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Toshiba RAV-SM801AT-E User Manual

Toshiba RAV-SM801AT-E
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R410A
FILE NO. A05-001
PRINTED IN JAPAN, Apr.,2005 ToMo
SERVICE MANUAL
SPLIT TYPE
<NEW DIGITAL INVERTER>
OUTDOOR UNIT
RAV-SM561AT-E
RAV-SM801AT-E
RAV-SM1101AT-E
RAV-SM1401AT-E
INDOOR UNIT
This Service Manual describes contents of the new outdoor unit.
For the indoor unit, refer to the Service Manual with FILE NO. A03-003F.
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Toshiba RAV-SM801AT-E Specifications

General IconGeneral
CategoryAir Conditioner
TypeSplit System
Cooling Capacity (kW)8.0
Heating Capacity (kW)9.0
Power Supply220-240 V, 50 Hz
Energy Efficiency Ratio (EER)3.21
Coefficient of Performance (COP)3.61
RefrigerantR410A
Indoor Unit Weight15 kg
Outdoor Unit Noise Level52 dB(A)

Summary

Specifications Overview

Model Specifications (SM561AT-E, SM801AT-E)

Technical specifications for specific outdoor unit models, covering appearance, power, compressor, and refrigerant.

Pipe and Dimension Specifications

Details on piping lengths, height differences, and unit dimensions for models.

Specifications Overview (Continued)

Model Specifications (SM1101AT-E, SM1401AT-E)

Technical specifications for larger outdoor unit models, including fan and pipe details.

Construction Views and Dimensions

Outdoor Unit External Views (SM561AT-E)

Detailed external dimensions and mounting points for the SM561AT-E outdoor unit.

Service Space Requirements

Recommended clearance for installation and maintenance access.

Construction Views and Dimensions (Continued)

Outdoor Unit External Views (SM801AT-E)

Detailed external dimensions and mounting points for the SM801AT-E outdoor unit.

Construction Views and Dimensions (Continued)

Outdoor Unit External Views (SM1101AT-E, SM1401AT-E)

External dimensions and features for larger SM1101AT-E and SM1401AT-E units.

Installation Points for Larger Units

Details on mounting holes and service clearance for larger units.

Refrigerating Cycle Diagram and Data

System Component Overview

Diagram illustrating major components and refrigerant flow in the system.

Operating Data Table (SM561AT-E)

Pressure and temperature data for SM561AT-E under various conditions.

Refrigerating Cycle Diagram and Data (Continued)

System Component Overview (SM801AT-E)

Diagram showing components and refrigerant flow for SM801AT-E.

Operating Data Table (SM801AT-E)

Operating data for SM801AT-E under different cooling and heating modes.

Refrigerating Cycle Diagram and Data (Continued)

System Component Overview (SM1101AT-E, SM1401AT-E)

Diagrams for larger models illustrating system components and flow.

Operating Data Tables (SM1101AT-E, SM1401AT-E)

Performance data for larger models in cooling and heating modes.

Wiring Diagram

Outdoor Unit Wiring (SM561AT-E, SM801AT-E)

Electrical schematic detailing wiring for smaller outdoor units.

Outdoor Unit Wiring (SM1101AT-E, SM1401AT-E)

Electrical schematic detailing wiring for larger outdoor units.

Specifications of Electrical Parts

Electrical Parts List (SM561AT-E, SM801AT-E)

List of electrical components and their specifications for smaller models.

Electrical Parts List (SM1101AT-E, SM1401AT-E)

List of electrical components and their specifications for larger models.

Refrigerant R410A Safety and Handling

Safety During Installation and Servicing

Crucial safety precautions for working with R410A refrigerant.

Refrigerant Piping Installation Materials

Guidelines on copper pipes and joints suitable for R410A.

Refrigerant R410A Piping Installation

Copper Pipe Thickness Standards

Required thicknesses for annealed copper pipes used with R410A.

