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Toshiba RAV-GM1601ATP-E (TR) Service Manual
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Toshiba RAV-GM1601ATP-E (TR) Service Manual

Outdoor unit digital inverter
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SERVICE MANUAL
AIR-CONDITIONER
OUTDOOR UNIT
<DIGITAL INVERTER>
RAV-GM1601ATP-E (TR)
RAV-GM1601ATJP-E
R32
(SPLIT TYPE)
FILE NO. SVM-20046
March, 2020

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Summary of Contents for Toshiba RAV-GM1601ATP-E (TR)

  • Page 1 FILE NO. SVM-20046 SERVICE MANUAL AIR-CONDITIONER (SPLIT TYPE) OUTDOOR UNIT <DIGITAL INVERTER> RAV-GM1601ATP-E (TR) RAV-GM1601ATJP-E March, 2020...

  • Page 2: Table Of Contents

    Adoption of R32 Refrigerant Original instruction This air conditioner adopts the HFC refrigerant (R32) which does not destroy the ozone layer. This outdoor unit is designed exclusively for use with R32 refrigerant. Be sure to use in combination with a R32 refrigerant indoor unit. CONTENTS SAFETY CAUTION .......................

  • Page 3: Safety Caution

    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 4 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 5 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. Meaning of symbols displayed on the unit This mark is for R32 refrigerant only.
  • Page 6 WARNING Capacitor connected within WARNING this disconnect or Open the service valves before the downstream upon shutdown operation, otherwise there might be the burst. wait 5 minute to allow capacitors to discharge. CAUTION CAUTION BURST HAZARD BURST HAZARD Open the service valves before the Open the service valves before operation, otherwise there might be the burst.
  • Page 7 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 When you access inside of the electric cover to repair electric parts, wait for about five minutes after turning off the breaker. Do not start repairing immediately. Otherwise you may get electric shock by touching terminals of high-voltage capacitors. Natural discharge of the capacitor takes Electric about five minutes.
  • Page 9 When performing repairs using a gas burner, replace the refrigerant with nitrogen gas because the oil that coats the pipes may otherwise burn. When repairing the refrigerating cycle, take the following measures. 1) Be attentive to fire around the cycle. When using a gas stove, etc., be sure to put out fire before work;...
  • Page 10 When the refrigerant gas leaks, find up the leaked position and repair it surely. If the leaked position cannot be found up and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. When gas touches to fire such as fan heater, stove or cocking stove, it may generate noxious gases, causing a fire though the refrigerant gas itself is innocuous.
  • Page 11 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 12 1) Refer to the “Definition of Qualified Installer or Qualified Service Person.” Declaration of Conformity Manufacturer: TOSHIBA CARRIER (THAILAND) CO., LTD. 144 / 9 Moo 5, Bangkadi Industrial Park, Tivanon Road, Tambol Bangkadi, Amphur Muang, Pathumthani 12000, Thailand TOSHIBA CARRIER EUROPE S.A.S...
  • Page 13 Specification Sound power level (dBA) Model Weight (kg) Cooling Heating RAV-GM1601ATP-E RAV-GM1601ATJP-E RAV-GM1601ATP-TR - 13 -...
  • 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 3) Do not mix the other refrigerant or refrigerating oil with the refrigerant.
  • Page 16 4. Tools Tools exclusive for R410A (The following tools for R410A are required.) : 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...

  • Page 17: Specifications

    1. SPECIFICATIONS 1-1. Outdoor Unit <Digital Inverter> Model name Outdoor unit RAV-GM 1601AT 1 phase 220-240V, 50Hz Power supply 1 phase 220V, 60Hz (Power exclusive to outdoor is required.) Type Hermetic compressor Compressor Motor (kW) 3.75 Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Standard length...

  • Page 18: Operation Characteristic Curve

    1-2. Operation Characteristic Curve RAV-GM1601AT P <Cooling> < > 32.0 32.0 30.0 30.0 68.4 28.0 28.0 26.0 26.0 24.0 24.0 22.0 22.0 20.0 20.0 18.0 18.0 16.0 16.0 14.0 14.0 12.0 12.0 10.0 10.0 Compressor speed (RPS) Compressor speed (RPS) ë...

