Instruction/ maintenance manual of the product RAV-SM1603ATZG-E Toshiba
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R410A PRINTED IN JAP AN, Jun, 2008 T oMo FILE NO. A07-009 SER VICE MANUAL AIR-CONDITIONER SPLIT TYPE OUTDOOR UNIT <DIGIT AL INVER TER> RA V -SM1603A T -E RA V -SM1603A TZ-E RA V -SM1603A TZG-E INDOOR UNIT <DIGIT AL INVER TER> RA V -SM1403DT -A RA V -SM1603DT -A ∗ Ref er to the Ser vice Manual with File No .
– 2 – Adoption of New Refrigerant This Air Conditioner is a new type which adopts a ne w refr igerant HFC (R410A) instead of the con v entional refrigerant R22 in order to pre vent destruction of the ozone la yer .
– 3 – 6. REFRIGERANT R410A ............................................................................ 35 6-1. Safety During Installation/Servicing ............................................................... 35 6-2. Refrigerant Piping Installation .
– 4 – SAFETY CA UTION The impor tant contents concer ned to the saf ety are described on the product itself and on this Ser vice Manual. Please read this Ser vice Manual after understanding the descr ibed items thoroughly in the follo wing contents (Indications/Illustrated marks), and keep them.
– 5 – Check earth wires. Prohibition of modification. Use specified par ts. Do not bring a child close to the equipment. Insulating measures No fire Refrigerant Assembly/Cab ling Before tr oublesh.
– 6 – After the work has finished, be sure to use an insulation tester set (500V Megger) to chec k the resistance is 2M Ω Ω Ω Ω Ω or more between the charge section and the non-c harge metal section (Earth position). If the resistance v alue is low , a disaster such as a leak or electric shock is caused at user ’ s side.
– 7 – • Ne w Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the oz one la yer . 1 . Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the f or mer refrigerant (R22).
– 8 – 4 . T ools 1. Required T ools f or R410A Mixing of diff erent types of oil ma y cause a trouble such as generation of sludge , clogging of capillar y , etc.
– 9 – 1. SPECIFICA TIONS 1-1. Indoor Unit 1-1-1. High Static Duct T ype <Single type> ∗ : IEC standard, ∗∗ : AS standard Model Indoor unit RA V - Outdoor unit RA V - Cooling capacity (.
– 10 – 1-1-2. 4-way Air Dischar ge Cassette T ype <Single type> Model Indoor unit RA V - Outdoor unit RA V - Cooling capacity (kW) Heating capacity (kW) P ower supply Running current (A) P o.
– 11 – <T win type> Indoor unit 1 RA V - SM804UT - E Model Indoor unit 2 RA V - SM804UT - E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 21.
– 12 – <T riple type> Indoor unit 1 RA V - SM564UT - E Model Indoor unit 2 RA V - SM564UT - E Indoor unit 3 RA V - SM564UT - E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 21.
– 13 – 1-1-3. Concealed Duct T ype <T win type> Indoor unit 1 RA V - SM802BT - E Model Indoor unit 2 RA V - SM802BT - E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 24.
– 14 – <T riple type> Indoor unit 1 RA V - SM562BT - E Model Indoor unit 2 RA V - SM562BT - E Indoor unit 3 RA V - SM562BT - E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 24.
– 15 – 1-1-4. Under Ceiling T ype <T win type> Indoor unit 1 RA V - SM802CT - E Model Indoor unit 2 RA V - SM802CT - E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 23.
– 16 – <T riple type> Indoor unit 1 RA V - SM562CT - E Model Indoor unit 2 RA V - SM562CT - E Indoor unit 3 RA V - SM562CT - E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 23.
– 17 – 1-1-5. High Wall T ype <T win type> Indoor unit 1 RA V - SM802KRT -E Model Indoor unit 2 RA V - SM802KRT -E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 24.
– 18 – <T riple type> Indoor unit 1 RA V - SM562KRT -E Model Indoor unit 2 RA V - SM562KRT -E Indoor unit 3 RA V - SM562KRT -E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.0 Indoor unit P ower supply 1 phase 230V (220 – 240V) 50Hz Running current (A) 24.
– 19 – 1-1-6. Compact 4-way Cassette (600 × 600) T ype <T riple type> Indoor unit 1 RA V - SM562MUT -E Model Indoor unit 2 RA V - SM562MUT -E Indoor unit 3 RA V - SM562MUT -E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.
– 20 – 1-1-7. Slim Duct T ype <T riple type> Indoor unit 1 RA V - SM564SDT -E Model Indoor unit 2 RA V - SM564SDT -E Indoor unit 3 RA V - SM564SDT -E Outdoor unit RA V - SM1603A T(Z)(ZG)-E Cooling capacity (kW) 14.0 Heating capacity (kW) 16.
– 21 – 1-2. Outdoor Unit Model name P ower supply T ype Compressor Motor (kW) P ole Refrigerant charged (kg) Refrigerant control Standard length (m) Min.
