. board. Defect à Replace YES Correct wiring circuit of the connector connection. YES Check the corresponding indoor unit and outdoor unit. [P01 error] Isn’t there any connection error/disconnection of CN076 connector? NO NO Replace condenser.
[P10 error] Is connection of float switch connector (Indoor control board CN34) normal? NO Correct connection of connector. YES YES NO Does float switch work? Is circuit wiring normal? YES NO Check and correct wiring and wire circuit. NO Does drain pump work? YES Is power of drain pump turned on? ∗ NO YES Check the drain pipe, etc. Replace drain pump. Check wiring. Check indoor P.C. board. Defect → Replace ∗ Check that voltage of 1-3 pin of CN68 on the indoor P.C. board is +200V.
[P12 error] Turn off the power. Is there no connection error or disconnection on connectors CN333 and CN334 of indoor unit P.C. board (MCC-1402)? YES Correct connection of connector. CN333 NO Remove connectors CN333 and CN334 of indoor unit P.C. board (MCC-1402). CN334 Does the fan rotate without trouble when handling the fan with hands? NO Replace indoor fan motor. YES Are resistance values between phases at fan motor connector CN333 motor side of indoor P.C.
[P22 error] Are connections of CN300, CN301, CN302 and CN303 of P.C. board correct? Correct connection of connector. YES Does the fan rotate without trouble when handling the fan with hands under condition of removing CN300, CN301, CN302 and CN303 from P.C. board? NO CN301, ∗ CN303 YES The status that the resistance values between leads below are 12 to 22Ω.
[P19 error] Is operation of 4-way valve normal? NO YES YES Is flow of refrigerant by electron expansion valve normal? NO NO 4-way valve coil conduction? YES Is 4-way valve coil terminal 200V Check 4-way valve Defect → Replace NO YES Is circuit cable normal? Connection of CN01 on CDB and CN13 on IPDU (Both connectors are Red) Check and replace electron expansion valve. NO YES NO Are characteristics of TC sensor resistance value normal? ∗ Check and correct circuit. YES Defect Check CDB P.
[F01 error] Is connection of TCJ sensor connector (Indoor P.C. board CN102) normal? NO Correct connection of connector. YES Are characteristics of TCJ sensor resistance value normal? ∗ NO Replace TCJ sensor. YES ∗ Refer to 10-2-6. Relational graph of Check indoor P.C. board. Defect → Replace temperature sensor resistance value and temperature Characteristics-2. [P26 error] NO Is power voltage normal? Improve the power supply line.
[P29 error] Are connections of cable/connector normal? NO Check and correct circuit cabling such as cabling to compressor. YES NO Is not earthed? Is compressor normal? YES YES NO Is not winding shorted? (Is resistance between windings 0.6 to 1.2Ω?) YES NO YES Is not winding opened? NO Check IPDU P.C. board. Defect → Replace Compressor error → Replace [F06 error] Are connections of TE/TS sensor connectors of CDB CN604/CN605 normal? NO Correct connection of connector.
[F08 error] NO Is connection of TO sensor connector of CDB CN601 normal? Correct connection of connector. YES NO Are characteristics of TO sensor resistance value normal? ∗ Replace TO sensor. YES ∗ Refer to relational graph of temperature sensor resistance value Check CDB. Defect → Replace and temperature Characteristics-5. [L29 error] Are connections of CDB CN800 and IPDU CN06 connectors normal? NO Correct connection of connector.
[P03 error] Is protective control such as discharge temprelease control normal? NO Are connections of cable/connector normal? NO Correct the cabling and connection of connector. YES YES Check parts. Defect → Replace Is charged refrigerant amount normal? NO Check and correct the charged refrigerant amount. YES YES Improve and delete the cause Is not abnormal overload? NO Are characteristics of TD sensor resistance value normal? ∗ NO Replace TD sensor. YES Check CDB.
[P04 error] Is high-voltage protective operation by TE sensor normal? NO YES Is connection of cabling connector normal? NO Correct connection of cabling connector. YES Check TE sensor. Defect → Replace NO Does cooling outdoor fan normally operate? YES Is connection of connector normal? NO Correct connection of connector. YES NO Replace fan motor. Is fan motor normal? YES NO Does PMV normally operate? YES Check TE, TC, TS sensors. Replace electron expansion valve.
