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Toshiba RAV-GM561ATP-TR1 Service Manual
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Toshiba RAV-GM561ATP-TR1 Service Manual

Toshiba RAV-GM561ATP-TR1 Service Manual

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SERVICE MANUAL
AIR-CONDITIONER
OUTDOOR UNIT
<DIGITAL INVERTER>
RAV-GM561ATP-E1
RAV-GM561ATJP-E1
RAV-GM561ATP-TR1
R32
(SPLIT TYPE)
FILE NO. SVM-24005
February, 2024

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  • Page 1 FILE NO. SVM-24005 SERVICE MANUAL AIR-CONDITIONER (SPLIT TYPE) OUTDOOR UNIT <DIGITAL INVERTER> RAV-GM561ATP-E1 RAV-GM561ATJP-E1 RAV-GM561ATP-TR1 February, 2024...

  • 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

    SAFETY CAUTION Please read carefully through these instructions that contain important information which complies with the Machinery Directive (Directive 2006/42/EC), and ensure that you understand them. Some of the details provided in these instructions differ from the service manual, and the instructions provided here take precedence.
  • 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 CAUTION CAUTION Do not touch the aluminum Do not touch the aluminum fins of the unit. fins of the unit. You might get burned. You might get burned. CAUTION CAUTION Do not touch the aluminum fins Do not touch the aluminum fins of the of the unit.
  • 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 For disposal of the product above 12 kW in rating you should use a registered company in accordance with any national or EU legislation. <Model names with a rating of 12 kW and below (outdoor units)> DI series RAV-GM561ATP-E1 RAV-GM561ATJP-E1 RAV-GM561ATP-TR1 - 12 -...
  • Page 13 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 TCF holder: TOSHIBA CARRIER EUROPE S.A.S Route de Thil 01120 Montluel FRANCE Hereby declares that the machinery described below:...
  • Page 14 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 UK LTD. TCF holder: Porsham Close Belliver Industrial Estate Roborough Plymouth Devon...
  • Page 15 Specifications Sound power level (dBA) Model Weight (kg) Cooling Heating ∗ ∗ RAV-GM561ATP-E1 ∗ ∗ RAV-GM561ATJP-E1 ∗ ∗ RAV-GM561ATP-TR1 ∗ : Under 70 dBA - 15 -...
  • Page 16 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 17 <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 18 4. Tools Tools exclusive for R32 (The following tools for R32 are required.) : R32 tools available : Partly unavailable, : R32 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 19: Specifications

    1. SPECIFICATIONS 1-1. Outdoor Unit <Digital Inverter> Model name Outdoor unit RAV-GM561AT(J)P-E1, -TR1 1 phase 220-240V, 50Hz Power supply 1 phase 220V, 60Hz (Power exclusive to outdoor is required.) Type Hermetic compressor Compressor Motor (kW) Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Standard length Min.

  • Page 20: Operation Characteristic Curve

    1-2. Operation Characteristic Curve <Cooling> < > Conditions Conditions Indoor : DB 20 C/WB 15 Indoor : DB 27 C/WB 19 Outdoor : DB 7 C/WB 6 Outdoor : DB 35 C/WB 24 Indoor Air Flow : High Indoor Air Flow : High : 7.5m Pipe Length : 7.5m Pipe Length...

  • Page 21: Construction Views (External Views)

    2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) - 21 -...
  • Page 22 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 - 22 -...

  • Page 23: Systematic Refrigerating Cycle Diagram

    3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 3-1. Indoor Unit 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 24: Outdoor Unit

    3-2. Outdoor Unit Packed valve Packed valve Outer dia. Ø12.7 Outer dia. Ø6.35 TŌ sensor Pressure TS sensor (Pulse Motor Valve) switch DPF(T01)1.5C-04 TL sensor Strainer Ø25.4× 90L TD sensor Strainer Strainer Ø19.05 × 70L Ø19.05 × 70L 4-way valve SHF(L)-4H-23U sensor Heat exchanger...

