Toshiba RAV-GM2241AT8-TR Service Manual
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Toshiba RAV-GM2241AT8-TR Service Manual

Toshiba RAV-GM2241AT8-TR Service Manual

Air-conditioner split type
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SERVICE MANUAL
AIR-CONDITIONER
OUTDOOR UNIT
<DIGITAL INVERTER>
RAV-GM2241AT8-E
RAV-GM2801AT8-E
RAV-GM2241AT8J-E
RAV-GM2801AT8J-E
SPLIT TYPE
RAV-GM2241AT8-TR
RAV-GM2801AT8-TR
RAV-GM2241AT8J-TR
RAV-GM2801AT8J-TR
PRINTED IN JAPAN, Mar., 2019, TOMO
FILE No. A10-1901

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Summary of Contents for Toshiba RAV-GM2241AT8-TR

  • Page 1 FILE No. A10-1901 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE OUTDOOR UNIT <DIGITAL INVERTER> RAV-GM2241AT8-E RAV-GM2241AT8-TR RAV-GM2801AT8-E RAV-GM2801AT8-TR RAV-GM2241AT8J-E RAV-GM2241AT8J-TR RAV-GM2801AT8J-E RAV-GM2801AT8J-TR PRINTED IN JAPAN, Mar., 2019, TOMO...

  • Page 2: Table Of Contents

    CONTENTS Precaution for Safety ................. 7 1. SPECIFICATIONS................ 19 1-1. Outdoor Unit ........................19 1-2. Operation Characteristic Curve ..................20 2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)......21 2-1. Outdoor Unit ........................21 3. OUTDOOR UNIT REFRIGERATING CYCLE DIAGRAM .... 25 4. WIRING DIAGRAM ..............27 4-1.
  • Page 3 8. TROUBLESHOOTING ..............51 8-1. Summary of Troubleshooting .................... 51 8-2. Diagnostic Procedure for Each Check Code (Outdoor Unit) ......... 63 8-3. Sensor characteristics ....................... 78 9. SETUP AT LOCAL SITE AND OTHERS ........79 9-1. Calling of Check code History ..................79 9-2.
  • Page 4 Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
  • Page 5 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 6 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. Warning indication Description WARNING WARNING ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK HAZARD...

  • Page 7: Precaution For Safety

    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 WARNING Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions. Only qualified service person (∗1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.
  • Page 9 WARNING Before troubleshooting or repair work, check the earth wire is connected to the earth terminals of the main unit, otherwise an electric shock is caused when a leak occurs. If the earth wire is not correctly connected, contact an electric engineer for rework. After completing the repair or relocation work, check that the earth wires are connected properly.
  • Page 10 The refrigerant used by this air conditioner is the R32. Check the used refrigerant name and use tools and materials of the parts, which match with it. For the products, which use R32 refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see.
  • Page 11 When the refrigerant gas leaks, find out the leaked position and repair it surely. If the leaked position cannot be found out 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 cooking stove, it may generate noxious gases, causing a fire though the refrigerant gas itself is innocuous.
  • Page 12 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 13 Declaration of Conformity Manufacturer: TOSHIBA CARRIER CORPORATION 336 Tadehara, Fuji-shi, Shizuoka-ken 416-8521 JAPAN TCF holder: TOSHIBA CARRIER EUROPE S.A.S Route de Thil 01120 Montluel FRANCE Hereby declares that the machinery described below: Generic Denomination: Air Conditioner Model/type: RAV-GM2241AT8-E, RAV-GM2801AT8-E, RAV-GM2241AT8J-E, RAV-GM2801AT8J-E,...
  • 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 R410A. 2) Be careful not to charge refrigerant by mistake. Should the different type of refrigerant mix in, be sure to recharge the refrigerant.
  • Page 16 4. Tools Tools exclusive for R410A (The following tools for R410A are required.) : R410A tools available : Partly unavailable, : R410A 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 Combination Pattern (Indoor Unit / Outdoor Unit) <RAV-GM224 series> Single Concealed Duct High Static Pressure Type RAV-RM2241DTP-E Simultaneous twin Concealed 4-way cassette type Ceiling type duct type RAV-RM1101UTP-E ×2 RAV-RM1101BTP-E ×2 RAV-RM1101CTP-E ×2 Simultaneous triple Concealed 4-way cassette type Ceiling type duct type RAV-RM801UTP-E ×3 RAV-RM801BTP-E ×3...
  • Page 18 RAV-GM224 series Branch kit Simultaneous twin RBC-TWP101E RM110 — RM110 Simultaneous triple RBC-TRP100E RM80 — RM80 — RM80 Simultaneous double twin RBC-DTWP101E RM56 — RM56 — RM56 — RM56 RAV-GM280 series Branch kit Simultaneous twin RBC-TWP101E RM140 — RM140 Simultaneous triple RBC-TRP100E RM80 —...

