TOSHIBA Carrier SUPER DIGITAL INVERTER RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL split-system air conditioner SERVICE MANUAL

FILE NO. A09-010-2

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)


(3 HP)


(4 HP)


(4, 5 HP)


(5 HP)

R410A

PRINTED IN JAPAN, Dec., 2009 ToMo

Adoption of New Refrigerant

This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer.

WARNING

Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have a service person do it. Do not attempt it yourself.

The cleaning diagram for the air filter is there for the service person, and not for the customer.

– 2 –

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. Outdoor Unit...................................................................................................... 16

4. WIRING DIAGRAM ................................................................................... 19

4-1. Outdoor Unit...................................................................................................... 19

5. SPECIFICATIONS OF ELECTRICAL PARTS .......................................... 22

5-1. Outdoor Unit (Parts Ratings) ........................................................................... 22

6. REFRIGERANT R410A ............................................................................ 23

6-1. Safety During Installation/Servicing ............................................................... 23

6-2. Refrigerant Piping Installation ....................................................................... 23

6-3. Tools .................................................................................................................. 27

6-4. Recharging of Refrigerant................................................................................ 27

6-5. Brazing of Pipes................................................................................................ 28

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS ........... 30

7-1. Print Circuit Board <MCC-1571> ..................................................................... 30

7-2. Outline of Main Controls .................................................................................. 32

8. TROUBLESHOOTING .............................................................................. 45

8-1. Summary of Troubleshooting........................................................................... 45

8-2. Troubleshooting ................................................................................................ 47

9. REPLACEMENT OF SERVICE P.C. BOARD............................................ 74

9-1. Outdoor Unit...................................................................................................... 74

10. SETUP AT LOCAL SITE AND OTHERS .................................................. 75

10-1. Outdoor Unit...................................................................................................... 75

11. DETACHMENTS ....................................................................................... 83

11-1. Outdoor Unit..................................................................................................... 83

12. EXPLODED VIEWS AND PARTS LIST .................................................. 107

12-1. Outdoor Unit.................................................................................................... 107

– 3 –

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

DANGER

Indicates contents assumed that an imminent danger causing a death or serious injury of the repair engineers and the third parties when an incorrect work has been executed.

WARNING

CAUTION

Indicates possibilities assumed that a danger causing a death or serious injury of the repair engineers, the third parties, and the users due to troubles of the product after work when an incorrect work has been executed.

Indicates contents assumed that an injury or property damage (

∗

) may be caused on the repair engineers, the third parties, and the users due to troubles of the product after work when an incorrect work has been executed.

∗

Property damage : Enlarged damage concerned to property, furniture, and domestic animal/pet

[Explanation of illustrated marks]

Mark Explanation

Indicates prohibited items (Forbidden items to do)

The sentences near an illustrated mark describe the concrete prohibited contents.

Indicates mandatory items (Compulsory items to do)

The sentences near an illustrated mark describe the concrete mandatory contents.

Indicates cautions (Including danger/warning)

The sentences or illustration near or in an illustrated mark describe the concrete cautious contents.

[Confirmation of warning label on the main unit]

Confirm that labels are indicated on the specified positions

(Refer to the Parts disassembly diagram (Outdoor unit).)

If removing the label during parts replace, stick it as the original.

Turn off breaker.

Execute discharge between terminals.

DANGER

Turn “OFF” the breaker before removing the front panel and cabinet, otherwise an electric shock is caused by high voltage resulted in a death or injury.

During operation, a high voltage with 400V or higher of circuit (

∗

) at secondary circuit of the high-voltage transformer is applied.

If touching a high voltage with the naked hands or body, an electric shock is caused even if using an electric insulator.

∗

: For details, refer to the electric wiring diagram.

When removing the front panel or cabinet, execute short-circuit and discharge between high-voltage capacitor terminals.

If discharge is not executed, an electric shock is caused by high voltage resulted in a death or injury.

After turning off the breaker, high voltage also keeps to apply to the high-voltage capacitor.

Do not turn on the breaker under condition that the front panel and cabinet are removed.

An electric shock is caused by high voltage resulted in a death or injury.

Prohibition

– 4 –

Check earth wires.

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.

Do not modify the products.

Do not also disassemble or modify the parts. It may cause a fire, electric shock or injury.

Prohibition of modification.

Use specified parts.

Do not bring a child close to the equipment.

Insulating measures

For spare parts, use those specified (

∗∗∗∗∗

).

If unspecified parts are used, a fire or electric shock may be caused.

∗

: For details, refer to the parts list.

Before troubleshooting or repair work, do not bring a third party (a child, etc.) except the repair engineers close to the equipment.

It causes an injury with tools or disassembled parts.

Please inform the users so that the third party (a child, etc.) does not approach the equipment.

Connect the cut-off lead wires with crimp contact, etc, put the closed end side upward and then apply a water-cut method, otherwise a leak or production of fire is caused at the users’ side.

No fire

Refrigerant

Assembly/Cabling

When repairing the refrigerating cycle, take the following measures.

1) Be attentive to fire around the cycle. When using a gas stove, etc, be sure to put out fire before work; otherwise the oil mixed with refrigerant gas may catch fire.

2) Do not use a welder in the closed room.

When using it without ventilation, carbon monoxide poisoning may be caused.

3) Do not bring inflammables close to the refrigerant cycle, otherwise fire of the welder may catch the inflammables.

Check the used refrigerant name and use tools and materials of the parts which match with it.

For the products which use R410A refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see. To prevent miss-charging, the route of the service port is changed from one of the former R22.

For an air conditioner which uses R410A, never use other refrigerant than R410A.

For an air conditioner which uses other refrigerant (R22, etc.), never use R410A.

If different types of refrigerant are mixed, abnormal high pressure generates in the refrigerating cycle and an injury due to breakage may be caused.

Do not charge refrigerant additionally.

If charging refrigerant additionally when refrigerant gas leaks, the refrigerant composition in the refrigerating cycle changes resulted in change of air conditioner characteristics or refrigerant over the specified standard amount is charged and an abnormal high pressure is applied to the inside of the refrigerating cycle resulted in cause of breakage or injury.

Therefore if the refrigerant gas leaks, recover the refrigerant in the air conditioner, execute vacuuming, and then newly recharge the specified amount of liquid refrigerant.

In this time, never charge the refrigerant over the specified amount.

When recharging the refrigerant in the refrigerating cycle, do not mix the refrigerant or air other than R410A into the specified refrigerant.

If air or others is mixed with the refrigerant, abnormal high pressure generates in the refrigerating cycle resulted in cause of injury due to breakage.

After installation work, check the refrigerant gas does not leak.

If the refrigerant gas leaks in the room, poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.

Never recover the refrigerant into the outdoor unit.

When the equipment is moved or repaired, be sure to recover the refrigerant with recovering device. The refrigerant cannot be recovered in the outdoor unit; otherwise a serious accident such as breakage or injury is caused.

After repair work, surely assemble the disassembled parts, and connect and lead the removed wires as before. Perform the work so that the cabinet or panel does not catch the inner wires.

If incorrect assembly or incorrect wire connection was done, a disaster such as a leak or fire is caused at user’s side.

– 5 –

Insulator check

Ventilation

WARNING

After the work has finished, be sure to use an insulation tester set (500V Megger) to check the resistance is 2M

Ω

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.

When the refrigerant gas leaks during work, execute ventilation.

If the refrigerant gas touches to a fire, poisonous gas generates.

A case of leakage of the refrigerant and the closed room full with gas is dangerous because a shortage of oxygen occurs. Be sure to execute ventilation.

When checking the circuit inevitably under condition of the power-ON, use rubber gloves and others not to touch to the charging section.

If touching to the charging section, an electric shock may be caused.

Be attentive to electric shock

Compulsion

When the refrigerant gas leaks, find up the leaked position and repair it surely.

If the leaked position cannot be found up and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room.

The poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.

When installing equipment which includes a large amount of charged refrigerant such as a multi air conditioner in a sub-room, it is necessary that the density does not the limit even if the refrigerant leaks.

If the refrigerant leaks and exceeds the limit density, an accident of shortage of oxygen is caused.

For the installation/moving/reinstallation work, follow to the Installation Manual.

If an incorrect installation is done, a trouble of the refrigerating cycle, water leak, electric shock or fire is caused.

After repair work has finished, check there is no trouble.

If check is not executed, a fire, electric shock or injury may be caused.

For a check, turn off the power breaker.

Check after repair

Check after reinstallation

After repair work (installation of front panel and cabinet) has finished, execute a test run to check there is no generation of smoke or abnormal sound.

If check is not executed, a fire or an electric shock is caused.

Before test run, install the front panel and cabinet.

Check the following items after reinstallation.

1) The earth wire is correctly connected.

2) The power cord is not caught in the product.

3) There is no inclination or unsteadiness and the installation is stable.

If check is not executed, a fire, an electric shock or an injury is caused.

Put on gloves

Cooling check

CAUTION

Be sure to put on the gloves (

∗

) and a long sleeved shirt: otherwise an injury may be caused with the parts, etc.

(

∗

) Heavy gloves such as work gloves

When the power was turned on, start to work after the equipment has been sufficiently cooled.

As temperature of the compressor pipes and others became high due to cooling/heating operation, a burn may be caused.

– 6 –

• 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.

Therefore, 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 new refrigerant during installation work or service work.

If an incorrect work or incorrect service is performed, there is a possibility to cause a serious accident.

Use the tools and materials exclusive to R410A to purpose a safe work.

2. Cautions on Installation/Service

1) Do not mix the other refrigerant or refrigerating oil.

For the tools exclusive to R410A, shapes of all the joints including the service port differ from those of the former refrigerant in order to prevent mixture of them.

2) As the use pressure of the new refrigerant is high, use material thickness of the pipe and tools which are specified for R410A.

3) In the installation time, use clean pipe materials and work with great attention so that water and others do not mix in because pipes are affected by impurities such as water, oxide scales, oil, etc.

Use the clean pipes.

Be sure to brazing with flowing nitrogen gas. (Never use gas other than nitrogen gas.)

4) For the earth protection, use a vacuum pump for air purge.

5) R410A refrigerant is azeotropic mixture type refrigerant.

Therefore use liquid type to charge the refrigerant. (If using gas for charging, composition of the refrigerant changes and then characteristics of the air conditioner change.)

3. Pipe Materials

For the refrigerant pipes, copper pipe and joints are mainly used.

It is necessary to select the most appropriate pipes to conform to the standard.

Use clean material in which impurities adhere inside of pipe or joint to a minimum.

1) Copper pipe

<Piping>

The pipe thickness, flare finishing size, flare nut and others differ according to a refrigerant type.

When using a long copper pipe for R410A, it is recommended to select “Copper or copper-base pipe without seam” and one with bonded oil amount 0.0001 lbs / 32’ 10” (40 mg / 10 m) or less.

Also do not use crushed, deformed, discolored (especially inside) pipes.

(Impurities cause clogging of expansion valves and capillary tubes.)

<Flare nut>

Use the flare nuts which are attached to the air conditioner unit.

2) Joint

The flare joint and socket joint are used for joints of the copper pipe.

The joints are rarely used for installation of the air conditioner. However clear impurities when using them.

– 7 –

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.

No.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

Used tool Usage

R410A air conditioner installation

Existence of Whether convennew equipment tional equipment for R410A can be used

Yes *(Note)

Conventional air conditioner installation

Whether conventional equipment can be used

Yes c d e f g h

Flare tool

Copper pipe gauge for adjusting projection margin

Pipe flaring

Flaring by conventional flare tool

Tightening of flare nut Torque wrench

Gauge manifold

Charge hose

Evacuating, refrigerant charge, run check, etc.

i j k

Vacuum pump adapter

Electronic balance for refrigerant charging

Refrigerant cylinder

Leakage detector

Vacuum evacuating

Refrigerant charge

Refrigerant charge

Gas leakage check

Yes

Yes

Yes

Yes

Yes

Yes

Yes

*(Note)

No

No

No

Yes

No

No

*(Note)

No

No

Yes

Yes

No

Yes

NOTE

When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

1) Vacuum pump. Use vacuum pump by attaching vacuum pump adapter.

2) Torque wrench 8) Spanner or Monkey wrench

3) Pipe cutter

4) Reamer

5) Pipe benderr

6) Level vial

9) Hole core drill

10) Hexagon wrench (Opposite side 4mm)

11) Tape measure

12) Metal saw

7) Screwdriver (+, –)

Also prepare the following equipments for other installation method and run check.

1) Clamp meter

2) Thermometer

3) Insulation resistance tester (Megger)

4) Electroscope

– 8 –

1. SPECIFICATIONS

1-1. Outdoor Unit

<Super Digital Inverter>

Size

Outdoor model

Operating range

Cooling

Outdoor Min - Max DB

∗

1 (°F)

Indoor Min - Max DB (°F)

Indoor Min - Max WB

018 024 030 036 042

RAVSP180AT2-UL SP240AT2-UL SP300AT2-UL SP360AT2-UL SP420AT2-UL

23 to 109.4

(°F)

69.8 to 89.6

59 to 75.2

Heating

Outdoor WB Min - Max

Indoor DB Min - Max

Standard Piping Length

(°F)

(°F)

(ft.)

–4 to 59

59 to 86

25

Piping

Electrical

Min. Piping Length

Max. Piping Length

Lift (Outdoor below Indoor)

Lift

Gas Pipe

(Outdoor above Indoor)

(Size / connection type)

Liquid Pipe (Size / connection type)

Additional refrigerant charge under long piping connection

Voltage

Maximum Running Current Amps

Fuse Rating

∗

2

Type

Compressor Motor

Pole

Outdoor

Height

Dimensions Width

Length

Weight -Gross / Net

Refrigerant charged

Appearance (Munsell symbol)

Sound Pressure

(in.)

(in.)

(in.)

(lbs.)

(ft.)

(ft.)

(ft.)

16’ 5”

164’ 1”

16’ 5”

164’ 1”

9’ 8”

246’ 1”

(ft.)

(A)

1/2” 5/8”

98’ 5”

5/8”

24

40

Hermetic compressor

5/8”

1/4” 3/8”

0.22 oz / ft 0.43 oz / ft

(65’7”ft to164’1”ft) (98’5”ft to 164’1”ft)

3/8”

208 V / 230 V-1-60 Hz

3/8”

0.43 oz / ft

(98’5”ft to 246’1”ft)

17

30

24

40

24

40

(kw)

9’ 8”

246’ 1”

98’ 5”

(dBa)

1.1

4

21.7

30.7

11.4

98 / 105

3.1

48 / 49

2

4

35.0

35.4

12.6

144.5 / 157

4.6

3.75

4

52.8

35.4

12.6

211.5 / 226

Silky shade (Muncel 1Y8.5/0.5)

49 / 50

6.8

50 / 51

3.75

4

52.8

35.4

12.6

211.5 / 226

6.8

52 / 52

9’ 8”

246’ 1”

5/8”

3/8”

24

40

3.75

4

52.8

35.4

12.6

211.5 / 226

6.8

52 / 52

∗

1 When installed a duct or wind shield so that it is not affected by the wind.

The minimum outside temperature will be 5°F

∗

2 UL value

– 9 –

1-2. Operation Characteristic CurveRAV*

• Operation characteristic curve <Super Digital Inverter>

RAV-SP180AT2-UL

<Cooling> <Heating>

10 16

9

8

7

6

5

4

3

2

1

• Conditions

Indoor : DB 80.6˚F (27˚C)/

WB 66.2˚F (19˚C)

Outdoor : DB 95˚F (35˚C)

Air flow : High

Pipe length : 295.3” (7.5m)

230V

0

0 10 20 30 40 50 60 70 80

Compressor speed (rps)

14

12

10

8

6

4

2

• Conditions

Indoor : DB 68˚F (20˚C)

Outdoor : DB 44.6˚F (7˚C)/

WB 42.8˚F (6˚C)

Air flow : High


230V

0

0 10 20 30 40 50 60 70 80 90 100 110 120


RAV-SP240AT2-UL

<Cooling>

2

1

0

0

4

3

6

5

13

12

11

10

9

8

7

10 20

• Conditions

Indoor : DB 80.6˚F (27˚C)/

WB 66.2˚F (19˚C)


Air flow : High


230V

30 40 50 60 70 80


– 10 –

<Heating>

22

20

18

16

14

12

10

8

6

4

2

• Conditions



WB 42.8˚F (6˚C)

Air flow : High


230V

0

0 10 20 30 40 50 60 70 80 90 100 110 120


RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL


22

20

18

16

14

12

10

8

22

20

18

16

14

12

10

8

6

4

2

0

0

• Conditions

Indoor : DB 80.6˚F (27˚C)/

WB 66.2˚F (19˚C)


Air flow : High


230V

20 40 60


80

6

4

2

0

0

• Conditions



WB 42.8˚F (6˚C)

Air flow : High


230V

20 40 60


80

• Capacity variation ratio according to temperature

RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL


90

85

80

75

70

105

100

95

65

60

• Conditions

55

WB (19˚C)

Indoor air flow : High


50

89.6

(32)

91.4

(33)

93.2

(34)

95

(35)

96.8

(36)

98.6

(37)

100.4

(38)

102.2

(39)

104

(40)

105.8

(41)

107.6

(42)

109.4

(43)

Outdoor temp. ˚F (˚C)

120

110

100

90

80

70

60

50

40

30

20

10

• Conditions


Indoor air flow : High


0

–4 –0.4

(–20) (–18)

3.2

6.8

10.4

14

(–16) (–14) (–12) (–10)

17.6

(–8)

21.2

(–6)

24.8

(–4)

28.4

(–2)

32

(0)

35.6

(2)

39.2

(4)

42.8

(6)

46.4

(8)

50

(10)

Outdoor temp. ˚F (˚C)

– 11 –

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)


RAV-SP180AT2-UL

– 12 –

RAV-SP240AT2-UL

– 13 –


– 14 –

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Indoor Unit

• Single type (Combination of 1 indoor unit and 1 outdoor unit)

(Indoor unit)

Distributor

(Strainer incorporated)

TCJ sensor

Air heat exchanger

TC sensor

Strainer

Refrigerant pipe at liquid side

(Outer dia : ØB)

To outdoor unit

Refrigerant pipe at gas side

(Outer dia : ØA)

To outdoor unit

Heating

Cooling

Dimension table

Indoor unit

RAV-SP180AT2-UL

RAV-SP240, 300, 360, 420AT2-UL

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

1/2” (12.7)

5/8” (15.9)

1/4” (6.4)

3/8” (9.5)

– 15 –

Revised : Feb. 2010


RAV-SP180AT2-UL

TO sensor

PMV

(Pulse Motor Valve)

(CAM-B30YGTF-2)

TS sensor

TD sensor

TE sensor

Accumulator

(1L)

Rotary compressor

(DA150A1F-21F)

4-way valve

(STF-0213Z)

Muffler

Ø19.05 × 160L

Heat exchanger

Ø8 ripple, 2 rows, 20 stages

FP1.3, flat fin

Muffler

Ø31.75 × 200L

Distributor

2-step muffler

Ø25 × 200L

Strainer

Refrigerant pipe at liquid side Ø6.4

Packed valve

Refrigerant pipe at gas side Ø12.7

Packed valve

In cooling operation

In heating operation

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pd

(psi)

Pressure

Ps

(MPa)

Pd Ps

416.2 145.0 2.87

1.00

517.7 159.5 3.57

1.10

248.0 110.2 1.71

0.76

327.7 98.6 2.26

0.68

471.3 165.3 3.25

1.14

290.0 36.3 2.00

0.25

Pipe surface temperature °F (°C)

Discharge Suction

Indoor heat Outdoor heat exchanger exchanger

(TD)

161.6

(72)

190.4

(88)

113.0

(45)

(TS)

60.8

(16)

68

(20)

53.6

(12)

(TC)

55.4

(13)

66.2

(19)

44.6

( 7)

(TE)

107.6

(42)

125.6

(52)

55.4

(13)

150.8

(66)

172.4

(78)

172.4

(78)

42.8

( 6)

68

.0

(20)

–0.4

(–18)

98.6

(37)

127.4

(53)

93.2

(34)

37.4

( 3)

60.8

(16)

–0.4

(–18)

Compressor drive revolution frequency

(rps)

58

65

30

64

30

88

Indoor fan

HIGH

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor temp. conditions

(DB/WB) °F °C)

Indoor

80.6/66.2

(27/19)

89.6/75.2

(32/24)

64.4/59.9

(18/15.5)

68/–

(20/–)

86/–

(30/–)

59/–

(15/–)

Outdoor

95/–

(35/–)

109.4/–

(43/–)

23/–

(–5/–)

44.6/42.8

(7/6)

75.2/64.4

(24/18)

5/–

(–15/–)

– 16 –


RAV-SP240AT2-UL

Accumulator

Sub-ass’y

TS sensor

TD sensor

4-way valve

(STF-0218G)

Ø25 × L180

Accumulator

(1.8L)

Rotary compressor

(DA220A2F-22L)

Ø25 × L210

TO sensor TL sensor

Ø2 × Ø3 × 600L

PMV

(Pulse Motor Valve)

(CAM-B30YGTF-2)

Ø2 × Ø3 × 550L

Strainer

Ø2 × Ø3 × 450L

TE sensor

Ø2 × Ø3

× 450L

Capillary

Heat exchanger

Ø8, 2 rows, 34 stages

FP1.45, flat fin


Packed valve

Strainer


Ball valve



Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pd

(psi)

Pressure

Ps

(MPa)

Pd Ps

404.6 129.1 2.79 0.89

511.9 155.2 3.53 1.07

248.0 104.4 1.71 0.72

384.3 98.6 2.65 0.68

464.0 161.0

3.2

1.11

337.9 30.5 2.33 0.21


Discharge Suction Indoor heat Outdoor heat exchanger exchanger

(TD)

158 .0

(70)

177.8

(81)

107.6

(42)

(TS)

55.4

(13)

62.6

(17)

44.6

( 7)

(TC)

51.8

(11)

57.2

(14)

37.4

( 3)

(TE)

102.2

(39)

118.4

(48)

64.4

(18)

165.2

(74)

168.8

(76)

199.4

(93)

39.2

( 4)

66.2

(19)

–0.4

(–18)

111.2

(44)

125.6

(52)

87.8

(31)

37.4

( 3)

59

(15)

–4

(–20)

Compressor drive revolution frequency

(rps)

58.2

65

30

.0

.0

61.5

28 .0

99.6

Indoor fan

HIGH

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor temp. conditions

(DB/WB) °F °C)

Indoor

80.6/66.2

(27/19)

89.6/75.2

(32/24)

64.4/59.9

(18/15.5)

68

(20/–)

86/–

(30/–)

59/–

(15/–)

Outdoor

95/–

(35/–)

109.4/–

(43/–)

23/–

(–5/–)

44.6/42.8

(7/6)

75.2/64.4

(24/18)

5/–

(–15/–)

– 17 –


TO sensor

TS sensor

PMV

TL sensor

Strainer

Check joint

Cooling: High pressure

Heating: Low pressure

TE sensor

Capillary

Ø4 ×Ø3 (6 pcs.)