  • Page 25: Wiring Diagram

    4. WIRING DIAGRAM - 25 -...

  • Page 26: Specifications Of Electrical Parts

    5. SPECIFICATIONS OF ELECTRICAL PARTS Parts name Type Specification Compressor KTN130D30UFZ 3 phase, 4P, 1075W Fan motor WDF-340-A43-1 Output 43 W 3-way valve coil SHF(L)-4H-23U PMV coil PQ-M01012-000313 High-pressure SW ACB-4UB166W OFF:4.5MPa CHT-01-Z-T 19mH, 13A Reactor P.C. board WP-044 Fuse (Mounted on P.C. board) AC250 V, 25 A Fuse AC250 V, 6.3 A...

  • Page 27: Refrigerant R32

    6. . REFRIGERANT R 6. When an air conditioning system charged with a This air conditioner adopted the R32 refrigerant 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. R32 or conventional flare tool. Use either a flare tool for 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 18) 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

    6-5. Brazing of Pipes 3. Types of flux • Noncorrosive flux 6-5-1. Materials for Brazing Generally, it is a compound of borax and boric 1. . Silver brazing fill acid. Silver brazing filler is an alloy mainly composed It is effective in case where the brazing of silver and copper.
  • Page 33 6-5-3. Brazing As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified. In order to prevent the oxide film from occurring in Flow meter the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas flow.

  • Page 34: Instructions For Re-Use Piping Of R410A Or R22

    6-6. Instructions for Re-use Piping of R410A or R22 Instruction of Works: 5. When a commercially available dryer is attached to The existing R22 and R410A piping can the existing pipes. be reused for our super digital inverter There is the possibility that copper green rust has been R32 products installations.
  • Page 35 Placement Term Curing manner location 1 month or more Pinching Outdoors Less than Pinching or 1 month Taping Indoors Every time 6-6-4. 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

    6-6-6. Recovering Refrigerant • (Airtight test), Vacuum dry, Refrigerant charge, Gas Use the refrigerant recovery equipment to recover leak check the refrigerant. 6-7. Charging additional refrigerant Test run 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 refrigerant cycle, causing a rupture, a injury and 6-6-5.

  • Page 37: 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 • 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 38 6-8-3. Pump down process 1. Turn off the Air Conditioner system. 2. Connect the charge hose from the manifold valve to the service port of the packed valve at gas side. 3. Turn on the Air Conditioner system in cooling operation more than 10 minutes.

  • Page 39: Outdoor Control Circuit

    7. OUTDOOR CONTROL CIRCUIT 7-1. Outline of Main Controls 1. Pulse Modulating Valve (PMV) control 1) For PMV withGM56 : 50 to 500 pulses during operation, respectively. 2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.
  • Page 40 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 GM56 Model...
  • Page 41 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 42 ˚C No power ˚C Intermittent power-ON • Power-ON 10 minutes: ON / condition ˚C 5 minutes: OFF TD < 30˚C ˚C Continuous power-ON GM56 Output power REQUIREMENT While heating the coil, the power sound may be heard. However it is not a trouble. 6.
  • Page 43 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 44: Outdoor Print Circuit Board

    7-2. Outdoor Print Circuit Board <WP-044> - 44 -...

