Toshiba RAV-GM561ATP-E Service Manual
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Toshiba RAV-GM561ATP-E Service Manual

Outdoor unit, digital inverter
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Table Of Contents
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Table of Contents

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See also: Installation Manual
FILE NO. SVM-18043-1
SERVICE MANUAL
AIR-CONDITIONER
(SPLIT TYPE)
RAV-GM561ATP-E (TR)
RAV-GM801ATP-E (TR)
RAV-GM1101ATP-E (TR)
RAV-GM1401ATP-E (TR)
RAV-GM561ATJP-E
RAV-GM801ATJP-E
RAV-GM1101ATJP-E
RAV-GM1401ATJP-E
R32
Revised on June, 2018
Table of Contents
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Summary of Contents for Toshiba RAV-GM561ATP-E

  • Page 1: Service Manual

    FILE NO. SVM-18043-1 SERVICE MANUAL AIR-CONDITIONER (SPLIT TYPE) OUTDOOR UNIT RAV-GM561ATP-E (TR) RAV-GM801ATP-E (TR) RAV-GM1101ATP-E (TR) RAV-GM1401ATP-E (TR) RAV-GM561ATJP-E RAV-GM801ATJP-E RAV-GM1101ATJP-E RAV-GM1401ATJP-E Revised on June, 2018...

  • Page 2: Table Of Contents

    ....................96 13-2. RAV-GM1101AT , GM1401AT ................... 104 14. EXPLODED VIEWS AND PARTS LIST ............... 114 14-1. RAV-GM561ATP-E, GM561ATJP-E, GM561ATP-TR ..............114 14-2. RAV-GM801ATP-E, GM801ATJP-E, GM801ATP-TR ..............118 14-3. RAV-GM1101ATP-E, GM1101ATJP-E, GM1101ATP-TR RAV-GM1401ATP-E, GM1401ATPJ-E, GM1401ATP-TR ............... 122 - 2 -...

  • 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 FILE NO. SVM-18043 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

    FILE NO. SVM-18043 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 FILE NO. SVM-18043 CAUTION CAUTION Do not touch the aluminum fins of Do not touch the aluminum fins of the unit. the unit. Doing so may result in Doing so may result in injury. injury. 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

    FILE NO. SVM-18043 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 FILE NO. SVM-18043 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 FILE NO. SVM-18043 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 FILE NO. SVM-18043 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 FILE NO. SVM-18043 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: Declaration Of Conformity

    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 FILE NO. SVM-18043 Specifications Sound power level (dBA) Model Weight (kg) Cooling Heating RAV-GM561ATP-E RAV-GM561ATJP-E RAV-GM801ATP-E RAV-GM801ATJP-E RAV-GM1101ATP-E RAV-GM1101ATJP-E RAV-GM1401ATP-E RAV-GM1401ATJP-E RAV-GM561ATP-TR RAV-GM801ATP-TR RAV-GM1101ATP-TR RAV-GM1401ATP-TR : Under 70 dBA - 13 -...
  • Page 14 FILE NO. SVM-18043 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 FILE NO. SVM-18043 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 FILE NO. SVM-18043 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...

  • Page 17: Specifications

    FILE NO. SVM-18043-1 1. SPECIFICATIONS 1-1. Outdoor Unit Model name Outdoor unit RAV-GM 561AT 801AT 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...
  • Page 18 FILE NO. SVM-18043-1 Model name Outdoor unit RAV-GM 1101AT 1401AT 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 19: Operation Characteristic Curve

    FILE NO. SVM-18043 1-2. Operation Characteristic Curve RAV-GM561AT P ,GM801AT P < > GM80 GM80 GM56 GM56 Compressor speed (rps) Compressor speed (rps) Capacity variation ratio according to temperature < > < > GM80 GM56 Outdoor temp. (°C) Outdoor temp. (°C) - 19 -...

  • Page 20: Capacity Variation Ratio According To Temperature

    FILE NO. SVM-18043 Operation Characteristic Curve RAV-GM1101AT P , GM1401AT P < > < > GM140 GM140 GM110 GM110 Compressor speed (rps) Compressor speed (rps) Capacity variation ratio according to temperature < > < > GM110 GM140 Outdoor temp. (°C) Outdoor temp.