  • Page 19: Specifications

    1. SPECIFICATIONS 1-1. Outdoor Unit 2241AT8(J)-E 2801AT8(J)-E Model Outdoor unit RAV-GM 2241AT8(J)-TR 2801AT8(J)-TR 3 phase 380-415, 50Hz (Power exclusive to outdoor Power supply is required) Hermetic compressor Type Pulse motor valve Refrigerant control Pipe Height Outdoor lower difference Outdoor Height Silky shade Appearance (Munsell 1Y8.5/0.5)

  • Page 20: Operation Characteristic Curve

    1-2. Operation Characteristic Curve • Operation characteristic curve <Digital Inverter> <Cooling> <Heating> GM280 GM280 GM224 GM224 • Conditions • Conditions Indoor : DB27˚C/WB19˚C Indoor : DB20˚C outdoor : DB35˚C Outdoor : DB 7˚C/WB6˚C Indoor air flow:High Indoor air flow : High Pipe length : 7.5m Pipe length : 7.5m Compressor speed (rps)

  • Page 21: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Outdoor Unit – 21 –...
  • Page 22 RBC-DTWP101E (Simultaneous Double Twin) <Branch pipe> <Joint pipe> Inner diameter Outer diameter Ø C Ø25.4 Inner Inner diameter diameter Ø D Ø D Inner diameter Ø28.6 1 pc. (Units: mm) Model Q’ty 25.4 15.9 Gas side 15.9 15.9 15.9 12.7 RBC-DTWP101E 12.7 Liquid side...
  • Page 23 RBC-TRP100E (Simultaneous Triple) <Gas side> Header assemb (Units: mm) Inner diameter Ø15.9 1 pc. <Liquid side> Branch pipe assembly Inner diameter Ø9.52 1 pc. Insulator Gas side socket Liquid side socket Outer diameter Ø25.4 Ø15.9 Ø12.7 Ø9.5 Ø6.4 Ø15.9 Ø25.4 Ø9.5 Ø12.7 (External...
  • Page 24 RBC-TWP101E (Simultaneous Twin) <Branch pipe> <Joint pipe> Inner diameter Outer diameter Ø C Ø25.4 Inner Inner diameter diameter Ø D Ø D Inner diameter Ø28.6 1 pc. (Units: mm) Model Q’ty Gas side 25.4 15.9 RBC-TWP101E Liquid side 12.7 – 24 –...

  • Page 25: Outdoor Unit Refrigerating Cycle Diagram

    3. OUTDOOR UNIT REFRIGERATING CYCLE DIAGRAM – 25 –...
  • Page 26 Systematic diagram of refrigerating cycle RAV-GM224 series Pressure Pipe surface temperature Compressor Indoor/outdoor Indoor heat Outdoor heat Indoor drive revolution temp.condition (Mpa) (kg/cm g) Discharge Suction exchanger exchanger frequency (rps) (TD) (TS) (TC) (TL) (TE) Indoor Outdoor Standard 23.5 12.2 91.3 14.5 12.0...

  • Page 27: Wiring Diagram

    4. WIRING DIAGRAM 4-1. Outdoor Unit PTC thermistor t° CN05 CN10 CN852 CN06 (HWI) CN16 CN101 CN07 CN17 (WHI) Noise Filter Compressor CN18 P.C. board IPDU board CN04 CN203 MCC-1600 CN19 MCC-1698 CN20 CN01 CN202 CN22 CN02 CN201 (RED) CN08 CN03 CN09 CN10...

