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Toshiba RAV-GP1101AT8-E Service Manual
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Toshiba RAV-GP1101AT8-E Service Manual

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SERVICE MANUAL
AIR-CONDITIONER
OUTDOOR UNIT
<SUPER DIGITAL INVERTER>
RAV-GP1101AT8-E
RAV-GP1101AT8J-E
RAV-GP1401AT8-E
RAV-GP1401AT8J-E
RAV-GP1601AT8-E
RAV-GP1601AT8J-E
Revision 1: Sep., 2019
Revision 2: Oct., 2019
SPLIT TYPE
RAV-GP1101AT8-TR
RAV-GP1101AT8J-TR
RAV-GP1401AT8-TR
RAV-GP1401AT8J-TR
RAV-GP1601AT8-TR
RAV-GP1601AT8J-TR
PRINTED IN JAPAN, Mar., 2019, TOMO
FILE No. A10-1902

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Summary of Contents for Toshiba RAV-GP1101AT8-E

  • Page 1 FILE No. A10-1902 Revision 1: Sep., 2019 Revision 2: Oct., 2019 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE OUTDOOR UNIT <SUPER DIGITAL INVERTER> RAV-GP1101AT8-E RAV-GP1101AT8-TR RAV-GP1101AT8J-E RAV-GP1101AT8J-TR RAV-GP1401AT8-E RAV-GP1401AT8-TR RAV-GP1401AT8J-E RAV-GP1401AT8J-TR RAV-GP1601AT8-E RAV-GP1601AT8-TR RAV-GP1601AT8J-E RAV-GP1601AT8J-TR PRINTED IN JAPAN, Mar., 2019, TOMO...

  • Page 2: Table Of Contents

    CONTENTS Precaution for Safety ................. 7 1. SPECIFICATIONS................ 17 1-1. Outdoor Unit ........................17 1-2. Operation Characteristic Curve ..................18 2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)......19 2-1. Outdoor Unit ........................19 3. OUTDOOR UNIT REFRIGERATING CYCLE DIAGRAM .... 22 4. WIRING DIAGRAM ..............23 4-1.
  • Page 3 8. TROUBLESHOOTING ..............45 8-1. Summary of Troubleshooting .................... 45 8-2. Diagnostic Procedure for Each Check Code (Outdoor Unit) ......... 57 8-3. Sensor characteristics ....................... 68 9. SETUP AT LOCAL SITE AND OTHERS ........70 9-1. Calling of check Code History ..................70 9-2.
  • Page 4 Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
  • Page 5 Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’ work clothing. In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below.
  • Page 6 Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positions. If removing the label during parts replace, stick it as the original. Warning indication Description WARNING WARNING ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK HAZARD...

  • Page 7: Precaution For Safety

    Precaution for Safety The appliance shall be installed in accordance with national wiring regulations. Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position.
  • Page 8 WARNING Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions. Only qualified service person (∗1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.
  • Page 9 WARNING Before troubleshooting or repair work, check the earth wire is connected to the earth terminals of the main unit, otherwise an electric shock is caused when a leak occurs. If the earth wire is not correctly connected, contact an electric engineer for rework. After completing the repair or relocation work, check that the earth wires are connected properly.
  • Page 10 The refrigerant used by this air conditioner is the R32. Check the used refrigerant name and use tools and materials of the parts, which match with it. For the products, which use R32 refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see.
  • Page 11 When the refrigerant gas leaks, find out the leaked position and repair it surely. If the leaked position cannot be found out and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. When gas touches to fire such as fan heater, stove or cooking stove, it may generate noxious gases, causing a fire though the refrigerant gas itself is innocuous.
  • Page 12 Only a qualified installer (∗1) or qualified service person (∗1) is allowed to install the air conditioner. If the air conditioner is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result. Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner.
  • Page 13 Declaration of Conformity Manufacturer: TOSHIBA CARRIER CORPORATION 336 Tadehara, Fuji-shi, Shizuoka-ken 416-8521 JAPAN TCF holder: TOSHIBA CARRIER EUROPE S.A.S Route de Thil 01120 Montluel FRANCE Hereby declares that the machinery described below: Generic Denomination: Air Conditioner Model/type: RAV-GP1101AT8-E, RAV-GP1401AT8-E, RAV-GP1601AT8-E...
  • Page 14 Refrigerant R32 This air conditioner adopts a new HFC type refrigerant (R32) which does not deplete the ozone layer. 1. Safety Caution Concerned to Refrigerant R32 Be sure that water, dust, the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with refrigerant R32 during installation work or service work.
  • Page 15 <Caution items> 1) The opposite side dimension of the air-conditioner’s flared nut using R32 and the shape of the charge port are the same as those of R410A. 2) Be careful not to charge refrigerant by mistake. Should the different type of refrigerant mix in, be sure to recharge the refrigerant.
  • Page 16 4. Tools : R410A tools available : Partly unavailable, : R410A tools unavailable Installation/service tools Applicability to R32 air Applicability to R22 air conditioner or not conditioner or not Tools / Equipment specification 1 Flare tool Clutch type Pipe flaring Copper pipe gauge for Flaring by —...

