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Toshiba RAV-SP804ATP-A User Manual

Toshiba RAV-SP804ATP-A
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SERVICE MANUAL
OUTDOOR UNIT
<SUPER DIGITAL INVERTER>
RAV-SP564ATP-A
RAV-SP804ATP-A
AIR-CONDITIONER
(SPLIT TYPE)
FILE NO. SVM-13047-1
SVM-12085_001-050.indd 1SVM-12085_001-050.indd 1 12/06/12 11:06 AM12/06/12 11:06 AM
Revised on May, 2013
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Toshiba RAV-SP804ATP-A Specifications

General IconGeneral
BrandToshiba
ModelRAV-SP804ATP-A
CategoryAir Conditioner
LanguageEnglish

Summary

SAFETY CAUTION

Qualified Installer and Service Person Definitions

Defines requirements for qualified personnel for installation, maintenance, and repair.

Protective Gear and Safety Symbols

Protective Gear Guidelines

Details protective gear required for various work tasks.

Safety Indication and Mark Explanations

Explains the meaning of safety indications (DANGER, WARNING, CAUTION) and illustrated marks.

Air Conditioner Unit Warning Labels

Electrical and Mechanical Safety Warnings

Lists warnings for electrical shock, moving parts, high temperatures, and fin hazards.

General Safety Precautions

DANGER: Electrical Safety Procedures

Emphasizes circuit breaker use and capacitor discharge for electrical safety.

WARNING: Operational Safety Rules

Covers general safety practices, use of protective clothing, and qualified personnel.

Operational Safety and Handling Warnings

Wiring, Grounding, and Part Usage Safety

Details safety for wiring, grounding, and using specified parts.

Refrigerant Leakage and Fire Prevention

Provides precautions for refrigerant handling, brazing, and fire safety.

R410A Refrigerant Information

R410A Properties and Handling Cautions

Discusses R410A pressure, potential hazards, and proper handling.

Compliance and Disposal

Declaration of Conformity and Standards

States compliance with directives and harmonized standards.

Product Disposal Guidelines

Provides instructions for disposing of the unit according to WEEE regulations.

Technical Specifications Overview

Outdoor Unit Specifications Summary

Lists key specifications for outdoor units, including sound levels and weight.

New Refrigerant (R410A) Guidelines

R410A Safety and Installation Cautions

Highlights R410A pressure, tool requirements, and installation precautions.

Pipe Material Requirements for R410A

Specifies suitable copper pipe and joint materials for R410A systems.

Tools and Equipment for Installation

Required Tools for R410A Systems

Lists tools exclusive to R410A and their interchangeability.

General Tools for Refrigeration Service

Lists common tools required for both R22 and R410A systems.

1. SPECIFICATIONS

1-1. Outdoor Unit Specifications

Provides detailed technical specifications for the outdoor units.

Operation Characteristic Curves

Compressor Speed vs. Current (Cooling/Heating)

Illustrates current draw based on compressor speed under different conditions.

Capacity Variation Ratio by Temperature

Cooling and Heating Capacity Variation

Shows how the unit's capacity changes with outdoor temperature.

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

2-1. RAV-SP56*ATP* External Views

Presents external views and dimensions for the RAV-SP56*ATP* model.

External Views and Dimensions

2-2. RAV-SP80*ATP* External Views

Details external views and dimensions for the RAV-SP80*ATP* model.

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Indoor Unit Refrigerating Cycle

Shows the refrigerating cycle for single and twin indoor unit configurations.

Outdoor Unit Refrigerating Cycle Details

3-2. Outdoor Unit RAV-SP56*ATP* Cycle

Illustrates the refrigerating cycle and operating parameters for RAV-SP56*ATP*.

Outdoor Unit Refrigerating Cycle Details

3-2. Outdoor Unit RAV-SP80*ATP* Cycle

Shows the refrigerating cycle and operating parameters for RAV-SP80*ATP*.

4. WIRING DIAGRAM

4-1. RAV-SP56*ATP* Wiring Diagram

Presents the electrical wiring diagram for the RAV-SP56*ATP* outdoor unit.

Outdoor Unit Wiring Diagrams

4-2. RAV-SP80*ATP* Wiring Diagram

Displays the electrical wiring diagram for the RAV-SP80*ATP* outdoor unit.

5. SPECIFICATIONS OF ELECTRICAL PARTS

Electrical Parts for RAV-SP56*ATP*

Lists specifications for electrical components in the RAV-SP56*ATP*.

Electrical Parts for RAV-SP80*ATP*

Lists specifications for electrical components in the RAV-SP80*ATP*.