– 22 – 1-3. Operation Characteristic Curve • Operation characteristic curve RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E <Cooling> <Heating> 0 2 04 06 0 Compressor speed (rps) 79 100 120 Current (A) 0 2 04 06 0 Compressor speed (rps) 78.
– 23 – 2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Indoor Unit RA V -SM1403DT -A, RA V -SM1603DT -A 20 10 296 316 15 25 10 25 25 20 60 276 (Inside) 274 (Inside) 757 (Inside) 845 (Inside) 25 25 20 20 12 65 65 12 25 67.5 250 250 885 11 × 65 = 715 250 67.
– 24 – 2-2. Outdoor Unit RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E 365 17.5 74 17.5 128 46 48 655 121 534 534 85 65 7 55 95 55 94 95 55 95 24 1340 155 605 613 70 74 581 581 360 4.
– 25 – RBC-TWP30E2, RBC-TWP50E2 (Simultaneous T win) Inner diameter Ø C Inner diameter Ø D Inner diameter Ø D A B Model (RBC-) TWP30E2 Liquid side Gas side TWP50E2 Liquid side Gas side ABCD 36 14 Ø 9.5 Ø6.4 43 23 Ø 15.9 Ø12.7 34 14 Ø 9.5 Ø9.
– 26 – RBC-TRP100E (Simultaneous T riple) <Gas side> Header assemb ly Ø15.9 (External diameter) Ø25.4 (External diameter) Ø9.5 (External diameter) Ø12.7 (External diameter) Inner diameter Ø25.4 Inner diameter Ø12.7 Inner diameter Ø15.
– 27 – 3. SYSTEMA TIC REFRIGERA TING CYCLE DIA GRAM 3-1. Indoor Unit <Indoor unit to be connected to RA V -SM1403DT -A, RA V -SM1603DT -A> • Single type (Combination of one indoor unit and one outdoor unit) Indoor unit SM140, 160 type Outer diameter of refrigerant pipe Gas side ØA Liquid side ØB 15.
– 28 – Indoor unit TCJ sensor Air heat e xchanger TC sensor Distributor (Strainer incor porated) Refrigerant pipe at liquid side Outer diameter Ø9.
– 29 – 3-2. Outdoor Unit RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E Systematic Diagram of Refrigerating Cyc le * This compressor has 4-pole motor . The v alue when compressor frequency (Hz) is measured by a clamp meter becomes 2 times of No .
– 30 – 4. WIRING DIA GRAM 4-1. Indoor Unit RA V -SM1403DT -A, RA V -SM1603DT -A 1. indicates the terminal board and the number indicates the terminal number . 2. The dashed line indicates wiring at the local site. 3. indicates P .C. board. 4. When install Drain Pump.
– 31 – • Single type Notes) 1. : indicates a ter minal bloc k 2. Brok en line and chain line indicate wiring at local site. 3. F or the inner wir ing diagram of the outdoor unit and the indoor unit, ref er to the wiring diagram of each model. 4.
– 32 – 4-2. Outdoor Unit RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E Fuse, 50A, 250V~ WHI RED RED PNK ORN BLU WHI BLK RED WHI RED P ower supply 220 – 240V~, 50Hz WHI BLK BLU YEL .
– 33 – 4-3. Fan Characteristics Current value as a criterion, adjust the air volume v alue to become within the range of the char t below . REQUIREMENT Install the v olume damper in the air outlet, and adjust the airflow t o become within the range of the char t abov e.
– 34 – 5. SPECIFICA TIONS OF ELECTRICAL P AR TS 5-1. Indoor Unit RA V -SM1403DT -A, RA V -SM1603DT -A No. 1 2 3 4 P ar ts name F an motor T A sensor TC sensor TCJ sensor T ype SWF-240-600-4A Lead .
– 35 – 6. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone la yer . The working pressure of the new refrigerant R410A is 1.
– 36 – T able 6-2-1 Thicknesses of annealed copper pipes 1. Joints F or copper pipes, flare joints or soc ket joints are used. Pr ior to use, be sure to remov e all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used f or pipings whose outer diameter e xceeds 20 mm.
– 37 – c) Inser tion of Flare Nut d) Flare Processing Make certain that a clamp bar and copper pipe hav e been cleaned. By means of the clamp bar , perform the flare processing correctly . Use either a flare tool f or R410A or conv entional flare tool.
– 38 – 43˚to 45˚ 45˚to 46˚ B A C D 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 por tions do not hav e any scar or dust, etc. b) Correctly align the processed flare surf ace with the union axis.
– 39 – 6-3. T ools 6-3-1. Required T ools Ref er to the “ 4. T ools ” (P age 8) 6-4. Rechar ging of Refrigerant When it is necessar y to recharge refrigerant, charge the specified amount of new refrigerant according to the f ollowing steps .
– 40 – Gauge manifold [ Cylinder with siphon ] [ Cylinder without siphon ] OUTDOOR unit Gauge manifold OUTDOOR unit Refrigerant cylinder Electronic balance Refrigerant cylinder Electronic balance Siphon 1) Be sure to make setting so that liquid can be charged.
