Toshiba RAV-GV1601AT8P-E Service Manual
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Toshiba RAV-GV1601AT8P-E Service Manual

Toshiba RAV-GV1601AT8P-E Service Manual

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SERVICE MANUAL
AIR-CONDITIONER
OUTDOOR UNIT
<DIGITAL INVERTER>
RAV-GV1601AT8P-E
RAV-GV1601AT8P-TR
R32
(SPLIT TYPE)
FILE NO. SVM-22086
September, 2022

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  • Page 1 FILE NO. SVM-22086 SERVICE MANUAL AIR-CONDITIONER (SPLIT TYPE) OUTDOOR UNIT <DIGITAL INVERTER> RAV-GV1601AT8P-E RAV-GV1601AT8P-TR September, 2022...

  • Page 2: Table Of Contents

    Adoption of R32 Refrigerant Original instruction This air conditioner adopts the HFC refrigerant (R32) which does not destroy the ozone layer. This outdoor unit is designed exclusively for use with R32 refrigerant. Be sure to use in combination with a R32 refrigerant indoor unit. CONTENTS SAFETY CAUTION ......................

  • Page 3: Safety Caution

    SAFETY CAUTION 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.
  • Page 4 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.
  • Page 5 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. Meaning of symbols displayed on the unit This mark is for R32 refrigerant only.
  • Page 6 CAUTION CAUTION Do not touch the aluminum fins of Do not touch the aluminum fins of the unit. the unit. Doing so may result in Doing so may result in injury. injury. CAUTION CAUTION BURST HAZARD BURST HAZARD Open the service valves before the Open the service valves before operation, otherwise there might be the burst.
  • Page 7 Precaution for Safety The appliance shall be installed in accordance with national wiring regulations. Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position.
  • Page 8 When you access inside of the electric cover to repair electric parts, wait for about five minutes after turning off the breaker. Do not start repairing immediately. Otherwise you may get electric shock by touching terminals of high-voltage capacitors. Natural discharge of the capacitor takes Electric about five minutes.
  • Page 9 When performing repairs using a gas burner, replace the refrigerant with nitrogen gas because the oil that coats the pipes may otherwise burn. When repairing the refrigerating cycle, take the following measures. 1) Be attentive to fire around the cycle. When using a gas stove, etc., be sure to put out fire before work;...
  • Page 10 When the refrigerant gas leaks, find up the leaked position and repair it surely. If the leaked position cannot be found up and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. When gas touches to fire such as fan heater, stove or cocking stove, it may generate noxious gases, causing a fire though the refrigerant gas itself is innocuous.
  • Page 11 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. Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner.
  • Page 12 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.
  • Page 13 Specification Sound power level (dBA) Model Weight (kg) Cooling Heating RAV-GV1601AT8P-E RAV-GV1601AT8P-TR - 13 -...
  • Page 14 Refrigerant R32 This air conditioner adopts a new HFC type refrigerant (R32) which does not deplete the ozone layer. 1. Safety Caution Concerned to Refrigerant R32 Be sure that water, dust, the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with refrigerant R32 during installation work or service work.
  • Page 15 <Caution items> 1) The opposite side dimension of the air-conditioner's flared nut using R32 and the shape of the charge port are the same as those of R32. 2) Be careful not to charge refrigerant by mistake. Should the different type of refrigerant mix in, be sure to recharge the refrigerant 3) Do not mix the other refrigerant or refrigerating oil with the refrigerant.
  • Page 16 4. Tools Tools exclusive for R32 (The following tools for R32 are required.) : R32 tools available : Partly unavailable, : R32 tools unavailable Installation/service tools Applicability to R32 air Applicability to R22 air conditioner or not conditioner or not Tools / Equipment specification 1 Flare tool...

  • Page 17: Specifications

    1. SPECIFICATIONS 1-1. Outdoor Unit <Digital Inverter> Model name Outdoor unit RAV-GV 1601AT8P-E(TR) 3 phase 380-415V, 50Hz 3 phase 380V, 50Hz Power supply (Power exclusive to outdoor is required) Type Hermetic compressor Compressor Motor (kW) Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Standard length Min.