[97 error] (Central controller) NO Are X and Y communication lines normal? Correct communication line. YES Are CN01, CN02 and CN03 of the network adapter P.C. board (MCC-1401) and CN309 and CN41 connectors correctly connected? NO Correct connection of connector. YES NO Are A and B communication lines normal? Check connection of A and B terminal blocks. Correct communication line of remote controller. YES YES Is there no connection error of power supply wire? Correct power supply wire.
[E03 error] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receive a signal sent from the main remote controller (and central controller). In this case, check the communication cables of the remote controllers A and B, the central control system X and Y. As communication is disabled, [E03] is not displayed on the main remote controller and the central controller. [E01] is displayed on the main remote controller and [97 error] on the central controller, respectively.
10-2-6.
11. REPLACEMENT OF SERVICE P.C. BOARD 11-1. Indoort Unit 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.
[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. Step 1 Push SET , CL and TEST button on the remote controller simultaneously for more than 4 seconds. ∗ When the group operation control is performed, the unit No. displayed for the first time is the header unit No. At this time, the CODE No. (DN) shows “ ”.
[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. Step 1 Push SET , CL and TEST buttons on the remote controller simultaneously for more than 4 seconds. ∗ In the group control operation, the unit No. displayed for the first time is the header unit No. At this time, the CODE No. (DN) shows “ ”. Also, the fan of the indoor unit selected starts its operation and the swing operation starts if it has the louvers.
Table 1 DN Item Setting data Factory-set value 01 Filter sign lighting time Depending on Type 02 Filter pollution leve 0000: standard 03 Central control address 0099: Not determined 06 Heating suction temperature shift 0002: +2°C (flooring installation type: 0) OF Cooling only 0000: Heat pump 10 Type Depending on model type 11 Indoor unit capacity Depending on capacity type 12 System address 0099: Not determined 13 Indoor unit address 0099: Not determined 14 Group address 00
12. SETUP AT LOCAL SITE AND OTHERS 12-1. Indoor Unit 12-1-1. Test Run Setup on 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. • “TEST” is displayed on LC display during operation of Test Run. • During Test Run, temperature cannot be adjusted but air volume can be selected. • In heating and cooling operation, a command to fix the Test Run frequency is output.
12-1-3. LED Display on P.C. Board 1. D02 (Red) • Goes on at the same time when power was turned on (Main microcomputer operates and goes on.) • Flashes with 1-second interval (every 500ms): When EEPROM is not provided or writing was an error. • Flashes with 10-seconds interval (every 5S): When the mode is DISP 2. D203 (Red) • Goes on when power is supplied to remote controller (Lights on the hardware) 12-1-4. Function Selection Setup Perform setting while the air conditioner stops.
Function selection item No. (DN) list DN Item Contents 0001: 150H 0003: 5000H 0005: Clogging sensor used At shipment from factory 01 Filter sign lighting time 0000: None 0002: 2500H 0004: 10000H 03 Central control address 0001: No.1 unit 0099: Undecided 06 Heating suction temp.
12-1-5. Wiring and Setting of Remote Controller Control 2-remote controller control (Controlled by 2 remote controllers) This control is to operate 1 or multiple indoor units are operated by 2 remote controllers. (Max. 2 remote controllers are connectable.) (Setup method) One or multiple indoor units are controlled by 2 remote controllers. (Max. 2 remote controllers are connectable.
12-1-6. 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 CL TEST 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 item code is displayed. ò TEMP.
n Calling of error history The error contents in the past can be called. 1 SET TEST TEMP. Push + buttons simultaneously for 4 seconds or more to call the service check mode. Service Check goes on, the item code 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.
n Indoor unit power-ON sequence • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way Power ON 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 / sub units are not intermingled.
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. board CN050 Indoor control P.C.
4. Wiring specifications • Use 2-core with no polar wire. • Match the length of wire to wire length of the central Size No. of wires control system. Up to 1000m: twisted wire 1.25mm2 If mixed in the system, the wire length is lengthened 2 Up to 2000m: twisted wire 2.0mm2 with all indoor/outdoor inter-unit wire length at side. • To prevent noise trouble, use 2-core shield wire. • Connect the shield wire by closed-end connection and apply open process (insulating process) to the last terminal.
6. External view of P.C. board assembly Terminator (SW01) 52 85 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. How to Set up Central Control Address Number When connecting the indoor unit to the central control remote controller using TCC-LINK adapter, it is necessary to set up the central control address number.
How to confirm the central control address (New function for AMT32 remote controller) It can be confirmed even during operation or stopping. 1 2 3 Push UNIT LOUVER button for 4 seconds or more. ò In the frame at left side of the remote controller screen, the lighting set contents are displayed. During unset time, '' (At shipment from factory) is displayed. ò After lighting display for 3 seconds, the display automatically disappears.