  • Page 21: Construction Views (External Views)

    FILE NO. SVM-18043 2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) , GM801AT 2-1. RAV-GM561AT - 21 -...
  • Page 22 FILE NO. SVM-18043 , GM1401AT 2-2. RAV-GM1101AT - 22 -...
  • Page 23 FILE NO. SVM-18043 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 - 23 -...

  • Page 24: Systematic Refrigerating Cycle Diagram

    FILE NO. SVM-18043 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)

  • Page 25: Outdoor Unit

    FILE NO. SVM-18043 3-2. Outdoor Unit RAV-GM561AT P Packed valve Packed valve Outer dia. Ø12.7 Outer dia. Ø6.35 TŌ sensor Pressure TS sensor switch (Pulse Motor Valve) (DPF(S01)1.8C-15) TL sensor 2-step muffler Ø19 .05 × 200L TD sensor Strainer 4-way valve (STF-H0108) sensor Heat exchanger...
  • Page 26 FILE NO. SVM-18043 RAV-GM801AT P Packed valve Packed valve Outer dia. Ø15.88 Outer dia. Ø9.52 Pressure TŌ sensor switch Strainer (Pulse Motor Valve) 2-step TL sensor (DPF(S01)1.8C-15) muffler Ø25 × 200L sensor sensor Muffler Ø 19.05 × 160L 4-way valve (STF-H0218) sensor Strainer...
  • Page 27 FILE NO. SVM-18043 RAV-GM1101AT P , GM1401AT P Ball valve Packed valve Outer dia. Ø15.88 Outer dia. Ø9.52 Pressure Strainer TŌ sensor switch TS sensor (Pulse Motor Valve) (CAM-BD25TCTH-1) TL sensor TD sensor Strainer 4-way valve (STF-H0218) sensor Heat exchanger Muffler Ø8, 2 rows, 40 steps FP1.3 flat fin...

  • Page 28: Rav-Gm561At P , Gm801At P

    FILE NO. SVM-18043 4. WIRING DIAGRAM 4-1. RAV-GM561AT ,GM801AT - 28 -...
  • Page 29 FILE NO. SVM-18043 , GM1401AT 4-2. RAV-GM1101AT - 29 -...

  • Page 30: Specifications Of Electrical Parts

    FILE NO. SVM-18043 5. SPECIFICATIONS OF ELECTRICAL PARTS , GM801AT RAV-GM561AT Parts name Type Specifications Compressor DX150A1T-20F 3 phase, 4P, 1100 W Fan motor ICF-140-43-4R Output 43 W 4-way valve coil STF-H01AZ1724A1 PMV coil PQ-M01012-000082 High-pressure SW ACB-4UB83W OFF:4.15MPa Reactor CH-57-Z-T 8.88~10mH, 16A P.C.

  • Page 31: Refrigerant R32

    FILE NO. SVM-18043 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 32 FILE NO. SVM-18043 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 33 FILE NO. SVM-18043 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. R410A/R32 or conventional flare tool. Use either a flare tool for Flare processing dimensions differ according to the type of flare tool.
  • Page 34 FILE NO. SVM-18043 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 35: Tools

    FILE NO. SVM-18043 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 36: Brazing Of Pipes

    FILE NO. SVM-18043 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 37 FILE NO. SVM-18043 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. •...
  • Page 38 6-6-3 Branching pipe for simultaneous operation system * Pipe diameter and thickness (mm) In the concurrent twin system, when TOSHIBA has Reference Wall specified that branching pipe is to be used, it can be outside...

  • Page 39: Final Installation Checks

    FILE NO. SVM-18043 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? •...

  • Page 40: Recovering Refrigerant

    FILE NO. SVM-18043 • (Airtight test), Vacuum dry, Refrigerant charge, Gas RAV-GM801ATP leak check To use an existing Ø19.1 mm pipe, set bit 3 of SW802 (switch for existing pipe) on the P.C. board of the outdoor unit to ON. Test run In this case, the heating performance may be reduced depending on the outside air temperature...