Socket Joint Thickness and Processing

Specifications for socket joints and pipe material processing.

Refrigerant R410A Flare Processing

Flare Processing Dimensions for R410A

Dimensions for flare processing specific to R410A refrigerant.

Flare Processing Dimensions for R22

Comparison dimensions for R22 flare processing.

Flare and Flare Nut Dimensions for R410A

Dimensions for flare nuts and pipe ends for R410A.

Refrigerant R410A Flare Connections

Flare and Flare Nut Dimensions for R22

Dimensions for flare nuts and pipe ends for R22 refrigerant.

Flare Seal Surface and Tightening Torque

Proper sealing techniques and torque specifications for flare connections.

Refrigerant R410A Required Tools

Tools Exclusive for R410A

List of essential R410A-specific tools and their interchangeability.

General Tools for R410A and R22

Commonly used tools applicable to both R410A and R22 refrigerants.

Refrigerant Recharging Procedure

Steps for Refrigerant Recharging

Detailed step-by-step guide for recharging refrigerant into the system.

Refrigerant Charging Configuration Diagram

Diagram illustrating the setup for charging refrigerant.

Refrigerant R410A Brazing Procedures

Refrigerant Charging Method (Liquid vs Gas)

Instructions for charging R410A as liquid refrigerant for proper composition.

Brazing Materials for Pipes

Types of brazing fillers suitable for joining refrigerant pipes.

Refrigerant R410A Brazing Procedures (Continued)

Flux Characteristics and Types

Properties and types of flux required for effective brazing.

Brazing Method to Prevent Oxidation

Techniques for brazing using nitrogen flow to prevent interior oxidation.

Control Specifications: Outdoor Unit

Print Circuit Board Layout (MCC-5009)

Identification of components on the outdoor unit's main PCB.

Outdoor Unit Control Components

Key sensors and connectors on the outdoor unit's P.C. board.

Control Specifications: Outdoor Unit (Continued)

Print Circuit Board Layout (IPDU: MCC-1438)

Component layout of the IPDU module in the outdoor unit.

Control Specifications: Outdoor Unit (Continued)

Print Circuit Board Layout (CDB: MCC-1531)

Component layout of the CDB module in the outdoor unit.

Control Specifications: Main Control Logic

Pulse Modulating Valve (PMV) Control

How the PMV regulates refrigerant flow based on temperature differences.

Discharge Temperature Release Control

Mechanism to prevent overheating by adjusting operation frequency.

Control Specifications: Fan Control

Cooling Fan Control Logic

How fan speed is adjusted during cooling operation based on sensors.

Fan Speed Tables and Operation

Tables showing fan tap revolutions and operating ranges.

Control Specifications: Fan and Coil Heating Control

Heating Fan Control Logic

Fan speed control logic during heating operation.

Coil Heating Control Operation

Compressor pre-heating function to prevent oil slugging.

Control Specifications: Protective Controls

Intermittent Operation Preventive Control

Control to prevent frequent compressor start/stop cycles.

High-Pressure and Over-Current Protection

Controls to prevent damage from high pressure or over-current.

Current Release Value Shift Control

Adjusting current limits based on outdoor temperature sensor values.

Control Specifications: Defrost Control

Defrost Operation Conditions

Criteria for initiating and ending defrost cycles.

Defrost Operation Sequence

Steps taken after defrost operation finishes.

Troubleshooting: Summary of Procedures

Required Tools and Initial Checks

Tools needed and initial confirmation points before troubleshooting.

Wired Controller Troubleshooting Flow

General troubleshooting steps for wired remote controllers.

Troubleshooting: Summary of Procedures (Continued)

Wireless Controller Troubleshooting Flow

General troubleshooting steps for wireless remote controllers.

Indoor Unit Error Judgment Method

How the indoor unit indicates self-diagnosis errors.

Troubleshooting: Check Code List (Indoor Unit Errors)

Indoor Unit Errors E03 to E18

List of indoor unit errors, causes, and remedies.

