Toshiba Carrier RAV-SP180AT2-UL Service Manual
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Toshiba Carrier RAV-SP180AT2-UL Service Manual

Ac split type outdoor unit super digital inverter
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SERVICE MANUAL

<SUPER DIGITAL INVERTER>
RAV-SP180AT2-UL
RAV-SP240AT2-UL
RAV-SP300AT2-UL
RAV-SP360AT2-UL
RAV-SP420AT2-UL
R410A
FILE NO. A09-010-2
Revised : Feb. 2010
REVISION 2 : Jan.2012
Re-edit version.( file volume down)
Contents have NOT been changed.
SPLIT TYPE
(2 HP)
(3 HP)
(4 HP)
(4, 5 HP)
(5 HP)
PRINTED IN JAPAN, Dec., 2009 ToMo

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Summary of Contents for Toshiba Carrier RAV-SP180AT2-UL

  • Page 1: Service Manual

    Revised : Feb. 2010 REVISION 2 : Jan.2012 Re-edit version.( file volume down) Contents have NOT been changed. SERVICE MANUAL SPLIT TYPE OUTDOOR UNIT <SUPER DIGITAL INVERTER> RAV-SP180AT2-UL (2 HP) RAV-SP240AT2-UL (3 HP) RAV-SP300AT2-UL (4 HP) RAV-SP360AT2-UL (4, 5 HP)

  • Page 2: Adoption Of New Refrigerant

    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: Table Of Contents

    CONTENTS SAFETY CAUTION .................... 4 1. SPECIFICATIONS ..................9 1-1. Outdoor Unit......................9 1-2. Operation Characteristic Curve ............... 10 2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)........12 2-1. Outdoor Unit...................... 12 3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ......15 3-1. Indoor Unit......................15 3-2.

  • 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. [Explanation of indications] Indication Explanation...
  • 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 Insulator check side.
  • 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. Outdoor Unit <Super Digital Inverter> Size Outdoor model RAV- SP180AT2-UL SP240AT2-UL SP300AT2-UL SP360AT2-UL SP420AT2-UL Outdoor Min - Max DB ∗1 (°F) 23 to 109.4 Cooling Indoor Min - Max DB (°F) 69.8 to 89.6 Operating Indoor Min - Max WB (°F) 59 to 75.2 range...
  • Page 10 1-2. Operation Characteristic CurveRAV* • Operation characteristic curve <Super Digital Inverter> RAV-SP180AT2-UL <Cooling> <Heating> RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL RAV-SP180UT-UL RAV-SP180UT-UL RAV-SP180UT-UL RAV-SP180UT-UL RAV-SP180UT-UL RAV-SP180UT-UL • Conditions • Conditions Indoor : DB 68˚F (20˚C) Indoor : DB 80.6˚F (27˚C)/...
  • Page 11 Pipe length : 295.3” (7.5m) Pipe length : 295.3” (7.5m) 230V 230V Compressor speed (rps) Compressor speed (rps) • Capacity variation ratio according to temperature RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL <Cooling> <Heating> • Conditions Indoor : DB 80.6˚F (27˚C)/ • Conditions WB 66.2˚F (19˚C) Indoor : DB 68˚F (20˚C)

  • Page 12: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Outdoor Unit RAV-SP180AT2-UL – 12 –...
  • Page 13 RAV-SP240AT2-UL – 13 –...
  • Page 14 RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL – 14 –...

  • Page 15: Systematic Refrigerating Cycle Diagram

    (Outer dia : ØA) To outdoor unit To outdoor unit Dimension table Outer diameter of refrigerant pipe Indoor unit Gas side ØA Liquid side ØB RAV-SP180AT2-UL 1/2” (12.7) 1/4” (6.4) RAV-SP240, 300, 360, 420AT2-UL 5/8” (15.9) 3/8” (9.5) – 15 –...