  • Page 18: Operation Characteristic Curve

    1-2. Operation Characteristic Curve < > <Cooling> Compressor speed (rps) Compressor speed (rps) Capacity variation ratio according to temperature < > <Cooling> Condition Indoor: 27°C DB/19°C WB Condition Indoor Air flow volume: High Pipe length: 7.5m Indoor: 20°C DB Indoor Air flow volume: High Pipe length: 7.5m 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 -15 -13 -11...

  • Page 19: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) - 19 -...

  • Page 20: Systematic Refrigerating Cycle Diagram

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

  • Page 21: Outdoor Unit

    3-2. Outdoor Unit Packed valve Packed valve Outer dia. Ø15.88 Outer dia. Ø9.52 Pressure Strainer TŌ sensor switch TS sensor (Pulse Motor Valve) (DPF(TS1)2.5C-01) TL sensor TD sensor Strainer Strainer 4-way valve (SHF(L)-7H-34U) sensor Heat exchanger Muffler Ø8, 2 rows, 40 steps FP1.3 flat fin Distributor Ø25 ×...

  • Page 22: Wiring Diagram

    4. WIRING DIAGRAM - 22 -...

  • Page 23: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS Parts name Type Specification Compressor RX330A2T-20M 3 phase, 4P, 3000W Fan motor WDF-340-A100-1 Output 100 W 4-way valve coil SQ-D27012-000752 PMV coil PQ-M10012-000554 High-pressure SW ACB-4UB166W OFF: 4.5MPa Reactor CH-85-Z-T 5.46~6.14mH, 14A P.C. board (CDB Board) WP-507 P.C.

  • Page 24: Refrigerant R32

    6. . REFRIGERANT R 6. When an air conditioning system charged with a This air conditioner adopted the R32 refrigerant which does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, The working pressure of the refrigerant R32 is even when refrigerant leaks, its concentration 1.6 times higher than conventional refrigerant...
  • Page 25 Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) R3 2 Nominal diameter Outer diameter (mm) 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 1. Join For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm.
  • Page 26 c) Insertion of Flare Nut d) Flare Processing ØD Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. R32 or conventional flare tool. Use either a flare tool for Flare processing dimensions differ according to the type of flare tool.
  • Page 27 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.

  • Page 28: Tools

    6-3. Tools 6-3-1. Required Tools Refer to the “4. Tools” (Page 14) 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.

  • Page 29: Brazing Of Pipes

    6-5. Brazing of Pipes 3. Types of flux • Noncorrosive flux 6-5-1. Materials for Brazing Generally, it is a compound of borax and boric 1. . Silver brazing fill acid. Silver brazing filler is an alloy mainly composed It is effective in case where the brazing of silver and copper.
  • Page 30 6-5-3. Brazing As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified. In order to prevent the oxide film from occurring in Flow meter the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas flow.

  • Page 31: Instructions For Re-Use Piping Of R22 Or R407C

    6-6-3. Branching pipe for simultaneous operation system * Pipe diameter and thickness (mm) In the concurrent twin system, when TOSHIBA has Reference Wall specified that branching pipe is to be used, it can be outside...
  • Page 32 Placement Term Curing manner location 1 month or more Pinching Less than Outdoors Pinching or 1 month Taping Indoors Every time 6-6-5. Final Installation Checks Existing pipes: Cannot be used. Are there scratches or dents on the existing pipes? • Use new pipes. Is it possible to operate the existing air conditioner? •...

  • Page 33: Charging Additional Refrigerant

    6-6-7. Recovering Refrigerant • (Airtight test), Vacuum dry, Refrigerant charge, Gas Use the refrigerant recovery equipment to recover leak check the refrigerant. 6-7. Charging additional refrigerant Test run Amount of additional refrigerant shall be restricted by the following explanation to ensure the reliability. Miss-charging leads to the abnormal high pressure in the refrigerant cycle, causing a rupture, a injury and 6-6-6.