  • Page 28: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit Parts name Type Specifications Compressor RX640A3F-21M — DC 340V, 200W Outdoor fan motor ICF-340-A200-1 4-way valve coil STF-H01AJ1736A1 AC 220-240V AC 220-240V 2-way valve coil VPV-MOAJ510B0 PMV coil PQM10441 DC12V High pressure switch ACB-4UB83W OFF: 4.15 MPa Low-pressure sensor...

  • Page 29: Refrigerant R32

    6. REFRIGERANT R32 This air conditioner adopts the R32 refrigerant which 7. Be sure to carry out installation or removal does not damage the ozone layer. according to the installation manual. The working pressure of the new refrigerant R32 is Improper installation may cause refrigeration 1.6 times higher than conventional refrigerant (R22).

  • Page 30: Processing Of Piping Materials

    Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A or R32 12.7 0.80 0.80 1 1/8 28.6 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 piping whose outer diameter exceeds 20 mm.
  • Page 31 c) Insertion of Flare Nut d) Flare Processing Make certain that a clamp bar and copper pipe have been ØD cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A / R32 or conventional flare tool.
  • Page 32 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 33: Tools

    6-3. Tools 6-3-1. Required Tools Refer to the “4. Tools” (Page 16) 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 34: Brazing Of Pipes

    1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. R32 refrigerant is a Single-component refrigerant that does not change its composition. Although it is possible to charge the refrigerant with either liquid or gas, charge it with liquid.

  • Page 35: Brazing

    2. Characteristics required for flux 6-5-3. Brazing • Activated temperature of flux coincides with the As brazing work requires sophisticated techniques, brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is In order to prevent the oxide film from occurring in the hard to carbonize.

  • Page 36: Instructions For Re-Use Piping Of R22 Or R407C

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

  • Page 37: Final Installation Checks

    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? • After the existing air conditioner is operated in cooling mode for approx.

  • Page 38: Handling Of Existing Pipe

    6-6-6. Handling of Existing Pipe 6-6-7. Recovering Refrigerant When using the existing pipe, carefully check it for Use the refrigerant recovery equipment to recover the the following: refrigerant. • Wall thickness (within the specified range) 6-7. Charging additional refrigerant • Scratches and dents •...

  • Page 39: 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 for • Before carrying out this procedure, it is essential servicing or decommissioning, it is recommended that the technician is completely familiar with the good practice that all refrigerants are removed equipment and all its details.

  • Page 40: Circuit Configuration And Control Specifications

    7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1698 (Compressor IPDU) CN04 CN01 Terminal for Terminal for power relay PTC-thermistor CN02 Connector for MCC-1600 (CN17) CN03 CN09,10 Terminal for CN203 (RED), CN202 (WHI), Terminal for CH-90 power relay CN201 (BLK) Compressor output terminal...

  • Page 41: Print Circuit Board, Mcc-1597 (Fan Motor Ipdu)

    7-1-2. Print Circuit Board, MCC-1597 (Fan Motor IPDU) CN750 CN700 CN500 (White) (Blue) (Red) Fan motor output (Upper side) Fan motor output (Down side) Connector for MCC-1600 (CN22) and reactor CH68 CN504 CN602 F500 (Blue) (Black) Connector for MCC-1698 Connector for MCC-1600 (CN51) Electric circuit protective fuse (CN852) (250V, 15A)

  • Page 42: Print Circuit Board, Mcc-1675 (Interface (Cdb))

    7-1-3. Print Circuit Board, MCC-1675 (Interface (CDB)) – 42 –...

  • Page 43: Print Circuit Board, Mcc-1600 (Noise Filter)

    7-1-4. Print Circuit Board, MCC-1600 (Noise Filter) CN05 CN16 (Red) CN10 (Red) (Red) ower supply terminal (L1) erminal for power relay erminal for MCC-1675 (CN02) and Terminal for PTC thermistor aristor protective fuse (250V, 6.3A) CN06 (White) ower supply terminal (L2) CN17 (White) erminal for...