  • Page 16: Outdoor Unit

    Revised : Feb. 2010 3-2. Outdoor Unit RAV-SP180AT2-UL TO sensor (Pulse Motor Valve) (CAM-B30YGTF-2) sensor sensor TE sensor Muffler 4-way valve Ø31.75 × 200L (STF-0213Z) Muffler Heat exchanger Ø19.05 × 160L Ø8 ripple, 2 rows, 20 stages FP1.3, flat fin...
  • Page 17 Revised : Feb. 2010 RAV-SP240AT2-UL TS sensor TO sensor TL sensor (Pulse Motor Valve) (CAM-B30YGTF-2) Ø2 × Ø3 × 600L Accumulator Sub-ass’y sensor Ø2 × Ø3 × 550L Strainer Ø2 × Ø3 × 450L 4-way valve TE sensor (STF-0218G) Ø2 × Ø3 ×...
  • Page 18 RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL TO sensor TS sensor TL sensor Strainer TE sensor Check joint Capillary Cooling: High pressure Ø4 ×Ø3 (6 pcs.) Heating: Low pressure Heat exchanger Distributor Refrigerant pipe TD sensor Ø8, 2 rows, 52 stages at liquid side Ø9.5 FP1.45, flat fin Packed valve In cooling operation...

  • Page 19: Wiring Diagram

    4. WIRING DIAGRAM 4-1. Outdoor Unit RAV-SP180AT2-UL CN500 P.C. Board HP SW (MCC-5009) Compressor CN300 Q200~205 Q300~305 IGBT MOS-FET R221 R321 Fan motor R220 R320 R219 R319 CN700 Pulse motor valve DB01 CN603 Power Fuse, T3.15A relay AC250V (Suction pipe temp. sensor)
  • Page 20 RAV-SP240AT2-UL Reactor Reactor (RED) (WHI) (BLK) (GRY) (GRY) (WHI) (WHI) P04 P05 P06 P07 CN200 CN201 CN202 CN300 (WHI) CN609 (BLU) SW804 SW801 SW800 CN690 (RED) CN610 (YEL) Control P.C. Board MCC-1571 SW803 CN604 (WHI) CN603 (WHI) Fuse, F01 T25A, 250V~ CN602 (BLK) (YEL)
  • Page 21 RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL Reactor (RED) (WHI) (BLK) Reactor (GRY) (GRY) (WHI) (WHI) P04 P05 P06 P07 CN200 CN201 CN202 CN400 FM01 (WHI) CN300 FM02 (WHI) CN609 (BLU) SW804 SW801 SW800 CN690 (RED) CN610 (YEL) Control P.C. Board MCC-1570 SW803 CN604 (WHI) CN603 (WHI)

  • Page 22: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit (Parts Ratings) RAV-SP180AT2-UL Parts name Type Specifications Fan motor ICF-140-43-4R Output (Rated) 43 W Compressor DA150A1F-21F 3 phase, 4P, 1100 W Reactor CH-57 10mH, 16A Outdoor temp. sensor (To sensor) — 10 kΩ at 77°F (25°C) Heat exchanger sensor (Te sensor) —...

  • Page 23: 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 24 Table 6-2-1 Thicknesses of annealed copper pipes Thickness (In (mm)) Outer diameter (In (mm)) R410A 1/4” (6.4) 0.03” (0.80) 0.03” (0.80) 3/8” (9.5) 0.03” (0.80) 0.03” (0.80) 1/2” (12.7) 0.03” (0.80) 0.03” (0.80) 5/8” (15.9) 0.04” (1.00) 0.04” (1.00) 1. Joints For copper pipes, flare joints or socket joints are used.
  • Page 25 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. ØD Use either a flare tool for R410A or conventional flare tool. Flare processing dimensions differ according to the type of flare tool.
  • Page 26 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 27: Recharging Of Refrigerant

    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 28: 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 29 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 30: Circuit Configuration And Control Specifications

    7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Print Circuit Board <MCC-5009> RAV-SP180AT2-UL – 30 –...
  • Page 31 <MCC-1571> RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL Fan motor output Fan motor output Compressor output terminal Electrolytic (Lower side) (Upper side) CN202 condenser CN300 (White) CN400 (White) CN201 CN200 Case thermostat connector CN609 (Blue) High pressure SW CN690 (Red) Power supply circuit protective fuse F100 250V, 3.15A, Plastic case) 4-way valve connector CN701 (White)

  • Page 32: Outline Of Main Controls

    7-2. Outline of Main Controls RAV-SP180AT2-UL 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between (20 to 500) pulsed during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming (2 to 5K) as the target value.