TD sensor

Heat exchanger

Ø8, 2 rows, 52 stages

FP1.45, flat fin



Distributor

Strainer

Cooling: Low pressure

Heating: High pressure


Packed valve


Ball valve

Accumulator

(2500cc)

Rotary compressor

(DA422A3F-25M)

Ø25 × L210

Ø25 × L180

RAV-SP300AT2-UL

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

Pd

(psi)

Ps

(MPa)

Pd Ps

372.7 143.6 2.57

0.99

478.5 158.1 3.30

1.09

252.3 108.8 1.74

0.75

336.4 105.9 2.32

0.73

466.9 169.7 3.22

1.17

314.7 43.5

2.17

0.30

(TD)

150.8

(66)

172.4

(78)

114.8

(46)

149 .0

(65)

163.4

(73)

(87)


(TS)

57.2

(14)

48.2

( 9)

44.6

( 7)

37.4

( 3)

66.2

(19)

(–15) exchanger

(TC)

41 .0

exchanger

(TL)

(44)

(49)

(32)

( 2)

(14)

(–14)

(TE)

(38)

(43)

(25)

( 3)

59 .0

(–13)

Compressor drive revolution

38

53

21

43

26

71

HIGH

HIGH

LOW

HIGH

LOW

HIGH

Indoor

80.6/66.2

(27/19)

89.6/75.2

(32/24)

64.4/59.9

(18/15.5)

68/–

(20/–)

86/–

(30/–)

(15/–)

Outdoor

95/–

(35/–)

109.4/–

(43/–)

23/–

(–5/–)

44.6/42.8

(7/6)

75.2/64.4

(24/18)

(–15/–)

∗

This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp meter becomes 2 times of No. of compressor revolutions (rps).

RAV-SP360AT2-UL, RAV-SP420AT2-UL

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

(psi)

Pressure

(MPa)

Pd Ps Pd Ps

394.4 130.5 2.72

0.90

484.3 155.2 3.34

1.07

253.8 110.2 1.75

0.76

375.6 100.1 2.59

0.69

453.9 152.3 3.13

1.05

348.0 30.45 2.40

0.21

(TD)

163.4

(73)

(80)

(45)

161.6

(72)

(97)


(TS)

53.6

exchanger

(TC) exchanger

(TL) (TE)

114.8

100.4

(12)

( 9)

(46)

(51)

(38)

(45)

91.4

77 .0

35.6

35.6

( 2) ( 2)

53.6

55.4

(12)

(–19)

(13)

(–18)

Compressor drive revolution

51

55

21

53

26

90

HIGH

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

(DB/WB) °F (°C)

Indoor

80.6/66.2

(27/19)

(32/24)

Outdoor

95/–

(43/–)

(18/15.5)

68/–

(20/–)

86/–

(30/–)

(15/–)

∗

This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp meter becomes 2 times of No. of compressor revolutions (rps).

– 18 –

4. WIRING DIAGRAM


RAV-SP180AT2-UL

3 3

49C

CN500

2

1

2

1

ORN

BLK

P.C. Board

(MCC-5009)

L

1

L

2

S

L

1

L

2

1 1

3 3

HP SW

Compressor

CM

1

2

3 3

1

2

RED

WHI

BLK

Reactor

YEL

YEL

BRN

YEL

ORN

2

1

2

1

P04

P05

P06

Q200~205

IGBT

R221

Q300~305

MOS-FET

R321

To indoor Power supply

208/230-1-60

CN300

3

2

P25

P24

P23

P22

P21

P20

P35

P34

R220

R219

L03 C13

R320

R319

CN700

DB01

CN603

P19

P18 Power relay

F03

Fuse, T3.15A

AC250V

C12 C14

Varistor

CN602

DB02

CT

L1

Relay

P11

P08

Surge absorber

CN601

CN605

BLK

1

1

1

1

Q404

2

2

2

2

3

3

3

3

SW802

P33 P32 CN701

PUR

P31

2

2

1

1

P30

1

1

Reactor

3

3

Coil for

4-way valve

Reactor

P7

Varistor

F01

Fuse, T25A

AC250V

P03

CN600

P10 P02 CN806

1 2 3 4 5

For optional

P.C. Board

GRN/YEL

MCC-1530

Sub P.C. Board

CAUTION : HIGH VOLTAGE

The high voltage circuit is incorporated.

Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand.

High voltage

3

2

1 1

6

5

6

4 4

3

2

3

2

1 1

BLK

WHI

RED

3 3

2

1 1

TS

(Suction pipe temp. sensor)

2 2

1 1

3

2

1 1

TD

(Discharge pipe temp. sensor)

2

1

3

2

1

1 1

FM

Fan motor

PMV

Pulse motor valve

TO

(Outdoor temp. sensor)

TE

(Condenser pipe temp. sensor)

Color

Identification

BLK : BLACK

BLU : BLUE

RED : RED

GRY : GRAY

PNK : PINK

GRN : GREEN

WHI : WHITE

BRN : BROWN

ORN : ORANGE

YEL : YELLOW

PUR : PURPLE

The 4-way valve coil is turned on while the cooling operation

1. indicates the terminal block.

Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

NOTE

Compressor

PMV : Pulse

Fan

TE : Heat Exchanger Temp. Sensor

Discharge

TO :

Suction

IGBT : Insulated Gate Bipolar Transistor

Rectifier

CT :

Compressor

HP SW : High pressure switch

– 19 –

RAV-SP240AT2-UL

Reactor

(GRY) (GRY) (WHI) (WHI)

Reactor

CM

(RED) (WHI) (BLK)

U V W

FM

1 1

2 2

3 3

CN300

(WHI)

P04 P05 P06 P07 CN200 CN201 CN202

49C

TL

TD

TO

TE

TS

HP SW

1 1

2 2

CN609

(BLU)

SW804 SW801 SW800

1 1

2 2

1 1

2 2

3

4

1

2

5

6

1 1

2 2

1 1

2

3 3

1 1

2

3 3

1 1

2 2

CN690

(RED)

CN610

(YEL)

CN604

(WHI)

CN603

(WHI)

CN602

(YEL)

CN601

(WHI)

CN600

(WHI)

SW803

SW802

CN710

(WHI)

1 2 3 4 5 6

1 2 3 4 6

1 3

CN704

(BLU)

Control P.C. Board

1

1

MCC-1571

RY704

CN701

(WHI)

4

4

CN04

(WHI)

1

1

3

3

5

5

Fuse, F01

T25A, 250V~

Fuse, F03

T10A, 250V~

7

7

P01

(RED)

PMW 20SF

L/F

P09

P02

(WHI)

(BLK)

Earth screw

Symbol

CM

FM

PMV

TD

TS

TE

TL

TO

20SF

49C

HP SW

RY

L/F

Parts name

Compressor

Fan Motor

Pulse Motor Valve

Pipe temp. sensor (Discharge)

Pipe temp. sensor (Suction)

Heat exchanger sensor 1


Outside temp. sensor

4-way valve coil

Compressor case thermostat

High pressure switch

Relay

Line Filter

Outdoor unit

Indoor unit

Earth screw

L

1

L

2

L






1

L

2

S

High voltage

S

Earth screw

L

1

L

2

Power supply

208/230-1-60

Color

Identification

– 20 –


Reactor

(GRY)

PMW

(GRY) (WHI) (WHI)

20SF

Reactor

CM

(RED) (WHI) (BLK)

U V W

FM01

FM02

TL

TD

TO

TE

TS

49C

HP SW

1 1

2 2

3 3

1 1

2 2

3 3

1 1

2 2

CN400

(WHI)

P04 P05

CN300

(WHI)

CN609

(BLU)

P06 P07 CN200 CN201 CN202

SW804 SW801 SW800

1 1

2 2

1 1

2 2

3

4

1

2

5

6

1 1

2 2

1 1

2

3 3

1 1

2

3 3

1 1

2 2

CN690

(RED)

CN610

(YEL)

CN604

(WHI)

CN603

(WHI)

CN602

(YEL)

CN601

(WHI)

CN600

(WHI)

SW803

SW802

CN704

(BLU)

CN710

(WHI)

1 2 3 4 5 6

1 2 3 4 6

1 3

Control P.C. Board

1

1

MCC-1570

RY704

CN701

(WHI)

4

4

CN04

(WHI)

1

1

3

3

5

5

Fuse, F01

T25A, 250V~

Fuse, F03

T10A, 250V~

7

7

P01

L/F

P09

P02

(RED) (WHI)

(BLK)

Symbol

CM

FM01, 02

PMV

TD

TS

TE

TL

TO

20SF

49C

HP SW

RY

L/F

Parts name

Compressor

Fan Motor

Pulse Motor Valve

Pipe temp. sensor (Discharge)

Pipe temp. sensor (Suction)



Outside temp. sensor

4-way valve coil

Compressor case thermostat

High pressure switch

Relay

Line Filter

Outdoor unit

Indoor unit

Earth screw

Earth screw

L






1

L

2

High voltage

L

1

L

2

S

S

Earth screw

L

1

L

2

Power supply

208/230-1-60

Color

Identification

– 21 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Outdoor Unit (Parts Ratings)

RAV-SP180AT2-UL

No.

1

8

9

6

7

4

5

2

3

10

11

12

Parts name

Fan motor

Compressor

Reactor

Outdoor temp. sensor (To sensor)

Heat exchanger sensor (Te sensor)

Suction temp. sensor (Ts sensor)

Discharge temp. sensor (Td sensor)

Fuse (Switching power (Protect))

Fuse (Inverter, input (Current protect))

4-way valve solenoid coil

Compressor thermo. (Protection)

Coil (Pulse Motor Valve)

13 Pressure switch

Type

ICF-140-43-4R

DA150A1F-21F

CH-57

—

—

—

—

—

—

STF-01AJ502E1

US-622

CAM-MD12TF-12

ACB-4UB82W

Specifications

Output (Rated) 43 W

3 phase, 4P, 1100 W

10mH, 16A

10 k

Ω

at 77°F (25°C)

10 k

Ω

at 77°F (25°C)

10 k

Ω

at 77°F (25°C)

50 k

Ω

at 77°F (25°C)

T3.15 A, AC 250 V

AC 240 V, 25 A

—

OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C)

—

OFF : 601.8 + 0

601.8

– 29 psi

⎛

4.15 + 0 .2 MPa

⎞

601.8 – 29 psi

⎝

4.15 – 0.2 MPa

⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

RAV-SP240AT2-UL

No.

9

10

11

12

13

7

8

5

6

3

4

1

2

14

Parts name

Compressor

Outdoor fan motor

Reactor

4-way valve coil

PMV coil

P.C. board

Fuse (Mounted on P.C. board)



Outdoor temp. sensor (TO sensor)



Heat exchanger Temp sensor (Ts sensor)


15 Pressure switch

Type

DA220A2F-22L

ICF-280-A60-1

CH-56

VHV-01AP552B1

CAM-MD12TF-15

MCC-1571

—

—

—

—

—

—

—

US-622

ACB-4UB82W

Specifications

—

Output 60 W

5.8 mH, 18.5 A

AC200 – 240 V

DC12 V

AC208 / 230 V

AC250 V, 25 A

AC250 V, 10 A

AC250 V, 3.15 A

10 k

Ω

at 77°F (25°C)

10 k

Ω

at 77°F (25°C)

50 k

Ω

at 77°F (25°C)

10 k

Ω

at 77°F (25°C)

OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C)

OFF : 601.8 + 0

601.8

– 29 psi

⎛

4.15 + 0 .2 MPa

⎞

601.8 – 29 psi

⎝

4.15 – 0.2 MPa

⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)


No.

11

12

13

8

9

10

6

7

4

5

1

2

3

14

Parts name

Compressor

Outdoor fan motor

Reactor

4-way valve coil

PMV coil

P.C. board




Outdoor temp. sensor (TO sensor)



Heat exchanger mid. Temp sensor (TL sensor)


Type

DA422A3F-25M

ICF-280-A100-1

CH-62

VHV-01AP552B1

UKV-A038

MCC-1571

—

—

—

—

—

—

—

US-622

15 Pressure switch ACB-4UB82W

Specifications

—

Output 100W

5.7mH, 18.5A

AC240V

DC12V

AC208 / 230 V

AC250V, 25A

AC250V, 10A

AC250V, 3.15A

10 k

Ω

at 77°F (25°C)

10 k

Ω

at 77°F (25°C)

50 k

Ω

at 77°F (25°C)

10 k

Ω

at 77°F (25°C)

OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C)

OFF : 601.8 + 0

601.8

– 29 psi

⎛

4.15 + 0 .2 MPa

⎞

601.8 – 29 psi

⎝

4.15 – 0.2 MPa

⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

– 22 –

6. REFRIGERANT R410A

This air conditioner adopts the new refrigerant HFC

(R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant

(R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

The next section describes the precautions for air conditioner using the new refrigerant.

Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

6. When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

7. Be sure to carry out installation or removal according to the installation manual.

Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc.

8. Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair may result in water leakage, electric shock and fire, etc.

6-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

1. Never use refrigerant other than R410A in an air conditioner which is designed to operate with

R410A.

If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.

2. Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant

R410A.

The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant.

To prevent mischarging, the diameter of the service port differs from that of R22.

3. If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire, a poisonous gas may occur.

4. When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle.

Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused.

5. After completion of installation work, check to make sure that there is no refrigeration gas leakage.

If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

6-2. Refrigerant Piping Installation

6-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes and joints are mainly used.

Copper pipes and joints suitable for the refrigerant must be chosen and installed.

Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

1. Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 0.0001 lbs / 32’ 10” (40 mg/10 m).

Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table 6-2-1. Never use copper pipes thinner than 0.03” (0.8 mm) even when it is available on the market.

– 23 –

Outer diameter (In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Table 6-2-1 Thicknesses of annealed copper pipes

R410A

0.03” (0.80)

Thickness (In (mm))

R22

0.03” (0.80)

0.03” (0.80)

0.03” (0.80)

0.04” (1.00)

0.03” (0.80)

0.03” (0.80)

0.04” (1.00)

1. Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a) Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds

20 mm. In such a case, socket joints can be used.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 6-2-3 to 6-2-5 below.

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 0.79” (20 mm). Thicknesses of socket joints are as shown in Table 6-2-2.

Table 6-2-2 Minimum thicknesses of socket joints

Reference outer diameter of copper pipe jointed

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Minimum joint thickness

(In (mm))

0.02” (0.50)

0.02” (0.60)

0.03” (0.70)

0.03” (0.80)

6-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner is used, and that refrigerant does not leak.

When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

1. Flare Processing Procedures and Precautions a) Cutting the Pipe

By means of a pipe cutter, slowly cut the pipe so that it is not deformed.

b) Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur.

Carefully remove all burrs and clean the cut surface before installation.

– 24 –

c) Insertion of Flare Nut d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perform the flare processing correctly.

Use either a flare tool for R410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool.

When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

ØD

A

Fig. 6-2-1 Flare processing dimensions

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Table 6-2-3 Dimensions related to flare processing for R410A / R22

Thickness

(In (mm))

0.03” (0.8)

0.03” (0.8)

0.03” (0.8)

0.04” (1.0)

Flare tool for

R410A, R22clutch type

0 – 0.02” (0 – 0.5)

0 – 0.02” (0 – 0.5)

0 – 0.02” (0 – 0.5)

0 – 0.02” (0 – 0.5)

A (In (mm))

Conventional flare tool (R410A)

Clutch type Wing nut type

0.04” – 0.06” (1.0 – 1.5) 0.06” – 0.08” (1.5 – 2.0)

0.04” – 0.06” (1.0 – 1.5)

0.04” – 0.06” (1.0 – 1.5)

0.04” – 0.06” (1.0 – 1.5)

0.06” – 0.08” (1.5 – 2.0)

0.08” – 0.10” (2.0 – 2.5)

0.08” – 0.10” (2.0 – 2.5)

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Thickness

(In (mm))

0.03” (0.8)

0.03” (0.8)

0.03” (0.8)

0.04” (1.0)

Table 6-2-4 Flare and flare nut dimensions for R410A

A B

Dimension (In (mm))

C

0.36” (9.1) 0.36” (9.2) 0.26” (6.5)

0.52” (13.2) 0.53” (13.5) 0.38” (9.7)

0.65” (16.6) 0.63” (16.0) 0.51” (12.9)

0.78” (19.7) 0.75” (19.0) 0.63” (16.0)

D

0.51” (13)

0.79” (20)

0.91” (23)

0.98” (25)

Flare nut width

(In (mm))

0.67” (17)

0.87” (22)

1.02” (26)

1.14” (29)

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

3/4” (19.0)

Thickness

(In (mm))

0.03” (0.8)

0.03” (0.8)

0.03” (0.8)

0.04” (1.0)

0.04” (1.0)

Table 6-2-5 Flare and flare nut dimensions for R22

A B

Dimension (In (mm))

C

0.36” (9.1) 0.36” (9.2) 0.26” (6.5)

0.51” (13.0) 0.53” (13.5) 0.38” (9.7)

0.64” (16.2) 0.63” (16.0) 0.51” (12.9)

0.76” (19.4) 0.75” (19.0) 0.63” (16.0)

0.92” (23.3) 0.94” (24.0) 0.76” (19.2)

D

0.51” (13)

0.79” (20)

0.79” (20)

0.91” (23)

1.34” (34)

Flare nut width

(In (mm))

0.67” (17)

0.87” (22)

0.94” (24)

1.06” (27)

1.42” (36)

– 25 –

45˚to 46˚

B A

C

D

43˚to 45˚

Fig. 6-2-2 Relations between flare nut and flare seal surface

2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc.

b) Correctly align the processed flare surface with the union axis.

c) Tighten the flare with designated torque by means of a torque wrench.

The tightening torque for R410A is the same as that for conventional R22.

Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable.

When choosing the tightening torque, comply with values designated by manufacturers.

Table 6-2-6 shows reference values.

NOTE

When applying oil to the flare surface, be sure to use oil designated by the manufacturer.

If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

Table 6-2-6 Tightening torque of flare for R410A [Reference values]

Outer diameter (In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Tightening torque (ft • lbs (N • m))

10 – 13 (14 – 18)

24 – 31 (33 – 42)

37 – 46 (50 – 62)

50 – 60 (68 – 82)

– 26 –

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.

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

When the compound gauge’s pointer has indicated

–101 kpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Connect the charge hose of the vacuum pump adapter.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Open fully both packed valves at liquid and gas sides.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge

liquid refrigerant.

(For refrigerant charging, see the figure below.)

1) Never charge refrigerant exceeding the specified amount.

2) If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3) Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

(INDOOR unit)

(Liquid side)

(OUTDOOR unit)

Opened

(Gas side)


(With siphon pipe)

Check valve

Closed

Open/Close valve for charging

Service port

Electronic balance for refrigerant charging

Fig. 6-4-1 Configuration of refrigerant charging

– 27 –

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.

[ Cylinder with siphon ]

Gauge manifold

OUTDOOR unit

[ Cylinder without siphon ]

Gauge manifold

OUTDOOR unit


Electronic balance cylinder ant

Electronic balance

Refriger

Siphon

R410A refrigerant is HFC mixed refrigerant.

Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

Fig. 6-4-2

6-5. Brazing of Pipes

6-5-1. Materials for Brazing

1. Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper.

It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

2. Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

3. Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead.

Since it is weak in adhesive strength, do not use it for refrigerant pipes.

1) Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage.

Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2) When performing brazing again at time of servicing, use the same type of brazing filler.

– 28 –

6-5-2. Flux

1. Reason why flux is necessary

• By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

• In the brazing process, it prevents the metal surface from being oxidized.

• By reducing the brazing filler's surface tension, the brazing filler adheres better to the treated metal.

2. Characteristics required for flux

• Activated temperature of flux coincides with the brazing temperature.

• Due to a wide effective temperature range, flux is hard to carbonize.

• It is easy to remove slag after brazing.

• The corrosive action to the treated metal and brazing filler is minimum.

• It excels in coating performance and is harmless to the human body.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

3. Types of flux

• Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 1,472°F (800°C).

• Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

4. Piping materials for brazing and used brazing filler/flux

Piping material

Used brazing filler

Copper - Copper Phosphor copper

Copper - Iron

Iron - Iron

Silver

Silver

Used flux

Do not use

Paste flux

Vapor flux

6-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas flow.

Never use gas other than Nitrogen gas.

1. Brazing method to prevent oxidation

1) Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3) Apply a seal onto the clearance between the piping material and inserted copper pipe for

Nitrogen in order to prevent backflow of the

Nitrogen gas.

4) When the Nitrogen gas is flowing, be sure to keep the piping end open.

5) Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m³/Hr or 2.9 psi (0.02 MPa) by means of the reducing valve.

6) After performing the steps above, keep the

Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7) Remove the flux completely after brazing.