  • Page 41: General Safety Precautions For Using R32 Refrigerant

    FILE NO. SVM-18043 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 42: Outdoor Control Circuit

    FILE NO. SVM-18043 7. OUTDOOR CONTROL CIRCUIT 7-1. Outline of Main Controls 1. Pulse Modulating Valve (PMV) control 1) For PMV withGM56, 80 : 50 to 500, GM110, 140 : 30 to 500 pulses during operation, respectively. 2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.
  • Page 43 FILE NO. SVM-18043 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...
  • Page 44 FILE NO. SVM-18043 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 45 FILE NO. SVM-18043 ˚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, 80 GM110, 140 Output power REQUIREMENT While heating the coil, the power sound may be heard. However it is not a trouble. 6.
  • Page 46 FILE NO. SVM-18043 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 47: Outdoor Print Circuit Board

    FILE NO. SVM-18043 7-2. Outdoor Print Circuit Board , GM801AT RAV-GM561AT - 47 -...
  • Page 48 FILE NO. SVM-18043 , GM1404AT RAV-GM1104AT - 48 -...

  • Page 49: Troubleshooting

    FILE NO. SVM-18043 8. TROUBLESHOOTING 8-1. Summary of Troubleshooting 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 50: Before Troubleshooting

    FILE NO. SVM-18043 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 51 FILE NO. SVM-18043 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 52 FILE NO. SVM-18043 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.
  • Page 53 FILE NO. SVM-18043 8-2-3. Monitor Function of Remote Controller Switch Calling of sensor temperature display Each data of the remote controller, indoor unit and outdoor unit can be shown by calling the service monitor mode from the remote controller. ...
  • Page 54 FILE NO. SVM-18043 - 54 -...
  • Page 55 FILE NO. SVM-18043 - 55 -...
  • Page 56 FILE NO. SVM-18043 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...
  • Page 57 FILE NO. SVM-18043 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.
  • Page 58 FILE NO. SVM-18043 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.
  • Page 59 FILE NO. SVM-18043 Error mode detected by remote controller or central controller (TCC-LINK) Operation of diagnostic function Judgment and measures Status of Check code Cause of errors 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 60 FILE NO. SVM-18043 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 61 FILE NO. SVM-18043 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 62 FILE NO. SVM-18043 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 63 FILE NO. SVM-18043 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F04] [Discharge temp. sensor (TD) error] Correct connector. Is CN601 connection correct? Sensor error → Replace Is resistance value of TD sensor correct? Check outdoor P.C.
  • Page 64 FILE NO. SVM-18043 Check Outdoor Check and troubleshooting code LED display (Item without special mention Indicates part of outdoor unit.) [F08] [Outside air temp. sensor (TO) error] Is CN602 connection correct? Correct connector. Sensor error → Replace Is resistance value of TO sensor correct? Check outdoor P.C.
  • Page 65 FILE NO. SVM-18043 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 66 FILE NO. SVM-18043 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.
  • Page 67 FILE NO. SVM-18043 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 68 FILE NO. SVM-18043 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 69 FILE NO. SVM-18043 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 70 FILE NO. SVM-18043 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 71 FILE NO. SVM-18043 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 72 FILE NO. SVM-18043 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 73 FILE NO. SVM-18043 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...

  • Page 74: Table Inspection Of Outdoor Unit Main Parts

    FILE NO. SVM-18043 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 : DX150A1T-20F) Position Resistance value Red – White White – Black 1.03 Ω White Black Black –...