  • Page 33: Outdoor Fan Control

    3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] RAV-SP 180AT2-UL 3-1) Cooling fan control The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. It is controlled by every 1 tap of DC fan control (15 taps). Only for 60 seconds after start-up of operation, it is fixed by the maximum fan tap corresponded to the zone in the following table, and then the fan is controlled by temperature of TE sensor.
  • Page 34 3-2) Heating fan control The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (Control from minimum W1 to maximum (according to the following table)) For 3 minutes after the operation has started, the maximum fan tap corresponding to the zone in the following table is fixed and then the fan is controlled by temperature of TE sensor.

  • Page 35: Current Release Control

    3) Using TD sensor and TE sensor, RAV-SP180AT2-UL judges the power-on. 4) The power is turned off when TD is 86°F (30°C) or more.

  • Page 36: Auto Restart

    Current release control value (I1) 1) This control purposes to prevent troubles of the electronic parts such as the compressor driving elements and the compressor during Temperature range RAV-SP180AT2-UL cooling operation. 122°F (50°C) ≤ TO 2) The current release control value ( 1) is selected from the following table according 113°F (45°C) ≤...

  • Page 37: Defrost Control

    11. Defrost control 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 53.6°F (12°C) or continued 41°F (5°C) ≤ TE <...
  • Page 38 RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between 30 and 500 pulsed during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming 1 to 4K as the target value. 3) In heating operation, PMV is usually controlled with the temperature difference between TS sensor and TE sensor aiming –1 to 4K (SP240: 2 to 4K) as the target value.
  • Page 39 Revised : Feb. 2010 3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] RAV- SP240AT2-UL RAV- SP300AT2-UL SP360AT2-UL Down — — SP420AT2-UL 3-1) Cooling fan control ˚F (˚C) The outdoor fan is controlled by TL sensor, WE tap TO sensor and the operation frequency.
  • Page 40 3-2) Heating fan control The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (Control from minimum W1 to maximum (according to the following table)) For 3 minutes after the operation has started, the maximum fan tap corresponding to the zone in the following table is fixed and then the fan is controlled by temperature of TE sensor.
  • Page 41 4. Coil heating control 1) This control function heats the compressor by turning on the stopped compressor instead of a case heater. It purposes to prevent stagnation of the refrigerant inside of the compressor. 2) As usual, turn on power of the compressor for the specified time before a test run after installation; otherwise a trouble of the compressor may be caused.
  • Page 42 7. Current release value shift control Current release control value (I1) 1) This control purposes to prevent troubles of the electronic parts such as the compressor driving elements and the compressor during cooling operation. RAV-SP300AT2-UL Temperature range RAV-SP360AT2-UL 2) The current release control value (I1) is RAV-SP420AT2-UL selected from the following table 111.2°F (44°C) ≤...
  • Page 43 10. Defrost control 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 53.6°F (12°C) or higher for 3 seconds or continued 44.6°F (7°C) ≤...
  • Page 44 11. Compressor protective control <RAV-SP240AT2-UL only> 1) This control purposes to raise the operation frequency until 45Hz for 2 minutes in order to protect the compressor (Prevention of oil accumulation in the refrigerating cycle) when the status that the operation frequency is 45Hz or less has continued for 10 hours was calculated.

  • Page 45: Summary Of Troubleshooting

    Revised : Feb. 2010 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 46 Revised : Feb. 2010 <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.

  • Page 47: Troubleshooting

    Revised : Feb. 2010 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 48 Revised : Feb. 2010 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 ⎭...
  • Page 49 Revised : Feb. 2010 8-2-2. Others (Other than Check Code) Lamp indication Check code Cause of trouble occurrence Operation Timer Ready — During test run Simultaneous flash – 49 –...
  • Page 50 8-2-3. 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 Representative defective position Detection...
  • Page 51 : 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 52: Error Mode Detected By Indoor Unit

    Revised : Feb. 2010 Error mode detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of Cause of operation Condition code air conditioner No communication from remote 1. Check wires of remote controller and communication adapters. Stop Displayed when controller (including wireless) and...