M

Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

1) Do not enter flux into the refrigeration cycle.

2) When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates.

Therefore, use a flux which does not contain chlorine.

3) When adding water to the flux, use water which does not contain chlorine

(e.g. distilled water or ion-exchange water).

4) Remove the flux after brazing.

Pipe

Nitrogen gas

Rubber plug

Fig. 6-5-1 Prevention of oxidation during brazing

– 29 –

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS

7-1. Print Circuit Board

<MCC-5009>

RAV-SP180AT2-UL

– 30 –

<MCC-1571>

RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Fan motor output

(Lower side)

CN300 (White)

Fan motor output

(Upper side)

CN400 (White)

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)

Compressor ON output connector

CN704 (Blue)

Heater output connector

CN610 (Gray)

Outside input connector

CN610 (Yellow)

Specific operation switch

SW801

SW804

Display select switch

SW800

SW803

Temp. sensor connector

Compressor output terminal

CN202

CN201

CN200

Electrolytic condenser

Power-ON, error display LED

D800 to 804 (Yellow)

D805 (Green)

PMV connector

CN710 (White)

Initial setting switch

SW802

Indoor/Outdoor communication signal LED

D503 (Green, Outdoor

→

Indoor)

D502 (Orange, Indoor

→

Outdoor)

Inter-unit cable connector

CN04 (White)

4-way valve protective fuse

F700 (250V, 3.15A, Plastic case)

Inter-unit cable protective fuse

F03 (250V, 25A)

Power supply protective fuse

F01 (250V, 25A)

Lead wire for connection of power supply

P01 (Red)

P02 (White)

– 31 –

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.

3) In heating operation, PMV is usually controlled with the temperature difference between TS sensor and

TE sensor aiming (–2 to 4K) as the target value.

4) When the cycle excessively heated in both cooling and heating operation, PMV is controlled by TD sensor.

The target value is 213.8°F (101°C) for both cooling and heating operations.

REQUIREMENT

A sensor trouble may cause a liquid back-flow or abnormal overheat resulting in excessive shortening of the compressor life.

In a case of trouble on the compressor, be sure to check there is no error in the resistance value or the refrigerating cycle of each sensor after repair and then start the operation.

2. Discharge temperature release control

1) When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control, this control lowers the operation frequency.

It subdivides the frequency control up to 0.6Hz to stabilize the cycle.

2) When the discharge temperature detected an abnormal stop zone, the compressor stops and then restarts after 2 minutes 30 seconds.

The error counting is cleared when the operation continued for A minutes. If the error is detected by

B times without clearing, the error is determined and restarting is not performed.

∗

The cause is considered as excessively little amount of refrigerant, PMV error or clogging of the cycle.

3) For displayed contents of error, confirm on the check code list.

TD ˚F (˚C)

242.6 (117)

224.6 (107)

221 .0

(105)

215.6 (102)

199.4 (93)

Abnormal stop

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up

(Up to command)

As command is

A

B

SP180

6

8

– 32 –

3. Outdoor fan control

RAV-SP

180AT2-UL

Revolution frequency allocation of fan taps [rpm]

W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF

200 250 300 400 480 500 520 560 640 670 700 750 800 880 980

3-1) Cooling fan control

c

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).

d

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.

e

When temperature of TD sensor became high sufficiently, it is controlled so that the fan revolution frequency will become higher ignoring TE sensor temperature.

TE

˚F (˚C)

+1 tap / 20 sec

Up to the maximum revolution frequency of each zone

∗

Operation with W1 in case of fan-OFF

89.6 (32)

Revolution frequency hold

84.2 (29)

–1 tap / 20 sec

Down to the minimum revolution frequency of each zone

TD

˚F (˚C)

185 (85)

176 (80)

167 (75)

149 (65)

Operation with WF

Operation with the maximum tap of each zone

Normal fan control by TE sensor

Temp. range

100.4°F (38°C)

≤

TO

82.4°F (28°C)

≤

TO < 100.4°F (38°C)

59°F (15°C)

≤

TO < 82.4°F (28°C)

41.9°F (5.5°C)

≤

TO < 59°F (15°C)

32°F (0°C)

≤

TO < 41.9°F (5.5°C)

23°F (–5°C)

≤

TO < 32°F (0°C)

TO < 23°F (–5°C)

TO error

W3

W2

W1

W1

20 Hz or lower

Min.

Max.

W6

W5

WB

WA

OFF

W1

OFF

WB

W7

W5

W3

W2

– 33 –

W4

W3

W2

W1

20Hz to 45Hz

Min.

Max.

W7

W6

WE

WD

OFF

W1

OFF

WE

W9

W7

W5

W3

W6

W5

W3

W2

45Hz or higher

Min.

Max.

W9

W8

WF

WE

W1

W1

W3

WF

WB

W9

W7

W4

3-2) Heating fan control

c

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)) d

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.

e

When TE

≥

75.2°F (24°C) continues for 5 minutes, the compressor stops.

It is the same status as the normal THERMO OFF without error display. The compressor restarts after approx. 2 minutes 30 seconds and this intermittent operation is not abnormal.

f

In case that the status in item e

generates frequently, stain on filter of the suction part of the indoor unit is considered. Clean the filter and then restart the operation.

75.2 (24)

69.8 (21)

64.4 (18)

59.0 (15)

TE ˚F (˚C)

–2 taps / 20 sec. (Down to W1)

Stop timer count

–2 taps / 20 sec. (Down to W1)

–1 tap / 20 sec. (Down to W1)


+1 tap / 20 sec

(Up to the maximum tap of each zone)

Temp. range

50°F (10°C)

≤

TO

41.9°F (5.5°C)

≤

TO < 50°F (10°C)

23°F (–5°C)

≤

TO < 41.9°F (5.5°C)

TO < 23°F (–5°C)

TO error

20 Hz or lower

Max.

W7

WA

WD

WE

WE

20Hz to 45Hz

Max.

W8

WC

WE

WF

WF

45Hz or higher

Max.

W9

WE

WF

WF

WF

– 34 –

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.

As same as a test run, it is recommended to turn on power of the compressor beforehand when starting operation after power of the compressor has been interrupted and left as it is for a long time.

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.

TE [˚C]

(Normal time)

32.0 ( 0)

No power

30.2 (–1)

21.2 (–6)

Continuous power-ON

Output [10W or equivalent]

19.4 (–7)

Continuous power-ON

Output [20W or equivalent]

• Power-ON condition TD < 86˚F (30˚C)

REQUIREMENT

In some cases, the sound of power-ON may be heard.

It is not abnormal.

REQUIREMENT

While heating the coil, the power sound may be heard. However it is not a trouble.

5. Short intermittent operation preventive control

1) For 3 to 10 minutes after operation start, in some cases, the compressor does not stop to protect the compressor even if receiving the THERMO OFF signal from indoor.

However it is not abnormal status. (The operation continuance differs according to the operation status.)

2) When the operation stops by the remote controller, the operation does not continue.

6. Current release control

No. of revolutions of the compressor is controlled by AC current value detected by the outdoor P.C. board so that the input current of the inverter does not exceed the specified value.

I

Current [A]

I

1

1–1.0

Frequency down

Hold

Normal operation

Hold

Model

I

1 value [A]

RAV-SP180AT2-UL

COOL

10.80

HEAT

13.05

– 35 –

7. Current release value shift control

1) This control purposes to prevent troubles of the electronic parts such as the compressor driving elements and the compressor during cooling operation.

2) The current release control value ( to TO sensor value.

I

1) is selected from the following table according

Current release control value (I1)

Temperature range

122°F (50°C)

≤

TO

113°F (45°C)

≤

TO < 122°F (50°C)

102.2°F (39°C)

≤

TO < 113°F (45°C)

TO < 102.2°F (39°C)

TO error

[A]

RAV-SP180AT2-UL

5.1

5.1

7.8

10.8

5.1

8. Over-current protective control

1) When the over-current protective circuit detected an abnormal current, stop the compressor.

2) The compressor restarts after 2 minutes 30 seconds as setting [1] as an error count.

3) When the error count [8] was found, determine an error and restart operation is not performed.

4) For the error display contents, confirm on the check code list.

9. High-pressure SW control

1) The operation frequency is controlled to restrain abnormal rising of high pressure by the High-pressure SW.

2) When cooling operation detects abnormal pressure of the stop zone, stop the compressor and the error count becomes +1.

3) When the compressor stopped with 2), the compressor will restart only when the pressure lowers under the reset pressure after 2 minutes and 30 seconds.

4) The error count when the compressor stopped with 2) is cleared after the operation continued for 10 minutes.

Pressure of High-pressure switch control

If the error count becomes [8] without clearing, the error is determined and reactivation is not performed.

STOP pressure 601.8 + 0

⎛

⎝

4.15 +0

.2 psi

⎞

–0.2 MPa

⎠


RESET pressure 464 ± 29 psi (3.20 ± 0.2 MPa)

10. Auto restart

1) Object

It restarts the operation automatically after resetting the unexpected stop of power supply such as power failure.

2) Contents

After returning from a power failure, the auto restart function reads the operation status from EEPROM and then restarts the operation automatically according to the operation contents.

3) Setup of function exchange by wired remote controller CODE No. (DN): 28

SET DATA 0000 0001

Auto restart None Provided

– 36 –

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 < 53.6°F (12°C) for 80 seconds. The defrost operation also finishes when it continued for 15 minutes even if TE sensor temperature was 41°F (5°C) or lower.

3) After defrost operation was reset, the compressor stopped for approx. 40 seconds and then the heating operation starts.

Start of heating operation

10 15

TE

˚F (˚C)

0

24.8 (–4)

21.2 (–6)

14 (–10)

29 35 91

[min.]

–25

∗

B zone

C zone

D zone

* The minimum TE value and To value between 10 and 15 minutes after heating operation has started are stored in memory as TE0 and To0, respectively.

A zone

In normal To

When status (TE0 – TE) – (To0 – To)

≥

37.4°F (3°C) continued for 20 seconds

In abnormal To

When status (TE0 – TE)

≥



≥

36.5°F (2.5°C) continued for 20 seconds

When status (TE0 – TE) 36.5°F (2.5°C) continued for 20 seconds

When the status (TE

≤

–14.8°F (–26°C)) continued for 20 seconds

When the status (TE

≤

14°F (–10°C)) continued for 20 seconds

– 37 –

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.

4) When the cycle excessively heated in both cooling and heating operation, PMV is controlled by TD sensor. The target value is usually 195.8°F (91°C) in cooling operation and 204.8°F (96°C) in heating operation.

REQUIREMENT

A sensor trouble may cause a liquid back-flow or abnormal overheat resulting in excessive shortening of the compressor life. In a case of trouble on the compressor, be sure to check there is no error in the resistance value or the refrigerating cycle of each sensor after repair and then start the operation.

2. Discharge temperature release control

1) When the discharge temperature did not fall or the discharge temperature rapidly went up by PMV control, this control lowers the operation frequency. It subdivides the frequency control up to 0.6Hz to stabilize the cycle.

2) When the discharge temperature detected an abnormal stop zone, the compressor stops and then restarts after 2 minutes 30 seconds.

The error counting is cleared when the operation continued for 10 minutes. If the error is detected by

4 times without clearing, the error is determined and restarting is not performed.

∗

The cause is considered as excessively little amount of refrigerant, PMV error or clogging of the cycle.

3) For displayed contents of error, confirm on the check code list.

TD

˚F (˚C)

231.8 (111)

228.2 (109)

222.8 (106)

217.4 (103)

204.8 (96)

Abnormal stop

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up

(Up to command)

As command is

– 38 –

RAV-

SP240AT2-UL


3. Outdoor fan control

Revolution frequency allocation of fan taps [rpm]

W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE WF

200 230 260 300 340 380 420 460 520 570 600 630 670 710 740

RAV-

SP300AT2-UL

SP360AT2-UL

SP420AT2-UL

W1 W2 W3 W4 W5 W6 W7 W8 W9 WA WB WC WD WE

Up 200 240 240 260 320 380 480 500 530 610 640 660 720 780

Down — — 200 280 360 400 500 520 550 630 660 700 740 820

3-1) Cooling fan control

c

The outdoor fan is controlled by TL sensor,

TO sensor and the operation frequency.

The outdoor fan is controlled by every 1 tap of DC fan control (SP240: 15 taps,

SP300, SP360, SP400: 14 taps).

d

Only for 60 seconds 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 TL sensor.

TL

˚F (˚C)

136.4 (58)

131.0 (55)

100.4 (38)

95.0 (35)

WE tap

+1 tap / 20 sec

Up to the maximum revolution frequency of each zone


–1 tap / 20 sec

Up to the minimum revolution frequency of each zone

<RAV-SP240AT2-UL>

Temp. range

100.4°F (38°C)

≤

TO

84.2°F (29°C)

≤

TO < 100.4°F (38°C)

59°F (15°C)

≤

TO < 84.2°F (29°C)

41°F (5°C)

≤

TO < 59°F (15°C)

32°F (0°C)

≤

TO < 41°F (5°C)

24.8°F (–4°C)

≤

TO < 32°F (0°C)

TO < 24.8°F (–4°C)

TO error

20 Hz or lower

Min.

W6

W5

Max.

WC

WB

W4

W3

W2

W2

OFF

OFF

W8

W6

W4

W3

OFF

WC

20Hz to 45Hz

Min.

W8

W7

Max.

WE

WD

W6

W5

W4

W3

OFF

OFF

WA

W8

W6

W5

W2

WE

45Hz or higher

Min.

WA

W9

Max.

WE

WD

W8

W7

W5

W4

OFF

OFF

WC

WA

W8

W6

W3

WE

<RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL>

Temp. range

100.4°F (38°C)

≤

TO

84.2°F (29°C)

≤

TO < 100.4°F (38°C)

59°F (15°C)

≤

TO < 84.2°F (29°C)

41°F (5°C)

≤

TO < 59°F (15°C)

32°F (0°C)

≤

TO < 41°F (5°C)

24.8°F (–4°C)

≤

TO < 32°F (0°C)

TO < 24.8°F (–4°C)

TO error

W2

W2

W1

W1

20 Hz or lower

Min.

Max.

W6 WC

W5

W4

W3

WB

W8

W6

W4

W3

W2

WC

W4

W3

W1

W1

20Hz to 45Hz

Min.

Max.

W8 WC

W7

W6

W5

WC*

WA

W8

W6

W5

W4

WC

W5

W4

W2

W2

45Hz or higher

Min.

Max.

WA WE

W9

W8

W7

WC

WC

WA

W8

W6

W6

WD

∗

: WB for SP300

– 39 –

3-2) Heating fan control

c

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)) d

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.

e

When TE

≥

75.2°F (24°C) continues for

5 minutes, the compressor stops.

It is the same status as the normal

THERMO-OFF without error display.

TE

˚F (˚C)

–2 taps / 20 sec. (Up to W1)

Stop timer count The compressor restarts after approx.

2 minutes 30 seconds and this intermittent operation is not abnormal.

75.2 (24)

–2 taps / 20 sec. (Up to W1)

69.8 (21) f

In case that the status in item e generates frequently, stain on filter of the suction part of the indoor unit is considered. Clean the filter and then restart the operation.

64.4 (18)

59.0 (15)

–1 tap / 20 sec. (Up to W1)


+1 tap / 20 sec

(Up to the maximum tap of each zone)

Object: RAV-SP240AT2-UL

Temp. range

50°F (10°C)

≤

TO

41°F (5°C)

≤

TO < 50°F (10°C)

26.6°F (–3°C)

≤

TO < 41°F (5°C)

14°F (–10°C)

≤

TO < 26.6°F (–3°C)

TO < 14°F (–10°C)

TO error

Object: RAV-SP300AT2-UL

Temp. range

50°F (10°C)

≤

TO

41°F (5°C)

≤

TO < 50°F (10°C)

26.6°F (–3°C)

≤

TO < 41°F (5°C)

14°F (–10°C)

≤

TO < 26.6°F (–3°C)

TO < 14°F (–10°C)

TO error

20 Hz or lower

Max.

W7

W9

WD

WE

WF

WF

20 Hz or lower

Max.

W7

W9

WA

WB

WD

WD

Object: RAV-SP360AT2-UL, RAV-SP420AT2-UL

Temp. range

50°F (10°C)

≤

TO

41°F (5°C)

≤

TO < 50°F (10°C)

26.6°F (–3°C)

≤

TO < 41°F (5°C)

14°F (–10°C)

≤

TO < 26.6°F (–3°C)

TO < 14°F (–10°C)

TO error

20 Hz or lower

Max.

W7

W9

WB

WC

WD

WD

– 40 –

20Hz to 45Hz

Max.

W8

WB

WD

WE

WF

WF

20Hz to 45Hz

Max.

W8

WA

WA

WB

WD

WD

20Hz to 45Hz

Max.

W8

WA

WB

WC

WD

WD

45Hz or higher

Max.

W9

WD

WE

WE

WF

WF

45Hz or higher

Max.

W9

WA

WB

WB

WD

WD

45Hz or higher

Max.

W9

WB

WC

WC

WD

WD

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.

As same as a test run, it is recommended to turn on power of the compressor beforehand when starting operation after power of the compressor has been interrupted and left as it is for a long time.

3) A judgment for electricity is performed by TD and TO sensors.

If TO sensor is defective, a backup control is automatically performed by TE sensor.

For a case of defective TO sensor, judge it with outdoor LED display.

4) For every model, the power is turned off when TD is 86°F (30°C) or more.

TO

˚F (˚C)

(Normal time)

64.4 (18)

59 (15)

50 (10)

46.4 (8)

No power

Intermittent power-ON

10 minutes: ON /

5 minutes: OFF

Output

[40W or equivalent]

Continuous power-ON

Output

[40W or equivalent]


TE

˚F (˚C)

(In defective TO sensor)

68 (20)

64.4 (18)

53.6 (12)

50 (10)

No power

Intermittent power-ON

10 minutes: ON /

5 minutes: OFF

Output

[40W or equivalent]

Continuous power-ON

Output

[40W or equivalent]


REQUIREMENT

While heating the coil, the power sound may be heard. However it is not a trouble.

5. Short intermittent operation preventive control

1) For 3 to 10 minutes after operation start, in some cases, the compressor does not stop to protect the compressor even if receiving the thermostat-OFF signal from indoor.

However it is not abnormal status. (The operation continuance differs according to the operation status.)

2) When the operation stops by the remote controller, the operation does not continue.

6. Current release control

No. of revolutions of the compressor is controlled by AC current value detected by T620 on the outdoor P.C.

board so that the input current of the inverter does not exceed the specified value.

I

Current [A]

I

1

1–1.0

Frequency down

Hold

Normal operation

Hold

Objective model

RAV-

IIIII 1 value [A]

SP240AT2-UL

COOL

16.0

HEAT

20.0

SP300AT2-UL

SP360AT2-UL

SP420AT2-UL

COOL

20.0

HEAT

20.0

– 41 –

7. Current release value shift control

1) This control purposes to prevent troubles of the electronic parts such as the compressor driving elements and the compressor during cooling operation.

2) The current release control value ( I 1) is selected from the following table according to TO sensor value.

Current release control value (I1)

Temperature range

111.2°F (44°C)

≤

To

102.2°F (39°C)

≤

To < 111.2°F (44°C)

To < 102.2°F (39°C)

TO error

[A]

RAV-SP300AT2-UL

RAV-SP360AT2-UL

RAV-SP420AT2-UL

15.0

17.7

20.0

15.0

8. Over-current protective control

1) When the over-current protective circuit detected an abnormal current, stop the compressor.

2) The compressor restarts after 2 minutes 30 seconds setting [1] as an error count.

3) When the error count [8] was found, determine an error and restart operation is not performed.


9. High-pressure SW control

1) The operation frequency is controlled to restrain abnormal rising of high pressure by the High-pressure SW.

2) When cooling operation detects abnormal pressure of the stop zone, stop the compressor and the error count becomes +1.

3) When the compressor stopped with 2), the compressor will restart only when the pressure lowers under the reset pressure after 5 minutes.

4) The error count when the compressor stopped with 2) is cleared after the operation continued for 10 minutes.

If the error count becomes [10] without clearing, the error is determined and reactivation is not performed.


Pressure of High-pressure switch control

STOP pressure

RESET pressure

601.8 + 0

⎛

⎝

4.15 +0

.2 psi

⎞

–0.2 MPa

⎠

464 ± 29 psi (3.20 ± 0.2 MPa)

– 42 –


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)

≤

TE < 53.6°F (12°C) for 1 minute.

The defrost operation also finishes when it continued for 10 minutes even if TE sensor temperature was

44.6°F (7°C) or lower.

3) After defrost operation was reset, the compressor stopped for approx. 40 seconds and then the heating operation starts.

Start of heating operation

TE ˚F (˚C)

0 10 15 39 45 55 d [min.]

28.4 (–2)

23.0 (–5)

14.0 (–10)

–9.4 (–23)

∗

∗

The minimum TE value and To value between 10 and 15 minutes after heating operation has started are stored in memory as TE0 and To0, respectively.

A zone

B zone

C zone

D zone

In normal To


≥



≥


In abnormal To


≥



≥


When status (TE

≤

–9.4°F (–23°C)) continued for 20 seconds

When compressor operation status of TE < 28.4°F (–2°C) is calculated by d portion

4) The time of above d can be changed by exchanging jumper [J805] and [J806] of the outdoor control P.C. board.

(Setting at shipment: 150 minutes)

J805

{

{

×

×

J806

{

×

{

×

d

150 minutes

Setting at shipment

90 minutes

60 minutes

30 minutes

{ : Short circuit,

×

: Open

– 43 –

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.

The operation frequency follows the normal indoor command after controlling.

2) Although the compressor may stop by THERMO-OFF control when the room temperature varies and then attains the set temperature by this control, it is not abnormal.

3) During this control works, if stopping the operation by the remote controller, the operation does not continue.

12. Auto restart

1) Object

It restarts the operation automatically after resetting the unexpected stop of power supply such as power failure.

