RAV-SM564KRT-E RAV-SM804KRT-E RAV-SM564KRT-TR RAV-SM804KRT-TR

Transcription

1 FILE. A0-03 SERVICE MANUAL AIR-CONDITIONER HI WALL TYPE (INDOOR UNIT) RAV-SM564KRT-E RAV-SM804KRT-E RAV-SM564KRT-TR RAV-SM804KRT-TR ŸThe service parts will be supplied by TCTC. R40A PRINTED IN JAPAN, May., 0 ToMo

2 CONTENTS Precaution for Safety SPECIFICATIONS.... CONSTRUCTION VIEWS (EXTERNAL VIEWS) SYSTEMATIC REFRIGERATING CYCLE DIAGRAM WIRING DIAGRAM SPECIFICATIONS OF ELECTRICAL PARTS REFRIGERANT R40A INDOOR UNIT CONTROL TROUBLESHOOTING HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT ON-SITE SETTING AND OTHERS ADDRESS SETTING EXPLODED VIEWS AND PARTS LIST TE : This Service Manual describes explanation for the High Wall type indoor unit. For the combined outdoor unit, refer to the following Service Manual. Outdoor unit Model name SVM to be referred DI : RAV-SMXXXAT-E A06-00, A07-009, A SDI : RAV-SPXXXAT-E A08-007, A07-003, A0-00

3 Original instruction Please read carefully through these instructions that contain important information which complies with the Machinery Directive (Directive 006/4/EC), and ensure that you understand them. Generic Denomination: Air Conditioner Definition of Qualified Installer or Qualified Service Person The air conditioner must be installed, maintained, repaired and removed by a qualified installer or qualified service person. When any of these jobs is to be done, ask a qualified installer or qualified service person to do them for you. A qualified installer or qualified service person is an agent who has the qualifications and knowledge described in the table below. Agent Qualified installer ( ) Qualified service person ( ) Qualifications and knowledge which the agent must have The qualified installer is a person who installs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Corporation. He or she has been trained to install, maintain, relocate and remove the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations. The qualified installer who is allowed to do the electrical work involved in installation, relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by 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. The qualified installer who is allowed to do the refrigerant handling and piping work involved in installation, relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by 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. The qualified installer who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by 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. The qualified service person is a person who installs, repairs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Corporation. He or she has been trained to install, repair, maintain, relocate and remove the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations. The qualified service person who is allowed to do the electrical work involved in installation, repair, relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by 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. The qualified service person who is allowed to do the refrigerant handling and piping work involved in installation, repair, relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by 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. The qualified service person who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by 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. 3

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. Failure to wear the proper protective gear is dangerous because you will be more susceptible to injury, burns, electric shocks and other injuries. Work undertaken All types of work Electrical-related work Work done at heights (50 cm or more) Transportation of heavy objects Repair of outdoor unit Protective gloves Safety working clothing Protective gear worn Gloves to provide protection for electricians and from heat Insulating shoes Clothing to provide protection from electric shock Helmets for use in industry Shoes with additional protective toe cap Gloves to provide protection for electricians and from heat The important contents concerned to the safety are described on the product itself and on this Service Manual. Please read this Service Manual after understanding the described items thoroughly in the following contents (Indications/Illustrated marks), and keep them. [Explanation of indications] Indication DANGER WARNING CAUTION Explanation Indicates contents assumed that an imminent danger causing a death or serious injury of the repair engineers and the third parties when an incorrect work has been executed. Indicates possibilities assumed that a danger causing a death or serious injury of the repair engineers, the third parties, and the users due to troubles of the product after work when an incorrect work has been executed. Indicates contents assumed that an injury or property damage ( ) may be caused on the repair engineers, the third parties, and the users due to troubles of the product after work when an incorrect work has been executed. Property damage : Enlarged damage concerned to property, furniture, and domestic animal/pet [Explanation of illustrated marks] Mark Explanation Indicates prohibited items (Forbidden items to do) The sentences near an illustrated mark describe the concrete prohibited contents. Indicates mandatory items (Compulsory items to do) The sentences near an illustrated mark describe the concrete mandatory contents. Indicates cautions (Including danger/warning) The sentences or illustration near or in an illustrated mark describe the concrete cautious contents. 4

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. Warning indication Description WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing. WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing. WARNING Moving parts. Do not operate unit with grille removed. Stop the unit before the servicing. WARNING Moving parts. Do not operate unit with grille removed. Stop the unit before the servicing. CAUTION High temperature parts. You might get burned when removing this panel. CAUTION High temperature parts. You might get burned when removing this panel. CAUTION Do not touch the aluminum fins of the unit. Doing so may result in injury. CAUTION Do not touch the aluminum fins of the unit. Doing so may result in injury. CAUTION BURST HAZARD Open the service valves before the operation, otherwise there might be the burst. CAUTION BURST HAZARD Open the service valves before the operation, otherwise there might be the burst. 5

6 Precaution for Safety The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual. WARNING General 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 ( ) 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. Only a qualified installer ( ) or qualified service person ( ) is allowed to carry out the electrical work of the air conditioner. Under no circumstances must this work be done by an unqualified individual since failure to carry out the work properly may result in electric shocks and/or electrical leaks. Wear protective gloves and safety work clothing during installation, servicing and removal. When connecting the electrical wires, repairing the electrical parts or undertaking other electrical jobs, wear gloves to provide protection for electricians and from heat, insulating shoes and clothing to provide protection from electric shocks. Failure to wear this protective gear may result in electric shocks. Use wiring that meets the specifications in the Installation Manual and the stipulations in the local regulations and laws. Use of wiring which does not meet the specifications may give rise to electric shocks, electrical leakage, smoking and/or a fire. Only a qualified installer ( ) or qualified service person ( ) is allowed to undertake work at heights using a stand of 50 cm or more or to remove the intake grille of the indoor unit to undertake work. When working at heights, use a ladder which complies with the ISO 4 standard, and follow the procedure in the ladder s instructions. Also wear a helmet for use in industry as protective gear to undertake the work. When working at heights, put a sign in place so that no-one will approach the work location, before proceeding with the work. Parts and other objects may fall from above, possibly injuring a person below. Do not touch the aluminum fin of the outdoor unit. You may injure yourself if you do so. If the fin must be touched for some reason, first put on protective gloves and safety work clothing, and then proceed. Do not climb onto or place objects on top of the outdoor unit. You may fall or the objects may fall off of the outdoor unit and result in injury. When transporting the air conditioner, wear shoes with additional protective toe caps. When transporting the air conditioner, do not take hold of the bands around the packing carton. You may injure yourself if the bands should break. This air conditioner has passed the pressure test as specified in IEC Annex EE. DENGER Turn off breaker. Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position. Otherwise, electric shocks may result. Before opening the intake grille of the indoor unit or service panel of the outdoor unit, set the circuit breaker to the OFF position. Failure to set the circuit breaker to the OFF position may result in electric shocks through contact with the interior parts. Only a qualified installer ( ) or qualified service person ( ) is allowed to remove the intake grille of the indoor unit or service panel of the outdoor unit and do the work required. Before starting to repair the outdoor unit fan or fan guard, be absolutely sure to set the circuit breaker to the OFF position, and place a Work in progress sign on the circuit breaker. When cleaning the filter or other parts of the indoor unit, set the circuit breaker to OFF without fail, and place a Work in progress sign near the circuit breaker before proceeding with the work. 6

7 Execute discharge between terminals. Prohibition Stay on protection Even if the circuit breaker has been set to the OFF position before the service panel is removed and the electrical parts are repaired, you will still risk receiving an electric shock. For this reason, short-circuit the high-voltage capacitor terminals to discharge the voltage before proceeding with the repair work. For details on the short-circuiting procedure, refer to the Service Manual. You may receive an electric shock if the voltage stored in the capacitors has not been sufficiently discharged. Place a Work in progress sign near the circuit breaker while the installation, maintenance, repair or removal work is being carried out. There is a danger of electric shocks if the circuit breaker is set to ON by mistake. 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. You may receive an electric shock if you fail to heed this warning. Only qualified service person ( ) is allowed to do this kind of work. WARNING Check earth wires. Prohibition of modification. Use specified parts. Do not bring a child close to the equipment. Insulating measures No fire Before troubleshooting or repair work, check the earth wire is connected to the earth terminals of the main unit, otherwise an electric shock is caused when a leak occurs.if the earth wire is not correctly connected, contact an electric engineer for rework. After completing the repair or relocation work, check that the ground wires are connected properly. Be sure to connect earth wire. (Grounding work) Incomplete grounding causes an electric shock. Do not connect ground wires to gas pipes, water pipes, and lightning rods or ground wires for telephone wires. Do not modify the products.do not also disassemble or modify the parts. It may cause a fire, electric shock or injury. When any of the electrical parts are to be replaced, ensure that the replacement parts satisfy the specifications given in the Service Manual (or use the parts contained on the parts list in the Service Manual). Use of any parts which do not satisfy the required specifications may give rise to electric shocks, smoking and/or a fire. 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, place "Keep out" signs around the work site before proceeding. Third-party individuals may enter the work site and receive electric shocks if this warning is not heeded. Connect the cut-off lead wires with crimp contact, etc, put the closed end side upward and then apply a water-cut method, otherwise a leak or production of fire is caused at the users side. 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. ) Be attentive to fire around the cycle. When using a gas stove, etc, be sure to put out fire before work; otherwise the oil mixed with refrigerant gas may catch fire. ) Do not use a welder in the closed room. When using it without ventilation, carbon monoxide poisoning may be caused. 3) Do not bring inflammables close to the refrigerant cycle, otherwise fire of the welder may catch the inflammables. 7

8 Refrigerant Assembly/ Cabling Insulator check Ventilation The refrigerant used by this air conditioner is the R40A. Check the used refrigerant name and use tools and materials of the parts which match with it. For the products which use R40A refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see. To prevent miss-charging, the route of the service port is changed from one of the former R. Do not use any refrigerant different from the one specified for complement or replacement. Otherwise, abnormally high pressure may be generated in the refrigeration cycle, which may result in a failure or explosion of the product or an injury to your body. For an air conditioner which uses R40A, never use other refrigerant than R40A. For an air conditioner which uses other refrigerant (R, etc.), never use R40A. If different types of refrigerant are mixed, abnormal high pressure generates in the refrigerating cycle and an injury due to breakage may be caused. Do not charge refrigerant additionally. If charging refrigerant additionally when refrigerant gas leaks, the refrigerant composition in the refrigerating cycle changes resulted in change of air conditioner characteristics or refrigerant over the specified standard amount is charged and an abnormal high pressure is applied to the inside of the refrigerating cycle resulted in cause of breakage or injury. Therefore if the refrigerant gas leaks, recover the refrigerant in the air conditioner, execute vacuuming, and then newly recharge the specified amount of liquid refrigerant. In this time, never charge the refrigerant over the specified amount. When recharging the refrigerant in the refrigerating cycle, do not mix the refrigerant or air other than R40A into the specified refrigerant. If air or others is mixed with the refrigerant, abnormal high pressure generates in the refrigerating cycle resulted in cause of injury due to breakage. After installation work, check the refrigerant gas does not leak. If the refrigerant gas leaks in the room, poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous. Never recover the refrigerant into the outdoor unit. When the equipment is moved or repaired, be sure to recover the refrigerant with recovering device. The refrigerant cannot be recovered in the outdoor unit; otherwise a serious accident such as breakage or injury is caused. After repair work, surely assemble the disassembled parts, and connect and lead the removed wires as before. Perform the work so that the cabinet or panel does not catch the inner wires. If incorrect assembly or incorrect wire connection was done, a disaster such as a leak or fire is caused at user s side. After the work has finished, be sure to use an insulation tester set (500V Megger) to check the resistance is MΩ or more between the charge section and the non-charge metal section (Earth position). If the resistance value is low, a disaster such as a leak or electric shock is caused at user s side. When the refrigerant gas leaks during work, execute ventilation. If the refrigerant gas touches to a fire, poisonous gas generates. A case of leakage of the refrigerant and the closed room full with gas is dangerous because a shortage of oxygen occurs. Be sure to execute ventilation. 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. The poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous. When installing equipment which includes a large amount of charged refrigerant such as a multi air conditioner in a sub-room, it is necessary that the density does not the limit even if the refrigerant leaks. If the refrigerant leaks and exceeds the limit density, an accident of shortage of oxygen is caused. Compulsion Tighten the flare nut with a torque wrench in the specified manner. Excessive tighten of the flare nut may cause a crack in the flare nut after a long period, which may result in refrigerant leakage. Nitrogen gas must be used for the airtight test. The charge hose must be connected in such a way that it is not slack. For the installation/moving/reinstallation work, follow to the Installation Manual. If an incorrect installation is done, a trouble of the refrigerating cycle, water leak, electric shock or fire is caused. 8