  • Page 45: 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 46 <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 47: 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 48 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 49 8-2-3. Monitoring function of wired remote controller <RBC-AMT > TEMP. ON / OFF TIMER SET MODE TIME SAVE VENT FILTER RESET TEST SWING/FIX UNIT LOUVER Content Enter the service monitoring mode using the remote controller to check the sensor temperature or operation status of the remote controller, indoor unit, and outdoor unit.
  • Page 50 CODE No. Data name Unit CODE No. Data name Unit Room temperature °C Outdoor heat exchanger (Coil) temperature (TE) °C (Remote controller) Outside temperature (TO) °C Indoor suction temperature (TA) °C Compressor discharge temperature (TD) °C Indoor heat exchanger (Coil) °C Compressor suction temperature (TS) °C...
  • Page 51 - 51 -...
  • Page 52 - 52 -...
  • Page 53 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 54 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 55 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 56 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 57 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. : ON, : OFF, : Rapid flashing (5 times /second)
  • Page 58 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 unit to narrow the contents to be confirmed. 3) The check code on the wired remote controller is displayed only when the same error occurred continu- ously by multiple times while LED of the outdoor unit displays even an error which occurred once.
  • Page 59 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [E04] — [Indoor/Outdoor communication error] Is setting of group address Check CODE No. [14]. of remote controller correct? Refer to “10 ADDRESS SETUP” Are inner wiring and indoor/outdoor Correct wiring indoor/outdoor control wires (1, 2, 3) correct?
  • Page 60 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] [Discharge temp. sensor (TD) error] Is CN601 connection correct? Correct connector. Is resistance value of TD sensor correct? Sensor error → Replace Check outdoor P.C.
  • Page 61 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F08] [Outside air temp. sensor (TO) error] Correct connector. Is CN602 connection correct? Is resistance value of TO sensor correct? Sensor error → Replace Check outdoor P.C.
  • Page 62 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F31] [EEPROM error] Check outdoor P.C. board. Defect → Replace [H01] [Compressor break down] Is power supply voltage correct? Correct power supply line. 50 Hz : AC 198 to 264 V 60 Hz : AC 198 to 242 V Is wire connection correct?
  • Page 63 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [H03] [Current detection circuit error] Check outdoor P.C. board. Defect → Replace [H04] [Case thermostat operation] Are CN500 connection and Correct connector. case thermostat correct? Case thermostat error →...
  • Page 64 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P04] [High pressure SW system error] Wiring check, Does high pressure switch operate? Is circuit wiring correct? Correct. Are parts of Parts check high pressure switch correct? Defective →...
  • Page 65 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P05] [Power supply error] Is the power supply voltage is lower than or over the range? Confirm power supply, etc. 50 Hz : AC 198 to 264 V 60 Hz : AC 198 to 242 V Check outdoor P.C.
  • Page 66 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [4-way valve inverse error] [P19] Is the 4-way valve Is operation of 4-way valve coil is normal? correct? Replace coil (Check the resistance value (Check pipe temp.
  • Page 67 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P20] [High pressure protective operation] Is service valve fully opened? Open service valve fully. Reset the power supply and then make a test run Cooling season matching to the season.
  • Page 68 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P22] [Fan system error] Is the power supply voltage is lower than or over the range? Check wiring construction. 50 Hz : AC 198 to 264 V Ask to repair the power supply.
  • Page 69 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [P26] [Short-circuit of compressor driving elements] Are connections of compressor lead and reactor lead correct? Correct wiring. (Check referring to Wiring diagram.) Does the same error occur in Replace outdoor P.C.
  • Page 70 8-2-5. 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 71 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 : KTN130D30UFZ) Position Resistance value Red – White 1.03 Ω White – Black White Black Black –...

  • Page 72: Setup At Local Site And Others

    9. SETUP AT LOCAL SITE AND OTHERS 9-1. Troubleshooting based on information displayed on remote controller <RBC-AMT > (1) Checking and testing When a trouble occurs to an air conditioner, a check code and indoor unit No. are displayed on the display window of the remote controller.
  • Page 73 <RBC-ASCU11- > (1) Confirmation and check If a problem occurs with the air conditioner, the OFF timer indicator alternately shows the check code and the indoor Unit No. in which the problem occurred. Check code The indoor Unit No. in which the problem occurred.