  • Page 53: Error Mode Detected By Outdoor Unit

    Error mode detected by outdoor unit Operation of diagnostic function Check code Indoor unit Judgment and measures Status of Cause of operation Condition air conditioner 4-Way Under High Ceiling Wall 1. Check discharge temp. sensor (TD). Disconnection, short of discharge Displayed when Stop temp.
  • Page 54 Operation of diagnostic function Check code Indoor unit Judgment and measures Status of Condition Cause of operation air conditioner 4-Way Under High Ceiling Wall 1. Check refrigerating cycle (Gas leak) Discharge temp. error Displayed when Stop 2. Trouble of electronic expansion valve ∗...
  • Page 55 8-2-4. Diagnostic Procedure for Each Check Code (Outdoor Unit) RAV-SP180AT2-UL 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) When “APPLICATION CONTROL KIT” (TCB-PCOS1UL) sold separately is connected, the error contents can be judged by LED on the APPLICATION CONTROL KIT.
  • Page 56 CODE APPLICATION CONTROL KIT Check / Countermeasures LED display (Part without special mention indicates a part of the outdoor unit.) [F08] [Outside temp. sensor (TO) error] (Red) (Yellow) (Yellow) (Yellow) Is connection of CN602 correct? Correct connector. Sensor error → Replace Is resistance value of TO sensor correct? Check outdoor P.C.
  • Page 57 CODE APPLICATION CONTROL KIT Check / Countermeasures LED display (Part without special mention indicates a part of the outdoor unit.) [H03] [Power supply error, Current detection circuit error] (Red) (Yellow) (Yellow) (Yellow) Are connections of wires correct? Between power cable and terminal block Correct wires Between outdoor P.C.
  • Page 58 CODE APPLICATION CONTROL KIT Check / Countermeasures LED display (Part without special mention indicates a part of the outdoor unit.) [P04] [High-pressure SW error] (Red) (Yellow) (Yellow) (Yellow) 1. High-pressure SW error 2. Service valve closed. 3. Indoor/Outdoor fan error 4.
  • Page 59 Indoor TC sensor Defective → Correct or replace ∗ In case of RAV-SP180AT2-UL, the coil of 4-way valve is electrified during cooling cycling. ∗ In cooling operation, [P19] error may be displayed when the refrigerant pressure rises high abnormally. In this case, remove the cause of pressure rising and then diagnose it again.
  • Page 60 RAV-SP240AT2-UL, RAV-SP300AT2-UL, SP360AT2-UL, SP420AT2-UL 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 61 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [F04] <Display 1> <Display 2> [Discharge temp. sensor (TD) error] Correct connector. Is CN603 connection normal? Sensor error → Replace Is resistance value of TD sensor normal? Check outdoor P.C.
  • Page 62 CODE Outdoor Check and troubleshooting 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? Check outdoor P.C.
  • Page 63 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [H01] <Display 1> <Display 2> [Compressor break down] Is power supply voltage normal? Correct power supply line. 208/230V ± 10V Is wire connection normal? Compressor lead Check wire connection (Board side, Compressor side),...
  • Page 64 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [H04] <Display 1> <Display 2> [Case thermostat operation] Are CN609 connection Correct connector. Case thermostat error → Replace and case thermostat normal? Is cooling/heating operation Check outdoor P.C.
  • Page 65 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [L29] <Display 1> <Display 2> [EEPROM error] → Refer to [F31] column. (Continued) <Display 1> <Display 2> [Unset model type] → Refer to [L10] column. <Display 1>...
  • Page 66 Revised : Feb. 2010 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) * There is a possibility that it is one of the following errors. [P04] Confirm LED on outdoor P.C. board to judge which error it is. Power supply error (Vdc), High pressure protective operation, Case thermostat operation <Display 1>...
  • Page 67 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [P04] <Display 1> <Display 2> [Power supply error (Vdc)] → Refer to [P05] column. (Continued) <Display 1> <Display 2> [High pressure protective operation] → Refer to [P20] column. [P05] <Display 1>...
  • Page 68 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [P07] <Display 1> <Display 2> [Heat sink overheat error] Is there no loosening of screws of motor drive element of outdoor P.C. board Q200, Q300, Q400 and rectifier DB01, DB02, DB03? Did not forget to apply radiation grease to rear side of...
  • Page 69 CODE Outdoor Check and troubleshooting LED display (Item without special mention Indicates part of outdoor unit.) [P19] <Display 1> <Display 2> [4-way valve inverse error] Temperature sensor check Is operation of TE sensor CN601 4-way valve normal? TS sensor CN600 (Check pipe temp., etc.
  • Page 70 CODE Outdoor Check and troubleshooting 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 and then perform test run Cooling season matching to the season.
  • Page 71 CODE Outdoor Check and troubleshooting 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. 208/230V ± 10V Ask repair of power supply. Does the fan rotate without trouble when rotating shaft of fan motor with hands during power-OFF? Is there no problem on coil resistance of fan motor?