2) Contents

After returning from a power failure, the auto restart function reads the operation status from EEPROM and then restarts the operation automatically according to the operation contents.

3) Setup of function exchange by wired remote controller CODE No. (DN): 28

SET DATA 0000 0001

Auto restart None Provided

– 44 –


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.

1. Compressor does not operate.

• Is not 3-minutes delay (3 minutes after compressor OFF)?

• Is not the outdoor unit in standby status though the remote controller reached the setup temperature?

• Does not timer operate during fan operation?

• Is not an overflow error detected on the indoor unit?

• Is not outside high-temperature operation controlled in heating operation?

2. Indoor fan does not rotate.

• Does not cool air discharge preventive control work in heating operation?

3. Outdoor fan does not rotate or air volume changes.

• Does not high-temperature release operation control work in heating operation?

• Does not outside low-temperature operation control work in cooling operation?

• Is not defrost operation performed?

4. ON/OFF operation cannot be performed from remote controller.

• Is not automatic address being set up?

(When the power is turned on at the first time or when indoor unit address setting is changed, the operation cannot be performed for maximum approx. 5 minutes after power-ON.)

• Is not being carried out a test run by operation of the outdoor P.C. board?

b) Did you return the cabling to the initial positions?

c) Are connecting cables of indoor unit and remote controller correct?

2. Troubleshooting procedure

When a trouble occurred, check the parts along with the following procedure.

Trouble

→

Confirmation of check code display

→

Check defective parts.

NOTE :

For cause of a trouble, power conditions or malfunction/erroneous diagnosis of microcomputer due to outer noise is considered except the items to be checked. If there is any noise source, change the cables of the remote controller to shield cables.

– 45 –


<Wireless remote controller type>

1. Before troubleshooting

1) Required tools/instruments

•

+

and

–

screwdrivers, spanners, radio cutting pliers, nippers, etc.

• Tester, thermometer, pressure gauge, etc.

2) Confirmation points before check a) The following operations are normal.

1. Compressor does not operate.

• Is not 3-minutes delay (3 minutes after compressor OFF)?

• Is not the outdoor unit in standby status though the remote controller reached the setup temperature?

• Does not timer operate during fan operation?

• Is not an overflow error detected on the indoor unit?

• Is not outside high-temperature operation controlled in heating operation?

2. Indoor fan does not rotate.

• Does not cool air discharge preventive control work in heating operation?

3. Outdoor fan does not rotate or air volume changes.

• Does not high-temperature release operation control work in heating operation?

• Does not outside low-temperature operation control work in cooling operation?

• Is not defrost operation performed?

4. ON/OFF operation cannot be performed from remote controller.

• Is not forced operation performed?

• Is not the control operation performed from outside/remote side?

• Is not automatic address being set up?

• Is not being carried out a test run by operation of the outdoor controller?

b) Did you return the cabling to the initial positions?

c) Are connecting cables between indoor unit and receiving unit correct?

2. Troubleshooting procedure

(When the power is turned on at the first time or when indoor unit address setting is changed, the operation cannot be performed for maximum approx. 5 minutes after power-ON.)

When a trouble occurred, check the parts along with the following procedure.

Trouble

→

Confirmation of lamp display

(When 4-way air discharge cassette type,

Under ceiling type wireless remote controller is connected)

→

Check defective position and parts.

1) Outline of judgment

The primary judgment to check where a trouble occurred in indoor unit or outdoor unit is performed with the following method.

Method to judge the erroneous position by flashing indication on the display part of indoor unit

(sensors of the receiving unit)

The indoor unit monitors 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.

– 46 –


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.

: Go off, : Go on, : Flash (0.5 sec.)

Lamp indication

Operation Timer Ready

Check code

—

No indication at all

Operation Timer

Flash

Ready

E01

E02

E03

E08

E09

E10

E18


Cause of trouble occurrence

Power supply OFF or miswiring between lamp indication unit and indoor unit

Receiving error

Sending error

⎫

⎬

⎭

Receiving unit

Communication stop

Duplicated indoor unit No.

⎬

⎪

⎫

⎪

⎭

Miswiring or wire connection error between receiving unit and indoor unit

Duplicated master units of remote controller

⎫

⎬

⎭

Setup error

Communication error between CPUs on indoor unit P.C. board

Wire connection error between indoor units, Indoor power OFF

(Communication stop between indoor header and follower)

E04

Miswiring between indoor unit and outdoor unit or connection erorr

(Communication stop between indoor and outdoor units)

Flash


P10

Alternate flash

Operation Timer

Alternate flash

Ready

P12

P15

P19

P20

P22

P03

P04

P05

P07

P26

P29

P31

Overflow was detected.

Indoor DC fan error

⎬

⎪

⎫

⎪

⎭

Protective device of indoor unit worked.

Outdoor unit discharge temp. error

Outdoor high pressure system error

⎫

⎬

⎭

Protective device of outdoor unit worked.

Negative phase detection error

Heat sink overheat error

Gas leak detection error

⎬

⎪

⎫

⎪

⎭

Outdoor unit error

4-way valve system error (Indoor or outdoor unit judged.)

Outdoor unit high pressure protection

Outdoor unit: Outdoor unit error

Outdoor unit: Inverter Idc operation

Outdoor unit: Position detection error

⎬

⎪

⎫

⎪

⎭

Protective device of outdoor unit worked.

Stopped because of error of other indoor unit in a group

(Check codes of E03/L03/L07/L08)

∗

∗

1

1

∗

1: These are representative examples and the check code differs according to the outdoor unit to be combined.

– 47 –

Lamp indication


Alternate flash


Alternate flash

Check code

F01

F02

F10

F04

F06

F07

F08

F12

F13

F15



Heat exchanger sensor (TCJ) error

Heat exchanger sensor (TC) error

Heat exchanger sensor (TA) error

Discharge temp. sensor (TD) error

Temp. sensor (TE) error

Temp. sensor (TL) error

Temp. sensor (TO) error

Temp. sensor (TS) error

Temp. sensor (TH) error

Temp. Sensor miswiring (TE, TS)

⎪

⎪

⎭

⎪

⎪

⎪

⎪

⎪

⎬

⎪

⎪

⎪

⎪

⎫

⎪

⎬

⎪

⎫

⎪

⎭

Indoor unit sensor error

Sensor error of outdoor unit


F29 Indoor EEPROM error

Simultaneous flash


F31 Outdoor EEPROM error

Simultaneous flash


Flash


Simultaneous flash


Simultaneous flash

L10

L20

L29

L30

L31

H01

H02

H03

H04

H06

L03

L07

L08

L09

Compressor break down

Compressor lock

Current detection circuit error ⎪

⎪

⎭

⎪

⎬

⎫

⎪

Outdoor compressor system error

Case thermostat worked.

Outdoor unit low pressure system error

Duplicated header indoor units

There is indoor unit of group connection in individual indoor unit.

Unsetting of group address

Missed setting

(Unset indoor capacity)

⎪

⎪

⎭

⎪

⎬

⎫

⎪

→

∗

AUTO address

If group construction and address are not normal when power supply turned on, automatically goes to address setup mode.

Unset model type (Service board)

Duplicated indoor central addresses

Outdoor unit and other error

Outside interlock error

Negative phase error

⎪

⎪

⎪

⎬

⎪

⎪

⎫

⎪

⎪

⎪

⎭

Others

– 48 –

8-2-2. Others (Other than Check Code)

Lamp indication


Check code

—

Simultaneous flash

During test run



– 49 –

8-2-3. Check Code List (Outdoor)

{ : Go on, : Flash, z

: Go off

ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED

P03

P04

P05

P07

P15

P20

P22

P26

P29

E01

E02

E03

E04

E08

E09

E10

E18

L03

L07

L08

L09

P19

Remote controller indication

F04

F06

F08

F07

F12

F13

F15

F31

H01

H02

H03

H04

L10

L29

Sensor lamp part

Block indication

Operation Timer Ready Flash

{

ALT

{

ALT

{

ALT

{

ALT

{

ALT

{

ALT

{

ALT

{

SIM z

z z

z z

z z

z

{

SIM

{ SIM z

ALT z

ALT z

ALT z

ALT z

ALT z

ALT z

ALT z

ALT z

ALT z z z z

z z z z

z z

z z z z z z z

SIM z

SIM z

SIM z

SIM

z

ALT

Representative defective position

Outdoor unit Discharge temp. sensor (TD) error

Outdoor unit Temp. sensor (TE) error

Outdoor unit Outside temp. sensor (TO) error

Outdoor unit Temp. sensor (TL) error

Outdoor unit Temp. sensor (TS) error

Outdoor unit Temp. sensor (TH) error

Outdoor unit Misconnection of temp. sensor (TE, TS)

Outdoor unit EEPROM error

Outdoor unit Compressor break down

Outdoor unit Compressor lock

Outdoor unit Current detection circuit error

Outdoor unit Case thermostat operation

Outdoor unit Setting error of service P.C. board type

Outdoor unit Other outdoor unit error

Outdoor unit Discharge temp. error

Outdoor unit

High pressure system error, Power supply voltage error

Power supply error

Outdoor unit Heat sink overheat

Gas leak detection

Outdoor unit High pressure system error

Outdoor unit Outdoor fan error

Outdoor unit Inverter Idc operation

Outdoor unit Position detection error

No remote controller master unit

Remote controller communication error

Remote controller send error

Regular communication error between indoor and remote controller

Indoor/Outdoor serial error

Duplicated indoor addresses

Duplicated main remote controllers

Communication error between CPU

Regular communication error between header and follower indoor units

Duplicated indoor header units

There is group cable in individual indoor unit.

Unset indoor group address

Unset indoor capacity

4-way valve inverse error

Detection

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Outdoor

Remote controller

Remote controller

Indoor

Indoor

Indoor

Remote controller

Indoor

Indoor

Indoor

Indoor

Indoor

Indoor

Indoor

Outdoor

Explanation of error contents

Open/Short of discharge temp. sensor was detected.

Open/Short of heat exchanger temp. sensor was detected.

Miswiring between TE sensor and TS sensor

Open/Short of outside temp. sensor was detected.

Open/Short of heat exchanger temp. sensor was detected.

Open/Short of suction temp. sensor was detected.

Open/Short of heat sink temp. sensor (Board installed) was detected.

Misconnection of outdoor heat exchanger temp. sensor and suction temp. sensor was detected.

Outdoor P.C. board part (EEPROM) error was detected.

When reached min-Hz by current release control, short-circuited current (Idc) after

DC excitation was detected.

Compressor lock was detected.

Current detection circuit error

Case thermostat operation was detected.

When outdoor service P.C. board was used, model type select jumper setting was inappropriate.

1) Defective parts on outdoor P.C. board (MCU communication, EEPROM, TH sensor error)

2) When outdoor service P.C. board was used, model type selection was inappropriate.

3) Other error (Heat sink abnormal overheat, gas leak, 4-way valve inverse error) was detected.

Error was detected by discharge temp. release control.

When case thermostat worked or High-pressure SW worked error was detected by high release control from indoor/outdoor heat exchanger temp. sensor. Power supply voltage error

Power supply voltage error

Abnormal overheat was detected by outdoor heat sink temp. sensor.

Abnormal overheat of discharge temp. or suction temp. was detected.

Error was detected by high release control from indoor/outdoor heat exchanger temp. sensor.

Error (Over-current, lock, etc.) was detected on outdoor fan drive circuit.

Short-circuited protective operation of compressor drive circuit element (G-Tr /IGBT) worked.

Position detection error of compressor motor was detected.

Signal was not received from indoor unit.

Main remote controller was not set. (including 2 remote controllers)

Signal cannot be sent to indoor unit.

No communication from remote controller and network adapter

Serial communication error between indoor and outdoor

Same address as yours was detected.

In 2-remote controller control, both were set as master.

(Indoor header unit stops warning and follower unit continues operation.)

MCU communication error between main motor micro computer and micro computer

Regular communication was impossible between master and follower indoor units.

There are multiple header units in a group.

When even one group connection indoor unit exists in individual indoor unit

Indoor address group was unset.

Capacity of indoor unit was unset.

In heating operation, error was detected by temp. down of indoor heat exchanger or temp. up ofTE, TS.

Automatic Operation reset continuation

—

{

{

{

×

{

{

×

×

×

{

×

×

×

×

×

×

—

{

×

×

{

×

×

×

×

×

×

—

—

×

×

×

×

×

×

×

When this warning was detected before group construction/address check finish at power supply was turned on, the mode shifts automatically to AUTO address setup mode.

{

: Go on,

: Flash, z

: Go off

ALT (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED

Remote controller indication

F01

F02

F10

F29

P01

P10

P12

P31

Sensor lamp part

Block indication

Operation Timer Ready Flash

z z z

ALT

ALT

ALT z

SIM z

ALT z

ALT z

ALT

z

ALT

Representative defective position

Indoor unit Heat exchanger sensor (TCJ) error

Indoor unit Heat exchanger sensor (TC) error

Indoor unit Room temp. sensor (TA) error

Indoor unit Other indoor P.C. board error

Indoor unit Indoor fan error

Indoor unit Overflow detection

Indoor unit Indoor fan error

Other indoor unit error

Detection

Indoor

Indoor

Indoor

Indoor

Indoor

Indoor

Indoor

Indoor

Explanation of error contents

Open/Short of heat exchanger (TCJ) was detected.

Open/Short of heat exchanger (TC) was detected.

Open/Short of room temp. (TA) was detected.

EEPROM error (Other error may be detected. If no error, automatic address is repeated.

Indoor AC fan error was detected. (Fan thermal relay worked.)

Float switch worked.

Indoor fan error (Over-current / Lock, etc.) was detected.

Other indoor under condition of warning in group. E03/L07/L03/L08 warning

Automatic Operation reset continuation

{

{

{

×

{

×


Error mode detected by indoor unit

Check code

E03

E04

E08

L03

L07

L08

Operation of diagnostic function

Cause of operation

Status of air conditioner

No communication from remote controller (including wireless) and communication adapter

The serial signal is not output from outdoor unit to indoor unit.

• Miswiring of inter-unit wire

• Defective serial sending circuit on outdoor P.C. board

• Defective serial receiving circuit on indoor P.C. board

Duplicated indoor unit address

Duplicated indoor header unit

There is group wire in individual indoor unit.

Unset indoor group address

Stop

(Automatic reset)

Displayed when error is detected

1. Check wires of remote controller and communication adapters.

• Remote controller LCD display OFF (Disconnection)

Stop

(Automatic reset)

Stop

Condition


Judgment and measures

1. Outdoor unit does not completely operate.

• Inter-unit wire check, correction of miswiring

• Check outdoor P.C. board. Correct wiring of P.C. board.

• Check case tharmostat operation. (SP180 only)

2. When outdoor unit normally operates

Check P.C. board (Indoor receiving / Outdoor sending).


1. Check whether remote controller connection (Group/Individual) was changed or not after power supply turned on

(Finish of group construction/Address check).

* If group construction and address are not normal when the power has been turned on, the mode automatically shifts to address setup mode. (Resetting of address)

L09

L30

P10

Unset indoor capacity

Abnormal input of outside interlock

Float switch operation

• Float circuit, Disconnection,

Coming-off, Float switch contact error

Stop

Stop

Stop


1. Set indoor capacity (DN=11)


1. Check outside devices.

2. Check indoor P.C. board.


1. Trouble of drain pump

2. Clogging of drain pump

3. Check float switch.


P12

P19

P31

F01

Indoor DC fan error

4-way valve system error

• After heating operation has started, indoor heat exchangers temp. is down.

Own unit stops while warning is output to other indoor units.

Stop


1. Position detection error

2. Over-current protective circuit of indoor fan driving unit operated.

3. Indoor fan locked.


Stop

(Automatic reset)


1. Check 4-way valve.

2. Check 2-way valve and check valve.

3. Check indoor heat exchanger (TC/TCJ).


Stop

(Follower unit)

(Automatic reset)


1. Judge follower unit while header unit is [E03], [L03], [L07] or [L08].


Stop

(Automatic reset)


1. Check indoor heat exchanger temp. sensor (TCJ).


F02

F10

F29

E10

Coming-off, disconnection or short of indoor heat exchanger temp. sensor

(TCJ)


(TC)


(TA)

Indoor EEPROM error

• EEPROM access error

Communication error between indoor

MCU

• Communication error between fan driving MCU and main MCU

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)





1. Check indoor heat exchanger temp. sensor (TC).


1. Check indoor heat exchanger temp. sensor (TA).


1. Check indoor EEPROM. (including socket insertion)



E18

Regular communication error between indoor header and follower units and between main and sub units

Stop

(Automatic reset)


1. Check remote controller wiring.

2. Check indoor power supply wiring.


– 52 –

Error mode detected by outdoor unit


Check code

Indoor unit

Under

Ceiling

4-Way

High

Wall

F04 F04

F06

F08

L29

F06

F07

F12

F15

F08

F13

F31


Disconnection, short of discharge temp. sensor (TD)

Disconnection, short of outdoor temp.

sensor (TE)

Disconnection, short of outdoor temp.

sensor (TL)

Disconnection, short of suction temp.

sensor (TS)

Miss-mounting of outdoor temp.

sensor (TE, TS)

Disconnection, short of outside temp.

sensor (TO)

Disconnection, short of heat sink temp. sensor (TH)

Outdoor P.C. EEPROM error


Stop

Stop

Stop

Stop

Stop

Continue

Stop

Stop

H01

H02

H03

L10

L29

P07

P15

P19

H01

H02

H03

Unset jumper of service P.C. board

Communication error between outdoor P.C. board MCU


∗

Heat sink temp. sensor detected over specified temperature.

Detection of gas leak

∗

Discharge temp. sensor (TD),

Suction temp. sensor (TS) detected temperature over specified temp.

4-way valve inverse error

∗

After heating operation has started, indoor heat exchanger temp. lowers under the specified temp.

∗

After heating operation has started, outdoor heat exchanger / suction temp. rises over the specified temp.


∗

Although operation has started, operation frequency decreases and operation stops.

Compressor lock

∗

Over-current detection after compressor start-up


Stop

Stop

Stop

Stop

Stop

Stop

Stop

Stop

Condition







1. Check discharge temp. sensor (TD).

2. Check outdoor P.C. board.

1. Check temp. sensor (TE).


1. Check temp. sensor (TL).


1. Check suction temp. sensor (TS).


1. Check temp. sensor (TE, TS).


1. Check outside temp. sensor (TO).









1. Outdoor service P.C. board

Check model type setting jumper wire.





1. Check screw tightening between PC. Board and heat sink and check radiator grease.

2. Check heat sink blast path.

1. Check gas leak, recharge

2. Check full open of service valve.

3. Check PMV (Pulse Motor Valve).

4. Check broken pipe.

5. Check discharge temp. sensor (TD), suction temp.

sensor (TS).

1. Check operation of 4-way valve.

2. Check outdoor heat exchanger (TE), suction temp.

sensor (TS).

3. Check indoor heat exchanger sensor (TC).

4. Check 4-way valve coil.



1. Check power supply voltage. (AC187, 253V)

2. Overload operation of refrigerating cycle.

3. Wiring error of compressor (Open phase)



1. Trouble of compressor (Lock, etc.): Replace compressor.

2. Wiring error of compressor (Open phase)

1. Check outdoor P.C. board. (AC current detection circuit)

– 53 –


Check code

Indoor unit

Under

Ceiling

4-Way

High

Wall

P03


P03

Discharge temp. error

∗

Discharge temp. (TD) over specified value was detected.


Stop

P04

P22

P26

P29

H04

P04

P05

P20

P22

P26

P29

Case thermostat operation

∗

Abnormal overheat of compressor

High-pressure SW error

Power supply voltage error

High pressure protective operation

• During cooling operation, outdoor temp. sensor (TL) detected temperature over specified temp.

• During heating operation, indoor temp. sensor (TC, TCJ) detected temperature over specified temp.

Outdoor fan system error

Short-circuit error of compressor driving element

Position detection circuit error

Stop

Stop

Stop

Stop

Stop

Stop

Stop

Condition





1. Check refrigerating cycle (Gas leak)

2. Trouble of electronic expansion valve

3. Check discharge temp. sensor (TD).

1. Check case thermostat and connector.

2. Check gas leak, recharge



5. Check broken pipe.

• Check full-open of service valve.

• Check outdoor fan error.

• Check outdoor fan motor error.

• Check clogging of outdoor PMV.

• Check loading of indoor/outdoor heat exchangers.

• Short-circuit of outdoor discharge/suction air

• Check outdoor P.C. board (I/F) error.

• Check error of fan system (air volume drop) at indoor side.

• Check miswiring of communication line between indoor and outdoor.

• Check overcharge of refrigerant.

1. Check power supply voltage. AC198 to 253V Displayed when error is detected





1. Check outdoor heat exchanger sensor (TL).

2. Check indoor heat exchanger sensor (TC, TCJ).


4. Check indoor/outdoor fan.


6. Check clogging and short circuit of indoor/outdoor heat exchanger.

7. Overcharge of refrigerant. Recharge

1. Check lock of fan motor.

2. Check power supply voltage. AC198 to 253V


1. When performing operation while taking-off compressor wire, P26 error occurs. Check control P.C. board.

2. When performing operation while taking-off compressor wire, an error does not occur. (Compressor rare short)

1. Check control P.C. board.

– 54 –

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. In this case, turn off both bit 1 and 2 of DIP switch 01 on the All-purpose control kit.

CODE

No.

[E04]

APPLICATION CONTROL KIT

LED display

—

Check / Countermeasures

(Part without special mention indicates a part of the outdoor unit.)

[Indoor / Outdoor communication error]

NO

Is setting of group address on the remote controller correct?

YES

Check CODE No. [14].

NO

Are inner wiring of the indoor unit and inter-unit wires (1, 2, 3) correct?

YES

Correct wiring and inter-unit wires.

NO

Is wiring of the outdoor terminal block correct?