  • Page 34: General Safety Precautions For Using R32 Refrigerant

    6-8. General safety precautions for using R32 refrigerant 6-8-1. Recovery 6-8-2. Decommissioning • When removing refrigerant from a system, either • Before carrying out this procedure, it is essential that for servicing or decommissioning,　it is recommended the technician is completely familiar with the good practice that all refrigerants are removed safely.
  • Page 35 6-8-3. Pump down process 1. Turn off the Air Conditioner system. 2. Connect the charge hose from the manifold valve to the service port of the packed valve at gas side. 3. Turn on the Air Conditioner system in cooling operation more than 10 minutes.

  • Page 36: Outdoor Control Circuit

    7. OUTDOOR CONTROL CIRCUIT 7-1. Outline of Main Controls 1. Pulse Modulating Valve (PMV) control 1) For PMV : 30 to 500 pulses during operation, respectively. 2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.
  • Page 37 3. Current release control The output frequency and the output voltage are controlled by AC current value detected by current transformer on the outdoor P.C. board so that input current of the inverter does not exceed the specified value. Current [A] Frequency down GV160 Model...
  • Page 38 4-2. Heating fan control 1) An outdoor fan is controlled by TE sensor, TO sensor and compressor frequency. (It is controlled with W1 for minimum and the maximum is controlled according to the following table.) 2) At the start time, the fan is fixed for 3 minutes only with the maximum fan tap corresponded to the zone in the following table but it is controlled with TE sensor temperature after then.
  • Page 39 REQUIREMENT While heating the coil, the power sound may be heard. However it is not a trouble. 6. Heat sink temperature detection control 1) IPM overheating prevention is protective control performed by a thermistor (TH sensor) in proximity to IPM. 2) When a temperature of TH e”...
  • Page 40 11. Defrost control 1 In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition in A zone to D zone. 2 The defrost operation is immediately finished if TE sensor temperature has become 12°C continuing for 3 seconds or more, or it also is finished when condition of 7°C <...

  • Page 41: Outdoor Print Circuit Board

    7-2. Outdoor Print Circuit Board 7-2-1. Print Circuit Board WP-507 (Interface (CDB)) - 41 -...
  • Page 42 7-2-2. Print Circuit Board WP-508 (Compressor IPDU) - 42 -...
  • Page 43 7-2-3. Print Circuit Board WP-512 (Noise Filter) - 43 -...

  • Page 44: Troubleshooting

    8. TROUBLESHOOTING 8-1. Summary of Troubleshooting <Wired remote controller type> 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 the following points before check a) The following operations are normal.
  • Page 45 <Wireless remote controller type> 1. Before troubleshooting 1) Required tools/instruments • ⊕ and ⊖ screwdrivers, spanners, radio cutting pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation the following points before check a) The following operations are normal. 1.

