Toshiba RAV-SP1104AT-A1 User manual

SERVICE MANUAL
AIR CONDITIONER (SPLIT TYPE)
PRINTED IN JAPAN, May 2014, TOMO
FILE No. A10-1410
<DIGITAL INVERTER>
RAV-SM1603AT-A1..........A07-009-2
Model name: FILE NO.
These models are DRED (Demand response enabling device) models for
Australia and New Zealand.
Please refer to the service manual of the following base European model for
details of the content of service.
Outdoor Unit

– 2 –
CONTENTS
1. SUMMARIES OF PRODUCT CHARACTERISTICS ................................................ 3
2. WIRRING DIAGRAM ................................................................................................. 4
3. SPECIFICATIONS OF ELECTRICAL PARTS .......................................................... 5
4. DRED INSTALLATION MANIUAL ............................................................................ 6
5. TROUBLESHOOTING ............................................................................................. 8
6. EXPLODED VIWES AND PARTS LIST .................................................................. 10

– 3 –
1. SUMMARIES OF PRODUCT CHARACTERISTICS
These air conditioners are commodities for DRED (Demand Response Enabling Device)
that complies with AS/NZS 4755.3.1.
These models supports DRM1.
AS/NZS 4755 DRM1 DRM2 DRM3
DRED installation
p
osition
Outline of DRED wiring
Demand response mode Description
Compressor off
Not available
Not available
DRM1
DRM2
DRM3
DRED t
e
rmin
a
l
b
lo
c
k
c
onn
ec
tion
s
Demand connectin
g
wir
e
Fixin
g
ban
d
Fixin
g
ban
d
Att
ac
hm
e
nt
b
o
a
r
d
Indoor/Outdoor connectin
g
wir
e
CN101 CN104
CN102
CN100
COM DRM1 DRM2 DRM3
MCC-1653
Trans-
former
Demand response interface
Outdoor control
P.C. board
DRED
Locally procured
To indoor
unit
Power supply
Single
phase
model
1 2 3 LN

– 4 –
2. WIRRING DIAGRAM
CM
FM01,02
RY
T-01
Symbol
49C
20SF
TE
TO
TS
Symbol
PMV
TD
Parts name
The 4-way valve coil is turned on while the cooling operation
Parts name
The high voltage circuit is incorporated.
Be careful to do the check service, as the electric shock may be
caused in case of touching parts on the P.C.board by hand.
Field wiring Color Indication
BLK : BLACK
BLU : BLUE
GRY : GRAY
RED : RED
YEL : YELLOW
WHI : WHITE
Protective earth
Terminal block
Terminal
Connector
P.C.board
Pulse motor valve
Pipe temp. sensor(discharge)
Outside temp. sensor
Pipe temp. sensor (suction)
AS/NZS 4755 DRM1 DRM2 DRM3
Heat exchange temp. sensor
Compressor case thermostat
Compressor
Fan motor
Relay
TRANS
4-way valve coil
CAUTION : HIGH VOLTAGE
CN606
RED CN605
WHI
CN604
WHI
CN804
BLU
CN801
WHI
CN500
BLU
Fuse
F300
T5A,
250V~
CN607
YEL
CN302
WHI
CN303
WHI
CN300
WHI
CN104
(WHI)
CN100
(WHI)
Fuse
T3.15A
250V
~
CN101
(YEL) CN102
(WHI)
Dmand P.C.board
MCC-1653
CDB P.C.BOARD
MCC-1531
IPDU
P.C.BOARD
MCC-1535
NOISE FILTER
P.C.BOARD
MCC-1551
P02
CN01
(BLK)
COM
DRM1
DRM2
DRM3
CN301
WHI
CN02
BLK
CN700
YEL
RY700
Serial
communi-
cation
circuit
CN702
WHI
CN01
RED
CN08
WHI
CN01
CN02
CN04
CN03
P01
CN04
WHI CN800
RED
CN03
WHI CN601
WHI
CN600
WHI
CN06
WHI
CN13
RED
CN04
WHI
CN05
WHI
CN22
BLU
MS
3~
MS
3~
MS
3~
CAPA
CM
49C
FM02
FM01
PMV
M
20SF
REACTOR
REACTOR
Earth
screw
Earth
screw
L N
Fuse
T10A,250V~
Fuse 50A,250V~
Fuse F01 T3.5A,250V~
To outdoor unit
Power Supply
220-240V~50Hz
To DRMD
T-01
TS TE TO TD
t˚ t˚ t˚ t˚
t˚>
CN09
CN20 CN21
CN10
CN11
CN02
CN01
RED
RED
BLK
WHI
BLK
RED
ORN
YEL
WHI
RED
WHI
RED
RED
RED
RED
RED
BLK WHI
WHI
WHI
WHI
WHI
WHI
BLK
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5 6 7 8
1 2 3 4 5
1 2 3 4 5
1 3 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5 1 2 3
1 2 3
1 2 3
1 2 3
1
1
32
2
1
2
3
4
5
1
2
3
4
5
6
1
3
13 1
2
2
3
3
61
2
1
2
1
12 12 1
5
3
YEL
BLU
BLU
7
5
3
1

