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Toshiba RAV-SM2244AT8-A Service Manual

Split type air conditioner
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FILE NO. A10-028

SERVICE MANUAL

SPLIT TYPE
OUTDOOR UNIT
<DIGITAL INVERTER>
RAV-SM2244AT8-A
RAV-SM2804AT8-A
R410A
PRINTED IN JAPAN, Feb., 2011 ToMo

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Summary of Contents for Toshiba RAV-SM2244AT8-A

  • Page 1: Service Manual

    FILE NO. A10-028 SERVICE MANUAL SPLIT TYPE OUTDOOR UNIT <DIGITAL INVERTER> RAV-SM2244AT8-A RAV-SM2804AT8-A R410A PRINTED IN JAPAN, Feb., 2011 ToMo...

  • Page 2: Table Of Contents

    Adoption of New Refrigerant This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer. WARNING Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have a service person do it.
  • Page 3 7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS ... 27 7-1. Outdoor Unit Control ..................27 7-2. Outline of Main Controls .................. 31 8. TROUBLESHOOTING ................37 8-1. Summary of Troubleshooting ................37 8-2. Troubleshooting ....................39 9. SETUP AT LOCAL SITE AND OTHERS ..........61 9-1.

  • Page 4: Safety Caution

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

  • Page 9: Specifications

    1. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. Concealed Duct High static pressure Type Indoor unit RAV-SM2242DT-E RAV-SM2802DT-E Model Outdoor unit RAV-SM2244AT8-A RAV-SM2804AT8-A Cooling capacity (kW) 16.7 20.0 Heating capacity (kW) 22.4 27.0 Power supply 1 phase 220-240V~ 50Hz Running current 5.25 – 4.81 5.25 –...

  • Page 10: Outdoor Unit

    1-2. Outdoor Unit Model Outdoor unit RAV-SM 2244AT8-A 2804AT8-A 1 phase 380 – 415V 50Hz Power supply (Power exclusive to outdoor is required.) Type Hermetic compressor Compressor Motor (kW) 3.75 3.75 Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Max.

  • Page 11: Operation Characteristic Curve

    1-3. Operation Characteristic Curve • Operation characteristic curve <Digital Inverter> RAV-SM2244AT8-A, RAV-SM2804AT8-A <Cooling> <Heating> SM280 SM280 SM280 SM280 SM280 SM280 SM224 SM224 SM224 SM224 SM224 SM224 • Conditions • Conditions Indoor : DB27˚C/WB19˚C Indoor : DB20˚C Outdoor : DB35˚C Outdoor : DB7˚C/WB6˚C...

  • Page 12: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Outdoor Unit – 12 –...

  • Page 13: Outdoor Unit Refrigeranting Cycle Diagram

    3. OUTDOOR UNIT REFRIGERANTING CYCLE DIAGRAM RAV-SM2244AT8-A, RAV-SM2804AT8-A Solenoid valve Check joint High-pressure side TO sensor Pressure switch Check Muffler valve Ø45 × 230 L TL sensor 4-way valve Check joint Low-pressure side TD sensor TE sensor Pressure Distributor sensor Heat exchanger Ø8, 2 rows, 60 stages + Ø9.5, 1 row, 60 stages...
  • Page 14 Systematic diagram of refrigerating cycle RAV-SM2244 series Pressure Pipe surface temperature (°C) Indoor/Outdoor Compressor temp. conditions Indoor heat Outdoor heat drive revolution Indoor (DB/WB) (°C) (MPa) (kg/cm²g) Discharge Suction exchanger exchanger frequency ∗ (rps) (TD) (TS) (TC) (TE) Indoor Outdoor Standard 3.14 0.88...

  • Page 15: Wiring Diagram

    4. WIRING DIAGRAM 4-1. Outdoor Unit RAV-SM2244AT8-A, RAV-SM2804AT8-A Compressor IPDU board Noise Filter MCC-1596 P.C. board MCC-1600 Fan IPDU board MCC-1597 Interface (CDB) MCC-1436 P.C. board MCC-1599 – 15 –...

