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Toshiba RAV-GP561ATW-E Service Manual
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Toshiba RAV-GP561ATW-E Service Manual

Air-conditioner split type
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AIR-CONDITIONER SPLIT TYPE
Service Manual
Model name:
Outdoor unit
<SUPER DIGITAL INVERTER>
RAV-GP561ATW-E
RAV-GP801ATW-E
RAV-GP561ATW-TR
RAV-GP801ATW-TR
FILE No. AEO-2103W
Revision 1: May, 2021

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Summary of Contents for Toshiba RAV-GP561ATW-E

  • Page 1 FILE No. AEO-2103W Revision 1: May, 2021 AIR-CONDITIONER SPLIT TYPE Service Manual Model name: Outdoor unit <SUPER DIGITAL INVERTER> RAV-GP561ATW-E RAV-GP561ATW-TR RAV-GP801ATW-E RAV-GP801ATW-TR...

  • Page 2: Table Of Contents

    Original instruction (English) Contents SAFETY CAUTION ............4 1 SPECIFICATIONS.
  • Page 3 6-6-5.Final Installation Checks ..........50 6-6-6.Handling of Existing Pipe .

  • Page 4: Safety Caution

    • The qualified installer is a person who installs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Air-conditioning Europe Sp. z o.o. He or she has been trained to install, main- tain, relocate and remove the air conditioners made by Toshiba Carrier Air-conditioning Europe Sp.
  • 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. This mark is for R32 refrigerant only. Refrigerant type is written on nameplate of outdoor unit.
  • Page 7 CAUTION CAUTION Do not touch the aluminum fins of the unit. Do not touch the aluminum fins of the unit. Doing so may result in injury. Doing so may result in injury. CAUTION CAUTION Do not touch the aluminum fins of Do not touch the aluminum fins of the unit.
  • Page 8 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 9 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 10 WARNING If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, wear insulated heat-resistant gloves, insulated boots and insulated work overalls, and take care to avoid touching any live parts.
  • Page 11 WARNING 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 12 WARNING 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, reclaim 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 13 WARNING 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 14 Declaration of Conformity Manufacturer: Toshiba Carrier Air-conditioning Europe Sp. z o.o. ul. Gdańska 131, 62-200 Gniezno, Poland TCF holder: Toshiba Carrier Air-conditioning Europe Sp. z o.o. ul. Gdańska 131, 62-200 Gniezno, Poland Hereby declares that the machinery described below: Generic Denomination: Air Conditioner...
  • Page 15 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 16 <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 17 (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 Flaring by Copper pipe gauge for...

  • Page 18: Specifications

    SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Smart Cassette <Single type> Indoor unit RAV-GM 561UT* 801UT* Model Outdoor unit RAV-GP 561ATW* 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 5.72-5.24...

  • Page 19: 1-1-2.4-Way Cassette

    1-1-2. 4-Way Cassette <Single type> Indoor unit RAV-RM 561UTP* 801UTP* Model Outdoor unit RAV-GP 561ATW* 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 6.04-5.54 7.72-7.08 Power consumption (kW)

  • Page 20: 1-1-3.Compact 4-Way Cassette

    1-1-3. Compact 4-Way Cassette <Single type> Indoor unit RAV-RM 561MUT* Model Outdoor unit RAV-GP 561ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 7.49-6.87 Power consumption (kW) 1.56 Power factor...

  • Page 21: 1-1-4.Compact 4-Way Cassette

    1-1-4. Compact 4-Way Cassette <Twin type> Indoor unit RAV-RM 401MUT* Model Indoor unit2 RAV-RM 401MUT* Outdoor unit RAV-GP 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 8.46-7.75 Power consumption...

  • Page 22: 1-1-5.Slim Duct

    1-1-5. Slim Duct <Single type> Indoor unit RAV-RM 561SDT* Model Outdoor unit RAV-GP 561ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 7.57-6.94 Power consumption (kW) 1.56 Power factor...

