Carrier AIRCONDITIONER ZC- Manuals

– 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 par ts replace, stick it as the original. Warning indication WARNING ELECTRICAL SHOCK HAZARD Disconnect all...

– 6 – Precaution for Safety WARNING General Before star ting to repair the air conditioner, read carefully through the Service Manual, and repairthe air conditioner by following its instructions. Only qualified service person ( 1) is allowed to repair the air conditioner. Repair of the air condition...

– 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 removedand the electrical par ts are repaired, you will still risk receiving an electric shock.For this reason, shor t-circuit the high-v...

– 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 rep...

– 11 – New Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer. 1. Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of refrigerant...

– 12 – 4. Tools 1. Required Tools for R410A Mixing of different types 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. 1) Tools exclusive for R410A (Those which cannot be used for conv...

– 31 – • Capacity variation ratio according to temperature RAV-SP1104AT8 (Z) (ZG)-E, -TRRAV-SP1404AT8 (Z) (ZG)-E, -TRRAV-SP1604AT8 (Z) (ZG)-E, -TR RAV-SP1104AT7 (Z) (ZG)RAV-SP1404AT7 (Z) (ZG)RAV-SP1604AT7 (Z) (ZG) <Cooling> <Heating> 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 3...

– 34 – RBC-TRP100E (Simultaneous Triple) <Gas side> Header assembly <Liquid side> Branch pipe assembly Gas side socket Liquid side socket Ø15.9 (External diameter) Ø9.5 (External diameter) Ø12.7 (External diameter) Inner diameter Ø25.4 Inner diameter Ø12.7 Inner diameter Ø15.9 Inner diam...

– 35 – In cooling operationIn heating operation Ø25 × L180 Ø25 × L210 TS sensor P Pressure switch TO sensor TE sensor TD sensor TL sensor Cooling: High pressureHeating: Low pressure Cooling: Low pressureHeating: High pressure Check joint Heat exchanger Ø8, 2 rows, 52 stages FP1.45, flat fin Accumula...

– 37 – 5. SPECIFICATIONS OF ELECTRICAL PARTS 5-1. Outdoor Unit No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Parts name Compressor Outdoor fan motor 4-way valve coil PMV coil High pressure switch Reactor Reactor Reactor P.C. board (Compressor drive) P.C. board (Fan moto...

– 38 – 6. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC(R410A) which does not damage the ozone layer. The working pressure of the new refrigerant R410Ais 1.6 times higher than conventional refrigerant(R22). The refrigerating oil is also changed inaccordance with change of ref...

– 39 – Table 6-2-1 Thicknesses of annealed copper pipes 1. 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 exceeds20 mm. In...

– 40 – c) Inser tion of Flare Nut d) Flare Processing Make cer tain 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 R410A or conventional flare tool. Flare processing dimensions differ accordingto the ...

– 41 – 43˚to 45˚ 45˚to 46˚ A B C D Fig. 6-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union por tions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Ti...

– 42 – 6-3. Tools 6-3-1. Required Tools Refer to the “ 4. Tools ” 6-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to thefollowing steps. (INDOOR unit) (Liquid side) Refrigerant cylinder (With siphon pipe) Check val...

– 43 – Gauge manifold [ Cylinder with siphon ] [ Cylinder without siphon ] OUTDOOR unit Gauge manifold OUTDOOR unit Refrigerant cylinder Electronic balance Refriger ant cylinder Electronic balance Siphon 1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with...

– 44 – Nitrogen gas cylinder Pipe Flow meter M Stop valve From Nitrogen cylinder Nitrogen gas Rubber plug 2. 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 ...

– 45 – 6-6. Instructions for Re-use Piping of R22 or R407C Instruction of Works:The existing R22 and R407C piping can bereused for our digital inverter R410A productsinstallations. NOTE) Confirmation of existence of scratch or dent of theformer pipes to be applied and also confir mation ofreliabilit...

– 46 – 6-6-5. Final Installation Checks Do not apply the refrigerator oil to the flare surface. Existing pipe: NO * Use a new pipes. Clean the pipes or use the new pipes. Trial run Is it possible to operate the existing air conditioner? Was not largely discolored oil or a large quantity of remains d...