  • Page 74: Group Control Operation

    9-2. Group Control Operation In a group control, operation of maximum 8 indoor units can be controlled by a remote controller. The indoor unit connected with outdoor unit (Individual/Master of twin) controls room temperature according to setting on the remote controller. <System example>...
  • 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 displays and various operations are enabled by push buttons (service) switches and LED on the outdoor control P.C. board. Service switch (SW01, SW02) operations LED display • 4 patterns are provided for LED display. : ON, : OFF, : Rapid flashing (5 times/second), : Slow flashing (Once/second)
  • Page 77 9-3-2. Various settings on outdoor unit (Existing piping etc.) (1) Service switch setting Various settings are available by setting service switches. [Operating method] 1) Check LED display is the initial status. If it is not so, set the initial status. 2) Push and hold SW01 for 5 seconds or more and then check D804 flashes slowly.
  • Page 78 In the case to return the setting to one at shipment from factory When to return the setting to one at shipment from the factory due to reinstallation and so on, the setting can be returned in the following procedure. 1) Check LED display is the initial status.
  • Page 79 Setting method 1. Check the LED display is an initial state. (Fig. 1) If the initial status is not established (if D805 is flashing), hold down the SW01 and SW02 service switches simultaneously for at least 5 seconds to return the LED displays to the initial status. 2.
  • Page 80 Cancel 1. 1. and 2. of the setting methods are executed. 2. Several times press SW01 to set the LED displays of the selection mode shown below. (Fig. 6) 3. Press SW02, D805 is turned off. (Fig. 7) 4. Hold down SW02 for at least 5 seconds, and when D804 flashes slowly and D805 lights, and the setting is completed.
  • Page 81 9-3-3. Service support function (LED display, service switch operating method) 1. LED display switching 1-1. Display switching list The displayed contents of LED D800 to D805 on the outdoor P.C. board can be switched by handling the service switches SW01 and SW02. [Operating method] 1) Check LED display is the initial status.
  • Page 82 1-2. Error display The error which is occurring at present and the latest error (the latest error data including one which is occur- ring now) can be confirmed by lighting LED D800 to D805 on the outdoor control P.C. board. A.
  • Page 83 C. Sensor, current, compressor operation frequency, PMV opening display The values, such as the temperature sensor or the current value, which the controller detects are easily confirmed. * Temperature sensor: TD, TE, TL, TS, TO, TH, TA, TC, TCJ LED display Temp.
  • Page 84 2. Special operation for maintenance check (SW01 and SW02 operations) The following special operations for maintenance check can be performed by handling the service switches SW01 and SW02. [Operating method] 1) Check LED display is the initial status. If it is not so, set the initial status. 2) Push and hold SW01 for 5 seconds or more and then check D804 flashes slowly.

  • Page 85: Refrigerant Leak Detection Function

    9-4. Refrigerant leak detection function Monitors the amount of refrigerant being calculated base on the temperature sensors, PMV opening during test run operation, and detects any refrigerant leaks during operation and indicates it using the LEDs on the outdoor unit or remote controller. Refrigerant leak detection is not performed in usual operation.
  • Page 86 [Confirmation method with LEDs on outdoor unit] 1) Ensure the LED display shows the initial state. If not then it can be returned to the initial state by pushing and holding down SW01 and SW02 at the same time for at least 5 seconds. 2) Push SW01 several times unit reaching the 'refrigerant leak indication' LED display.

  • Page 87: Applicable Control Of Outdoor Unit

    9-5. Applicable Control of Outdoor unit The following controls are enabled by connecting the part “Application control kit” (TCB-PCOS1E2) sold separately. (1) Power peak cut control * The capacity of the outdoor unit is saved by the Demand signal from outside and corresponds to the temporary peak cut.

  • Page 88: 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 89: 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 90 10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single (Master/Sub) Individual 2) Group operation (Twin operation) (Multiple outdoor units = Miltiple indoor units only with serial communication) Sub/Header Sub/Header Sub/Follower Master/Header Sub/Follower Only turning on source power supply (Automatic completion) •...
  • Page 91 10-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Twin (1-1) (1-2) Individual Master/Header Sub/Follower (Master/Header) Only turning on source power supply (Automatic completion) 2. Group operation (Multiple outdoor units = Multiple indoor units with serial communication only, without twin) Sub/Header Sub/Header Master/Header...

  • Page 92: 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 93: Manual Address Setting Using The Remote Controller

    10-5. Manual address setting using the remote controller Procedure when setting indoor units’ addresses first under the condition that indoor wiring has been completed and outdoor wiring has not been started (manual setting using the remote controller) Wiring example of 2 refrigerant lines Refrigerant line 1 Refrigerant line 2 Outdoor...
  • Page 94 <Indoor unit address> 13 13 13 13 13 Push the TEMP. buttons repeatedly to set the CODE No. to Push the TIME buttons repeatedly to set an indoor unit address. Push the button. (It is OK if the display turns on.) <Group address>...
  • Page 95 Confirming the indoor unit addresses and the position of an indoor unit using the remote controller Confirming the numbers and positions of indoor units To know the indoor unit addresses though position of the indoor unit is recognized When the unit is individual (the indoor unit is paired with a wired remote controller one-to-one), or it is a group-controlled one.
  • Page 96 To find an indoor unit’s position from its address When checking unit numbers controlled as a group <RBC-AMT > TEMP. ON / OFF TIMER SET MODE TIME SAVE VENT Stop FILTER RESET TEST SWING/FIX UNIT LOUVER (Execute it while the units are stopped.) The indoor unit numbers in a group are indicated one after another.
  • Page 97 <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 98: 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 99: 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 100: Detachments