  • Page 19: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) - 19 -...
  • Page 20 RAV-TWP30E2, RAV-TWP50E2 (Simultaneous Twin) Inner diameter Ø C Inner Inner diameter Ø D diameter Ø D Model (RBC-) Liquid side Ø9.5 Ø6.4 TWP30E2 Gas side Ø15.9 Ø12.7 Liquid side Ø9.5 Ø9.5 TWP50E2 Gas side Ø15.9 Ø15.9 - 20 -...
  • Page 21 RBC-TRP100E (Simultaneous Triple) <Gas side> Header assembly Inner diameter Ø15.9 <Liquid side> Branch pipe assembly Inner diameter Ø9.52 Insulator Gas side socket Liquid side socket Ø15.9 Ø12.7 Ø9.5 Ø6.4 Ø15.9 Ø25.4 Ø9.5 Ø12.7 (External (External (External (External diameter) diameter) diameter) diameter) 3 pcs.

  • Page 22: Systematic Refrigerating Cycle Diagram

    3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3-1. Indoor Unit ë Single type (Combination of 1 indoor unit and 1 outdoor unit) (Indoor unit) Distributor (Strainer incorporated) TCJ sensor Strainer Air heat exchanger TC sensor Heating Cooling Refrigerant pipe Refrigerant pipe at liquid side at gas side (Outer dia : ØB) (Outer dia : ØA)
  • Page 23 <Indoor unit to be connected to RAV-RM1601ATP* • Single type Indoor unit Distributor (Combination of one indoor unit and (Strainer TCJ sensor one outdoor unit) incorporated) Air heat exchanger TC sensor Refrigerant pipe Refrigerant pipe at liquid side at gas side Outer diameter Ø9.5 Outer diameter Ø15.9 Heating...

  • Page 24: Outdoor Unit

    3-2. Outdoor Unit RAV-GM1601AT P Ball valve Packed valve Outer dia. Ø15.88 Outer dia. Ø9.52 Pressure Strainer TŌ sensor switch TS sensor (Pulse Motor Valve) TL sensor TD sensor Strainer 4-way valve sensor Heat exchanger Muffler Ø8, 2 rows, 52 steps FP1.3 flat fin Distributor Ø25 ×...

  • Page 25: Wiring Diagram

    4. WIRING DIAGRAM - 25 -...

  • Page 26: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS Parts name Type Specification Compressor 3 phase, 4P, 3750W DX380A2T-20M Fan motor ICF-280-A100-1 Output 100 W 4-way valve coil DXQ-1490 PMV coil CAM-MD12TF-18 High-pressure SW ACB-4UB166W OFF:4.15MPa Reactor CH-57-Z-T;R 8.88~10.01mH, 16A P.C. board MCC-1758 Fuse (Mounted on P.C. board) AC250 V, 50 A Fuse AC250 V, 10 A...

  • Page 27: Refrigerant R32

    6. . REFRIGERANT R This air conditioner adopted the R32 refrigerant 6. When an air conditioning system charged with a which does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, The working pressure of the refrigerant R32 is even when refrigerant leaks, its concentration 1.6 times higher than conventional refrigerant...
  • Page 28 Table 6-2-1 Thicknesses of annealed copper pipes Thickness (mm) R3 2 Nominal diameter Outer diameter (mm) 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 1. Join 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.
  • Page 29 c) Insertion of Flare Nut d) Flare Processing ØD 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. Flare processing dimensions differ according to the type of flare tool.
  • Page 30 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 31: Tools

    6-3. Tools 6-3-1. Required Tools Refer to the “4. Tools” (Page 14) 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 32: 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 33 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 hard to carbonize.