  • Page 17: Specifications

    1. SPECIFICATIONS 1-1. Outdoor Unit 1101AT8(J)-E 1401AT8(J)-E 1601AT8(J)-E Outdoor unit 1101AT8(J)-TR 1401AT8(J)-TR 1601AT8(J)-TR 3 phase 380-415, 50Hz Power supply (Power exclusive to outdoor is required) Type Hermetic compressor Pulse motor valve Refrigerant control Pipe Height Outdoor lower Difference Outdoor Height Silky shade Appearance (Munsell 1Y8.5/0.5)

  • Page 18: Operation Characteristic Curve

    1-2. Operation Characteristic Curve • Operation characteristic curve, 50Hz <Super Digital Inverter> <Cooling> <Heating> GP160 SP160 SP160 GP140 SP140 SP140 SP110 SP110 GP110 • Conditions • Conditions Indoor : DB27˚C/WB19˚C Indoor : DB20˚C Outdoor : DB7˚C/WB6˚C Outdoor : DB35˚C Air flow : High Air flow : High Pipe length : 7.5m Pipe length : 7.5m...

  • Page 19: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. Outdoor Unit RAV-GP1101AT8(J)-E, -TR RAV-GP1401AT8(J)-E, -TR RAV-GP1601AT8(J)-E, -TR – 19 –...
  • Page 20 RBC-TWP30E2, RBC-TWP50E2 (Simultaneous Twin) Inner diameter DIA C Inner Inner diameter DIA D diameter DIA D (Units: mm) Model (RBC-) Liquid side TWP30E2 Gas side 15.9 12.7 Liquid side TWP50E2 Gas side 15.9 15.9 – 20 –...
  • Page 21 RBC-TRP100E (Simultaneous Triple) <Gas side> Header assembly (Units: mm) Inner diameter DIA 15.9 1 pc. <Liquid side> Branch pipe assembly Inner diameter DIA 9.52 1 pc. Insulator Gas side socket Liquid side socket DIA 15.9 DIA 12.7 DIA 9.5 DIA 6.4 DIA 15.9 DIA 25.4 DIA 9.5...

  • Page 22: Outdoor Unit Refrigerating Cycle Diagram

    3. OUTDOOR UNIT REFRIGERATING CYCLE DIAGRAM TO sensor TS sensor TL sensor Pressure switch Strainer TE sensor Check joint Capillary Cooling: High pressure DIA 4 × DIA 3 (6 pcs.) Heating: Low pressure Heat exchanger Distributor Refrigerant pipe DIA 8, 2 rows, 52 stages TD sensor at liquid side DIA 9.5 FP1.45, flat fin...

  • Page 23: Wiring Diagram

    4. WIRING DIAGRAM 4-1. Outdoor Unit RAV-GP1101AT8(J)-E, -TR RAV-GP1401AT8(J)-E, -TR RAV-GP1601AT8(J)-E, -TR – 23 –...

  • Page 24: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit Parts name Type Specifications Compressor RX420A3F-27M — Outdoor fan motor ICF-280-A100-1 DC 280 V, 100 W 4-way valve coil STF-H01AJ1736A1 AC 220 – 240 V, 50/60 Hz PMV coil UKV-A038 DC 12 V High pressure switch ACB-4UB83W OFF : 4.15 MPa...