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. The operation of the remote controller is not accepted while automatic address works. (Approx.
13-2. 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.
4. Single group operation • Each indoor unit controls the outdoor unit individually. 2-1 Sub/Header 1-1 Sub/Header 4-1 Master/Header 3-1 Sub/Header 8-1 Sub/Header 5.
13-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple 1-2 Sub/Header 1-1 Sub/Follower 1-2 Master/Header (1-2) (1-3) 1-3 Master/Follower 1-1 Sub/Follower (1-1) (1-2) (1-1) 1-1 Individual (Master/Header) Only turning on source power supply (Automatic completion) 2.
13-3. 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.
n 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 ON / OFF Push 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.
14. DETACHMENTS 14-1. Indoor Unit REQUIREMENT • At the service replacing time of the heat exchanger, the following tools are necessary. Prepare them before the service work. • Necessary tools: Plus screwdriver, monkey wrench, spanner, etc CAUTION • Be sure to place the heat exchanger at safe and flat place and then start the work. • Necessarily put gloves when starting the work. Working with the naked hands may cause injury on the hands. 1.
2. How to replace the parts (Continued) No. 2 Work procedure Remove the foaming part. Explanatory drawing Foaming part Note) Remove the foaming part carefully so that corners of the foaming part of the inner plate are not chipped off by being caught. 3 Remove the right side plates (2) and (3). Note) Remove the side plates so as not to damage the pipe cover. Right side plate (2) Right side plate (3) 4 Take off the shield plate from the heat exchanger. Shield plate 5 Pull up the heat exchanger.
2. How to replace the parts (Continued) No. 6 Work procedure Explanatory drawing Take off the pipe fixing bracket (1) and the drain shield plate. Pipe fixing bracket (1) 7 Remove the left side plate. 8 Remove the inner foaming plate and the insulator material. 1) Pull off the insulator material between the drain pan and the mounting plate. 2) Take off the inner foaming which is fit into between the fan base and the drain pan.
REQUIREMENT • At the service replacing time of the fan motor, the following tools are necessary. Prepare them before the service work. • Necessary tools: Plus screwdriver, L-shape hexagonal wrench (For ØM8mm (Face to face 4mm)), ratchet wrench (For Ø6mm nut (Face to face 10mm)), monkey wrench, spanner, etc. CAUTION • The weight of the fan motor which is mounted on this product is heavy (Approx. 20kg) (including peripheral parts).
4. How to replace the parts (Continued) No. 2 Work procedure Explanatory drawing Remove the electric parts box. Note) • When keeping the electric parts box, be sure not to damage or take off the sensor lead wire connected to the main unit. Motor lead wire 3 Remove the right side plates (1) and (2). 1) First remove the right side plate (2) and then the right side plate (1).
4. How to replace the parts (Continued) No. 7 Work procedure Explanatory drawing Remove the reinforcing plate. Note) • The reinforcing plate is provided to protect the transportation. Scrap it after unpacking because it is unnecessary to attach when reassembling. Reinforcing plate 8 Take off the screws which fix the bell mouth at the rear side of the motor and also take off the screws of the motor mounting plate of the mounted fan motor.
6. How to replace the sensor No. Work procedure 1 As same as the work procedure of the fan motor replacing, remove the right side plates (1) and (2). Explanatory drawing Right side plate (1) 2 Remove the shielding plate. As the shielding plate is assembled with screws, take the fixing screws off to divide the plate. Shielding plate 3 Right side plate (2) Cut the bunding band which ties 3 sensors together and then remove each sensor to replace them.
6. How to replace the sensor (Continued) No. 4 Explanatory drawing Work procedure Insert the connectors into the specified positions on P.C. board. Check carefully the directions on P.C. board so that wrong insertion is not done. • TA sensor : CN104 (Yellow) • TC sensor : CN101 (Black) • TCJ sensor : CN102 (Red) CN102 CN101 Red White CN104 7. How to clean the drain port No.
14-2. Outdoor Unit No. 1 Part name Remarks Procedure Common procedure XREQUIREMENTX Front panel Be sure to put on the gloves at any process; otherwise an injury will be caused by the parts, etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker. 2) Remove the front panel. (Hexagonal screws Ø4 × 10, 2 pcs.) • Remove the screws and then remove the front panel by pulling it downward.