  • Page 23: 1-1-6.Slim Duct

    1-1-6. Slim Duct <Twin type> Indoor unit RAV-RM 401SDT* Model Indoor unit2 RAV-RM 401SDT* Outdoor unit RAV-GP 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 9.14-8.38 Power consumption (kW)

  • Page 24: 1-1-7.Duct

    1-1-7. Duct <Single type> Indoor unit RAV-RM 561BTP* 801BTP* Model Outdoor unit RAV-GP 561ATW* 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 7.36-6.75 7.97-7.30 Power consumption (kW) 1.52...

  • Page 25: 1-1-8.Ceiling

    1-1-8. Ceiling <Single type> Indoor unit RAV-RM 561CTP* 801CTP* Model Outdoor unit RAV-GP 561ATW* 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 6.70-6.14 7.82-7.17 Power consumption (kW) 1.37...

  • Page 26: 1-1-9.Ceiling

    1-1-9. Ceiling <Twin type> Indoor unit RAV-RM 401CTP* Model Indoor unit2 RAV-RM 401CTP* Outdoor unit RAV-GP 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 7.82-7.17 Power consumption (kW)

  • Page 27: 1-1-10.High Wall

    1-1-10. High Wall <Single type> Indoor unit RAV-RM 561KRTP* 801KRTP* Model Outdoor unit RAV-GP 561ATW* 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 6.13-5.62 10.07-9.23 Power consumption (kW)

  • Page 28: 1-1-11.Floor Standing

    1-1-11. Floor Standing <Single type> Indoor unit RAV-RM 561FT* 801FT* Model Outdoor unit RAV-GP 561ATW* 801ATW* Cooling capacity (kW) Heating capacity (kW) Power supply 220 - 240 V ~, 50 Hz (Power supply from outdoor unit) Cooling Running current 6.94-6.36 9.97-9.14 Power consumption (kW)

  • Page 29: 1-2.Outdoor Unit

    1-2. Outdoor Unit Model Outdoor unit RAV-GP 561ATW* 801ATW* Power supply 220 - 240 V ~, 50 Hz Type Hermetic compressor Compressor Motor (kW) 1.10 2.00 Pole Refrigerant charged (kg) 1.35 Refrigerant control Pulse motor valve Max. Min. Length of refrigerant pipe Outdoor lower Height...

  • Page 30: 1-3.Operation Characteristic Curve

    1-3. Operation Characteristic Curve Operation characteristic curve GP561 <Cooling> <Heating> 110% 120% 105% 110% 100% 100% • Conditions • Conditions Indoor: DB27 ˚C / WB19 ˚C Indoor: DB20˚C Indoor air flow: High Indoor air flow: High Pipe length: 7.5 m Pipe length: 7.5 m 230 V, 50 Hz (1 phase) 230 V, 50 Hz (1 phase)
  • Page 31 Capacity variation ratio according to temperature GP561 <Heating> <Cooling> • Conditions • Conditions Indoor: DB27 ˚C / WB19 ˚C Indoor: DB20 ˚C Outdoor: DB35 ˚C Outdoor: DB7 ˚C / WB6 ˚C Indoor air flow: High Indoor air flow: High Pipe length: 7.5 m Pipe length: 7.5 m 230 V, 50 Hz (1 phase) 230 V, 50 Hz (1 phase)

  • Page 32: Construction Views (External Views)

    CONSTRUCTION VIEWS (EXTERNAL VIEWS) 2-1. RAV-GP561ATW*...

  • Page 33: 2-2.Rav-Gp801Atw

    2-2. RAV-GP801ATW*...

  • Page 34: 2-3.Branch Pipe

    2-3. Branch pipe RBC-TWP30E2, RBC-TWP50E2 (Simultaneous Twin) Inner diameter C Inner Inner diameter D diameter D (Units: mm) Model (RBC-) Liquid side TWP30E2 Gas side 15.9 12.7 Liquid side TWP50E2 Gas side 15.9 15.9...

