RAV-SM 1401AT-E | RAV-SM 1101AT-E | RAV-SM 801AT-E | TOSHIBA RAV-SM 561AT-E, 801AT-E, 1101AT-E, 1401AT-E split-system air conditioner Service Manual

FILE NO. A05-001

SERVICE MANUAL

SPLIT TYPE

<NEW DIGITAL INVERTER>

OUTDOOR UNIT

RAV-SM561AT-E

RAV-SM801AT-E

RAV-SM1101AT-E

RAV-SM1401AT-E

INDOOR UNIT

This Service Manual describes contents of the new outdoor unit.

For the indoor unit, refer to the Service Manual with FILE NO. A03-003F.

R410A

PRINTED IN JAPAN, Apr.,2005 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.

CONTENTS

1. SPECIFICATIONS ........................................................................................................... 3

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) ............................................................. 5

3. REFRIGERATING CYCLE DIAGRAM ............................................................................ 8

4. WIRING DIAGRAM ....................................................................................................... 11

5. SPECIFICATIONS OF ELECTRICAL PARTS ............................................................... 12

6. REFRIGERANT R410A ................................................................................................. 13

6-1. Safety During Installation/Servicing ................................................................................ 13

6-2. Refrigerant Piping Installation ....................................................................................... 13

6-3. Tools ................................................................................................................................... 17

6-4. Recharging of Refrigerant ................................................................................................ 18

6-5. Brazing of Pipes ................................................................................................................ 19

7. CONTROL SPECIFICATIONS ...................................................................................... 21

7-1. Outdoor Controls .............................................................................................................. 21

7-2. Outline of Main Controls ................................................................................................... 24

8. TROUBLESHOOTING .................................................................................................. 29

8-1. Summary of Troubleshooting ........................................................................................... 29

8-2. Check Code List ................................................................................................................ 31

8-3. Error Mode Judgment by LED Display of Outdoor Unit ................................................ 34

8-4. Contents of Error Display ................................................................................................. 35

8-5. Troubleshooting Procedure for Each Check Code ......................................................... 36

8-5. Other Function ................................................................................................................... 57

9. DETACHMENTS ............................................................................................................ 58

10. EXPLODED VIEWS AND PARTS LIST ........................................................................ 73

– 2 –

1. SPECIFICATIONS

RAV-SM561AT-E, RAV-SM801AT-E

Appearance

Power supply

Compressor

Refrigerant charged

Pole

Refrigerant control

Type

Motor

Pipe

Standard length

Max. total length (m)

Over 20m

(kW)

(kg)

Height difference

Outdoor lower (m)

Outdoor higher (m)

Height

Outer dimension Width

Depth

(mm)

(mm)

(mm)

(kg) Total weight

Heat exchanger

Fan unit

Connecting pipe

Fan

Standard air flow High

Motor

Gas side

Liquid side

(m³/h)

(W)

(mm)

(mm)

Protection device

Model name RAV-SM561AT-E RAV-SM801AT-E

Silky shade (Muncel 1Y8.5/0.5)

1 phase 230 V (220 – 240 V) 50 Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

1.1

1.6

4 poles

R410A 1.0

R410A 1.7

Pulse motor valve

20 (without additional charge)

30

Add 20 g/m (Max. 200 g) Add 40 g/m (Max. 400 g)

30

30

550

780

290

38 42

Finned tube

Propeller fan

2400 2700

43

Ø12.7 (1/2”)

Ø6.4 (1/4”)

Ø15.9 (5/8”)

Ø9.5 (3/8”)

Discharge temp. sensor

Over-current sensor

Compressor thermo.

Sound level

(Note 2)

High (Mid./Low)

(Cooling/Heating)

(dB•A) 46 / 48 48 / 50

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions speciied by JIS B 8616 based on the reference piping 7.5m.

Note 2 : The sound level is measured in an anechoic chamber in accordance with JIS B8616. Normally, the values measured in the actual operating environment become larger than the indicated values due to the effects of external sound.

Note

: Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB

Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB

– 3 –


Appearance

Power supply

Model name

Compressor

Refrigerant charged

Pole

Refrigerant control

Type

Motor

Standard length

Max. total length (m)

Pipe

(kW)

(kg)

Over 20m

Height difference

Outdoor lower (m)

Outdoor higher (m)

Outer dimension

Total weight

Heat exchanger

Fan unit

Connecting pipe

Protection device

Height

Width

Depth

Fan

Standard air flow High

Motor

Gas side

Liquid side

(mm)

(mm)

(mm)

(kg)

(m³/h)

(W)

(mm)

(mm)

RAV-SM1101AT-E RAV-SM1401AT-E

Silky shade (Muncel 1Y8.5/0.5)

1 phase 230 V (220 – 240 V) 50 Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

2.5

3.0

4 poles

R410A 2.8

Pulse motor valve

30 (without additional charge)

50

Add 40 g/m (Max. 800 g)

30

30

795

780

320

77

Finned tube

Propeller fan

4500

100

Ø15.9 (5/8”)

Ø9.5 (3/8”)

Discharge temp. sensor

Over-current sensor

Compressor thermo.

Sound level

(Note 2)

High (Mid./Low)

(Cooling/Heating)

(dB•A) 53 / 54

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions speciied by JIS B 8616 based on the reference piping 7.5m.

Note 2 : The sound level is measured in an anechoic chamber in accordance with JIS B8616. Normally, the values measured in the actual operating environment become larger than the indicated values due to the effects of external sound.

Note

: Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB

Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB

– 4 –

RAV-SM561AT-E

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

A legs

Drain hole

(2-Ø20 × 88 long hole)

30

B legs

600

Drain hole (Ø25)

90

108 125

54

2-Ø11-14 U-hole

(For Ø8–Ø10 anchor bolts)

Connecting pipe port

(Flare Ø12.7 at gas side)


(Flare Ø6.4 at liquid side)

8-Ø6 hole

(For fixing outdoor unit)

2-Ø11 × 14 long hole


69.5

147

483

108

257

157 79

25

22

31

145

143

54

32

Guard for air discharge

500

780

71

342

Charge port

4-Ø4.5 embossing (Ø4 STS used)

(For mounting air direction guide)

Earth terminal

600

54

38

11

R15

2-Ø6 hole

R5.5

Details of A legs

Product external line


2-Ø6 hole

38

54

R15

600

R5.5

Details of B legs

Space required for service

2-Ø11 × 14 U-shape holes

(For Ø8–Ø10 anchor bolt)

Suction port

150 or more

150 or more

Anchor bolt mounting dimension

600

Suction port

300 or more

500 or more

(Minimum distance up to wall)

Discharge port



– 5 –

RAV-SM801AT-E

69.5

147

A legs

Drain hole

(2-Ø20 × 88 long hole)

30

B legs

600

Drain hole (Ø25)

90

108 125

54

2-Ø11–14 U-hole



(Flare Ø15.9 at gas side)


(Flare Ø9.5 at liquid side)

8-Ø6 hole

(For fixing outdoor unit)



483

108

257

157 79

25

22

31

145

143

54

32

Guard for air discharge

500

780

71

Charge port

342

4-Ø4.5 embossing (Ø4 STS used)

(For mounting air direction guide)

Earth terminal

600

54

38

11

R15

2-Ø6 hole

R5.5

Details of A legs



2-Ø6 hole

38

54

R15

600

R5.5

Details of B legs




Suction port

150 or more

150 or more

Anchor bolt mounting dimension

600

Suction port

300 or more

500 or more


Discharge port



– 6 –


Knockout

(For draining)

29 90

Drain hole (Ø20 × 88 Burring hole)

191

Suction port

20

Drain hole (Ø25 Burring hole)

Part B

Suction port

Knockout

(For draining)

26 60

150

314

Discharge port

300

900

Part A

95

43

Installation bolt hole

(Ø12 × 17 U-shape holes)

Details of B part

Details of A part

Installation bolt hole

(Ø12 × 17 U-shape holes)

Handles

(Both sides)

Refrigerant pipe connecting port

(Ø9.5 Flare at liquid side)

Refrigerant pipe connecting port

(Ø15.9 Flare at gas side)

2

Discharge guide mounting hole

(4-Ø4 Embossing)

28 320

300

1

27 58

161

400

2

Z

307

60

96

27

1

Knockout for lower piping

86 7

Z views

2 46

1

30 45



(For Ø8–Ø10 Anchor bolt)

600

Suction port

150 or more

150 or more

150 or more

Discharge port


500 or more

Discharge port


(For Ø8–Ø10 Anchor bolt)

– 7 –

3. REFRIGERATING CYCLE DIAGRAM

RAV-SM561AT-E

Indoor unit

TC sensor

Air heat exchanger

TCJ sensor

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

12.7mm

6.4mm

TS sensor

2-step muffler

Ø19.05 × 200L

Refrigerant pipe at gas side

Ø12.7

Packed valve

Packed valve

Outer dia. ØA

TO sensor

Refrigerant pipe at liquid side

Ø6.4

Packed valve

Min.

5m

Packed valve

Outer dia. ØB

Max.

30m

Outdoor unit

PMV

(Pulse Motor Valve)

(CAM-B30YGTF-1)

TD sensor

Strainer

Rotary compressor

(DA150A1F-20F)

4-way valve

(STF-0108Z)

Muffler

Ø19 × L160

Heat exchanger

Ø8 ripple, 2 rows,

14 steps

FP1.3, flat fin

TE sensor

Distributor

Cooling

Heating

Pressure

(MPa) (kg/cm²G)

Pd Ps Pd Ps

Discharge Suction

(TD)

Pipe surface temperature (°C)

(TS)

Indoor heat Outdoor heat exchanger exchanger

(TC) (TE)

Compressor revolutions per second (rps)

*

Indoor fan

Indoor/Outdoor temp. conditions

(DB/WB) (°C)

Indoor Outdoor

Standard 3.50

0.97

35.7

9.9

Cooling Overload 3.90

1.08

39.8

11.0

Low load 1.90

0.70

19.4

7.1

Standard 2.31

0.61

13.6

6.2

Heating Overload 2.86

0.89

29.2

9.1

Low load 1.86

0.25

19.0

2.6

87

86

69

85

93

48

5

17

–14

14

26

7

40

47

31

12

17

5

1

11

–15

48

54

30

97

95

98

70

70

50

HIGH 27/19 35/–

HIGH

LOW

32/24 43/–

18/15.5

–5/–

HIGH

HIGH

HIGH

20/–

28/–

7/6

24/18

15/– –10/

(70%)

*

4 poles are provided to this compressor.

The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.

– 8 –

RAV-SM801AT-E

Indoor unit

Air heat exchanger

TCJ sensor

TC sensor



15.9mm

9.5mm

TS sensor

TD sensor

Accumulator

(1000cc)

Rotary compressor

(DA150A1F-20F)

2-step muffler

Ø25 × 200L

Pd


Ø15.9

Packed valve

Packed valve

Outer dia. ØA

TO sensor


Ø9.5

Packed valve

Min.

5m

Max.

50m

Packed valve

Outdoor unit

Outer dia. ØB

PMV

(Pulse Motor Valve)

(CAM-B30YGTF-1)

Ps

Strainer

4-way valve

(STF-0213Z)

TE sensor

Heat exchanger

Ø8 ripple,

2 rows, 20 steps

FP1.3, flat fin

Distributor

Cooling

Heating

Pressure


Pd Ps Pd Ps


(TD)


(TS)


(TC) (TE)


*

Indoor fan


(DB/WB) (°C)

Indoor Outdoor

Standard 3.28

0.86

33.4

8.8

Cooling Overload 3.59

1.00

33.6

10.2

Low load 1.85

0.83

18.9

8.5

Standard 2.53

0.62

25.8

6.3

Heating Overload 3.42

1.07

34.9

10.9

Low load 1.99

0.23

20.3

2.3

75

80

89

84

82

42

3

20

–19

11

17

8

42

54

34

10

16

6

2

17

–18

45

51

23

95

50

120

83

76

35

HIGH 27/19 35/–

HIGH

LOW

32/24 43/–

18/15.5

–5/–

HIGH

LOW

HIGH

20/–

28/–

7/6

24/18

15/– –10/

(70%)

*



– 9 –

SM801BT-E /

SM800AT-E, SM800UT-E,

SM800BT-E, SM800KRT-E




15.9mm

9.5mm

Cooling: Low pressure

TS sensor

Indoor unit

TCJ sensor Distributor

(Strainer incorporated)

Strainer


Ø15.9

Ball valve

Ball valve

Outer dia. ØA

Strainer

TO sensor

Air heat exchanger

TC sensor

Outdoor unit


Ø9.5

Packed valve

Min.

5m

Packed valve

Max.