  • Page 16: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit RAV-SM2244AT8-A, RAV-SM2804AT8-A Parts name Type Specifications Compressor DA550A3F-11M — Outdoor fan motor ICF-280-A100-1 DC 280 V, 100 W 4-way valve coil STF-01AJ502E1 AC 220 – 240 V, 50 Hz 2-way valve coil VPV-MOAJ524C0 AC 220 –...

  • Page 17: Refrigerant R410A

    6. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC 6. When an air conditioning system charged with a (R410A) which does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, The working pressure of the new refrigerant R410A even when refrigerant leaks, its concentration is 1.6 times higher than conventional refrigerant...
  • Page 18 Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 1. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm.
  • Page 19 c) Insertion of Flare Nut d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool. ØD Flare processing dimensions differ according to the type of flare tool.
  • Page 20 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 21: Tools

    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.

  • Page 22: Brazing Of Pipes

    1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.
  • Page 23 2. Characteristics required for flux 6-5-3. Brazing • Activated temperature of flux coincides with As brazing work requires sophisticated techniques, the brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is hard to carbonize.

  • Page 24: Instructions For Re-Use Piping Of R22 Or R407C

    6-6. Instructions for Re-use Piping of R22 or R407C Instruction of Works: 4. Refrigerant recovery is impossible. (Refrigerant recovery by the pump-down operation The existing R22 and R407C piping can be on the existing air conditioner) reused for our digital inverter R410A products installations.

  • Page 25: Final Installation Checks

    6-6-4. Final Installation Checks Is there no scratch or dent on the existing pipes? Existing pipe: NO * Use a new pipes. Is it possible to operate the existing air conditioner? ∗ After the existing air conditioner operated in cooling mode for approx.
  • Page 26 6-6-5. Handling of Existing Pipe 6-6-6. Recovering Refrigerant When using the existing pipe, carefully check it for Use the refrigerant recovery equipment to recover the following: the refrigerant. • Wall thickness (within the specified range) • Scratches and dents • Water, oil, dirt, or dust in the pipe •...

  • Page 27: Circuit Configuration And Control Specifications

    7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1596 (Compressor IPDU) CN851 CN07 , CN08 CN101 (Red) (Blue) (Blue) (White) Connector for MCC-1597 (CN505) Terminal for reactor CH44 Connector for MCC-1597 (CN502) CN03 (Black) Terminal for power relay Electric circuit protective fuse (500V, 31.5A)
  • Page 28 7-1-2. Print Circuit Board, MCC-1597 (Fan Motor IPDU) CN750 CN700 CN500 (White) (Blue) (Red) Fan motor output (Upper side) Connector for MCC-1436 (CN03 or CN07) Connector for MCC-1600 (CN23) and reactor CH68 CN504 CN602 F500 (Blue) (Black) Connector for MCC-1599 Connector for MCC-1600 (CN51) Electric circuit protective fuse (CN802)
  • Page 29 7-1-3. Print Circuit Board, MCC-1599 (Interface (CDB)) CN708 CN608 (Blue) (White) Connector for power relay coil Connector for MCC-1600 (CN50) CN02 (Red) CN802 CN702 (White) Connector for (White) MCC-1600 (CN10 and CN19) Connector for MCC-1597 (CN504) 2-way valve connector CN700 (Yellow) Power supply protective fuse (250V, 3.15A)
  • Page 30 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-1599 (CN02) and Terminal for PTC thermistor aristor protective fuse (250V, 6.3A) CN06 (White) ower supply terminal (L2) CN17 (White) erminal for...

  • Page 31: 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 32 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 SM224 Lower Fan Upper Fan SM280 Lower Fan 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 33 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 34 7. Heat sink temperature detection control 1) IGBT overheating prevention is protective control performed by a thermistor (TH sensor) in proximity to IGBT. 2) When a temperature of TH ≥ 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 35 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 36 14. 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 37: Troubleshooting

    8. TROUBLESHOOTING 8-1. Summary of Troubleshooting <Wired remote controller type> 1. Before troubleshooting 1) Required tools/instruments • screwdrivers, spanners, radio cutting pliers, nippers, push pins for reset switch – • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal.
  • Page 38 <Wireless remote controller type> 1. Before troubleshooting 1) Required tools/instruments – • screwdrivers, spanners, radio cutting pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1. Compressor does not operate. •...