  • Page 44: Outline Of Main Controls

    7-2. Outline of Main Controls 1. PMV (Pulse Motor Valve) control 1) The aperture of the PMV (1, 2) is controlled between 88(44+44) to 1000 (500 + 500) pulses during operation. 2) During cooling and heating operations, the PMV aperture is controlled by the temperature difference between a detected temperature from a TS sensor and a saturation temperature equivalent value (TU temperature) from a Ps sensor.
  • Page 45 3. Outdoor fan revolution number control Control of fan revolution number and the fan taps in this unit are shown below. Fan Taps Revolution number Allocation [rpm] Upper Fan GM224 Lower Fan 1000 Upper Fan GM280 Lower Fan 1000 3-1. Cooling fan control 1) Cooling operations of the outdoor fan are controlled by a TL sensor, TO sensor and the compressor revolution number.
  • Page 46 3-2. Heating fan control 1) Heating operations of the outdoor fan are controlled by a TE sensor, TO sensor and the compressor revolution number. (Control from a minimum W1 to a maximum is performed according to the table below). 2) Operation is fixed for 3 minutes after start up by a maximum fan tap corresponding to the zones in the table below.
  • Page 47 4. Defrost control 1) During heating operations, defrost operations are performed when the temperature from the TE sensor satisfies any of the conditions in the A to D zones. 2) During defrosting operations, defrost will be terminated if the temperature from the TE sensor continues at 12°C or higher for 3 seconds or if the temperature is 7°C ≤...
  • Page 48 7. 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” 83°C is detected, the fan tap is moved by 1 step up. Thereafter step-up is performed at a rate of +1 tap/5 seconds until a maximum fan tap is reached.
  • Page 49 12. SV2 valve control The conditions for opening and closing the SV2 valve are shown in the table below. SV2 Valve “Open” Conditions SV2 Valve “Close” Conditions When operation stopped after operating When operation started after operating or when 30 minutes Non-operation elapsed after opening SV2 under conditions (1) (2) When power placed “ON”...
  • Page 50 13. Coil heating control 1) This control has the function of heating the compressor by applying a current to the compressor when not operating instead using a case heater. This control is for the purpose of preventing stagnation of the refrigerant inside the compressor. 2) Malfunction in the compressor may result if a current is not applied for a specified time before a test run after installation as was previously the case.

  • Page 51: 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 points before check a) The following operations are normal.
  • Page 52 <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 points before check a) The following operations are normal. 1. Compressor does not operate. •...
  • Page 53 Outline of troubleshooting 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 troubleshooting by flashing indication on indoor unit lamp display (the signal receiving unit of wireless remote controller) When the protective function operates the self-diagnosis contents appear in flashing indication on indoor unit lamp display.
  • Page 54 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready Heat exchanger sensor (TCJ) trouble Heat exchanger sensor (TC) trouble Indoor unit sensor trouble Heat exchanger sensor (TA) trouble Alternate flash Discharge temp. sensor (TD) trouble Temp. sensor (TE) trouble Operation Timer Ready Temp.
  • Page 55 Others (Other than Check Code) Lamp indication Check code Cause of trouble occurrence Operation Timer Ready — During test run Simultaneous flash Operation Timer Ready Disagreement of cool/heat — (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model) Alternate flash –...
  • Page 56 8-1-1. Monitor Function of Remote Controller Calling of sensor temperature display <Contents> Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. <Procedure> Push buttons simultaneously for 4 seconds to call the service monitor mode.
  • Page 57 – 57 –...
  • Page 58 – 58 –...
  • Page 59 Check code table The contents of trouble 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 60 Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit Disconnection, short of discharge Displayed when 1. Check discharge temp. sensor (TD). Stop temp. sensor (TD) trouble is detected 2. Check outdoor P.C. board (MCC-1675). Disconnection, short of outdoor temp.
  • Page 61 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 2. Trouble of electronic expansion valve Stop trouble is detected specified value was detected.
  • Page 62 The contents of trouble 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.