6. REFRIGERANT R410A

6-1. Safety During Installation/Servicing

Emphasizes safety precautions for R410A installation and servicing due to higher pressure.

Refrigerant Piping Installation Procedures

6-2-1. Piping Materials and Joints

Details copper pipe and joint specifications suitable for R410A.

6-2-2. Piping Material Processing

Covers pipe cutting, burr removal, and cleanliness requirements.

Flare Processing and Dimensions

Flare Processing Techniques

Explains flare processing methods and dimensions for R410A/R22.

Flare Nut and Pipe Dimensions

Provides tables for flare nut and pipe dimensions for R410A and R22.

Flare Connecting Precautions

2. Flare Connecting Procedures

Details flare connection, torque values, and oil application precautions.

Tools and Refrigerant Recharging

6-3. Required Tools

Lists the tools necessary for refrigerant handling.

6-4. Recharging of Refrigerant

Outlines the procedure for recovering and charging refrigerant.

Brazing of Pipes and Flux Usage

6-5-1. Materials for Brazing

Describes different brazing filler materials and their applications.

6-5-2. Flux Requirements

Explains the necessity and types of flux for brazing.

Brazing Methods and Oxidation Prevention

6-5-3. Brazing Procedure

Details brazing techniques, nitrogen flow for oxidation prevention, and flux removal.

Re-using Existing Piping for R410A

6-6-1. Basic Conditions for Pipe Reuse

Lists conditions for reusing existing pipes (dryness, cleanliness, tightness).

6-6-2. Restrictions on Existing Pipe Reuse

Identifies cases where existing pipes cannot be reused and require cleaning or replacement.

6-6-3. Branching Pipe Reuse for Twin Systems

Addresses reuse of branching pipes for simultaneous operation systems.

6-6-4. Pipe Curing Procedures

Explains how to cure pipes to prevent rust and moisture entry when units are opened.

Final Installation Checks for Pipe Reuse

6-6-5. Final Installation Checks

Details checks for trial run, existing pipe condition, and switch settings.

Handling of Existing Piping

6-6-6. Handling of Existing Pipe

Lists checks for existing pipes and cautions for reuse, including model-specific settings.

6-7. Replenishing Refrigerant

Additional Refrigerant Charging Restrictions

Outlines limitations on additional refrigerant charging and measures for leakage.

7. OUTDOOR CONTROL CIRCUIT

7-1. Outdoor Controls Overview

Describes controls like PMV operation, discharge temperature release, and sensor functions.

Outdoor Fan Control in Cooling Mode

3-1) Cooling Fan Control Logic

Explains cooling fan speed control based on sensors and operation frequency.

Outdoor Fan Control in Heating Mode

3-2) Heating Fan Control Logic

Details heating fan speed control related to temperature sensors and compressor status.

Coil Heating Control Function

4. Coil Heating Control

Describes heating the compressor to prevent refrigerant stagnation.

Compressor Operation Management

5. Short Intermittent Operation Prevention

Explains compressor protection during short intermittent operation.

6. Current Release Control

Controls compressor speed based on current to prevent inverter overload.

Current Release and Over-Current Controls

7. Current Release Value Shift Control

Details control values based on TO sensor for electronic part protection.

8. Over-current Protective Control

Explains compressor stopping due to abnormal current.

9. High-pressure Release Control (SP80 Only)

Restrains high pressure rise using TL/TC sensors, stopping the compressor.

Defrost Control Operation

10. Defrost Control (SP56 Only)

Explains defrost initiation and termination conditions for SP56.

Defrost and Compressor Protection Control

SP80 Defrost Control Logic

Details defrost logic and jumper settings for SP80.

11. Compressor Protective Control (SP80 Only)

Explains compressor protection against oil accumulation.

7-2. Outdoor Print Circuit Board Layout

RAV-SP56*ATP* P.C. Board Components

Identifies components and connectors on the RAV-SP56*ATP* P.C. board.

Outdoor P.C. Board Component Layout

RAV-SP80*ATP* P.C. Board Components

Lists components and connectors on the RAV-SP80*ATP* P.C. board.

8. TROUBLESHOOTING

8-1. Troubleshooting Summary

Provides general guidelines, required tools, and confirmation points for troubleshooting.

Troubleshooting Procedures and Error Judgment

2. Troubleshooting Procedure Outline

Outlines the process for diagnosing issues using error codes and lamp indications.

Error Code Interpretation (Indoor Unit)

8-2-1. Outline of Error Judgment

Explains how to interpret indoor unit error codes via lamp indications.

Indoor Unit Sensor and System Errors

Indoor Unit Error Code List

Lists various indoor unit errors including sensor, EEPROM, and compressor issues.