  • Page 39: Troubleshooting

    8-2. Troubleshooting 8-2-1. Outline of judgment The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method. Method to judge the erroneous position by flashing indication on the display part of the indoor unit (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
  • Page 40 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready Heat exchanger sensor (TCJ) error ⎫ ⎪ Heat exchanger sensor (TC) error Indoor unit sensor error ⎬ Heat exchanger sensor (TA) error ⎪ Alternate flash ⎭ Discharge temp. sensor (TD) error ⎫...
  • Page 41 8-2-2. Others (Other than Check Code) Lamp indication Check code Cause of trouble occurrence Operation Timer Ready — During test run Simultaneous flash Operation Timer Ready Disagreement of cool/heat — (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model) Alternate flash –...

  • Page 42: Monitor Function Of Remote Controller Switch

    8-2-3. Monitor Function of Remote Controller Switch Calling of sensor temperature display <Contents> Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. <Procedure> TEST Push buttons simultaneously for 4 seconds to call the service monitor mode.
  • Page 43 8-2-4. Check Code List (Outdoor) ¡ ¥ : Go on, : Flash, : Go off ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED Sensor lamp part Remote Automatic Operation controller Block indication...
  • Page 44 ¡ : Go on, ¥ : Flash, : Go off ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED Sensor lamp part Remote Automatic Operation controller Block indication Representative defective position Detection Explanation of error contents reset...

  • Page 45: Error Mode Detected By Indoor Unit

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

  • Page 46: Error Mode Detected By Outdoor Unit

    Error mode detected by outdoor unit Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner 1. Check discharge temp. sensor (TD). Disconnection, short of discharge Displayed when Stop temp. sensor (TD) error is detected 2.
  • Page 47 Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner Displayed when 1. Check outdoor P.C. board (MCC-1596). Current detection circuit error Stop error is detected (AC current detection circuit) 1. Check open phase of 3-phase power supply. Open phase of 3-phase power Displayed when Stop...

  • Page 48: Error Mode Detected By Remote Controller Or Central Controller (Tcc-Link)

    Error mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner Power supply error of remote controller, Indoor EEPROM error 1. Check remote controller inter-unit wiring. No communication with master indoor unit 2.
  • Page 49 8-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board to narrow the contents to be confirmed. 3) The check code on the remote controller is displayed only when the same error occurred continuously by multiple times while LED of the outdoor P.C.
  • Page 50 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] <Display 1> <Display 2> [Discharge temp. sensor (TD) error] ¡ ¡ ¡ Is CN603 connection normal? Correct connector. Sensor error → Replace Is resistance value of TD sensor normal? ¥...
  • Page 51 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F08] <Display 1> <Display 2> [Outside air temp. sensor (TO) error] ¡ ¡ ¡ ¥ Correct connector. Is CN602 connection normal? Sensor error → Replace Is resistance value of TO sensor normal? ¡...
  • Page 52 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F23] <Display 1> <Display 2> [PS sensor error] ¡ ¡ ¥ ¡ Is connector of Correct connection of connector. Ps sensor correctly connected? ¥...
  • Page 53 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H02] <Display 1> <Display 2> [Compressor lock] ¡ ¡ ¡ Is power supply voltage normal? Correct power supply line. AC342 to 457V ¡ ¥...
  • Page 54 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H06] <Display 1> <Display 2> [Low pressure protective operation] ¡ ¡ ¡ Are gas pipe, liquid pipe and service valve of the Open the service valve fully. outdoor unit fully opened? ¥...
  • Page 55 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [L29] ∗ There is a possibility that it is one of the following errors. Confirm LED on outdoor P .C. board to judge which error it is. Communication error between MCU, Heat sing temp.
  • Page 56 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P03] <Display 1> <Display 2> [Discharge temp. error] ¡ ¡ ¡ Repair defective position. Is there no gas leak? Recharge refrigerant. Is refrigerant charge amount adequate? ¡...
  • Page 57 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P04] Heating operation Are connections of Does the heating indoor fan connectors,capacitors normally operate? and fan motor normal? Is there any element which blocks indoor heat exchanger? Elimination of Repair...
  • Page 58 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P05] <Display 1> <Display 2> [Power supply error (Voltage error)] ¡ ¡ Is there no open phase ¡ Correct wiring. of the power supply? ¥...
  • Page 59 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] <Display 1> <Display 2> [High pressure protective operation] ¡ ¡ ¥ ¡ Is valve fully opened? Open valve fully. ¥ ¡ ¡ Reset the power supply ¡...
  • Page 60 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] <Display 1> <Display 2> [Fan system error] ¡ ¡ ¥ ¡ Is there no problem on power supply voltage? Check wiring construction. (342 to 457V) Ask repair of power supply.