– 41 – Nitrogen gas cylinder Pipe Flow meter M Stop valv e F rom Nitrogen cylinder Nitrogen gas Rubber plug 2. Characteristics required for flux • Activ ated temperature of flux coincides with the brazing temperature . • Due to a wide eff ectiv e temperature range , flux is hard to carbonize .
– 42 – 6-6. Instructions f or Re-use Piping of R22 or R407C Instruction of W orks: The existing R22 and R407C piping can be reused for our digital in ver ter R410A products installations.
– 43 – 6-6-5. Final Installation Checks Do not apply the refrigerator oil to the flare surface . Existing pipe: NO * Use a new pipes. Clean the pipes or use the new pipes .
– 44 – 6-6-6. Handling of Existing Pipe When using the e xisting pipe, carefully chec k it for the f ollowing: • W all thickness (within the specified range) • Scratches and dents • W ater ,.
– 45 – 1234 ON 1234 ON P .C. boar d Refrigerant recovery switch SW801 Optional connector CN610 Special operation select switch SW804 Existing pipe switch SW802 6-6-7. Recovery Method of Refrig erant RA V -SM1603A T(Z)(ZG)-E • Use the refrigerant recov er y switch SW802 on the P .
– 46 – 6-7. T olerance of Pipe Length and Pipe Head n T win system CA UTION When planning a la yout f or Units A and B, comply with the f ollowing: 1.
– 47 – n T riple system CA UTION When planning a la yout f or Units A, B and C, comply with the f ollowing: 1. The lengths after branching ( “a” and “b” , “b” and “c” , “a” and “c” ) should be equal if f easible .
– 48 – 6-8. Additional Refrigerant Amount n T win system <Formula f or Calculating Additional Refrigerant Amount> Do not remov e the refr igerant e ven if the additional refrigerant amount becomes minus result as a result of calculations b y the f ollowing f or mula and operate the air conditioner as it is.
– 49 – n T riple system <Formula f or Calculating Additional Refrigerant Amount> Do not remov e the refr igerant e ven if the additional refrigerant amount becomes minus result as a result of calculations b y the f ollowing f or mula and operate the air conditioner as it is.
– 50 – 6-9. Piping Materials and Sizes n T win system Use copper tube of Copper and copper allo y seamless pipes and tubes , with 40mg/10m or less in the amount of oil stuc k on inner w alls of pipe and 0.8mm in pipe w all thic kness for diameters f or diameters 6.
– 51 – 6-10. Branch Pipe n T win system Now the refrigerant pipe is installed using br anch pipes supplied as accessories. • Bend and adjust the refrigerant piping so that the branch pipes and pipe after branching become horizontal. • Fix the branch pipes onto a wall in a ceiling or onto a column.
– 52 – 7. INDOOR CONTR OL CIRCUIT 7-1. Indoor Contr oller Block Dia gram RA V -SM1403DT -A, RA V -SM1603DT -A 7-1-1. Connection of Main (Sub) Remote Controller Max. 8 units are connectable. ∗ 1 ∗ 1 How e ver when mounting a netw or k adapter while 2 main (sub) remote controllers are connected, Max.
– 53 – 7-2. Control Specifications Cooling thermo. OFF (F an) • Setup air volume Cooling operation Heating operation Ta (˚C) -1.0 Ts + α +1.0 No.
– 54 – Ta ( ˚ C) -1.5 Tsc Tsh +1.5 Heating (Cooling OFF) (Cooling ON) or Cooling No. 3 4 5 Item Room temp . control A utomatic capacity control (GA control) A utomatic cooling/ heating control Outline of specifications 1) Adjustment range: Remote controller setup temperature ( ° C) Setting at shipment Setup data 2 Setup data Setup temp .
– 55 – Ta ( ˚ C) +1.0 +0.5 Tsc – 0.5 +1.5 Normal cooling Cooling in Cooling/Heating [A UTO] HH (High wind) HH (High wind) HH (High wind) HH (High wind) HH (High wind) HH (High wind) L (Low wind) HH (High wind) L L (Low wind) Normal heating Cooling in Cooling/Heating [A UTO] UL (Ultra low wind) only during compressor-OFF Ta ( ˚ C) Tsc – 0.
– 56 – 5 2 A J K I ( ˚ C) No. 8 Item F reeze pre v entive control (Low temper ature release) Outline of specifications 1) The cooling operation (including Dry operation) is perf or med as follo ws based on the detected temperature of Tc sensor or Tcj sensor .
– 57 – A B L N M ( ˚ C) Tc Tcj No. 9 10 11 Item High-temp . release control Drain pump control (Sold separately) After-heat elimination Outline of specifications 1) The heating operation is perf or med as f ollows based on the detected temperature of Tc sensor or Tcj sensor .
– 58 – No. 13 Item Filter sign displa y (Except wireless type) ∗ It is provided on the separately sold type TCB-AX21E2. Outline of specifications 1) The operation time of the indoor f an is calculated, the filter reset signal is sent to the remote controller when the specified time (2500H) has passed, and it is displa yed on LCD .