  • Page 25: Refrigerant R32

    6. REFRIGERANT R32 This air conditioner adopts the R32 refrigerant which 7. Be sure to carry out installation or removal does not damage the ozone layer. according to the installation manual. The working pressure of the new refrigerant R32 is Improper installation may cause refrigeration 1.6 times higher than conventional refrigerant (R22).

  • Page 26: Processing Of Piping Materials

    Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A or R32 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 1. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for piping whose outer diameter exceeds 20 mm.
  • Page 27 c) Insertion of Flare Nut d) Flare Processing DIA D 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 / R32 or conventional flare tool.
  • Page 28 Fig. 6-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench.

  • Page 29: Tools

    6-3. Tools 6-3-1. Required Tools Refer to the “4. Tools” (Page 16) 6-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment.

  • Page 30: Brazing Of Pipes

    1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. R32 refrigerant is a Single-component refrigerant that does not change its composition. Although it is possible to charge the refrigerant with either liquid or gas, charge it with liquid.

  • Page 31: Brazing

    2. Characteristics required for flux 6-5-3. Brazing • Activated temperature of flux coincides with the As brazing work requires sophisticated techniques, brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is In order to prevent the oxide film from occurring in the hard to carbonize.

  • Page 32: Instructions For Re-Use Piping Of R22 Or R407C

    Operation System case. • In the concurrent twin system, when TOSHIBA- ∗ ∗ ∗ ∗ ∗ Pipe diameter and thickness (mm) specified branching pipe is used, it can be reused.

  • Page 33: Final Installation Checks

    6-6-5. Final Installation Checks Existing pipes: Cannot be used. Are there scratches or dents on the existing pipes? • Use new pipes. Is it possible to operate the existing air conditioner? • After the existing air conditioner is operated in cooling mode for approx.

  • Page 34: Handling Of Existing Pipe

    6-6-6. Handling of Existing Pipe 6-6-7. Recovering Refrigerant When using the existing pipe, carefully check it for Use the refrigerant recovery equipment to recover the the following: refrigerant. • Wall thickness (within the specified range) 6-7. Charging additional refrigerant • Scratches and dents •...

  • Page 35: General Safety Precautions For Using R32 Refrigerant

    6-8. General safety precautions for using R32 refrigerant 6-8-1. Recovery 6-8-2. Decommissioning • When removing refrigerant from a system, either for • Before carrying out this procedure, it is essential servicing or decommissioning, it is recommended that the technician is completely familiar with the good practice that all refrigerants are removed equipment and all its details.

  • Page 36: Circuit Configuration And Control Specifications

    7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1596 (Compressor IPDU) CN851 CN101 (Red) (White) Connector for MCC-1597 (CN505) Connector for MCC-1597 (CN502) CN13 (Black) Terminal for power relay Electric circuit protective fuse (500V, 31.5A) CN12 (White) Terminal for MCC-1600 (CN17)

  • Page 37: Print Circuit Board, Mcc-1597 (Fan Motor Ipdu)

    7-1-2. Print Circuit Board, MCC-1597 (Fan Motor IPDU) CN750 CN700 CN500 (White) (Blue) (Red) Fan motor output (Upper side) Fan motor output (Lower side) Connector for MCC-1600 (CN23) and reactor CH68 CN504 CN602 F500 (Blue) (Black) Connector for MCC-1599 Connector for MCC-1600 (CN51) Electric circuit protective fuse (CN802) (250V, 15A)

  • Page 38: Print Circuit Board, Mcc-1599 (Interface (Cdb))

    7-1-3. Print Circuit Board, MCC-1599 (Interface (CDB)) CN708 CN608 (Blue) (White) Connector for power relay coil Connector for MCC-1600 (CN50) CN02 (Red) CN802 (White) Connector for MCC-1600 (CN10 and CN19) Connector for MCC-1597 (CN504) CN700 (Yellow) Power supply protective fuse (250V, 3.15A) 4-way valve connector Temp.sensor connector...