Troubleshooting: Check Code List (Outdoor Unit Errors)

Outdoor Unit Errors H01 to F08

List of outdoor unit errors, causes, and remedies.

Troubleshooting: Check Code List (Controller Errors)

Controller and Network Errors E01 to L20

Errors related to communication and controller setup.

Troubleshooting: Outdoor Unit LED Error Judgment

LED Display Interpretation

How to interpret outdoor unit LED status for error diagnosis.

Troubleshooting: Error Display Contents

Error Code to LED Display Mapping

Correlation between check codes and LED indicators.

Troubleshooting Procedures: Communication Errors

E01/99 and E09/99 Error Procedures

Step-by-step guide for specific communication errors.

Troubleshooting Procedures: Communication Errors (Continued)

E04/04 Error Procedures

Diagnostic steps for E04/04, related to outdoor unit operation.

Troubleshooting Procedures: Communication and Setting Errors

E10/CF, E18/97/99, E08/L03/L07/L08/96/99, L09/46 Error Procedures

Procedures for various communication and setting errors.

Troubleshooting Procedures: Network and Controller Errors

L20/98, L30/B6, b7 Error Procedures

Steps for network and central control communication issues.

Troubleshooting Procedures: Component Errors (Fans, Pumps, Valves)

P01/11, P10/Ob, F10/Oc Error Procedures

Diagnostic steps for fan motor, float switch, and drain pump issues.

Troubleshooting Procedures: Component Errors (Fans, Pumps, Valves) (Continued)

P12/11 Error Procedures (Indoor Fan)

Steps to diagnose indoor fan motor issues.

Troubleshooting Procedures: Component Errors (Fans, Pumps, Valves) (Continued)

P22/1A Error Procedures (Outdoor Fan)

Steps to diagnose outdoor fan motor issues.

Troubleshooting Procedures: Sensor and Valve Errors

P19/08 and F02/0d Error Procedures

Procedures for 4-way valve and TC sensor errors.

Troubleshooting Procedures: Sensor and Board Errors

F01/0F and P26/14 Error Procedures

Steps for TCJ sensor and inverter over-current protection.

Troubleshooting Procedures: IPDU and Current Sensor Errors

P29/16 and H03/17 Error Procedures

Procedures for IPDU position detection and current sensor errors.

Troubleshooting Procedures: Sensor Errors

F06/18, F04/19, F08/1b Error Procedures

Steps for TE/TS, TD, and TO sensor errors.

Troubleshooting Procedures: Compressor and Overload Errors

L29/1C and H02/1d Error Procedures

Procedures for compressor drive and overload errors.

Troubleshooting Procedures: Compressor and Temperature Errors

P03/1E and H01/1F Error Procedures

Steps for discharge temperature and compressor breakdown errors.

Troubleshooting Procedures: Protection and Fan Errors

P04/21 Error Procedures

Procedures for high-voltage protection and fan/PMV errors.

Troubleshooting Procedures: Central Controller Errors

97 Error Procedures (Central Controller)

Steps for central controller communication and network issues.

Troubleshooting Procedures: Communication and EEPROM Errors

E03, F29/12, P31 Error Procedures

Procedures for master/sub unit communication and EEPROM errors.

Temperature Sensor Resistance Graphs

TA, TC, TCJ Sensor Resistance Graphs

Resistance vs. temperature curves for TA, TC, TCJ sensors.

TE, TO, TS Sensor Resistance Graphs

Resistance vs. temperature curves for TE, TO, TS sensors.

TD Sensor Resistance Graph

Resistance vs. temperature curve for TD sensor.

Troubleshooting: Central Remote Controller Display

Operation for Check Display

How to activate and use the check display function.

Reading the Check Monitor Display

Interpreting the 7-segment and CHECK monitor displays.

Troubleshooting: Check Code Tables (Indoor Unit Errors)

Indoor Unit Error Modes (Part 1)

Correlation of error codes with causes and judgments.