– 59 – 7-3. Optional Connector Specifications of Indoor P .C. Board ∗ This option is not provided to o versea models . Function V entilation output Option output Outside error input A UT O up/ down g rille ( ∗ ) FIL TER Option error / Humidifier setting ( ∗ ) CHK Operation chec k DISP Exhibition mode EXCT Demand Connector No.
– 60 – 7-4. Indoor Print Cir cuit Board RA V -SM1403DT -A, RA V -SM1603DT -A <MCC-1403> Drain pump output Power transformer (Primary side) (AC240V) Optional power supply AC fan output EXCT F.
– 61 – 7-5. Outdoor Print Cir cuit Board RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E In ver ter P .C. board <MCC-1535> [IPDU1] Electrolytic condenser ( – ) Electrolytic con.
– 62 – Noise filter P .C. boar d <MCC-1551>.
– 63 – Model selection jumpers (A vailab le only ser vice P .C. board) J800 to J803 Refrigerant recov er y Switch SW802 Dip s witch for service SW801 EEPROM-IC IC801 P .
– 64 – 2. Dischar ge temperature release control 1) This function controls the operation frequency , that is, low ers the operation frequency when the discharge temperature has not low er or the discharge temperature has rapidly risen during PMV control.
– 65 – 4. Outdoor fan contr ol Allocations of fan tap rev olutions [rpm] SM160 High Low W1 W2 W3 W4 W5 W6 W7 W8 W9 W A WB WC WD WE WF 250 260 260 320 380 480 500 530 610 640 660 720 720 720 780 .
– 66 – 2) Heating f an control Q The outdoor f an is controlled b y TE sensor , T O sensor and the oper ation frequency . (F rom Min. W1 to Max. are controlled according to the follo wing tab le.) R During 3 minutes after star t-up , the f an is fix ed with the maximum f an tap corresponding to zone in the f ollowing tabl e .
– 67 – 6. Short intermittent operation preventive contr ol 1) F or 3 to 10 minutes after operation star t, in some cases, the compressor does not stop to protect the compressor e ven if receiving the thermostat-OFF signal from indoor . How ev er it is not abnor mal status.
– 68 – 1 0 . Defr ost contr ol Q In heating operation, defrost operation is perf or med when TE sensor temperature satisfies any condition in A zone to D z one.
– 69 – T rouble Confirmation of chec k code display Check defective position and parts. →→ 9. INDOOR UNIT TR OUBLESHOO TING 9-1. Summary of T r oub leshooting <Wired remote controller type> 1.
– 70 – 9-2. T roub leshooting 9-2-1. Check Code List (Indoor) (Indoor unit detected) ² When this warning was detected before group construction/address check finish at po wer supply was turned on, the mode shifts automatically to A UTO address setup mode .
– 71 – Err or mode detected b y indoor unit Operation of diagnostic function Check code E03 E04 E08 L03 L07 L08 L09 L30 P10 P19 P31 F01 F02 F10 F29 E10 E18 Cause of operation No communication from remote controller (including wireless) and communication adapter The serial signal is not output from outdoor unit to indoor unit.
– 72 – Err or mode detected b y remote contr oller or central contr oller (TCC-LINK) ∗ 2 The check code cannot be displa yed b y the wired remote controller . (Usual operation of air conditioner becomes una v ailable .) F or the wireless models, an error is notified with indication lamp .
– 73 – 9-2-2. Diagnostic Pr ocedure f or Each Check Code (Indoor Unit) Check code [E01 error] Is inter-unit cable of A and B normal? Is group control operation? Is power of all indoor units turned on? Is power supplied to remote controller? AB terminal: Appro x.
– 74 – [E04 error] Is there no disorder of power supply? Does outdoor operate? Is group address setup of remote controller correct? Are wiring in indoor unit and 1, 2, 3 inter-unit cables correct? Are wirings of ter minal bloc ks (1, 2, 3) wired to CN04 normal? Does D502 (Orange LED) flash after power supply turned on again? Check indoor P .
– 75 – Is not yet capacity setting of indoor unit set up? Is group control operation? Is power of all indoor units turned on? Is T win or T riple control? Is inter-unit cable of A and B normal? Is.
– 76 – [L20 error] Is group operation carried out? Do outside de vices nor mally work? Check cause of oper ation. Check corresponding indoor unit/outdoor unit.
– 77 – Does float switch work? Does drain pump work? Is circuit wiring normal? Is connection of T A sensor connector (CN104 on indoor P .C. board) correct? Are characteristics of T A sensor resistance value normal? Check indoor P .C. board (MCC -1403).
– 78 – [P19 error] Chec k method of outdoor P .C. board operation (Self-hold valve type : SP110, SP140) 1) Set SW804 of Dip switch as the f ollowing figure and then push SW801 f or appro x. 1 second to check e xchange operation to cooling cycle/heating cycle.
– 79 – [F02 error] Correct connection of connector . Are characteristics of TC sensor resistance value normal? Is connection of TC sensor connector (CN101 on Indoor P .C. board) correct? ∗ Refer to TC sensor (T emperature-Resistance value characteristic table) Replace TC sensor .