YES

Correct wiring of terminal block.

NO

Is connection of case thermo (CN500) correct?

YES

Correct connection of connector.

YES

Check and correct charged refrigerant amount.

Does the case thermo operate?

Is the compressor abnormally heated?

NO

Check outdoor P.C. board.

Defect

→

Replace

[F04]

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow)

{ { z z

[Discharge temp. sensor (TD) error]

Is connection of CN601 correct?

Is resistance value of TD sensor correct?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[F06]

∗

There is a possibility that any of the following items is not correct.

Checking LED on the APPLICATION CONTROL KIT enables you to judge what is incorrect.

[Heat exchanger temp. sensor (TE) error]

D01 D02 D03 D04


{ z z z


Is resistance value of TE sensor correct?

NO

Correct connector.

Sensor error

→

Replace

YES


Defect

→

Replace

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow) z z

{ z

[Suction temp. sensor (TS) error]

→

Refer to column of [F12].

LED display legend: z

Go off,

{

Go on,

Flash (5Hz)

– 55 –

CODE

No.

[F08]


LED display

D01 D02 D03 D04

(Red) (Yellow) (Yellow) (Yellow) z

{ z z



[Outside temp. sensor (TO) error]


Is resistance value of TO sensor correct?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[F12]

D01 D02 D03 D04


{ z



Is resistance value of TS sensor correct?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[H01]

D01 D02 D03 D04


z

z

[Compressor breakdown]

Is AC mains voltage correct?

208/230V ± 10V

YES

Is wiring connection correct?

Compressor lead

(P.C. board side, Compressor side)

Reactor cord, Power supply lead

YES

Does abnormal overload happen?

NO

NO

NO

Correct power supply line.

Check and correct wiring connection.

YES

Remove and improve the cause of overload.


Defect

→

Replace

[H02]

D01 D02 D03 D04


z

[Compressor lock]

NO


208/230V ± 10V

YES


Is wiring connection correct?

Compressor lead

(P.C. board side, Compressor side)

Reactor cord, Power supply lead

YES

NO

YES

Is compressor under correct conditions?

NO

Is there stagnation of refrigerant?

YES

NO

Does PMV operate correctly?

YES


Defect

→

Replace correct connection of wires.

NO

Check and

Compressor lock

→

Replace

TE, TS sensor,

Check PMV.

Defective

→

Replace


Go off,

{

Go on,

Flash (5Hz)

– 56 –

CODE

No.

[H03]


LED display

D01 D02 D03 D04


z z



[Power supply error, Current detection circuit error]

Are connections of wires correct?

Between power cable and terminal block

Between outdoor P.C. board and terminal block

YES

NO

Correct wires


Defect

→

Replace

[L29]

D01 D02 D03 D04


{ z

or

z

{ z

z

[Power supply error, Current detection circuit error]


208/230V ± 10V

YES

NO


Is compressor under correct conditions?

YES

NO Compressor trouble

Rare short check

Defective

→

Replace


Defect

→

Replace

[P03]

D01 D02 D03 D04


{ { z

[Discharge temp. error]

Is there gas leak?

Is there refrigerant shortage?

NO

Is PMV under correct conditions?

YES

YES

NO

YES

Does an abnormal overload happen?

NO


Is resistance value of TD sensor correct?

YES

NO

Repair defective position.

Recharge refrigerant.


Replace defective part.

Remove and improve the cause of overload.

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[P04]

D01 D02 D03 D04


{ z z

{

[Power supply error (Voltage error)]


208/230V ± 10V

YES

NO

Confirm power supply construction, etc.


Defect

→

Replace


Go off,

{

Go on,

Flash (5Hz)

– 57 –

CODE

No.

[P04]


LED display

D01 D02 D03 D04


{ z

or

z

{ z

{ z

{



[High-pressure SW error]

1. High-pressure SW error

2. Service valve closed.

3. Indoor/Outdoor fan error

4. Clogging of indoor/outdoor PMV

5. Loading of indoor/outdoor heat exchangers or short-circuit

6. Overcharge of refrigerant

Doesn’t high-pressure SW operate?

YES

NO

Is the circuit wiring normal?

YES

NO

Are parts of high-pressure SW normal?

YES

Are service valves fully opened?

YES

Reset the power supply and perform a test run appropriate to the season

NO

NO

Cooling operation

→

B

Heating operation

→

C

Check and repair wiring.

Check P.C. board.

Defective

→

Replace

Check parts.

Defective

→

Replace

Open service valve fully.

B

Cooling operation

Does outdoor fan normally operate?

YES

NO

Is there any element to disturb heat exchange of outdoor unit?

Loading of heat exchanger

Short-circuit

YES

Overcharge of refrigerant

Clogging / Pipe breakage /

Abnormal overload

NO

Isn’t there fan crack or getting-out of fan?

YES

NO

Take measures for defective position.

Connector connection /

Fan IPDU / Fan motor / Wiring

Eliminate disturbing element.

C

Heating operation

Does the indoor fan normally operate?

YES

Is there any element to disturb heat exchange of indoor unit?

Clogging of filter


Short-circuit

YES



Abnormal overload

NO

Are connector connection, capacitor and fans of the fan motor normal?

YES

Are resistance value characteristics of the sensors

(TC, TCJ) normal?

YES

NO

NO


Replace TC or TCJ sensor.

Check indoor P.C. board.

Defective

→

Replace

[P05]

D01 D02 D03 D04


{ z

or

z z z

{


→

Refer to columns [H03] and [P04] and then check power supply and voltage erro


Go off,

{

Go on,

Flash (5Hz)

– 58 –

CODE

No.

[P19]


LED display

—



[4-way reversal error]

Does 4-way valve work correctly?

(Check pipe temperature, etc.

during cooling/heating operation.)

YES

NO

NO

Is coil of 4-way valve electrified during heating mode?

YES


Defect

→

Replace

Check 4-way valve.

Defect

→

Replace

[P22]

Is flow of refrigerant by

PMV under correct conditions?

YES

NO

Check PMV.

Defect

→

Replace

Check temperature sensors.

TE sensor CN600, TS sensor CN603

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.

[Outdoor fan system error]

D01 D02 D03 D04


{ { { z

Is connection of connector

CN300 correct?

YES

NO

Correct connection of connector.

After pulling out the connector of the fan motor CN300, rotate its shaft by hands.

Can it rotate smoothly?

Is the fan motor coil resistance within the range described below?

Between red and white lead : 18 to 30

Ω

Between white and black lead : 18 to 30

Ω

Between black and red lead : 18 to 30

Ω

YES

NO

Fan motor exchange


Defective

→

Replace

[P26]

D01 D02 D03 D04


z z z

[Short-circuit of compressor driving device]


208/230V ± 10V

YES

Is there any problem on connection of compressor lead or reactor?

(Check connection referring to the wiring diagram.)

NO

YES

Correct power line.

Correct wiring.

NO

After disconnection of the compressor leads from

P.C. board, the air conditioner operates in heating mode.

Does the fan motor run?

YES

NO

Replace outdoor P.C. board.

Check compressor. (Rare short, etc.)

Defective

→

Replace

[P29]

D01 D02 D03 D04


z z

[Position detection circuit error]


Defective

→

Replace


Go off,

{

Go on,

Flash (5Hz)

– 59 –

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. board displays even an error which occurred once.

Therefore the display on the remote controller may differ from that of LED.

LED display on outdoor P.C. board

Dip switch setup

• When turning on 1) only of SW803, the latest error is displayed. As the memory is stored, it can be confirmed even if the power supply is turned off once. (excluding outside temp. sensor (TO) error)

• When the work finished or the outdoor temp.

sensor (TO) error was found, turn off all of SW803.

(The error which occurs at present is displayed.)

<Latest error display>

Only 1) of SW803 is ON.

<Error display, which occurs at present>

All SW803 are OFF. (Initial status)

Display selection

• When even a LED of D800 to D804 (Yellow) goes on, error occurrence is indicated.

<Display 1>

• If pushing the button switch SW800 for 1 second under the above condition, the yellow LED is displayed with flashing.

<Display 2>

• When pushing SW800 for 1 second again, the status returns to

<Display 1>

.

• The error contents can be confirmed by combining

<Display 1>

and

<Display 2>

.

D800 (Yellow)

D801 (Yellow)

D802 (Yellow)

D803 (Yellow)

D804 (Yellow)

D805 (Green)

<Display 1>

Ù

<Display 2>

(No error) (Error occurred) (Push SW800) z z z z z

{

{ z z

{ z z

z z

{ { {

(Example of discharge temp. sensor error) z

: Go off,

{

: Go on,

: Flash

CODE

No.

[E04]

Outdoor

LED display

—

Check and troubleshooting

(Item without special mention Indicates part of outdoor unit.)

[Indoor/Outdoor communication error]

NO

Is setting of group address of remote controller correct?

YES

Check CODE No. [14].

NO

Are inner wiring and inter-unit wires (1, 2, 3) normal?

YES

Correct wiring and inter-unit wires.

NO

Are CN04 connection and wiring of terminal blocks (1, 2, 3) normal?

YES

Correct wiring of connectors and terminal blocks.

NO

Does D502 (Orange LED) flash after power supply is turned on again?

YES


Defect

→

Replace


Defect

→

Replace

– 60 –

CODE

No.

[F04]

Outdoor

LED display

<Display 1> <Display 2>

{

{ z z

{

{ z z

z z

{



[Discharge temp. sensor (TD) error]

Is CN603 connection normal?

Is resistance value of TD sensor normal?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[F06]


{

{ z z

{

{ z

z z

{

• 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.

Heat exchanger temp. sensor (TE) error, Heat exchanger temp. sensor (TL) error,

Suction temp. sensor (TS) error, Miswiring of heat exchanger sensor (TE, TS)

Heat exchanger temp. sensor (TE) error]


Is resistance value of TE sensor normal?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[F07]


{

{ z z

{

{

z z

{


{

{ z z

{

{ z z

z

{


{

{ z z

{

{

z

{


{

{ z z

{

{

z z

{

[Heat exchanger temp. sensor (TL) error]

→

Refer to

[F07]

column.


→

Refer to

[F12]

column.

[Miswiring of heat exchanger sensor (TE, TS)]

→

Refer to

[F15]

column.

[Heat exchanger temp. sensor (TL) error]


Is resistance value of TL sensor normal?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

– 61 –

CODE

No.

[F08]

Outdoor

LED display


{

{ z z

{

{ z z z

z

{



[Outside air temp. sensor (TO) error]


Is resistance value of TO sensor normal?

YES

NO

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

[F12] <Display 1> <Display 2>

{

{ z z

{

{ z z

z

{



Is resistance value of TS sensor normal?

YES


Defect

→

Replace

NO

Correct connector.

Sensor error

→

Replace

[F13]

[F15]


{

{ z z

{

{

z

z

{


{

{ z z

{

{

z

{

[Heat sink temp. sensor (TH) error]


Defect

→

Replac

[Miswiring of heat exchanger sensor (TE, TS)]

Is mounting status of

TE and TS sensors normal?

YES

NO

NO


Is resistance value of TS sensor normal?

YES

NO


Is resistance value of TE sensor normal?

YES


Defect

→

Replace

Correct sensor mounting.

Correct connector.

Sensor error

→

Replace

Correct connector.

Sensor error

→

Replace

[F31] <Display 1> <Display 2>

{

{ z z

{

{

{

[EEPROM error]


Defect

→

Replace

– 62 –

CODE

No.

[H01]

Outdoor

LED display


z z

{ z

{

{

z z z z

{



[Compressor break down]

Is power supply voltage normal?

208/230V ± 10V

YES

NO


Is wire connection normal?

Compressor lead

(Board side, Compressor side),

Reactor lead, Power supply lead

YES

NO

Check wire connection and correct it.

YES

Is it not abnormal overload?

NO

Correct and clear the cause.


Defect

→

Replace

[H02] <Display 1> <Display 2>

z z

{ z

{

{ z

z z z

{

[Compressor lock]

Is power supply voltage normal?

208/230V ± 10V

YES

Is wire connection normal?

Compressor lead

(Board side, Compressor side),

Reactor lead, Power supply lead

YES

Is compressor normal?

NO

Is there no refrigerant stagnation?

YES

Does PMV normally operate?

YES

NO

NO

YES

NO

NO


Defect

→

Replace


Check wire connection and correct it.


Defect

→

Replace

Compressor lock

→

Replace

Check TE, TS sensors and PMV.

Defect

→

Replace

[H03] <Display 1> <Display 2>

z z

{ z

{

{

z z z

{

[Current detection circuit error]


Defect

→

Replace

– 63 –

CODE

No.

[H04]

Outdoor

LED display


z z

{ z

{

{ z z z

z

{



[Case thermostat operation]

Are CN609 connection and case thermostat normal?

YES

NO

Correct connector.

Case thermostat error

→

Replace

Is cooling/heating operation available when short-circuiting case thermostat?

YES

NO


Defect

→

Replace

NO

Is there no gas leak?

Is it not refrigerant shortage?

YES

Repair defectives position.


NO

Is valve fully opened?

YES

Open valve fully.

NO

Is PMV normal?

YES

Correct defective position.


Check crushed or broken pipe.

Defect

→

Correct and Replace

[L10]

[L29]


z

{

{ z

{

{ z

z

z

{

[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.

∗

There is a possibility that it is one of the following errors.


Communication error between MCU, Heat sing temp. sensor (TH) error, EEPROM error,

Unset model type, Heat sink overheat error, Gas leak detection, 4-way valve inverse error


z

{

{ z

{

{

z

{


{

{

{ z

{

{

z z

{

[Communication error between MCU]


Defect

→

Replace

[Heat sink temp. sensor (TH) error]

→

Refer to

[F13]

column.

– 64 –

CODE

No.

[L29]

(Continued)

[P03]

Outdoor

LED display


{

{ z z

{

{

{


z

{

{ z

{

{ z

z

z

{


{

{

{

z

{

{ z z

{


{

{

{ z

{

{

z

{


{

{

{ z

{

{

z z

{


{

{

{ z

{

{

z z z

{



[EEPROM error]

→

Refer to

[F31]

column.

[Unset model type]

→

Refer to

[L10]

column.

[Heat sink overheat error]

→

Refer to

[P07]

column.

[Gas leak detection]

→

Refer to

[P15]

column.

[4-way valve inverse error]

→

Refer to

[P19]

column.

[Discharge temp. error]


Is refrigerant charge amount adequate?

YES

Is PMV normal?

YES

Is it not abnormal overload?

NO


Is resistance value of TD sensor normal?

YES

NO

NO

YES

NO





Correct and clear the cause.

Correct connector.

Sensor error

→

Replace


Defect

→

Replace

– 65 –

CODE

No.

[P04]

Outdoor

LED display




* There is a possibility that it is one of the following errors.


Power supply error (Vdc), High pressure protective operation, Case thermostat operation


z z

{ z

{

{ z z

z z

{


z

{

{

{

{

{ z z

z z

{

[Case thermostat operation]

→

Refer to

[H04]

column.

[High-pressure SW error]

1. High-pressure SW error

2. Service valve closed.

3. Indoor/Outdoor fan error

4. Clogging of outdoor PMV

5. Loading of indoor/outdoor heat exchangers or short-circuit

6. Overcharge of refrigerant

NO NO

Doesn’t high-pressure SW operate?

YES

Is the circuit wiring normal?

YES

Check and repair wiring.

Check P.C. board.

Defective

→

Replace

Are parts of high-pressure SW normal?

YES

Are service valves fully opened?

YES

Reset the power supply and perform a test run appropriate to the season

NO

NO

Cooling operation

→

B

Heating operation

→

C

Check parts.

Defective

→

Replace

Open service valve fully.

B

Cooling operation

Does outdoor fan normally operate?

YES

NO

Is there any element to disturb heat exchange of outdoor unit?


Short-circuit

YES



Abnormal overload

NO

Isn’t there fan crack or getting-out of fan?

YES

NO

Take measures for defective position.

Connector connection /

Fan IPDU / Fan motor / Wiring

Eliminate disturbing element.

C

Heating operation

Does the indoor fan normally operate?

YES

Is there any element to disturb heat exchange of indoor unit?

Clogging of filter


Short-circuit

YES



Abnormal overload

NO

Are connector connection, capacitor and fans of the fan motor normal?

YES

Are resistance value characteristics of the sensors

(TC, TCJ) normal?

YES

NO

NO


Replace TC or TCJ sensor.


Defective

→

Replace

– 66 –

CODE

No.

[P04]

(Continued)

[P05]

Outdoor

LED display


{

{

{

z

z

{

{ z z

{


z

{

{

{

{

{ z z

z

{


{

{

{

z

z

{

{ z z

{



[Power supply error (Vdc)]

→

Refer to

[P05]

column.

[High pressure protective operation]

→

Refer to

[P20]

column.


Is there no down or up of power supply voltage?

208/230V ± 10V

NO

YES

Confirm electric construction, etc.


Defect

→

Replace

– 67 –

CODE

No.

[P07]

Outdoor

LED display


{

{

{

z

{

{ z z

{



[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

Q200, DB01, DB02 or DB03?

NO

YES

Apply radiation grease to objective part.

Retightening of screws.

(Be sure not to forget to attach insulating sheet between heat sink and Q300, Q400.)

Is not the ventilation flue of the heat sink blocked?

Is not the fan blocked?

(Short-circuit, etc.)

YES


Defect

→

Replace

NO

Remove blocking matter.

Correct short-circuit.

[P15] <Display 1> <Display 2>

{

{

{ z

{

{

z

{

[Gas leak detection]


Is refrigerant charge amount adequate?

YES

Is PMV normal?

YES

NO

NO

NO


YES

Is there no crushed pipe?

NO

Check temp. sensor.

TD sensor CN603

TS sensor CN600

OK

YES

Error


Defect

→

Replace





Open valve fully.

Correct and replace piping.

Correct connector.

Sensor error

→

Replace

– 68 –

CODE

No.

[P19]

Outdoor

LED display


{

{

{ z

{

{

z z

{



[4-way valve inverse error]

Is operation of

4-way valve normal?

(Check pipe temp., etc. in cooling/heating operation.)

NO

YES

Temperature sensor check

TE sensor CN601

TS sensor CN600

Indoor TC sensor

Defect

→

Correct and repair

Is the coil resistance value of 4-way valve between 1.3 and 1.6k

Ω

?

YES

Check operation of outdoor P.C. board.

(See below.)

OK

NO

Error

Replace coil of 4-way valve.


Defect

→

replace

Check 4-way valve.

Defect

→

Replace

Check method of outdoor P.C. board operation (Self-hold valve type)

1) Set SW804 of Dip switch as the following figure and then push SW801 for approx. 1 second to check exchange operation to cooling cycle/heating cycle.

• Power is turned on for approx. 10 seconds.

• When checking again, check operation 1 minute or more after the first check because exothermic of part (Coil, resistance R700) is large.

(There is no problem when coil is not connected.)

2) After check, turn off all the Dip switch SW804.

Exchange to cooling cycle Exchange to heating cycle

SW804 SW801 CN701

1

Push

4

DC200V or more

SW804 SW801 CN701

1

Push

4

DC200V or more

Note)

Check by tester

Analog tester : Good if over DC200V

Digital tester : Good if Max. value is over DC200V though the varied value may be displayed.

– 69 –

CODE

No.

[P20]

Outdoor

LED display


z

{

{

{

{

{ z z

z

{



[High pressure protective operation]


YES

Reset the power supply and then perform test run matching to the season.

NO

Open valve fully.

Cooling season

Cooling operation

Heating season

Heating operation

Is there no problem on outdoor TL sensor?

(Measurement of resistance value)

YES

NO

Replace sensor.

Is there no crack or loosening of outdoor fan?

YES

NO

Check outdoor fan.

Defect

→

Replace, retightening

Does not the outdoor fan perform abnormal operation?

YES

NO

Check the same items as

[P22] error.

Is there no element which interfere heat exchange of outdoor unit?

• Clogging of heat exchanger

• Short circuit

NO

YES

Eliminate interfering element.

Check overcharge of refrigerant, clogging of cycle, broken pipe, abnormal overload, etc.

Defect

→


Does indoor fan normally operate?

YES

NO

Are indoor fan motor and connector normal?

YES

NO


Is there no element which interfere heat exchange of indoor unit?

• Clogging of filter

• Clogging of heat exchanger

• Short circuit

NO

Are resistance values of indoor TC and TCJ sensors normal?

YES

NO

Replace sensor.


Defect

→

Replace

YES

Eliminate interfering element.

Check overcharge of refrigerant, clogging of cycle, broken pipe, abnormal overload, etc.

Defect

→


– 70 –

CODE

No.

[P22]

Outdoor

LED display


z

{

{

{

{

{ z

z

{



[Fan system error]

Is there no problem on power supply voltage?

208/230V ± 10V

YES

NO

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?

Between red and white lead wire : 12 to 20

Ω

Between white and black lead wire : 12 to 20

Ω

Between black and red lead wire : 12 to 20

Ω

NO

Check wiring construction.

Ask repair of power supply.

YES

Replace fan motor.


Defect

→

Replace

Single operation check for outdoor fan

1) Set SW804 of Dip switch as the following figure and then push SW801 for approx. 1 second to check single operation of outdoor fan. Use this method to check which fan, upper or lower fan, has a trouble.

• When pushing SW801 for 1 second again or 2 minutes passed, the fan stops.

Outdoor fan single operation

2) After check, turn off all Dip switch

SW804.

SW804 SW801

Push

[P26] <Display 1> <Display 2>

z

{

{

{

{

{ z

z

{

[Short-circuit of compressor drive element]

Is there no problem on connection of compressor lead or reactor?

(Check referring to Wiring diagram.)

YES

The same error does not occur in operation without compressor lead.

YES

NO

NO

Check compressor. (Rear short, etc.)

Defect

→

Replace

Correct wiring.

Replace outdoor P.C. board.