  • Page 75: Setup At Local Site And Others

    FILE NO. SVM-18043 9. SETUP AT LOCAL SITE AND OTHERS 9-1. Calling of Error History The error contents in the past can be called. TEST Push buttons simultaneously for 4 seconds or more to call the service check mode. TEMP.
  • Page 76 FILE NO. SVM-18043 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 3 minutes elapse Gr construction check Normal...
  • Page 77 FILE NO. SVM-18043 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),...
  • Page 78 FILE NO. SVM-18043 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 79 FILE NO. SVM-18043 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 80 FILE NO. SVM-18043 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 81 FILE NO. SVM-18043 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.
  • Page 82 FILE NO. SVM-18043 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.
  • Page 83 FILE NO. SVM-18043 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 84 FILE NO. SVM-18043 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 85 FILE NO. SVM-18043 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 86: Applicable Control Of Outdoor Unit

    FILE NO. SVM-18043 9-4. 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 87: Address Setup

    FILE NO. SVM-18043 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 88: Address Setup & Group Control

    FILE NO. SVM-18043 10-2. Address Setup & Group Control 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 89 FILE NO. SVM-18043 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 90 FILE NO. SVM-18043 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 91: Remote Controller Wiring

    FILE NO. SVM-18043 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 92: Confirmation Of Indoor Unit No. Position

    FILE NO. SVM-18043 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. button. (OK when display goes on.) Push (←...
  • Page 93 FILE NO. SVM-18043 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.) ...

  • Page 94: Replacement Of The Service P.c. Board

    FILE NO. SVM-18043 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 95: How To Exchange Compressor

    FILE NO. SVM-18043 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 96: Detachments

    FILE NO. SVM-18043 13. DETACHMENTS , GM801AT 13-1. RAV-GM561AT Part name Procedure Remarks Common procedure CAUTION 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 97 FILE NO. SVM-18043 Part name Procedure Remarks Front Motor base 1. How to remove cabinet 1) Perform 1 of 1. 2) Remove the screw between front cabinet and side cabinet (right). (ST1T Ø4 × 8, 1 pc.) 3) Remove the screw between front cabinet and inverter.
  • Page 98 FILE NO. SVM-18043 Procedure Part name Remarks 1. Detachment Inverter Screws assembly 1) Perform work of item 1 of 2) Take off screws of the upper part of the front cabinet. (ST1T Ø4 × 8L, 2 pcs.) • If removing the inverter cover under this condition, P .C.
  • Page 99 FILE NO. SVM-18043 Procedure Part name Remarks Connector Inverter assembly ･･･(3P：Relay connector white） ※ (Warning 1) Reactor (2P：Relay connector white) Inverter CN300･･･ Outdoor fan (3P：white) assembly ※ (Warning 1) CN701･･･ 4 directional valve (3P：yellow) ※ (Warning 1) CN700･･･ PMV coil (6P：white) ※...
  • Page 100 FILE NO. SVM-18043 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 101 FILE NO. SVM-18043 Part name Procedure Remarks Rear cabinet 1) Perform works of items 1 of 1 and 2 , 3 . 2) Take off fixed screws for the bottom plate. (ST1T Ø4 × 8L, 2 pcs.) 3) Take off fixed screw for the valve mounting plate.
  • Page 102 FILE NO. SVM-18043 Part name Procedure Remarks Compressor 1) Perform works of items 1 of 1 and 2 , Partition plate 2) Discharge refrigerant gas. 3) Remove the partition plate. (ST1T Ø4 × 8L, 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 103 FILE NO. SVM-18043 Part name Procedure Remarks Pulse Motor Valve 1. Detachment GM56 type (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 104 FILE NO. SVM-18043 , GM1401AT 13-2. RAV-GM1104AT Procedure Part name Remarks Common procedure CAUTION Be sure to put on the gloves at working time; otherwise an injury may be caused by a part, etc. 1. Detachment 1) Stop operation of the air conditioner and then turn off switch of the breaker.
  • Page 105 FILE NO. SVM-18043 Part name Procedure Remarks Discharge 1. Detachment port cabinet Heat exchanger Discharge port cabinet 1) Carry out work of 1 of Motor base Partition plate 2) Remove screws for the discharge port cabinet and the partition plate. (ST1T Ø4 ×...
  • Page 106 FILE NO. SVM-18043 Part name Procedure Remarks Exchange of 1. Control P.C. board Cover inverter electric parts 1) Carry out work of 1 of WARNING Screws Never disassemble the inverter for 1 minute after power has been turned off because an electric shock may be caused.
  • Page 107 FILE NO. SVM-18043 Part name Procedure Remarks Exchange of 2. Reactor Reactor relay connector electric parts 1) Carry out works of 1 of (Connected to lead wire (Continued) (White) at P.C. board side) 2) Remove the relay connector connected to the control P .C.
  • Page 108 FILE NO. SVM-18043 Part name Procedure Remarks Fan motor 1) Carry out works of 1 of 1 and 2 . Loosened by Propeller fan turning clockwise 2) Remove the flange nut fixing the fan motor and the propeller fan. ∗ The flange nut is loosened by turning clockwise. (To tighten it, turn it counterclockwise.) 3) Remove the propeller fan.
  • Page 109 FILE NO. SVM-18043 Part name Procedure Remarks Compressor 1. Removal of broken compressor Compressor lead 1) Recover the refrigerant gas. 2) Carry out works of 1 of 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and the bottom plate. (Hexagonal screw Ø4 ×...
  • Page 110 FILE NO. SVM-18043 Part name Procedure Remarks Compressor 10) Using a burner, remove the discharge Remove Remove Compressor lead pipe and the suction pipe connected to (Discharge pipe) (Suction pipe) (Continued) the compressor. WARNING In case of removing the piping by broiling the welded part with a burner, if the piping includes oil, it may burst into flames at the moment when wax melted, so take...
  • Page 111 FILE NO. SVM-18043 Part name Procedure Remarks Compressor 2. Mounting of compressor Suction pipe Compressor lead Header pipe 1) Mount the compressor in the reverse Accumulator (Continued) procedure of removal. Discharge pipe NOTES: ∗ After exchange of the compressor, be sure to exchange the compressor lead.
  • Page 112 FILE NO. SVM-18043 Part name Procedure Remarks Compressor 3. Vacuuming Compressor lead 1) Connect the vacuum pump to the charge (Continued) port of the gas pipe valve and then drive the vacuum pump. 2) Carry out vacuuming until the vacuum low pressure gauge indicates 1 (mmHg).
  • Page 113 FILE NO. SVM-18043 Part name Procedure Remarks Fan guard 3. Detachment Bell mouth Discharge port cabinet 1) Carry out works of 1 of CAUTION To prevent scratching on the product, handle the product on a cardboard or cloth. 2) Remove the discharge port cabinet and then put on it so that the fan guard side directs downward.