50m

Outer dia. ØB

PMV

(Pulse Motor Valve)

(UKV-25D22)

TD sensor

Accumulator

(2500cc)

Rotary

Muffler

4-way valve

(STF-0213Z) compressor

(DA420A3F – 21M)

Ø25 × L210

Ø25 × L180

TE sensor

Heat exchanger

Outer side Ø8, 2 rows, 20 steps

FP1.3, flat fin

Inner side Ø9.52, 1 row, 30 steps

FP1.5, flat fin

Distributor

Strainer

Cooling

Heating

RAV-SM1101AT-E

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure


Pd Ps Pd Ps

3.44

0.92

35.1

9.4

3.73

1.18

38.1

12.0

1.49

0.70

15.2

7.1

2.80

0.61

28.6

6.2

3.43

1.08

35.0

11.0

2.20

0.25

22.4

2.6

(TD)

82



(TS)

8


(TC)

10

(TE)

39


*

47

82

39

80

82

76

15

8

0

14

–19

17

3

46

55

36

48

22

1

13

–16

42

30

48

24

55

Indoor fan

HIGH

HIGH

LOW

HIGH

LOW

HIGH


(DB/WB) (°C)

Indoor Outdoor

27/19 35/–

32/24 43/–

18/15.5

–5/–

20/–

30/–

7/6

24/18

15/– –10/

(70%)

RAV-SM1401AT-E

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure


Pd Ps Pd Ps

3.52

0.85

35.9

8.7

3.78

1.12

38.6

11.4

1.51

0.71

15.4

7.2

2.88

0.60

29.4

6.1

3.41

1.08

34.8 11.0

2.35

0.24

24.0

2.4

(TD)

87



(TS)

8


(TC)

9

(TE)

39


*

54

84

40

85

81

80

15

7

1

14

–19

17

3

47

54

40

47

23

1

13

–16

45

30

61

24

73

Indoor fan

HIGH

HIGH

LOW

HIGH

LOW

HIGH


(DB/WB) (°C)

Indoor Outdoor

27/19 35/–

32/24 43/–

18/15.5

–5/–

20/–

30/–

7/6

24/18

15/– –10/

(70%)

*



– 10 –

4. WIRING DIAGRAM


Compressor

RED

WHI

BLK

P04

P05

P06

Q200~205

IGBT

R221

P25

YEL

P24

YEL

BRW

P21

P22

P20

P35

YEL

P23

P34

R220

R219

L03

P.C. Board

(MCC-5009)

C13

F03

Fuse

T3.15A

AC250V

Reactor

P19

P18

P11

P08

Q404

Power relay

DB02

CT

C12 C14

Relay

P33

PUR

P32

CN701

P31 P30

CN300

BLK

WHI

RED

Fan motor

CN700

L01

Varistor

CN603

Surge absorber

Varistor

CN602

F01 Fuse

T25A, AC250V

P03 P10

ORN BLK

P02

WHI

CN601

CN600

Pulse motor valve

TS

(Suction pipe

Temp. sensor)

TO

(Outdoor

Temp. sensor)

TD

(Discharge pipe

Temp. sensor)

TE

(Condensor pipe

Temp. sensor)

P7

BLK

Coil for

4-way valve

To indoor unit

Power supply

220-240V~,

50Hz

Reactor


Reactor

1 2

1 2

1 2

1 2

Reactor

+

~

~

~

–

YEL BLU

RED

CN01

F01 Fuse

T25A, 250V~

RY01

WHI

CN02

CN03

Power factor control

P.C. Board

(MCC-1438)

CN09 RED

CN10 WHI

TO

CN11 BLK

W V U

CM

TD

Compressor

1

1

3

3

5

5

CN13

RED

1 2

1 2

CN05

WHI

1 2

1 2

3 4

3 4

5

5

CN06

RED

1

1

3

3

CN04

WHI

1

1

2

2

CN600

BLK

TS TE

1

RED

2

WHI

BLK

3 L

CN02

BLK

1 1

1

1

3 3

5 5

N

Power supply

220V~240V~,50Hz

3

3

5

5

CN01

RED

1 2

1 2

CN04

WHI

1 2

1 2

3 4

3 4

5

5

CN800

RED

CN03

WHI

1

1

3

3

TH

1

1

3

3

CN605

WHI

1

1

2

2

1

1

2

2

CN604

WHI

CN601

WHI

1

1

CN600

WHI

3

3

SUB P.C. Board

(MCC-1531)

1 2

1 2

3 4

3 4

5

5

6

6

CN702

WHI

CN301

WHI

PMV

Pulse motor valve

RED

BLK

1 2

1 2

FM

3

3

Fan motor

1 2

1 2

3 4

3 4

5

5

CN300

WHI

1 2

1 2

3 4

3 4

5

5

CN804

BLU

ORN

1

1

2

2

CN500

BLU

3 3

1 1

1 2

1 2

3 4

3 4

5

5

Optional

P.C.Board

MCC-1522

49C

1 2 3 4 5 6

CN801

7 8

CN700 YEL

3 3

RED

20SF

1 1

RED

Coil for 4-way valve

To indoor unit

– 11 –

5. SPECIFICATIONS OF ELECTRICAL PARTS


5

6

3

4

No.

1

2

9

10

7

8

11

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)

Type

ICF-140-43-4

DA150A1F-20F

CH-57

—

—

—

—

VHV-01AJ503C1

US-622

Specifications

Output (Rated) 43 W

3 phase, 4P, 1100 W

10 mH, 16A

10 k

Ω

at 25°C

10 k

Ω

at 25°C

10 k

Ω

at 25°C

50 k

Ω

at 25°C

T3.15 A, AC 250 V

25 A, AC 250 V

ON : 90 ± 5°C, OFF : 125 ± 4°C


5

6

3

4

No.

1

2

9

10

7

8

11

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)

Type

ICF-280-100-1

DA420A3F-21M

CH-56-2Z-T

—

—

—

—

VHV-01AJ503C1

US-622

Specifications

Output (Rated) 100 W

3 phase, 4P, 3750 W

6 mH, 18.5 A

10 k

Ω

at 25°C

10 k

Ω

at 25°C

10 k

Ω

at 25°C

50 k

Ω

at 25°C

T3.15 A, AC 250 V

25 A, AC 250 V

ON : 90 ± 5°C, OFF : 125 ± 4°C

– 12 –

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’s 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 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 0.8 mm even when it is available on the market.

– 13 –

Nominal diameter

1/4

3/8

1/2

5/8

Table 6-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Outer diameter (mm)

6.35

9.52

12.70

15.88

(2) 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-

2-6 below.

R410A

0.80

0.80

0.80

1.00

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm.

Thicknesses of socket joints are as shown in

Table 6-2-2.

R22

0.80

0.80

0.80

1.00


1/4

3/8

1/2

5/8

Table 6-2-2 Minimum thicknesses of socket joints

Reference outer diameter of copper pipe jointed (mm)

6.35

9.52

12.70

15.88

Minimum joint thickness

(mm)

0.50

0.60

0.70

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.

– 14 –

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


1/4

3/8

1/2

5/8

Fig. 6-2-1 Flare processing dimensions

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

Outer diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

0.8

0.8

1.0

Flare tool for

R410A clutch type

0 to 0.5

0 to 0.5

0 to 0.5

0 to 0.5

A (mm)

Conventional flare tool

Clutch type

1.0 to 1.5

Wing nut type

1.5 to 2.0

1.0 to 1.5

1.0 to 1.5

1.0 to 1.5

1.5 to 2.0

2.0 to 2.5

2.0 to 2.5


1/4

3/8

1/2

5/8

Table 6-2-4 Dimensions related to flare processing for R22

Outer diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

0.8

0.8

1.0

Flare tool for

R22 clutch type

0 to 0.5

0 to 0.5

0 to 0.5

0 to 0.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

0.5 to 1.0

0.5 to 1.0

0.5 to 1.0

0.5 to 1.0

1.0 to 1.5

1.0 to 1.5

1.5 to 2.0

1.5 to 2.0


1/4

3/8

1/2

5/8

Table 6-2-5 Flare and flare nut dimensions for R410A

Outer diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

0.8

0.8

1.0

A

9.1

13.2

16.6

19.7

Dimension (mm)

B

9.2

C

6.5

13.5

16.0

19.0

9.7

12.9

16.0

D

13

20

23

25

Flare nut width (mm)

17

22

26

29

– 15 –


1/4

3/8

1/2

5/8

3/4

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

Outer diameter

(mm)

6.35

9.52

12.70

15.88

19.05

Thickness

(mm)

0.8

0.8

0.8

1.0

1.0

A

9.0

13.0

16.2

19.4

23.3

B

Dimension (mm)

C

9.2

13.5

6.5

9.7

16.0

19.0

24.0

12.9

16.0

19.2

D

13

20

20

23

34

Flare nut width (mm)

17

22

24

27

36

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.

NOTE:

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 6-2-7 shows reference values.

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.


1/4

3/8

1/2

5/8

Table 6-2-7 Tightening torque of flare for R410A [Reference values]

Outer diameter

(mm)

6.35

9.52

12.70

15.88

Tightening torque

N•m (kgf•cm)

14 to 18 (140 to 180)

33 to 42 (330 to 420)

50 to 62 (500 to 620)

63 to 77 (630 to 770)

Tightening torque of torque wrenches available on the market

N•m (kgf•cm)

16 (160), 18 (180)

42 (420)

55 (550)

65 (650)

– 16 –

6-3. Tools

6-3-1. Required Tools

The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing 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.

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

Tools whose specifications are changed for R410A and their interchangeability

R410A air conditioner installation

Conventional air conditioner installation

No.

Used tool Usage

Existence of new equipment for R410A

Whether conventional equipment can be used

Whether new equipment can be used with conventional refrigerant

Flare tool Pipe flaring Yes *(Note 1) OK

Copper pipe gauge for adjusting projection margin

Flaring by conventional flare tool

Yes *(Note 1) *(Note 1)

Torque wrench

Gauge manifold

Charge hose

Vacuum pump adapter

Electronic balance for refrigerant charging

Refrigerant cylinder

Leakage detector

Charging cylinder

Connection of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating

Refrigerant charge

Refrigerant charge

Gas leakage check

Refrigerant charge

Yes

Yes

Yes

Yes

Yes

Yes

(Note 2)

NO GOOD

NO GOOD

NO GOOD

NO GOOD

NO GOOD

NO GOOD

NO GOOD

NO GOOD

NO GOOD

OK

OK

NO GOOD

OK

NO GOOD

(Note 1) 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.

(Note 2) Charging cylinder for R410A is being currently developed.

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

(3) Pipe cutter

(4) Reamer

(5) Pipe bender

(6) Level vial

(7) Screwdriver (+, –)

(8) Spanner or Monkey wrench

(9) Hole core drill (Ø65)

(10) Hexagon wrench

(Opposite side 4mm)

(11) Tape measure

(12) Metal saw

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

(1) Clamp meter

(2) Thermometer

(3) Insulation resistance tester

(4) Electroscope

– 17 –

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

–0.1 Mpa (–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.

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.)

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.

Never charge refrigerant exceeding the specified amount.

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

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)

Opened

(Gas side)


(With siphon pipe)

Check valve

Open/Close valve for charging

Closed

Service port

Electronic balance for refrigerant charging

Fig. 6-4-1 Configuration of refrigerant charging

– 18 –

(OUTDOOR unit)

Be sure to make setting so that liquid can be charged.

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 cylinder ant Refriger


Electronic balance

Electronic balance

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.

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.

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

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.

– 19 –

(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 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

Used flux

Copper - Copper Phosphor copper Do not use

Copper - Iron

Iron - Iron

Silver

Silver

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

(N2) flow.

Never use gas other than Nitrogen gas.

(1) Brazing method to prevent oxidation

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

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

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.

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

Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m³/Hr or 0.02 MPa (0.2kgf/ cm²) by means of the reducing valve.

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).

Remove the flux completely after brazing.

Nitrogen gas cylinder

M

Flow meter

Stop valve

From Nitrogen cylinder

Do not enter flux into the refrigeration cycle.

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

Therefore, use a flux which does not contain chlorine.

When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

Remove the flux after brazing.

Pipe

Rubber plug

Nitrogen gas

Fig. 6-5-1.