  • Page 35: Outdoor Unit Refrigeranting Cycle Diagram

    OUTDOOR UNIT REFRIGERANTING CYCLE DIAGRAM GP561 sensor Fan motor Pulse motor sensor High pressure switch valve Automatic restoration OFF: 4.15 MPa : 3.2 MPa sensor Strainer Strainer 4-way valve sensor sensor Heat exchanger Capillary tube DIA 7, 2 rows, 28 stages (DIA 1.2 ×...
  • Page 36 GP801 Pulse motor valve TS sensor Fan motor Capillary tube TO sensor Outdoor heat exchanger TL sensor 4-way valve High pressure switch Automatic restoration TD sensor OFF: 4.15 MPa ON : 3.2 MPa sensor Distributor Strainer DIA 12.7 Liquid pipe DIA 9.5 Packed valve Accumulator...
  • Page 37 RAV-GP561 series Pressure Pipe surface temperature (˚C) Indoor / Outdoor Compressor temp. conditions Indoor heat Outdoor heat drive revolution Indoor (Mpa) (kg/cm g) Discharge Suction (DB/WB) (˚C) exchanger exchanger frequency (rps) (TD) (TS) (TC) (TL) (TE) Indoor Outdoor Standard 2.8 1.0 29.0 10.6 81.0 14.0...

  • Page 38: Wiring Diagram

    WIRING DIAGRAM 4-1. RAV-GP561ATW*...

  • Page 39: 4-2.Rav-Gp801Atw

    4-2. RAV-GP801ATW*...

  • Page 40: Specifications Of Electrical Parts

    SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit RAV-GP561ATW* Parts name Type Specifications Compressor DX150A1T-21F — Outdoor fan motor ICF-140-A43-1 DC140 V, 43 W 4-way valve coil STF-H01AZ1724A1 DC12 V PMV coil PQ-M10012-000313 DC12 V High pressure switch ACB-4UB154W OFF: 4.15 Mpa Compressor thermostat (Protection) CS-12AL OFF: 125 ±...

  • Page 41: 5-2.Winding Resistance Of Outdoor Unit Main Parts

    5-2. Winding resistance of outdoor unit main parts Parts name Checking procedure Compressor Measure and compare each winding resistance by digital tester. (Model: DX150A1T-21F) Position Resistance value Red - White 1.10 Ω ± 0.055 White - Black Black - Red (all same resistance is ok.) at 20°C Compressor Measure and compare each winding resistance by digital tester.

  • Page 42: Refrigerant R32

    REFRIGERANT R32 This air conditioner adopts the R32 refrigerant which (6) When an air conditioning system charged with a does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even The working pressure of the new refrigerant R32 is 1.6 when refrigerant leaks, its concentration does not times higher than conventional refrigerant (R22).

  • Page 43: 6-2-2.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 (2) Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. (a) Flare Joints Flare joints used to connect the copper pipes cannot be used for piping whose outer diameter exceeds 20 mm.
  • Page 44 (c) Insertion of Flare Nut (d) Flare Processing Make certain that a clamp bar and copper pipe Outer diameter 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 45 Fig. 6-2-2 Relations between flare nut and flare seal surface (2) Flare Connecting Procedures and Precautions (a) Make sure that the flare and union portions do not have any scar or dust, etc. (b) Correctly align the processed flare surface with the union axis. (c) Tighten the flare with designated torque by means of a torque wrench.

  • Page 46: 6-3.Tools

    6-3. Tools 6-3-1. Required Tools Refer to the “(4) Tools” (Page 17) 6-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment.

  • Page 47: 6-5.Brazing Of Pipes

    NOTE (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 48: 6-5-3.Brazing

    6-5-3. Brazing (2) Characteristics required for flux • Activated temperature of flux coincides with the As brazing work requires sophisticated techniques, brazing temperature. experiences based upon a theoretical knowledge, it • Due to a wide effective temperature range, flux is must be performed by a person qualified.

  • Page 49: 6-6.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. Reference outside...