– 47 – 6-6-6. Handling of Existing Pipe When using the existing pipe, carefully check it forthe following: • Wall thickness (within the specified range) • Scratches and dents • Water, oil, dir t, or dust in the pipe • Flare looseness and leakage from welds • Deterioration of copper pipe and heat ins...

– 48 – 7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor Unit Control 7-1-1. Print Circuit Board, MCC-1596 (Compressor IPDU) CN851 (Red) Connector for MCC-1597 (CN505) CN101 (White) Connector for MCC-1597 (CN502) CN13 (Black) Terminal for power relay F02 Electric circuit protective fu...

– 52 – 7-2. Outline of Main Controls 1. PMV (Pulse Motor Valve) control 1) PMV is controlled between 30 and 500 pulses during operation. 2) In cooling operation, PMV is usually controlled with the temperature difference between TS sensor and TC sensor aiming 1 to 4K as the target value. 3) In heatin...

– 53 – 3. Outdoor fan control Revolution frequency allocation of fan taps [rpm] 3-1) Cooling fan control  The outdoor fan is controlled by TL sensor, TO sensor and the operation frequency.The outdoor fan is controlled by every 1 tap of DC fan control (14 taps). ‚ Only for 60 seconds after the opera...

– 54 – 4. Coil heating control 1) This control function heats the compressor by turning on the stopped compressor instead of a case heater. It purposes to prevent stagnation of the refrigerant inside of the compressor. 2) As usual, turn on power of the compressor for the specified time before a test...

– 55 – 8. Over-current protective control 1) When the over-current protective circuit detected an abnormal current, stop the compressor. 2) The compressor restar ts after 2 minutes 30 seconds setting [1] as an error count. 3) When the error count [8] was found, determine an error and restar t operat...

– 56 – 10. Defrost control 1) In heating operation, defrost operation is performed when TE sensor satisfies any condition in A zone to D zone. 2) During defrosting operation, it finishes if TE sensor continued 12°C or higher for 3 seconds or continued 7°C # TE < 12°C for 1 minute. The defrost ope...

– 57 – 8. TROUBLESHOOTING 8-1. Summary of Troubleshooting <Wired remote controller type> 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, radio cutting pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmati...

– 62 – <Operation procedure> 1 2 3 4 Returned to usual display 2 4 1 3 SET TIME TIMER SET TEST FILTER LL RESET TEMP. CL FAN SAVE A A SWING/FIX VENT MODE ON / OFF UNIT LOUVER T 8-2-3. Monitor Function of Remote Controller Switch n Calling of sensor temperature display <Contents> Each data...

– 65 – Error mode detected by indoor unit Operation of diagnostic function Check code E03 E04 E08 L03 L07 L08 L09 L30 P10 P12 P19 P31 F01 F02 F10 F29 E10 E18 Cause of operation No communication from remotecontroller (including wireless) andcommunication adapter The serial signal is not output fromou...

– 66 – Error mode detected by outdoor unit The check code has been ramified from 4 series and after. The ramified check code is displayed only when both the indoor unit and the outdoor unit are 4 series and after. (Ex. Combination of RAV-SM140 4 UT-E with RAV-SP140 4 AT8-E) When the indoor unit is 3...

– 68 – Error mode detected by remote controller or central controller (TCC-LINK) 2 The check code cannot be displayed by the wired remote controller. (Usual operation of air conditioner becomes unavailable.) For the wireless models, an error is notified with indication lamp. 3 This trouble is relate...

– 73 – Check code [H03] [H04] Outdoor LED display <Display 1> <Display 2> ¡ ¡ ¡ l l l ¡ l l ¥ l ¥ <Display 1> <Display 2> ¡ ¡ ¡ l l l ¡ ¥ ¡ l ¡ ¥ <Display 1> <Display 2> ¡ ¡ ¡ l l l ¡ ¥ l l l l Check and troubleshooting (Item without special mention Indicates part...

– 80 – Resistance (k Ω ) (50˚C or lo w er) Resistance (k Ω ) (50˚C or higher) 0 0 50 100 150 200 0 5 10 15 20 10 20 30 40 50 60 70 80 90 100 Temperature (˚C) Resistance (k Ω ) 0 0 10 20 30 40 Output v oltage (V) 10 20 30 40 50 60 70 80 90 100 Temperature (˚C) Temperature sensor Temperature – Resista...