  • Page 61: Temperature Sensor

    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) (°C) (Minimum value) (Standard value) (Maximum value)

  • Page 62: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Error History <Contents> The error contents in the past can be called. <Procedure> TEMP. ON / OFF TEST Push buttons simultaneously for TIMER SET MODE 4 seconds or more to call the service check mode. TIME SAVE VENT...
  • Page 63 n Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way <By feed unit> <Automatic address judgment> Not normal Gr construction check 3 minutes elapse Normal...

  • Page 64: Outdoor Unit

    9-3. Outdoor Unit 9-3-1. Various Setting on Outdoor Unit (Existing piping, Power save, Cooling-only, etc.) The following settings are available by DIP switch setup and jumper line setup. Function Set position Control contents Turn the switch to ON when Ø19.1 is used for the existing pipe. Existing In this case, the heating capacity may lower according to outside piping setup...
  • Page 65 9-3-2. Service Support Function (LED Display, Switch Operation) 1. Outline A various setup and operation check can be performed by DIP switches at 3 positions (SW802, SW803, SW804) and the pushdown button switches (SW800, SW801) at 2 positions. Operation part Part No.
  • Page 66 9-3-3. Others 1. Selection of LED display (SW800, SW803 operation) 1) Display selection list The displayed contents of LED D800 to D804 on the outdoor control P .C. board can be exchanged by operation of SW803. Switch Function / Contents Refer Error display (Error generating at present) Refer to...
  • Page 67 2) Error display The error which is generating at present and the latest error (Latest error information including present) can be confirmed by lighting LED D800 toD804 on the outdoor control P .C. board. a) When all DIP switch SW803 are OFF, the status of error which is generating at present is displayed. b) <1>...
  • Page 68 3) Sensor, current, compressor operation frequency, PMV opening display The values detected by the controller, such as temperature sensor or current value are simply confirmed. (Legend) ¥ ¡ D800 D801 D802 D803 D804 D805 ¡ : Go off, : Go on (Yellow) (Yellow) (Yellow) (Yellow) (Yellow) (Green) Temperature sensor (°C) Compressor...
  • Page 69 4) Specific operation for maintenance check (SW801, SW804) The following specific operations for the maintenance check are performed by operation of SW801 or SW804. a) Select DIP switch SW804. (See table below) b) Push the pushdown button switch SW801 for approx. 1 second. c) The following functions start.
  • Page 70 SW804 Operation when pushdown button switch SW801 is pushed 4-way valve relay operation (For RY700, CN70 check) SW804 Turn on 4-way valve power relay (RY700). When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control. SV valve relay operation (For RY702, CN702 check) SW804 Turn on SV valve relay (RY702).

  • Page 71: 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 72: 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 73 10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single (Master/Sub) Individual 2) Group operation (Twin, Triple operation) (Multiple outdoor units = Miltiple indoor units only with serial communication) Sub/Header Sub/Header Sub/Follower Master/Header Sub/Follower Sub/Follower Only turning on source power supply (Automatic completion) •...
  • Page 74 10-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple (1-1) (1-2) (1-1) (1-2) (1-3) Individual Master/Header Sub/Follower Sub/Header Master/Follower Sub/Follower (Master/Header) Only turning on source power supply (Automatic completion) 2.

  • Page 75: Remote Controller Wiring

    10-3. Remote Controller Wiring • Strip off approx. 9 mm the wire to be connected. Simultaneous twin system • For single system, use non polarity, 2 core wire is used for wiring of the remote controller. (0.5 mm² to 2.0 mm² wires) •...