  • Page 50: 6-6-5.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 51: 6-6-6.Handling Of Existing Pipe

    6-7. Charging additional 6-6-6. Handling of Existing Pipe refrigerant When using the existing pipe, carefully check it for the following: Amount of additional refrigerant shall be restricted by • Wall thickness (within the specified range) the following explanation to ensure the reliability. •...

  • Page 52: 6-8.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 that servicing or decommissioning, it is recommended the technician is completely familiar with the good practice that all refrigerants are removed equipment and all its details.

  • Page 53: Circuit Configuration And Control Specifications

    CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1768 Lead wire compressor motor CN807 Connector for Fuse for MCC-1646 Power supply circuit (3.15 A / 250 VAC) CN300 FAN motor CN600 TE sensor Main Fuse (25 A / 250 VAC) CN700 Fuse for varistor...

  • Page 54: 7-1-2.Print Circuit Board, Mcc-1705

    7-1-2. Print Circuit Board, MCC-1705 CN805 (BLU) Connector for temperature sensor CN807 (WHI) Connector for TL CN604 (WHI), TD CN603 (WHI), TO CN602 (YEL) Option P.C. board Connector for Display TE CN601 (WHI), TS CN600 (WHI) P.C. board MCC-1646 CN609 (BLU) Connector for Compressor case thermostat...

  • Page 55: 7-2.Outline Of Main Controls

    7-2. Outline of Main Controls (1) PMV (Pulse Motor Valve) control (1) The aperture of the PMV is controlled between 30 to 500 pulses during operation. (2) During cooling operations, the PMV aperture is controlled by the temperature difference between TS sensor and TC sensor, the temperature difference in cooling operations is usually controlled using a 1 to 4K target value.
  • Page 56 (3) Outdoor fan revolution number control Control of fan revolution number and the fan taps in this unit are shown below. Fan Taps Revolution number Allocation [rpm] GP56 GP80 (3)-1. Cooling fan control (1) Cooling operations of the outdoor fan are controlled by a TL sensor, TO sensor and the compressor revolution number.
  • Page 57 (3)-2. Heating fan control (1) Heating operations of the outdoor fan are controlled by a TE sensor, TO sensor and the compressor revolution number. (Control from a minimum W1 to a maximum is performed according to the table below.) (2) Operation is fixed for 3 minutes after start up by a maximum fan tap corresponding to the zones in the table below.
  • Page 58 (4) Defrost control (1) During heating operations, defrost operations are performed when the temperature from the TE sensor satisfies any of the conditions in the A to D zones. (2) During defrosting operations, defrost will be terminated if the temperature from the TE sensor continues at 12°C or higher for 3 seconds or if the temperature is 7°C ≤...
  • Page 59 (7) Heat sink temperature detection control (1) IGBT overheating prevention is protective control performed by a thermistor (TH sensor) in proximity to IGBT. (2) When a temperature of TH < 90°C is detected, the fan tap is moved by 1 step up. Thereafter step-up is performed at a rate of +1 tap / 5 seconds until a maximum fan tap is reached.
  • Page 60 (12) Coil heating control (1) This control has the function of heating the compressor by applying a current to the compressor when not operating instead using a case heater. This control is for the purpose of preventing stagnation of the refrigerant inside the compressor. (2) Malfunction in the compressor may result if a current is not applied for a specified time before a test run after installation as was previously the case.

  • Page 61: Troubleshooting

    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 62 <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 63: 8-2.Troubleshooting

    8-2. Troubleshooting 8-2-1. Outline of judgment The primary judgment to check whether a trouble occurred in the indoor unit or outdoor unit is carried out with the following method. Method to judge the troubled position by flashing indication on the display part of the indoor unit. (sensors of the receiving part) The indoor unit monitors the operating status of the air conditioner, and the blocked contents of self-diagnosis are displayed restricted to the following cases if a protective circuit works.
  • Page 64 Check Lamp indication Cause of trouble occurrence code Operation Timer Ready Heat exchanger sensor (TCJ) trouble Indoor unit sensor trouble Heat exchanger sensor (TC) trouble Room air temperature sensor (TA) trouble Alternate flash Discharge temp. sensor (TD) trouble Temp. sensor (TE) trouble Operation Timer Ready Temp.