Circuit Configuration and Control Specifications

– 20 –

F01, 02, 25A fuse P.C. board earth lead

(Black)

L-phase power supply lead

(Black)

N-phase power supply lead

(White)

Serial lead (Orange)

Reactor lead connector

(White)

CN701:

4-way valve connector

RY701:

4-way valve relay

CN300:

Fan motor connector

CN602:

Outdoor temperature

(TO) sensor connector

CN806:

Optional connector

CN600:

Heat exchange temperature

(TE) sensor connector

CN603:

Suction temperature

(TS) sensor connector

CN601:

Discharge temperature

(TD) sensor connector

CN500:

Case thermo connector

CN700:

PMV connector

Fan drive circuit

Q300 to Q305:

FET (QTY: 6P)

CN605:

Sub SW board connector

J800 to 803, 806

Model switch jumper line

DB02:

High power factor diode

Q404:

High power factor circuit IGBT

Comp. drive circuit

Comp. lead

(Red) (White) (Black)

Q200 to Q205: IGBT (QTY: 6P)

IC200: Drive IG (QTY: 1P)

IGBT

(Compressor drive device)

Compressor output

CN09, CN10, CN11

Rectifier

Reactor connector DC15V output

(To MCC-1531)

CN05

Communication signal

(To MCC-1531)

CN06

AC output

(To MCC-1531)

CN13

TH sensor

CN600

Earth ground

CN03

DC320V output

(To MCC-1531)

CN04

Mains (Neutral) input

CN02

Mains (Live) input

CN01

Rectifier connectors

P29 (Red), P28 (Black),

P21 (Orange), P24 (Brown)

Reactor Connector Capacitor

Serial signal

(To terminal block)

CN02

AC input

(To MCC-1438)

CN01

4-way valve

CN700

EEPROM-IC

IC801

Refrigerant recovery Switch

SW802

Dip switch

SW801

Model selection jumpers

(Available only service P.C. board)

J800 to J803

P.M.V. CN702

Case thermo. switch

CN500

Communication signal

(To MCC-1438)

CN800

TD sensor

CN600

TO sensor

CN601

TE sensor

CN604

TS sensor

CN605

Optional connector

CN804

Fan motor revolution

CN300

Fan motor output

CN301

DC15V input

(To MCC-1438)

CN04

DC320V input

(To MCC-1438)

CN03

7-2. Outline of Main Controls

1. Pulse Modulating Valve (PMV) control

1) For PMV with 50 to 500 pulses during operation, respectively.

2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.

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

4) For the temperature difference in items 2) and 3), 1 to 5K is aimed as the target in both cooling and heating operations.

5) When the cycle excessively rose in both cooling and heating operations, PMV is controlled by TD sensor.

The aimed value is usually 103°C for SM561, SM801 and 92°C for SM1101, SM1401 in 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 an the refrigerating cycle of each sensor after repair and then start the operation.

2. Discharge temperature release control

1) This function controls the operation frequency, that is, lowers the operation frequency when the discharge temperature has not lower or the discharge temperature has rapidly risen during

PMV control. It subdivides the frequency control up to a unit of 0.6 Hz to stabilize the cycle.

2) When the discharge temperature is detected in an abnormal stop zone, the unit stops the compressor and restarts after 2 minutes 30 seconds. The error counter is cleared when it has continued the operation for 10 minutes.

If the abnormal stop zone has been detected by 4 times without clearing of counter, an error “P03” is displayed.

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

[°C]

SM561, SM801

SM1101, SM1401 a

117

111

b

107

106

c

103

100

d

100

95

e

93

90 a b c d e

TD [˚C]

Error stop ("P03" display with 4 times of error counts)

As command is

Current [A]

Frequency down

Frequency holding

Frequency slow-up

(Up to command)

I

1

Frequency down

Hold

3. Current release control

The output frequency and the output voltage are controlled by AC current value detected by T02 on the outdoor P.C. board so that input current of the inverter does not exceed the specified value.

I

1–0.5

Objective model

1

1 value [A]

SM561

COOL HEAT COOL HEAT COOL HEAT COOL HEAT

10.1

12.0

SM801

12.2

14.0

SM1101

18.9

19.7

SM1401

19.7

19.7

Hold

Normal operation

– 24 –

4. Outdoor fan control

SM561

SM801

SM1101

SM1401

Allocations of fan tap revolutions [rpm]

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

200 300 350 410 480 500 530 560 640 670 700 750 800 840 840

200 300 350 410 480 500 530 560 640 670 700 750 840 940 980

250 280 320 360 410 460 520 580 640 700 760 860 860 900 930

250 280 320 360 410 460 520 580 640 700 760 860 860 900 970

1) Cooling fan control

The outdoor fan is controlled by TE, TD, and TO sensors and also revolution frequency of the operation. The outdoor is controlled by every 1 tap of DC fan control (15 taps).

Only during 60 seconds after the operation has started, the fan is fixed with the maximum fan tap which corresponds to the zone in the following table.

After then the fan is controlled by TE sensor temperature.

Considering a case that TE sensor has come out of the holder, the fan is controlled so that revolution frequency of the fan increases regardless of TE if temperature of TD sensor has risen.

SM561, SM801

SM1101, SM1101 a

36

29

b

32

26

TE [˚C]

TD [˚C]

Operation with WE

+1 tap/20 seconds a b rpm hold

–1 tap/20 seconds

85

80

75

65

Operation with maximum tap in each zone

Usual fan control

(The operation frequency differs according to the model type.)

Temp. range

29°C < TO

15 < TO < 29°C

5 < TO < 15°C

0 < TO < 5°C

TO < 0°C

TO error

Min

Below 30Hz

Max

W5

W3

W2

WA

W7

W5

W1

W1

W1

W3

W2

WF

Above 30 Hz below 45 Hz

Min Max

W7

W5

W4

WC

W9

W7

W3

W2

W1

W5

W4

WF

– 25 –

Above 45 Hz

Min Max

W9

W7

W6

WF

WB

W9

W4

W3

W1

W7

W5

WF

2) Heating fan control

The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency.

(From Min. W1 to Max. are controlled according to the following table.)

During 3 minutes after start-up, the fan is fixed with the maximum fan tap corresponding to

TE [˚C] zone in the following table. After then the fan is controlled by temperature of TE sensor.

–2 tap/20 seconds

STOP timer count

If status, TE

≥

24°C continues for 5 minutes, the operation stops. This status is same to the usual

24

–2 tap/20 seconds

Thermo-OFF which has no alarm display, and the

21 fan restarts after 2 minutes and 30 seconds. This

–1 tap/20 seconds

18 intermittent operation is not abnormal.

When the above status

occurs frequently, it is considered that the filter of suction part of the

15 rpm hold

+1 tap/20 seconds indoor unit is stain. Clean the filter and then restart the operation.

(The operation frequency differs according to the model type. The case of SM1101 is shown in the table below.)

Maximum

Temp. range

10°C < TO

5 < TO < 10°C

TO < 5°C

TO error

Below 33 Hz

W7

WA

WF

WF

Above 33 Hz below 51 Hz

W8

WB

WF

WF

Above 51 Hz

W9

WF

WF

WF

5. 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 slackness 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 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 the outdoor LED display.

4) Coil heating is controlled by TD and TE sensor.

5) For every model, the power is turned off when TD is 30°C or more.

(In trouble of TE sensor)

TO [˚C] TE [˚C]

Power-ON condition

TD < 30˚C

18

15

10

8

No power-ON

Continuous ON (L)

20

18

12

10

No power-ON

Continuous ON (L)

Continuous ON (M) Continuous ON (M)

* TO sensor is read in once per 15 minutes

(Object: SM561, SM801)

TE [˚C]

0

–1

–6

–7

No power-ON

Continuous ON (L)

Continuous ON (H)

L

M

SM1101, SM1401

20W and equivalent

40W and equivalent

L

H

SM561, SM801

10W and equivalent

30W and equivalent

– 26 –

NOTIFICATION

It is not an abnormal phenomenon that electro-noise may be heard while heating the coil.

6. Short intermittent operation preventive control

The compressor may not stop for preventing the compressor for 3 to 10 minutes after start of the operation even if Thermo-OFF signal has been received from the indoor. This phenomenon is not abnormal. (Continuous operation time of the compressor differs according to the operating status.)

If the equipment is stopped from the remote controller, the operation does not continue.

7. High-pressure suppression TE control (Only for SM1101, SM1401)

This control suppresses that voltage becomes abnormally higher during cooling operation.

Stop the compressor under condition of TE

≥

67°C, and count 1 on the error count.

After 2 minutes 30 seconds passed, if TE < 67°C, the compressor restarts and the error count is cleared when the operation continues for 10 minutes.

When TE

≥

67°C is detected again within 10 minutes, 1 is added to the error count and restart is repeated.

If the error counts 10 are recognized, it is determined as an error and restart is not performed. Error code ‘P04’ is displayed.

After restarting the compressor, continue controlling by using 70% to 90% of the control value of the current release control for minimum 30 minutes.

8. Over-current preventive control

This control function stops the compressor when over-current preventive circuit has detected an abnormal current.

The compressor restarts with error count 1 after 2 minutes 30 seconds.

If the error counts 8 are recognized, it is determined as an error and restart is not performed. Error code ‘H01’, ‘H02’ or ‘P26’ is displayed.

9. Current release value shift control (Cooling and Dry operation)

1) Object: SM1101, SM1401

This control function prevents troubles of the electron parts such as G-Tr of inverter of compressor drive system and troubles of the compressor during cooling operation.

This control function corrects the current release control value (

1

1) in item 7-2. by TO sensor value.

The value to be corrected is based upon the following control diagram and correction value table.

TO [˚C]

T+8

T+7

T+5

T+4

T+2

T+1

T

T-1

I

1 x a%

I 1 x b%

I

1 x c%

I

1 x d%

As

I

1

2) Object: SM561, SM801

The current release value of the models above are selected from the right table according to TO sensor value.

Corrected value

SM1101, SM1401

T a b c d

39°C 70% 80% 85% 90%

Current release value shift control

TO

45

≤

TO

40

≤

TO < 45

TO < 40

SM561

4.7

6.2

10.1

SM801

5.1

7.1

12.2

– 27 –

10. Defrost control

In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition in A zone to D zone.

The defrost operation is immediately finished if TE sensor temperature has become 12°C or more, or it also is finished when condition of 7°C

≤

TE < 12°C has continued for 1 minute. The defrost operation is also finished when defrost operation has continued for 10 minutes even if TE sensor temperature has become 7°C or lower.

After defrost operation has finished, the compressor and the outdoor fan start heating operation after stopped for approx. 50 seconds.

Start of heating operation

TE [ºC]

0

–4 (–5)

–6 (–10)

–10 (–13)

–25 (–18)

10 15 c b a d [min.]

*

Numerals enclosed with parentheses represent numeral values of SM1101 and SM1401.

* The minimum TE value between 10 and 15 minutes after heating operation has started is stored in memory as TE0.

A zone

B zone

C zone

D zone

Defrost operation is performed in this zone when TE0-TE

≥

3 continued for T seconds.

Defrost operation is performed in this zone when TE0-TE

≥

3 continued for T seconds.

Defrost operation is performed when this zone continued for T seconds.

Defrost operation is performed when this zone continued for T seconds.

a b c d

T

SM561, SM801

35

29

29

90

20

SM1101, SM1401

50

35

30

90

20

– 28 –

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

The following operations are normal.

a) Compressor does not operate.

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

• Does not thermostat turn off?

• Does not timer operate during fan operation?

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

• Is not Thermo-OFF setup by “Application Control Kit” (TCB-PCOS1E) sold separately?

b) Indoor fan does not rotate.

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

c) 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?

d) ON/OFF operation cannot be performed from remote controller.

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

• 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.)

Did you return the cabling to the initial positions?

Are connecting cables of indoor unit and remote controller correct?

3) Troubleshooting procedure

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

Trouble

→

Confirmation of check code display

→

Check defective position and 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.

– 29 –

<Wireless remote controller type> (Only for 4-way air discharge cassette type models)

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

The following operations are normal.

a) Compressor does not operate.

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

• Does not thermostat turn off?

• Does not timer operate during fan operation?

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

• Is not Thermo-OFF setup by “Application Control Kit” (TCB-PCOS1E) sold separately?

b) 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?

Did you return the cabling to the initial positions?

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 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.

– 30 –

8-2. Check Code List

Wireless sensor lamp display

Wired remote controller

Operation Timer Ready Check code

¥ l

¥

¥

¥

¥

¥

¥ l l l

¥ l

¥

¥ l

¡

¥

¥ l

¥ ¥ l l

¥

¥

¥

¥

¥

¥

¥

¥ l l

¥

¥ l l

¥

¥

¥

¥ l

¥

¥ l

¥

¥

¥ l l l l l l l

E03

E04

E08

L03

L07

L08

L09

L30

P01

P10

P12

P19

P31

F01

F02

F10

F29

E10

E18

Error mode detected by indoor unit

¥

: Flash,

¡

: Go on, l

: Go off

Diagnostic function

Cause of operation

Status of air conditioner

Condition

Judgment and measures

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

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

• Miswiring of inter-unit wires

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

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

Stop

(Automatic reset)

Stop

(Automatic reset)

Displayed when error is detected


1. Check cables of remote controller and communication adapters.

• Handy remote controller LCD display OFF (Disconnection)

• Central remote controller [97] check code

1. Outdoor unit does not completely operate.

• Inter-unit wire check, correction of miswiring, case thermo operation

• Outdoor P.C. board check, P.C. board wires check

2. In normal operation

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

Duplicated indoor unit addresses

Duplicated indoor master units

There is group line in individual indoor units.

Unsetting of indoor group address

Stop


1. Check whether there is modification of remote controller connection (Group/Individual) or not after power has been turned on (finish of group configuration/address check).

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

Unset indoor capacity

Abnormal outside interlock input

Fan motor thermal protection

Float switch operation

• Disconnection, coming-off, defective float switch contactor of float circuit

Indoor DC fan error

Error in 4-way valve system

• Indoor heat exchanger temperature lowered after start of heating operation.