– 81 – Red White Black Connector : White Red White Black Table Inspection of outdoor unit main parts No. 1 2 3 Parts name Compressor(Model : DA422A3F-27M) Outdoor fan motor(Model : ICF-280-A100-1) 4-way valve coil(Cooling/heating switching)(Model : STF-01AJ502E1) Checking procedure Measure the resis...

– 82 – 9. SETUP AT LOCAL SITE AND OTHERS 1. Display range on remote controller The setup range (Operation mode/Air volume select/Setup temp) of the indoor unit which was set to themaster unit is reflected on the remote controller. 2. Address setup Turn on power of the indoor unit to be controlled in...

– 83 – n Indoor unit power-ON sequence <Cautions at test run> • Power supply/Indoor/Outdoor serial and Gr wiring: OK• Powers of all indoor units are turned on within 3 minutes.• Reception time for remote controller operation (After power supply was turned on) 1) When address is OK : Approx. 50...

– 85 – 9-3-2. Service Support Function (LED Display, Switch Operation) 1. Outline A various setup and operation check can be performed by DIP switches at 3 positions(SW802, SW803, SW804) and the pushdown button switches (SW800, SW801) at 2 positions. Operation part Display part All LED are colorless...

– 86 – ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 TC SW803 TL SW803 TE SW803 TA SW803 TO SW803 TD SW803 TCJ SW803 TH SW803 TS SW803 SW803 SW803 SW803 SW803 SW803 SW803 9-3-3. Oth...

– 88 – 3) Sensor, current, compressor operation frequency, PMV opening display The values detected by the controller, such as temperature sensor or current value are simply confirmed. (Legend) l l ¥ l l ¡ D800 D801 D802 D803 D804 D805 (Yellow) (Yellow) (Yellow) (Yellow) (Yellow) (Green) l : Go off, ...

– 90 – ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 ON 2 3 4 1 SW804 SW804 SW804 SW804 SW804 SW804 SW804 Operation when pushdown button switch SW801 is pushed 4-way valve relay operation (For RY700, CN70 check) Turn on 4-way valve power relay (RY700).When pushing SW801 again or when 2 minu...

– 91 – Setup of line address of outdoor unit, indoor unit address, and group address Completion of cabling work Turn on power of outdoor unit. Turn on power of outdoor unit. Connect one remote controller with one indoor unit (1 : 1) tentatively with communication cable. END Turn on power of outdoor ...

– 92 – 10-2. Address Setup & Group Control <Terminology> Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Single (Not group control) 1 = Master unit in group control2 = Sub unit in group control Master unit (= 1) : The re...

– 93 – 1-1 Individual (Master/Sub) 2-1 Sub/Header 1-1 Sub/Header 1-2 Sub/Follower 3-1 Master/Header 3-2 Sub/Follower 3-3 Sub/Follower 10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Group operation (Twin, Triple operation) (Multiple out...

– 94 – 2-1 Single Twin Triple 1-1 1-2 3-1 3-2 3-3 2-1 Sub/Header 1-1 Sub/Header 3-1 Master/Header 8-1 Sub/Header 2-1 Sub/Header 1-1 Sub/Header 2-3 Master/Follower 3-1 Sub/Header 3-3 Sub/Follower 1-2 Sub/Follower 1-2 Sub/Header (1-1) (1-2) (1-3) 1-3 Master/Follower 1-1 Sub/Follower 1-1 Individual (Ma...

– 95 – AB AB Terminal block for remote controller wiring of indoor unit Terminal block Remote controller unit Remote controller wire (Procured locally) 10-3. Remote Controller Wiring • Strip off approx. 9 mm the wire to be connected. • For single system, use non polarity, 2 core wire is used for wir...

– 96 – (Example of 2-lines cabling)(Real line: Cabling, Broken line: Refrigerant pipe) For the above example, perform setting by connecting singly the wired remote controller without remote controller inter-unit cable. Group address Individual : 0000 Master unit : 0001 Sub unit : 0002 In case of gro...

– 97 – 1 2 END Operation <Operation procedure> 2 1 SET TIME TIMER SET TEST FILTER LL RESET TEMP. CL FAN SAVE A A SWING/FIX VENT MODE ON / OFF UNIT LOUVER T 1 2 3 END <Operation procedure> 3 1 2 SET TIME TIMER SET TEST FILTER LL RESET TEMP. CL FAN SAVE A A SWING/FIX VENT MODE ON / OFF UNI...