  • Page 65: 8-2-2.Others (Other Than Check Code)

    8-2-2. Others (Other than Check Code) Check Lamp indication Cause of trouble occurrence code 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 66: 8-2-3.Monitor Function Of Remote Controller Switch

    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 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 69 Failure mode detected by indoor unit Operation of diagnostic function Judgment and measures Check Status of air Cause of operation Condition code conditioner No communication from remote 1.Check control wires of remote controller and Stop Displayed controller (including wireless) and communication adapters.
  • Page 70 Failure mode detected by outdoor unit Operation of diagnostic function Judgment and measures Check Status of air Cause of operation Condition code conditioner Disconnection, short-circuit of 1.Check discharge temp. sensor (TD). Displayed discharge temp. sensor (TD) Stop when trouble is 2.Check outdoor P.C.
  • Page 71 Operation of diagnostic function Judgment and measures Check Status of air Cause of operation Condition code conditioner Case thermostat operation 1.Check case thermostat and connector. * Abnormal overheat of compressor 2.Check gas leak, recharge. Displayed Stop when trouble is 3.Check full open of service valve. detected 4.Check PMV (Pulse Motor Valve).
  • Page 72 Failure mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of air Check code Cause of operation Condition conditioner No communication with header indoor Power supply trouble of remote controller, Indoor unit EEPROM trouble •...

  • Page 73: 8-2-5.Diagnostic Procedure For Each Check Code (Outdoor Unit)

    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 74 Check Outdoor LED Check and troubleshooting code indication (Item without special mention indicates part of outdoor unit.) [F04] [Discharge temp. sensor (TD) trouble] Is connection of Correct connector. GP56: CN601, GP80: CN603 correct? Replace TD sensor Is resistance value of TD sensor correct? Replace outdoor P.C.
  • Page 75 Check Outdoor LED Check and troubleshooting code indication (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 Correct connector.
  • Page 76 Check Outdoor LED Check and troubleshooting code indication (Item without special mention indicates part of outdoor unit.) [H02] [Compressor lock] Is power supply voltage normal? Correct power supply line. (AC198 to 264 V) Is wire connection correct? Compressor lead wires Check wire connection (P.C.
  • Page 77 Check Outdoor LED Check and troubleshooting code indication (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] Replace outdoor P.C.
  • Page 78 Check Outdoor LED Check and troubleshooting code indication (Item without special mention indicates part of outdoor unit.) [P07] [Heat sink overheat trouble] Are radiation grease properly applied? Is the screw stop of the motor drive Apply radiation grease element IC200 on the outdoor P.C. board, to objective, retightening the sub heat sink, and the diode bridge of screw...
  • Page 79 Check Outdoor LED Check and troubleshooting code indication (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 80 Check Outdoor LED Check and troubleshooting code indication (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 81 Check Outdoor LED Check and troubleshooting code indication (Item without special mention indicates part of outdoor unit.) [P22] [Fan system trouble] Is power supply voltage normal? Check wiring construction. AC198 to 264 V Ask repair of power supply. Rotate shaft of the fan motor by hands during power-OFF.
  • Page 82 Check Outdoor LED Check and troubleshooting code indication (Item without special mention indicates part of outdoor unit.) [P29] [Position detection circuit trouble] Replace outdoor P.C. board. * When replacing outdoor P.C. board, replace the fuse. — [Other trouble] --- Compressor step-out from sudden changes in load etc. No code * Outdoor LED indication occurs but it automatically restarts and does not confirm any trouble.
  • Page 83 Temperature sensor Temperature – Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors TD, TL sensors Representative value Representative value Resistance value (kΩ) Resistance value (kΩ) Temperature Temperature (°C) (°C) (Minimum value) (Standard value) (Maximum value) (Minimum value) (Standard value) (Maximum value) 32.33 33.80 35.30...