  • Page 39: Print Circuit Board, Mcc-1600 (Noise Filter)

    7-1-4. Print Circuit Board, MCC-1600 (Noise Filter) CN05 CN16 (Red) CN10 (Red) (Red) ower supply terminal (L1) erminal for power relay erminal for MCC-1599 (CN02) and Terminal for PTC thermistor aristor protective fuse (250V, 6.3A) CN06 (White) ower supply terminal (L2) CN17 (White) erminal for...

  • Page 40: Outline Of Main Controls

    7-2. Outline of Main Controls 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between 30 and 500 pulses during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming 1 to 4K as the target value. 3) In heating operation, PMV is usually controlled with the temperature difference between TS sensor and TE sensor aiming –1 to 4K as the target value.
  • Page 41 3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] GP110 to GP160 Down — — 3-1) Cooling fan control The outdoor fan is controlled by TL sensor, TO sensor and the operation frequency. The outdoor fan is controlled by every 1 tap of DC fan control (14 taps). Only for 60 seconds after the operation has started, the maximum fan tap corresponding to the zone in the following table is fixed and then the fan is controlled by temperature of TL sensor.
  • Page 42 4. Coil heating control 1) This control function heats the compressor by turning on the stopped compressor instead of a case heater. It purposes to prevent stagnation of the refrigerant inside of the compressor. 2) As usual, turn on power of the compressor for the specified time before a test run after installation; otherwise a trouble of the compressor may be caused.
  • Page 43 7. Current release value shift control Current release control value (I1) 1) This control purposes to prevent troubles of the electronic parts such as the compressor driving Temperature range GP110 GP140 GP160 elements and the compressor during cooling 47˚C≤ TO operation.
  • Page 44 10. Defrost control 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 12°C or higher for 3 seconds or continued 7°C ≤...

  • Page 45: Troubleshooting

    8. TROUBLESHOOTING 8-1. Summary of Troubleshooting <Wired remote controller type> 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, long-nose pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal.
  • Page 46 <Wireless remote controller type> 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, long-nose pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1. Compressor does not operate. •...
  • Page 47 Outline of troubleshooting The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method. Method to judge the troubleshooting by flashing indication on indoor unit lamp display (the signal receiving unit of wireless remote controller) When the protective function operates the self-diagnosis contents appear in flashing indication on indoor unit lamp display.
  • Page 48 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready Heat exchanger sensor (TCJ) trouble Heat exchanger sensor (TC) trouble Indoor unit sensor trouble Room air temperature sensor (TA) trouble Alternate flash Discharge temp. sensor (TD) trouble Temp. sensor (TE) trouble Operation Timer Ready Temp.
  • Page 49 Others (Other than Check Code) Lamp indication Check code Cause of trouble occurrence Operation Timer Ready — During test run Simultaneous flash Operation Timer Ready Disagreement of cool/heat — (Automatic cool/heat setting to automatic cool/heat prohibited model, or setting of heating to cooling-only model) Alternate flash –...
  • Page 50 8-1-1. Monitor Function of Remote Controller Calling of sensor temperature display <Contents> Each data of the remote controller, indoor unit and outdoor unit can be understood by calling the service monitor mode from the remote controller. <Procedure> Push buttons simultaneously for 4 seconds to call the service monitor mode.
  • Page 51 – 51 –...
  • Page 52 – 52 –...
  • Page 53 Check code table The contents of trouble detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of Cause of operation Condition code air conditioner 1. Check cables of remote controller and communication adapters. No communication from remote Displayed when Stop controller (including wireless) and...
  • Page 54 Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit Disconnection, short-circuit of Displayed when 1. Check discharge temp. sensor (TD). Stop discharge temp. sensor (TD) trouble is detected 2. Check outdoor P.C. board (MCC-1599). Disconnection, short-circuit of outdoor Displayed when 1.
  • Page 55 Operation of diagnostic function Check code Judgment and measures Status of Cause of operation Condition air conditioner Indoor unit Discharge temp. trouble 1. Check refrigerating cycle (Gas leak) Displayed when ∗ Discharge temp. (TD) over 2. Trouble of electronic expansion valve Stop trouble is detected specified value was detected.
  • Page 56 The contents of trouble detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Check code Cause of operation Condition air conditioner Power supply trouble of remote controller, Indoor EEPROM trouble Not displayed 1.