9 Check after repair Do not operate the unit with the valve closed. Check after reinstallation Cooling check Installation Once the repair work has been completed, check for refrigerant leaks, and check the insulation resistance and water drainage. Then perform a trial run to check that the air conditioner is running properly. After repair work has finished, check there is no trouble. If check is not executed, a fire, electric shock or injury may be caused. For a check, turn off the power breaker. After repair work (installation of front panel and cabinet) has finished, execute a test run to check there is no generation of smoke or abnormal sound. If check is not executed, a fire or an electric shock is caused. Before test run, install the front panel and cabinet. Check the following matters before a test run after repairing piping. Connect the pipes surely and there is no leak of refrigerant. The valve is opened. Running the compressor under condition that the valve closes causes an abnormal high pressure resulted in damage of the parts of the compressor and etc. and moreover if there is leak of refrigerant at connecting section of pipes, the air is suctioned and causes further abnormal high pressure resulted in burst or injury. Only a qualified installer ( ) or qualified service person ( ) is allowed to relocate the air conditioner. It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire, electric shocks, injury, water leakage, noise and/or vibration may result. Check the following items after reinstallation. ) The earth wire is correctly connected. ) The power cord is not caught in the product. 3) There is no inclination or unsteadiness and the installation is stable. If check is not executed, a fire, an electric shock or an injury is caused. When carrying out the pump-down work shut down the compressor before disconnecting the refrigerant pipe. Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly resulting in reputing, injury, etc. When the service panel of the outdoor unit is to be opened in order for the compressor or the area around this part to be repaired immediately after the air conditioner has been shut down, set the circuit breaker to the OFF position, and then wait at least 0 minutes before opening the service panel. If you fail to heed this warning, you will run the risk of burning yourself because the compressor pipes and other parts will be very hot to the touch. In addition, before proceeding with the repair work, wear the kind of insulated heat-resistant gloves designed to protect electricians. When the service panel of the outdoor unit is to be opened in order for the fan motor, reactor, inverter or the areas around these parts to be repaired immediately after the air conditioner has been shut down, set the circuit breaker to the OFF position, and then wait at least 0 minutes before opening the service panel. If you fail to heed this warning, you will run the risk of burning yourself because the fan motor, reactor, inverter heat sink and other parts will be very hot to the touch. In addition, before proceeding with the repair work, wear the kind of insulated heat-resistant gloves designed to protect electricians. Only a qualified installer ( ) or qualified service person ( ) 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. Do not install the air conditioner in a location that may be subject to a risk of expire to a combustible gas. If a combustible gas leaks and becomes concentrated around the unit, a fire may occur. Install the indoor unit at least.5 m above the floor level since otherwise the users may injure themselves or receive electric shocks if they poke their fingers or other objects into the indoor unit while the air conditioner is running. Install a circuit breaker that meets the specifications in the installation manual and the stipulations in the local regulations and laws. Install the circuit breaker where it can be easily accessed by the qualified service person ( ). Do not place any combustion appliance in a place where it is directly exposed to the wind of air conditioner, otherwise it may cause imperfect combustion. 9

10 Explanations given to user If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person to have the repairs done. Do not set the circuit breaker to the ON position until the repairs are completed. Relocation Only a qualified installer ( ) or qualified service person ( ) is allowed to relocate the air conditioner. It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire, electric shocks, injury, water leakage, noise and/or vibration may result. When carrying out the pump-down work shut down the compressor before disconnecting the refrigerant pipe. Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly resulting in reputing, injury, etc. ( ) Refer to the Definition of Qualified Installer or Qualified Service Person. Declaration of Conformity Manufacturer: TOSHIBA CARRIER (THAILAND) CO., LTD. 44/9 Moo 5, Bangkadi Industrial Park, Tivanon Road, Amphur Muang, Pathumthani 000, Thailand Authorized Nick Ball Representative/TCF holder: Toshiba EMEA Engineering Director Toshiba Carrier UK Ltd. Porsham Close, Belliver Industrial Estate, PLYMOUTH, Devon, PL6 7DB. United Kingdom Hereby declares that the machinery described below: Generic Denomination: Air Conditioner Model/type: RAV-SM564KRT-E, RAV-SM804KRT-E RAV-SM564KRT-TR, RAV-SM804KRT-TR Commercial name: Digital Inverter Series / Super Digital Inverter Series Air Conditioner Complies with the provisions of the Machinery Directive (Directive 006/4/EC) and the regulations transposing into national law. Complies with the provisions of the following harmonized standard: EN 378-: A: 009 Note: This declaration becomes invalid if technical or operational modifications are introduced without the manufacturer s consent. Specifications Model RAV-SM564KRT-E RAV-SM804KRT-E RAV-SM564KRT-TR RAV-SM804KRT-TR Under 70 dba Sound power level (dba) Cooling 0 Heating Weight (kg) Main unit (Ceiling panel)

11 -. High-Wall Type (Indoor unit). SPECIFICATIONS Model name Standard capacity (Note ) (kw) Heating low temp. capacity (Note ) (kw) Energy consumption effect ratio (Cooling) Power supply Running current (A) Electrical Power consumption (kw) characteristics (Low temp.) (kw) Power factor (%) Main unit Appearance Ceiling panel Model (Sold separately) Panel color Height (mm) Main unit Width (mm) Outer Depth (mm) dimension Height (mm) Ceiling panel (Sold separately) Width (mm) Depth (mm) Total weight Main unit (kg) Ceiling panel Heat exchanger Soundproof/Heat-insulating material Fan Fan unit Standard air flow High (Mid./Low) (m³/h) Motor (W) Air filter Controller (Sold separately) Gas side (mm) Connecting pipe Liquid side (mm) Drain port (Nominal dia.) Sound level High (Mid./Low) (Note ) (db.a) RAV-SM564KRT-E (TR) RAV-SM804KRT-E (TR) Cooling Heating Average Cooling Heating Average (.5-5.6) (.5-6.3) (.- 8.0) (.-9.0) [D] 3.9 [C] [E] 3.00 [D] 3.4 phase 30V (0-40V) 50Hz Inflammable polyethylene foam Pure white Finned tubu Turbo fan Foamed polyethylen Attached main unit Wired remote controller RBC-AMTE Ø.7 (/ ) Ø5.9 (5/8 ) Ø6.4 (/4 ) Ø9.5 (3/8 ) 5 (Polyvinyl chloride tube) Note : The cooling capacities and electrical characteristics are measured under the conditions speciied by JIS B 866 based on the reference piping. The reference piping consists of 3 m of main piping and m of branch piping connected with 0 meter height. Note : The sound level is measured in an anechoic chamber in accordance with JIS B866. Normally, the values measured in the actual operating environment become larger than the indicated values due to the effects of external sound. Note: Rated conditions Cooling : Indoor air temperature 7 C DB/9 C WB, Outdoor air temperature 35 C DB Heating : Indoor air temperature 0 C DB, Outdoor air temperature 7 C DB/6 C WB

12 Operation characteristic curve Operation characteristic curve <Cooling> 4 <Heating> 6 0 SM80 4 SM80 Current (A) Conditions Indoor : DB7 C/WB9 C Outdoor : DB35 C Air flow : High Pipe length : 7.5m 30V Compressor speed (rps) SM56 Current (A) SM56 4 Conditions Indoor : DB0 C Outdoor :DB7 C/WB6 C Air flow : High Pipe length : 7.5m 30V Compressor speed (rps) Capacity variation ratioaccor ding to temperature Capacity variation ratioaccor ding to temperature <Cooling> <Heating> Capacity ratio (%) Conditions Indoor : DB7 C/WB9 C 55 Indoor air flow : High Pipe length : 7.5m Outsoor temp. ( C) Capacity ratio (%) Conditions Indoor : DB0 C 0 Indoor air flow : High Pipe length : 7.5m Outsoor temp. ( C)

13 . CONSTRUCTION VIEWS (EXTERNAL VIEWS) High Wall Type Back body Front panel Grille inlet Air inlet Air outlet 50 8 Knock out system Knock out system Wireless remote control 55 or more Minimum distance to ceiling Connection pipe (0.39 m) (For SM80 : Flare Ø5.88) (For SM56 : Flare Ø.7) Outline of indoor unit Drain hose (0.54 m) 57 8 Connection pipe (0.49 m) (Flare Ø6.35) (For stud bolt Ø6) (For stud bolt Ø8 - Ø0) Ø Installation Plate outline 00 Ø

14 3-. Hi Wall type 3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM Indoor unit Model Outer diameter of refrig erant pipe Gas side ØA Liquid side ØB TC sensor Air heat exchanger TCJ sensor SM56.7 mm 6.4 mm SM mm 9.5 mm Refrigerant pipe at gas side Outer dia. ØA Refrigerant pipe at liquid side Outer dia. ØB Pd Packed valve Outer dia. ØA Packed valve Outer dia. ØB Ps Outdoor unit TE : The refigerating cycle differs according to the combined outdoor units. For the cycle diagram, cycle pressure, ect., refer to the following Service Manual. RAV-SMXXXXAT-E : A06-00, A07-009, A RAV-SPXXXXAT-E : A08-007, A07-003, A0-00 Cooling Heating 4

15 4. WIRING DIAGRAM 4-. Hi Wall type (Indoor unit) TERMINAL BLOCK BLK 3 3 Indoor unit earth screw BLK Outdoor unit earth screw L N Serial signal Single phass 0V, 50Hz HA BLU BLU BLU BLU BLU BLU BLU BLU BLU WHI BRW RED ORN YEL PNK BLK WHI YEL BLU RED BLU BLU BLU RED WHI BLK CN67 (BLK) F30 FUSE T3.5A 50V~ WHI BLK HEAT EXCHANGER SENSOR (TC) BLK BLK BLK BLK BLK BLK CN3 (WHI) CN S BLK F CN33 (WHI) CN0 (WHI) CN40 (BLU) CN44 (BRW) CN50 (WHI) CN4 (BLU) CN00 (BRW) CN0 (BLU) WIERD REMOTE CONTROLLER HEAT EXCHANGER SENSOR (TCJ) THERMO SENSOR (TA) (MCC-50) Control P.C.board for indoor unit POWER SUPPKY CIRCUIT INFARED RAYS RECEIVE AND INDICATION PARTS CN80 (GRN) 3 PNL/EMG CN8 (BLU) LOUVER MOTOR FAN MOTOR TERMINAL BLOCK U3 U CN03 (GRN) CN0 (YEL) CN8 (BLK) CN6 (YEL) CN60 (WHI) B CN04 (WHI) OPTION A TE FM : Fan motor TA : Indoor temp. sensor TC : Temp. sensor TCJ:Temp. sensor LM : Louver motor Color Identification BLK : BLACK GRN : GREEN BLU : BLUE WHI : WHITE RED : RED BRW : BROWN GRY : GRAY ORN : ORANGE PNK : PINK YEL : YELLOW 5

16 5. SPECIFICATIONS OF ELECTRICAL PARTS 5-. Indoor Unit High Wall Type No. Parts name Type Specifications Fan motor (for indoor) ICF X, MF X Output (Rated) 30 W, 0-40 V Grille motor MP35EA 3 Thermo. sensor (TA-sensor) 68 mm 0 kω at 5 C 4 Heat exchanger sensor (TC-sensor) Ø6 mm, 400 mm 0 kω at 5 C 5 Heat exchanger sensor (TCJ-sensor) Ø6 mm, 400 mm 6