  • Page 72: 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 (Minimum (Standard (Maximum...
  • Page 73 Revised : Feb. 2010 8-2-5. Outdoor Unit Part name Checking procedure Compressor Measure the resistance value of each winding by using the tester. (Model :DA111A1FD-21F) Position Resistance value Red – White White – Black 1.07 Ω Black – Red White Black Under 20°C Compressor...

  • Page 74: Replacement Of Service P.c. Board

    9. REPLACEMENT OF SERVICE P.C. BOARD 9-1. Outdoor Unit 1. Setting the jumper wires and DIP switches Part name Function Setting J800 to J803 Model switching Cut these jumper wires according to the following table. Jumper wire Set these jumper wires to the settings of the P.C. board before J804 to J810 Settings replacement.

  • Page 75: Setup At Local Site And Others

    10. SETUP AT LOCAL SITE AND OTHERS 10-1. Outdoor Unit 10-1-1. Various Setting on Outdoor Unit (Power save, Cooling-only, etc.) The following settings are available by DIP switch setup and jumper line setup. <RAV-SP180AT2-UL> Function Set position Control contents When using the power saving function, turn on switches.
  • Page 76 10-1-2. 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 77 10-1-3. Others <RAV-SP240, SP300, SP360, SP420AT2-UL> 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)
  • Page 78 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 79 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 (Yellow) D803 (Yellow) : Go off, : Go on D801 (Yellow) D804 (Yellow) D802 (Yellow) D805 (Green) Temperature sensor °F (°C)
  • Page 80 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 81 SW804 Operation when pushdown button switch SW801 is pushed 4-way valve relay operation (For RY700, CN70 check) Turn on 4-way valve power relay (RY700). SW804 When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control. [NOTE] In case of these models adopting the self hold valve, the coil develops fever.
  • Page 82 <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. Check periodically signs of rust or scratches, etc.
  • Page 83 11. DETACHMENTS 11-1. Outdoor Unit 11-1-1. RAV-SP180AT2-UL Remarks Part name Procedure Common procedure CAUTION Never forget to put on the gloves at working time, otherwise an injury will be caused by the parts, etc. 1. Detachment 1) Stop operation of the air conditioner, and turn...
  • Page 84 Part name Procedure Remarks 1. Detachment Front cabinet Motor support Motor support Motor support 1) Perform work of Detachment 1 of Inverter cover Inverter cover Inverter cover 2) Remove screws (M4, 8 mm, 2 pcs.) of the front cabinet and the inverter cover. 3) Take off screws of the front cabinet and the bottom plate.