  • Page 114: Exploded Views And Parts List

    FILE NO. SVM-18043 14. EXPLODED VIEWS AND PARTS LIST 14-1. RAV-GM561ATP-E, GM561ATJP-E, GM561ATP-TR 17,18 12,13 16,30 15,29 24,25,26 - 114 -...
  • Page 115 FILE NO. SVM-18043 RAV- Location Part No. Description GM561ATP-E GM561ATJP-E GM561ATP-TR 43T42352 ASM-COAT-BASE 43T00605 ASM-CABI-F-S 43T00599 ASM-CABI-SIDE-R 43T00603 ASM-COAT-C-S-L 43T19352 ASM-COVER-PV 43T00604 ASM-COAT-CABI-U 43T39348 ASM-M-BASE 43T39347 ASM-M-BASE 43T41493 COMP ASSY 43T46375 VALVE-4WAY 43T63352 COIL-V-4WAY 43T46425 BODY-PMV 43T63354 COIL-PMV 43T63353 SW-PRESS 43T46374 PACKEDVALVE 43T46358...
  • Page 116 FILE NO. SVM-18043 - 116 -...
  • Page 117 FILE NO. SVM-18043 RAV- Location Part No. Description GM561ATP-E GM561ATJP-E GM561ATP-TR 43T6W332 ASM-L-PCB 43T6V418 ASM-PCB 43T60422 REACTOR(CH-76) 43T62313 BASE-PLATE-PC 43T61320 ASM-BASE-PL-SUB-PC 43T60423 TERMINAL 43T60426 FUSE 43T60425 FUSE-HOLDER 43T50352 TC-SENSOR(TE) 43T50353 TC-SENSOR(TS) 43T50334 SENSOR(TD) 43T50337 SENSOR(TO) 43T50335 SENSOR(TL) 43T63318 HOLDER-SENSOR(TE) 43T63317 HOLDER-SENSOR(TD) 43T63323 HOLDER-SENSOR(TS)