  • Page 46: Troubleshooting

    8-2. Troubleshooting 8-2-1. Outline of judgment The following method can be done to check whether the problem occurred in indoor or outdoor unit. The error is indicated by indication lamp on the display of the indoor unit. (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
  • Page 47 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready Heat exchanger sensor (TCJ) error ⎫ ⎪ Heat exchanger sensor (TC) error ⎬ Indoor unit sensor error ⎪ ⎭ Alternate flash Heat exchanger sensor (TA) error Discharge temp. sensor (TD) error ⎫...
  • Page 48 8-2-3. Monitoring function of wired remote controller <RBC-AMT > TEMP. ON / OFF TIMER SET MODE TIME SAVE VENT FILTER RESET TEST SWING/FIX UNIT LOUVER Content Enter the service monitoring mode using the remote controller to check the sensor temperature or operation status of the remote controller, indoor unit, and outdoor unit.
  • Page 49 CODE No. Data name Unit CODE No. Data name Unit Room temperature °C Outdoor heat exchanger (Coil) temperature (TE) °C (Remote controller) Outside temperature (TO) °C Indoor suction temperature (TA) °C Compressor discharge temperature (TD) °C Indoor heat exchanger (Coil) °C Compressor suction temperature (TS) °C...
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  • Page 51 - 51 -...
  • Page 52 Failure mode detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of Cause of operation Condition code air conditioner 1. Check cables of remote controller and communication adapters. No communication from remote Displayed when Stop controller (including wireless) and •...
  • Page 53 Failure mode detected by outdoor unit Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit 1. Check discharge temp. sensor (TD). Disconnection, short of discharge Displayed when Stop 2. Check outdoor P.C. board (WP-507). temp.
  • Page 54 Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit Discharge temp. trouble 1. Check refrigerating cycle (Gas leak) Displayed when ∗ Discharge temp. (TD) over Stop 2. Trouble of electronic expansion valve trouble is detected specified value was detected.
  • Page 55 Failure mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner Power supply trouble of remote controller, Indoor EEPROM trouble Not displayed 1. Check remote controller inter-unit wiring. No communication with header indoor unit at all 2.
  • Page 56 Contents Error Display When the errors were overlapped, the latest error is displayed. When D800 to D804 are slowly flashing or D805 is flashing, push and hold SW01 and SW02 simultaneously for 5 seconds or more. The error display changes to the error which is generated. : ON, : OFF, : Rapid flashing (5 times /second)
  • Page 57 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 wired 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 trouble occurred continuously by multiple times while LED of the outdoor P.C.
  • Page 58 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] [Discharge temp. sensor (TD) trouble] Is connection of CN60 correct? Correct connector. Is resistance value of TD sensor correct? Replace TD sensor Check control P.C.
  • Page 59 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F15] [Miswiring of heat exchanger sensor (TE, TS)] Is mounting status of Correct sensor mounting. TE and TS sensors correct? Is connection of CN64 correct? Correct connector.
  • Page 60 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H01] [Compressor break down] Is power supply voltage normal? Correct power supply line. AC342 to 457V Is wire connection correct? Compressor lead Check wire connection (P.C.
  • Page 61 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H03] [Current detection circuit trouble] Replace compressor IPDU P.C.board [H04] [Case thermostat operation] Are CN67 connection and Correct connector. Case thermostat trouble → Replace case thermostat correct? Check compressor CDB P.C.
  • Page 62 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [L10] [Heat sink temp. sensor (TH) trouble] Replace compressor IPDU P.C.board [L29] [Communication trouble MCUs] Is the communication line between Correct wiring the compressor IPDU P.C. board (CN82) Check compressor IPDU P.C.
  • Page 63 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) ∗ There is a possibility that it is one of the following trouble. [P04] Confirm LED on outdoor P.C. board to judge which trouble it is. (1) high-pressure SW system trouble, (2) power supply trouble (Vdc), (3) high-pressure protective operation, (4) case thermostat operation.
  • Page 64 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P05] [Powersupply trouble] Voltage failure, open phase Check the same items as [P04] trouble. Is there no open phase of the Correct wiring power supply? Does the supply voltage drop or rise Confirmation of...
  • Page 65 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P15] [Gas leak detection] Is there gas leak? Fault part repair. Is there refrigerant shortage? Recharge refrigerant. Is PMV normal? Replace the PMV. Is service valve fully opened? Open service valve fully.
  • Page 66 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [4-way valve inverse error] [P19] Is the 4-way valve Is operation of 4-way valve coil is normal? correct? Replace coil (Check the resistance value (Check pipe temp.
  • Page 67 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] [High pressure protective operation] [P04] Is service valve Open service valve fully. fully opened? Reset the power supply and then perform test run Cooling season matching to the season.
  • Page 68 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] [Fan system trouble] Is power supply voltage normal? Check wiring construction. AC342 to 457V Ask repair of power supply. Rotate shaft of the fan motor by hands during power-OFF.
  • Page 69 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P26] [Short-cuit of compressor drive element] Are connections of compressor lead and reactor correct? Correct wiring. (Check referring to the Wiring diagram.) Does the same trouble occur in Replace compressor operation without compressor lead? IPDU P.C.
  • Page 70 8-2-6. Diagnostic Procedure for Each Check Code (Outdoor Unit) Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (kΩ Ω Ω Ω Ω ) Resistance value (kΩ Ω Ω Ω Ω ) Temperature Temperature (°C)
  • Page 71 8-3. Table Inspection of outdoor unit main parts Parts name Checking procedure Measure the resistance value of each winding by using the tester. Compressor (Model : RX330A2T-20M) Position Resistance value Red – White White – Black 0.37 Ω White Black Black –...