– 99 – 11. REPLACEMENT OF THE SERVICE P.C. BOARD (4316V417) MCC-1599 1. Setting the jumper wires and DIP switches Model switching (J800 to J803) Since this service P.C. board is available for several models, cut the jumper wires according to the following table. If they are not cut correctly, an err...

– 100 – 12. HOW TO EXCHANGE COMPRESSOR 12-1. Exchanging Procedure of Compressor (Outline) 12-2. Exchange of Compressor For exchange of compressors, refer to (11) Compressor in Section 14. Detachments . START Has refrigerant recovery work been done? YES Remove the defective compressor. Mount a servic...

– 101 – S u p e r D ig it a l In v e rt e r EN-i i C o n te n ts 1 P RECAUTIO NS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 A C C E S S O R Y P A R T S A N D R E F R IG E R A N T . . . . . . . . . . . . . . . . . . . . . . . . . ....

– 102 – E N -2 2 S u p e r D i g i ta l I n v e rt e r D efi n i t i on o f Prot ec t i v e G e ar W h e n th e a i r c o n d i t i o n e r i s to b e tr a n s p o rt e d , i n s ta ll e d , m a i n ta i n e d , re p a i re d o r re m o v e d , w e a r p ro te c t i v e g l o v e s a n d “ s a fe ty...

– 103 – E N -4 4 S u p e r D ig it a l In v e rt e r 1 PRECAUTIONS FOR SAFETY W A R N IN G General • B e fo re s ta rt in g t o i n s ta ll th e a ir c o n d it io n e r, r e a d c a re fu lly t h ro u g h t h e I n s ta lla ti o n M a n u a l, a n d f o llo w i ts i n s tr u c ti o n s t o in s ta ...

– 105 – EN-8 8 S u p e r D i g i ta l I n v e rt e r 2 A CC E SSOR Y P A R T S A N D R E F R I G E R A N T A c c e s s o  ry P a rt s P a rt n a m e Q ’ ty S h a p e U s a g e O u td o o r u n i t i n s ta ll a t i o n m a n u a l 1 H a n d th i s d i re c t l y to th e c u s to m e r . ( F o r o t...

– 108 – E N - 1 4 1 4 S u p e r D i g i ta l I n v e rt e r S e r i a l i n s ta ll a t i o n i n f ro n t a n d r e a r O p e n a b o v e a n d to th e r i g h t a n d l e ft o f th e u n i t . T h e h e i g h t o f a n o b s ta c l e i n b o th th e fr o n t a n d re a r o f th e u n i t s h o u l...

– 113 – E N -2 4 2 4 S u p e r D ig it a l In v e rt e r 8 EARTHING C o n n e c t th e e a rt h l in e p ro p e rl y f o llo w in g a p p lic a b le t e c h n ic a l s ta n d a rd s . C o n n e c ti n g t h e e a rt h l in e i s e s s e n ti a l to p re v e n ti n g e le c tr ic s h o c k a n d t o ...

– 115 – E N -2 8 2 8 S u p e r D ig it a l In v e rt e r 1 5 APPENDIX W o r k i n s tr u c ti o n s T h e e x is ti n g R 2 2 a n d R 4 0 7 C p ip in g c a n b e r e u s e d f o r o u r d ig it a l in v e rt e r R 4 1 0 A p ro d u c t in s ta lla ti o n s . W A R N IN G C o n fi rm in g t h e e x is...

– 117 – E N -3 2 3 2 S u p e r D ig it a l In v e rt e r D e c la ra ti o n o f C o n fo rm it y N o te : T h is d e c la ra ti o n b e c o m e s i n v a lid i f te c h n ic a l o r o p e ra ti o n a l m o d if i c a ti o n s a re i n tr o d u c e d w it h o u t th e m a n u fa c tu re r’ s c o n s ...

– 118 – 14. DETACHMENTS 14-1. Outdoor Unit RAV-SP1104AT8 (7), RAV-SP1404AT8 (7), RAV-SP1604AT8 (7) series No. 1 Part name Commonprocedure Procedure WARNING Stop operation of the air conditioner and turn offbreaker switch. CAUTION Ensure wearing of gloves when performing any workin order to avoid inj...