– 80 – [C06 error] (TCC-LINK central contr oller) Check centr al controller . Def ect → Replace Is there no noise source? Did a power f ailure occur? Is not the source power supply turned on? Is.
– 81 – [E03 err or] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receiv e a signal from the remote controller (also central controller). Chec k A and B remote controllers and communication lines of the central control system U3 and U4.
– 82 – Resistance (k Ω ) (50˚C or low er) Resistance (k Ω ) (50˚C or higher) 0 0 50 100 150 200 0 5 10 15 20 10 20 30 40 50 60 70 80 90 100 T emperature ( ˚ C) Resistance (k Ω ) 0 0 10 20.
– 83 – 10. OUTDOOR UNIT TR OUBLESHOO TING 10-1. Summary of T r oub leshooting <Wired remote controller type> 1. Bef ore tr oubleshooting 1) Required tools/instruments • + and – scre wdrivers , spanners, radio cutting pliers , nippers, push pins f or reset s witch • T ester , ther mometer , pressure gauge, etc.
– 84 – <Wireless remote contr oller type> 1. Bef ore tr oubleshooting 1) Required tools/instruments • + and – screwdriv ers, spanners , radio cutting pliers, nippers , etc. • T ester , ther mometer , pressure gauge, etc. 2) Confir mation points before chec k a) The follo wing operations are normal.
– 85 – 10-2. T roub leshooting 10-2-1. Outline of Judgment The primar y judgment to check whether a troub le occurred in the indoor unit or outdoor unit is carried out with the f ollowing method.
– 86 – ∗ 1: These are representativ e e xamples and the check code diff ers according to the outdoor unit to be combined. Lamp indicat.
– 87 – 10-2-2. Others (Other than Chec k Code) Lamp indication Operation Timer Ready Simultaneous flash Operation Timer Ready Alternate flash Check code — — Cause of troub le occurrence During.
– 88 – 10-2-3. Chec k Code List (Outdoor) ¡ : Go on, ¥ : Flash, l : Go off AL T (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when the.
– 89 – ¡ : Go on, ¥ : Flash, l : Go off AL T (Alternate): Alternate flashing when there are two flashing LED SIM (Simultaneous): Simultaneous flashing when there are two flashing LED Remote cont.
– 90 – Err or mode detected b y indoor unit Operation of diagnostic function Check code E03 E04 E08 L03 L07 L08 L09 L30 P01 P10 P12 P19 P31 F01 F02 F10 F29 E10 E18 Cause of operation No communication from remote controller (including wireless) and communication adapter The serial signal is not output from outdoor unit to indoor unit.
– 91 – Err or mode detected b y remote contr oller or central contr oller (TCC-LINK) ∗ 2 The check code cannot be displa yed b y the wired remote controller . (Usual operation of air conditioner becomes una v ailable .) F or the wireless models, an error is notified with indication lamp .
– 92 – Err or mode detected b y outdoor unit Operation of diagnostic function Check code Indoor unit F04 F06 F08 H01 H02 H03 H06 L29 L31 ∗ 1 P03 P04 P22 P26 P29 Cause of operation Disconnection, shor t of discharge temp . sensor (TD) Disconnection, shor t of outdoor temp .
– 93 – 10-2-4. Distinction of error mode b y LED indication of outdoor unit On the T ype AP112, AP140 and AP160, a Dip s witch (SW801) and LED are provided on the P .C . board of the outdoor unit. Exchanging this Dip s witch enables users to kno w the status of the outdoor unit in that time.
– 94 – Y ou can perform fault diagnosis of the outdoor unit with the LEDs on the P .C . board of the outdoor unit in addition to check codes displa yed on the wired remote controller of the indoor unit. Use the LEDs and check codes f or various chec ks.
– 95 – 10-2-5. Diagnostic Pr ocedure for Eac h Check Code (Indoor Unit) Check code [E01 error] Is inter-unit cable of A and B normal? Is group control operation? Is power of all indoor units turned on? Is power supplied to remote controller? AB terminal: Appro x.
– 96 – [E04 error] Correct connection of connector . Replace IPDU. Check indoor P .C. board. Defect → Replace Check item code [14]. Correct inter -unit cable. Correct connection of connector . Check/Correct charged refrigerant amount. Check indoor P .
– 97 – Is there no disorder of power supply? Check pow er supply voltage . Correct lines. Check and eliminate noise , etc. YES NO Check indoor control P .
– 98 – [L09 error] YES YES NO NO NO NO Check cause of operation. Check central controller (including network adapter). Defect → Replace Check indoor P .
– 99 – Replace fan motor . Check indoor P .C. board. Defect → Replace Check the corresponding indoor unit and outdoor unit. Is group operation carried out? Is the condenser normal? Isn’t there.
– 100 – Does float switch work? Does drain pump work? Is circuit wiring normal? Is connection of T A sensor connector (CN104 on indoor P .C. board) correct? Are characteristics of T A sensor resistance value normal? ∗∗ Check indoor P .C. board.
– 101 – [P12 error] Does the fan rotate without trouble when handling the fan with hands? Remove connectors CN333 and CN334 of indoor unit P .C. board (MCC -1402). Is output of indoor fan motor position detection signal correct? ∗ 3 Is resistance value of fan motor connector CN334 motor side of indoor P .