  • Page 57: Diagnostic Procedure For Each Check Code (Outdoor Unit)

    8-2. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board to narrow the contents to be confirmed. 3) The display on the remote controller may differ from that of LED.
  • Page 58 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] <Display 1> <Display 2> [Discharge temp. sensor (TD) trouble] Is CN603 connection normal? Correct connector. Sensor trouble → Replace Is resistance value of TD sensor normal? Replace outdoor P.C.
  • Page 59 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F08] <Display 1> <Display 2> [Outside air temp. sensor (TO) trouble] Is CN602 connection normal? Correct connector. Sensor trouble → Replace Is resistance value of TO sensor normal? Replace outdoor P.C.
  • Page 60 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F31] <Display 1> <Display 2> [EEPROM trouble] Replace outdoor P.C. board (MCC-1599). [H01] <Display 1> <Display 2> [Compressor break down] Is power supply voltage normal? Correct power supply line.
  • Page 61 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H03] <Display 1> <Display 2> [Current detection circuit trouble] Replace outdoor P.C. board (MCC-1596). [Power supply trouble (Vdc)] → Refer to [P05] column. <Display 1>...
  • Page 62 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) ∗ There is a possibility that it is one of the following trouble. [L29] Confirm LED on outdoor P.C. board to judge which trouble it is. Communication trouble between MCU, Heat sink temp.
  • Page 63 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P03] <Display 1> <Display 2> [Discharge temp. trouble] Repair trouble position. Is there no gas leak? Recharge refrigerant. Is refrigerant charge amount adequate? Replace PMV.
  • Page 64 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P04] Heating operation Are connections of Does the heating indoor fan connectors, capacitors normally operate? and fan motor normal? Is there any element which blocks indoor heat exchanger? Elimination of Repair...
  • Page 65 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P05] <Display 1> <Display 2> [Power supply trouble (Voltage trouble)] Is there open phase Correct wiring. of the power supply? Is power supply voltage normal? Confirm electric construction, etc.
  • Page 66 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] <Display 1> <Display 2> [High pressure protective operation] Is valve fully opened? Open valve fully. Reset the power supply and then perform test run Cooling season matching to the season.
  • Page 67 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] <Display 1> <Display 2> [Fan system trouble] Is power supply voltage normal? Check wiring construction. (342 to 457V) Ask repair of power supply. Does the fan rotate without trouble when rotating shaft of fan motor with hands during power-OFF? Is coil resistance of fan motor correct?

  • Page 68: Sensor Characteristics

    8-3. Sensor characteristics Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (k Ω) Resistance value (k Ω) Temperature Temperature (˚C) (˚C) (Minimum value) (Standard value) (Maximum value) (Minimum value) (Standard value) (Maximum value) 32.33 33.80...
  • Page 69 Table Inspection of outdoor unit main parts Parts name Checking procedure Compressor Measure the resistance value of each winding by using the tester. (Model : RX420A3F-27M) Position Resistance value Red – White 0.79 ± 0.04 Ω White – Black White Black Black –...

  • Page 70: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of check Code History <Contents> The trouble contents in the past can be called. <Procedure> TEMP. ON / OFF Push buttons simultaneously for 4 seconds or more to call the service check mode. TIMER SET MODE Service Check goes on, the CODE No.
  • Page 71 Indoor unit power-ON sequence Power ON • The unit without power feed waits entirely → Waiting status is released by system start • Reboot when power is fed on the way <By feed unit> <Automatic address judgment> Not normal 3 minutes elapse Gr construction check Normal ∗...