17 6. REFRIGERANT R40A This air conditioner adopts the new refrigerant HFC (R40A) which does not damage the ozone layer. The working pressure of the new refrigerant R40A is.6 times higher than conventional refrigerant (R). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time. The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work. 6-. Safety During Installation/Servicing As R40A s pressure is about.6 times higher than that of R, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R40A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.. Never use refrigerant other than R40A in an air conditioner which is designed to operate with R40A. If other refrigerant than R40A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.. Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R40A. The refrigerant name R40A is indicated on the visible place of the outdoor unit of the air conditioner using R40A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R. 3. If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire, a poisonous gas may occur. 4. When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused. 5. After completion of installation work, check to make sure that there is no refrigeration gas leakage. If the refrigerant gas leaks into the room, coming into contact with fire in the fandriven heater, space heater, etc., a poisonous gas may occur. 6. When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level. If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result. 7. Be sure to carry out installation or removal according to the installation manual. Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc. 8. Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician. Improper repair may result in water leakage, electric shock and fire, etc. 6-. Refrigerant Piping Installation 6--. Piping Materials and Joints Used For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.. Copper Pipes It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/0 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface). Otherwise, the expansion valve or capillary tube may become blocked with contaminants. As an air conditioner using R40A incurs pressure higher than when using R, it is necessary to choose adequate materials. Thicknesses of copper pipes used with R40A are as shown in Table 6--. Never use copper pipes thinner than 0.8 mm even when it is available on the market. 7

18 Table 6-- Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R40A R /4 3/8 / 5/ 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 pipings whose outer diameter exceeds 0 mm. In such a case, socket joints can be used. Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 6--3 to 6--6 below. b) Socket Joints Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 0 mm. Thicknesses of socket joints are as shown in Table 6--. Table 6-- Minimum thicknesses of socket joints Nominal diameter /4 3/8 / 5/8 Reference outer diameter of copper pipe jointed (mm) Minimum joint thickness (mm) Processing of Piping Materials When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil than lubricating oils used in the installed air-water heat pump is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.. Flare processing procedures and precautions a) Cutting the Pipe By means of a pipe cutter, slowly cut the pipe so that it is not deformed. b) Removing Burrs and Chips If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation. c) Insertion of Flare Nut 8

19 d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R40A or conventional flare tool. Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure dimension A by using a gauge for size adjustment. ØD Fig. 6-- Flare processing dimensions A Table 6--3 Dimensions related to flare processing for R40A Nominal diameter Outer diameter (mm) Thickness (mm) A (mm) Flare tool for R40A Conventional flare tool clutch type Clutch type Wing nut type / to to.5.5 to.0 3/ to to.5.5 to.0 / to to.5.0 to.5 5/ to to.5.0 to.5 Table 6--4 Dimensions related to flare processing for R Nominal diameter Outer diameter (mm) Thickness (mm) A (mm) Flare tool for R Conventional flare tool clutch type Clutch type Wing nut type / to to.0.0 to.5 3/ to to.0.0 to.5 / to to.0.5 to.0 5/ to to.0.5 to.0 Table 6--5 Flare and flare nut dimensions for R40A Nominal diameter Outer diameter (mm) Thickness (mm) Dimension (mm) A B C D Flare nut width (mm) / / / /

20 Table 6--6 Flare and flare nut dimensions for R Nominal diameter Outer diameter (mm) Thickness (mm) Dimension (mm) A B C D Flare nut width (mm) / / / / / to 46 B A C D 43 to 45 Fig. 6-- Relations between flare nut and flare seal surface. 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. The tightening torque for R40A is the same as that for conventional R. Incidentally, when the torque is weak, the gas leakage may occur. When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 6--7 shows reference values. TE : When applying oil to the flare surface, be sure to use oil designated by the manufacturer. If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out. Table 6--7 Tightening torque of flare for R40A [Reference values] Nominal diameter Outer diameter (mm) Tightening torque N m (kgf cm) Tightening torque of torque wrenches available on the market N m (kgf cm) / to 8 (40 to 80) 6 (60), 8 (80) 3/ to 4 (330 to 40) 4 (40) / to 6 (500 to 60) 55 (550) 5/ to 77 (630 to 770) 65 (650) 0

21 6-3. Tools Required Tools The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R40A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø.7 copper pipe) of the refrigerant piping are lengthened. The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.. Tools exclusive for R40A (Those which cannot be used for conventional refrigerant (R)). Tools exclusive for R40A, but can be also used for conventional refrigerant (R) 3. Tools commonly used for R40A and for conventional refrigerant (R) The table below shows the tools exclusive for R40A and their interchangeability. No (Note ) (Note ) Flare tool Tools exclusive for R40A (The following tools for R40A are required.) Tools whose specifications are changed for R40A and their interchangeability Used tool Copper pipe gauge for adjusting projection margin Torque wrench Gauge manifold Charge hose Vacuum pump adapter Electronic balance for refrigerant charging Refrigerant cylinder Leakage detector Charging cylinder Pipe flaring Usage Flaring by conventional flare tool Connection of flare nut Evacuating, refrigerant charge, run check, etc. Vacuum evacuating Refrigerant charge Refrigerant charge Gas leakage check Refrigerant charge R40A air-water heat pump installation Existence of new equipment for R40A Whether conventional equipment can be used Yes (Note ) Yes (Note ) Yes Yes Yes Yes Yes Yes (Note ) Conventional air-water heat pump installation Whether new equipment can be used with conventional refrigerant When flaring is carried out for R40A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary. Charging cylinder for R40A is being currently developed. (Note ) General tools (Conventional tools can be used.) In addition to the above exclusive tools, the following equipments which serve also for R are necessary as the general tools. ) Vacuum pump 7) Screwdriver (+, ) Use vacuum pump by attaching vacuum pump adapter. 8) Spanner or Monkey wrench ) Torque wrench 9) Hole core drill (Ø65) 3) Pipe cutter 0) Hexagon wrench (Opposite side 4mm) 4) Reamer ) Tape measure 5) Pipe bender ) Metal saw 6) Level vial Also prepare the following equipments for other installation method and run check. ) Clamp meter 3) Insulation resistance tester ) Thermometer 4) Electroscope

22 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. Connect the charge hose to packed valve service port at the outdoor unit s gas side. When the compound gauge s pointer has indicated 0. Mpa ( 76 cmhg), place the handle Low in the fully closed position, and turn off the vacuum pump s power switch. Connect the charge hose to the vacuum pump adapter. Keep the status as it is for to minutes, and ensure that the compound gauge s pointer does not return. Open fully both packed valves at liquid and gas sides. Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump s power switch. Then, evacuating the refrigerant in the cycle. Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant. (For refrigerant charging, see the figure below.) CAUTION. Never charge refrigerant exceeding the specified amount.. If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode. 3. Do not carry out additional charging. When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury. (INDOOR unit) (Liquid side) (OUTDOOR unit) Opened (Gas side) Refrigerant cylinder (With siphon pipe) Check valve Closed Open/Close valve for charging Service port Electronic balance for refrigerant charging Fig Configuration of refrigerant charging

23 . Be sure to make setting so that liquid can be charged.. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. It is necessary for charging refrigerant under condition of liquid because R40A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon. [ Cylinder with siphon ] [ Cylinder without siphon ] Gauge manifold OUTDOOR unit Gauge manifold OUTDOOR unit Refrigerant cylinder Refrigerant cylinder Electronic balance Electronic balance Siphon R40A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies. Fig Brazing of Pipes Materials for Brazing. Silver brazing filler Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.. Phosphor bronze brazing filler Phosphor bronze brazing filler is generally used to join copper or copper alloy. 3. Low temperature brazing filler Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes.. Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.. When performing brazing again at time of servicing, use the same type of brazing filler Flux. Reason why flux is necessary By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler. In the brazing process, it prevents the metal surface from being oxidized. By reducing the brazing filler s surface tension, the brazing filler adheres better to the treated metal. 3

24 . Characteristics required for flux Activated temperature of flux coincides with the brazing temperature. Due to a wide effective temperature range, flux is hard to carbonize. It is easy to remove slag after brazing. The corrosive action to the treated metal and brazing filler is minimum. It excels in coating performance and is harmless to the human body. As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc. 3. Types of flux Noncorrosive flux Generally, it is a compound of borax and boric acid. It is effective in case where the brazing temperature is higher than 800 C. Activated flux Most of fluxes generally used for silver brazing are this type. It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound. 4. Piping materials for brazing and used brazing filler/flux 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 the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N) flow. Never use gas other than Nitrogen gas.. Brazing method to prevent oxidation ) Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder. ) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder. 3) Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas. 4) When the Nitrogen gas is flowing, be sure to keep the piping end open. 5) Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m 3 /Hr or 0.0 MPa (0.kgf/cm ) by means of the reducing valve. 6) After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands). 7) Remove the flux completely after brazing. Piping material Used brazing filler Used flux Copper - Copper Phosphor copper Do not use Copper - Iron Silver Paste flux Iron - Iron Silver Vapor flux M Flow meter. Do not enter flux into the refrigeration cycle.. When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine. 3. When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water). 4. Remove the flux after brazing. Nitrogen gas cylinder Pipe Stop valve From Nitrogen cylinder Rubber plug Nitrogen gas Fig Prevention of oxidation during brazing 4

25 7. INDOOR UNIT CONTROL 7-. Indoor Control Circuit Wired (Simple) header remote controller (wired) Central remote controller Display LCD Function setup Display LCD LCD driver Display LED CPU Remote controller communication circuit Key switch DC5V Power circuit Sold separately CN CN Power circuit DC5V CPU Secondary battery Function setup Key switch Sold separately Indoor unit # Header unit Central control remote controller (Sold separately) Follower unit # #3 U3 U4 A B A B A B Indoor control P.C. board (MCC-50) Central control communication circuit DC0V Remote controller communication circuit Receiver and Display P.C. board (MCC-89) Display LED Receiver unit DCV DC5V Buzzer Driver Driver CPU H8/3039 EEPROM TA sensor TC sensor TCJ sensor HA Same as the left Same as the left Louver motor Indoor fan motor DC80V Power circuit DC5V Fan motor control circuit Outside output Run/ Alarm/ Ready/ Thermo. ON/ COOL/HEAT/ FAN AC synchronous signal input circuit Wireless remote signal setting (A/B) Serial send/ receive circuit Outdoor unit Outdoor unit Max. 8 units are connectable. When group and twin combination. Main remote controller shal be connected follower indoor unit. Weekly timer is not connectable to the sub remote controller. 3 Outdoor unit 5

26 INDOOR UNIT CONTROL CIRCUIT (CONTINUED) 7-. Control Specifications. Item Overview of specifications Remarks Control at power-on reset () Identification of outdoor unit Identifies outdoor unit at power-on reset, and switches control according to the identification result. () Setting of indoor unit fan speed and adjustment of air flow direction. Switches indoor unit fan speed, setting of air flow direction adjustment, etc. based on EEPROM data. The PREPARING lamp lights during initial setting (model recognition) after power-on reset. Fan speed, adjustment of air flow direction Operation mode switching () Switches operation mode according to mode select instruction from remote controller. R/C instructions Outline of control OFF Turns OFF air conditioner FAN Fan only operation COOL Cooling operation DRY Dehumidifying operation HEAT Heating operation AUTO Selects COOL or HEAT mode automatically according to Ta, Ts, and To. The first operation is as follows according to Ta. (COOL thermo sensor continues OFF (FAN mode with set fan speed) within the range of Ts +α <Ta < Ts +α +.) Ta : Room temperature Ts : Set temperature To : Outside air temperature Ta ( C) +.0 Ts + α COOL operation Fan mode with set fan speed.0 HEAT operation α is corrected according to outside air temperature. Outside air temp. No To To 4 C 4 > To 8 C To < 8 C Abnormal To Corrected value (α) 0K K 0 K + K 0 K k = deg 3 Room temperature control () Operation instruction permission mode HEAT and AUTO modes are not available for COOL only models. When instruction is issued from wireless remote controller in the HEAT or AUTO mode, it is indicated by a reception sound pi, pi and by alternate blinking of TIMER and PREPARING lamps. To cancel this alternate blinking, issue an instruction of mode other than HEAT or AUTO. () Adjustment range Remote controller set temperature ( C) A Wired type Wireless type COOL/DRY HERT AUTO When use of remote controller sensor is set (with DN3), even when sensor value is within the above range in HEAT or AUTO mode, the thermo sensor turns OFF when Ta sensor value exceeds 35 C. 6