  • Page 34: Instructions For Re-Use Piping Of R22 Or R407C

    6-6-3. Branching pipe for simultaneous operation system * Pipe diameter and thickness (mm) Reference Wall In the concurrent twin triple system, when TOSHIBA outside thickness Material has specified that branching pipe is to be used, it can diameter (mm) (mm) be reused.
  • Page 35 Placement Term Curing manner location 1 month or more Pinching Outdoors Less than Pinching or 1 month Taping Indoors Every time 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? •...

  • Page 36: Charging Additional Refrigerant

    • (Airtight test), Vacuum dry, Refrigerant charge, Gas 6-6-7. Recovering Refrigerant leak check Use the refrigerant recovery equipment to recover the refrigerant. Test run 6-7. Charging additional refrigerant Amount of additional refrigerant shall be restricted by the following explanation to ensure the reliability. Miss-charging leads to the abnormal high pressure in the 6-6-6.

  • Page 37: Tolerance Of Pipe Length And Pipe Head

    6-8. Tolerance of Pipe Length and Pipe Head n Twin system Total length (L + a or L + b) 50 m Pipe length Branch pipe length (a, b) 15 m (one way) Maximum difference between indoor units 10 m Refrigerant pipe (b –...
  • Page 38 n Triple system Total length (L + a, L +b, L+c) 50 m Pipe length Branch pipe length (a, b, c) 15 m (one way) Maximum difference between indoor units 10 m Refrigerant pipe (|a – b|, |b – c|, |c – d|) specification Between indoor units ( ∆...

  • Page 39: Additional Refrigerant Amount

    6-9. Additional Refrigerant Amount n Twin system <Formula for Calculating Additional Refrigerant Amount> Do not remove the refrigerant even if the additional refrigerant amount becomes minus result as a result of calculations by the following formula and operate the air conditioner as it is. Additional refrigerant amount (kg) = Main piping additional refrigerant amount (kg) + Branch piping additional refrigerant amount (kg) α...
  • Page 40 n Triple system <Formula for Calculating Additional Refrigerant Amount> Do not remove the refrigerant even if the additional refrigerant amount becomes minus result as a result of calculations by the following formula and operate the air conditioner as it is. Additional refrigerant amount (kg) = Main piping additional refrigerant amount (kg) + Branch piping additional refrigerant amount (kg) α...

  • Page 41: Piping Materials And Sizes

    6-10. Piping Materials and Sizes n Twin system Use copper tube of Copper and copper alloy seamless pipes and tubes, with 40mg/10m or less in the amount of oil stuck on inner walls of pipe and 0.8mm in pipe wall thickness for diameters for diameters 6.4, 9.5 and12.7mm and 1.0mm, for diameter 15.9mm.

  • Page 42: Branch Pipe

    6-11. Branch Pipe n Twin system Now the refrigerant pipe is installed using branch 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. •...

  • Page 43: General Safety Precautions For Using R32 Refrigerant

    6-13. General safety precautions for using R32 refrigerant 6-13-1. Recovery 6-13-2. Decommissioning • When removing refrigerant from a system, either • Before carrying out this procedure, it is essential that for servicing or decommissioning,　it is recommended the technician is completely familiar with the good practice that all refrigerants are removed safely.

  • Page 44: Outdoor Control Circuit

    7. OUTDOOR CONTROL CIRCUIT 7-1. Outline of Main Controls 1. Pulse Modulating Valve (PMV) control 1) For PMV with 40 to 500 pulses during operation, respectively. 2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.
  • Page 45 3. Current release control The output frequency and the output voltage are controlled by AC current value detected by current transformer on the outdoor P.C. board so that input current of the inverter does not exceed the specified value. Current [A] Frequency down Hold Hold...
  • Page 46 4-2. Heating fan control 1) An outdoor fan is controlled by TE sensor, TO sensor and compressor frequency. (It is controlled with W1 for minimum and the maximum is controlled according to the following table.) 2) At the start time, the fan is fixed for 3 minutes only with the maximum fan tap corresponded to the zone in the following table but it is controlled with TE sensor temperature after then.
  • Page 47 ˚C No power ˚C Intermittent power-ON • Power-ON 10 minutes: ON / condition ˚C 5 minutes: OFF TD < 30˚C ˚C Continuous power-ON Output power REQUIREMENT While heating the coil, the power sound may be heard. However it is not a trouble. 6.
  • Page 48 10. Defrost control 1 In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition in A zone to D zone. 2 The defrost operation is immediately finished if TE sensor temperature has become 12°C continuing for 3 seconds or more, or it also is finished when condition of 7°C <...