  • Page 72: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Troubleshooting based on information displayed on remote controller <RBC-AMT > (1) Checking and testing When a trouble occurs to an air conditioner, a check code and indoor unit No. are displayed on the display window of the remote controller.
  • Page 73 <RBC-ASCU11- > (1) Confirmation and check If a problem occurs with the air conditioner, the OFF timer indicator alternately shows the check code and the indoor Unit No. in which the problem occurred. Check code The indoor Unit No. in which the problem occurred.

  • Page 74: Group Control Operation

    9-2. Group Control Operation In a group control, operation of maximum 8 indoor units can be controlled by a remote controller. The indoor unit connected with outdoor unit (Individual/Master of twin) controls room temperature according to setting on the remote controller. <System example>...
  • Page 75 Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way <By feed unit> <Automatic address judgment> Gr construction check 3 minutes elapse Normal ∗...

  • Page 76: Outdoor Unit

    9-3. Outdoor Unit Various displays and various operations are enabled by push buttons (service) switches and LED on the outdoor control P.C. board. Service switch (SW01, SW02) operations LED display • 4 patterns are provided for LED display. : ON, : OFF, : Rapid flashing (5 times/second), : Slow flashing (Once/second)
  • Page 77 9-3-2. Various settings on outdoor unit (Existing piping etc.) (1) Service switch setting Various settings are available by setting service switches. [Operating method] 1) Check LED display is the initial status. If it is not so, set the initial status. 2) Push and hold SW01 for 5 seconds or more and then check D804 flashes slowly.
  • Page 78 In the case to return the setting to one at shipment from factory When to return the setting to one at shipment from the factory due to reinstallation and so on, the setting can be returned in the following procedure. 1) Check LED display is the initial status.
  • Page 79 Setting method 1. Check the LED display is an initial state. (Fig. 1) If the initial status is not established (if D805 is flashing), hold down the SW01 and SW02 service switches simultaneously for at least 5 seconds to return the LED displays to the initial status. 2.
  • Page 80 Cancel 1. 1. and 2. of the setting methods are executed. 2. Several times press SW01 to set the LED displays of the selection mode shown below. (Fig. 6) 3. Press SW02, D805 is turned off. (Fig. 7) 4. Hold down SW02 for at least 5 seconds, and when D804 flashes slowly and D805 lights, and the setting is completed.
  • Page 81 9-3-3. Service support function (LED display, service switch operating method) 1. LED display switching 1-1. Display switching list The displayed contents of LED D800 to D805 on the outdoor P.C. board can be switched by handling the service switches SW01 and SW02. [Operating method] 1) Check LED display is the initial status.
  • Page 82 1-2. Error display The error which is occurring at present and the latest error (the latest error data including one which is occur- ring now) can be confirmed by lighting LED D800 to D805 on the outdoor control P.C. board. A.
  • Page 83 C. Sensor, current, compressor operation frequency, PMV opening display The values, such as the temperature sensor or the current value, which the controller detects are easily confirmed. * Temperature sensor: TD, TE, TL, TS, TO, TH, TA, TC, TCJ LED display Temp.
  • Page 84 2. Special operation for maintenance check (SW01 and SW02 operations) The following special operations for maintenance check can be performed by handling the service switches SW01 and SW02. [Operating method] 1) Check LED display is the initial status. If it is not so, set the initial status. 2) Push and hold SW01 for 5 seconds or more and then check D804 flashes slowly.

  • Page 85: Applicable Control Of Outdoor Unit

    9-4. Applicable Control of Outdoor unit The following controls are enabled by connecting the part “Application control kit” (TCB-PCOS1E2) sold separately. (1) Power peak cut control * The capacity of the outdoor unit is saved by the Demand signal from outside and corresponds to the temporary peak cut.

  • Page 86: Address Setup

    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.

  • Page 87: Address Setup & Group Control

    10-2. Address Setup & Group Control <Terminology> Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/from the remote controllers and sub indoor units.
  • Page 88 10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single (Master/Sub) Individual Only turning on source power supply (Automatic completion) • Header unit: The header unit receives the indoor unit data (thermo status) of the follower (Without identical line address &...
  • Page 89 10-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single Individual (Master/Header) Only turning on source power supply (Automatic completion) 2. Group operation (Multiple outdoor units = Multiple indoor units with serial communication only, without twin) Sub/Header Sub/Header Master/Header...