– 5 –
3. SPECIFICATIONS OF ELECTRICAL PARTS
1. Parts for demand response (Common usage)
No. Parts name Type Specifications
1 Demand response P.C. board MCC-1653
2 Transformer TT-02
AC230-240V,50Hz
AC230V,50/60Hz,150mA
2. Demand response P.C. board
DRC signal
transmission
connector
CN104,CN105,
CN106
DRC signal reception connector CN01
Power supply
protection fuse
F100 (250V/3.15A)
Power supply input
connector CN100
Transfomer output
connector CN102
Transfomer intput
connector CN101
LED indicator D101
DB100

– 6 –
4. DRED INSTALLATION MANUAL
This model supports only DRM1.
Safety precautions
WARNING
CAUTION
· Wear heavy gloves during the installation work to avoid injury.
4-2 Connection procedure
Connect the wire (4-wire) with a round terminal to the Demand section (COM, DRM1, DRM2, DRM3) on the terminal block.
WARNING
· Do not connect the DRED mains cable to the terminal block of the outdoor unit (Power supply and Indoor/Outdoor connecting). Improper
installation may result in fire.
· For the power supply of the DRED, prepare exclusive power supply separated from that of the outdoor unit.
Wiring between DRED (Demand response enabling device)
and Outdoor Unit
AS/NZS 4755 DRM1 DRM2 DRM3
This air conditioner complies with AS/NZS 4755.3.1.
DRM available: DRM1
The terminal block meets ELV requirements
Demand response mode Description
COM DRM1 DRM2 DRM3
· Read these "Safety precautions" carefully before installation.
· Install in accordance with the wiring rules (AS/NZS 3000).
· The precautions described below include important items regarding safety.
Observe them without fail.
· Ask the customer to keep this Manual together the Installation Manual.
· The manufacturer shall not assume any liability for the damage caused by not observing the description of this Manual.
·Turn off the main power supply switch or breaker before attempting installation.
Make sure all power switches are off. Failure to do so may cause electric shock.
·Connect the connecting wire correctly.
If the connecting wire is incorrect, electric parts may be damaged.
·Ensure that all terminals are securely fixed, so preventing any external forces having a negative effect on the terminals.
·Do not connect the DRED mains cable to the terminal block of the outdoor unit (Power supply and Indoor/Outdoor connecting).
Improper installation may result in fire.
·Connect the demand connecting wires and relay connector (RJ45) so that they do not come into contact with the refrigerant cycle
parts or refrigerant pipes.
Wire breakage or water intrusion may cause electric shock or fire.
·Do not screw the DRED signal receiver directly to the outdoor unit.
The screw may damage the internal parts and cause an electric shock, fire or refrigerant leak.
DRM1
DRM2
DRM3
Compressor off
Not available
Not available
4-1
CN101 CN104
CN102
CN100
MCC-1653
Trans-
former
Demand response interface
Outdoor control
P.C. board
DRED
Locally procured
To indoor
unit
Power supply
Single
phase
model
Three-
phase
model
COM DRM1 DRM2 DRM3
123LN L1L2
L3 N

– 7 –
4-3 Wiring procedure
1 Use fixing bands (locally procured) to attach the demand connecting wires securely to the attachment board so that the
connections are not affected by external forces.
If the demand connecting wires contain the relay connector (RJ45), perform the wiring so that water does not enter the relay
connector.
2 Secure the demand connecting wires to the Indoor/Outdoor connecting wire using a fixing band.
1 Use fixing bands (locally procured) to attach the demand connecting wires securely to the attachment board so that the
connections are not affected by external forces.
If the demand connecting wires contain the relay connector (RJ45), perform the wiring so that water does not enter the relay
connector.
2 Secure the demand connecting wires to the Indoor/Outdoor connecting wire using a fixing band and cord clamp.
Model name: RAV-SP1104AT-A1, RAV-SP1404AT-A1
RAV-SP1404AT8-A1, RAV-SP1604AT8-A1
RAV-SM1603AT-A1
Model name: RAV-SM2244AT8-A1, RAV-SM2804AT8-A1
DRED terminal block connections
Demand connecting wire
Fixing band
Attachment board
Indoor/Outdoor connecting wire
Fixing band
DRED terminal block connections
Demand connecting wire
Cord clamp
Attachment board
Indoor/Outdoor connecting wire
Fixing band
Fixing band