  • Page 49: Outdoor Print Circuit Board

    7-2. Outdoor Print Circuit Board RAV-GM1601AT <MCC-1758> Lead and connector for Reactor CN200-CN202 : Compressor CN400 : Fan Motor (UPPER) CN300 : Fan Motor (LOWER) CN603 : TD sensor connector CN604 : TL sensor connector CN602 : TO sensor connector CN601 : TE sensor connector CN600 : TS sensor connector CN807 : Connector for display...

  • Page 50: Troubleshooting

    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 the following points before check a) The following operations are normal.
  • Page 51 <Wireless remote controller type> 1. Before troubleshooting 1) Required tools/instruments • ⊕ and ⊖ screwdrivers, spanners, radio cutting pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation the following points before check a) The following operations are normal. 1.

  • Page 52: Troubleshooting

    8-2. Troubleshooting 8-2-1. Outline of judgment The following method can be done to check whether the problem occurred in indoor or outdoor unit. The error is indicated by indication lamp on the display of the indoor unit. (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
  • Page 53 Lamp indication Check code Cause of trouble occurrence Operation Timer Ready Heat exchanger sensor (TCJ) error ⎫ ⎪ Heat exchanger sensor (TC) error ⎬ Indoor unit sensor error ⎪ ⎭ Alternate flash Heat exchanger sensor (TA) error Discharge temp. sensor (TD) error ⎫...
  • Page 54 8-2-3. Monitor Function of Remote Controller Switch Calling of sensor temperature display <Contents> Each data of the remote controller, indoor unit and outdoor unit can be shown by calling the service monitor mode from the remote controller. <Procedure> <RBC-AMT32E> TEST Push buttons simultaneously for 4 seconds to call the service monitor mode.
  • Page 55 - 55 -...
  • Page 56 - 56 -...
  • Page 57 Error mode detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of Cause of errors Condition code air conditioner 1. Check cables of remote controller and communication adapters. No communication from remote Stop Displayed when controller (including wireless) and (Automatically Remote controller LCD display OFF (Disconnection) error is detected...
  • Page 58 Error mode detected by outdoor unit Operation of diagnostic function Check code Status of Judgment and measures Cause of errors Condition air conditioner Indoor unit 1. Check discharge temp. sensor (TD). Disconnection, short of discharge Displayed when Stop temp. sensor (TD) error is detected 2.
  • Page 59 Operation of diagnostic function Check code Status of Judgment and measures Cause of errors Condition air conditioner Indoor unit Displayed when 1. Check outdoor P.C. board. Current detection circuit error Stop error is detected (AC current detection circuit) 1. Check case thermostat and its connector 2.
  • Page 60 Error mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Cause of errors Check code Condition air conditioner Power supply error of remote controller, Indoor EEPROM error 1. Check remote controller inter-unit wiring. No communication with master indoor unit 2.
  • Page 61 Contents Error Display When the errors were overlapped, the latest error is displayed. When D800 to D804 are slowly flashing or D805 is flashing, push and hold SW01 and SW02 simultaneously for 5 seconds or more. The error display changes to the error which is generated. TROUBLESHOOTING You can perform fault diagnosis of the outdoor unit with the LEDs on the Sub P.C.Board of the outdoor unit in addition to using the check codes displayed on the wired remote controller of the indoor unit.
  • Page 62 8-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board to narrow the contents to be confirmed. 3) The check code on the remote controller is displayed only when the same trouble occurred continuously by multiple times while LED of the outdoor P.C.
  • Page 63 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] [Discharge temp. sensor (TD) trouble] Is connection of CN603 correct? Correct connector. Is resistance value of TD sensor correct? Replace TD sensor Check outdoor P.C.
  • Page 64 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F15] [Miswiring of heat exchanger sensor (TE, TS)] Is mounting status of Correct sensor mounting. TE and TS sensors correct? Is connection of CN600 correct? Correct connector.
  • Page 65 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H02] [Compressor lock] Is power supply voltage normal? Correct power supply line. AC198 to 264V Is wire connection correct? Compressor lead Check wire connection (P.C.
  • Page 66 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [L10] [Heat sink temp. sensor (TH) trouble] Cut jumper line according to the explanation sheet packaged with the service P.C. board. [L29] [Communication trouble MCUs] Check outdoor P.C.board Failure →...
  • Page 67 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P07] [Heat sink overheat trouble] Is there any looseness in the screw stop of the motor drive element Apply radiation grease IC201 of the outdoor P.C. board, to objective, retightening the sub heat sink, and the diode bridge? of screw...
  • Page 68 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P19] [4-way valve inverse trouble] Does 4-way valve Is the coil work correctly? resistance Replace (Check pipe temp. etc. value of 4-way 4-way valve coil in cooling/heating valve normal? operation.)
  • Page 69 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] [High pressure protective operation] [P04] Is service valve Open service valve fully. fully opened? Reset the power supply and then perform test run Cooling season matching to the season.
  • Page 70 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] [Fan system trouble] Is power supply voltage normal? Check wiring construction. AC198 to 264V Ask repair of power supply. Rotate shaft of the fan motor by hands during power-OFF.
  • Page 71 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P26] [Short-circuit of compressor drive element] Are connections of compressor lead and reactor correct? Correct wiring. (Check referring to the Wiring diagram.) Does the same trouble occur in Replace outdoor operation without compressor lead? P.C.
  • Page 72 8-2-6. Diagnostic Procedure for Each Check Code (Outdoor Unit) Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (kΩ Ω Ω Ω Ω ) Resistance value (kΩ Ω Ω Ω Ω ) Temperature Temperature (°C)
  • Page 73 8-3. Table Inspection of outdoor unit main parts Parts name Checking procedure Compressor Measure the resistance value of each winding by using the tester. (Model : DX380A2T-20M) Position Resistance value Red – White White – Black 0.40Ω White Black Black – Red Under 20°C Outdoor fan motor Measure the resistance value of each winding by using the tester.