Other Indoor Unit Error Modes

8-2-2. Other Error Codes

Describes error codes not covered by specific check codes, like test run issues.

Outdoor Unit Error Code List

Error Codes and Detection Methods (Part 1)

Details outdoor unit error codes, detection methods, and their explanations.

Outdoor Unit Error Code List (Part 2)

Error Codes and Detection Methods (Part 2)

Continues listing outdoor unit error codes and their detection methods.

Indoor Unit Error Troubleshooting Guide

Troubleshooting Procedures for Indoor Errors

Provides step-by-step troubleshooting for indoor unit errors.

Remote and Central Controller Communication Errors

Error Modes Detected by Controllers

Lists error modes related to remote and central controller communication.

Outdoor Unit Error Code Troubleshooting

Outdoor Unit Error Mode Detection

Details error modes detected by the outdoor unit, including sensor and overheat issues.

Outdoor Unit Error Code Troubleshooting (Continued)

Troubleshooting Outdoor Unit Errors

Covers troubleshooting for discharge temperature, power supply, and fan system errors.

Outdoor Unit Diagnostic Procedures (E04)

E04: Indoor/Outdoor Communication Error Diagnosis (SP56)

Guides diagnosing communication errors using LED displays for SP56.

Outdoor Unit Diagnostic Procedures (F08, F12, H01, H02)

F08, F12, H01, H02 Error Diagnosis (SP56)

Provides troubleshooting for sensor errors, compressor breakdown, and lock for SP56.

Outdoor Unit Diagnostic Procedures (H03, L29, P03-P05)

H03, L29, P03-P05 Error Diagnosis (SP56)

Covers troubleshooting for current detection, power supply, and temperature errors for SP56.

Outdoor Unit Diagnostic Procedures (P19, P22, P26, P29)

P19, P22, P26, P29 Error Diagnosis (SP56)

Guides diagnosing valve, fan system, short-circuit, and position detection errors for SP56.

Outdoor Unit Diagnostic Procedures (SP80)

E04: Indoor/Outdoor Communication Error Diagnosis (SP80)

Details diagnosing communication errors using LED displays for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

F04, F06, F07 Error Diagnosis (SP80)

Covers troubleshooting for discharge, heat exchanger, and TL sensor errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

F08, F12, F13, F15, F31 Error Diagnosis (SP80)

Guides diagnosing TO, TS, TH sensor, miswiring, and EEPROM errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

H01, H02, H03 Error Diagnosis (SP80)

Details troubleshooting for compressor breakdown, lock, and current detection errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

H04, L10 Error Diagnosis (SP80)

Covers troubleshooting for case thermostat and unset model type errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

L29 Error Diagnosis (SP80)

Guides diagnosing communication, sensor, overheat, gas leak, and valve errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

P03, P04, P05 Error Diagnosis (SP80)

Details troubleshooting for discharge temp, power supply, and voltage errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

P07, P15 Error Diagnosis (SP80)

Guides diagnosing heat sink overheat and gas leak detection errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

P19 4-Way Valve Reversal Error Diagnosis (SP80)

Details troubleshooting for the 4-way valve reversal error for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

P20 High Pressure Protective Operation Diagnosis (SP80)

Guides diagnosing high pressure protective operation errors for SP80.

Outdoor Unit Diagnostic Procedures (SP80) (Continued)

P22, P26, P29 Error Diagnosis (SP80)

Details troubleshooting for fan system, short-circuit, and position detection errors for SP80.

Temperature Sensor Resistance Characteristics

Sensor Resistance Value Tables

Provides resistance values for temperature sensors at various temperatures.

Outdoor Unit Main Parts Inspection

Compressor and Fan Motor Resistance Checks

Shows resistance values for compressor windings and fan motor windings.

9. OTHERS

9-1. Refrigerant Recovery Control

Explains the operation of the refrigerant recovery switch (pump down).

Outdoor Unit Settings and Functions

9-2. Various Settings on Outdoor Unit

Details DIP switch and jumper settings for various operational modes.

Service Support Functions (LEDs and Switches)

9-3. Service Support Functions Overview

Explains the use of DIP switches and LEDs for setup and error display.

LED Display Selection Methods

2. LED Display Selection (SW800, SW803)

Describes how to use switches to select LED display modes for errors and sensor data.

Error Display and Remote Controller Codes

2) Error Display Confirmation

Details confirming errors using LED displays and wired remote controller codes.

Sensor, Current, Frequency, and PMV Display

3) Displaying Sensor, Current, Frequency, PMV Data

Explains how to view detected sensor values, current, compressor frequency, and PMV opening.