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

Coming-off, disconnection or short of indoor heat exchanger sensor (TCJ)

Coming-off, disconnection or short of indoor heat exchanger sensor (TC)

Coming-off, disconnection or short of indoor heat exchanger sensor (TA)

Indoor EEPROM error

• EEPROM access error

Stop (Sub unit)

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)

Communication error between indoor MCU

• Communication error between fan driving MCU and main MCU

Regular communication error between master and sub indoor units or between main and sub indoor units

Stop

Stop

Stop

Stop

Stop

Stop

(Automatic reset)

Stop

(Automatic reset)

Stop

(Automatic reset)














1. Set the indoor capacity. (DN=I1)

1. Check outside devices.

2. Check indoor P.C. board.

1. Check thermal relay of fan motor.


1. Defect of drain pump

2. Clogging of drain pump

3. Check float switch.


1. Defective detection of position

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

3. Lock of indoor fan


1. Check 4-way valve.

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


1. Judge sub unit while master unit is in [E03], [L03], [L07], [L08].


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


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


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


1. Check indoor EEPROM. (including socket insertion)


1. Check wires of remote controller.

2. Check power wires of indoor unit.


1. Check wires of remote controller.

2. Check indoor power wire.


Error mode detected by outdoor unit

¥

¥

¥

¥

¥



Operation Timer Ready Check code

l l l

¥

¥

¥

¥

¥

¥

¥

¥

¡

¡ l l l l l l

¥

¥

¥

¥

¥ l

¥ l

¥

¥ ¡

¥

¥

¡

¡

H01

H02

H03

L29

L31

P03

P04

P22

P26

P29

F04

F06

F08

¥

: Flash,

¡

: Go on, l

: Go off




Condition


Breakdown of compressor

• Displayed when error is detected

Compressor does not rotate.

• Over-current protective circuit operates after specified time passed when compressor had been activated.

Current detection circuit error

• Current value at AC side is high even during compressor-OFF.

• Phase of power supply is missed.

Outdoor unit and other errors

• Communication error between CDB and IPDU

(Coming-off of connector)

• Heat sink temperature error

(Detection of temperature over specified value)

Phase detection protective circuit operates. (Normal models)

Discharge temperature error

• Discharge temperature over specified value was detected.

High-pressure protection error by TE sensor

(Temperature over specified value was detected.)

Outdoor DC fan error

Inverter over-current protective circuit operates. (For a short time)

Short voltage of main circuit operates.

IPDU position detection circuit error

Coming-off, disconnection or short of outdoor temperature sensor (TD)

Coming-off, disconnection or short of outdoor temperature sensor (TE/TS)

Coming-off, disconnection or short of outdoor temperature sensor (TO)

Stop

Stop

Stop

Stop





1. Check power voltage. AC200V ± 20V

2. Overload operation of refrigerating cycle

3. Check current detection circuit at AC side.

1. Trouble of compressor (Compressor lock, etc.) : Replace compressor.

2. Defective wiring of compressor (Phase missing)

3. Phase-missing operation of power supply (3-phase model)

1. Compressor immediately stops even if restarted. : Check IPDU.

2. Phase-missing operation of power supply

Check 3-phase power voltage and wires.

1. Check wires of CDB and IPDU.

2. Abnormal overload operation of refrigerating cycle

Operation continues.

(Compressor stops.)

Stop

Stop

Stop

Stop

Stop

Stop

Stop











1. Check power phase order (Reversed phase)/phase missing.

2. Check outdoor P.C. board.

1. Check refrigerating cycle. (Gas leak)

2. Trouble of PMV

3. Check Td sensor.


2. Check outdoor temperature sensor (TE).

3. Check outdoor CDB P.C. board.

1. Defective detection of position

2. Over-current protective circuit of outdoor fan driving unit operates.

3. Lock of outdoor fan


1. Inverter immediately stops even if restarted. : Compressor motor rare short

2. Check IPDU. : Cabling error

1. Position detection circuit operates even if operating compressor by removing 3P connector. : Replace IPDU.

1. Check outdoor temperature sensor (TD).


1. Check outdoor temperature sensor (TE/TS).


1. Check outdoor temperature sensor (TO).


For an error mode detected in outdoor unit, the fan operates because sub unit of a group operation does not communicate with the outdoor unit.

Error mode detected by remote controller or network adapter


Operation Timer Ready

—

¥

¥

¥

¥

—

—

—

— l l l

¡

—

—

—

— l l l

¥

—

—

—

¥

: Flash,

¡

: Go on, l

: Go off


Check code

No check code is displayed.

(Remote controller does not operate.)

E01*2

E02


No communication with master indoor unit

• Power of indoor unit is not turned on.

• Automatic address cannot be completed.

No communication with indoor master unit

Signal sending error to indoor unit

(Detected at remote controller side)


• Remote controller wire is not correctly connected.

• Disconnection of inter-unit wire between remote controller and master indoor unit (Detected at remote controller side)

E09

Multiple master remote controllers are recognized.

(Detected at remote controller side)

L20

Central remote controller

98

—

*3


99

—

*3


97

—

Central remote controller b7

Duplicated indoor central addresses on communication of central control system (AI-NET)

(Detected by central controller side)

Multiple network adapters on remote controller communication line


Interruption of central control system (AI-NET) communication circuit


Indoor Gr sub unit error (Detected by central controller side)


Condition


Stop

Stop

(Automatic restart)

• When there is center, operation continues.

—


Remote controller power error, Defective indoor EEPROM

1. Check remote controller inter-unit wires.

2. Check remote controller.

3. Check indoor power wires.


5. Check indoor EEPROM. (including socket insertion)

: Phenomenon of automatic address repetition occurred.

Signal receiving of remote controller is defective.

1. Check remote controller inter-unit wires.

2. Check remote controller.

3. Check indoor power wires.


Stop

(Automatic restart)

• When there is center, operation continues.

Stop

(Sub unit continues operation.)



Signal sending of remote controller is defective.

1. Check sending circuit inside of remote controller.

: Replace remote controller.

1. Check there are multiple master units for 2 remote controllers

(including wireless).

: Master unit is one and others are sub units.

Stop

(Automatic restart)



(According to handy remote controller)

Continuation/stop

(Based on a case)





1. Check address setup of central control system network.

(Network adapter SW01)

2. Check network adapter P.C. board.

1. Check multiple network adapters.

2. Check inter-unit wire/miswiring of remote controller.

: Only one network adapter on remote controller communication line

1. Check communication line/miswiring. Check power of indoor unit.

2. Check communication. (XY terminals)

3. Check network adapter P.C. board.

4. Check central controller (such as central control remote controller, etc.).

Check the check code of corresponding unit by handy remote controller.

*2 Check code is not displayed by wired remote controller. (Usual operation of air conditioner is disabled.)

For wireless type models, E01 is notified by the display lamp.

*3 These errors are related to communication of remote controllers (A, B) and central system (AI-NET, X, Y), and [E01], [E02], [E03], [E09], or [E18] is displayed or no check code is displayed on the remote controller according to the error contents.

8-3. Error Mode Judgment by LED Display of Outdoor Unit

There provided Dip switch (SW801) and LED on the “Application Control Kit” (TCB-PCOS1E) sold separately for

SM56 and SM80 models, and on the outdoor unit P.C. board for SM110 and SM140 models respectively.

The status of the outdoor unit at that time can be known by switching this Dip switch. The lighting status of LED also notifies the judged stage before the outdoor error has been determined and displayed on the remote controller. An error of the outdoor temp. sensor (TO) may be confirmed only by LED display according to the indoor unit to be combined.

Model

SM56, 80

*

SM110, 140

(MCC-1531)

Dip SW

SW01

SW802

D01 (Red) D02 (Yellow)

LED

D03 (Yellow) D04 (Yellow)

D800 (Red) D801 (Yellow) D802 (Yellow) D803 (Yellow)

Bit 1 Bit 2

For error display, refer to

(Table A) on the next page.

OFF

ON

OFF

OFF

OFF

ON

² l

During timer short l l

During pump down operation

²

Protective operation count

In normal time, Count 1

Count 2, Count 3

Count 4, Count 5

Count 6, Count 7

Protective operation

² l

¡

² ²

PMV opening data (Lower 4 bit data) l

²

During backup control

¥

Add 16 pulses Add 8 pulses Add 4 pulses Add 2 pulses if this LED goes on.

if this LED goes on.



PMV opening data (Upper 4 bit data)

Add 256 pulses Add 128 pulses Add 64 pulses Add 32 pulses if this LED goes on.




ON ON

The total pulse counts equivalent to lighting LED at each position represents PMV opening degree. For example, the case of

¡

ll

4 bit) represents 256 + 32 + 4 + 2 = 294 pulses.

¡

ll

¡¡

(Upper 4 bit, Lower

¡

: Go on l

: Go off

²

: 1Hz-flash

¥

: 5Hz-flash

*

For Models ROA-AP40 to AP80, the error mode judgment by the above LED display is available under condition which “Application Control Kit” (TCB-PCOS1E) sold separately is connected.

(Note)

Never touch part other than Dip switch of “Application Control Kit” (TCB-PCOS1E).

AC230V is applied to all the electronic products, so an electric shock may be caused.

– 34 –

8-4. Contents of Error Display

• When multiple errors are detected, the latest error is displayed.

• When LED display is

¡

(Go on), there is the main cause of trouble on the objective part of control at CDB side and the unit stops.

• When LED display is

¥

(Flash), there is the main cause of trouble on the objective part of control at IPDU side and the unit stops.

• When case thermostat operates, the communication is interrupted on the serial circuit. If continuing the case thermostat operation, a serial communication error occurs because serial sending to the indoor unit is interrupted.

Check code

No.

Item

3

4

1

2

5

6

7

8

9

10

11

12

13

14

15

16

17

TE sensor error

TD sensor error

TS sensor error

TO sensor error

Discharge temp. error

DC outdoor fan error

Communication error between IPDU

(with system suspended)

High-pressure release operation

Case thermo operation

EEPROM error


(without system suspended)

G-Tr short-circuit protection

Detection circuit error

Current sensor error

Comp. lock error

Comp. breakdown

TH sensor error

¡

: Go on l

: Go off

¥

: Flash (5Hz)

Type A

F06

F04

F06

F08

P03

P22

P26

P29

H03

H02

H01

L29

L29

P04

E04

—

—

Type B

18

19

18

1B

1E

1A

14

16

17

1D

1F

1C

1C

21

04

—

—

D800

(Red)

¡

¡ l l l

¡

¡ l l

¡ l

¥ l

¥ l

¥

¥

LED display

D801

(Yellow)

l

¡ l

¡

¡

¡ l

¡

¡

¡ l l

¥

¥ l l

¥

D803

(Yellow)

l l l l l l

¡

¡

¡

¡

¡ l l l l l l

D802

(Yellow)

l l

¡ l

¡

¡ l l l l

¡ l l l

¥

¥

¥

<<Check code>>

The check codes are classified into Type A and Type B according to the used remote controller. Be sure to check the remote controller which you use.

Type A :

Neutral 2-cores type wired remote controller such as RBC-AMT21E, RBC-AS21E, and wireless remote controller kit such as TCB-AX21U (W)-E

Type B :

Polarized 3-cores type wired remote controller such as RBC-SR1-PE, RBC-SR2-PE, and central control remote controller such as RBC-CR64-PE

– 35 –

8-5. Troubleshooting Procedure for Each Check Code

8-5-1. New Check Code/Present Check Code (Central Control Side)

[E01 error]/

*

[99 error]

*

: When central controller [99] is displayed, there are other causes of error.

Is inter-unit cable of A and B normal?

YES

NO

Is there no disconnection or contact error of connector on harness from terminal block of indoor unit?

NO

YES

NO

Is group control operation?

YES

Is power of all indoor units turned on?

YES

NO

Correct inter-unit cable of remote controller.

Correct connection of connector.

Check circuit cables.

Check power connection of indoor unit.

(Turn on power again.)

Is power supplied to remote controller?

AB terminal: Approx. DC18V

YES

NO

YES

Are two remote controllers set without header unit?

NO

Check indoor P.C. board.

Defect

®

Replace

Correct as a master unit/a sub unit

(Remote controller address connector)

Check remote controller P.C. board.

Defect

®

Replace

[E09 error]/

*

[99 error]

*

: When central controller [99] is displayed, there are other causes of error.

YES

Are two remote controllers set without header unit?

NO

Correct as a header unit/a follower unit

(Remote controller address connector)

Check remote controller P.C. board.

Defect

®

Replace

– 36 –

[E04 error]/[04 error]

Does outdoor unit operate?

YES

NO

NO

Is setup of group address correct?

YES

Are 1, 2, 3 inter-unit wires normal?

YES

NO

Check item code [14].

Correct inter-unit wire.

Are connections from connectors of inter-terminal blocks (1, 2, 3) of indoor/outdoor units normal?