  • Page 72: Outdoor Unit

    9-3. Outdoor Unit 9-3-1. Various Setting on Outdoor Unit (Existing piping, Power save, Cooling-only, etc.) The following settings are available by DIP switch setup and jumper line setup. Function Set position Control contents Turn the switch to ON when mounting a duct to the discharge port of the outdoor unit.
  • Page 73 9-3-2. Service Support Function (LED Display, Switch Operation) 1. Outline A various setup and operation check can be performed by DIP switches at 3 positions (SW802, SW803, SW804) and the pushdown button switches (SW800, SW801) at 2 positions. Operation part Part No.
  • Page 74 9-3-3. Others 1. Selection of LED display (SW800, SW803 operation) 1) Display selection list The displayed contents of LED D800 to D804 on the outdoor control P.C. board can be exchanged by operation of SW803. Switch Function / Contents Refer Trouble display (Trouble generating at present) Refer to SW803...
  • Page 75 2) Trouble display The trouble which is generating at present and the latest trouble (Latest trouble information including present) can be confirmed by lighting LED D800 to D804 on the outdoor control P.C. board. a) When all DIP switch SW803 are OFF, the status of trouble which is generating at present is displayed. b) <1>...
  • Page 76 3) Sensor, current, compressor operation frequency, PMV opening display The values detected by the controller, such as temperature sensor or current value are simply confirmed. (Legend) D800 D801 D802 D803 D804 D805 : Go off, : Go on (Yellow) (Yellow) (Yellow) (Yellow) (Yellow) (Green) Temperature sensor (°C) Compressor SW803...
  • Page 77 4) Specific operation for maintenance check (SW801, SW804) The following specific operations for the maintenance check are performed by operation of SW801 or SW804. a) Select DIP switch SW804. (See table below) b) Push the pushdown button switch SW801 for approx. 1 second. c) The following functions start.
  • Page 78 SW804 Operation when pushdown button switch SW801 is pushed 4-way valve relay operation (For RY700, CN70 check) SW804 Turn on 4-way valve power relay (RY700). When pushing SW801 again or when 2 minutes elapsed, the operation returns to the normal control. [CAUTION] Although these operations can Heater output relay operation...

  • Page 79: Address Setup

    10. ADDRESS SETUP 10-1. Address Setup Procedure When an outdoor unit and an indoor unit are connected, or when an outdoor unit is connected to each indoor unit respectively in the group operation even if multiple refrigerant lines are provided, the automatic address setup completes with power-ON of the outdoor unit.

  • Page 80: Address Setup & Group Control

    10-2. Address Setup & Group Control <Definitions of terms> Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/...

  • Page 81: System Configuration

    10-2-1. System Configuration 1. Single Outdoor Indoor (Master/Header) Individual Remote controller 2. Twin 3. Triple Master/Header Sub/Follower Master/Header Sub/Follower Sub/Follower 4. Single group operation Sub/Header Sub/Header Sub/Header Master/Header Sub/Header (Max. : 8 units) • Each indoor unit controls the outdoor unit individually. 5.

  • Page 82: Automatic Address Example From Unset Address (No Miss-Wiring)

    10-2-2. Automatic Address Example from Unset Address (No miss-wiring) 1. Standard (One outdoor unit) 1. Single 2. Twin 3. Triple Individual Master/Header Sub/Follower Master/Header Sub/Follower Sub/Follower Only turning on source power supply (Automatic completion) 2. Single group operation (Multiple outdoor units = Multiple indoor units only with serial communication) Sub/Header Sub/Header Sub/Header...

  • Page 83: Remote Controller Wiring

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

  • Page 84: Address Setup (Manual Setting From Remote Controller)

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

  • Page 85: Confirmation Of Indoor Unit No. Position

    10-5. Confirmation of Indoor Unit No. Position 1. To know the indoor unit addresses though position of the indoor unit body is recognized • In case of individual operation (Wired remote controller : indoor unit = 1 : 1) (Follow to the procedure during operation) <Procedure>...
  • Page 86 <Maintenance/Check list> Aiming in environmental preservation, it is strictly recommended to clean and maintain the indoor/outdoor units of the operating air conditioning system regularly to secure effective operation of the air conditioner. It is also recommended to maintain the units once a year regularly when operating the air conditioner for a long time.

  • Page 87: Replacement Of The Service P.c. Board Mcc-1599

    11. REPLACEMENT OF THE SERVICE P.C. BOARD MCC-1599 1. Setting the jumper wires and DIP switches Part name Function Setting J800 to J803 Model switching Cut these jumper wires according to the following table. Jumper wire Set these jumper wires to the settings of the P.C. board J804 to J811 Settings before replacement...