No. Part name 4 Replacement of electric parts Common procedure 5 Replacement of electric parts CDB board Procedure Remarks 1. Detachment 1) Carry out works of 1 of 1 and 3 . 2) Remove the connectors connected to CDB board. (Connector of power supply and upper side fan motor) • Unlock the lock of the housing part and then remove the connectors. 3) Cut the bundling band which binds the power supply leads. 4) Remove the fixing screws for the electric parts box (B). (BT2T Ø4 × 6, 2 pcs.
No. Part name 7 Replacement of electric parts Electrolytic condenser Procedure Remarks 1. Detachment 1) Carry out works of 1 of 1 , 3 and 4 . 2) Remove the lead wire connected to the terminal block. (IPDU crossover wire) 3) Remove the connector connected to the noise filter. (IPDU crossover wire) 4) Remove the lead wire connected to the noise filter.
No. Part name 8 Replacement of electric parts IPDU P.C. board Procedure 1. Detachment 1) Carry out works of 1 of 1 , 3 and 4 . 2) Remove the lead wire connected to the terminal block. (IPDU crossover wire, reactor lead wire) 3) Remove the lead wire connected to the noise filter. (Fuse crossover wire, power supply crossover wire) Remarks Electric parts box (A) Terminal block Reactor lead wire IPDU crossover wire Fuse crossover wire 4) Close CDB part.
No. 9 Part name Reactor assembly Remarks Procedure 1. Detachment Bundling band 1) Carry out works of 1 of 1 , 3 and 4 . 2) Remove lead wires connected to the terminal block. 3) Cut the bundling band which binds the rector lead wires. Reactor lead 4) Remove screws of the rector assembly. (ST1T Ø4 × 8, 7 pcs.) 5) Lift up the reactor assembly and then remove it from the main unit. X Screws CAUTIONX The reactor assembly has heavy weight (9kg); be careful for handling it.
No. 10 Part name Fan motor Remarks Procedure 1) Carry out works of 1 and work of 2 . 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 CDB. 5) Remove fan motor lead wires at lower side from the fan motor lead fixing rubber of the penetrated part of the partition plate.
Part name 11 Compressor Compressor lead Remarks Procedure 1. Removal of defective compressor 1) Recover the refrigerant gas. 2) Carry out work of item 1 of 1 and work of 3. 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). Remove the piping panel (Rear) and screws of the bottom plate.
No. Part name 11 Compressor Compressor lead (Continued) Remarks Procedure 2. Mounting of compressor 1) Mount the compressor in the reverse procedure for removal. Note) • After replacement of the compressor, necessarily replace the compressor lead wires. (Spare parts code: 43160591) In this time, wind compressor lead around the ferrite core by 5 times. Treat the compressor lead wire which was wound around the ferrite core so that it does not come to contact with piping.
No. 12 Part name PMV coil Procedure Remarks 1. Detachment Concave part 1) Carry out work of item 1 of 1 . 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 13 Fan guard 1. Detachment 1) Carry out works of item 1 of 1 and work of 2 .
15. EXPLODED VIEWS AND PARTS LIST 15-1.
Location No. Part No.
RAV-SM1403DT-A, RAV-SM1603DT-A 411 403, 413 401 402 406 412 404, 410 405 409 408 Location No. Part No.
15-2.
Model Name RAV-SM Location No. Part No. 1603AT-E 1603ATZ-E 1603ATZG-E 1 43019904 Holder, Sensor, SUS 2 2 2 2 43032441 Nipple, Drain 1 1 1 3 43041794 Compressor, DA422A3F-25M 1 1 1 4 43047246 Bonnet, 3/8 IN 1 1 1 5 43047669 Nut, Flange 2 5 43197164 Nut, Flange, SUS304-WSB 2 2 6 43049739 Cushion, Rubber 3 3 3 7 43050407 Thermostat, Bimetal 1 1 1 8 43063317 Holder, Thermostat 1 1 1 3 3 3 Description 9 43097212 Nut 9 43197174 Nut, Comp.
RAV-SM1603AT-E, RAV-SM1603ATZ-E, RAV-SM1603ATZG-E 708 716, 717 712 702 704 707 703 718 713 718 701 711 705 709, 710 714, 715 706 Location No. Part No. 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 43050425 43063325 43150319 43155211 43160565 43160581 43160579 43163055 43160594 43160595 4316V370 4316V371 4316V372 43060859 43060700 43282001 43183020 43063248 Description Sensor TC (F6) Ass’y, Service Holder, Sensor, 6 - 6.
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 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 2007 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.