  • Page 76: Address Setup (Manual Setting From Remote Controller)

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

  • Page 77: 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 78 <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 79: Installation Manual

    Digital Inverter Installation Manual 11. INSTALLATION MANUAL ACCESSORY PARTS Please read this Installation Manual carefully before installing the Air Conditioner. • This Manual describes the installation method of the outdoor unit. • For installation of the indoor unit, follow the Installation Manual attached to the indoor unit. Accessory parts ADOPTION OF NEW REFRIGERANT Part name...

  • Page 80: Safety Precautions

    Digital Inverter Installation Manual SAFETY PRECAUTIONS • Electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive power supply. An insufficient power supply capacity or inappropriate installation may cause fire. •...
  • Page 81 Digital Inverter Installation Manual INSTALLATION OF NEW REFRIGERANT AIR Tools/equipment How to use tools/equipment CONDITIONER Flare tool Flare machining of pipes Usable if dimensions are adjusted. Bender Bending pipes R22 (Conventional tools) Refrigerant recovery equipment Refrigerant recovery CAUTION For R410A only Torque wrench Tightening flare nuts Exclusive for Ø12.7 mm and Ø19.1 mm...

  • Page 82: Installation Conditions

    Digital Inverter Installation Manual INSTALLATION CONDITIONS Installation Location • A location in which organic solvent is used • A location where high-frequency equipment (including inverter equipment, private power generator, medical WARNING equipment, and communication equipment) is used Before installation Electrical wiring (Installation in such a location may cause malfunction of the air conditioner, abnormal control or problems Install the outdoor unit properly in a location that is...

  • Page 83: Installation Of Outdoor Unit

    Digital Inverter Installation Manual Serial installation in front and rear Consider the wind direction during the operational Obstacles on both right and left sides Serial installation of two or more units season of the air conditioner, and install the unit The height of the Open above and to the right and left of the unit.

  • Page 84: Optional Installation Parts

    Digital Inverter Installation Manual REFRIGERANT PIPING • As shown in the figure below, install the foundation • When collectively draining discharged water and vibration-proof rubber pads to directly support the completely, use a drain pan. bottom surface of the fixing leg that is in contact with and underneath the bottom plate of the outdoor unit.

  • Page 85: Refrigerant Piping Connection

    Digital Inverter Installation Manual Refrigerant Piping Connection Tightening of Connecting Part Projection margin in flaring: B (Unit: mm) Align the provided Ø19.1 mm pipe with the pipe lead-out direction, and shape it so that its end Align the centers of the connecting pipes and fully comes out from the outdoor unit.

  • Page 86: Air Purging

    Digital Inverter Installation Manual AIR PURGING • After the installation work, be sure to check for gas CAUTION leaks of the pipe connections with nitrogen. • Pressure of R410A is higher than that of R22 (Approx. 1.6 times). Do not put the crescent wrench on the cap or cover. Therefore, using a torque wrench, tighten the flare Airtight Test Vacuum pump...

  • Page 87: Replenishing Refrigerant

    Digital Inverter Installation Manual Replenishing Refrigerant Valve handling precautions Adding additional refrigerant Use the vacuum pump, vacuum pump adapter, and gauge manifold correctly referring to the manuals supplied with • Open the valve stem until it strikes the stopper. each tool before using them. This model is a 30 m chargeless type that does not need It is unnecessary to apply further force.

  • Page 88: Electrical Work

    Digital Inverter Installation Manual ELECTRICAL WORK Secure the power supply wire and indoor/outdoor connecting wires using the cord clamp of the Input power outdoor unit. 380-415 V 3N~, 50Hz For interconnecting wires, do not use a wire joined to another on the way. Furthermore, be sure to secure these wires with the pipe WARNING Use wires long enough to cover the entire length.

  • Page 89: Test Run

    Digital Inverter Installation Manual EARTHING TEST RUN Indoor/outdoor Power supply wire connecting wire Earth Earth screw screw • Turn on the circuit breaker at least 12 hours before starting a test run to protect the compressor during WARNING startup. To protect the compressor, power is supplied from the 380-415 VAC input to the unit to preheat the compressor. •...