  • Page 63: Diagnostic Procedure For Each Check Code (Outdoor Unit)

    8-2. 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 display on the remote controller may differ from that of LED.
  • Page 64 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 CN603 correct? Correct connector. Is resistance value of TD sensor correct? Replace TD sensor Replace Interface P.C.
  • Page 65 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F15] [Miss-wiring of heat exchanger sensor (TE, TS)] Is mounting status of Correct sensor mounting. TE and TS sensors correct? Is connection of CN600 correct? Correct connector.
  • Page 66 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 67 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 CN609 connection and Correct connector. Case thermostat trouble → Replace case thermostat correct? Replace compressor IPDU P.C.
  • Page 68 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H06] [Low pressure(PS) lowering trouble] Is indoor fan motor relation normal? Trouble part When cooling, the indoor unit 1. Connector connection repair fan operate normally? 2.
  • Page 69 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [L10] [Unset model type] Only when service P.C. board is used. Cut jumper line according to the explanation sheet packaged with the service P.C. board. [L29] [Communication trouble MCUs] Is the communication line between...
  • Page 70 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 71 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P05] [Power supply 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 72 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? Trouble part repair. Is there refrigerant shortage? Recharge refrigerant. Is PMV normal? Replace the PMV. Is service valve fully opened? Open service valve fully.
  • Page 73 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P19] [4-way valve inverse trouble] Does 4-way valve Is the coil work correctly? resistance Replace (Check pipe temp. etc. value of 4-way 4-way valve coil in cooling/heating valve normal? operation.)
  • Page 74 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 75 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 76 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P26] [Short-circuit 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 77 Table Inspection of outdoor unit main parts Parts name Checking procedure Compressor Measure the resistance value of each winding by using the tester. (Model : RX640A3F-21M) Position Resistance value Red – White 0.56 ± 0.04 Ω White – Black White Black Black –...

  • Page 78: Sensor Characteristics

    8-3. Sensor characteristics Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (k Ω) Resistance value (k Ω) Temperature Temperature (˚C) (˚C) (Minimum value) (Standard value) (Maximum value) (Minimum value) (Standard value) (Maximum value) 32.33 33.80...

  • Page 79: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Check code History <Contents> The trouble contents in the past can be called. <Procedure> TEMP. ON / OFF Push buttons simultaneously for 4 seconds or TIMER SET MODE more to call the service check mode. TIME SAVE VENT...
  • Page 80 Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way <By feed unit> <Automatic address judgment> Not normal 3 minutes elapse Gr construction check Normal ∗...

  • Page 81: Outdoor Unit

    9-2. Outdoor Unit Various status displays and operations can be accessed using the push buttons (service switches) on the outdoor Control P.C. board and LED display. Service switch (SW01 and SW02) operation Concerning the LED display • The LED display has 4 patterns. : Go ON : Go OFF : flash (5 times/sec)
  • Page 82 1. Various settings available via the outdoor unit (Existing pipe, Maximum frequency change, Snow guard fan control, Cooling only setup, etc.) (1) Service switch setting Various settings can be made using the service switches [Method of operation] 1) Ensure the LED display shows the initial status. If not then ensure to restore the initial status. 2) Press SW01 for at least 5 seconds.
  • Page 83 Various settings confirmation method Whether the various settings are in effect or not can be confirmed. 1) Ensure the LED display shows the initial status. If not then ensure to restore the initial status. 2) Push SW01 for at least 5 seconds. D804 will start slowly flashing. 3) Push SW01 several times until reaching the desired function on the LED display.
  • Page 84 2. Service support functions (LED display and switch operation) (1) LED display switching (SW01 and SW02 operation) (1)-1. Display switch list Service switches SW01 and SW02 can be used to change the display content of LEDs D800 to D805 on the outdoor unit.
  • Page 85 (1)-2. Trouble display Current and the latest trouble (latest and including the present trouble) can be checked using the lighting status of the LEDs D800 to D805 on the outdoor unit. (1)-2-1. Current trouble indication LED indication Wired remote Name of trouble control trouble code D800 D801 D802 D803 D804 D805 Normal...
  • Page 86 (1)-3. Sensor, current, compressor operation frequency, PMV opening indication Interface (CDB) P.C. board detected values (for example temperature and current sensor values) can be easily checked. ∗ Temperature sensors ... TD, TE, TL, TS, TO, TH, TA, TC, TCJ ∗ Current ......Current sensor (CT) value detected ∗...
  • Page 87 (1)-4. Refrigerant leak detection function Monitors the amount of refrigerant being circulated based on the temperature sensors, compressor rotation speed, PMV opening during operation, and detects any refrigerant leaks during operation and indicates it using the LEDs on the outdoor unit. CAUTION ∗...
  • Page 88 (2) Maintenance inspections Special operations (SW01 and SW02 operations) The following special maintenance and inspection operations can be carried out using the service switches SW01 and SW02. [Method of operation] 1) Ensure the LED display shows the initial state. If not then please ensure to return it to the initial state. 2) Push and hold down SW01 for at least 5 seconds.
  • Page 89 3. Outdoor application operation Optional connector kit (TCB-KBOS4E) (1) Peak-cut control • Saves the power of the outdoor unit by the external peak-cut signal to suppress temporary peak power dissipation. • The power saving can be switched to three levels: 75%, 50%, and operation stop. (2) Night operation •...