  • Page 85: Electric Shock

    No. Part name Procedure Remarks 1. Turn off the power supply. Inverter assembly Screws Screws Screws 1) Perform work of Detachment 1 of 2) Take off screws, which fix the upper part of the front cabinet and the inverter cover. (M4, 8 mm, 2 pcs.) •...
  • Page 86 Part name Procedure Remarks Control P.C. 1) Remove the sub-board base from the inverter board assembly assembly. (M4, 8 mm, 2 pcs.) • Remove connector at the control P.C. board assembly side. 2) Remove the lead wires and connectors that are connected from the control P.C.
  • Page 87 Part name Procedure Remarks Fan motor 1) Perform works of Detachment 1 of Flange nut Flange nut Flange nut 2) Take off the flange nut fixing the fan motor and the propeller. • Turning it clockwise, the flange nut can be loosened. (To tighten the flange nut, turn counterclockwise.) 3) Remove the propeller fan.
  • Page 88 Part name Procedure Remarks Reactor 1) Perform works of Detachment 1 of Reactors Reactors Reactors Partition Partition Partition plate plate plate 2) Take off the fixing screw for the reactor. (M4, 8 mm) Reactor Reactor Reactor support board support board support board 1.
  • Page 89 11-1-2. RAV-SP240AT2-UL Part name Procedure Remarks Common Front panel 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 90 Part name Procedure Remarks 1. Detachment Discharge port cabinet Motor base 1) Perform work of Detachment 1 of Heat exchanger Partition plate 2) Remove screws for the discharge port cabinet and the partition plate. (M4, 8 mm, 3 pcs.) 3) Remove screws for the discharge port cabinet and the bottom plate.
  • Page 91 Part name Procedure Remarks 1. Control P.C. board Exchange of electric parts Pressure Compressor 1) Perform work of Detachment 1 of switch lead Compressor case thermo. Fan motor WARNING Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused.
  • Page 92 Part name Procedure Remarks 1. Reactor Exchange of electric parts Reactor relay connector 1) Perform work of Detachment 1 of (Connected to lead wire (Continued) (White) at P.C. board side) 2) Remove the relay connector connected to the control P.C. board. 3) Cut off the bundling band binding the compressor lead and the relay connector.
  • Page 93 No. Part name Procedure Remarks Fan motor 1) Perform work of Detachment 1 of Propeller fan Loosened by 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 94 Part name Procedure Remarks 1. Removal of broken compressor Compressor Compressor lead 1) Recover the refrigerant gas. 2) Perform work of Detachment 1 of Wiring Wiring Wiring guide guide guide 3) Remove the wiring guide (vertical). Take off screw of the wiring guide (vertical) and volve fixing plate.
  • Page 95 Part name Procedure Remarks Compressor 12) Using a burner, remove the discharge Compressor lead pipe and the suction pipe connected to Remove Remove (Discharge pipe) (Suction pipe) (Continued) the compressor. 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 96 Part name Procedure Remarks 2. Mounting of compressor Compressor Compressor lead Compressor lead Wind the ferrite core Wind the ferrite core Wind the ferrite core 1) Mount the compressor in the reverse with the compressor with the compressor with the compressor (Continued) procedure of removal.
  • Page 97 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 98 Part name Procedure Remarks 3. Detachment Fan guard 1) Perform work of Detachment Discharge port cabinet Discharge port cabinet Discharge port cabinet CAUTION To prevent scratching on the product, handle the product on a cardboard or cloth. 2) Remove the discharge port cabinet and Fan guard Fan guard Fan guard...
  • Page 99 11-1-3. RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL Part name Procedure Remarks Common XCAUTIONX procedure Front panel Never forget to put on the gloves at working time; otherwise an injury will be caused by the parts, etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker.
  • Page 100 Part name Procedure Remarks 1. Detachment Discharge port cabinet Motor base Partition board 1) Perform work of Detachment 1 of 2) Remove screws for the discharge port Heat exchanger Discharge port cabinet cabinet and the partition board. (M4, 8 mm, 4 pcs.) 3) Remove screws for the discharge port cabinet and the bottom plate.
  • Page 101 Part name Procedure Remarks 1. Control P.C. board Replacement of electric parts Pressure switch Upper fan motor 1) Perform work of Detachment 1 of Compressor Lower fan motor case thermo. Compressor lead WARNINGX Never disassemble the inverter for 1 minute after power supply has been turned off because an electric shock may be caused.
  • Page 102 Part name Procedure Remarks 2. Reactor Replacement of electric parts Bundling band 1) Perform work of Detachment 1 of (Compressor lead, Reactor lead) (Continued) 2) Remove relay connector connected to the control P.C. board. (2 positions) 3) Cut the bundling band which bind compressor lead, relay connector and fan Relay connector Relay connector...
  • Page 103 No. Part name Procedure Remarks Fan motor 1) Perform work of Detachment 1 of 2) Remove the flange nut fixing the fan motor and the Propeller fan Propeller fan Propeller fan Loosened by Loosened by Loosened by turning clockwise turning clockwise turning clockwise propeller fan.
  • Page 104 Part name Procedure Remarks 1. Removal of defective compressor Compressor Compressor 1) Recover the refrigerant gas. lead 2) Perform work of Detachment 1 of Wiring guide Wiring guide Wiring guide 3) Remove the wiring guide (vertical). Take off screw of the wiring guide (vertical) and the valve fixing plate.

  • Page 105: Refrigerant Charge

    Part name Procedure Remarks 2. Mounting of compressor Compressor Wrap the ferrite core with Compressor lead 1) Mount the compressor in the reverse the compressor lead wire for 4 times. (Continued) procedure for removal. Compressor lead Compressor lead Compressor lead NOTE : •...
  • Page 106 Part name Procedure Remarks 1. Detachment PMV coil Discharge port cabinet 1) Perform work of Detachment 1 of 2) Take off screws that fix the wiring division panel and the side cabinet. (M4, 8 mm, 2 pcs.) 3) Turn the coil while pulling upward and then remove the coil from the PMV main unit.