[P29]

—

No code


{

{

{ z

{

{

z

{


z

{

{ z

{

{

{

[Position detection circuit error]


Defect

→

Replace

[Other error]

Compressor disorder due to sudden change of load, etc.

∗

Although the display of outdoor LED outputs, the unit automatically restarts and error is not determined.

∗

LED display also may output due to negative phase of compressor or wire coming-off.

– 71 –

Temperature sensor Temperature – Resistance value characteristic table

Temperature

°F (°C)

32 ( 0)

50 ( 10)

68 ( 20)

77 ( 25)

86 ( 30)

104 ( 40)

122 ( 50)

140 ( 60)

158 ( 70)

176 ( 80)

194 ( 90)

212 (100)

TA, TC, TCJ, TE, TS, TO sensors

Representative value

(Minimum value)

32.33

19.63

12.23

9.75

7.764

5.013

3.312

2.236

1.540

1.082

0.7740

0.5634

Resistance value (k

Ω

)

(Standard value)

(Maximum value)

33.80

20.35

12.59

35.30

21.09

12.95

10.00

7.990

5.192

3.451

2.343

1.623

1.146

0.8237

0.6023

10.25

8.218

5.375

3.594

2.454

1.709

1.213

0.8761

0.6434

Temperature

°F (°C

32 ( 0)

50 ( 10)

68 ( 20)

77 ( 25)

86 ( 30)

104 ( 40)

122 ( 50)

140 ( 60)

158 ( 70)

176 ( 80)

194 ( 90)

212 (100)

TD, TL sensors

Representative value

(Minimum value)

150.5

Resistance value (k

Ω

)

(Standard value)

(Maximum value)

161.3

172.7

92.76

58.61

47.01

37.93

25.12

17.00

11.74

8.269

5.925

4.321

3.205

99.05

62.36

49.93

40.22

26.55

17.92

12.34

8.668

6.195

4.507

3.336

105.6

66.26

52.97

42.59

28.03

18.86

12.95

9.074

6.470

4.696

3.468

TA, TC, TCJ, TE, TS, TO sensors

40

30

20

10

150

100

50

0

(0)

32

(10)

50

(20)

68

(30)

86

(40)

104

(50)

122

(60)

140

(70)

158

(80)

176

(90)

194

(100)

212

Temperature ˚F (˚C)

TD, TL sensors

200 20

15

10

5

0

(0)

32

(10)

50

(20)

68

(30)

86

(40)

104

(50)

122

(60)

140

(70)

158

(80)

176

(90)

194

(100)

0

212

Temperature ˚F (˚C)

∗

As TH sensor (Outdoor unit heat sink temp. sensor) is incorporated in the outdoor control P.C. board, the resistance value cannot be measured.

– 72 –


8-2-5. Outdoor Unit

No.

Part name

Compressor

(Model :DA111A1FD-21F)

1

Checking procedure

Measure the resistance value of each winding by using the tester.

Red

Resistance value Position

Red – White

White – Black

Black – Red

White Black

1.07

Ω

Under 20°C

2

3

Compressor

(Model :DA220A2-22L)

Compressor

(Model :DA422A3F-25M)


Red

Position

Red – White

White – Black

Black – Red

Resistance value

0.606

Ω

White Black

Under 20°C


Red

Position

Red – White

White – Black

Black – Red

Resistance value

White Black

0.264

Ω

Under 20°C

– 73 –

9. REPLACEMENT OF SERVICE P.C. BOARD


1. Setting the jumper wires and DIP switches

Part name

J800 to J803

Jumper wire

J804 to J810

DIP switch

SW802

SW803

SW804

Function

Model switching

Settings

Settings

LED indication switching

Special operations for service

Setting

Cut these jumper wires according to the following table.

Set these jumper wires to the settings of the P.C. board before replacement.

Set SW802 to the setting of the P.C. board before replacement.

Set SW803 to all OFF.

Set SW804 to all OFF.

Model switching (J800 to J803)

Since this service P.C. board is available for several models, cut the jumper wires according to the following table.

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

Factory setting (default)

RAV-SP300AT2-UL

RAV-SP360AT2-UL

RAV-SP420AT2-UL

J 800 J 801 J 802 J 803

{ { { {

{

×

{

×

× ×

{

×

{ {

× ×

{

: Connected,

×

: Cut

J800 to J803

2. Installing the P.C. board

1) Apply thermal grease to the back (heat sink contacting side) of devices Q200, Q650, DB01, and DB02.

( Q300 and Q400 are not necessary to be applied thermal grease.)

2) Reuse the insulating sheet. When a small amount of thermal grease is applied to the back of the insulating sheet, it adheres temporarily to the heat sink, which makes it easy to attach the insulating sheet.

3) Insert the P.C. board, align the holes of the insulating sheets, semiconductor devices, and heat sinks, and then secure them with screws.

4) Connect the lead wires according to the wiring diagram sticked on the backside of the pannel .

Apply thermal grease to the back (heat sink contacting side) of

Q200, Q650, DB01, and DB02.

– 74 –

Reuse the insulating sheet.

Applying thermal grease to the back of the insulating sheet makes it easy to attach the insulating sheet.


10. SETUP AT LOCAL SITE AND OTHERS


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

Power save setup

Power saving setting

Cooling only setting

SW802

When using the power saving function, turn on switches.

The maximum operating current of the COOL/HEAT operation can be limited by dropping the current release point of the outdoor unit.

Cooling-only setup

When using the outdoor unit as a cooling-only machine, turn on switches. (“OF” of DN cord on the remote controller also can be used for changing the machine to the cooling-only model.)

<RAV-SP240, SP300, SP360, SP420AT2-UL>

Function Set position

High static pressure setup

Power save setup

Snow-proof fan control

Defrost time change

Max.

frequency change

SW802

High static pressure setup

Power save setup

Snow-proof fan control

∗

all are OFF at shipment.

J805, J806

J807

Control contents

Turn the switch to ON when mounting a duct to the discharge port of the outdoor unit.

Add 3 taps to the upper limit value of the outdoor fan tap.

The operation is performed with

(Max: Upper fan: 890 rpm / Lower fan: 910 rpm (WF)).

In this case, the upper limit value of static pressure for duct is 5Pa or less on 77°F (25°C) degrees and please use straight duct.

In this case, the outdoor noise level may increase.

Turn the switch to ON when using the power save function.

The control to lower the compressor frequency (Approx. –10%) is performed by indoor heat exchanger temp. in heating operation.

When snow enters from clearance of the fan guard or heat exchanger into blast path and it is accumulated, the control to prevent generation of motor lock is validated.

When outside temp. is below 32°F (0°C) though the compressor stops, the outdoor fan operates with W5.

The defrost interval is cut to shorten it than the standard status.

For contents of control and cutting method, refer to


(See to Page 43).

When it is needed to lower the maximum value of the compressor frequency, cut the jumper line. Max. frequency at cooling/heating is lowered.

In this case the Max. capacity decreases.

Max. frequency of compressor

RAV-

Model

Standard status

When J807 is cut

SP240

COOL HEAT

72.0

72.0

99.6

79.2

SP300

COOL HEAT

53.4

53.4

71.4

64.2

SP360, SP420

COOL HEAT

64.2

64.2

90.6

72.0

Cooling-only setup

J808

When using the air conditioner as a cooling-only conditioner, cut the jumper line. (An air conditioner can be changed to cooling-only conditioner by “0F” of DN code on the remote controller.)

– 75 –

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.

SW800

SW803

SW801

SW804

SW802

Specifications

Pushdown button switch

DIP switch

Pushdown button switch

DIP switch

DIP switch

Operation contents

Exchanges the displayed contents of LED (D800 to D804) on the outdoor control P.C. board.

Performs the specific operation to check maintenance.

Performs various initial settings. (Refer to 10-1-2.)

Display part

Part No.

D502

D503

D800 to

D804

D805

Specifications

Orange LED

Green LED

Yellow LED

Green LED

∗

All LED are colorless when it goes off.

Operation contents

Indoor/Outdoor communication (Serial communication) signal display

(Receive signal from indoor signal)

Indoor/Outdoor communication (Serial communication) signal display

(Send signal from outdoor signal)

Error display

When all SW803 are OFF, or when any of D800 to D804 goes on, LED displays that the outdoor controller detects an error.

When status of SW803 is other than OFF, various indications are displayed.

Power-ON display

When the power of the outdoor unit is turned on, LED goes on.

When SW801 and SW804 operate the specific operation, LED flashes.

SW804

SW801

Specific operation switch

(Various operations during maintenance check operation)

SW800

SW803

LED display select switch

D800

D801

D802

D803

D804

D805

D800 (Yellow LED)

D801 (Yellow LED)

D802 (Yellow LED)

D803 (Yellow LED)

Error display / various display

D804 (Yellow LED)

D805 (Green LED) : Display while power is ON

D503 (Green LED) : Serial signal (Outdoor

→

Indoor)

D502 (Orange LED) : Serial signal (Indoor

→

Outdoor)

SW802 : Selection of various initial settings

– 76 –

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

SW803

Function / Contents

Error display (Error generating at present)

Error generating at present is displayed.

This switch goes off when an error does not generate.

Refer

Refer to

Page 78.

SW803

TD

SW803

TE

SW803

TS

SW803

Error display (The latest error: Latest error including present)

After error status was cleared, the error which generated before can be confirmed by this setting. (Reconfirmation is available even if power supply was turned off once.)

• If an error generates at present, the same contents as those of error which is generating at present are displayed.

• Only error of TO sensor is not displayed by this setting.

(Confirm it by setting of error which is generating at present.)

Temperature sensor display

The detected value of temperature sensor is displayed.

Refer to

Page 78.

Refer to

Page 79.

TO

SW803

TL

SW803

TH

SW803

TA

SW803

TC

SW803

TCJ

SW803

SW803

SW803

SW803

Current display

The current value which flows in the outdoor unit is displayed.

Refer to

Page 77.

Compressor operation frequency display

The operation frequency of the compressor is displayed.

Refer to

Page 79.

PMV opening display

The opening of PMV (Pulse Motor Valve) is displayed.

Refer to

Page 79.

– 77 –

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> only of DIP switch SW803 is turned on, the error which generated before

(Latest error information including present) is displayed.a) c) If there is an error, any of LED D800 to D804 goes on. (Display 1) d) When pushing the pushdown button switch SW800 for approx. 1 second, the display is exchanged.

(Display 2) e) When pushing SW800 again or after 2 minutes, the status returns to that of Display 1.

Present error

SW803

Latest error

SW803

(Legend)

z

D800 (Yellow) z

D801 (Yellow)

D802 (Yellow) z

D803 (Yellow) z

D804 (Yellow)

{

D805 (Green) z

: Go off, { : Go on, : Flash

Display 1)

(Initial display)

zzzzz

{

{{ zz z zz

{{

{

{{

{{{ z z

{{

{{ z

{{

Display 2)

(SW800 operation)

zzzzz

{ zz

zz

{ z

zz

{

zz

{ zzz

z

{ zz

z

{

z

z

{

z

{

{

zzzz

{ z

zzz

{

zzz

{ zz

zz

{ z

z

z

{

z

{

{

zzz

{ zz

zz

{

z

zz

{

zz

{

z

{

zz

{ zz

z

{ z

z

{ z

z

{

z

{

Error contents

Normal

Discharge temp. sensor (TD) error

Heat exchanger temp. sensor (TE) error

Heat exchanger temp. sensor (TL) error

Outside temp. sensor (TO) error

Suction temp. sensor (TS) error

Heat sink temp. sensor (TH) error

Heat exchanger sensor (TE, TS) miswiring

EEPROM error


Compressor lock


Case thermostat operation

Model unset

Communication error between MCU

Other error (Compressor disorder, etc.)

Discharge temp. error

High-pressure SW error

Power supply error


Gas leak detection

4-way valve reverse error

High pressure protective operation

Fan system error

Driving element short-circuit

Position detection circuit erro

Wired remote controller

Error code

—

F04

F06

F06, F07

F08

F06, F12

F13, L29

F06, F15

F31, L29

H01

H02

H03

H04

L10, L29

L29

Error is not determined.

P03

P04

P05

P07, L29

P15, L29

P19, L29

P04, P20

P22

P26

P29

∗

As the error code displayed on the wired remote controller may differ according to type of indoor model, multiple codes are described.

– 78 –

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)

z

D800 (Yellow) z

D801 (Yellow) z

D802 (Yellow) z

D803 (Yellow) z

D804 (Yellow)

{

D805 (Green) z

: Go off,

{

: Go on

Item setup

TD

SW803

Temperature sensor °F (°C)

TE

SW803

TS

SW803

TO

SW803

TL

SW803

Current

(A)

Compressor operation frequency

(rpm)

PMV

opening

(Pulse)

SW803 SW803 SW803

TH

SW803

TA

SW803

TC

SW803

TCJ

SW803

LED display

zzzzz

{

{ zzzz

{ z

{ zzz

{

{{ zzz

{ zz

{ zz

{

{ z

{ zz

{ z

{{ zz

{

{{{ zz

{ zzz

{ z

{

{ zz

{ z

{ z

{ z

{ z

{

{{ z

{ z

{ zz

{{ z

{

{ z

{{ z

{ z

{{{ z

{

{{{{ z

{ zzzz

{{

{ zzz

{{ z

{ zz

{{

{{ zz

{{ zz

{ z

{{

{ z

{ z

{{ z

{{ z

{{

{{{ z

{{ zzz

{{{

{ zz

{{{ z

{ z

{{{

{{ z

{{{ zz

{{{{

{ z

{{{{ z

{{{{{

{{{{{{

Below –13 (–25)

–13 (–25) to –5.8 (–21)

–4 (–20) to 3.2 (–16)

5 (–15) to 12.2 (–11)

14 (–10) to 23 ( – 5)

23 ( –5) to 30.2 ( –1)

32 ( 0) to 39.2 ( 4)

41 ( 5) to 48.2 ( 9)

50 ( 10) to 57.2 ( 14)

59 ( 15) to 66.2 ( 19)

68 ( 20) to 75.2 ( 24)

77 ( 25) to 84.2 ( 29)

86 ( 30) to 93.2 ( 34)

95 ( 35) to 102.2 ( 39)

104 ( 40) to 111.2 ( 44)

113 ( 45) to 120.2 ( 49)

122 ( 50) to 129.2 ( 54)

131 ( 55) to 138.2 ( 59)

140 ( 60) to 147.2 ( 64)

149 ( 65) to 156.2 ( 69)

158 ( 70) to 165.2 ( 74)

167 ( 75) to 174.2 ( 79)

176 ( 80) to 183.2 ( 84)

185 ( 85) to 192.2 ( 89)

194 ( 90) to 201.2 ( 94)

203 ( 95) to 210.2 ( 99)

212 (100) to 219.2 (104)

221 (105) to 228.2 (109)

230 (110) to 237.2 (114)

239 (115) to 246.2 (119)

Over 248 (120)

Sensor error, unconnected

13 to 13.9

14 to 14.9

15 to 15.9

16 to 16.9

17 to 17.9

18 to 18.9

19 to 19.9

20 to 20.9

21 to 21.9

22 to 22.9

23 to 23.9

24 to 24.9

25 to 25.9

26 to 26.9

27 to 27.9

28 to 28.9

29 to 29.9

30 to 30.9

Over 31

0 to 0.9

1 to 1.9

2 to 2.9

3 to 3.9

4 to 4.9

5 to 5.9

6 to 6.9

7 to 7.9

8 to 8.9

9 to 9.9

10 to 10.9

11 to 11.9

12 to 12.9

∗

As TD, TL and TH are sensors for high temperature, there is error at normal temperature or below position.

∗

For current value, the current for the outdoor unit only is displayed.

65 to 69

70 to 74

75 to 79

80 to 84

85 to 89

80 to 84

95 to 99

100 to 104

105 to 109

110 to 114

115 to 119

120 to 124

125 to 129

130 to 134

135 to 139

140 to 144

145 to 149

150 to 154

Over 155

0 to 4

5 to 9

10 to 14

15 to 19

20 to 24

25 to 29

30 to 34

35 to 39

40 to 44

45 to 49

50 to 54

55 to 59

60 to 64

260 to 279

280 to 299

300 to 319

320 to 339

340 to 359

360 to 379

380 to 399

400 to 419

420 to 439

440 to 459

460 to 479

480 to 499

500

—

—

—

—

—

—

0 to 19

20 to 39

40 to 59

60 to 79

80 to 99

100 to 119

120 to 139

140 to 159

160 to 179

180 to 199

200 to 219

220 to 239

240 to 259

– 79 –

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. While each function starts, LED D805 (Green) flashes.

d) When pushing the pushdown button switch SW801 again for approx. 1 second, when selecting DIP switch SW804 or when the specified time of each function elapsed, each function stops and

LED D805 (Green) returns to the continuous lighting.

<Specific operation>

SW804

SW804

Operation when pushdown button switch SW801 is pushed

Refrigerant recovery operation

The outdoor unit performs cooling operation. The indoor unit does not work by this operation alone. Therefore operate the fan beforehand.

SW804 Indoor cooling test run demand

The cooling test run is performed. (

→

Note 1

)

SW804

Indoor heating test run demand

The heating test run is performed. (

→

Note 1

)

SW804

SW804

Fan motor forced operation

Drive the fan motor forcedly.

When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control.

(No operation especially)

SW804

SW804

SW804

PMV full open operation

Open PMV (Pulse Motor Valve) fully.


PMV full close operation

Close PMV (Pulse Motor Valve) fully.


PMV middle opening operation

Set PMV (Pulse Motor Valve) to middle opening (250 pulses).


[NOTE]

Although these operations can be performed even during operation, basically perform operation while the unit stops.

If performing this operation during driving the unit, it is dangerous because the pressure may change suddenly.

Note 1)

Indoor cooling test run demand / Indoor heating test run demand

Only when combining with the following indoor unit, cooling/heating operation can be performed from the outdoor unit. Test run is available: Indoor unit (4-Way, Under ceiling, High wall)

Test run is unavailable: Indoor units other than the above-mentioned indoor units.

Note 2)

The forced test run by this setting cannot be cleared on the indoor remote controller.

Be sure to clear the test run by operation of the outdoor unit. (Push SW801 again for 1 second.)

– 80 –

SW804

SW804

SW804

SW804

SW804

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).


[NOTE]

In case of these models adopting the self hold valve, the coil develops fever. Therefore do not perform this operation as coil is connected.

Self-hold valve suction operation (Exchange to heating cycle)

(For RY700 RY701, RY705, CN701 check)

Turn on relay RY700, RY701, RY705.

(CN701 between c

and f

: Voltage=Approx. +198 to 380V)

This function works for 10 seconds and then is OFF.

Self-hold valve separation operation (Exchange to cooling cycle)

Turn on relay RY700.

(CN701 between 1) and 4): Voltage=Approx. –198 to 380V)

This function works for 10 seconds and then is OFF.

SV valve relay operation (For RY702, CN702 check)

Turn on SV valve relay (RY702).


* For these models, the part is not mounted, so do not operate.

Heater output relay operation (For check RY703, CN703 check)

Turn on relay for option heater (RY703).


[CAUTION]

Although these operations can be performed even during operation, basically perform operation while the unit stops.

If performing this operation during driving the unit, it is dangerous because the pressure may change suddenly.

SW804

Outside output relay operation (RY704, CN704)

Turn on relay for outside output (RY704).


SW804

(No operation especially)

SW804

Relay operation change for outside output

[CAUTION]

Do not use this setting.

– 81 –

<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. on coating of the outdoor units.

Repair the defective position or apply the rust resisting paint if necessary.

Although the customer has to pay the charge for the maintenance, the life of the unit can be prolonged.

Failure to clean the indoor/outdoor units regularly will cause shortage of capacity, freezing, water leakage or trouble on the compressor.

Periodic Maintenance - periodic maintenance is recommended to ensure proper operation of the unit.

Recommended maintenance intervals may vary depending on the installation environment, e.g. dusty zones, etc.

Refer to table below.

Periodic Maintenance

INDOOR UNIT

Clean Air Filter ∗

1

Clean Drain Pan

Clean indoor heat exchanger ∗

2

Clean fan ∗

2

Change Remote Control Batteries

INDOOR UNIT

Clean Outdoor Coil from Outside

Clean Outdoor Coil from Inside ∗

2

Blow Air Over Electric Parts ∗

2

Check Electric Connection Tightening ∗

2

Clean Fan Wheel ∗

2

Check Fan Tightening ∗

2

Clean Drain Pans ∗

2

EVERY MONTH

1

EVERY MONTH

EVERY 4 MONTHS

1

EVERY 4 MONTHS

EVERY YEAR

∗

1: Increase frequency in dusty zones.

∗

2: Maintenance to be carried out by qualified service personal Refer to the Installation Manual.

1

1

1

EVERY YEAR

– 82 –

11. DETACHMENTS


11-1-1. RAV-SP180AT2-UL

No.

c

Part name

Common procedure

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 off the main switch of the breaker for air conditioner.

2) Remove the valve cover. (M4, 8 mm, 3 pcs.)

• After removing screw, remove the valve cover pulling it downward.

3) Remove connecting cable.

4) Remove the conduit mounting plate by taking off 2 screws. (M4, 8 mm, 2 pcs.)

5) Remove the upper cabinet.

(M4, 8 mm, 5 pcs.)

• After taking off screws, remove the upper cabinet pulling it upward.

6) Remove the waterproof cover.

2. Attachment

1) Attach the waterproof cover.

CAUTION

Be sure to attach a waterproof cover.

If it is not attached, there is a possibility that water enters inside of the outdoor unit.

2) Attach the upper cabinet. (M4, 8 mm, 5 pcs.)

3) Attach the conduit mounting plate.

(M4, 8 mm, 2 pcs.)

4) Perform cabling of connecting cables.

5) Attach the valve cover. (M4, 8 mm, 3 pcs.)

• Insert the upper part of the upper cabinet, set hooking claw of the valve cover to the slit (at three positions) of the main body, and then attach it pushing upward.