YES

NO


Does voltage between

2 and 3 of inter-terminal blocks (1, 2, 3) of indoor unit vary?*

YES

NO


Defect

®

Replace

*

As shown in the following figure, perform measurement within

20 seconds after power ON.

S5277G

Black 3

White

2

1

Inter-terminal block

For SM56, SM80 main circuit on control

P.C. board

NO Is DC280V applied between terminals of electrolytic capacitor of IPDU main circuit?

YES

For SM56, SM80, check case thermo.

Replace IPDU.

Check indoor P.C. board .

Defect

®

Replace

Check CDB.

Defect

®

Replace

NO

Is DC7V power supplied to CDB?

Are cablings between Pin 2 and Pin 5 of CN800 and between IPDU and CDB normal?

YES

NO

NO

Is case thermo (CN500) connected?

YES

Does case thermo operate?

YES

Check/Correct charged refrigerant amount.

Replace IPDU.



– 37 –

[E10 error]/[CF error]

Check indoor control P.C. board.

Defect

®

Replace

[E18 error]/[97 error]

*

[99 error]

*

: When central controller [99] is displayed, there are other causes of trouble.

NO

Is inter-unit wire of A and B normal?

Correct inter-unit wire of remote controller.

YES

Is there no disconnection or contact error of connector on harness from terminal block of indoor unit?

NO

YES

YES

Is group control operation?

NO


Check circuit wires.

Is power of all indoor units turned on?

YES

NO

NO


Defect

®

Replace

Is Twin connection control?

YES

YES

Is there no contact error between indoor/outdoor inter-unit wires (signal lines)?

NO

Correct indoor/outdoor inter-unit wires

(serial signal lines).

Check power connection of indoor unit.

(Turn on power again.)

[E08, L03, L07, L08 error]/

*

[96 error] [99 error]

*

: When central controller [99] is displayed, there are other causes of trouble.

E08 : Duplicated indoor unit numbers

L03 : Two or more header units in a group control

L07 : One or more group addresses of [Individual] in a group control

L08 : Unset indoor group address (99)

If the above is detected when power has been turned on, the mode automatically enters in automatic address setup mode. (Check code is not displayed.)

However, if the above is detected during automatic address setup mode, the check code may be displayed.

[L09 error]/[46 error]

Is capacity of indoor unit unset?

NO

YES

Set capacity data of indoor unit.

(Setup item code (DN) = 11)


Defect

®

Replace

– 38 –

[L20 error]/[98 error]

Are wire connections to communication line X, Y normal?

YES

Is central controller [98] displayed?

YES

Is indoor remote controller

[L20] displayed?

YES

Are not multiple same central control network addresses connected?

NO

NO

NO

YES

Check central controller

(including network adapter).

Defect

®

Replace.

[L30 error]/[B6 error]

Are outside devices of connector CN80 connected?

YES

NO

Do outside devices normally operate?

YES

NO

Check operation cause.

[b7 error] (Central controller)

NO

Is group operation performed?

YES

Is check code displayed on follower unit of header or follower remote controller?

YES

NO

Check corresponding indoor/outdoor units.

– 39 –

Correct wire connection


Defect

®

Replace

Correct central control network address.


Defect

®

Replace

Check outside devices.

Defect

®

Replace


Defect

®

Replace

[P01 error]/[11 error]

Is there no connection error/disconnection of CN076 connector?

NO

Is capacitor normal?

YES

Is there no mechanical lock of fan motor?

NO

YES

NO

YES

Correct connector connection/wire circuit.

Replace capacitor.

Replace fan motor


Defect

®

Replace

[P10 error]/[Ob error]

Is connection of float switch connector

(Indoor control P.C. board CH34) normal?

YES

NO

Does float switch operate?

NO

YES

Is circuit cabling normal?

YES


NO

Does drain pump operate?

YES

Is power of drain pump turned on?

YES

NO

Check drain pipe, etc.

Replace drain pump.

Check cabling.

NO

Check and correct cabling/wiring.


Defect

®

Replace


Defect

®

Replace

[F10 error] [0C error]

Is connection of TA sensor connector

(indoor P.C. board CN104) normal?

YES

Are characteristics of TA sensor resistance value normal?

YES


Defect

®

Replace

NO

NO

* Refer to Characteristics-1.

– 40 –


Replace TA sensor.


Turn off the power.

Are not there connections errors or disconnection on connectors CN333 and CN334 of indoor unit P.C. board?

NO

YES

Remove connectors CN333 and

CN334 of indoor unit P.C. board.


Does the fan rotate without trouble when handling the fan with hands?

YES

Are resistance values between phases at fan motor connector CN333 motor side of indoor P.C. board correct? *1

YES

Is resistance value of fan motor connector CN333 at motor side of indoor P.C. board correct? *2

YES

Is signal output of indoor fan motor position detection correct? *3

YES

NO

NO

Replace indoor fan motor.


*

1

• Are not coil windings between (Red lead) and (White lead), between

3

(White lead) and (Black lead), between

(Black lead) and (Red lead) opened or shorted?

®

For resistance, see the following values.

RAV-SM56

RAV-SM110

*

*

, SM80

*

UT

®

Approx. 70 to 100

W

, SM140

*

UT

®

Approx. 35 to 50

W

• Is not earthed between cabinet and 1, 3, 5

®

10M

W

or more

NO


*

2

Check resistance of fan motor position detection circuit.

Is not coil winding between (Yellow lead) and (Pink lead) opened or shorted?

®

Resistance: Approx. 5 to 20k

W

NO


*

3

Check fan motor position detection signal.

indoor P.C. board (MCC-1402) under condition that CN333 and

CN334 are mounted and the power is turned on.

®

Rotate the fan slowly with hands, and check the pin voltage swings between 0 to 5V voltage.

CN333


Defect

®

Replace

CN334

– 41 –

[P22 error]/[1A error]

In case of RAS-SM56, SM80

Is connection of CN300 of P.C. board normal?

YES

Does fan rotate by hands without trouble when removing CN300 from P.C. board?

YES

Are 18 to 30

W

applied for the resistance between

1

(Red lead) and

2

(White lead)

2

(White lead) and

3

(Black lead)

3

(Black lead) and

1

(Red lead) of connector CN300 (Motor winding) at motor side?

YES

Fan motor – Normal

(Control (Main) P.C. board error)

NO

NO

NO

Fan motor – Error


Fan motor winding connector

CN300 (AP40

*

CN301 (AP140

*

to AP80

*

)

, AP160

*

)


Are connections of CN300 and

CN301 of P.C. board normal?

YES

Does fan rotate by hands without trouble when removing CN300 and CN301 from P.C. board?

YES

Are 12 to 22

W


1

(Red lead) and

2

(White lead)

2

(White lead) and

3

(Black lead)

3

(Black lead) and

1

(Red lead) of connector CN301 (Motor winding) at motor side?

Are 10k to 12 k

W


1 (Yellow lead) and 4 (Pink lead) of connector CN300 (Connector for detection motor position) at motor side?

YES

NO

NO

Connector for detection of motor position

CN300 (AP140

*

, AP160

*

)

Fan motor – Normal Fan motor – Error


(Control (Main) P.C. board error)

NOTE)

However, GND circuit error inside of the motor is rarely detected as OK by the above check.

When GND circuit does nor become normal even if P.C. board has been replaced, replace the outdoor fan motor.

Objective P.C. board

Fan motor winding connector

Motor position detection connector

Fan motor name

Fan motor winding resistance value

SM56 SM80

Control (Main) P.C. board

MCC-5009

Control (Main) P.C. board

CN300

MCC-1513

No connector for position detection

ICF-140-43

18 to 30

W

SM110, SM140

CDB P.C. board

MCC-1531

CN301

CN300

ICF-280-100

12 to 22

W

– 42 –


In case of SM56, SM80

Is 230V applied to terminal of 4-way valve coil in heating operation?

YES

NO

Check 4-way valve.

Defect

®

Replace

Is operation of

4-way valve normal?

YES

NO

Outdoor P.C. board error

®

Replace

Is flow of P.M.V. normal?

NO

YES

In case of SM110, SM140

Is there continuity to coil of 4-way valve?

YES

NO

4-way valve coil

Defect

®

Replace

Is 230V applied to terminal of 4-way valve coil in heating operation?

NO

YES

Check 4-way valve.

Defect

®

Replace

Check and replace P.M.V.

NO Are characteristics of TC sensor resistance value normal?


YES

Is wiring normal?

Especially wiring connection of

( ) of IPDU P.C. board (Red leads)

YES

Check CDB P.C. board.

NO

No problem

NO

Check wiring.

Correct

Check CDB P.C. board.

Defect

®

Replace


Defect

®

Replace

Replace TC sensor.

• In cooling operation, if high pressure is abnormally raised, [P19 error]/[08 error] may be displayed. In this case, remove cause of pressure up and then check again referring to the item [P04 error]/[21 error].

[F02 error]/[0d error]

Is connection of TC sensor connector

(Indoor P.C. board CN101) normal?

YES

NO

Are characteristics of

TC sensor resistance value normal?

YES

NO



Defect

®

Replace

– 43 –


Replace TC sensor.

[F01 error]/[0F error]

Is connection of TCJ sensor connector

(Indoor P.C. board CN102) normal?

YES

NO


TCJ sensor resistance value normal?

YES

NO



Defect

®

Replace


Replace TCJ sensor.


NO

Is power voltage normal?

YES

Are connections of wiring/connector normal?

YES

NO

Are not “14” errors output when an operation is performed by removing 3P connector of compressor?

YES

NO

NO

Is compressor normal?

YES

Check IPDU.

Defect

®

Replace

* Replace control P.C. board of SM56, SM80.

Improve the power supply line.

Check and correct circuit wires.


Check and correct reactor connection.

Replace IPDU.

* Replace control P.C. board of SM56, SM80.

Check rare short of compressor trouble.

Defect

®

Replace

– 44 –


Are connections of wire/connector normal?

YES

NO

NO


YES

YES

Is not earthed?

NO

Is not winding shorted?

(Is resistance between windings 0.6 to 1.2

W

?)

NO

YES

YES

Is not winding opened?

NO

Check and correct circuit wiring such as wiring to compressor.

Compressor trouble

Compressor trouble

Compressor trouble

®

®

®

Replace

Replace

Replace

Check IPDU P.C. board.

Defect

®

Replace

* For SM56, SM80, replace control P.C. board.

[H03 error]/[17 error]

Are wirings of power and current sensor normal?

YES

Check IPDU.

Defect

®

Replace

NO


Check and correct circuit wires.

– 45 –

[F06 error]/[18 error]

Are connections of

TE/TS sensor connectors of

CDB CN604/CN605 normal?

YES

NO


Are characteristics of TE/TS sensor resistance values normal?

YES

* (For SM56, SM80, CN600 TE sensor and CN603 TS sensor)

NO

Replace TE and TS sensors.

Check CDB.

Defect

®

Replace



[F04 error]/[19 error]

Is connection of TD sensor connector of CDB CN600 normal?

YES

NO

* (For SM56, SM80, CN601 TD sensor)

NO

Are characteristics of TD sensor resistance value normal?

YES

Check control P.C. board.

Defect

®

Replace




Replace TD sensor.

[F08 error]/[1b error]

Is connection of TO sensor connector of CDB CN601 normal?

YES

NO

* (For SM56, SM80, CN602 TO sensor)

NO

Are characteristics of TO sensor resistance value normal?

YES

Check CDB.

Defect

®

Replace




Replace TO sensor.

– 46 –

[L29 error]/[1C error]


Is power supply voltage normal?

YES


YES

NO

NO

Modify power supply line.

Check compressor error and rear short.

Defect

®

Replace

Check outdoor control P.C. board.

Defect

®

Replace


Are connections of

CDB CN800 and CDB IPDU CN06 connectors normal?

YES

NO

YES

Was the error just after power ON determined?

NO

Are cabling/connector normal?

YES

NO


Check cabling between IPDU and CDB and connector.

IPDU P.C. board error

Defect

®

Replace

YES

Is there no abnormal overload?

NO

Is IPDU P.C. board come to closely contact with heat sink?

YES

NO

Improve and eliminate the cause.

Correct mounting.

IPDU P.C. board error

Defect

®

Replace

[H02 error]/[1d error]


YES

NO

NO


YES

NO


YES

Improve power line.

Check and correct circuit wiring such as cabling to compressor

(phase missing) and connector.

Compressor lock

®

Replace

Is there no slackened refrigerant?

YES

Does P.M.V.

normally operate?

YES

Check IPDU and CDB.

Defect

®

Replace

NO

NO

Check TE and TS sensors.

®

Replace

Check P.M.V.

®

Replace


– 47 –

[P03 error]/[1E error]

Is protective control such as discharge temprelease control normal?

YES

NO


YES

NO

Correct the wiring and connection of connector.

Check parts.

Defect

®

Replace

Is charged refrigerant amount normal?

YES

NO

YES

Is not abnormal overload?

NO


TD sensor resistance value normal?

YES

NO


Check and correct the charged refrigerant amount.

Improve and delete the cause

Replace TD sensor.

Check CDB.