  • Page 74: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Error History <Contents> The error contents in the past can be called. <Procedure> TEST Push buttons simultaneously for 4 seconds or more to call the service check mode. TEMP. ON / OFF Service Check goes on, the CODE No.
  • Page 75 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> Gr construction check 3 minutes elapse Normal ∗...

  • Page 76: Outdoor Unit

    9-3. Outdoor Unit Various status displays and operations can be accessed using the push buttons (service switches) on the outdoor Control P.C. board and LED display. Service switch (SW01 and SW02) operation SW02 SW01 LED(D800 to D805) Concerning the LED display •...
  • Page 77 1. Various settings available via the outdoor unit (Existing pipe, Maximum frequency change, Snow guard fan control, Cooling only setup, etc.) (1) Service switch setting Various settings can be made using the service switches [Method of operation] 1) Ensure the LED display shows the initial status. If not then ensure to restore the initial status. 2) Press SW01 for at least 5 seconds.
  • Page 78 Various settings confirmation method Whether the various settings are in effect or not can be confirmed. 1) Ensure the LED display shows the initial status. If not then ensure to restore the initial status. 2) Push SW01 for at least 5 seconds. D804 will start slowly flashing. 3) Push SW01 several times until reaching the desired function on the LED display.
  • Page 79 2. Service support functions (LED display and switch operation) (1) 1) LED display switching (SW01 and SW02 operation) (1)-1. Display switch list Service switches SW01 and SW02 can be used to change the display content of LEDs D800 to D805 on the outdoor unit.
  • Page 80 (1)-2. Trouble display Current and the latest trouble (latest and including the present trouble) can be checked using the lighting status of the LEDs D800 to D805 on the outdoor unit. (1)-2-1. Current trouble indication LED indication Wired remote Name of trouble control trouble code D800 D801 D802 D803 D804 D805 Normal...
  • Page 81 (1)-3. Sensor, current, compressor operation frequency, PMV opening indication Interface (CDB) P.C. board detected values (for example temperature and current sensor values) can be easily checked. ∗ Temperature sensors ... TD, TE, TL, TS, TO, TH, TA, TC, TCJ ∗ Current ......Current sensor (CT) value detected LED indication Temperature Compressor...
  • Page 82 (1)-4. Refrigerant leak detection function Monitors the amount of refrigerant being circulated based on the temperature sensors, compressor rotation speed, PMV opening during operation, and detects any refrigerant leaks during operation and indicates it using the LEDs on the outdoor unit. CAUTION ∗...
  • Page 83 (2) Maintenance inspections Special operations (SW01 and SW02 operations) The following special maintenance and inspection operations can be carried out using the service switches SW01 and SW02. [Method of operation] 1) Ensure the LED display shows the initial state. If not then please ensure to return it to the initial state. 2) Push and hold down SW01 for at least 5 seconds.
  • Page 84 3. . Outdoor application operati Optional connector kit (TCB-PCOS1E2) (1) Peak-cut control • Saves the power of the outdoor unit by the external peak-cut signal to suppress temporary peak power dissipation. • The power saving can be switched to three levels: 75%, 50%, and operation stop. (2) Night operation •...