  • Page 90: Functions To Be Implemented Locally

    Digital Inverter Installation Manual FUNCTIONS TO BE IMPLEMENTED LOCALLY TROUBLESHOOTING Handling Existing Pipe • Do not use any pipe with a wall thickness less than You can perform fault diagnosis of the outdoor unit with the LEDs on the P.C. board of the outdoor unit in addition to these thicknesses due to insufficient pressure using the check codes displayed on the wired remote controller of the indoor unit.
  • Page 91 Digital Inverter Installation Manual Display mode 1 Display mode 2 Display mode 1 Display mode 2 Cause Cause D800 D801 D802 D803 D804 D800 D801 D802 D803 D804 D800 D801 D802 D803 D804 D800 D801 D802 D803 D804 Normal Ps sensor error Discharge (TD) sensor error Ps drop down error Heat exchanger (TE) sensor error...
  • Page 92 Digital Inverter Installation Manual APPENDIX When temporary installation and removal of the air conditioner are repeated such as when leased etc. If the type of refrigerator oil of the existing air conditioner is other than the following oil (Mineral Work instructions oil), Suniso, Freol-S, MS (Synthetic oil), alkyl * Pipe diameter and thickness (mm) benzene (HAB, Barrel-freeze), ester series, PVE...
  • Page 93 Digital Inverter Installation Manual Are there scratches or dents on the existing pipes? Existing pipes: Cannot be used. • 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 94 Digital Inverter Installation Manual WARNINGS ON REFRIGERANT LEAKAGE Important Check of Concentration Limit NOTE 2 The room in which the air conditioner is to be installed requires a design that in the event of The standards for minimum room volume are as follows. refrigerant gas leaking out, its concentration will not exceed a set limit.

  • Page 95: Replacement Of The Service P.c. Board (4316V392) Mcc-1599

    If they are not cut correctly, an error code “L10” or “L29” appears on the remote controller and the operation of the air conditioner is disabled. Model name J 800 J 801 J 802 J 803 Factory setting (default) × RAV-SM2244AT8-A : Connected, × RAV-SM2804AT8-A × : Cut MCC-1599 SW805 SW804...