Remarks

– 83 –

No.

d

Part name

Front cabinet

Procedure

1. Detachment

1) Perform work of Detachment 1 of c

.

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. (M4, 8 mm, 3 pcs.)

4) Take off screws of the front cabinet and the motor support. (M4, 8 mm, 2 pcs.)

5) Take off screws of the front cabinet and side cabinet (Right). (M4, 8 mm, 1 pc.)

• The left side of the front side if made to insert to the rear cabinet, so remove it pulling upward.

2. Attachment

1) Insert hook at the left side of the front side into the rear cabinet.

2) Hook the lower part at the right side of the front to concavity of the bottom plate. Insert the hook of the rear cabinet into the slit of the front cabinet.

3) Attach the removed screws to the original positions.

Remarks

e

Side cabinet

(Right)

1) Perform works of Detachment 1 of c

and d

.

2) Take off screw of the side cabinet (Right) and the heat exchanger. (M4, 8 mm, 1 pc.)

3) Take off fixed screws between the main unit and the inverter box. (Wiring port side) (M4, 8 mm, 2 pcs.)

4) Take off screws of the side cabinet (Right) and the bottom plate. (M4, 8 mm, 2 pcs.)

5) Take off screw of the side cabinet (Right) and the valve fixed plate. (M4, 8 mm, 1 pc.)

– 84 –

No.

Part name

f

Inverter assembly

Procedure

1. Turn off the power supply.


.

2) Take off screws, which fix the upper part of the front cabinet and the inverter cover.

(M4, 8 mm, 2 pcs.)

• If removing the inverter cover under the above condition, P.C. board can be checked.

ELECTRIC SHOCK

The control circuits (including each sensor circuit and 5V, 12V of PMV circuit, etc.) of this control P.C.

board are high-voltage circuits.

Before work, be sure to turn off the power supply.

Take sufficient care to an electric shock on the control circuits and the conductive parts of their parts.

3) Using the discharging resistor (100

Ω

/40W or equivalent) or plug of the soldering iron, electrify continuously between

+

and

–

poles of the electrolytic capacitor of 3 phases: C10, 11 and single phase: C12, 13, 14 (“CAUTION HIGH VOLTAGE” is printed) on P.C. board, and then discharge power.

For the products that the rear side are coated, perform normal discharge.

NOTES:

According to the trouble condition, the electrolytic capacitor may not normally discharge and the voltage may remain.

Therefore be sure to discharge the capacitor.

As the electrolytic capacitor is one with a large capacity, never use a screwdriver and others for short-circuiting between generate.

+

and

–

electrodes for discharging; otherwise it is very dangerous because a large electric spark will

4) Perform works Detachment 1 of d

and e

.

5) Take off fixing screw between the partition plate and the inverter box. (M4, 8 mm, 1 pc.)

6) Remove various lead wires from the holder at upper part of the inverter box.

7) Pull the inverter box upward.

In this time, cut the bundling bands which bind each lead wire.

8) Remove connectors of various lead wires.

NOTE:

When removing the connectors, do not hold lead wires by hands, but hold the connectors.

Remarks

– 85 –

No.

g

Part name

Control P.C.

board assembly

Procedure

1) Remove the sub-board base from the inverter 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. board assembly to the other parts.

1. Lead wires:

Connected to the power supply terminal block;

3 pcs.

Black, White, Orange (Single phase), Red,

White, Black, Orange (3 phases)

Earth wire (Black); 1 pc

2. Connector

Connected to compressor;

(3P: Relay connector White)

Reactor (2P: Relay connector White)

∗

(NOTE 1)

CN300; Outdoor fan (3P: White)

∗

(NOTE 1)

CN701; 4-way valve (3P: Yellow)

∗

(NOTE 1)

CN700; PMV coil (6P: White)

CN601; TD sensor (3P: White)

CN603; TS sensor (3P: White)

∗

(NOTE 1)

CN600; TE sensor (2P: White)

∗

(NOTE 1)

CN602; TO sensor 2P: White)

CN500; Case thermo + Pressure SW (2P: Blue)

∗

(NOTE 1)

CN605; Sub SW P.C. base (3P: Black)

NOTE 1):

Unlock the lock of the housing part and then remove the connector.

3) Remove the inverter box (Sheet metal).

4) Remove the control P.C. board assembly from

P.C. board base.

(For the heat sink and the control P.C. board assembly, remove them as they are screwed.)

NOTE 2):

Take off claws (4 positions) of P.C. board base, hold the heat sink and then remove it upward.

5) Take off 2 screws that fix the heat sink and the control P.C. board assembly.

6) Mount a new control P.C. board assembly.

NOTE 3):

Mount a new control P.C. board assembly while it is correctly inserted in the P.C. board-receiving groove.

Mount it so that the heat sink surely contact with the sheet metal.

Remarks

Inverter box

(Sheet metal)

Control P.C. board assembly

P.C. board base

Control P.C. board assembly

P.C. board base

– 86 –

No.

h

Part name

Fan motor

Procedure


and d

.

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.

4) Disconnect the connector for fan motor from the inverter.

5) Take off the fixing screws (2 pcs.) holding by hands so that the fan motor does not fall.

NOTE:

Tighten the flange nut with torque 4.9Nm (50kgf/cm).

Remarks

Flange nut

Loosen the nut by turning clockwise i

Compressor 1) Perform works of Detachment 1 of c

, d

, e

and f

.

2) Discharge refrigerant gas.

3) Remove the partition plate. (M4, 8 mm, 3 pcs.)

4) Remove the noise-insulator.

5) Remove the terminal covers of the compressor, and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal.

6) Remove pipes connected to the compressor with a burner.

CAUTION

Pay attention to that flame does not involve 4-way valve,

PMV, pressure SW, or fusible plug.

(If doing so, a malfunction may be caused.)

7) Remove the side cabinet (Left). (M4, 8 mm, 3 pcs.)

8) Take off the fixing screws of the bottom plate and heat exchanger. (M4, 8 mm)

9) Take off the fixing screws of the valve clamping plate to the bottom plate. (M4, 8 mm, 1 pc.)

10) Pull upward he refrigerating cycle.

11) Take off nut fixing the compressor to the bottom place.

CAUTION

When reconnecting the lead wires to the compressor terminals after replacement of the compressor, be sure to caulk the Faston terminal without loosening.

Remove

(Discharge pipe)

Pressure switch

Remove

(Suction pipe)

Valve support board

Compressor bolt

(3 pcs.)

Fusible plug

– 87 –

No.

j

Part name

Reactor

Procedure


, d

, e

and f

.

2) Take off the fixing screw for the reactor.

(M4, 8 mm)

Remarks

Reactors Partition plate

Reactor support board k

Pulse Motor

Valve (PMV) coil

1. Detachment

1) Perform works of Detachment c

and d

.

2) Release the coil from the concavity by turning it, and remove coil from the PMV.

l

Fan guard

2. Attachment

1) Put the coil deep into the bottom position.

2) Fix the coil firmly by turning it to the concavity.

1. Detachment

1) Perform works of Detachment 1 of and d

.

c

2) Remove the front cabinet, and put it down so that fan guard side directs downward.

CAUTION

Perform works on a corrugated cardboard, cloth, etc. to prevent flaw on the product.

3) Remove the fan guard stopper.

(4 positions)

2. Attachment

1) Insert the fan guard stopper and then fix the fan guard. (4 positions)

CAUTION

All the attaching works have completed.

Check that all the hooking claws and the fan guard stopper are fixed to the specified positions.

– 88 –

11-1-2. RAV-SP240AT2-UL

No.

c

Part name

Common procedure

Procedure

CAUTION

Be sure to put on the gloves at working time; otherwise an injury may be caused by a part, etc.

Remarks

Front panel

1. Detachment

1) Stop operation of the air conditioner and then turn off switch of the breaker.

2) Remove the front panel.

(Hexagonal screw M4, 10 mm, 2 pcs.)

∗

After removing screws, remove the front panel while pulling it downward.

3) Remove the power wire and indoor/outdoor connecting wire from the cord clamp and the terminals.

4) Remove the top plate.


2. Attachment

1) Attach the top plate.


In this time, insert the fin guard of rear side between the top plate and the heat exchanger

(Rear side).

2) Connect the power supply wire and the indoor/outdoor connecting wire to the terminal and fix it with cord clamp.

CAUTION

Using bundling band on the market, be sure to fix the power wire and indoor/outdoor connecting wire along the crossover pipe so that they do not come to contact with the compressor, valve at gas side, pipe at gas side and discharge pipe.

Top plate

Insert the fin guard of rear side between the top plate and the heat exchanger

(at rear side).

3) Attach the front panel.


– 89 –

No.

d

Part name

Discharge port cabinet

Procedure

1. Detachment

1) Perform work of Detachment 1 of c .

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.


4) Remove screws of the discharge port cabinet and the motor base.

(M4, 8 mm, 2 pcs.)

5) Remove screws of the discharge port cabinet and the heat exchanger.

(M4, 8 mm, 1 pc.)

6) Remove screws of the discharge port cabinet and the fin guard.


Remarks

Heat exchanger

Motor base

Partition plate e

Side cabinet 1) Perform work of Detachment 1 of c .

2) Remove screws which fix the inverter assembly and the side cabinet.

(M4, 8 mm, 2 pcs.)

3) Remove screws of the side cabinet and the valve fixing plate. (M4, 8 mm, 2 pcs.)

4) Remove screws of the side cabinet and the pipe panel (Rear).


5) Remove screws of the side cabinet and the bottom plate.

(Hexagonal screw M4, 10 mm, 1 pc.)

6) Remove screws of the side cabinet and the heat exchanger.


7) Slide the side cabinet upward and then remove it. (Hook of inverter) f

Inverter protective cover


2) Take off screw which fixes the inverter assembly and the inverter protective cover.

(M4, 8 mm, 1 pc.)

– 90 –

No.

g

Part name

Exchange of electric parts

Procedure

1. Control P.C. board

1) Perform work of Detachment 1 of c and f .

WARNING

Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused.

2) Remove the connectors connected to the control P.C. board.

(Indoor power supply, temperature sensors,

PMV coil, 4-way valve coil, compressor case thermo, fan motor, reactor, pressure switch.)

∗

Unlock the lock of the housing part and then remove the connectors.

3) Remove the lead wires connected to the control

P.C. board.

(Torque at tightening time: 1.47 ± 0.1N•m)

Compressor lead

U: CN200 Red

V: CN201 White

W: CN202 Black

Reactor lead

Relay connector: 2 positions

Remove the power wire from the power supply terminal block.

(Torque at tightening time: 2.5 ± 0.1N•m)

4) Remove the earth wire from the control P.C.

board. (Truss B tight screw M4, 6 mm, 1 pc.)

5) Remove the fixing screws of the control P.C. board.

(Screw with collar for fixing element M3, 16 mm,

7 pcs. Pan S tight screw for fixing P.C. board M3,

20 mm, 1 pc.)

6) Remove the control P.C. board.

(Supporter: 5 positions)

NOTE:

It is difficult to take out it because of radiator grease for heat sink.

7) Mount a new control P.C. board.

NOTE:

Do not forget to attach the aluminum plate (Q201) and the insulating sheet (Q300).

(Applying a little of radiator grease at the rear surface of the insulating sheet in advance to adhere to the heat sink makes easy the work.)

Remarks

Compressor case thermo.

Pressure switch

Compressor lead

Fan motor

Relay connector

Bundling band

(Reactor lead)

Ground screw

Inter unit cable

Senser

PMV coil 4-way valve coil

Indoor power supply

Screw for fixing element (7 positions)

– 91 –

No.

g

Part name

Exchange of electric parts

(Continued)

Procedure

1. Reactor

1) Perform work of Detachment 1 of and f .

c , e

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.

4) Remove each reactor.

(Truss B tight screw M4, 6 mm, 2 pcs. each)

5) Attach a new reactor.

Remarks

Reactor relay connector

(Connected to lead wire

(White) at P.C. board side)

NOTE:

Be sure to bind the removed bundling band with the bundling band on the market.

Be careful that the fan motor lead does not come to contact with the reactor body.

Reactor relay connector

(Connected to lead wire

(Charcoal gray) at P.C. board side)

Bundling band

(Compressor lead, reactor lead)

Upper reactor

Connected to reactor relay connector

(Connected to lead wire (White) at P.C. board side)

– 92 –

Bundling band

Lower reactor

Connected to reactor relay connector

(Connected to lead wire (Charcoal gray) at P.C. board side)

No.

Part name

h

Fan motor

Procedure

1) Perform work of Detachment 1 of f .

c

, d

, e

and

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.)


4) Remove the connector for fan motor from the inverter.

5) Remove the fan motor lead from the fan motor lead fixing rubber of the penetrated part of the partition plate.

6) Remove the fixing screws (4 pcs. each) while supporting the fan motor so that it does not fall.

[

Cautions when assembling the fan motor

∗

Tighten the flange nut with 4.95N•m

(50kgf.cm).

∗

Adjust length on the fan motor lead fixing rubber so that the fan motor lead does not slacken in order not to put the fan motor lead into contact with the propeller fan.

Attach the fan motor lead fixing rubber to the partition plate so that projection directs to the refrigerating cycle side.

∗

Be sure that the rector body does not come to contact with the fan motor lead.

∗

Be sure to bind the removed bundling band with the bundling band on the market.

CAUTION

Use the metal band of the motor base to fix the fan motor lead on the motor base so that the fan motor lead does not come to contact with the propeller fan.

Remarks

Propeller fan Loosened by turning clockwise

Propeller fan

Fan motor lead fixing rubber

– 93 –

No.

i

Part name

Compressor

Compressor lead

Procedure

1. Removal of broken compressor

1) Recover the refrigerant gas.


, d

, e

and f

.

3) Remove the wiring guide (vertical).

Take off screw of the wiring guide (vertical) and volve fixing plate. (M4, 8 mm, 1 pc.)

Take off screw of the wiring guide (vertical) and piping panel (Front). (M4, 8 mm, 1 pc.)

4) Remove the wiring division panel.

Take off screw of the wiring division panel and the inverter assembly. (M4, 8 mm, 1 pc.)

Take off screw of the wiring division panel and the valve fixing plate. (M4, 8 mm, 1 pc.)

5) Remove the piping panel (Front).

Remove screws of the piping panel (Front) and the bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

Remove screws of the piping panel (Front) and the piping panel (Rear).


6) Remove the piping panel (Rear).

Remove screws of the piping panel (Rear) and the bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

7) Remove the valve fixing plate.

Remove bolts of the valve.


Remove screws of the valve fixing plate and the partition plate. (M4, 8 mm, 1 pc.)

Remove screws of the valve fixing plate and the accumulator. (M4, 8 mm, 1 pc.)

Cut off the bundling band for the discharge pipe and the suction pipe and then remove each sensor and coil lead of PMV.

8) Remove the sound insulating plate.

(Upper side, outer winding, inner winding)

9) Remove terminal cover from the compressor and then remove the compressor lead and also the compressor case thermo.

10) Remove TD sensor fixed to the discharge pipe.

11) Remove the compressor lead.

(Leave the ferrite core attached to the electric parts box as it is.)

Control P.C. board

U : CN200 Red

V : CN201

W : CN202

White

Black

(Tightening torque: 1.47 ± 0.1 N•m)

Wiring guide

Remarks

Piping panel (Front)

Bundling band for heat proof

Pipe cover

TD sensor

Compressor lead

TS sensor

Compressor case thermo

Pipe cover, bundling band

Pipe cover, bundling band, each sensor

(TL, TO, TE, TD,

TS sensors)

PMV coil lead

Black pipe cover for heat proof, bundling band for heat proof, each sensor

(TL, TO, TE, TD, TS sensors)

PMV coil lead

– 94 –

No.

i

Part name

Compressor

Compressor lead

(Continued)

Procedure

12) Using a burner, remove the discharge pipe and the suction pipe connected to 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.

Remove

(Discharge pipe)

Remarks

Remove

(Suction pipe)

CAUTION

Note so that the frame does not catch the

4-way valve, PMV and pressure switch.

(An operation may become an error.)

13) Pull off the discharge pipe and the suction pipe of the refrigerating cycle upward.

14) Remove the compressor bolts which fix the compressor to the bottom plate.

(3 pcs.)

15) Pull out the compressor toward you.

CAUTION

X

The weight of the compressor is 15kg or more, so handle it by 2 workers.

Compressor bolt (3 pcs.)

– 95 –

No.

i

Part name

Compressor

Compressor lead

(Continued)

Procedure

2. Mounting of compressor

1) Mount the compressor in the reverse procedure of removal.

Remarks

Compressor lead Wind the ferrite core with the compressor lead wire by 4 times.

NOTES:

∗

After exchange of the compressor, be sure to exchange the compressor lead. (Repair part code of compressor lead: 43160591)

In this time, wrap the ferrite core with the compressor lead wire by 4 times.

Using bundling band on the market, bind the compressor lead. As the compressor lead is long, be sure that the compressor lead does not contact with the discharge pipe.

∗

Fix the removed each sensor and PMV coil lead wire to the discharge pipe and the suction pipe with the bundling band via the pipe cover.

In this time, take note that each sensor and

PMV coil lead wire do not come to contact with the discharge pipe and the reactor.

(For fixing to the discharge pipe, use the black heat-proof pipe cover and the bundling band for heat-proof which is sold on the market.)

∗

As shown in the right figure, mount the sound-insulation plate (inner side, outer side) by inserting between the compressor and the piping, and between piping and the partition plate.

∗

Put the compressor lead wire and the compressor case thermo between inner side and outer side of the sound-insulation as if dropping them in.

0 to 2” (0 to 50mm)

(Positioning standard of compressor lead wire)

Using the bundling band on the market, fix the bundle at 2 positions.

Pass the sound-insulation plate (outer side) through between the suction pipe and the accumulator.

Suction pipe

Accumulator

Pipe cover, bundling band, TS sensor

Pass the sound-insulation plate (inner side) through between compressor and discharge pipe, suction pipe and then put it on the other

Put the sound-insulation plate (outer side) on the other side at this position.

Sound-insulation plate

(upper)

Discharge pipe

Suction pipe

Do not make clearance between the sound-insulation plate (upper) and the sound-insulation plate (outer side).

PMV coil lead

Set each sensor so that it does not come to contact with the discharge pipe.

Pipe cover, bundling band, each sensor (TL, TO, TE, TS sensor)

PMV coil lead

– 96 –

No.

i

Part name

Compressor

Compressor lead

(Continued)

Procedure

3. Vacuuming

1) Connect the vacuum pump to the charge 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. If PMV is closed, vacuuming may be impossible between the liquid pipe valve and PMV of the outdoor unit.

Forced full-opening method of PMV

∗

Turn on the leakage breaker.

∗

Turn on 1 and 3 of DIP SW804 on the control

P.C. board of the outdoor unit.

∗

Keep pushing SW801 on the control P.C. board of the outdoor unit for 1 second or more.

∗

After pushing SW801 for 1 second or more, turn off the leakage breaker within 2 minutes.

4. Refrigerant charging

1) Add the quantity of refrigerant specified by the pipe length into the charge port of the valve.

SW804

Remarks

SW801 j

PMV coil

1. Detachment

1) Perform work of Detachment c

and e

.

2) While pulling the coil upward and removing the spring which pinches the copper pipe, remove the coil from PMV main body.

2. Attachment

1) Match the spring to the copper pipe and fix it.

PMV coil

Spring PMV main body

– 97 –

No.

k

Part name

Fan guard

Procedure

3. Detachment

1) Perform work of Detachment c and d .

CAUTION

To prevent scratching on the product, handle the product on a cardboard or cloth.

2) Remove the discharge port cabinet and then put on it so that the fan guard side directs downward.

3) Remove the fan guard stopper.

(8 positions)

2. Attachment

1) Insert the fan guard stopper to fix the fan guard. (8positions)

CAUTION

X

Check that entire fan guard stoppers are fixed at the specified positions.

Remarks

– 98 –

11-1-3. RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Procedure No.

c

Part name

Common procedure

X

CAUTION

X

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.

2) Remove the front panel.


• Remove the screws and then remove the front panel by pulling it downward.

3) Remove the power supply wire and the indoor/outdoor connecting wire from the cord clamp and the terminal.

4) Remove the top plate.


2. Attachment

1) Attach the top plate.


2) Connect the power supply wire and the indoor/outdoor connecting wire to the terminal and then fix them with the cord clamp.

X

REQUIREMENT

X

For the power supply wire and the indoor/ outdoor connecting wire, be sure fix them using the bundling band on the market along the crossover pipe so that they do not come to contact with the compressor, valve at gas side, pipe at gas side and discharge pipe.

3) Attach the front panel.


Remarks

Front panel

Top plate

– 99 –

No.

d

Part name


Procedure

1. Detachment


2) Remove screws for the discharge port cabinet and the partition board.

(M4, 8 mm, 4 pcs.)

3) Remove screws for the discharge port cabinet and the bottom plate.


4) Remove screws for the discharge cabinet and the motor base. (M4, 8 mm, 2 pcs.)

5) Remove screw for the discharge cabinet and the heat exchanger. (M4, 8 mm, 1 pc.)

6) Remove screws for the discharge port cabinet and the fin guard.


Motor base Partition board

Heat exchanger Discharge port cabinet

Fin guard

Remarks

e

Side cabinet 1) Perform work of Detachment 1 of c .

2) Remove the screws which fix the inverter assembly and the side cabinet.

(M4, 8 mm, 2 pcs.)

3) Take off screws that fix the wiring division panel and the side cabinet.

4) Remove the screws for the side cabinet and the valve fixing plate.

(M4, 8 mm, 2 pcs.)

6) Remove screws for the side cabinet and the piping panel (Rear).


6) Remove screw for the side cabinet and the bottom plate.


7) Remove screws for the side cabinet and the fin guard (Heat exchanger).