    13. DETACHMENTS Part name Procedure Remarks Common CAUTION procedure Never forget to put on the gloves at working Valve cover time, otherwise an injury will be caused by the parts, etc. 1. Detachment Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner.
  • Page 101 Part name Procedure Remarks 1. How to remove Motor base Front cabinet 1) Perform 1 of 1. 2) Remove the screw between front cabinet and side cabinet (right). (ST1T Ø4 × 10L,1 pc.) 3) Remove the screw between front cabinet and inverter.
  • Page 102 Part name Procedure Remarks 1. Detachment Screws Inverter assembly 1) Perform work of item 1 of 2) Take off screws of the upper part of the front cabinet. (ST1T Ø4 × 10L, 2 pcs.) • If removing the inverter cover under this condition, P .C.
  • Page 103 Part name Procedure Remarks Connector Inverter assembly ･･･(3P：Relay connector white） ※ (Warning 1) Reactor (2P：Relay connector white) Inverter CN300･･･ Outdoor fan (3P：white) assembly CN701･･･ 4 directional valve (2P：white) CN700･･･ PMV coil (6P：white) CN601･･･ TD sensor (3P：white) CN603･･･ TS sensor (3P：white) CN600･･･...
  • Page 104 Part name Procedure Remarks 1) Remove sub board base from inverter Control P.C. board frame. (BT 2T Ø4 × 10, 2 pcs.) Sub board assembly base ※  Remove connector of control board frame side. 2) Remove lead wire ・ connector that are connected from control board frame to other parts.
  • Page 105 Part name Procedure Remarks 1) Perform works of items 1 of 1 and 2 , 3 . Rear cabinet 2) Take off fixed screws for the bottom plate. (ST1T Ø4 × 10L, 2 pcs.) 3) Take off fixed screw for the valve mounting plate.
  • Page 106 Part name Procedure Remarks 1) Perform works of items 1 of 1 and 2 , Compressor Partition plate 2) Discharge refrigerant gas. 3) Remove the partition plate. (ST1T Ø4 × 10L, 3 pcs.) 4) Remove the terminal covers of the compressor, and disconnect lead wires of the compressor and the compressor thermo assembly from the terminal.
  • Page 107 Part name Procedure Remarks 1. Detachment Pulse Motor Valve (PMV) coil 1) Perform works of items Attachment state 2) Release the coil from the concavity by turning it, and remove coil from the PMV. 2. Attachment 1) Put the coil deep into the bottom posi- Coil tion.

  • Page 108: Exploded Views And Parts List

    14. EXPLODED VIEWS AND PARTS LIST Outdoor Unit - 108 -...
  • Page 109 Model name Location RAV-GM Part No. Description 561ATP-E1 561ATP-TR1 561ATJP-E1 43T42387 BASE COATING ASSEMBLY 43T00605 ASM-CABI-F-S 43T00599 ASM-CABI-SIDE-R 43T00602 ASM-COAT-C-S-L 43T19352 ASM-COVER-PV 43T00604 ASM-COAT-CABI-U 43T39347 ASM-M-BASE 43T41572 COMPRESSOR 43T46367 4 WAY VALVE 43T46577 COIL-3WAY-VALVE 43T46469 BODY PMV 43T63360 COIL PMV 43T63373 SWITCH PRESSURE 43T46461...
  • Page 110 <Inverter assembly> TE Sensor TS Sensor TD Sensor TO Sensor TL Sensor Model name Location RAV-GM Part No. Description 561ATP-E1 561ATP-TR1 561ATJP-E1 43TNV413 PC BOARD 43TN9875 PC BOARD ASSY(LED) 43T58326 REACTOR,CH-76 43T62313 PC PLATE BASE 43T61320 BASE, PC BOARD 43T60423 SERV-TERMINAL 43T60426 FUSE...
  • Page 111 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 112 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

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