27 . Item Overview of specifications Remarks 3 Room temperature control () The set temperature for HEAT operation can be corrected by code No. 06. Set data Correction of set temp Heat intake temperature shift (When unit s temperature sensor is used) +0 C + C +4 C +6 C Factory setting Set data When use of remote controller sensor is set (with DN3), no correction is performed. 4 Capacity auto control (GA control) () Issues instruction of operating frequency to outdoor unit according to the difference between Ta and Ts. () COOL operation Calculates room temp. difference between Ta and Ts as well as room temp. variation every 90 seconds to find correction value of specified operating frequency and to correct the current operating frequency. Ta (n) Ts (n) : Room temp. difference n : Number of detection times Ta (n ) Ta (n) : Room temp. variation n : Number of detection times (90 seconds before) (3) HEAT operation Calculates room temp. difference between Ta and Ts as well as room temp. variation every 60 seconds to find correction value of specified operating frequency and to correct the current operating frequency. Ts (n) Ts (n) : Room temp. difference n : Number of detection times Ta (n) Ta (n_) : Room temp. variation n : Number of detection times (60 seconds before) (4) DRY operation The frequency correction control is the same as that for COOL operation. However, the maximum frequency is limited to S6 or so. Note) When LOW fan speed is set, the maximum frequency is limited to SB or so. 5 COOL/HEAT/AUTO control () Switching between COOL and HEAT is determined based on the following control. Ta ( C) +.5 Tsc or Tsh COOL (COOL ON).5 (COOL OFF) HEAT After 0 minutes pass from thermo sensor OFF, operation mode changes from HEAT (thermo sensor OFF) to COOL if Ta exceeds Tsh +.5. ( ) shows an example of COOL ON/OFF. After 0 minutes pass from thermo sensor OFF, operation mode changes from COOL (thermo sensor OFF) to HEAT if Ta lowers below Tsc -.5. Tsc : COOL set temp. Tshc : HEAT set temp. + room temp. control/correction () The GA control after determination of operation mode follows the description in No. 4. (3) The room temperature control and temperature correction follow the descriptions in No. 3 and No. 5. 7

28 INDOOR UNIT CONTROL CIRCUIT (CONTINUED). Item Overview of specifications Remarks 6 Fan speed control () A fan speed HH (quick high), H (high), L (low) or AUTO is selected according to the instruction from remote controller for FAN mode operation. () Fan speed is switched according to the difference between Ta and Ts in the AUTO mode. HH > H+ > H > L+ > L > UL Wireless type allows HH, H+, H, L+, L, and AUTO. [Cooling] Ta ( C) Tsc 0.5 HH (HH) H+ (HH) H (HH) L+ (H+) L (H) L (H) L (L+) A B C D E F G [HH] [H+] [H] [L+] [L] The fan speed control is the same for temperature setting by remote controller or the unit. Once fan speed is changed, it remains unchanged for 3 minutes unless different fan speed is selected by instruction. At the beginning of cooling, a falling gradient (higher fan speed) is selected. When the temperature difference between Ta and Ts is on a threshold line, fan speed does not change. ( ): Auto cooling [Heating] Ta ( C) ( 0.5).0 (0) Tsh (+0.5) +.0 (+.0) +.0 (+.5) +3.0 (+.0) +4.0 L (L+) L+ (H) H (H+) H+ (HH) HH (HH) E D C B A ( ): Temperature setting by remote controller Other than ( ): Temperature setting by unit Once fan speed is changed, it remains unchanged for one minute unless different fan speed is selected by instruction. At the beginning of heating, a rising gradient (higher fan speed) is selected. When the temperature difference between Ta and Ts is on a threshold line, fan speed does not change. ( ): Auto heating Fan speed is switched to a higher level when Tc reaches 60 C. Tc: Indoor unit heat exchange sensor temp. 8

29 . Item Overview of specifications Remarks 6 Fan speed control COOL HEAT COOL HEAT HH L+ HH L+ L H+ H+ L H UL UL H (3) When thermo sensor turns OFF during heating, the fan speed mode becomes UL (weak). (4) When Ta is 5 C or above at the beginning of HEAT operation or when canceling defrost mode, H or HH mode continues for one minute from the time when Tc enters zone E shown in the figure in No.7 below. (5) The HH fan speed for auto cooling/heating is set to a speed higher than that for normal cooling/heating. However, it varies depending on the temperature difference of Tc during auto heating. HEAT PREPARING indication Ta ( C) 47 HH+α 4 HH 7 Cool air prevention control () Performs indoor unit fan control in the HEAT mode according to the Tc (or Tcj) sensor detect temperature. The maximum speed is limited as shown below. Shifts Tc control value by +6 C during defrosting. However, zone B is regarded as zone C after 6 minutes pass from the startup of compressor. Fan speed select setting by remote controller takes precedence in zones D and E. HEAT PREPARING is indicated in zones A and B. Tc, Tcj ( C) HH H L UL OFF Zone E Zone D Zone C Zone B Zone A 9

30 INDOOR UNIT CONTROL CIRCUIT (CONTINUED). Item Overview of specifications Remarks 8 Freezing prevention control (low-temp. release) () Performs the following operation control in the COOL or DRY mode according to the Tc (or Tcj) sensor detect temperature. When zone J in the figure below is detected for 6 minutes, the specified operating frequency is decreased from the actual operating frequency, and the specified operating frequency is changed every 30 seconds in zone J. Timer count stops and is maintained in zone K. Timer count is cleared to restore normal operation when zone I is detected. If the specified operating frequency becomes SO due to continuation of zone J, return temperature A is raised from 5 to C, and operation with L fan speed continues until zone I is detected. Tcj: Indoor unit heat exchange sensor temp. Tc( C) 5 I K A J If 4-way valve cannot be switched during heating and the following conditions become true, freezing prevention control is performed. (However, zone J entering control temperature is changed from to -5 C.) Tcn: Tc after 5 minutes from operation start Tc (n-): Tc at operation start [Conditions] The following () or () becomes true after 5 minutes pass from operation start. () Tcn Tc (n-) 5 () Tcn < Tc (n-) and Tcn Ta < 5 C 9 High-temp. release control () Performs the following operation control in the HEAT mode according to the Tc (or Tcj) sensor detect temperature. When zone M is detected, the specified operating frequency is decreased from the actual operating frequency, and the specified operating frequency is changed every 30 seconds in zone M. The specified operating frequency is maintained in zone N. When zone L is detected, the specified operating frequency is returned by approx. 6 Hz every 60 seconds. This control is disabled for twin follower indoor units. Factory setting Control temp. ( C) A B 56 (54) 5 (5) Tc, Tcj ( C) A B L M N Note) At the beginning of operation or when Tc (or Tcj) lowers below 30 C after operation start, values (54) and (5) in the table are used as control temperature. Even when the thermo is set to OFF, the control is implemented in the same way. 0 Residual heat removal Runs indoor unit fan in L (low) mode for about 30 seconds after HEAT operation stops to remove residual heat. 30

31 . Item Overview of specifications Remarks Louver control () During the first operation after power on, louver position is controlled automatically according to operation mode (COOL/HEAT). Louver angle: 0 C (full close) COOL HEAT Full ciose 45 C 03 0 () When louver position is controlled by remote controller, the unit s microcomputer memorizes the position for use in the next operation. The memorized louver position is cleared when power is turned off, and returns to the state of () above. (3) Louver position setting Louver position can be set within the range below. COOL/DRY HEAT/FAN Alarm : A code number (except F08 and L3) appears on the remote controller and the indoor unit stops. Louver position can be set collectively or individually in the group twin or triple operation mode. (Wireless remote controller allows individual setting only.) (4) Swing setting Louver moves within the range below. All operation modes Louver swing range can be set collectively or individually in the group twin or triple operation mode. (Setting by wireless remote controller is disabled when the main remote controller is used.) (5) When air conditioner operation stops, louver closes automatically. It keeps its position in the event of an alarm. (6) Louver tilts upward automatically during preparation for heating. (7) In the twin or triple operation mode selected by wireless remote controller, swing setting interlocks with the header indoor unit. If this setting is transmitted from a follower indoor unit, operation does not change with a reception sound pi, pi, pi if operatio mode differs between header unit and follower unit. 3

32 INDOOR UNIT CONTROL CIRCUIT (CONTINUED). Item Overview of specifications Remarks HA control () When connected to a remote control system (tele-control or remote on/off interface), operation ON/OFF can be controlled by the HA signal input. () Outputs operation ON/OFF status to the HA output terminal. (3) HA signal input/output specifications conform to the JEMA standard. A connector (separately available) is required when using the HA terminal CH6 for remote ON/ OFF control. When group operation is in use, connect the connector to either header or follower indoor unit. 3 Filter sign indication (unavailable for wireless type) () Transmits filter replacement signal to remote controller for indication on the LCD when accumulated operation hours of indoor unit fan exceeds the specified time (50 hours). () Clears accumulation timer upon receiving the filter reset signal from remote controller. At this time, when the specified time has already passed, the accumulated time is reset and the filter sign disappears from the LCD. FILTER lamp ON 4 Central control mode switching () The scope of operation by remote controller on the indoor unit side can be switched by the setting of remote controller. () Scope of operation by remote controller on the indoor unit side [Individual]: [Central ] : [Central ] : [Central 3] : [Central 4] : All settings and ON/OFF operations are available. ON/OFF operations are disabled. ON/OFF operations, operation mode selection, and temperature setting are disabled. Operation mode selection and temperature setting are disabled. Operation mode selection is disabled. No indication display flash display flash display flash display flash When wired remote controller is not used, operation range is the same as above though lamp indication remains unchanged. If an unavailable operation mode is transmitted from wireless remote controller, it is indicated with a reception sound pi, pi, pi, pi, pi (5 times). 5 Power-saving control () Power-saving operation is available in the AUTO mode. () The set temperature is corrected using various sensor data within the range where comfort is maintained. (3) By using various sensor data including room temp. Ta, outside air temp. To, fan speed, and indoor unit heat exchange sensor temp. Tc, 0 minute data is averaged to calculate a set temperature correction value. (4) The set temperature is corrected every 0 minutes with the following shift range. Cooling : Heating : +.5 to -.0K -.5 to +.0K 3

33 . Item Overview of specifications Remarks 6 Maximum frequency limit control () This control is performed when AUTO mode is selected. () COOL mode: When To is under 8 C, the control is as follows. Ta ( C) Normal control Tsc Maximum frequency is limited to the rating of cooling. (3) HEAT mode: When To is over 5 C, the control is as follows. Ta ( C) Tsh 3 4 Normal control Maximum frequency is limited to the rating of heatong. 7 DC motor () When the fan operation has started, positioning of the stator and the rotor are performed. (Moves slightly with tap sound) () The motor operates according to the command from the indoor controller. Notes) When the fan rotates while the air conditioner stops due to entering of outside air, etc, the air conditioner may operate while the fan motor stops. When a fan lock is found, the air conditioner stops, and an error is displayed. Check code [P} 8 Save operation (Wired remote controller specific operation) SAVE () Turn on button on the wired remote controller. () During operation of save operation, lights on the wired remote controller. (3) During save operation, the current release control is performed with the restriction ratio set in EEPROM on the outdoor unit. (4) The restriction ratio can be set by keeping SAVE button pushed for 4 seconds or more on the remote controller. (5) When validating the save operation, the next operation starts with save operation valid because contents are held even when operation stops, operation mode changes or power supply is reset. (6) The restriction ratio can be set by changing the setup data of CODE No. (DN) [C] in the range of 50 to 00% (every %, Setting at shipment: 75%). Carry out setting operation during stop of the unit; otherwise the unit stops operation. For the setup operation, refer to How to set up contents of save operation of 0. ON-SITE SETTING AND OTHERS. 33

34 No. Item Outline of specifications] Remarks 9 8 C Heating/ Frost protective operation (Wired remote controller specific operations) () This function is intended for the cold latitudes and performs objective heating operation (8 C heating operation). () This function is valid only for combination with the outdoor units. (3) Using the indoor CODE No. [D] ( bit), Valid/Invalid of this function is set up at the customer s side. The setup by CODE No. is Invalid [0]/Valid [] and Invalid [0] has been set at the shipment. (4) This operation is the heating operation which sets 8 C as the setup temperature of the target. (5) This function starts operation by pushing temperature button during heating operation; besides by pushing button for 4 seconds or more after temperature reached the minimum set temperature. (6) To stop/release this operation, select and execute one from the following operations. ) Push button: Heating operation (8 C setting) continues. ) Push [START/STOP] button: Air conditioner stops.(heating 8 C operation at the next start) MODE 3) Push : Other operation mode is selected and the operation continues. (7) As the setup temperature is 8 C and the human heating is not targeted, the cold air discharge preventive control (Item 7) is made invalid to suppress the intermittent operation. (8) The settings of the air direction and air volume are changeable during this operation. (9) The indoor fan stops to protect the compressor for minutes after start of heating operation (Thermo-ON) by this function. In a group connection, if there is even one combination with other unit, This function is not provided. is displayed. The setup temperature jumps from [8] to [8]. 0 Hi POWER operation (Wireless remote controller specific operations) When you push the Hi POWER button during cooling, heating or AUTO, the air conditioner will start the following operation. Cooling operation Performs the cooling operation at C lower than the setting temperature. Only when the fan speed before the Hi POWER operation is not high, the fan speed will be increased. Heating operation Performs the heating operation at C higher than the setting temperature. Only when the fan speed before the Hi POWER operation is not high, the fan speed will be increased. [Hi POWER] Display 34