Troubleshooting: Check Code Tables (Indoor Unit Errors) (Continued)

Indoor Unit Error Modes (Part 2)

Continued list of indoor unit errors and their solutions.

Troubleshooting: Check Code Tables (Outdoor Unit Errors)

Outdoor Unit Error Modes

Summary of outdoor unit errors and troubleshooting steps.

Other Functions and Controls

Refrigerant Recovery Method

Procedures for recovering refrigerant during servicing.

Applicable Outdoor Unit Controls

Demand control, night operation, and compressor output features.

Detachments: General Procedures (SM56/80)

Common Detachment and Attachment Steps

General precautions and steps for disassembling/assembling units.

Detachments: Front Cabinet

Front Cabinet Detachment

Steps to remove the front cabinet of the outdoor unit.

Front Cabinet Attachment

Steps to reattach the front cabinet of the outdoor unit.

Detachments: Inverter Assembly

Inverter Assembly Power Off and Discharge

Safety steps for discharging capacitors before handling the inverter.

Detachments: Control P.C. Board Assembly

Control P.C. Board Removal and Installation

Procedures for replacing the main control circuit board.

Detachments: Fan Motor

Fan Motor Removal and Installation

Steps to detach and attach the outdoor unit fan motor.

Detachments: Compressor and Reactor

Compressor Removal and Installation

Procedures for removing and installing the compressor.

Reactor Removal

Steps to remove the reactor component.

Detachments: PMV Coil and Fan Guard

PMV Coil Detachment and Attachment

Procedures for removing and installing the Pulse Modulating Valve coil.

Fan Guard Detachment and Attachment

Steps to remove and install the fan guard.

Detachments: General Procedures (SM110/140)

General Detachment and Attachment Steps

Initial detachment and attachment steps for larger unit models.

Detachments: Cabinet Components

Discharge Port Cabinet Removal

Steps to detach the discharge port cabinet.

Side Cabinet Removal

Steps to detach the side cabinet.

Detachments: Inverter Assembly (SM110/140)

Inverter Assembly Disconnection and Removal

Procedures for disconnecting and removing the inverter assembly.

Detachments: Cycle P.C. Board

Cycle P.C. Board Removal and Installation

Steps to remove and install the cycle control P.C. board.

Detachments: IPDU P.C. Board

IPDU P.C. Board Removal and Installation

Procedures for replacing the IPDU P.C. board.

Detachments: Fan Motor (SM110/140)

Fan Motor Removal and Installation (SM110/140)

Steps to detach and attach the fan motor on larger units.

Detachments: Compressor and PMV Coil

Compressor Removal and Installation (SM110/140)

Procedures for removing and installing the compressor on larger units.

PMV Coil Detachment and Attachment

Steps for handling the PMV coil.

Detachments: Fan Guard

Fan Guard Detachment and Attachment

Steps to remove and install the fan guard.

Exploded Views and Parts List (SM56/80)

Exploded View Diagram (SM561AT-E, SM801AT-E)

Visual breakdown of outdoor unit parts for SM56/80 models.

Parts List (SM561AT-E, SM801AT-E)

Detailed list of components for SM56/80 outdoor units.

Exploded Views and Parts List (Internal Components)

Internal Component Exploded View

Diagram showing breakdown of internal electronic components.

Internal Component Parts List

List of internal electronic parts.

Exploded Views and Parts List (SM110/140)

Exploded View Diagram (SM1101AT-E, SM1401AT-E)

Visual breakdown of outdoor unit parts for SM110/140 models.

Parts List (SM1101AT-E, SM1401AT-E)

Detailed list of components for SM110/140 outdoor units.

Exploded Views and Parts List (Internal Components) (Continued)

Internal Component Exploded View (Continued)

Further breakdown of internal electronic components.

Internal Component Parts List (Continued)

List of additional internal electronic parts.

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