  • Page 107: Exploded Views And Parts List

    12. EXPLODED VIEWS AND PARTS LIST 12-1. Outdoor Unit 12-1-1. RAV-SP180AT2-UL – 107 –...
  • Page 108 Compressor, Thermostat Ass’y, US-622KXTMQO-SS 43063339 Holder, Sensor (TO) 43042485 Rubber, Cushion 43063321 Holder, Sensor, 4-8, 9.52 43063322 Holder, Sensor, 6-11.4, 12.7 43063325 Holder, Sensor, 6-6.35, 8 43148220 Plug, Fusible 43148205 Accumulator Ass’y, 1L 43039392 Base, Motor 4311M654 Mark, TOSHIBA Carrier – 108 –...
  • Page 109 <Inverter assembly> Reactor TD sensor TS sensor TE sensor TO sensor Model Name Location Part No. Description RAV-SP180AT2-UL 43050422 Sensor, TE 43050423 Sensor, TS 43050427 Sensor, TO 43050430 Sensor, TD 43162058 Base, P.C.board 43160608 Terminal block, 6P, 20A, AC250V 43158192...
  • Page 110 12-1-2. RAV-SP240AT2-UL – 110 –...
  • Page 111 4314N035 Valve, 4-Way, STF-02U18G 4314N037 Coil, Valve, 4-Way Ass’y, VHV-01AP552B1 4314Q031 Strainer, DIA 9.52 4314Q056 Strainer, DIA 25.4 43107284 Stopper, Guard, Fan 4311M654 Mark, TOSHIBA Carrier 4311M655 Lavel, Caution, Refrigerant 4311M656 Lavel, Warning 4311M657 Lavel, Caution, Wiring – 111 –...
  • Page 112 <Inverter assembly> Model Name Location Part No. Description RAV-SP240AT2-UL 43155188 Reactor, CH-56-2Z-T 43050425 Sensor Ass’y, Service, TC (F6) 43050319 Sensor Ass’y, Service, TD (F4) 43160607 Terminal Block, 3P, 20A, AC250V 43160609 Terminal Block, 3P, 60A, AC600V 43063325 Holder, Sensor, 6-6.35, 8 43163055 Holder, Sensor 43163059...
  • Page 113 12-1-3. RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL – 113 –...
  • Page 114 Valve, Pulse, Modulaing, UKV-25D129 4314N036 Coil, PMV, UKV-A120U 4314N037 Coil, Valve, 4-Way Ass’y, VHV-01AP552B1 4314Q031 Strainer, DIA 9.52 4314Q032 Strainer 43107284 Stopper, Guard, Fan 4311M654 Mark, TOSHIBA Carrier 4311M655 Lavel, Caution, Refrigerant 4311M656 Lavel, Warning 4311M657 Lavel, Caution, Wiring – 114 –...
  • Page 115 <Inverter assembly> Model Name RAV- Location Part No. Description SP240AT2-UL SP360AT2-UL SP420AT2-UL 43158190 Reactor, CH-62-ZT 43050425 Sensor Ass’y, Service, TC (F6) 43050319 Sensor Ass’y, Service, TD (F4) 43160607 Terminal Block, 3P, 20A, AC250V 43160609 Terminal Block, 3P, 60A, AC600V 43063325 Holder, Sensor, 6-6.35, 8 43163055 Holder, Sensor...
  • Page 116 WARNINGS ON REFRIGERANT LEAKAGE Important Check of Concentration Limit The room in which the air conditioner is to be installed requires a design that in the event of NOTE 2 : refrigerant gas leaking out, its concentration will The standards for minimum room volume are as follows. not exceed a set limit.
  • Page 117 TOSHIBA CARRIER CORPORATION 23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN Copyright © 1999 to 2012 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved. 2nd publication in Jan.2012 ; File No.A10-010-2,REVISED EDITION 2 1st publication in Dec.2009 ; File No. A10-010 Specifications subject to change without notice.

This manual is also suitable for:

Carrier rav-sp300at2-ulCarrier rav-sp240at2-ulCarrier rav-sp360at2-ulCarrier rav-sp420at2-ul

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