– 122 – Support (4 positions) Statue of control board when removed Interface board (Control board) No. 5 Part name Interface board(Control board) MCC-1599 Procedure 1. Detachment 1) Carry out the operation in 1. of  , and 1. of ƒ above. 2) Remove lead wires and connectors to other components from t...

– 124 – Interface board Fan-IPDU boardg Using the hook, it is possible to temporarily suspendthe inverter assembly (front). Screws (2 positions) Inverter assembly (front) Using Noize filter board State of noize filter board when removed State of noize filter board when removed No. 7 Part name Noise ...

– 125 – No. 8 Part name CompressorIPDU board MCC-1596 Procedure 1. Detachment 1) Carry out the operation in 1. of  , 1. of „ , 1. of … , 1. of † and 1. of ‡ . 2) Remove the screw (4 positions) fixing the inver ter assembly (IPDU). 3) Remove the lead wire and connector to other components from the c...

– 127 – No. 10 Part name Compressor Compressorlead Procedure 1. Removal of defective compressor 1) Recover the refrigerant gas. 2) Carry out work of item 1 of  , 1 of ƒ and 1 of ‡ . 3) Remove the piping panel (Front). Remove the piping panel (Front) and screws of thebottom plate. (Hexagonal screw Ø...

– 128 – No. 10 Part name Compressor Compressor lead (Continued) Procedure 2. Mounting of compressor 1) Mount the compressor in the reverse procedure for removal. NOTE • After replacement of the compressor, be sure to replace the compressor lead. (Repair par tcode of compressor lead: 43160612)In this...

– 130 – 15. EXPLODED VIEWS AND PARTS LIST Outdoor Unit RAV-SP1104AT8-E, RAV-SP1104AT8Z-E, RAV-SP1104AT8ZG-ERAV-SP1104AT8-TR, RAV-SP1104AT8Z-TR, RAV-SP1104AT8ZG-TRRAV-SP1104AT7, RAV-SP1104AT7Z, RAV-SP1104AT7ZG 23 18 20 25 38, 39, 40 41, 42, 43 16 48 2 1 8 21 13 15 37 24 4, 10 32, 33 29, 30 44, 45 22 ...

– 132 – 711 701 717 713 720 TETS TO TD TL 718, 719 708 709 715 706 707 721 710 718, 719 720 702 704 705 714 712 720 Inverter Assembly RAV-SP1104AT8-E, RAV-SP1104AT8Z-E, RAV-SP1104AT8ZG-ERAV-SP1104AT8-TR, RAV-SP1104AT8Z-TR, RAV-SP1104AT8ZG-TRRAV-SP1104AT7, RAV-SP1104AT7Z, RAV-SP1104AT7ZG

– 133 – Location Part No. Description No. 701 43058288 Reactor, CH-56-4Z 702 43154177 Relay, 480V, 20A 704 43158207 Reactor, CH-68 705 43153006 PTC-Thermistor, ZPROYCE101A500 706 43050425 Sensor Ass’y, TC (F6) 707 43150319 Sensor Ass’y, TD (F4) 708 43160565 Terminal Block, 3P, 20A, AC250A 709 431605...

– 136 – 711 701 717 713 720 TETS TO TD TL 718, 719 708 709 715 706 707 721 710 718, 719 720 702 704 705 714 712 720 Inverter Unit RAV-SP1404AT8-E, RAV-SP1404AT8Z-E, RAV-SP1404AT8ZG-ERAV-SP1404AT8-TR, RAV-SP1404AT8Z-TR, RAV-SP1404AT8ZG-TRRAV-SP1404AT7, RAV-SP1404AT7Z, RAV-SP1404AT7ZG

WARNINGS ON REFRIGERANT LEAKAGE (2) When there is an effective opening with the adjacent room for ventilation of leaking refrigerantgas (opening without a door, or an opening 0.15%or larger than the respective floor spaces at the topor bottom of the door). (3) If an indoor unit is installed in each ...

TOSHIBA CARRIER CORPORATION 23-17, TAKANAWA 3 CHOME, MINATOKU, TOKYO, 108-8580, JAPAN Copyright © 1999 to 2010 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.