Defect

®

Replace


[H01 error]/[1F error]


YES

Is not abnormal overload?

YES

NO

YES

Improve power line.

Improve and delete the cause.

Check IPDU.

Defect

®

Replace


– 48 –


Is high-voltage protective operation by

TE sensor normal?

YES

NO

Is connection of wiring connector normal?

YES

NO

Correct connection of wiring connector.

Check TE sensor.

Defect

®

Replace

Does cooling outdoor fan normally operate?

YES

NO

Is connection of connector normal?

YES

NO


NO

Check TE, TC, TS sensors.

Replace P.M.V.

NO

Does PMV normally operate?

YES

Is fan motor normal?

YES

Do not TD and TO sensors come off the detection part?

YES

NO

Replace fan motor.

Correct coming-off.


TD, TO, TC sensor resistance values normal?

YES

NO

Replace TD, TO, and TC sensors.

* Refer to Characteristics-3 and 4.

Check charged refrigerant amount.

Check liquid/gas valves.

Check abnormal overload.

Check CDB.

Defect

®

Replace


– 49 –

[97 error] (Central controller)

NO

Is X, Y communication line normal?

YES

Correct communication line.

Are connections between connectors

CN02, CN03 of network adapter P.C. board and connectors CN309, CN41 of indoor P.C. board normal?

YES

NO

NO

Is A, B communication line normal?

YES

YES

Is there no connection error of power line?

NO

YES

Is not power of source power supply turned on?

NO

YES

Did a power failure occur?

NO

Is the network address changed form remote controller?

NO

YES

YES

Is there no noise source, etc.?

NO

Can central remote controller control normally other indoor units?

Is handling of central remote controller reflected on the operation status of indoor unit?

YES

NO

(Same as others)


Check connections of A, B terminal blocks.

Correct communication line of remote controller.

Correct power cable.

Turn on the source power supply.

Clear the check code.

Eliminate noise, etc.

Check central controller.

Defect

®

Replace

Does network adapter P.C. board

LED (D01) go on?

YES

NO

Can handy remote controller control normally other indoor units?

YES

NO

Check network adapter P.C. board and power transformer.

Defect

®

Replace


Defect

®

Replace

– 50 –

[E03 error] (Master indoor unit)

[E03 error] is detected when the indoor unit cannot receive a signal sent from the main remote controller (and central controller).

In this case, check the communication cables of the remote controllers A and B, the central control system X and Y. As communication is disabled, [E03] is not displayed on the main remote controller and the central controller. [E01] is displayed on the main remote controller and [97 error] on the central controller, respectively.

If [E03] occurs during an operation, the air conditioner stops.

[F29 error] / [12 error]

[F29 error] or [12 error] indicates detection of trouble which occurred on IC10 non-volatile memory (EEPROM) on the indoor unit P.C. board during operation of the air conditioner. Replace the service P.C. board.

* If EEPROM has not been inserted when the power was turned on or if EEPROM data never be read/written, the automatic address mode is repeated. In this time, the central controller displays [97 error].

(Power ON)

(Approx. 3 minutes)

[SET] is displayed on main remote controller.

(Approx. 1 minute)

[SET] goes off.

LED (D02) on indoor unit P.C. board flashes with 1Hz for approx. 10 seconds.

(Repetition)

Reboot

(Reset)

[P31 error] (Sub indoor unit)

When the master unit of a group operation has detected [E03], [L03], [L07], or [L08] error, the sub unit of the group operation detects [P31 error] and then it stops. There is no display of the check code or alarm history of the main remote controller.

(In this model, the mode enters in automatic address set mode when the master unit has detected [E03], [L03],

[L07], or [L08] error.)

– 51 –

8-4-2. Relational Graph of Temperature Sensor Resistance Value and Temperature

Resistance

(k )

10

20

0

10 20

40

TA sensor

Caracteristics-1

30

Resistance

(k )

20

30 40

Temperature [˚C]

50

TC, TCJ sensor


10

0

–10 0 10 20 30 40 50 60 70

Temperature [˚C]

20

TE, TO, TS sensor

200


Resistance

(k )

(10˚C or lower)

100

Resistance

(k )

(10˚C or higher)

10

0

200

-10 0 10 20 30 40

Temperature [˚C]

50 60 70

0

TD sensor


Resistance

(k )

(50˚C or lower)

100

20

Resistance

(k )

(50˚C or higher)

10

0

0

50

Temperature [˚C]

100

– 52 –

8-4-3. Troubleshooting with CHECK Display of Central Remote Controller

1. Operation for CHECK display

When pushing the CHECK switch, the indoor unit No. (Network address No.) including the check data is displayed in the UNIT No. display section, and the check code is displayed in the set up temp. display section.

ON

MONITOR

SET

ZONE

ALL UNIT

ON

OFF

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

CENTER

LOCKED

MODE

FAN ONLY

COOL

DRY

HEAT

AUTO

AUX. TYPE

TIMER No.

FAN

AUTO

HIGH

MED.

LOW

FIX

TEMP.

1

2

LOUVER

MANUAL

STANDBY

FILTER

CHECK

˚C

MONITOR/SET ALL/ZONE ZONE UNIT ON CENTER/LOCKED MODE TEMP.

FILTER RESET CHECK

ZONE SET/ENTER SELECT OFF TIMER ON FAN LOUVER

CHECK switch

Push for 0.5 seconds to display CHECK code.

Push for 3 seconds to reset indoor microprocessor.

(While indoor microprocessor is locked by ALL STOP alarm)

Push for 10 seconds to clear check data.

RESET switch

Push the switch in the hole with pin.

The remote controller resets initialized.

(All data is cleared.)

2. Reading of CHECK monitor display

<7 segment display>

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Hexadecimal notation

Decimal notation

<Display on CHECK monitor>

Unit line No. (Network address No.)

MONITOR

SET

1

ZONE

ALL UNIT

ON

OFF

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

CENTER

LOCKED

MODE

FAN ONLY

COOL

DRY

HEAT

AUTO

AUX. TYPE

TIMER No.

FAN

AUTO

HIGH

MED.

LOW

FIX

TEMP.

1

2

LOUVER

MANUAL

STANDBY

FILTER

CHECK

˚C

Check code detected at first

Check code detected at last

(Example)

There is no check data.

UNIT

TEMP.

CHECK

<CHECK data>

(Example)

In No.1 unit, first the interconnection wire (bus communication line) of indoor/outdoor has failed.

Next, the room temp. sensor is defective.

For No.16 unit, the high pressure switch at the inverter unit side operates.

UNIT UNIT UNIT

TEMP.

CHECK

1

TEMP.

CHECK

2

TEMP.

CHECK

1

– 53 –

8-4-4. Check Code Table

Block display

[MODE]

[TIMER] lamp

5Hz flash

[MODE] lamp

5Hz flash

Check code A

Error mode detected by indoor unit (1)

Operation of diagnostic function

Check code B


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

• Miswiring of inter-unit wires

• Defective serial sending circuit on outdoor P.C.

board

• Defective serial receiving circuit on outdoor P.C.

board

• Compressor case thermo operation


Operation continues

Condition



1. Outdoor unit does not completely operate.

• Inter-unit wire check, correction of miswiring

• Outdoor P.C. board check, P.C.

board wires check

• Compressor case thermo check


When outdoor sending serial LED

(Green) flashes, the receiving serial

LED (Orange) also flashes. : Indoor

P.C. board (Main P.C. board) check

When the receiving serial LED

(Orange) does not flash: Outdoor

P.C. board check

*

BUS communication circuit error

* BUS communication was interrupted over the specified time.

Network address miss-setting

• Addresses of central controllers (Central control remote controller, etc.) are duplicated.

Operation continues

(According to remote controller of indoor unit)


1. Communication line check, miswiring check

Power supply check for central controller (Central control remote controller, etc.) and indoor unit

2. Communication check (XY terminal)

3. Indoor P.C. board check

4. Central controller check

(Communication P.C. board)

Operation continues


1. Check central control system network address setting. (SW02)

2. Indoor P.C. board check

3. Central controller check

(Communication P.C. board)

Error in 4-way valve system

• Indoor heat exchanger temperature rise after start of cooling operation.

• Indoor heat exchanger temperature fall after start of heating operation.

Error in other cycles

• Indoor heat exchanger temp (TC) does not vary after start of cooling/heating operation.

Operation continues

Operation continues


1. Check 4-way valve.

2. Check 2-way valve and non-return valve.

3. Check indoor heat exchanger sensor (TC).

4. Check indoor P.C. board

(Main P.C. board).


1. Compressor case thermo operation

2. Coming-off of detection part of indoor heat exchanger sensor

3. Check indoor heat exchanger sensor (TC).


(Main P.C. board).

Coming-off, disconnection or short of indoor temp sensor

(TA)


(TC)


(TCJ)

Operation continues

Operation continues

Operation continues


1. Check indoor temp sensor (TA).


(Main P.C. board).


1. Check indoor temp sensor (TC).


(Main P.C. board).


1. Check indoor temp sensor (TCJ).


(Main P.C. board).

*

: No display in the setting at shipment

– 54 –

Block display

[MODE] lamp

5Hz flash

Check code A



Check code B



Error in indoor fan system

Revolutions frequency error of fan

All stop

Condition



1. Check indoor fan motor connector circuit (CN210).

2. Check indoor fan.

Error in indoor unit or other positions

1. EEPROM access error

Operation continues

3. Check indoor P.C. board (Main P.C.

board).



(EEPROM and peripheral circuits)

(Main P.C. board).

Outside error input

Detected by input voltage level from outside devices

Operation continues

Outside interlock input

Detected by input voltage level from outside devices

All stop




(Main P.C. board).




(Main P.C. board).


Check code




Serial return signal is not sent from

No. 1 indoor unit to remote controller.

• Miswiring of inter-unit wire between remote controller and indoor unit

• Miss-setting of indoor unit No.

(Group address)

ON/OFF

Condition



1. Indoor unit does not completely operate.

• Check inter-unit wire.

• Check indoor P.C. board. (Main/Sub P.C. boards)

• Check remote controller.


• Check setting of indoor unit No.

(SW01) (Sub P.C. board)

• Check remote controller.

– 55 –

Check code A

Error mode detected by outdoor unit (3)

Check code B



Inverter over-current protective circuit operates. (For a short time)


Condition


All stop Displayed when error is detected

1. Inverter immediately stops even if restarted.

• Compressor rare short

2. Check IPDU.

• Cabling error

Error on current detection circuit

• Current value is high at AC side even while compressor stops.

• Phase of power supply is missed.

Coming-off, disconnection or short of outdoor temp sensor


1. Compressor immediately stops even if restarted.

: Check IPDU.

2. Phase-missing operation of power supply

• Check power voltage of R, S, T.


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

2. Check CDB.

Coming-off, disconnection or short of outdoor temp sensor


1. Check outdoor temp sensor (TD).

2. Check CDB.

Compressor drive output error

• Tin thermistor temp, Tin error

(IPDU heat sink temp. is high.)


• Connector coming-off between

CDB and IPDU

Compressor does not rotate.

(Over-current protective circuit works when constant time passed after activation of compressor.)

Discharge temp error

• Discharge temp over specified value was detected.

Compressor breakdown

• Operation frequency lowered and stops though operation had started.


1. Abnormal overload operation of refrigerating cycle

2. Loosening of screws and contact error of

IPDU and heat sink

3. Cooling error of heat sink

4. Check wiring of CDB and IPDU.


1. Compressor error (Compressor lock, etc.)

: Replace compressor.

2. Wiring trouble of compressor (Phase missing)


1. Check refrigerating cycle. (Gas leak)

2. Error of electron control valve

3. Check pipe sensor (TD).


1. Check power voltage. (AC200V ± 20V)


3. Check current detection circuit at AC side.



2. Check outdoor temp sensor (TE).

High-voltage protection error by TE sensor

• TE temp over specified value was detected.

DC outdoor fan motor error

• IDC operation or lock was detected by DC outdoor fan driving.

Error on IPDU position detection circuit

Coming-off, disconnection or short of outdoor temp. sensor


1. Position detection error

2. Over-current protection circuit operation of outdoor fan drive unit

• Check CDB.

• Refer to Judgment of outdoor fan.


1. Position detection circuit operates even if driving by removing 3P connector of compressor.

• Replace IPDU.

Operation continues


1. Check outdoor temp sensor (TO).

2. Check P.C. board.

– 56 –

8-5. Other Function

1. Recovery method of refrigerant


• When recovering refrigerant in case of reinstallation of the indoor or outdoor unit, etc., use the refrigerant recovery switch on the terminal block of the outdoor unit.

<Work procedure>

1. Turn on the power supply.

2. Using the remote controller, set FAN operation to the indoor unit.

3. Pushing the refrigerant recovery switch on the terminal block of the outdoor unit starts the forced cooling operation. (Max. 10 minutes), and then the refrigerant is recovered by operation of the valve.

4. After recovery of the refrigerant, push the refrigerant recovery switch together with closing the valve. The operation stops.