35 No. Item Outline of specifications Remarks COMFORT SLEEP operation (Wireless remote controller specific operations) When you push the COMFORTSLEEP button during cooling, heating or AUTO, the air conditioner will start the following operation. The fan speed display will indicate AUTO and low speed will be used. Cooling operation In the operation suppression zone, where capacity is kept to the minimum, overcooling is prevented by raising the temperature setting by C after hour and by C after hours of operation. The room temperature is thus regulated between the operation suppression zone and the set temperature. When the OFF timer is simultaneously set,, 3, 5 and 9 hours appear by turns every pushing COMFORT SLEEP button and one of them can be selected for OFF timer. [ ] display Heating operation In the operation suppression zone, where capacity is kept to the minimum, overheating is prevented by lowering the temperature setting by C after hour and by C after hours of operation. The room temperature is thus regulated between the set temperature and the operation suppression zone. When the OFF timer is simultaneously set,, 3, 5 and 9 hours appear by turns every pushing COMFORT SLEEP button and one of them can be selected for OFF timer. Operation suppression zone Set temperature Operation starts C hour C hours Set temperature Operation starts C hour hours C Operation suppression zone PRESET operation (Wireless remote controller specific operations) Start the air conditioner in the operation mode which you want the remote controller to memorize. () Push and hold the PRESET button for more than 3 seconds while the display flashes. The mark is indicated and the setting is memorized. If you do not push the PRESET button within 3 seconds or if you push another button, the memory setting is cancelled. Operation modes which can be memorized with the PRESET button are MODE, Temperatures, FAN, TIMER and Hi POWER. [ ] display To operate the air conditioner with the setting memorized by the PRESET button. () Push the PRESET button briefly. The setting memorized will be indicated and the air conditioner operates with regards to the setting. The lamp (green) on the display panel of the indoor unit goes on, and operation starts after approximately 3 minutes. Initial setting: MODE : AUTO Temperature : C 3 QUIET operation (Wireless remote controller specific operation) When you push the QUIET button during cooling, heating, fan only or AUTO, the air conditioner will start the following operation. The fan speed display will indicate AUTO and low speed will be used. [ ] display 4 SLEEP operation (Wireless remote controller specific operation) When the OFF timer is set,, 3, 5 and 9 hours appear by turns every pushing SLEEP button and one of them can be selected for OFF timer. 35

36 INDOOR UNIT CONTROL CIRCUIT (CONTINUED) 7-3. P. C. Board of Indoor Unit MCC-50 TC sensor CN0, DC 5V TCJ sensor CN0, DC 5V Microcomputer run LED D0 EEPROM IC0 Inter-unit - outdoor unit wire CN67, AC 00V HA (T0) CN6, DC V Option output CN60, DC V Option power supply CN309, AC 00V CHK CN7, DC 5V DISP CN7, DC 5V External alarm input CN80, DC V Central control CN40, DC ± 5V EXCT CN73, DC 5V R/C power LED D03 TA sensor CN04, DC 5V Remote controller CN4, DC 0V Fan drive CN3, DC V DC fan input/output CN0 Terminator resistor provided/not provided Remote controller A/B switch SW0 Louver CN33, DC V Indication output/wireless reception CN3, DC 5V 36

37 7-4. Optional Onboard Connector Specifications Function Connector No. Pin No. Specification Description Terminating resistor Remote controller A/B SW0 Bit OFF: No terminating resistor ON: Terminating resistor provided Factory setting OFF: No terminating resistor ON for one unit when performing central control by custom air conditioner only. Bit OFF: R/C A, ON: R/C B Factory setting OFF: Remote controller A 37 Ventilation output HA Option output External alarm input CHK Operation check DISP DISP mode EXCT Demand CN3 CN6 CN60 CN80 CN7 CN7 CN73 ƒ ƒ ƒ DCV Output ON/OFF input 0V (COM) R/C prohibition input Operation ON output DCV (COM) Alarm output DCV (COM) Defrost output Thermo sensor ON output COOL output HEAT output FAN output DCV (COM) DCV (COM) Filter/option/external alarm input Check mode input 0V Display mode input 0V Demand input 0V Factory setting: Interlocking with indoor unit operation ON/OFF Single operation setting is performed with VENT button on the remote controller (DN=3). HA ON/OFF input (J0: input/no input=pulse (factory setting) / static input changeover) Enables/disables operation OFF by remote controller using the R/C prohibition input. ON during operation (answerback of HA) ON during alarm ON while outdoor unit is defrosting ON when thermo sensor is ON (compressor ON) ON in cooling mode (COOL/DRY/auto cooling) ON in heating mode (HEAT/auto heating) ON while indoor unit fan is ON Factory setting: External alarm input setting (DN: A=) Indicates alarm code L30 when an alarm continues for one minute and performs forcible operation OFF. (DN: A=) Performs option alarm input control (indication of unit protection attached externally). Remote controller performs setting of option alarm input controller. Used for checking indoor unit operation. (Outputs specified operations such as indoor unit fan speed H, without communication with outdoor unit or remote controller.) DISP mode enables communication only between indoor unit and remote controller. (at power on) Timer short-circuited (always) Turns OFF indoor unit thermo sensor forcibly.

38 . Guide to Troubleshooting [Wired Remote Controller Type] () Before starting troubleshooting 8. TROUBLESHOOTING (a) Necessary tools/measuring equipment Phillips screwdrivers, flat-blade screwdrivers, wrenches, pliers, nipper, etc. Multimeter, thermometer, pressure gauge, etc. (b) Precheck The following operations are normal. ) Compressor does not work. Is 3-minute delay operation functioning? (for 3 minutes after compressor OFF) Is thermo sensor OFF? Is FAN mode or TIMER mode operation going? Is water overflow alarm detected? Is high outside air temperature operation control working during heating? ) Indoor unit fan does not work. Is cool air prevention control working during heating? 3) Outdoor unit fan does not work or its fan speed changes. Is high-temp. release operation control working during heating? Is low outside air temperature operation control working during cooling? Is defrosting operation going? 4) Operation ON/OFF by remote controller is disabled. Is any remote controller or external control working? Is auto address setting in progress? (At t he first power on or when indoor unit address is changed, operation control is disabled for about 5 minutes after power on.) Are all cables/wiring set in the initial state? ƒ Are indoor unit and remote controller connected correctly? () Troubleshooting procedure When an error occurs, check the unit in the following procedure. Error Check indication of check code Check faulty location and parts (Note) Other than the check items in the table, malfunction or wrong diagnosis of microcomputer due to effect of power or external noise is considered. If there is any source of noise, shield the remote controller wiring. [Wireless Remote Controller Type] () Before starting troubleshooting (a) Necessary tools/measuring equipment Phillips screwdrivers, flat-blade screwdrivers, wrenches, pliers, nipper, etc. Multimeter, thermometer, pressure gauge, etc. (b) Precheck The following operations are normal. ) Compressor does not work. Is 3-minute delay operation functioning? (for 3 minutes after compressor OFF) Is thermo sensor OFF? Is FAN mode or TIMER mode operation going? Is high outside air temperature operation control working during heating? 38

39 ) Indoor unit fan does not work. Is cool air prevention control working during heating? 3) Outdoor unit fan does not work or its fan speed changes. Is high-temp. release operation control working during heating? Is low outside air temperature operation control working during cooling? Is defrosting operation going? 4) Operation ON/OFF by remote controller is disabled. Is forcible operation OFF mode set? Is any remote controller or external control working? Is auto address setting in progress? (At the first power on or when indoor unit address is changed, operation control is disabled for about 5 minutes after power on.) Are all cables/wiring set in the initial state? ƒ Are indoor unit and receiver unit connected correctly? () Troubleshooting procedure When an error occurs, check the unit in the following procedure. Error Check indication of lamps Check faulty location and parts (Note) Other than the check items in the table, malfunction or wrong diagnosis of microcomputer due to effect of power or external noise is considered. If there is any source of noise, shield the signal lines. (a) Outline of judgment The following describes the primary judgment of locating faulty unit (indoor unit or outdoor unit). (In the case of group control operation, the header unit also indicates errors of follower unit by lamp.) Judging from lamp status of indoor unit The indoor unit monitors the operating status of air conditioner. When the protection circuit is activated, the indoor unit indicates the following self-diagnosis contents. l : OFF : ON : Blinking (0.5 seconds interval) Lamp indication Check code Possible causes Operation Timer Preparing All OFF E0 E0 Power OFF Poor connection/contact between receiver/indication unit and indoor unit control board Reception error Wired Wrong connection or poor Transmission error remote controller contact between wired Communication error remote controller and indoor unit Operation Timer Preparing E03 Blinking E08 E09 Duplication of indoor unit No. Duplication of remote controller header Invalid setting Operation Timer Preparing Blinking E8 E04 Poor connection/contact between indoor units or indoor unit power OFF (Communication error between header and follower indoor units or between twin header and follower indoor units) Wrong connection or poor contact between indoor unit and outdoor unit (Communication error between indoor and outdoor units) Operation Timer Preparing P Failure of indoor unit DC fan (Protection device of indoor unit is activated.) Alternate blinking 39

40 Troubleshooting (Continued) Outline of judgment (Contenued) Lamp indication Check code Possible causes P03 P04 Abnormal outdoor unit discharge temperature Outdoor unit high-pressure system error ( ) Protection device of outdoor unit is activated. Operation Timer Preparing P9 Four-way valve system error (judged by indoor unit) Alternate blinking P P6 P9 Outdoor unit: Malfunction of fan Outdoor unit: Inverter Idc activated Outdoor unit: Position detect error Protection device of outdoor unit is activated. P3 Header and follower indoor units in the group are not running due to the following alarm. (Alarm code: E03, L03, L07, L08) Operation Timer Preparing F0 F0 F0 Heat exchange sensor (TCJ) error Heat exchange sensor (TC) error Room temperature sensor (TA) error Indoor unit sensor error Alternate blinking Operation Timer Preparing Alternate blinking F04 F06 F08 Discharge temperature sensor (TD) error Temperature sensor (TE, TS) error Outside air temperature sensor (TO) error ( ) Outdoor unit sensor error Operation Timer Preparing F9 Failure of indoor unit EEPROM Simultaneous blinking Operation Timer Preparing Blinking H0 H0 H03 H06 Compressor breakdown Compressor locking Current detect circuit error Outdoor unit low-pressure system error ( ) Outdoor unit compressor system error Operation Timer Preparing Simultaneous blinking L03 L07 L08 L09 Duplication of header indoor unit Auto address Group connection indoor unit for individual indoor unit If group configuration or address at power on is invalid, Group address not set the unit enters enters address setting setting mode automatically. No setting (indoor unit capacity) Operation Timer Preparing Simultaneous blinking L0 L9 L30 L3 Duplication of indoor unit collective address Other errors of outdoor unit ( ) External interlock error Phase sequence error Others ( ) Check code detected by outdoor unit is a typical example. It varies with outdoor unit of combination. For details, see the Service Manual of applicable outdoor unit. 40