  • Page 90: Remote Controller Wiring

    10-3. Remote Controller Wiring • Strip off approx. 9 mm the wire to be connected. Wiring diagram • For single system, use non polarity, 2 core wire is used for wiring of the remote controller. Terminal block for remote controller Terminal block (0.5 mm²...

  • Page 91: Manual Address Setting Using The Remote Controller

    10-5. Manual address setting using the remote controller Procedure when setting indoor units’ addresses first under the condition that indoor wiring has been completed and outdoor wiring has not been started (manual setting using the remote controller) Wiring example of 2 refrigerant lines Refrigerant line 1 Refrigerant line 2 Outdoor...
  • Page 92 <Indoor unit address> 13 13 13 13 13 Push the TEMP. buttons repeatedly to set the CODE No. to Push the TIME buttons repeatedly to set an indoor unit address. Push the button. (It is OK if the display turns on.) <Group address>...
  • Page 93 Confirming the indoor unit addresses and the position of an indoor unit using the remote controller Confirming the numbers and positions of indoor units To know the indoor unit addresses though position of the indoor unit is recognized When the unit is individual (the indoor unit is paired with a wired remote controller one-to-one), or it is a group-controlled one.
  • Page 94 To find an indoor unit’s position from its address When checking unit numbers controlled as a group <RBC-AMT > TEMP. ON / OFF TIMER SET MODE TIME SAVE VENT Stop FILTER RESET TEST SWING/FIX UNIT LOUVER (Execute it while the units are stopped.) The indoor unit numbers in a group are indicated one after another.
  • Page 95 <Maintenance/Check list> Aiming in environmental preservation, it is strictly recommended to clean and maintain the indoor/outdoor units of the operating air conditioning system regularly to secure effective operation of the air conditioner. It is also recommended to maintain the units once a year regularly when operating the air conditioner for a long time.

  • Page 96: Replacement Of The Service P.c. Board

    11. REPLACEMENT OF THE SERVICE P.C. BOARD(MCC-1646) ! WARNING Don’t open the inverter cover before 1 minute after power has been turned off because an electric shock may be occurred. Assembly steps: LED side of P.C.Board (MCC-1646) shall be inserted to hook① along the guide② of mold. Switch side of P.C.Board (MCC-1646) shall be pressed to hook③...

  • Page 97: How To Exchange Compressor

    12. HOW TO EXCHANGE COMPRESSOR 12-1. Exchanging Procedure of Compressor (Outline) START Open PMV forcedly and then recover refrigerant Has refrigerant recovery work been done? using a refrigerant recovery unit. Turn off the leakage breaker. Never recover the refrigerant to the outdoor unit. For the refrigerant recovery work during reinstallation Remove the defective compressor.