  • Page 96: How To Exchange Compressor

    13. HOW TO EXCHANGE COMPRESSOR 13-1. 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 97: Detachments

    14. DETACHMENTS 14-1. Outdoor Unit RAV-SM224, RAV-SM280 series Part name Procedure Remarks Common Service panel T op plate WARNING procedure Service 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.
  • Page 98 Part name Procedure Remarks 1. Detachment Discharge port cabinet  ‚ Motor base 1) Carry out the operation in 1. of and 1. of above. Heat exchanger Inverter assembly 2) Remove the screws fixing the inverter assembly, the discharge port cabinet and the partition board. (ST1T Ø4 ×...
  • Page 99 Part name Procedure Remarks 1. Detachment Side cabinet  ‚ 1) Carry out the operation in 1. of and 1. of Side cabinet C Type screw above. (serration) 2) Remove the screws fixing the inverter assembly and the side cabinet. (ST1T Ø4 × 10, 3 pcs.) 3) Remove the screws for the side cabinet and the valve fixing plate.
  • Page 100 Part name Procedure Remarks 1. Detachment Inverter Remove the fan motor lead wire assembly  ‚ 1) Carry out the operation in 1. of , 1. of from the cord clamp. „ 1. of above. Fan-IPDU board Fan-IPDU board Fan-IPDU board 2) Remove the connectors connected to the fan motor relay board and the Fan IPDU board, the connector connected to other components from the control...
  • Page 101 Part name Procedure Remarks 1. Detachment Interface board (Control board)  ‚ 1) Carry out the operation in 1. of , 1. of „ MCC-1599 and 1. of above. 2) Remove lead wires and connectors to other components from the interface board (control board).
  • Page 102 Part name Procedure Remarks 1. Detachment Fan-IPDU FAN-IPDU board board  ‚ 1) Carry out the operation in 1. of , 1. of „ MCC-1597 1. of above. 2) Remove lead wires and connectors to other components from the Fan-IPDU board. CN700 : Relay connector (3P, Blue) CN750 : Outdoor fan motor (3P, White) CN500 : Connection between reactor and...
  • Page 103 Part name Procedure Remarks 1. Detachment Noise filter Fan-IPDU board board  ‚ 1) Perform the operation in 1. of , 1. of , 1. of „ † ‡ MCC-1600 , 1.-2 of and 1.-2 of 2) Remove the screws (4 positions) fixing the inverter assembly (front) to remove the lead wires from the upper left clamp.
  • Page 104 Part name Procedure Remarks 1. Detachment Compressor IPDU board  ‚ 1) Carry out the operation in 1. of , 1. of „ † ‡ ˆ MCC-1596 1. of , 1. of , 1. of and 1. of 2) Pull the compressor lead from the space in the partition plate.
  • Page 105 Part name Procedure Remarks 1. Detachment Fan motor  ‚ Flange nut Flange nut Flange nut Turn to right Turn to right Turn to right 1) Carry out the operation in 1. of , 1. of to loosen to loosen to loosen ƒ...
  • Page 106 Part name Procedure Remarks 1. Detachment Compressor Drip-proof sheet (rubber sheet) 1) Recover the refrigerant gas.  „ 2) Carry out the operation in 1. of above. 3) Remove the piping panel (front). Remove the piping panel (front) and screws of the bottom plate.
  • Page 107 Part name Procedure Remarks 2. Attachment Compressor (continued) 1) Mount the compressor by reversing the procedure for removal. CAUTION The fixing torque for the hexagonal bolts fixing the compressor is 19.6N•m (200kgf•cm). 3. Vacuuming 1) Connect the vacuum pump to the charge port and the high-pressure check joint of the liquid pipe and the gas pipe valve and then operate the vacuum pump.
  • Page 108 Part name Procedure Remarks 1. Detachment Fan guard  ƒ 1) Carry out work of item 1. of and 1. of above. Remover screw CAUTION (2 pcs.) To prevent scratches to the product, carry out the work on cardboard, cloth, etc. 2) Remove the discharge port cabinet and place the fan guard side facing upwards.

  • Page 109: Exploded Views And Parts List

    15. EXPLODED VIEWS AND PARTS LIST 15-1. Outdoor Unit RAV-SM2244AT8-A, RAV-SM2804AT8-A 13, 14 11, 12 36, 37 10, 49 9, 48 47, 55 33, 34, 57 5, 52 – 109 –...
  • Page 110 Model name Location Part No. Description RAV-SM2244AT8-A RAV-SM2804AT8-A 43120224 Fan, Proprller, PE492 43122065 Bell Mouth 43191651 Guard, Fan 43100323 Guard, Fin 43050407 Thermostat, Bimetal 43151301 Switch, Pressure 4312C037 Motor, Fan, ICF-280-A100-1 4316V135 Bush 43146680 Valve, Packed, 12.7 43146725 Valve, Ball, SBV-JA6GTC-1...

  • Page 111: Inverter Assembly

    15-2. Inverter Assembly RAV-SM2244AT8-A, RAV-SM2804AT8-A 718, 719 718, 719 (TE) (TS) (TO) (TD) (TL) – 111 –...
  • Page 112 Model name RAV-SM Location Part No. Description RAV-SM2244AT8-A, RAV-SM2804AT8-A 43058288 Reactor, CH-56-4Z 43154177 Relay, 480V, 20A (Contact) 43158199 Reactor, CH-44-FCZ-2 43158207 Reactor, CH-68 43153006 PTC-Thermistor, ZPROYCE101A500 43050425 Sensor Ass’y, Service, TC (F6) 43150319 Sensor Ass’y, Service, TD (F4) 43160565 Terminal Block, 3P, 20A, AC250V...
  • Page 113 WARNINGS ON REFRIGERANT LEAKAGE Important Check of Concentration Limit The room in which the air conditioner is to be NOTE 2: installed requires a design that in the event of The standards for minimum room volume are as follows. refrigerant gas leaking out, its concentration will 1) No partition (shaded portion) not exceed a set limit.
  • Page 114 TOSHIBA CARRIER CORPORATION 23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN Copyright © 1999 to 2009 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.

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