  • Page 88: How To Exchange Compressor

    12. HOW TO EXCHANGE COMPRESSOR 12-1. Exchanging Procedure of Compressor (Outline) START Open PMV forcedly and then recover refrigerant Has refrigerant recovery work been done? using a refrigerant recovery unit. Turn off the leakage breaker. Never recover the refrigerant to the outdoor unit. •...

  • Page 89: Detachments

    13. DETACHMENTS 13-1. Outdoor Unit RAV-GP1101AT8*, RAV-GP1401AT8*, RAV-GP1601AT8* series Part name Procedure Remarks Common procedure WARNING Stop operation of the air conditioner and turn off breaker switch. CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc. 1.
  • Page 90 Part name Procedure Remarks Discharge 1. Detachment Heat exchanger Motor base port cabinet 1) Carry out the operation in 1. of above. 2) Remove the screws fixing the inverter assembly, the discharge port cabinet and the partition board. (ST1T M4 × 8, 4 pcs.) 3) Remove the screws for the discharge port cabinet and the bottom plate.
  • Page 91 Part name Procedure Remarks Side cabinet 1. Detachment Discharge port cabinet Side cabinet 1) Carry out the operation in 1. of above. Inverter assembly 2) Remove the screws fixing the inverter assembly and the side cabinet. (ST1T M4 × 10, 3 pcs.) 3) Remove the screws for the side cabinet and the valve fixing plate.
  • Page 92 Part name Procedure Remarks Inverter 1. Detachment assembly 1) Carry out the operation in 1. of , 1. of above. 2) Remove the connectors connected to the Fan IPDU board, the connector connected to other components from the control board Cut the Cut the Cut the...
  • Page 93 Part name Procedure Remarks Interface board 1. Detachment (Control board) 1) Carry out the operation in 1. of , and MCC-1599 1. of above. 2) Remove lead wires and connectors to other components from the interface board (control board). CN01 : Indoor/Outdoor connection terminal (5P: White) CN02 : Power relay (3P: Red) CN600 : TS sensor (3P: White, tube: Gray)
  • Page 94 Part name Procedure Remarks Fan-IPDU board 1. Detachment FAN-IPDU board MCC-1597 1) Carry out the operation in 1. of , and 1. of above. 2) Remove lead wires and connectors to other components from the Fan-IPDU board. CN500 : Connection between reactor and noise filter board (7P, Red) CN502 : Compressor IPDU board (3P, White) CN504 : Interface board (5P, Blue)
  • Page 95 Part name Procedure Remarks Noise filter 1. Detachment Fan-IPDU board board 1) Perform the operation in 1. of ,1. of MCC-1600 1.-2 of and 1.-2 of 2) Remove the screws (3 positions) fixing the inverter assem- bly (front). Then slide the inverter assembly (front) upwardly and remove.
  • Page 96 Part name Procedure Remarks Compressor 1. Detachment IPDU board 1) Carry out the operation in 1. of , 1. of MCC-1596 1. of , 1. of and 1. of 2) Remove the screw (4 positions) fixing the inverter assembly (IPDU). 3) Remove the lead wire and connector to other components from the compressor IPDU board.
  • Page 97 Part name Procedure Part name Fan motor 1) Carry out works of item 1 of and work of 2) Remove the flange nut fixing the fan motor and the propeller Propeller fan Propeller fan Propeller fan fan. • The flange nut is loosened by turning it clockwise. Loosened by Loosened by Loosened by...
  • Page 98 Part name Procedure Remarks Compressor 1. Removal of trouble compressor Piping panel (Front) Piping panel (Front) Piping panel (Front) Compressor 1) Recover the refrigerant gas. lead 2) Carry out work of item 1 of , 1 of and 1 of 3) Remove the piping panel (Front).
  • Page 99 Part name Procedure Remarks Compressor 2. Mounting of compressor Wrap the ferrite core with the compressor Compressor lead 1) Mount the compressor in the reverse lead wire for 1 time. procedure for removal. (Continued) Compressor lead Compressor lead Compressor lead NOTE •...
  • Page 100 Part name Procedure Remarks PMV coil 1. Detachment Concave part PMV main unit 1) Carry out work of item 1 of 2) Turn the coil while pulling upward and then remove the coil from the PMV main unit. 2. Attachment 1) Surely match the positioning projection of the coil with the concave part of PMV main unit and then fix it.