41 Others (Excluding check code) Lamp indication Check code Possible causes Operation Timer Preparing Trial operation in progress Simultaneous blinking Operation Timer Preparing Alternate blinking Invalid setting (Auto cooling/heating setting for auto cooling/heating unavailable unit or heating setting for cool only unit) Error mode detected by remote controller or central controller Check code Diagnosis function Possible causes Air conditioner status Conditions Judgment and action No indication (remote controller disabled) No communication with header indoor unit Remote controller is not connected correctly. Indoor unit is not powered on. Auto address setting is not completed. OFF Failure of remote controller power supply or indoor unit EEPROM. Check remote controller wires.. Check remote controller. 3. Check indoor unit power wiring. 4. Check indoor unit P. C. board. 5. Check indoor unit EEPROM and insertion into socket. Auto address repetition occurs. E0 * No communication with header indoor unit Disconnection between remote controller and header indoor unit (detected by R/C) OFF (auto reset) * Operation continues under central control Indicated when an error is detected Remote controller signal reception error. Check remote controller wires.. Check remote controller. 3. Check indoor unit power wiring. 4. Check indoor unit P. C. board. E0 Signal transmission error to indoor unit (detected by R/C) OFF (auto reset) * Operation continues under central control Indicated when an error is detected Remote controller transmission error. Check remote controller transmitter. Replace remote controller. E09 Multiple remote controller headers (detected by R/C) OFF (Follower R/C continues operation) Indicated when an error is detected. Check for multiple remote controller headers. One header only, others are follower R/C. L0 Central controller L0 Duplication of indoor unit collective address during communication of central control system (detected by indoor unit/ central controller) OFF (auto reset) Indicated when an error is detected. Check central control network address setting. *3 Central controller (Transmission) C05 (Reception) C06 Failure of central control communication circuit (detected by central controller) Operation continues (following R/C) Indicated when an error is detected. Check communication line, wrong connection, and indoor unit power supply.. Check communication circuit (U3, U4, XY terminals). 3. Check central controller (including central control R/C). 4. Check terminating resistors (TCC-LINK). Central controller P30/b7 Failure of indoor unit group follower unit. Continue/OFF (depending on situation) Indicated when an error is detected Check the unit s check code with remote controller * No check code can be indicated by wired remote controller. (Normal operation of air conditioner cannot be controlled by wired remote controller.) Check codes are indicated by the lamps for wireless models. *3 This is an error related to communication of remote controller (A, B) or central control system (TCC-LINK U3, U4). Remote controller indicates E0, E0, E03, E09, E8 or no code according to situation. 4

42 TROUBLESHOOTING (CONTINUED) Check Code Table (Indoor Unit) (Detected by indoor unit) ON, Blinking, l OFF, Alternate: Two LEDs blink alternately, Simultaneous: Two LEDs blink simultaneously 4 Check code TCC-LINK central control and remote controller E03 E04 E08 E0 E8 F0 F0 F0 F9 L03 L07 L08 L09 L0 L30 P0 P0 P P9 P3 Lamp indication Block indication Operation Timer Preparing l l l l l l l l l l l l l l l l l l l l l l l (Detected by remote controller) Check code Remote controller E0 E0 E09 Lamp indication Block indication Blinking Alternate Alternate Alternate Simultaneous Simultaneous Simultaneous Simultaneous Simultaneous Simultaneous Simultaneous Alternate Alternate Alternate Alternate Alternate Operation Timer Preparing Blinking l l l l l l Main faulty location Indoor unit-r/c communication error Indoor unit-out door unit serial communication error Duplication of indoor unit address Communication error between indoor unit MCUs Communication error between header and follower indoor units Indoor unit heat exchange sensor TCJ Indoor unit heat exchange sensor TC Indoor unit room temp. sensor TA Indoor unit other boards Duplication of indoor group header unit setting Group line in individual indoor unit Indoor group address not set Indoor unit capacity not set Duplication of central control refrigerant line address External alarm input into indoor unit (interlock) Indoor unit AC fan Indoor unit water overflow Indoor unit DC fan Four-way valve system Other indoor unit errors Main faulty location No header R/C, R/C reception error R/C transmission error Duplication of header R/C Description of failures No signal from remote controller (no communication with central controller system) When indoor unit-out door unit serial communication is abnormal When same address as mine is detected When communication between main motor microcomputers is abnormal When communication between header and follower indoor units is disabled When open-circuit or short-circuit of TCJ is detected When open-circuit or short-circuit of TC is detected When open-circuit or short-circuit of TA is detected Failure of EEPROM (Other errors are also detected in some cases. Auto address repeated with no other errors.) When multiple header units exist in the group When there is at least one group connection indoor unit in individual indoor unit When indoor group address is not set Indoor unit capacity is not set. Duplicated central control refrigerant line address is set. Alarm stop by external alarm input (CN80) When indoor unit AC fan alarm is detected (Fan motor thermal relay is activated.) When float switch is turned on When indoor unit DC fan alarm (overcurrent, locking, etc.) is detected When an alarm is detected during heating due to temperature drop of heat exchange sensor Follower units in the group are disabled due to alarm (E03/L03/L07/L08) of header unit Auto reset A/C operation Operation continuation : When this alarm is detected before checking group configuration and address at power on, the unit enters auto address setting mode automatically. Description of failures When signals cannot be received from indoor unit or when header R/C is not set (including two R/Cs) When signal transmission to indoor unit is disabled When two remote controllers are set as header by double R/C control (Header unit stops alarm, and follower continues operation.) Auto reset A/C operation Operation continuation (Detected by central controller) Check code TCC-LINK central control Note: C05 C06 C P30 Lamp indication Block indication Operation Timer Preparing Blinking No indication (when R/C is used together) Depends on alarm No. above Main faulty location Central control system transmission error Central control system reception error General equipment control I/F total alarm Group follower unit error Description of failures When transmission of central control signals is disabled or when there are multiple central controllers with same address (AI-NET) When signal transmission to indoor unit is disabled A device connected to general equipment control interface (for TCC-LINK/AI-NET only) is abnormal. Group follower unit is abnormal. (R/C indicates unit No. and details.) Check code varies in some cases depending on the unit which detects errors even if its content is the same. Check codes detected by R/C or central controller are not always related to air conditioner operation. This table does not include check codes detected by outdoor unit or thermal storage unit Auto reset A/C operation Operation continuation

43 Check Code Table (Outdoor Unit) (Main errors detected by outdoor unit) ON, Blinking, l OFF, Alternate: Two LEDs blink alternately, Simultaneous: Two LEDs blink simultaneously Check code TCC-LINK central control and remote controller C5 F04 F06 F08 H0 H0 H03 H06 L9 L3 P03 P04 P P6 P9 Lamp indication Block indication Operation Timer Preparing l l l l l l l l l l l l l l Blinking Simultaneous Alternate Alternate Alternate Simultaneous Simultaneous Alternate Alternate Alternate Alternate Alternate Main faulty location Thermal storage unit error Outdoor unit heat discharge sensor TD error Outdoor unit temp. sensor TE, TS error Outdoor unit outside air temp. sensor TO error Compressor breakdown Compressor locking Current detect circuit error Low-pressure system error Other outdoor unit errors Phase sequence error or others Abnormal outdoor unit discharge temperature High-pressure system error Outdoor unit fan alarm Inverter Idc activated Position detect error Description of failures Typical error of thermal storage unit (Details are checked by R/C.) When open-circuit or short-circuit of TD is detected When open-circuit or short-circuit of TE,TS is detected When open-circuit or short-circuit of TO is detected Short-circuit current Idc after direct current excitation is detected when reaching minimum frequency in current release control. When compressor locking is detected When abnormal current is detected by AC-CT or when phase loss is detected Ps pressure sensor error. Low-pressure protection circuit is activated. Other outdoor unit errors ) MCU communication error between PDU and CDB, ) IGBT heatsink temp. detect error When phase sequence of 3-phase current is abnormal (thermo sensor OFF operation continued) or other errors When discharge temperature release control detects an error When high-pressure switch or IOL is activated or when high-pressure release control by TE detects an error When outdoor unit fan drive circuit error (overcurrent, locking, etc.) is detected When short-circuit prevention control for compressor drive circuit devices (G,Tr, IGBT) is activated When compressor motor position error is detected Auto reset A/C operation Operation continuation 43 Note: The above check codes are typical examples. They vary with outdoor unit (including thermal storage unit) of combination. For details, see the Service Manual of applicable outdoor unit.

44 TROUBLESHOOTING (CONTINUED) Check Code Table Failure mode detected by indoor unit Check code Possible causes Diagnosis function Air conditioner status Conditions Judgment and action E03 No signal reception from remote controller OFF (auto reset) Indicated when an error is detected. Check remote controller wiring. No indication on remote controller LCD (disconnection) Central controller [C06] check code E04 Serial signal from outdoor unit does not reach indoor unit. Wrong wire connection Failure of outdoor unit serial transmitter Failure of indoor unit serial receiver OFF (auto reset) Indicated when an error is detected. When outdoor unit does not work at all Check wires, correct wrong connection. Check outdoor unit boards and wiring.. When outdoor unit works normally Check boards (indoor unit receiver, outdoor unit transmitter) E08 L03 L07 L08 Duplication of indoor unit address Duplication of header indoor unit Group line in individual indoor unit Indoor unit group address not set OFF Indicated when an error is detected. Check remote controller connection (group/individual) change after power on. If group configuration or address is not correct, the unit enters auto address setting mode automatically for address re-setting. L09 Indoor unit capacity not set OFF Indicated when an error is detected. Set indoor unit capacity (DN=) L30 External interlock alarm input OFF Indicated when an error is detected. Check external devices.. Check indoor unit boards. P Failure of indoor unit DC fan OFF Indicated when an error is detected. Position detect error. Overcurrent protection circuit operation of indoor unit fan driver 3. Indoor unit fan lock 4. Check indoor unit boards. P9 Failure of 4-way valve system Indoor unit heat exchange temperature lowers after HEAT operation starts. OFF (auto reset) Indicated when an error is detected. Check 4-way valve.. Check -way valve/check valve. 3. Check indoor unit heat exchanger (TC/TCJ). 4. Check indoor unit boards. P3 Indoor unit OFF during alarming to other indoor units OFF (follower units) (auto reset) Indicated when an error is detected. Judging follower unit when header unit is E03, L03, L07 or L08. Check indoor unit boards. F0 Improper mounting, disconnection or short-circuit of indoor unit heat exchange sensor TCJ OFF (auto reset) Indicated when an error is detected. Check TCJ.. Check indoor unit boards. F0 Improper mounting, disconnection or short-circuit of indoor unit heat exchange sensor TC OFF (auto reset) Indicated when an error is detected. Check TC.. Check indoor unit boards. F0 Improper mounting, disconnection or short-circuit of indoor unit room temp. sensor TA OFF (auto reset) Indicated when an error is detected. Check TA.. Check indoor unit boards. F9 Failure of indoor unit EEPROM EEPROM access error OFF (auto reset) Indicated when an error is detected.check indoor unit EEPROM and insertion into socket.. Check indoor unit boards. E8 Communication error between header and follower indoor units OFF (auto reset) Indicated when an error is detected. Check remote controller wiring.. Check indoor unit power wiring. 3. Check indoor unit boards. 44

45 Failure mode detected by outdoor unit (Representative codes) The check code used varies depending on the combination with the outdoor unit. Check code Possible causes Diagnosis function Air conditioner status Conditions Judgment and action H0 Compressor breakdown Compressor stops due to operating frequency decrease. OFF Indicated when an error is detected. Check power voltages (00±0 VAC).. Freezing cycle overload operation 3. Check current detect circuit on the AC side. H0 Compressor does not work. Overcurrent protection circuit is activated after a certain time from compressor startup. OFF Indicated when an error is detected. Failure of compressor (lock, etc.) Replace the compressor.. Improper compressor wiring (phase loss) 3. Lost-phase operation of power supply (3-phase models) H03 Failure of current detect circuit Large AC current even during compressor OFF Phase loss in power supply OFF Indicated when an error is detected. Operation stops soon when restarted. Check IPDU.. Lost-phase operation of power supply Check 3-phase power voltages and wiring. H06 Low-pressure switch ON (applicable models) COOL : 30 seconds HEAT : 0 minutes OFF Indicated when an error is detected. Check freezing cycle (gas leakage).. Check low-pressure switch circuit. 3. Check outdoor unit CDB board. L9 Other outdoor unit errors CDB-IPDU communication error (connector disconnection) Abnormal heatsink temperature (over specified value) OFF Indicated when an error is detected. Check CDB/IPDU wiring.. Freezing cycle overload operation L3* Phase detection protection circuit activated (normal models) Operation continued (compressor OFF) Indicated when an error is detected. Check phase sequence, reverse phase, and phase loss.. Check outdoor unit boards. 3. Check high-pressure switch. 4. Check high-pressure switch circuit wiring. P03 Abnormal discharge temperature (over specified value) OFF Indicated when an error is detected. Check freezing cycle (gas leakage).. Failure of electronic expansion valve 3. Check piping sensor (Td). P04 Failure of high-pressure protection circuit (Temperature over specified value detected by TE sensor) High-pressure switch (normal models) OFF Indicated when an error is detected. Freezing cycle overload operation. Check outdoor unit TE sensor. 3. Check outdoor unit CDB board. 4. Check high-pressure switch and circuit. P Failure of outdoor unit DC fan OFF Indicated when an error is detected. Position detect error. Overcurrent protection circuit operation of outdoor unit fan driver 3. Outdoor unit fan lock 4. Check outdoor unit CDB board. P6 Inverter overcurrent protection circuit activated (short time) Main circuit short voltage operation OFF Indicated when an error is detected. Operation stops soon when restarted. Compressor partial short-circuit. Check IPDU for improper wiring. P9 Failure of IPDU position detect circuit OFF Indicated when an error is detected. The circuit is activated even after compressor s 3P connector is disconnected....replace IPDU. F04 Improper mounting, disconnection or short-circuit of outdoor unit temp. sensor TD OFF Indicated when an error is detected. Check TD.. Check outdoor unit CDB board. F06 Improper mounting, disconnection or short-circuit of outdoor unit temp. sensor TE, TS OFF Indicated when an error is detected. Check TE, TS.. Check outdoor unit CDB board. F08 Improper mounting, disconnection or short-circuit of outdoor unit outside air temp. sensor TO Operation continued Indicated when an error is detected. Check TO.. Check outdoor unit CDB board. DI series is not detected ( SDI 4 ~ 6HP only). Fan continues rotating in a failure mode detected by outdoor unit because there is no communication between outdoor unit and follower indoor unit in twin group. 45