  • Page 84: Setup At Local Site And Others

    SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Check code History <Contents> The trouble contents in the past can be called. <Procedure> more Push buttons simultaneously for 4 seconds or to call the service check mode. TEMP. ON / OFF Service check goes on, the CODE No.
  • Page 85 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 norma 3 minutes elapse Gr construction check Normal * Gr normal...

  • Page 86: 9-2.Outdoor Unit

    9-2. 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 <GP56> (D800 to D805) SW01 SW02 <GP80> SW01 SW02 (D800 to D805) Concerning the LED display...
  • Page 87 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 88 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 89 2. Service support functions (LED display and switch operation) (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 90 (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 controller check code D800 D801 D802 D803 D804 D805 Normal...
  • Page 91 (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 92 (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 * Detects any slow leaks at the stages of not cool not heat and trouble stoppages’...
  • Page 93 (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 94 3. Outdoor application operation Application Control 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 95: Address Setup

    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 96: 10-2.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 / from...

  • Page 97: 10-2-1.System Configuration

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

  • Page 98: 10-2-2.Automatic Address Example From Unset Address (No Miswiring)

    10-2-2. Automatic Address Example from Unset Address (No miswiring) (1) Standard (One outdoor unit) (1) Single (2) Twin Individual Master/Header 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 Master/Header Sub/Header...

  • Page 99: 10-4.Address Setup (Manual Setting From Remote Controller)

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

  • Page 100: 10-5.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 101 <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 102: Replacement Of The Service P.c. Board

    : Cut *: Characters indicate the country code (-E), (-TR), and etc. (Example: RAV-GP561ATW-E) (2) Jumper wires “J804 ~ J805” Set the jumper wires J804 ~ J805 of the service board to the same as settings of the P.C. board before...
  • Page 103 RAV-GP801ATW* (1) DN setting the jumper wires and DIP switches Part name Function Setting Jumper wire J800 ~ J804 Model switching Cut these jumper wires according to the following table. Set these jumper wires same as the settings of the P.C. board before J805 ~ J807 Settings replacement.

  • Page 104: How To Exchange Compressor

    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 circuit breaker. Never recover the refrigerant to the outdoor unit. •...

  • Page 105: Detachments

    DETACHMENTS 13-1.RAV-GP561ATW* Part name Procedure Remarks Common WARNING procedure 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. Detachment 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner.
  • Page 106 Part name Procedure Remarks Front cabinet 1. Detachment 1) Following to work of Detachment of (1). 2) Remove the fixing screw (1 pc, M4 × 8 truss screw) used to secure the front cabinet and inverter cover, the screws (4 pcs, M4 × 10 hexagon screws) used to secure the front cabinet at the bottom, and the fixing screws (2 pcs, M4 ×...
  • Page 107 Part name Procedure Remarks Inverter assembly 1. Detachment 1) Following to work of Detachment of (1). 2) Remove screw (1 pc, M4 × 8 truss screw) of the upper part of the front cabinet. • If removing the inverter cover in this condition, P.C.
  • Page 108 Part name Procedure Remarks Inverter assembly Disconnect the lead wires and connectors connected to CN700 CN601 (Continued) the other parts from the P.C. board assembly. 1) Lead wires CN604 CN600 • Lead wires connected to compressor: CN807 Disconnect the connector (3P). •...
  • Page 109 Part name Procedure Remarks Side cabinet 1. Side cabinet (right) Side cabinet (right) Side cabinet (right) Side cabinet (right) 1) Following to work of Detachment of (2) and (3). 2) Remove the fixing screws (3 pcs, M4 × 8 truss screws) used for securing the side cabinet (right) to the bottom plate and valve fixing plate.
  • Page 110 Part name Procedure Remarks Compressor 1) Following to work of Detachment of (1), (2), (3), (4) and (5). 2) Extract refrigerant gas. 3) Remove the partition plate. (4 pcs, M4 × 8 truss screws) 4) Remove the sound insulation material. Partition Partition Partition...
  • Page 111 Part name Procedure Remarks Electronic 1. Detachment expansion valve 1) Following to work of Detachment of (2), (3) and (5). coil 2) Remove the coil by pulling it up from the electronic control valve body. 2. Attachment 1) When assembling the coil into the valve body, ensure that the coil anti-turn lock is installed properly in the pipe.
  • Page 112 Part name Procedure Remarks (11) TE sensor (outdoor heat exchanging temperature sensor) • Attachment Install the sensor onto the straight pipe part of the condenser outlet pipe. (12) TS sensor (Suction pipe temperature sensor) • Attachment Install the senser onto the straight pipe part of the suction pipe. Be careful for the lead wires direction of the sensor.