– 102 – [P22 error] CN300 : Motor coil winding CN301 : Motor position detection ∗ CN301, CN303 : Motor coil winding CN300, CN302 : Motor position detection Are connections of CN300, CN301, CN302 and CN303 of P .
– 103 – [P19 error] Check 4-way valve Defect → Replace Check and replace electron expansion valve. Replace TC sensor . Correct connection of connector . Replace TC sensor . Check and correct circuit. Check indoor P .C. board. Defect → Replace Check CDB P .
– 104 – [F01 error] Improve the power supply line. Check IPDU. Defect → Replace. Replace IPDU. Check defective rear short of compressor . Defect → Replace Check and correct circuit cables. Correct connection of connector . Check and correct reactor connection.
– 105 – [P29 error] Is not earthed? Is not winding opened? Compressor error → Replace Correct connection of connector . Replace TE and TS sensors. Check and correct circuit cabling such as cabling to compressor . Check IPDU P .C. board. Defect → Replace Check CDB.
– 106 – Correct connection of connector . Replace TO sensor . Correct connection of connector . Improve and eliminate the cause. Improve power line. Compressor lock → Replace Correct mounting. Check cabling between IPDU and CDB and connector . IPDU P .
– 107 – [P03 error] [H01 error] Check parts. Defect → Replace Correct the cabling and connection of connector . Replace TD sensor . Check and correct the charged refrigerant amount. Improve and delete the cause Check CDB. Defect → Replace Improve power line.
– 108 – [P04 error] Does PMV normally operate? Is fan motor normal? Is connection of cabling connector normal? Do not TD and TO sensors come off the detection part? Is connection of connector norm.
– 109 – [97 err or] (Central contr oller) Correct communication line. Correct connection of connector . Check connection of A and B terminal blocks. Correct communication line of remote controller . Clear the check code. T urn on main power supply .
– 110 – [E03 err or] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receiv e a signal sent from the main remote controller (and central controller). In this case, chec k the communication cab les of the remote controllers A and B , the central control system X and Y .
– 111 – 10-2-6. Relational Graph of T emperature Sensor Resistance V alue and T emperature Resistance (k Ω ) Resistance (k Ω ) T emperature [˚C] T emperature [˚C] T emperature [˚C] T empera.
– 112 – 11. REPLA CEMENT OF SER VICE P .C. BO ARD 11-1. Indoort Unit <Note: when replacing the P .C. board f or indoor unit ser vicing> The nonv olatile memor y (hereafter called EEPROM, IC503) on the indoor unit P .
– 113 – [2] P .C. Board f or indoor unit ser vicing replacement pr ocedures Step 1 Replace the P .C . board to the P .C . board for indoor unit servicing. On the new P .C . board, set the same setting of the jumper wire and setting of shor tcut connection connec- tor as those of the P .
– 114 – 36 5 1 4 2 [3] Writing the setting data to EEPROM The settings stored in the EEPROM of the P .C. board for indoor unit servicing are the factory-set values. Step 1 Push SET , CL and TEST buttons on the remote controller sim ultaneously for more than 4 seconds .
– 115 – DN 01 02 03 06 OF 10 11 12 13 14 1E 28 2b 31 32 40 60 Item Filter sign lighting time Filter pollution le ve Central control address Heating suction temperature shift Cooling only T ype Ind.
– 116 – 12. SETUP A T LOCAL SITE AND O THERS 12-1. Indoor Unit 12-1-1. T est Run Setup on Remote Controller <Wired remote controller> 1. When pushing TEST b utton on the remote controller f or 4 seconds or more, “TEST” is displa yed on LC displa y .
– 117 – 12-1-3. LED Displa y on P .C. Boar d 1. D02 (Red) • Goes on at the same time when pow er was tur ned on (Main microcomputer operates and goes on.) • Flashes with 1-second inter v al (e very 500ms): When EEPR OM is not provided or writing was an error .
– 118 – Function selection item No. (DN) list DN 01 03 06 10 11 12 13 14 1E 28 2A 2b 31 32 40 60 C2 D0 Item Filter sign lighting time Central control address Heating suction temp . shift T ype Indoor unit capacity Line address Indoor unit address Group address In automatic cooling/heating, temp .
– 119 – 12-1-5. Wiring and Setting of Remote Contr oller Control (Setup method) One or multiple indoor units are controlled b y 2 remote controllers.
– 120 – 12-1-6. Monitor Function of Remote Contr oller Switch n Calling of sensor temperature displa y <Contents> Each data of the remote controller , indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller .
– 121 – n Calling of err or histor y <Contents> The error contents in the past can be called. <Pr ocedure> 1 Push SET + TEST buttons sim ultaneously for 4 seconds or more to call the service chec k mode . Ser vice Check goes on, the item code 01 is displa yed, and then the content of the latest alar m is displa yed.