Maintenance Check Operations

4) Specific Operations for Maintenance (SW801, SW804)

Describes maintenance operations like test runs and forced fan/PMV operation.

Maintenance Check Operations (Continued)

SW804 Operation Details for Relays

Details operations for 4-way valve, self-hold valve, SV valve, and output relays.

10. DETACHMENTS

10-1. RAV-SP56*ATP* Disassembly/Assembly

Provides instructions for detaching and attaching parts of the RAV-SP56*ATP* outdoor unit.

Front Cabinet Disassembly and Assembly

2. Front Cabinet Procedures

Details the procedure for removing and installing the front cabinet.

Inverter Assembly Disassembly and Safety

3. Inverter Assembly Detachment

Guides inverter assembly detachment, including capacitor discharging safety.

Inverter Assembly Component Removal

Inverter Assembly Connector Removal

Details removing inverter assembly connectors, highlighting lock mechanisms.

Control P.C. Board Replacement Procedure

4. Control P.C. Board Assembly Replacement

Guides replacing the control P.C. board, including heat sink and safety notes.

Rear Cabinet and Fan Motor Replacement

5. Rear Cabinet Procedures

Details detachment and attachment of the rear cabinet.

6. Fan Motor Replacement

Provides instructions for fan motor replacement, including torque specs.

Compressor and Reactor Replacement Procedures

7. Compressor Replacement

Details compressor removal and replacement, including safety precautions.

8. Reactor Replacement

Provides instructions for reactor removal and attachment.

PMV Coil and Fan Guard Replacement

9. PMV Coil Replacement

Details detachment and attachment of the PMV coil.

10. Fan Guard Replacement

Provides instructions for fan guard removal and attachment.

10-2. RAV-SP80*ATP* Detachments

1. Common Procedures for RAV-SP80*ATP*

General procedures for detaching/attaching parts of the RAV-SP80*ATP* unit.

Outdoor Unit Component Disassembly

2. Discharge Port Cabinet Removal

Details removal of the discharge port cabinet and related parts.

3. Side Cabinet Removal

Provides instructions for removing the side cabinet.

Control P.C. Board Replacement

4. Control P.C. Board Assembly Replacement

Guides replacing the control P.C. board, including connector removal and safety.

Reactor Replacement Procedures

4. Reactor Replacement (Continued)

Details reactor replacement, including connector and bundling band handling.

Fan Motor Replacement Procedures

5. Fan Motor Replacement

Provides instructions for fan motor replacement, including torque specs and lead routing.

Compressor Removal Procedures

6. Compressor Removal

Details compressor removal, including piping, sensors, and lead wires.

Compressor Removal Procedures (Continued)

6. Compressor Removal (Continued)

Continues compressor removal steps, including burner use and safety warnings.

Compressor Mounting Procedures

2. Compressor Mounting

Guides compressor mounting, including lead wire wrapping and sensor routing.

Vacuuming, Refrigerant Charging, and PMV Coil Replacement

3. Vacuuming Procedures

Explains the vacuuming process and PMV operation notes.

4. Refrigerant Charging Procedures

Details adding the specified quantity of refrigerant.

7. PMV Coil Replacement

Provides instructions for PMV coil detachment and attachment.

Fan Guard Replacement Procedures

8. Fan Guard Replacement

Details fan guard removal and attachment procedures.

11. EXPLODED VIEWS AND PARTS LIST

11-1. RAV-SP564ATP-A Exploded View

Shows an exploded view of the RAV-SP564ATP-A outdoor unit.

RAV-SP564ATP-A Parts List

Exploded View Parts List Details

Lists parts with location and part numbers for RAV-SP564ATP-A.

Inverter Assembly Exploded View

Inverter Assembly Components Diagram

Illustrates the components within the inverter assembly.

Inverter Assembly Parts List

Inverter Assembly Parts List Details

Lists part numbers for inverter assembly components.

11-2. RAV-SP804ATP-A Exploded View

Exploded View for RAV-SP804ATP-A

Presents an exploded view of the RAV-SP804ATP-A outdoor unit.

RAV-SP804ATP-A Parts List

Exploded View Parts List Details

Lists parts with location and part numbers for RAV-SP804ATP-A.

Inverter Assembly Exploded View (Continued)

Inverter Assembly Components Diagram (Continued)

Shows further components within the inverter assembly.

Inverter Assembly Parts List (Continued)

Inverter Assembly Parts List Details (Continued)

Lists part numbers for inverter assembly components.

Warnings on Refrigerant Leakage

Check of Concentration Limit in Rooms

Discusses refrigerant concentration limits and necessary ventilation measures.

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