46 TROUBLESHOOTING (CONTINUED). Troubleshooting by Remote Controller Check Indication Main Remote Controller (RBC-AMT3E) () Checking When an error occurs in the air conditioner, a check code and an indoor unit number appear on the LCD of remote controller. Check code is displayed only during operation. If indication disappears, check errors following Checking Error Log below. Check code Faulty indoor unit No. () Checking Error Log When an error occurs in the air conditioner, error log can be checked following the steps below. Up to 4 errors are memorized. Error log can be checked in both operation ON and OFF states. Step 3 Operation Push SET and TEST at the same time for 4 seconds or more. The LCD indication changes as shown below. Indication of SERVICE CHECK shows that the unit is in the error log mode. Code No. 0 (order of error log) is displayed. A check code is displayed. The address of faulty indoor unit is displayed in the UNIT No. area. Each pushing of TEMP. ( / ) buttons displays stored error log sequentially. Check code 0 shows the latest error, and 04 shows the oldest. Note Do not push CL as this button clears entire error log of indoor unit. After checking the error log, push or pushing TEST to return to the normal indication. CODE No. T No. R.C. No ON / OFF FAN MODE ME SAVE VENT FILTER RESET TEST SET CL SWING/FIX UNIT LOUVER Numbers appearing on the LCD <Seven-segment display> 3 Hexadecimal number 46

47 TCC-LINK Central Control Remote Controller (TCB-SC64TLE) () Checking When an error occurs in the air conditioner, a check code and an indoor unit number appear on the LCD of remote controller. Check code is displayed only during operation. If indication disappears, check errors following Checking Error Log below. Indication of unit number UNIT No. Alternate blinking R.C. No. Indication of alarm CHECK () Checking Error Log When an error occurs in the air conditioner, error log can be checked following the steps below. Up to 4 errors are memorized. Error log can be checked in both operation ON and OFF states. Press [SET] and [TEST] at the same time for 4 seconds or more. Indication of SERVICE CHECK and UNIT No. 0 appear. ƒ When selecting a group number (blinking), a unit number and the latest error log, if any, are displayed alternately. Temperature setting is disabled at this time. Indication of unit number UNIT No. Alternate blinking R.C. No. Indication of alarm CHECK To check other errors, choose a code (0 to 04) with TEMP. ( ) buttons. To check error log of another group, choose a group number with ( ) buttons. Do not press [CL] as this button clears entire error log of the selected group. Press [TEST] to finish the service check. 47

48 TROUBLESHOOTING (CONTINUED) 3. Troubleshooting for Each Check Code Check code Check code name Possible causes [E0] (New code) I/U - R/C communication error (detected by R/C) A.Improper R/C wire connection B.Failure of I/U power supply C. Failure of I/U board D. Invalid R/C address setting E.Failure of R/C board Are R/C wires A/B correct? Correct R/C wires.. Improper harness connection from I/U terminal block? Correct connector connection. Check circuit wiring. Group control operation? Are all indoor units powered ON? Check I/U power connection (power off and on). Is R/C powered ON? A/B terminals: Approx. 8VDC Check I/U boards. Replace defective board. Is gno header h set by double R/C? Correct one header/one follower. (R/C address connector) Check R/C board. Replace it if necessary. 48

49 Check code Check code name Possible causes [E0] (New code) R/C transmission error Signal transmission to indoor unit is disabled. * Not indicated on the central controller and outdoor unit 7-segment. Com. cable between R/C and I/U connected properly? Correct communication cable. Failure of R/C transmitter Replace R/C. Check code Check code name Possible causes [E03] (New code) I/U - R/C communication error (detected by I/U) No communication from R/C and communication adapter. Indoor unit (I/U) detects this error when it cannot receive signals from remote controller (R/C). Check communication wiring of R/C A and B. This code E03 is not displayed on the R/C because of communication error. This code is displayed on the TCC-LINK central controller. 49

50 Troubleshooting (Continued) Check code Check code name Possible causes [E04] (New code) I/U - O/U communication error (detected by I/U) A.Improper connector connection between I/U and O/U B. Improper wire connection between I/U and O/U C. Failure of I/U or O/U board D.Case thermo sensor ON E. Invalid I/U board switch setting Does O/U work? Is group address set correctly? Check code 4. Are //3 wires normal? Correct wires. Are connectors from I/U and O/U connected normally? Correct connector connection. Is I/U switch SW0 setting correct? Bit, : OFF Correct switch setting on MCC-50 board. Does voltage between I/U terminal and 3 fluctuate? (0-40 VDC) * Measure within 0 seconds from power on. Is 80VDC applied across IPDU main circuit capacitor? Is 80VDC supplied to CDB? (CN03) Check MCC-50 board. Replace it if necessary. Black C White B A Terminal block Replace IPDU. Replace IPDU. Is 7VDC supplied to CDB? Is CN06-CN800 connection normal? Replace IPDU. Correct connector connection. Is case thermo sensor connected? (CN500) Correct connector connection. Is case thermo sensor working? Check MCC-50 board. Replace it if necessary. Check CDB. Replace it if necessary. Check I/U boards. Replace defective board. Check and correct refrigerant volume. 50

51 Check code Check code name Possible causes [E09] (New code) Duplication of R/C header R/C header setting is duplicated. Are headers set by double R/C? Correct one header/one follower. (R/C address connector) Check R/C board. Replace it if necessary. Check code Check code name Possible causes [E8] (New code) Communication error between header and follower I/U A. Improper wire connection between I/U B. Improper wire connection between I/U and O/U C. Failure of I/U board D. Invalid I/U board switch setting Are A/B wires normal? Correct R/C wire connection. Improper harness connection from I/U terminal block? Correct connector connection. Check circuit wiring. Is I/U switch SW0 setting correct? Bit, : OFF Correct switch setting on MCC-50 board. Group control operation? Are all indoor units powered ON? Check I/U power connection (power off and on). Twin or triple control? Improper signal connection between I/U and O/U? Correct signal wire connection between I/U and O/U. Check MCC-50 board. Replace it if necessary. 5

52 Troubleshooting (Continued) Check code Check code name Possible causes [F0] (New code) I/U sensor TCJ error I/U sensor TCJ error Is TCJ connector CN0 connected normally? Correct connector connection. Is TCJ resistor characteristic normal? * See I/U temp. sensor characteristics-. Replace. sensor TCJ. Check I/U main board. Replace it if necessary. Check code Check code name Possible causes [F0] (New code) I/U sensor TC error Sensor TC open or short-circuit Is TC connector CN0 connected normally? Correct connector connection. Is TC resistor characteristic normal? * See I/U temp. sensor characteristics-. Replace sensor TC. Check I/U boards. Replace defective board. 5

53 Check code Check code name Possible causes [F0] (New code) I/U sensor TA error Sensor TA open or short-circuit Is TA connector CN04 connected normally? Correct connector connection. Is TA resistor characteristic normal? * See I/U temp. sensor characteristics-. Replace sensor TA. Check MCC-50 board. Replace it if necessary. Check code Check code name Possible causes [F9] (New code) Other indoor unit errors Failure of I/U board This is an error of non-volatile EEPROM IC0 on the indoor unit board, which occurs during operation. Replace the service board. * If EEPROM is not mounted at power on or if no data can be read/written from/in the EEPROM, auto address mode is repeated. At this time, the AI-NET central controller indicates code 97. (About 3 minutes) (About minutes) (Power on) SETTING appears SETTING disappears. on the R/C. LED (D0) on the I/U board blinks for about 0 seconds (Hz). Reboot (reset) (Repeated) 53

54 Troubleshooting (Continued) Check code Check code name Possible causes [F3] (New code) O/U EEPROM error A. Failure of O/U power supply (voltage, noise, etc.) B. Failure of O/U CDB board. Is O/U free from power fluctuation? Check power voltage. Improve power lines. Check external noise. Check CDB board. Check code [E08][L03][L07][L08] (New code/old code) E08: I/U number duplicated L03: Multiple header I/U under group control L07: One or more group address individual under group control L08: I/U group address not set (99) When any of these codes is detected at power on, the unit enters auto address setting mode automatically. (No code is indicated.) However, if any of these codes is detected in the auto address setting mode, a check code is displayed in some cases. Check code Check code name Possible causes [L09] (New code) Indoor unit capacity not set Indoor unit capacity not set Is indoor unit capacity set? Set I/U capacity data. (DN=) Check MCC-50 board. Replace it if necessary. 54

55 Check code Check code name Possible causes [L0] (New code) Duplication of central control address Central control address is duplicated. Are U3/U4 communication cables connected normally? Correct cable connection. When a unit connected to U3/U4 is in a group, is it set to header unit? Set the connected unit to header unit. Check and correct I/U address, central control address. Check code Check code name Possible causes [L30] (New code) I/U external interlock When an external alarm is input Is external device connected to CN80? Check I/U boards. Replace defective board. Is external device working normally? Check external device. Replace it if necessary. Check possible error causes. 55

56 Troubleshooting (Continued) Check code Check code name Possible causes P] (New code) Malfunction of I/U fan motor A.Failure of fan motor connector B. Failure of fan motor C. Failure of I/U board D.Failure of cross flow fan shaft Turn OFF the breaker. Turn it ON 0 seconds after. Does fan stop with operation OFF? Start cooling with LOW fan speed. Does fan rotate? Change fan speed to HH. Does fan speed increase? Fan motor is normal. Is min.vdc present between CN0 pin 5 and 3? Is min. 80VDC present between CN0 pin and 3? Is min. 5VDC present between CN0 pin 4 and 3 with motor connected? Operate I/U (except heating) by R/C. Is min. VDC present between CN0 pin 5 and 3?(Measure within 5 seconds.) Does cross flow fan rotate normally by hand? Rotate the fan by hand with operation OFF. Is 0 to 5VDC (rev return signal) generated between CN0 pin 6 and 3? Stop operation and turn OFF breaker. Disconnect CN0, turn ON breaker again, and then stop operation using R/C. Is min. 80VDC present between CN0 pin 4 and 3? Stop operation and unplug AC cord. Disconnect CN0, plug in AC cable again, and then stop operation using R/C. Operate I/U (except heating) by R/C. Is min. VDC present between CN0 pin 5 and 3? (Measure within 5 seconds.) Replace I/U fan motor. Replace I/U MCC-50 board. Repair cross flow fan shaft. 56

57 Check code Check code name Possible causes [P] (New code) Malfunction of I/U fan motor A. Failure of fan motor connector B. Failure of fan motor C. Failure of I/U board D. Failure of cross flow fan shaft When AC cord is plugged in, I/U fan starts rotating. P.C.board Check the fan motor output DC voltage on the I/U board. CN0 Check voltage on the motor connector CN0 pin 3 GND, black) and pin 5 (+V line, yellow) while fan is rotating. Yellow 6 (Blue) 5 (Yellow).0VDC or higher Below.0VDC Black 4 (White) 3 (Black) Failure of I/U MCC-50 board Failure of I/U fan motor (Red) DC Check code Check code name Possible causes [P3] (New code) Other I/U errors (Group follower I/U error) When an error occurs with other units in the group When header unit detects E03, L03, L07 or L08 during group operation, 3 is indicated on follower units in the group and their operation stops. No code or alarm log is displayed on the R/C. 57