  • Page 118: Rav-Gm801Atp-E, Gm801Atjp-E, Gm801Atp-Tr

    FILE NO. SVM-18043 14-2. RAV-GM801ATP-E, GM801ATJP-E, GM801ATP-TR 19,20 14,15 18,32 17,31 10,11 26,27,28 - 118 -...
  • Page 119 FILE NO. SVM-18043 RAV- Location Part No. Description GM801ATP-E GM801ATJP-E GM801ATP-TR 43T42352 ASM-COAT-BASE 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 43T39348 ASM-M-BASE 43T39347 ASM-M-BASE 43T41493 COMP ASSY 43T48302 ASM-ACCUM 43T48303 ASM-ACCUM 43T46383 VALVE-4WAY 43T63352 COIL-V-4WAY 43T46425 BODY-PMV 43T63354 COIL-PMV 43T63353...
  • Page 120 FILE NO. SVM-18043 - 120 -...
  • Page 121 FILE NO. SVM-18043 RAV- Location Part No. Description GM801ATP-E GM801ATJP-E GM801ATP-TR 43T6W333 ASM-L-PCB 43T6V418 ASM-PCB 43T60422 REACTOR(CH-76) 43T62313 BASE-PLATE-PC 43T61320 ASM-BASE-PL-SUB-PC 43T60423 TERMINAL 43T60426 FUSE 43T60425 FUSE-HOLDER 43T50352 TC-SENSOR(TE) 43T50353 TC-SENSOR(TS) 43T50334 SENSOR(TD) 43T50337 SENSOR(TO) 43T50335 SENSOR(TL) 43T63318 HOLDER-SENSOR(TE) 43T63317 HOLDER-SENSOR(TD) 43T63323 HOLDER-SENSOR(TS)

  • Page 122: Rav-Gm1101Atp-E, Gm1101Atjp-E, Gm1101Atp-Tr Rav-Gm1401Atp-E, Gm1401Atpj-E, Gm1401Atp-Tr

    FILE NO. SVM-18043 14-3. RAV-GM1101ATP-E, GM1101ATJP-E, GM1101ATP-TR RAV-GM1401ATP-E, GM1401ATPJ-E, GM1401ATP-TR 21,22 16,17 12,13 31,32,33 20,37 19,36 - 122 -...
  • Page 123 FILE NO. SVM-18043 RAV-GM Location Part No. Description 1101 1401 1101 1401 1101 1401 ATP-E ATP-E ATJP-E ATJP-E ATP-TR ATP-TR 43T42351 ASM-BASE ASM-COAT-C-A-T 43T00606 43T00601 ASM-PANEL-FRONT 43T00607 ASM-COAT-P-S-R 43T00600 ASM-CABI-UP 43T00608 ASM-COAT-P-P-FR 43T00609 ASM-COAT-P-P-BK BASE-MOTOR 43T39342 43T39349 ASM-COAT-BASE-M 43T19346 FIN GUARD COMPRESSOR 43T41537 43T48321...
  • Page 124 FILE NO. SVM-18043 - 124 -...
  • Page 125 FILE NO. SVM-18043 RAV- GM1101ATP-E GM1401ATP-E Location Part No. Description GM1101ATJP-E GM1401ATJP-E GM1101ATP-TR GM1401ATP-TR 43T6W334 ASM-L-PCB 43T6W335 ASM-L-PCB 43T6V418 ASM-PCB 43T95301 SUPPORT, SPACER 43T95302 SPACER (EDGE) 43T61319 SPACER(COLLAR) 43T61315 SPACER(BUSH) 43T61321 ASM-BASE-PL-SUB-PC 43T60405 TERMINAL (power supply) 43T60427 TERMINAL (to indoor unit) 43T60413 FUSE(10A/250V) 43T60425...
  • Page 126 FILE NO. SVM-18043 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 127 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

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