  • Page 113: 13-2.Rav-Gp801Atw

    13-2.RAV-GP801ATW* Part name Procedure Remarks Common WARNING Front panel procedures Front panel Stop operation of the air conditioner and turn off breaker Top cover switch. CAUTION Ensure wearing of gloves when performing any work in Left cl Left claw Left claw order to avoid injury from parts, etc.
  • Page 114 Part name Procedure Remarks 2. Attachment Common Valve fixing plate Cable-tie procedures 1) Attach the top cover. (6 pcs, M4 × 10 hexagon screws) 2) Connect the power and indoor / outdoor connection Front panel Top cover wires to the terminal. (Continued) * Check that the clamp filter is attached to the ground of the inside-outside connection wiring.
  • Page 115 Part name Procedure Remarks Air-outlet cabinet 1. Detachment 1) Following to work of Detachment of (1) and (2). Heat exchanger Heat exchanger Heat exchanger Motor base Motor base Motor base 2) Remove the screws from the Air-outlet cabinet andseparate partition. (3 pcs, M4 ×...
  • Page 116 Part name Procedure Remarks Electrical part 1. Detachment (P.C. board) (P.C. board) 1) Following to work of Detachment of (1). Inverter cover Inverter cover Inverter cover WARNING Do not disassemble the inverter for a minute after the power is turned off since there is a risk of electric shock. *1.
  • Page 117 Part name Procedure Remarks Electrical part 14)Remove a screws fixing heat sink duct and inverter Inverter box Inverter box Inverter box (P.C. board) box. (Continued) (2 pcs, M4 × 8 truss screws) Heat sink duct and Heat sink duct and Heat sink duct and Inverter box Inverter box...
  • Page 118 Part name Procedure Remarks Electrical part 3. Detachment (Reactor) (Reactor) 1) Following to work of Detachment of (4). Reactor 2) Remove the connector of the reactor lead wire connected to the reactor. (2 positions) 3) Remove the connector. (2 pcs, M4 × 8 truss screws) Reactor lead ×...
  • Page 119 Part name Procedure Remarks Fan motor 8) Cut the cable-tie for the air duct fixing fan motor and (Continued) the motor base (2 position). 9) Loosen the two claws on the motor base. 10)Remove the fixing screws (4 positions) while holding the fan motor so as not to fall it.
  • Page 120 Part name Procedure Remarks Compressor and 1. Detachment compressor lead WARNING wires When removing the brazing part of the suction / discharge pipe of the compressor, remove the brazing part in a wellventilated place after recovering the Pipe panel (front) Pipe panel (front) refrigerant.
  • Page 121 Part name Procedure Remarks Compressor and 2. Attachment compressor lead 1) Attach the compressor in the reverse process of Compressor Compressor Compressor lead wires connector lead wires connector lead wires connector wires “1. Detachment”. (Continued) NOTE Ferrite Ferrite Ferrite core core core Never reuse the compressor lead wires which you...
  • Page 122 Part name Procedure Remarks PMV coil 1. Detachment Bundle the all lead wires on Bundle the all lead wires on Bundle the all lead wires on 1) Following to work of Detachment of (4). the back face and then cut the the back face and then cut the the back face and then cut the 2) Cut the cable-tie (two positions) on the back surface...
  • Page 123 Part name Procedure Remarks (10) Fan guard 1. Detachment 1) Following to work of Detachment of (3). Correct Correct Incorrect Incorrect NOTE Perform work on a corrugated cardboard, cloth, etc. to prevent flaw to the product. Claw Claw Claw 2) Remove the outlet cabinet and place the fan guard side facing down.
  • Page 124 Part name Procedure Remarks (11) [Reference] 1) TD sensor: discharge pipe Sensor mount 2) TL sensor: heat exchanger upside 2) TL senser 2) TL senser 2) TL senser positions 3) TS sensor: 4-way valve - between accumulator 4) TE sensor: lowest capillary joint 5) TO sensor: Heat exchange surface 2) TL sensor 1) TD sensor...