  • Page 90: 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 91: Address Setup & Group Control

    10-2. Address Setup & Group Control <Definitions of terms> 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/...

  • Page 92: System Configuration

    10-2-1. System Configuration 1. Single 2. Double twin Outdoor Indoor (Master/Header) Individual Master/Header Sub/Follower Sub/Follower Sub/Follower Remote controller 3. Twin 4. Triple Master/Header Sub/Follower Master/Header Sub/Follower Sub/Follower 5. Single group operation Sub/Header Sub/Header Sub/Header Master/Header Sub/Header (Max. : 8 units) •...

  • Page 93: Automatic Address Example From Unset Address (No Miss-Wiring)

    10-2-2. Automatic Address Example from Unset Address (No miss-wiring) 1. Standard (One outdoor unit) 1. Single 2. Twin 3. Triple Individual Master/Header Sub/Follower Master/Header Sub/Follower Sub/Follower Only turning on source power supply (Automatic completion) 2. Single group operation (Multiple outdoor units = Multiple indoor units only with serial communication) Sub/Header Sub/Header Sub/Header...

  • Page 94: Remote Controller Wiring

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

  • Page 95: Address Setup (Manual Setting From Remote Controller)

    10-4. Address Setup (Manual setting from remote controller) (Example of 2-lines wiring) In case that addresses of the indoor units will be (Real line: Wiring, Broken line: Refrigerant pipe) determined prior to piping work after wiring work Outdoor Outdoor • Set an indoor unit per a remote controller. 1 2 3 1 2 3 •...

  • Page 96: Confirmation Of Indoor Unit No. Position

    10-5. Confirmation of Indoor Unit No. Position 1. To know the indoor unit addresses though position of the indoor unit body is recognized • In case of individual operation (Wired remote controller : indoor unit = 1 : 1) (Follow to the procedure during operation) <Procedure>...
  • Page 97 <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 98: Replacement Of The Service P.c. Board

    11. REPLACEMENT OF THE SERVICE P.C. BOARD 11-1. Interface (CDB) P.C. BOARD MCC-1675 (4316V693) 1. Setting the jumper wires Part name Function Setting Jumper wire J800 ~ J803 Model switching Cut these jumper wires according to the following table. Model switching (J800 to J803) Since this service P.C.

  • Page 99: 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 circuit breaker. Never recover the refrigerant to the outdoor unit. •...