(Hexagonal screw M4, 10 mm, 5 pcs.) f



2) Take off screw which fixes the inverter assembly and the inverter protective cover.

(M4, 8 mm, 1 pc.)


– 100 –

No.

g

Part name

Replacement of electric parts

Procedure

1. Control P.C. board

1) Perform work of Detachment 1 of f .

c and

X

WARNING

X

Never disassemble the inverter for 1 minute after power supply has been turned off because an electric shock may be caused.

2) Remove the connectors connected to the control P.C. board.

(Indoor power supply, Temperature sensor, PMV coil, 4-way valve coil,

Compressor case thermo, Fan motor, reactor, pressure switch)

• Unlock the lock of the housing part and then remove the connectors.

3) Remove the lead wires connected to the control P.C. board.

Compressor lead U : CN200 Red

V : CN201 White

W : CN202 Black

Reactor lead

Relay connector : 2 positions

4) Remove the earth wire from the control

P.C. board.

(Trust B tight screw M4, 6 mm, 1 pc.)

5) Remove the fixing screws of the control

P.C. board.

(Screw with collar for fixing element M3,

16 mm, 9 pcs. Pan S tight screw for fixing board M3, 20 mm, 1 pc.)

6) Remove the control P.C. board.

(Supporter: 5 positions)

NOTE :

Be careful to take out because there is sealing material for the heat sink.

Remarks

Pressure switch


Upper fan motor

Lower fan motor

Compressor lead

Element fixing screws

(9 positions)

7) Replace the control P.C. board with a new one.

NOTE :

• Be sure not to come-off of the insulating sheet.

Insulating sheet

– 101 –

No.

g

Part name

Replacement of electric parts

(Continued)

Procedure

2. Reactor

1) Perform work of Detachment 1 of and f .

c , e

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 motor lead. (4 positions)

4) Remove the reactor.

(Trust B tight screw, M4, 6 mm, 2 pcs.)

5) Replace the reactor with a new one.

NOTE :

Be sure to bundle the removed bundling band with the bundling band on the market.

Be careful so that the fan motor lead does not come to contact with the reactor body.

Remarks

Bundling band

(Compressor lead, Reactor lead)

Bundling band

(Compressor lead, Reactor lead)

– 102 –

No.

Part name

h

Fan motor

Procedure


, e

and f

.

2) Remove the flange nut fixing the fan motor and the propeller fan.

• The flange nut is loosened by turning it clockwise.

(When tightening it, turn it counterclockwise.)


4) Remove screws which fix the wiring division panel and the side cabinet. (M4, 8 mm, 2 pcs.)

5) Remove the connector for the fan motor from the inverter.

(Remove the ferrite core of the lower fan motor because it is used.)

6) Remove the fan motor lead from the fan motor lead fixed rubber of the penetrated part of the partition board.

7) Remove the fixing screws (4 pieces each) while supporting the fan motor so that it does not fall down.

∗

Cautions for assembling of fan motor

• Tighten the flange nut with 4.95N•m (50kgf•cm).

• Adjust length of the fan motor lead wire at the fan motor lead fixed rubber so that the fan motor lead is not slackened; otherwise the fan motor lead may come to contact with the propeller fan.

Attach the fan motor lead fixed rubber to the partition board so that the projection is set at the refrigerating cycle side.

• Be sure so that the rector body does not contact with the fan motor lead.

• Be sure to bundle the removed bundling band with the bundling band on the market.

• Necessarily attach the ferrite core of the lower fan motor again.

(Fix it with bundling band on the market.)

X

REQUIREMENT

X

Be sure to fix the fan motor lead to the motor base using the metal band of the motor base so that the fan motor lead does not come to contact with the propeller fan.

Remarks

Propeller fan Loosened by turning clockwise

Flange nut

Propeller fan

Fan motor

Wiring division panel

Screws

– 103 –

No.

i

Part name

Compressor

Compressor lead

Procedure

1. Removal of defective compressor

1) Recover the refrigerant gas.


, e

and f

.

3) Remove the wiring guide (vertical).

Take off screw of the wiring guide (vertical) and the valve fixing plate. (M4, 8 mm, 1 pc.)

Take off screw of the wiring guide (vertical) and the piping panel (front). (M4, 8 mm, 1 pc.)

4) Remove the wiring division panel.

Take off screws of the wiring division panel and the side cabinet. (M4, 8 mm, 2 pcs.)

5) Remove the piping panel (Front).

Remove the piping panel (Front) and screws of the bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

Remove screw of the piping panel (Front) and the piping panel (Rear). (Hexagonal screw M4, 10 mm, 1 pc.)

6) Remove the piping panel (Rear).

Remove the piping panel (Rear) and screws of the bottom plate. (Hexagonal screw M4, 10 mm, 2 pcs.)

7) Remove the sound-insulation plate.

(Upper, rolling in, rolling out)

8) Remove the terminal cover of the compressor and then remove the compressor lead and the compressor case thermo.

9) Remove TD sensor which is fixed to the discharge pipe.

10) Remove the compressor lead. (Leave the ferrite core as it is attached to the electric parts box.)

Control P.C. board U : CN200 Red

V : CN201 White

W : CN202 Black

11) Using a burner, remove the discharge pipe and the suction pipe which are connected to the compressor.

Remarks

Bundling band

(For thermal proof)

Pipe cover

Compressor lead

TD sensor


X

WARNING

X

In case of removing the piping by broiling the welded part with a burner, if there is oil in the pipe, it may burst into flames at the moment that wax melted, so take sufficient care.

CAUTION

Note so that the flame does not catch the 4-way valve, PMV and pressure switch. (A malfunction may be caused.)

12) Pull off the discharge pipe and the suction pipe of the refrigerating cycle upward.

13) Remove the compressor nuts which fix the compressor to the bottom plate. (3 pcs.)

14) Pull out the compressor toward you.

CAUTION

As weight of the compressor is 44 lbs (20kg) or more, handle it by 2 workers.

Remove

(Discharge pipe)

– 104 –

No.

i

Part name

Compressor

Compressor lead

(Continued)

Procedure

2. Mounting of compressor

1) Mount the compressor in the reverse procedure for removal.

NOTE :

• After replacement of the compressor, be sure to replace the compressor lead. (Repair part code of compressor lead: 43160591)

In this time, wrap the ferrite core with the compressor lead wire by 4 times.

• As shown in the right figure, mount the soundinsulation plate (inner side, outer side) by passing through it between the compressor and the piping, and between the piping and the partition board.

• Fix TD sensor by the bundling band for heatproof on the market via the pipe cover so that

TD sensor does not directly come to contact with the discharge pipe.

3. Vacuuming

1) Connect the vacuum pump to the charge port and the check joint 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.

If PMV is closed, vacuum may be impossible between liquid pipe valve and PMV of the outdoor unit.

Remarks

Wrap the ferrite core with the compressor lead wire for 4 times.

Put the end of sound-insulation plate

(outer side) on the other end at this position.

Pass through soundinsulation plate (outer side) between suction pipe and header pipe.

Pass through sound-insulation plate (inner side) between compressor and discharge pipe, suction pipe and then put the end of soundinsulation plate on the other end at this position

There should be no clearance between sound-insulation plate (upper) and sound-insulation plate (outer side).

Forced full-opening method of PMV

• Turn on the leakage breaker.

• Turn on 1 and 3 of Dip switch SW804 on the control P.C. board of the outdoor unit.

• Keep pushing SW801 on the control P.C. board of the outdoor unit for 1 second or more.

• After pushing SW801 for 1 second or more, turn off the leakage breaker within 2 minutes.

4. Refrigerant charge

1) Add the refrigerant amount determined by the pipe length from the charge port of the valve.

– 105 –

No.

j

Part name

PMV coil

Procedure

1. Detachment

1) Perform work of Detachment 1 of c and e .

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.

Remarks


2. Attachment

1) Surely match the positioning projection of the coil with the concave part of PMV main unit and then fix it.

k

Fan guard

1. Detachment

1) Perform work of Detachment 1 of c and d .

X

REQUIREMENT

X

To prevent scratch on the product, carry out the work on cardboard, cloth, etc.

2) Remove the discharge port cabinet and then put on it so that the fan guard side directs downward.

3) Remove the guard stopper. (8 positions × 2)

2. Attachment

1) Insert the guard stopper to fix the fan guard.

(8 positions × 2)

X

REQUIREMENT

X

Check that all the guard stopper are fixed at the specified positions.

Bell mouth

– 106 –

12. EXPLODED VIEWS AND PARTS LIST


12-1-1. RAV-SP180AT2-UL

– 107 –

Location

No.

26

27

28

29

22

23

24

25

18

19

20

21

14

15

16

17

34

35

36

37

30

31

32

33

38

39

10

11

12

13

6

7

8

9

3

4

5

1

2

Part No.

Description

43105043

43105041

43105044

43005672

43119503

Cabinet, Front

Cabinet, Upper

Cabinet, Side, Right

Cabinet, Side, Left

Guard, Fan

4301V053 Guard, Fin

43100346 Base Ass’y, RoHs

43119504 Cover, Valve, Packed Ass’y

4311M658 Lavel, Caution, Wiring

43041648 Compressor, DA150A1F-21F1

4311M656 Lavel, Warning

4314G281 Condenser Ass’y

4311M655 Lavel, Caution, Refrigerant

43107284

37546845

43146680

43147195

Stopper, Guard, Fan

Valve, Packed, 6.35

Valve, Packed, 12.7

Bonnet, 1/2 IN

43147196

43146740

Bonnet, 1/4 IN

Valve, 4-Way, STF-02U13Z

43146739 Coil, STF-01AQ503UC1

4314N034 Valve, Pulse, Modulating, CAM-BD18TF-1

43046487

43058277

Coil, PMV, CAM-MD12TF-12

Reactor, CH-57-Z-T

4312C063 Motor, Fan, ICF-340UA40-1

43020329 Fan, Propeller, PJ421

43047669

43151305

43032441

43089160

Nut, Flange

Switch, Pressure Ass’y, ACB-4UB82W

Nipple, Drain

Cap, Waterproof

43150340

43063339

43042485

43063321

43063322

43063325

43148220

43148205

Compressor, Thermostat Ass’y, US-622KXTMQO-SS

Holder, Sensor (TO)

Rubber, Cushion

Holder, Sensor, 4-8, 9.52

Holder, Sensor, 6-11.4, 12.7

Holder, Sensor, 6-6.35, 8

Plug, Fusible

Accumulator Ass’y, 1L

43039392 Base, Motor

4311M654 Mark, TOSHIBA Carrier

1

1

1

2

1

2

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

3

1

Model Name

RAV-SP180AT2-UL

1

1

1

1

1

1

1

1

1

1

1

1

1

– 108 –

<Inverter assembly>

705 706

708

Reactor

TD sensor

TS sensor

TE sensor

TO sensor

709

Location

No.

701

702

703

704

705

706

707

708

709

Part No.

Description

43050422

43050423

43050427

43050430

43162058

43160608

Sensor, TE

Sensor, TS

Sensor, TO

Sensor, TD

Base, P.C.board

Terminal block, 6P, 20A, AC250V

43158192 Reactor, CH-43-Z-T, RoHs

4316V293 P.C. board Ass’y, SW, MCC-1530

4316V412 P.C. board Ass’y, MCC-5009

– 109 –

707

704

702

701

703

Model Name

RAV-SP180AT2-UL

1

1

1

1

1

1

1

1

1

12-1-2. RAV-SP240AT2-UL

– 110 –

Location

No.

26

27

28

29

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

6

7

8

9

3

4

5

1

2

34

35

36

37

30

31

32

33

38

39

40

41

42

Part No.

Description

43019904

43032441

43041798

43046493

43047246

43047669

43049739

43100438

43100459

43100440

43100452

43100453

43100461

Holder, Sensor

Nipple, Drain

Compressor, DA220A2F-22L

Coil, PMV, CAM-MD12TF-15

Bonnet, 3/8 IN

Nut, Flange

Cushion, Rubber

Panel, Back, Piping

Plate, Front, Piping Ass’y

Plate, Roof

Panel, Side

Panel, Air outlet

Panel, Front

43100455

43107276

43107277

43107278

43109501

43120224

43122113

43146686

Base Ass’y

Hanger

Guard, Fin, Back

Guard, Fin, Side

Guard, Fan

Fan, Propeller, PB521

Bell Mouth

Valve, Packed, 9.52

4314N031 Valve, Ball, SBV-JA5GTC-2, RoHs

43148220 Plug, Fusible

43148232

43150338

Accumulator, Ass’y, 1.8L

Compressor, Thermostat Ass’y, US-622KXTMQO-SS

43151303

43160591

43194029

43197183

Switch, Pressure Ass’y, ACB-4UB82W

Lead Ass’y, Compressor

Bonnet

Bolt, Compressor, M6

4301V075 Cover, Screw

4312C061 Motor, Fan, ICF-34UA60-1, DC340V, 60W

4314G278 Condenser Ass’y

4314N034 Valve, Pulse, Modulating, CAM-BD18TF-1

4314N035 Valve, 4-Way, STF-02U18G

4314N037 Coil, Valve, 4-Way Ass’y, VHV-01AP552B1

4314Q031 Strainer, DIA 9.52


43107284 Stopper, Guard, Fan





– 111 –

1

1

1

3

1

1

1

1

1

1

1

1

1

2

1

1

Model Name

RAV-SP240AT2-UL

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

4

1

1

1

1

1

1

8

1


Location

No.

701

703

704

705

706

707

708

709

710

711

712

713

Part No.

Description

43155188

43050425

43050319

43160607

43160609

43063325

43163055

Reactor, CH-56-2Z-T

Sensor Ass’y, Service, TC (F6)

Sensor Ass’y, Service, TD (F4)

Terminal Block, 3P, 20A, AC250V

Terminal Block, 3P, 60A, AC600V


Holder, Sensor

43163059

43163060

43063321

Spacer, Bush

Spacer, Collar

Holder, Sensor, 4-8, 9.52

43063322 Holder, Sensor, 6-11.4, 12.7

4316V402 P.C.board Ass’y, MCC-1571

– 112 –

Model Name

RAV-SP240AT2-UL

2

3

2

1

1

1

1

1

1

1

1

1

12-1-3. RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

– 113 –

34

35

36

37

31

32

33

26

27

28

29

30

38

39

40

41

42

43

44

Location

No.

11

12

13

14

15

16

8

9

10

3

4

5

1

2

6

7

21

22

23

24

25

17

18

19

20

Part No.

Description

43019904 Holder, Sensor

43032441 Nipple, Drain

43041794 Compressor, DA422A3F-25M

43047246

43047669

Bonnet, 3/8 IN

Nut, Flange

43049739

43097212

Cushion, Rubber

Nut

43100438

43100459

43100460

Panel, Back, Piping

Panel, Front, Piping Ass’y

Panel, Front

43100440

43100441

Plate, Roof

Panel, Side

43100442 Panel, Air Outlet

43100443 Base Ass’y

43107274

43107275

Guard, Fin, Side

Guard, Fin, Back

43107276 Hanger

43119501 Guard, Fan

43120244

43122113

Fan, Propeller, PB521

Bell Mouth

43146676 Joint, Check

43146686 Valve, Packed, 9.52

43148170 Accumulator Ass’y, 2.5L

43148220 Plug, Fusible

43150339 Compressor, Thermostat Ass’y,

US-622KXTMQO-SS

43151303 Switch, Pressure Ass’y, ACB-4UB82W

43160591 Lead Ass’y, Compressor

43194029 Bonnet

4301V075 Cover, Screw

4312C062 Motor, Fan, ICF-340UA100-1,

DC340V, 100W

4314G266 Condenser Ass’y, Down

4314G269 Condenser Ass’y, Up

4314N031 Valve, Ball, SBV-JA5GTC-2, Rohs

4314N032 Valve, 4-Way, STF-04U1G

4314N033 Valve, Pulse, Modulaing, UKV-25D129

4314N036 Coil, PMV, UKV-A120U

4314N037 Coil, Valve, 4-Way Ass’y,

VHV-01AP552B1


4314Q032 Strainer

43107284 Stopper, Guard, Fan





1

1

1

1

1

1

1

16

1

1

1

1

1

1

1

8

1

1

2

3

2

2

2

1

1

1

1

1

1

1

1

1

1

Model Name RAV-

SP240AT2-UL SP360AT2-UL SP420AT2-UL

3 3 3

1

1

1

2

1

1

1

2

1

1

1

2

1

1

1

3

3

1

1

1

3

3

1

1

1

3

3

1

1

1

1

1

1

3

2

2

2

1

1

1

1

3

2

2

2

1

1

1

1

1

1

1

1

1

1

1 1 1

1

16

1

1

1

1

1

1

1

1

1

8

1

1

2

1

1

1

1

1

1

1

1

1

1

1

16

1

1

1

1

1

1

1

8

1

1

2

– 114 –


Location

No.

702

703

704

705

706

707

708

709

710

714

Part No.

Description

43158190

43050425

Reactor, CH-62-ZT

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

43163055


Holder, Sensor

43163059

43163060

Spacer, Bush

Spacer, Collar

4316V403 P.C.board Ass’y, MCC-1571

– 115 –

Model Name RAV-

SP240AT2-UL SP360AT2-UL SP420AT2-UL

2

3

2

3

2

3

1

1

1

2

1

1

1

1

2

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

WARNINGS ON REFRIGERANT LEAKAGE

Important

Check of Concentration Limit

The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its concentration will not exceed a set limit.

The refrigerant R410A which is used in the air conditioner is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws to be imposed which protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its concentration should rise excessively. Suffocation from leakage of R410A is almost non-existent. With the recent increase in the number of high concentration buildings, however, the installation of multi air conditioner systems is on the increase because of the need for effective use of floor space, individual control, energy conservation by curtailing heat and carrying power etc.

Most importantly, the multi air conditioner system is able to replenish a large amount of refrigerant compared with conventional individual air conditioners. If a single unit of the multi conditioner system is to be installed in a small room, select a suitable model and installation procedure so that if the refrigerant accidentally leaks out, its concentration does not reach the limit (and in the event of an emergency, measures can be made before injury can occur).

In a room where the concentration may exceed the limit, create an opening with adjacent rooms, or install mechanical ventilation combined with a gas leak detection device.

The concentration is as given below.

Total amount of refrigerant (kg)

Min. volume of the indoor unit installed room (m³)

≤

Concentration limit (kg/m³)

The concentration limit of R410A which is used in multi air conditioners is 0.3kg/m³.

NOTE 1 :

If there are 2 or more refrigerating systems in a single refrigerating device, the amounts of refrigerant should be as charged in each independent device.

e.g., charged amount (10kg)

Outdoor unit e.g., charged amount (15kg)

Room A Room B Room C Room D Room E Room F

Indoor unit

For the amount of charge in this example:

The possible amount of leaked refrigerant gas in rooms A, B and C is 10kg.

The possible amount of leaked refrigerant gas in rooms D, E and F is 15kg.

NOTE 2 :

The standards for minimum room volume are as follows.

1) No partition (shaded portion)

2) When there is an effective opening with the adjacent room for ventilation of leaking refrigerant gas (opening without a door, or an opening 0.15% or larger than the respective floor spaces at the top or bottom of the door).

Outdoor unit

Refrigerant piping

Indoor unit

3) If an indoor unit is installed in each partitioned room and the refrigerant piping is interconnected, the smallest room of course becomes the object.

But when a mechanical ventilation is installed interlocked with a gas leakage detector in the smallest room where the density limit is exceeded, the volume of the next smallest room becomes the object.

Refrigerant piping

Outdoor unit

Very small room

Indoor unit

Small room

Medium room

Large room

Mechanical ventilation device - Gas leak detector

NOTE 3 :

The minimum indoor floor area compared with the amount of refrigerant is roughly as follows:

(When the ceiling is 2.7m high)

40 m²

35

30

25

Range below the density limit of 0.3 kg/m³

(countermeasures not needed)

20

15

10

5

0

Range above the density limit of 0.3 kg/m³

(countermeasures needed)

10 20 30

Total amount of refrigerant kg

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.

TOSHIBA Carrier SUPER DIGITAL INVERTER RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL split-system air conditioner SERVICE MANUAL

Assistant Bot

REVISION 2 : Jan.2012

Re-edit version.( file volume down)

Contents have NOT been changed.

SERVICE MANUAL

SPLIT TYPE

OUTDOOR UNIT

<SUPER DIGITAL INVERTER>

– 2 –

CONTENTS

– 3 –

SAFETY CAUTION

– 4 –

– 5 –

– 6 –

• New Refrigerant (R410A)

1) Copper pipe

<Piping>

<Flare nut>

2) Joint

– 7 –

Tools exclusive for R410A (The following tools for R410A are required.)

General tools (Conventional tools can be used.)

– 8 –

– 9 –

• Operation characteristic curve <Super Digital Inverter>

– 10 –

• Capacity variation ratio according to temperature

– 11 –

– 12 –

– 13 –

– 14 –

• Single type (Combination of 1 indoor unit and 1 outdoor unit)

Dimension table

– 15 –

– 16 –

– 17 –

– 18 –

– 19 –

Color

Identification

– 20 –

Color

Identification

– 21 –

– 22 –

6-2-1. Piping Materials and Joints Used

– 23 –

6-2-2. Processing of Piping Materials

– 24 –

– 25 –

– 26 –

6-3-1. Required Tools

– 27 –

6-5-1. Materials for Brazing

1. Silver brazing filler

2. Phosphor bronze brazing filler

3. Low temperature brazing filler

– 28 –

6-5-2. Flux

1. Reason why flux is necessary

2. Characteristics required for flux

3. Types of flux

4. Piping materials for brazing and used brazing filler/flux

6-5-3. Brazing

1. Brazing method to prevent oxidation

– 29 –

RAV-SP180AT2-UL

– 30 –

<MCC-1571>

RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

– 31 –

– 32 –

3-1) Cooling fan control

– 33 –

3-2) Heating fan control

– 34 –

– 35 –

– 36 –