58 Troubleshooting (Continued) Check code Check code name Possible causes [C05], [C06] (Central controller) TCC-LINK central control communication error TCC-LINK central control communication error Is I/U powered ON? Power ON. Is harness from I/U terminal block connected properly? Correct connector connection. Can I/U be operated by R/C individually? Are U3/U4 com. cables. normal? * * Check wrong connection, disconnection, and shield wire s contact with com. cable. Correct com. cable. When a unit connected to U3/U4 is in a group, is it set to header unit? Set the connected unit to header unit. Free from noise? Remove noise source. Can other units controlled by central R/C? Is I/U operating status reflected? Check central controller. Replace it if necessary. Is the code [C05]? Is I/U onboard fuse F03 normal? Confirm normal connection of com. cable. Change connector connection CN40 to CN44 (EMG) on I/U board. Check I/U boards. Replace defective board. 58

59 TROUBLESHOOTING (CONTINUED) Temperature sensor Temperature Resistance value characteristic table TA, TC, TCJ, TE, TS, TO sensors Representative value TD, TL sensors Representative value Temperature ( C) Resistance value (kω) (Minimum value) (Standard value) (Maximum value) Temperature ( C) Resistance value (kω) (Minimum value) (Standard value) (Maximum value) Resistance (kω) Temperature ( C) Resistance (kω) (50 C or lower) Resistance (kω) (50 C or higher) Temperature ( C) As TH sensor (Outdoor unit heat sink temp. sensor) is incorporated in the outdoor control P.C. board, the resistance value cannot be measured. 59

60 9. HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT Requirements When Replacing Service Board of Indoor Unit The non-volatile EEPROM (IC0) on the board of indoor unit stores important data such as model-specific type and capacity code (written during factory shipping) as well as system/indoor unit/group addresses set automatically/manually (written during installation). Therefore, observe the following procedure when replacing indoor unit service boards. After installation of indoor unit, check whether the settings are correct by checking indoor unit number and group header/follower unit setting, and also check cycle through a trial operation. [Replacement Procedures] Case When it is possible to power ON indoor unit before replacement and when wired R/C can read settings Case Reading EEPROM Data (see page 6) ò Replacing Service Board and Power ON (see page 6) ò Writing Setting Data in EEPROM 3 (see page 6) ò Power ON reset (for all indoor units connected to R/C in group control mode) When it is impossible to power ON indoor unit before replacement or when wired R/C is disabled due to failure of power supply circuit (board failure) Case 3 Replacing EEPROM (For layout of components and replacement, see page 63.) Remove the EEPROM on the board, and replace it with the EEPROM on the service board. ò Replacing Service Board and Power ON (see page 6) ò Reading EEPROM Data (see page 6) If data cannot be read, go to Case 3. ò Replacing EEPROM (For layout of components and replacement, see page 63.) Replace EEPROM again. (Mount the original EEPROM on the service board.) ò Replacing Service Board and Power ON (see page 6) ò Writing Setting Data in EEPROM 3 (see page 6) ò Power ON reset (for all indoor units connected to R/C in group control mode) When the EEPROM before replacement is defective, and the settings cannot be read Replacing Service Board and Power ON (see page 6) ò Writing Setting Data in EEPROM (using customer information) 3 (see page 6) ò Power ON reset (for all indoor units connected to R/C in group control mode) 60

61 HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT (Continued) Reading EEPROM Data (Read EEPROM data that was updated at site in addition to factory setting.) ) Push SET, CL, and TEST on the remote controller simultaneously for 4 seconds or more. (see page 6) In the group control mode, the header unit number is displayed first. At this time, code (DN) 0 is displayed, and the fan of the selected indoor unit runs, its louver swings,and the OPERATION, TIMER, and PREPARING lamps blink. ) Each pushing of UNIT LOUVER indicates indoor unit number in the group sequentially. Specify indoor unit number whose board is to be replaced. 3) Each pushing of TEMP. / buttons increments or decrements DN. 3 4) Change DN from 0 to 0 first. (Setting of filter sign ON time) Write down the setting data displayed. 5) Change DN with TEMP. / buttons, and write down the setting data displayed. 6) Repeat step 5) in the same way, and write down the important setting data shown in the table (page 59). DN = 0 to Ab. DN does not always shift sequentially. 7) After writing down setting data, push TEST to return the operation mode to normal OFF. 6 (It takes about one minute until remote controller operation is enabled.) Essential DN codes DN Description Indoor unit capacity Refrigerant line address 3 Indoor unit address () Indoor unit capacity is necessary for fan speed setting. () If refrigerant line address, indoor unit address or group address differs from that before replacement, the unit enters auto address setting mode, which requires manual re-setting for group operation including twin or triple operation. 4 Group address Replacing Service Board and Power ON ) Replace the board with a service board. Reflect the jumper wire (cut) setting and switch setting on the board in the service board. For switch setting and component layout, see page 63. ) Power ON the indoor unit in either way of the following according to system configuration. a) Single (individual) operation. Power ON the indoor unit with no operation. i) Go to 3 when auto address setting mode ends (about 5 minutes). (Refrigerant line address=, indoor unit address=, and group address=0 are set automatically.) ii) Push SET, CL, and TEST on the remote controller simultaneously for 4 seconds or more ( ) to cancel auto address setting mode, and then go to 3. (UNIT No. is indicated.) b) Group operation (including twin/triple/double twin) Power ON the indoor unit whose service board is replaced in either way of the following. i) Power ON the indoor unit only whose service board is replaced in the same way as a) i) and ii) above. There must be remote controller connection. If not, operation *3 is disabled. ii) Power ON multiple indoor units including the unit whose service board is replaced. Twin, triple, double twin: One system only Group control: All indoor units Go to *3 when auto address setting mode ends (about 5 minutes). Header indoor unit may change depending on auto address setting. The refrigerant line address and indoor unit address of the indoor unit whose service board is replaced are automatically set to an address that is not used in other units. It is recommended that you take a memo beforehand that to which refrigerant system the indoor unit belongs and that the indoor unit is header or follower unit in the group. 6

62 3 Writing Setting Data in EEPROM (The data of the EEPROM on the service board is the factory setting data.) ) Push SET, CL, and TEST on the remote controller simultaneously for 4 seconds or more. (see page 6) In the group control mode, the header unit number is displayed first. (If auto address setting mode is canceled in -) a) ii) above, UNIT No. is indicated.) At this time, code (DN) 0 is displayed, and the fan of the selected indoor unit runs, its louver swings, and the OPERATION, TIMER, and PREPARING lamps blink. ) Each pushing of UNIT LOUVER indicates indoor unit number in the group sequentially. Specify indoor unit number whose board is replaced. (This operation is disabled if UNIT No. is ALL.) 3) Each pushing of TEMP. / buttons increments or decrements DN. 3 4) Set the indoor unit capacity first. The factory setting data is written in the EEPROM. i) Change DN to with TEMP. / buttons. ii) Set the indoor unit capacity with TIME / buttons. 4 (for example, 00 for 80 class) See the table (page 63). iii) Push SET Indication on the LCD shows normal operation. iv) Push TEST to return the operation mode to normal OFF. 6 (It takes about one minute until remote controller operation is enabled.) 5) Write the data set after installation (such as address) in the EEPROM. Repeat steps ) and ) above. 6) Specify DN 0 with TEMP. / buttons. (Setting of filter sign ON time) 7) Check the displayed data comparing the content written down in * (page 63). i) If the data is incorrect, change it with TIME / buttons to the data of the memo, and then push SET Indication on the LCD shows normal operation. ii) No operation is required for the same data. 8) Change DN with TEMP. / buttons. In the same way as above, check the displayed data comparing the content of the memo. If the data is incorrect, change it to the data of the memo. 9) Repeat steps 7) and 8) above. 0) When the setting is completed, push TEST to return the operation mode to normal OFF. 6 (It takes about one minute until remote controller operation is enabled.) * DN = 0 to Ab. DN does not always shift sequentially. Even if data is updated and SET button is pushed by mistake, the previous data can be restored with CL button unless DN is changed. <Remote Controller> RBC-AMT3E CODE No. SET DATA SETTING UNIT No. R.C. No. ON / OFF AN MODE VE VENT FILTER RESET TEST SET CL SWING/FIX UNIT LOUVER

63 HOW TO REPLACE SERVICE BOARD OF INDOOR UNIT (Continued) Example of Setting Contents to be Written Down (Code Table) DN Item Memo Factory setting 0 Filter sign ON time 000: 50 hours 0 Filter contamination level 0000: Average 03 Central control address 0099: Not determined 06 HEAT intake temp. shift 000: + C 0C PREPARING indication selection 0000: Normal 0F COOL only 0000: Heat pump type air conditioner 0 Type Must be set to : Wall type Indoor unit capacity Depends on capacity type Refrigerant line address 0099: Not determined 3 Indoor unit address 0099: Not determined 4 Group address 0099: Not determined E Temp. range at COOL/HEAT auto switching control 0003: 3 C (Ts±.5) 8 Auto restart after power failure 0000: Not provided A Option/alarm input (CN80) selection 000: External alarm input b Thermo output (T0-3) selection 0000: Thermo output ON E HA terminal (T0-) selection 0000: Operation input 3 Ventilation fan (single operation) 0000: Disabled 3 Sensor selection 0000: Unit sensor 60 Timer setting (wired remote controller) 0000: Available 69 Louver setting for cooling 0000: Normal 8b Correction of feeling of strong heating 0000: Not provided Onboard Component Layout <MCC-50> Indoor unit capacity Code Setting data Model 0000 Invalid type SW0 ON SW0 ON J0 DIP switches (SW0, SW0) IC0 EEPROM (IC0) * Default value of EEPROM on the service board Mount EEPROM aligning its notch with the notch of IC socket. Mount EEPROM aligning its notch with the notch of IC socket. Notch DIP switch setting IC socket Notch EEPROM Setting RAV-SM H Factory setting SW0 Bit Bit Terminating resistor (for central control) Selection of R/C A or B OFF (noelected) OFF (Ais selecccted) SW0 Bit Bit Selection of custom or multiple Not used OFF OFF OFF (custom models) OFF *: Set to the state before replacement 63

64 0. ON-SITE SETTING AND OTHERS. Indoor Unit. Test Operation Setting by Remote Controller only. The lamps on the unit blink during test operation. <Wired remote controller> Push TEST on the remote controller for 4 seconds. When TEST appears on the LCD, push ON / OFF. TEST appears on the LCD during test operation. Test operation disables temperature control, but allows fan speed control. An instruction of fixed frequency is issued for cooling and heating of test operation. Alarm detection is performed as usual. The test operation mode must be used for its original purpose only, because it stresses the air conditioner. Choose COOL or HEAT mode only for test operation. (Note) Outdoor unit does not run about 3 minutes after power on or operation stop. 3 Repush TEST after test operation and confirm that TEST disappears from the LCD. Wired remote controller has 60-minute timer reset function to prevent continuous test operation. 64

65 <Wireless remote controller> Procedure Turn on power of the air conditioner. Description The operation is not accepted for 5 minutes when power has been turned on at first time after installation, and minute when power has been turned on at the next time and after. After the specified time has passed, perform a test operation. Push [Start/Stop] button and change the operation mode to [COOL] or [HEAT] with [Mode] button. Then change the fan speed to [High] using [Fan] button Test cooling operation Set temperature to [8 C] using [Temperature set] button. After checking the receiving sound Pi, immediately push [Temperature set] button to set to [9 C] After checking the receiving sound Pi, immediately push [Temperature set] button to set to [8 C]. Test heating operation Set temperature to [30 C] using [Temperature set] button. After checking the receiving sound Pi, immediately push [Temperature set] button to set to [9 C]. After checking the receiving sound Pi, immediately push [Temperature set] button to set to [30 C]. 6 7 Then repeat the procedure After approx. 0 seconds, all the display lamps on the sensor part of wireless remote controller, [Operation] (Green), [Timer] (Green), and [Ready] (Orange) flash and the air conditioner starts operation. If the lamps do not flash, repeat the procedure and after. After the test operation, push [Start/Stop] button to stop the operation. <Outline of test operation from the wireless remote controller> Test cooling operation: Start/Stop 8 C 9 C 8 C 9 C 8 C 9 C 8 C (Test operation) Start/Stop Test heating operation: Start/Stop 30 C 9 C 30 C 9 C 30 C 9 C 30 C (Test operation) Start/Stop 3, 4, 5, 6, 7 65