  • Page 100: Detachments

    13. DETACHMENTS No. Part name Procedure Remarks WARNING Common procedures Front panel Stop operation of the air conditioner and turn off breaker switch. CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc. Left claw Left claw Left claw...
  • Page 101 No. Part name Procedure Remarks Side 1) Following to work of item 1of cabinet 2) Remove the side cabinet (left) and base plate screws. (left) (2 pcs, Ø4 ×10 hexagon screws) Side cabinet 3) Slide the side cabinet (left) downwards and remove. (left) Base plate Air-outlet...
  • Page 102 No. Part name Procedure Remarks Electrical WARNING part There is a risk of electric shock because the voltage replacement remains in the electrolytic capacitor on the P.C. board for a Inverter cover Inverter cover while after the power is turned off. Make sure that the voltage does not remain with a tester before disassembling the inverter assembly.
  • Page 103 No. Part name Procedure Remarks Electrical 2. FAN-IPDU P.C. board Screws part 1) Following to work of item to 2) of 1 of replacement (continued) 2) Remove the connectors (6 places) from the FAN-IPDU P.C. board. CN750 ... Fan motor (upper) connector (3P: White) CN700 ...
  • Page 104 No. Part name Procedure Remarks Electrical 3. Interface (CDB) P.C. board part 1) Following to work of item to 2) of 1 of replacement (continued) Supporters 2) Remove the Interface (CDB) P.C. board connectors (18 places) CN603 ... TD sensor (3P: White, tube: Red) CN602 ...
  • Page 105 No. Part name Procedure Remarks Electrical 5. Indoor unit reactor Indoor unit reactor (CH68) part 1) Following to work of item to 2) of 1 of replacement (continued) 2) Remove the connecter of the reactor lead wire connected to the reactor. 3) Remove the fixing screws of the reactor.
  • Page 106 No. Part name Procedure Remarks Fan motor 1) Following to work of item 1, Propeller fan 2) Remove the flange nut from the fan motor and Loosen by turning Loosen by turning Loosen by turning propeller fan. clockwise clockwise clockwise •...
  • Page 107 No. Part name Procedure Remarks Compressor 1. Removing a broken compressor 1) Recover refrigerant gas. compressor lead 2) Following to work of item 1 and 3) Remove the piping panel (front). Remove the screws from piping panel (front) and base plate.
  • Page 108 No. Part name Procedure Remarks Compressor 2. Compressor attachment Wind the compressor lead 4 times around the ferrite core 1) Detachment of the reverse order of removal. compressor lead NOTE (continued) • Also ensure to replace the compressor lead after replacing the compressor.
  • Page 109 No. Part name Procedure Remarks PMV coil 1. Detachment PMV coil 1) Following to work of item 1 of 2) Remove the coil from the PMV body by rotating the coil (about 45°) while drawing the coil upward. 2. Attachment (About 45˚) (About 45˚) 1) Fix the coil positioning protrusions securely in the...

  • Page 110: Exploded Views And Parts List

    14. EXPLODED VIEWS AND PARTS LIST 14-1. Outdoor Unit RAV-GM2241AT8(J)-E, RAV-GM2801AT8(J)-E, RAV-GM2241AT8(J)-TR, RAV-GM2801AT8(J)-TR – 110 –...
  • Page 111 PANEL, SIDE 4310A127 PANEL, SIDE, LEFT 43100437 PANEL, FRONT, PIPING 4310A115 PANEL, BACK, PIPING 43107276 HANGER 43107295 HADLE, HANGER 4311M691 MARK, TOSHIBA 43122160 PLATE 43122161 PLATE 43122162 SUPPORTER, MOTOR 43122163 SUPPORTER, MOTOR 4312C149 MOTOR, FAN, ICF-340-A200-1 43120270 FAN, PROPELLER, PS561...
  • Page 112 PANEL, SIDE 4310A127 PANEL, SIDE, LEFT 43100437 PANEL, FRONT, PIPING 4310A115 PANEL, BACK, PIPING 43107276 HANGER 43107295 HADLE, HANGER 4311M691 MARK, TOSHIBA 43122160 PLATE 43122161 PLATE 43122162 SUPPORTER, MOTOR 43122163 SUPPORTER, MOTOR 4312C149 MOTOR, FAN, ICF-340-A200-1 43120270 FAN, PROPELLER, PS561...

  • Page 113: Inverter Assembly

    14-2. Inverter Assembly RAV-GM2241AT8(J)-E, RAV-GM2801AT8(J)-E, RAV-GM2241AT8(J)-TR, RAV-GM2801AT8(J)-TR Q’ty/Set Location Part No. Description RAV-GM2241AT8(J)-E, GM2801AT8(J)-E RAV-GM2241AT8(J)-TR, GM2801AT8(J)-TR 43150360 SENSOR ASSY, SERVICE, TS 43150373 SENSOR ASSY, SERVICE, TO 43150376 SENSOR ASSY, SERVICE, TE 43150374 SENSOR ASSY, SERVICE, TD 43150375 SENSOR ASSY, SERVICE, TL 43163055 HOLDER, SENSOR 43F63325...
  • Page 114 72-34 Horikawa-cho, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8585, JAPAN Copyright © 2019 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.

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