  • Page 85: 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 86: Address Setup & Group Control

    10-2. Address Setup & Group Control <Terminology> 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/from the remote controllers and sub indoor units.
  • Page 87 4. Single group operation • Each indoor unit controls the outdoor unit individually. Sub/Header Sub/Header Master/Header Sub/Header Sub/Header 5. Multiple groups operation (Manual address setting) Sub/Header Sub/Header Sub/Follower Master/Header Sub/Follower Sub/Follower • Header unit: The header unit receives the indoor unit data (thermo status) of the follower (Without identical line address &...
  • Page 88 10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin 3) Triple (1-1) (1-2) (1-1) (1-2) (1-3) Individual Master/Header Sub/Follower Sub/Header Master/Follower Sub/Follower (Master/Header) Only turning on source power supply (Automatic completion) 2.

  • Page 89: Remote Controller Wiring

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

  • Page 90: Confirmation Of Indoor Unit No. Position

    TEST Push buttons simultaneously for 4 seconds or more. (← ← ← ← ← Line address) Using the temperature setup buttons, to the CODE No. Using timer time buttons, set the line address. Push button. (OK when display goes on.) (←...
  • Page 91 2. To know the position of indoor unit body by address • To confirm the unit No. in the group control (Follow to the procedure during operation) (in this procedure, the indoor units in group control stop.) <Procedure> The indoor unit numbers in the group control are successively displayed, and fan, louver, and drain pump of the corresponding indoor unit are turned on.

  • Page 92: Replacement Of The Service P.c. Board

    11. REPLACEMENT OF THE SERVICE P.C. BOARD(MCC-1646) ! WARNING Don’t open the inverter cover before 1 minute after power has been turned off because an electric shock may be occurred. Assembly steps: LED side of P.C.Board (MCC-1646) shall be inserted to hook① along the guide② of mold. Switch side of P.C.Board (MCC-1646) shall be pressed to hook③...

  • Page 93: 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. For the refrigerant recovery work during reinstallation Remove the defective compressor.