5. Turn off the power supply.

1 2 3 L N

ON

1 2 3

Refrigerant recovery switch

DANGER

Take care for an electric shock because the control P.C. board is electrified.

WARNING

Never touch these switches. Otherwise the air conditioner may not operate normally.


• When recovering refrigerant in case of reinstallation of the indoor or outdoor unit, etc., use the refrigerant recovery switch SW802 on the cycle control P.C. board of the outdoor unit.

<Work procedure>

1. Turn on the power supply.

2. Using the remote controller, set FAN operation to the indoor unit.

3. Pushing the refrigerant recovery switch SW802 on the cycle control P.C. board of the outdoor unit starts the forced cooling operation. (Max. 10 minutes), and then the refrigerant is recovered by operation of the valve.

4. After recovery of the refrigerant, push the refrigerant recovery switch SW802 together with closing the valve. The operation stops.

5. Turn off the power supply.

Outdoor unit cycle control

P.C. board

SW802

Refrigerant recovery

SW

DANGER

Take care for an electric shock because the control P.C. board is electrified.

SW801

CN804

Optional connector

2. Applicable Control of Outdoor Unit

You can response to the following items by attaching the parts sold separately “Application control kit” (TCB-PCOS1E).

<Demand control>

• It saves the capacity of the outdoor unit by outside Demand signal to correspond to the temporary peak cut.

• The capacity saving can be adjusted with three steps, 75%, 50%, and operation stop.

<Night operation control (Sound reduction)>

Sound is controlled to 45dB or less in inputting a timer point contact.

<Compressor operation output>

The check of the compressor operation time required of a maintenance etc.

– 57 –

9. DETACHMENTS


No.

Part name

Common procedure

Procedure

REQUIREMENT

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 switch of the breaker.

2) Remove the valve cover.

(ST1T Ø4 × 10, 1 pc.)

• After taking off screws, remove the valve cover while pulling downward.

3) Remove the wiring cover (ST1T Ø4 × 8,

2 pcs.), and remove the power supply cable and indoor/outdoor connecting cables.

4) Remove the upper cabinet.

(ST1T Ø4 × 8, 5 pcs.)

• After taking off screws, remove the front side of the upper cabinet while pulling upward.

2. Attachment

1) Attach the waterproof cover.

REQUIREMENT

Be sure to attach a waterproof cover to prevent entering of rainwater, etc.

2) Attach the upper cabinet.

(ST1T Ø4 × 8, 5 pcs)

• Hook the rear side of the upper cabinet, and then cover the front cabinet with upper cabinet.

3) Connect the power cable and indoor/ outdoor connecting cables to the terminal, and then fix them with cord clamp.

(ST1T Ø4 × 10, 3 pcs)

4) Attach the wiring cover.

(ST1T Ø4 × 8, 2 pcs)

5) Attach the valve cover.

(ST1T Ø4 × 10, 1 pc)

Remarks

Valve cover

Wiring cover

Upper cabinet

Waterproof cover

– 58 –

No.

Part name

Front cabinet

Procedure

1. Detachment

1) Perform work of item 1 of

.

2) Remove screws of the front cabinet and the inverter cover. (ST1T Ø4 × 8, 2 pcs)

3) Take off screws of the front cabinet and the bottom plate. (ST1T Ø4 × 8, 3 pcs)

4) Take off screws of the front cabinet and the motor support. (ST1T Ø4 × 8, 2 pcs)

* The left side of the front side is made to insert to the side cabinet (Left), so remove it while pulling upward.

2. Attachment

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

2) Insert hook at the right side of the side cabinet into square hole of the front cabinet.

3) Attach the removed screws at the original positions.

Remarks

Motor support

Front cabinet

Front cabinet (Left side)

Square hole Hook

Square hole Hook

– 59 –

No.

Part name

Inverter assembly

Procedure

1. Turn off the power supply.


.

2) Take off screws fixing the upper part of the front cabinet and the inverter cover.

(ST1T Ø4 × 8, 2 pcs)

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

The control circuits (including 5V and 12V of each sensor circuit, PMV circuit, etc.) of this control P.C. board are high-voltage circuits. Before work, be sure to turn off the power supply. Be careful sufficiently also for an electric shock at electrified portions of the control circuits and their parts.

3) Using resistance for discharge (approx.

100

Ω

/40W) or plug of soldering iron, electrify + , – electrodes between + and – terminals of 3-phase: C10, 11 and single phase: C12, 13, 14 (printed as

“CAUTION HIGH VOLTAGE”) electrolytic capacitor of P.C. board for discharge.

The electrolytic capacitor may not normally discharge according to error condition and the voltage may remain.

Be sure to discharge the capacitor.

NOTE :

The electrolytic capacitor has a large capacity. Therefore it is very dangerous to short-circuit between + , – electrodes with screwdrivers for discharge because big spark generates.

4) Perform work item 1 of

.

5) Take off screws fixing the main unit and the inverter box. (Wiring port side)

(ST1T Ø4 × 8, 2 pcs)

6) Take off screws fixing the partition board and the inverter box. (ST1T Ø4 × 8, 1 pc)

7) Remove various lead wires from the upper part of the inverter.

8) Pull up the inverter upward. In this time, cut off the bundling bands binding each lead wire.

9) Disconnect connectors of various lead wires.

NOTE :

When disconnecting each connector, avoid removing the connector by holding the lead wire, but by holding the connector.

Screws

Remarks

Inverter assembly

Remove the connectors with locking function by pushing the part indicated by the arrow mark.

Front cabinet

Inverter cover

Plug of soldering iron

(Discharging period

10 seconds or more)

Cord clamp

Screws

– 60 –

No.

Part name

Control P.C.

board assembly

Procedure

1) Remove the sub-board base from the inverter assembly. (ST1T Ø4 × 8, 2 pcs)

* Remove connector at control P.C. board assembly side.

2) Remove lead wires and connectors connected from the control P.C. assembly to the other parts.

1. Lead wires

* Connection with power terminal block:

3 wires

(Black, White, Orange: Single phase,

Red, White, Black, Orange: Three phase)

* Earth wire (Black): 1 wire

2. Connectors

Connection with compressor:

(3P: Relay connector, White) *(Note 1)

Reactor (2P: Relay connector, White)

CN300: Outdoor fan (3P: White) *(Note 1)

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

*(Note 1) (Note 2)

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. (2P: Blue) *(Note 1)

*(Note 1)

For connectors, unlock the lock of the housing section, and then remove connectors.

(Note 2)

It is not provided for a cooling-only model.

3) Remove the inverter box (Metal sheet).

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

(Remove heat sink and control P.C. board assembly as they are screwed.)

(Note3)

Remove 4 hooking claws of P.C. board support, and remove the heat sink with hands upward.

5) Take off 2 screws fixing the heat sink with the control P.C. board assembly.

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

(Note 4)

When installing a new control P.C. board assembly, be sure to insert the board correctly in the board groove.

Install it so that the heat sink comes to contact surely with the metal sheet.

– 61 –

Remarks

Power supply cable

Take off earth screws.

Inverter box

(Metal sheet)

P.C. board assembly

P.C. board base

Control P.C. board assembly

P.C. board base

Hooking claws

(4 positions)

Inverter box

(Metal sheet)

Heat sink

No.

Part name

Fan motor

Procedure

1) Perform works of items 1 of

and

.

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

• The flange nut is loosened by turning it clockwise.

(Turn it counterclockwise to tighten it.)

3) Remove the propeller fan.

4) Disconnect connector for fan motor from the inverter.

5) Take off the fixing screws (2 pcs) while supporting the fan motor so that it does not fall.

* Caution when assembling fan motor

Tighten the flange nut with torque

4.9 Nm (50kgf/cm).

Remarks

Flange nut

Loosen the nut by turning clockwise

Propeller fan

Fan motor

– 62 –

No.

Part name

Compressor

Procedure

1) Perform works of items 1 of and

.

, 1 of

,

2) Recover refrigerant gas.

3) Remove the partition board.

(ST1T Ø4 × 8, 3 pcs)

4) Take off screws of the motor base and the bottom plate. (ST1T Ø4 × 8, 2 pcs)

5) Remove the noise-insulator.

6) Remove the terminal cover, and then disconnect the lead wires of the compressor.

7) Using a burner, remove the pipes connected to the compressor.

NOTE :

Pay attention to that flame does not involve 4way valve or PMV.

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

8) Take off screws of the bottom plate and the heat exchanger. (ST1T Ø4 × 8, 1 pc)

9) Take off the fixing screws of the bottom plate and the valve clamping plate.

(ST1T Ø4 × 8, 2 pcs)

10) Pull out the refrigerating cycle with the heat exchanger.

11) Take off compressor bolts fixing the compressor to the bottom plate. (3 pcs)

Remarks

Partition board

Compressor lead

Case thermo

Heat exchanger

Screw

Reactor

Compressor bolt

(3 pcs)

Screws

(2 pcs)

Valve support board

1) Perform woks of item 1 of

and 1 of

.

2) Take off screw fixing the reactor.

(ST1T Ø4 × 8)

Partition board

Reactor

– 63 –

No.

Part name

Pulse Modulating

Valve (PMV) coi

Procedure

1. Detachment


.

and 1 of

2) Remove the side cabinet (Right).

3) Pull upward the coil, and remove the coil from PMV body.

2. Attachment

1) Fix the projection for coil positioning surely to pipe of PMV body and fix it.

PMV coil

Remarks

P.M.V. coil

Fan guard

1. Detachment


.

and 1 of

REQUIREMENT

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

2) Remove the front cabinet, and then put it downward on the floor.

3) Take off the hooking claw of the fan guard by pushing with minus screwdriver, etc.

2. Attachment

1) Insert the hooking claw of the fan guard into hole of the front cabinet. Fix claw while pushing the hooking claws

(10 positions) with hands.

REQUIREMENT

Check that all the hooking claws are fixed to the specified positions.

Minus screwdriver

Hooking claw Front cabinet

Front cabinet

Fan guard

– 64 –


No.

Part name

Common procedure

Procedure

REQUIREMENT

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 switch of the breaker.

2) Remove the front panel.

(Hex. screw Ø4 × 10, 3 pcs)

* After taking off screws, remove the front panel while pulling downward.

3) Disconnect the power supply cable and indoor/outdoor connecting cables from the cord clamp and terminals.

4) Remove the ceiling plate.


2. Attachment

1) Attach the ceiling plate.


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

REQUIREMENT

Using bundling band sold at a market, be sure to fix the power cables and indoor/ outdoor connecting cables along the interunit cable 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.

(Hex. screw Ø4 × 10, 3 pcs) and then cover the front cabinet with upper cabinet.

Remarks

Front panel

Ceiling panel

– 65 –

No.

Part name

Discharge port cabinet

Procedure

1. Detachment


.

2) Take off screws of the air outlet cabinet and the partition board.

(ST1T Ø4 × 8, 3 pcs)

3) Take off screws of the air outlet cabinet and the bottom plate.


4) Take off screws of the air outlet cabinet and the heat exchanger.

(ST1T Ø4 × 8, 1 pc)

5) Take off screws of the air outlet cabinet and the motor base.

(ST1T Ø4 × 8, 2 pcs)

6) Take off screws of the air outlet cabinet and the fin guard.


2. Attachment

1) Put the upper left side of the air outlet cabinet on the end plate of the heat exchanger, and then fix it with screw.

(ST1T Ø4 × 8, 1 pc)

2) Attach the removed screws to the original positions.

Remarks

Heat exchanger

Fin guard Motor base

Air outlet cabinet

Upper side of end plate of heat exchanger

Air outlet cabinet

Side cabinet 1) Perform work of item 1 of

.

2) Take off screw fixing the inverter and the side cabinet. (ST1T Ø4 × 8, 1 pc)

3) Take off screws of the side cabinet and the valve support plate. (ST1T Ø4 × 8, 2 pcs)

4) Take off screws of the side cabinet and the piping panel (Rear).

(HEX. screw Ø4 × 10, 1 pc)

5) Take off screws of the side cabinet and the bottom plate (Rear).


6) Take off screws of the side cabinet and the fin guard (Heat exchanger).

(HEX. screw Ø4 × 10, 2 pcs)

Inverter Side cabinet

Valve support plate Piping panel

(Rear)

– 66 –

No.

Part name

Inverter assembly

Procedure

1) Perform works of items of 1 of

, 1 of

, and

.

2) Disconnect connectors connected from the cycle P.C. board to other parts.






CN300: Position detection (5P: White)

CN500: Case thermo (2P: Blue) *(Note 1)

CN700: 4-way valve (3P: Yellow) *(Note 1)

CN702: PMV coil (6P: White) *(Note 1)

*(Note 1)

Unlock the lock of housing part, and then disconnect the connectors.

3) Cut the tie lap fixing various lead wires to the inverter assembly.

4) Remove the rubber sheet and noise-proof plate (upper).

5) Remove terminal cover of the compressor and Comp. lead wire.

6) Pull upward the hook (Rear left) with the partition board as if removing it.