– 122 – n Indoor unit power -ON sequence • In a group operation, if the indoor unit which w as f ed power after judgment of automatic address cannot receiv e regular communication from the master unit and regular communication on identical pipe within 120 seconds after pow er w as tur ned on, it reboots (system reset).
– 123 – 12-2. Setup at Local Site / Other s Model name: TCB-PCNT30TLE2 12-2-1. TCC-LINK Adapter (For TCC-LINK Central Control) 1. Function This model is an optional P .C . board to connect the indoor unit to TCC-LINK (Central controller). 2. Micropr ocessor block dia gram 3.
– 124 – • Use 2-core with no polar wire. • Match the length of wire to wire length of the central control system. If mix ed in the system, the wire length is lengthened with all indoor/outdoor inter-unit wire length at side. • T o prev ent noise trouble, use 2-core shield wire .
– 125 – 6. External view of P .C. board assemb ly 7. Address setup In addition to set up the central control address , it is necessar y to change the indoor unit number . (Line/Indoor/Group address). F or details, ref er to TCC-LINK Adapter Installation Manual.
– 126 – How to confirm the central contr ol address (New function f or AMT32 remote controller) <Procedure> It can be confirmed ev en dur ing operation or stopping. 1 Push UNIT LOUVER b utton for 4 seconds or more. ò 2 In the frame at left side of the remote controller screen, the lighting set contents are display ed.
– 127 – Setup of line address of outdoor unit, indoor unit address, and group address Completion of cabling work Turn on power of outdoor unit. Turn on power of outdoor unit. Connect one remote controller with one indoor unit (1 : 1) tentatively with communication cable.
– 128 – 13-2. Address Setup & Gr oup Control <T erminology> Indoor unit No . : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max.
– 129 – 4. Single group operation • Each indoor unit controls the outdoor unit individually . 5. Multiple groups operation (Manual address setting) • Header unit: The header unit receiv es the.
– 130 – 13-2-2. A utomatic Address Example from Unset Address (No mis wiring) 1. Standard (One outdoor unit) 1) Single 2) T win 3) T r iple 2-1 Single T win T r iple 1-1 1-2 3-1 3-2 3-3 2-1 Sub/He.
– 131 – (Example of 2-lines cabling) (Real line: Cabling, Broken line: Refrigerant pipe) For the above example, perform setting by connecting singly the wired remote controller without remote controller inter-unit cable.
– 132 – 1 2 END Operation <Operation procedure> 2 1 SET TIME TIMER SET TEST FIL TER RESET TEMP . CL FAN SA VE SWING/FIX VENT MODE ON / OFF UNIT LOUVER 1 2 3 END <Operation procedure> 3 1 2 SET TIME TIMER SET TEST FIL TER RESET TEMP . CL FAN SA VE SWING/FIX VENT MODE ON / OFF UNIT LOUVER n Confirmation of indoor unit No.
– 133 – 2 4 3 6 9 6 8 5 7 1 Top plate Foaming part 14. DET A CHMENTS 14-1. Indoor Unit REQUIREMENT • At the ser vice replacing time of the heat e xchanger , the follo wing tools are necessar y .
– 134 – No. 2 W ork procedure Remov e the foaming par t. Note) Remov e the foaming par t carefully so that cor ners of the f oaming par t of the inner plate are not chipped off by being caught. Explanatory drawing 2. How to replace the parts (Continued) 3 4 5 Remov e the r ight side plates (2) and (3).
– 135 – No. 6 2. How to replace the parts (Continued) W ork procedure T ake off the pipe fixing brac ke t (1) and the drain shield plate . Explanatory drawing 7 8 9 Remov e the left side plate. Remov e the inner foaming plate and the insulator material.
– 136 – REQUIREMENT • At the ser vice replacing time of the f an motor , the follo wing tools are necessar y . Prepare them bef ore the ser vice work. • Necessar y tools: Plus screwdriv er , L-shape he xagonal wrench (For Ø M8mm (F ace to face 4mm)), ratchet wrench (F or Ø 6mm nut (F ace to f ace 10mm)), monke y wrench, spanner , etc.
– 137 – 4. How to replace the parts (Continued) No. 2 W ork procedure Remov e the electr ic par ts box. Note) • When keeping the electric par ts bo x, be sure not to damage or take off the sensor lead wire connected to the main unit. Explanatory drawing 3 4 5 6 Remov e the r ight side plates (1) and (2).
– 138 – 4. How to replace the parts (Continued) No. 7 W ork procedure Remov e the reinforcing plate . Note) • The reinf orcing plate is provided to protect the transpor tation. Scrap it after unpac king because it is unnecessar y to attach when reassembling.
– 139 – 6. How to replace the sensor No. 1 W ork procedure As same as the work procedure of the f an motor replacing, remov e the r ight side plates (1) and (2). Explanatory drawing 2 3 Remov e the shielding plate. As the shielding plate is assembled with scre ws, tak e the fixing screws off to divide the plate .
– 140 – 6. How to replace the sensor (Contin ued) No. 4 W ork procedure 7. How to c lean the drain por t No. 1 W ork procedure As same as the work procedure of the sensor replacing, remov e the r ight side plates and the shielding plate, and then carr y on the wor k.