  • Page 94: Detachments

    13. DETACHMENTS Part name Procedure Remarks Common CAUTION procedure Be sure to put on the gloves at working time; Front panel otherwise an injury may be caused by a part, Top cover etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker.
  • Page 95 Part name Procedure Remarks 1. Detachment Plate-stay (Fin guard) 1. Following to work of Detachment 1 2. Remove screws for the Plate-stay(Fin-Guard) ( Ø4 x 10, 7 pcs.), (Ø4 x 14, 2 pcs.) 2. Attachment Attachment the Plate-stay (Fin guard) in the Plate-stay reverse process of "1.Detachment".
  • Page 96 Part name Procedure Remarks 1. Detachment Side cabinet (right) 1) Following to work of Detachment of 1 . Side cabinet (Right) 2) Remove the screws from the side panel (right) Inverter and the inverter box. (Ø4 × 10, 2 pcs.) 3) Remove the screws from the side panel (right) and the valve fixing plate, (Ø4 ×...
  • Page 97 Part name Procedure Remarks 2. Attachment Partition plate Fan motor Fixing rubber (Continued) Attachment the fan motor in the reverse process of "1. Detachment". Precaution when assembling the fan motor. • Tighten the flange nut to 4.95 N.m (50 kgf.cm) •...
  • Page 98 Part name Procedure Remarks Compressor WARNING TD sensor When removing the welding part of the suction / Compressor Sound discharge pipe of the compressor, remove lead insulation them after recovering the refrigerant in a well- (Upper) ventilated place. If recovery is insufficient the Sound refrigerant and refrigerating machine oil may insulation...
  • Page 99 Part name Procedure Remarks Compressor WARNING Compressor Ensure extreme caution when removing Cord clamp lead piping by melting the weld with a burner (Continued) as fire may result if there is any oil within the piping. CAUTION Partition plate Compressor lead Carefully avoid contact with the 4-way valve and PMV with the flame (could result in a malfunction)
  • Page 100 Part name Procedure Remarks P.C.board Detachment 1) Carry out work of 1 of Inverter ════════════════════════ box cover ⚠WARNING Never disassemble the inverter for 1 minute after power has been turned off because an Screw electric shock may be caused. ════════════════════════ 2) Take off screws to open inverter box cover, remove connector from P.C.board and then remove inverter box cover.
  • Page 101 Part name Procedure Remarks P.C.board 7) At the back of inverter box, disconnect (Continued) reactor connector from reactor. Pull reactor wires pass through hole of inverter box. 8) Take off screws that fix P.C.board and remove P.C.board out of inverter box. (Beware: Do not damage edge spacers).

  • Page 102: Exploded Views And Parts List

    14. EXPLODED VIEWS AND PARTS LIST - 102 -...
  • Page 103 Model name Location RAV-GM Part No. Description 1601ATP-E 1601ATJP-E 1601ATP-TR 43T42373 BASE PLATE ASSEMBLY 43T41547 COMPRESSOR(DX380A2T-20M) 43T60504 TEMPERATURE SENSOR 43T49357 RUBBER,CUSHION 43T97326 COMPRESSOR NUT 43T43626 DOWN CONDENSER ASSEMBLY 43T43628 DOWN CONDENSER ASSEMBLY 43T43627 UPPER CONDENSER ASSEMBLY 43T43629 UPPER CONDENSER ASSEMBLY 43T00781 VALVE FIXING PLATE COATING 43T46380...
  • Page 104 <Inverter assembly GM1601 LED displays Service Switches D800 D802 D804 SW01 SW02 D801 D803 D805 1115284101 Q201 CN202 CN200 CN201 C241 DB01 WHI CN801 RY01 GM1601ATP IC800 CN609 CN690 CN710 - 104 -...
  • Page 105 Model name RAV-GM Location Part No. Description 1601ATP-E 1601ATJP-E 1601ATP-TR 43T6W755 PC BOARD ASSY (MCC-1758) 43T6V418 PC BOARD ASSY(MCC-1646)-LED 43T96306 COLLAR 43T96307 BUSHING 43T61315 SPACER(BUSH) 43T61316 SPACER(COLLAR) 43T61321 BASE, PC BOARD 43T60424 ASM-SERV-Terminal block,3P,60A 43T60331 TERMINAL, 3P 43T60413 FUSE 43T50336 TEMPERATURE SENSOR 43T50385 TEMPERATURE SENSOR,TE...
  • Page 106 WARNINGS ON REFRIGERANT LEAKAGE Check of Concentration Limit The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its concentration will not exceed a set limit. The refrigerant R32 which is used in the air conditioner is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws to be imposed which protect the ozone layer.
  • Page 107 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

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