  • Page 98: Detachments

    13. DETACHMENTS Part name Procedure Remarks Common CAUTION procedure Be sure to put on the gloves at working time; otherwise an injury may be caused by a part, etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker.
  • Page 99 Part name Procedure Remarks 1. Detachment Discharge port cabinet Discharge port cabinet 1) Carry out work of 1 of 2) Remove screws for the discharge port cabinet Heat exchanger Partition plate and the partition plate. Motor base (ST1T Ø4 × 8, 3 pcs.) 3) Remove screws for the discharge port cabinet and the bottom plate.
  • Page 100 Step Component Procedure Remark Exchange of WARNING electric parts Do not detach the inverter for 5 minutes after truning off the braker as doing so may cause Screws electric shocks. CAUTION Wear glove when working on it. (Fig. 4-1) Failure to observe this precaution may cause injury due to components, etc.
  • Page 101 Step Component Procedure Remark Exchange of 8) Remove the ASM-INV from the electric parts ASM-PANEL-BACK (Fig. 4-7) (Continued) 9) Remove the ASM-INV from the ASM-PATITION (Fig. 4-8) Hook 10) Remove the all connectors from the ASM-PCB(CDB) (Fig. 4-9) 11) Cut the binding band and remove (Screw:M4x8, 1pc.) (Fig.
  • Page 102 Step Component Procedure Remark Exchange of 14) Remove the screws of HEATSINK from Screws M3 electric parts ASM-PCB(CDB) (Screws:M3x14, 2pcs.) (Continued) (Fig. 4-11) and (Fig. 4-12) 2. Attachment (Fig. 4-12) 1) Install it in the reverse of the procedure to remove it. 2) Apply heat silicones to E-parts.
  • Page 103 Step Component Procedure Remark Exchange of 20) Remove the ASM-S-BASE-CDB out of electric parts the ASM-INV-SUB (Fig. 4-19) (Continued) 21) Remove the all connectors and screws (Screws:M4x8, 4pcs.) (Fig. 4-20) Slide 21) Remove the screws of IC21 and DB01 (Fig. 4-19) (Screws:M4x16, 2pcs.) and (Screws:M3x14, 2pcs.) (Fig.
  • Page 104 Part name Procedure Remarks 1) Carry out works of 1 of 1 and 2 . Fan motor Loosened by Propeller fan turning clockwise 2) Remove the flange nut fixing the fan motor and the propeller fan. ∗ The flange nut is loosened by turning clockwise. (To tighten it, turn it counterclockwise.) 3) Remove the propeller fan.
  • Page 105 Part name Procedure Remarks 1. Removal of broken compressor Compressor Compressor lead 1) Recover the refrigerant gas. 2) Carry out works of 1 of 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and the bottom plate. (Hexagonal screw Ø4 ×...
  • Page 106 Part name Procedure Remarks Compressor 10) Using a burner, remove the discharge Compressor lead pipe and the suction pipe connected to (Continued) the compressor. Remove Remove (Suction pipe) (Discharge pipe) WARNING In case of removing the piping by broiling the welded part with a burner, if the piping includes oil, it may burst into flames at the moment when wax melted, so take sufficient care.
  • Page 107 Part name Procedure Remarks 2. Mounting of compressor Compressor Compressor lead 1) Mount the compressor in the reverse (Continued) procedure of removal. Discharge pipe Suction NOTES: Pipe ∗ Fix the removed each sensor and PMV coil lead wire to the discharge pipe and the suction pipe with the bundling band via the Pass the soundproof Pass the soundproof...
  • Page 108 Part name Procedure Remarks 3. Vacuuming Compressor Compressor lead 1) Connect the vacuum pump to the charge (Continued) port of the gas pipe valve and then drive the vacuum pump. 2) Carry out vacuuming until the vacuum low pressure gauge indicates 1 (mmHg). NOTE: Before vacuuming, open PMV fully.
  • Page 109 Part name Procedure Remarks 3. Detachment Fan guard Discharge port cabinet Bell mouth 1) Carry out works of 1 of CAUTION To prevent scratching on the product, handle the product on a cardboard or cloth. 2) Remove the discharge port cabinet and then put on it so that the fan guard side directs downward.

  • Page 110: Exploded Views And Parts List

    14. EXPLODED VIEWS AND PARTS LIST Outdoor Unit - 110 -...
  • Page 111 VALVE,PACKED,15.88 DIA 43T46503 VALVE ; PACKED 9.52 DIA 43T43589 CONDENSER ASSEMBLY 43T47372 STRAINER 43T47396 STRAINER 43T21537 SERVICE MOTOR ASSEMBLY 43T20352 FAN-PR(PB522) 43T19372 FAN GUARD(TOSHIBA) 43T22313 BELLMOUTH 43T19345 FIN GUARD 43T71302 HANDLE 43T60504 TEMPERATURE SENSOR 43T19333 HOLDER, SENSOR 43T49357 RUBBER,CUSHION 43T47410 BONNET (15.9D)
  • Page 112 <Inverter assembly> CN88 CN68 RY60 CN69 CN20 CN87 IC80 CN81 IC14 CN80 CN85 IC30 T100 CN82 IC11 R700 C340 CN55 X 01 IC80 CN01 CN81 S WRT RY50 DB 01 TH01 WP-512 COMPONENT SIDE Model name RAV-GV Location Part No. Description 1601AT8P-E 1601AT8P-TR...
  • Page 113 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 R32 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.
  • Page 114 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

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