  • Page 101: Exploded Views And Parts List

    14. EXPLODED VIEWS AND PARTS LIST 14-1. Outdoor Unit RAV-GP1101AT8-E, RAV-GP1101AT8J-E RAV-GP1101AT8-TR, RAV-GP1101AT8J-TR – 101 –...
  • Page 102 VALVE, BALL, SBV-JA5GTC-1, ROHS 43148294 ACCUMULATOR 43151301 SWITCH, PRESSURE 43160612 LEAD ASSY, COMPRESSOR 43147194 BONNET, 5/8 IN 4311M659 MARK, TOSHIBA 4314G266 CONDENSER ASSY, DOWN 4314G268 CONDENSER ASSY, DOWN 4314G269 CONDENSER ASSY, UP 4314G271 CONDENSER ASSY, UP 4314N023 VALVE, PLUS, MODULAING, UKV-25D100...
  • Page 103 Outdoor Unit RAV-GP1401AT8-E, RAV-GP1401AT8J-E RAV-GP1401AT8-TR, RAV-GP1401AT8J-TR – 103 –...
  • Page 104 VALVE, BALL, SBV-JA5GTC-1, ROHS 43148294 ACCUMULATOR 43151301 SWITCH, PRESSURE 43160612 LEAD ASSY, COMPRESSOR 43147194 BONNET, 5/8 IN 4311M659 MARK, TOSHIBA 4314G266 CONDENSER ASSY, DOWN 4314G268 CONDENSER ASSY, DOWN 4314G269 CONDENSER ASSY, UP 4314G271 CONDENSER ASSY, UP 4314N023 VALVE, PLUS, MODULAING, UKV-25D100...
  • Page 105 Outdoor Unit RAV-GP1601AT8-E, RAV-GP1601AT8J-E RAV-GP1601AT8-TR, RAV-GP1601AT8J-TR – 105 –...
  • Page 106 VALVE, BALL, SBV-JA5GTC-1, ROHS 43148294 ACCUMULATOR 43151301 SWITCH, PRESSURE 43160612 LEAD ASSY, COMPRESSOR 43147194 BONNET, 5/8 IN 4311M659 MARK, TOSHIBA 4314G266 CONDENSER ASSY, DOWN 4314G268 CONDENSER ASSY, DOWN 4314G269 CONDENSER ASSY, UP 4314G271 CONDENSER ASSY, UP 4314N023 VALVE, PLUS, MODULAING, UKV-25D100...

  • Page 107: Inverter Assembly

    14-2. Inverter Assembly RAV-GP1101AT8(J)-E, RAV-GP1401AT8(J)-E, RAV-GP1601AT8(J)-E RAV-GP1101AT8(J)-TR, RAV-GP1401AT8(J)-TR, RAV-GP1601AT8(J)-TR 718, 719 718, 719 721 710 – 107 –...
  • Page 108 Model name RAV-GP Location Part No. Description 1101AT8(J)-E, 1401AT8(J)-E, 1601AT8(J)-E 1101AT8(J)-TR, 1401AT8(J)-TR, 1601AT8(J)-TR 43F58288 REACTOR, CH-56-4Z 43154177 RELAY 43158207 REACTOR, CH-68 43153006 PTC-THERMISTOR 43050425 SENSOR ASSY, SERVICE 43150319 SENSOR ASSY, SERVICE 43160565 TERMINAL BLOCK, 3P, 20A 43160579 TERMINAL, 30A, 4P 43F60859 FUSE BLOCK, 30A, 250V 4316V416...
  • Page 109 72-34 Horikawa-cho, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8585, JAPAN Copyright © 2019 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved. Revision record First issue — — Mar., 2019 Revision 1 Words were corrected. All the pages Sep., 2019 The service part number was changed.

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