  • Page 125: Exploded Views And Parts List

    EXPLODED VIEWS AND PARTS LIST 14-1.Outdoor Unit RAV-GP561ATW-E, RAV-GP561ATW-TR...
  • Page 126 Q’ty/Set RAV-GP Location Part No. Description 561ATW-E 561ATW-TR PANEL, AIR OUTLET, ASSY 43P00012 PANEL, SIDE, RIGHT, ASSY 43P00013 PANEL, SIDE, LEFT, ASSY 43P00014 PANEL, ROOF, ASSY 43P00015 COVER, PACKED, VALVE 43P00016 GUARD, FAN 43P19003 COMPRESSOR, ASSY (WITH COMPRESSOR LEAD) 43P42004 BOLT, COMPRESSOR 43P42003 MOTOR, FAN, ICF-140-A43-1...
  • Page 127 RAV-GP801ATW-E, RAV-GP801ATW-TR...
  • Page 128 Q’ty/Set RAV-GP Location Part No. Description 801ATW-E 801ATW-TR 43P00005 PANEL, AIR OUTLET 43P00006 PANEL, FRONT, ASSY 43P00007 PANEL, SIDE, RIGHT, ASSY 43P00008 PANEL, ROOF, ASSY 43P00009 PANEL, FRONT, PIPING 43P00010 PANEL, BACK, PIPING, ASSY 43P00011 STAY 43P09001 GUARD, FAN 43P42006 COMPRESSOR, ASSY (WITH COMPRESSOR LEAD) 43P42001 BOLT, COMPRESSOR...

  • Page 129: 14-2.Inverter Assembly

    14-2.Inverter Assembly RAV-GP561ATW-E, RAV-GP561ATW-TR Q’ty/Set RAV-GP Location Part No. Description 561ATW-E 561ATW-TR 43P50012 SENSOR, TD 43P50013 SENSOR, TL 43P50010 SENSOR, TE 43P50004 SENSOR, TO 43P50011 SENSOR, TS 43P69008 PC BOARD ASSY, MCC1768 43P69002 PC BOARD ASSY, MCC1646, TERMINAL BLOCK...
  • Page 130 RAV-GP801ATW-E, RAV-GP801ATW-TR Q’ty/Set RAV-GP Location Part No. Description 801ATW-E 801ATW-TR SENSOR, TD 43P50002 SENSOR, TL 43P50003 43P50004 SENSOR, TE SENSOR, TO 43P50005 SENSOR, TS 43P50006 PC BOARD ASSY, MCC1705 43P69009 PC BOARD ASSY, MCC1646 43P69007 FUSE, 10A 43P60001 43P60002 TERMINAL BLOCK, 3P, 20A TERMINAL BLOCK, 3P, 60A 43P60003...
  • Page 131 Copyright © 2021 Toshiba Carrier Air-conditioning Europe Sp. z o.o. All Rights Reserved. Revision record Apr., 2021 First issue — — Expression and text were revised. May, 2021 Revision 1 Page 114...

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