• Caution when attaching inverter assembly

When installing the inverter assembly to the partition board, attach hook (Rear left) of the partition board surely.

Remarks

Cycle P.C. board Inverter assembly

Rubber sheet Noise-proof plate

(Upper)

Comp. lead

There is a hook with the partition board at rear side.

– 67 –

No.

Part name

Cycle P.C.

board

Procedure

1) Perform the work in item 1 of

.

2) Disconnect connectors and lead wires connected from cycle P.C. board to other parts.

1. Connector






CN300: Position detection (5P: White)

CN500: Case thermo (2P: Blue) *(Note 1)

CN700: 4-way valve (3P: Yellow)

*(Note 1)

CN702: PMV coil (6P: White) *(Note 1)

CN800: Connection with IPDU P.C. board

(5P: Red) *(Note 1)


(5P: Red) *(Note 1)

CN02: Indoor/outdoor connecting terminal block (3P: Black)

*(Note 1)


(3P: White) *(Note 1)



*(Note 1)

Unlock the lock of housing part, and then disconnect the connectors.

3) Remove claws fixing P.C. board at four corners, and then remove the cycle P.C.

board.

4) Install a new cycle P.C. board.

Remarks

Cycle P.C. board

P.C. board fixing hooks (4 positions)

– 68 –

No.

Part name

IPDU P.C.

board

Procedure

1) Perform the works in item

.

2) Take off screws of the inverter assembly, and then classify the inverter assembly.

(M4 × 8, 3 pcs. hooks at two positions)

3) Disconnect connectors and lead wires connected from IPDU P.C. board to other parts.

1. Connector

CN04: Connection with cycle P.C. board





(5P: Red)


(5P: Red) *(Note 1)

CN600: Heat sink sensor (2P: Black)

*(Note 1)

2. Lead wire

CN01: Connection with power supply terminal block (Red)

CN02: Connection with power supply terminal block (White)

CN03: Connection with power supply terminal block (Black)

CN07: Earth wire (Black)

CN14: Connection with reactor (White)

CN15: Connection with reactor (White)

CN09: Connection with compressor

(Red)


(White)


(Black)

*Note 1)

Unlock lock of the housing part, and then disconnect the connectors.

4) Remove lead wires of 3-phase rectifier.

(5 pcs)

5) Remove cover of the heat sink.

(M4 × 8, 3 pcs)

6) Take off screws (2 pcs) fixing the heat sink with IGBT, remove claws (4 positions) of P.C.

board support, and then remove IPDU P.C.

board.

7) Install a new IPDU P.C. board.

Screw

Remarks

Hooks

Screws

IPDU P.C. board

3-phase rectifier Gray

Orange

Heat sink cover

Black, Brown, Red from rear side

Screw

Screw

Heat sink

– 69 –

No.

Part name

Fan motor

Procedure

1) Perform the works in item 1 of

and 1 of

.

2) Take off flange nut fixing fan motor with propeller fan.

• The flange nut is loosened by turning it clockwise.

(Turn it counterclockwise to tighten it.)

3) Remove the propeller fan.

4) Disconnect connector for fan motor from the inverter.

5) Take off the fixing screws (4 pcs) while supporting the fan motor so that it does not fall.

* Caution when assembling fan motor

• Tighten the flange nut with torque

4.9Nm (50kgf/cm).

• Pay attention that the reactor at rear side of the inverter does not come to contact with the fan motor lead.

REQUIREMENT

Using bundling band sold at a market, be sure to fix the fan motor lead wires to the motor base so that they do not come to contact with the propeller fan.

Flange nut

Remarks

Loosened by turning clockwise

Propeller fan

Fan motor

Motor base Fix with bundling band

– 70 –

No.

Part name

Compressor

Procedure

1) Recover the refrigerant gas.


, 1 of

, and

,

.

3) Remove the piping panel (Front).

Take off screws of the piping panel (Front) and the bottom plate.

(HEX. screw Ø4 × 10, 2 pcs)

Take off screws of piping panel (Front) and piping panel (Rear).


4) Remove the valve fixing plate.

Take off screws of the valve fixing plate and the partition board. (ST1T Ø4 × 8, 2 pcs)

Take off screws of valve fixing plate and valves at liquid and gas sides. (M6, 4 pcs)

5) Remove the partition board.

Take off screws of the partition board and bottom plate. (ST1T Ø4 × 8, 1 pc)

Take off screws of the partition board and the end plate of the heat exchanger.

(ST1T Ø4 × 8, 2 pcs)

6) Remove the noise-proof plate.

7) Remove terminal cover of the compressor, and then remove case thermo of the compressor.

8) Remove the sensor and pipe cover fixed to the discharge pipe.

9) Using a burner, remove pipe connected to the compressor.

NOTE :

Pay attention to that flame does not involve 4way valve or PMV.

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

10) Pull out the discharge pipe and the suction pipe of the refrigerating cycle upward.

11) Take off the compressor bolts fixing the compressor to the bottom plate. (3 pcs)

12) Pull out the compressor toward you.

PMV coil

1. Detachment


and

.

2) Pull the coil upward while turning it, and then remove the coil from PMV body.

2. Attachment

1) Be sure to match the projection for coil positioning with the concave part of PMV body, and then fix the coil.

Remarks

Piping panel (Front)

Partition board

Valve fixing plate Valves

Sensor/pipe cover

Case thermo Remove

(Suction pipe)

Remove

(Discharge pipe)

Compressor bolts

(3 pcs)

Projection for positioning

PMV body Concave part

– 71 –

No.

Part name

Fan guard

Procedure

1. Detachment


and 1 of

.

REQUIREMENT

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

2) Remove the front cabinet, and then put it downward on the floor.

3) Take off screws fixing the bell mouth.

(ST1T Ø4 × 8, 2 pcs)

4) Remove the bell mouth.

5) Take off the hooking claw of the fan guard by pushing with minus screwdriver, etc.

2. Attachment

1) Insert the projection at upper side of the fan guard into square hole of the discharge port cabinet, and then insert the hooking claw. Fix hooking claws while pushing them (5 positions) with hands.

REQUIREMENT

Check that all the hooking claws are fixed to the specified positions.

2) Attach the fan guard by hooking claws

(3 positions) at upper side of the bell mouth to the square holes of the discharge port cabinet.

3) After attachment, fix it with screws.

(ST1T Ø4× 8, 2 pcs)

Bell mouth

Remarks


Bell mouth

Take off screws (2 pcs)

Minus screwdriver


Fan guard

Hooking claw


Square hole (3 positions)

Claw (3 positions) Bell mouth

– 72 –

10. EXPLODED VIEWS AND PARTS LIST


Location

No.

13

14

15

4

5

6

1

2

3

7

8

9

10

11

12

16

17

Part Description

43005619 Cabinet, Front

43005616 Cabinet, Upper

43005617 Cabinet, Side, Right

43005569 Cabinet, Side, Left

4301V035 Guard, Fan

4301V053 Guard, Fin

43042479 Base, Ass’y

43119471 Cover, Valve, Packed

43062230 Cover, Wiring, Ass’y

43041627 Compressor, Ass’y,

DA150, A1F-20F

43043730 Condenser, Ass’y

(SM561AT-E)

43043720 Condenser, Ass’y

(SM801AT-E)

43046392 Valve, Packed, 6.35

(SM561AT-E)

43046393 Valve, Packed, 12.7

(SM561AT-E)

43146584 Valve, Packed, 9.52 DIA

(SM801AT-E)

43146670 Valve, Packed, 15.9

(SM801AT-E)

43147196 Bonnet, 1/4 IN (SM561AT-E)

– 73 –

Location

No.

18

19

20

21

22

30

31

32

33

34

35

23

24

25

26

27

28

29

36

37

38


43147195 Bonnet, 1/2 IN (SM561AT-E)

43194029 Bonnet (SM801AT-E)

43047401 Bonnet, 3/8 IN (SM801AT-E)

43046439 Valve, 4-Way, STF-0108Z

(SM561AT-E)

43146619 Valve, 4-Way, STF-0213Z

(SM801AT-E)

43046348 Coil, Solenoid,

43146662 Valve, Pulse, Modulating

43046411 Coil, PMV, CAM-MD12TF-1

43058270 Reactor

4302C048 Motor, Fan, ICF-140-43-4

43020329 Fan, Propeller, PJ421

43047667 Nut, Flange

43032441 Nipple, Drain

43089160 Cap, Waterproof

43050407 Thermostat, Bimetal

43063339 Holder, Sensor (TO)

43049749 Rebber, Cushion

43063321 Holder, Sensor



43063317 Holder, Thermostat

705

707

708

706

Location

No.


701 43050410 Sensor, TD

702 43050412 Sensor, TE

703 43050413 Sensor, TS

704 43050415 Sensor, TO

705 43062228 Base, P.C. Board

– 74 –

Location

No.


706 4306A116 Terminal Block, 6P

707 4316V254 P.C. Board, Ass’y, SW,

MCC-1530

708 4316V268 P.C. Board, Ass’y, MCC-5009

701

702

703

704


Location

No.

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

16

17

18

19


43050406 Cabinet, Air Outled

43191636 Cabinet, Front, Ass’y

43191635 Cabinet, Side, Ass’y

43005491 Panel, Upper

43191633 Guard, Fin

43191651 Guard, Fan

43122065 Bell Mouth

43047667 Nut, Flange

43120224 Fan, Propeller, PE492

43121734 Motor, Fan, ICF-280-100-1

4314G178 Condenser, Ass’y

43191515 Panel, Front, Piping

43191605 Panel, Back, Piping

43119390 Hanger

43041774 Compressor, Ass’y,

DA420A3F-21M

43050407 Thermostat, Bimetal

43063317 Holder, Thermostat

43100248 Base, Ass’y

43197157 Bolt, Compressor

Location

No.

20

21

22

30

31

32

33

34

35

36

23

24

25

26

27

28

29

37


43149324 Rubber, Cushion, EPDM

43146619 Valve, 4-WAY, STF-0213Z

43146611 Coil, Solenoid,

VHV-01AJ502E1

43146634 Valve, Pulse, Modulating

43146663 Coil, PMV, UKV-U048E

43148170 Accumulator, Ass’y

43146584 Valve, Packed, 9.52 DIA

43146613 Valve, Ball

43047401 Bonnet, 3/8 IN

43194029 Bonnet

43158190 Reactor


43063188 Holder, TC Sensor


43147611 Strainer

43148176 Strainer

43089160 Cap, Waterproof

43032441 Nipple, Drain

– 75 –

707

706

708

704

701

TD

TO

TS

TE

702

703

705

Location

No.


701 43050354 Sensor TD

702 43050382 Sensor TC (F6)

703 43060750 Terminal Block, 3P

704 43150259 Rectifier

705 43160502 Terminal Block

– 76 –

Location

No.


706 4316V255 P.C. Board, Ass’y, CDB,

MCC-1531

707 4316V264 P.C. Board Ass’y, IPDU,

MCC-1438

708 43050398 Sensor TG (F4)

TOSHIBA CARRIER CORPORATION

2 CHOME 12-32, KONAN, MINATOKU, TOKYO, 108-0075, JAPAN

Copyright © 2005 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.

RAV-SM 1401AT-E | RAV-SM 1101AT-E | RAV-SM 801AT-E | TOSHIBA RAV-SM 561AT-E, 801AT-E, 1101AT-E, 1401AT-E split-system air conditioner Service Manual 77 Pages

RAV-SM 1401AT-E | RAV-SM 1101AT-E | RAV-SM 801AT-E | TOSHIBA RAV-SM 561AT-E, 801AT-E, 1101AT-E, 1401AT-E split-system air conditioner Service Manual

SERVICE MANUAL

SPLIT TYPE

<NEW DIGITAL INVERTER>

OUTDOOR UNIT

INDOOR UNIT

This Service Manual describes contents of the new outdoor unit.

For the indoor unit, refer to the Service Manual with FILE NO. A03-003F.

ADOPTION OF NEW REFRIGERANT

WARNING

CONTENTS

– 2 –

1. SPECIFICATIONS

– 3 –

– 4 –

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

– 5 –

– 6 –

– 7 –

3. REFRIGERATING CYCLE DIAGRAM

– 8 –

– 9 –

– 10 –

4. WIRING DIAGRAM

– 11 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

– 12 –

6. REFRIGERANT R410A

– 13 –

– 14 –

– 15 –

– 16 –

– 17 –

– 18 –

– 19 –

– 20 –

REQUIREMENT

– 24 –

– 25 –

– 26 –

NOTIFICATION

– 27 –

– 28 –

8. TROUBLESHOOTING

– 29 –

– 30 –

8-2. Check Code List

¡

¡

¡

¡¡

– 34 –

– 35 –

*

*

*

*

– 36 –

*

– 37 –

*

*

*

*

– 38 –

– 39 –

– 40 –

– 41 –

– 42 –

– 43 –

– 44 –

– 45 –

– 46 –

– 47 –

– 48 –

– 49 –

– 50 –

– 51 –

– 52 –