– 141 – Heat exchanger P ar tition plate Fin guard Motor base Motor base Reactor assembly V alve fixing plate T op plate T op plate F ront panel F ront panel Side cabinet Side cabinet Motor base Air outlet Air outlet cabinet cabinet Air outlet cabinet T op plate F ront panel Side cabinet 14-2.
– 142 – No. 4 P art name Replacement of electric par ts Common procedure Pr ocedure 1. Detachment 1) Carry out wor ks of 1 of 1 and 3 . 2) Remov e the connectors connected to CDB board. (Connector of pow er supply and upper side f an motor) • Unlock the loc k of the housing par t and then remov e the connectors.
– 143 – No. 7 P art name Replacement of electric par ts Electrolytic condenser Pr ocedure 1. Detachment 1) Carry out wor ks of 1 of 1 , 3 and 4 . 2) Remov e the lead wire connected to the terminal block. (IPDU crossov er wire) 3) Remov e the connector connected to the noise filter .
– 144 – No. 8 P art name Replacement of electric par ts IPDU P .C . board Pr ocedure 1. Detachment 1) Carr y out works of 1 of 1 , 3 and 4 . 2) Remov e the lead wire connected to the terminal bloc k. (IPDU crossov er wire, reactor lead wire) 3) Remov e the lead wire connected to the noise filter .
– 145 – No. 9 P art name Reactor assembly Pr ocedure 1. Detachment 1) Carry out wor ks of 1 of 1 , 3 and 4 . 2) Remov e lead wires connected to the terminal bloc k. 3) Cut the bundling band which binds the rector lead wires. Remarks Service reactor N side L side Marking No Ye s 1.
– 146 – No. 10 P art name F an motor Pr ocedure 1) Carr y out works of 1 and wor k of 2 . 2) Remov e the flange nut fixing the f an motor and the propeller f an. ∗ The flange nut is loosened b y turning it clockwise. (When tightening it, turn it counterclockwise.
– 147 – No. 11 P art name Compressor Compressor lead Remarks Pr ocedure 1. Remov al of defective compressor 1) Recov er the refrigerant gas. 2) Carr y out work of item 1 of 1 and wor k of 3 . 3) Remov e the piping panel (F ront). Remov e the piping panel (F ront) and scre ws of the bottom plate.
– 148 – No. 11 P art name Compressor Compressor lead (Continued) Remarks Pr ocedure 2. Mounting of compressor 1) Mount the compressor in the re verse procedure f or remov al. Note) • After replacement of the compressor , necessarily replace the compressor lead wires.
– 149 – Hooking claw Concave part PMV main unit Positioning projection PMV coil F an guard Bell mouth Discharge port cabinet Earth screw Earth screw T erminal block T erminal block mounting plate .
– 150 – 15. EXPLODED VIEWS AND P ARTS LIST 15-1. Indoor Unit RA V -SM1403DT -A, RA V -SM1603DT -A 203 202 206 210 214 216 215 201 212 213 208 204 207 211 205 207 209 213.
– 151 – Location P ar t No. Description No. 201 43172203 P an Ass ’ y , Drain 202 4312C041 Motor , F an, AC240V , 50Hz, 600W 203 43019830 Bushing 204 43020352 F an 205 43020353 F an 206 43170244.
– 152 – Location P ar t No. Description No. 401 43050425 Sensor TC (F6) Ass ’ y , Ser vice 402 43050426 Sensor T A, Service 403 43055529 Capacitor , AC450V , 8µF 404 43060859 Fuse Block, 30A, 2.
– 153 – 15-2. Outdoor Unit RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E 14 11 10 12 19 38 39 15 20 22 2 41 1 40 21 5 23 17 18 28 35 34 4, 25 27, 37 3 24 31, 33 26, 32 16 6, 9 13 30 .
– 154 – Location P art No. Description No. 1 43019904 Holder , Sensor , SUS 2 43032441 Nipple, Dr ain 3 43041794 Compressor , DA422A3F-25M 4 43047246 Bonnet, 3/8 IN 5 43047669 Nut, Flange 5 431971.
– 155 – 716, 717 712 718 711 705 714, 715 706 713 707 708 702 704 718 701 703 709, 710 RA V -SM1603A T -E, RA V -SM1603A TZ-E, RA V -SM1603A TZG-E Location P ar t No. Description No. 701 43050425 Sensor TC (F6) Ass ’ y , Ser vice 702 43063325 Holder , Sensor , 6 - 6.
W ARNINGS ON REFRIGERANT LEAKA GE For the amount of charge in this example: The possible amount of leaked refrigerant gas in rooms A, B and C is 10kg. The possible amount of leaked refrigerant gas in rooms D, E and F is 15kg. NOTE 2 : The standards for minimum room volume are as follows.
TOSHIBA C ARRIER CORPORA TION 23-17, T A KANA W A 3 CHOME, MINA TOKU, TOK YO , 108-8580, JAP AN Cop yright © 1999 to 2007 T OSHIBA CARRIER CORPORA TION, ALL Rights Reser ved.
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