– 8 –
Diagnosis when compressor does not work
Disconnect the
connecting wiring
of DRED.
Remove wiring of
CN106 on DRED
P.C. board.
Normal
(Demand operation)
or DRED is failed.
Inverter Ass’y
is failed *1
Compressor works.
NO
YES
YES
YES
Demand P.C.
board is failed.
∗Refer to next page.
NO
NO
Compressor works.
Indoor thermostat
is off.
Exchange of Demand
P.C.board
NO
Indoor unit
satisfies ON conditions
of the compressor.
LED of the demand
P.C. board is on.
YES
When a failure with *1 appears,
advance the diagnosis further according
to the basic service manual.
Each condition is within the operating condition,
but the compressor does not work.
Operating conditions of air conditioner
Air conditioner demand response
Australian demand response model A1 series corresponds to DRED (Demand response enabling device) by AS/NZS
4755.3.1.
DRM1 is executed as follows, upon directions from the power company.
Be sure to confirm they are not operated before usually troubleshooting.
When a symptom such as the following table is found without a check code is not displayed on the remote controller,
there is a possibility that a demand operation or demand P.C. board is failed, therefore diagnose it according to the
following diagram.
Demand response mode Description
DRM1 Compressor off
DRM2 Not available
DRM3 Not available
5. TROUBLESHOOTING
5-1. Before Troubleshooting
5-2. Troubleshooting Procedure

– 9 –
Troubleshooting for Demand Unit
Demand P.C.
board failed.
Exchange of transformer,
exchange of Demand
P.C. board
Exchange of
Demand
P.C. board
Fuse
F100 is melted.
NO
NO
YES
Exchange of transformer,
exchange of Demand
P.C. board
YES
Exchange of transformer
YES
Short-circuit is
found between 1 and 2
pins of connector connected to
CN102 of
transformer.
Take off wiring of
CN102. Short-circuit is
found between “~” and
“~” of DB100.
NO

– 10 –
6. EXPLODED VIWES AND PARTS LIST
1
2
40
17
30
41
29
22
15
20
21
5
23 7, 8, 36
6, 9
16
3
27, 37
4, 25
35
34
24
31, 33
26, 32
28
18
42
13
19
12
14
45
43
44
40
38
39
10
11

– 11 –
Location No. Part No. Description Qfty/Set
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
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
2
1
1
1
2
3
1
1
3
1
1
1
1
1
1
1
1
1
3
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
43F19904
43F32441
43041794
43F47401
43F47669
43049739
43F50407
43F63317
43F97212
43100437
43100438
43100439
43100451
43100470
43100442
43100443
43107274
43107275
43107276
43109422
43120244
43122113
43121744
43146676
4314N092
43146687
43146724
43148170
4314G266
4314G269
4314N023
43146722
4314N025
4314Q031
4314Q032
43160591
43147194
4301P703
4301P729
43F60029
43155216
43158197
4316V537
43158234
43063240
HOLDER, SENSOR (TS)
NIPPLE, DRAIN
COMPRESSOR, DA422A3F-25M
BONNET, 3/8 IN
NUT, FLANGE
CUSHION, RUBBER
THERMOSTAT,BIMETAL
HOLDER,THERMOSTAT
NUT
PANEL, FRONT, PIPING
PANEL, BACK, PIPING
PANEL, FRONT
PANEL, ROOF
PANEL, SIDE
PANEL, AIR OUTLET
BASE ASSY
GUARD, FIN, SIDE
GUARD, FIN, BACK
HANGER
GUARD, FAN
FAN, PROPELLER, PB521
BELL MOUTH
MOTOR, FAN, ICF-280-100-1R
J0INT,CHECK
VALVE, PACKED, 9.52
VALVE, 4-WAY, STF-0401G
VALVE, BALL, SBV-JA5GTC-1, ROHS
ACCUMULATOR ASS'Y, 2.5L
CONDENSER ASSY, DOWN
CONDENSER ASSY, UP
VALVE, PLUS, MODULAING, UKV-25D100
COIL, SOLENOID, STF-01AJ502E1
COIL, PMV, UKV-A038
STRAINER, DIA 9.52
STRAINER
LEAD ASSY, COMPRESSOR
BONNET, 5/8 IN
MARK, TOSHIBA
MARK, INVERTER
FILTER,N0ISE
FILTER, NOISE
REACTOR, CH-65
PC BOARD ASSY, MCC-1653
TRASNFORMER, POWEER, TT-02-2
SUPPORTER, ASSY

– 12 –
Inverter Assembly
716, 717
712
718
711
705
714, 715 706
718
709, 710
713
704
707 708
702
703
701
(TD)
(TE)
(TO)
(TS)
Location No. Part No. Description Qfty/Set
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
43050425
43F63325
43150319
43155211
43160565
43160581
43160579
43163055
43160594
43160595
4316V532
4316V371
4316V372
43F60859
43060700
43282001
43183020
43F63248
SENSOR ASSY, SERVICE,TC(F6)
HOLDER, SENSOR (TE)
SENSOR ASSY, SERVICE,TD(F4)
CAPACITOR
TERMINAL BLOCK, 3P, 20A
TERMINAL,60A, 3P
TERMINAL,30A, 4P
HOLDER, SENSOR
FUSE, 50A, AC250V
HOLDER-FUSE
PC BOARD ASSY, CDB, MCC-1531
PC BOARD ASSY, A3-IPDU, MCC-1535
PC BOARD ASSY, NOISE-FILTER, MCC-1551
FUSE BLOCK, 30A, 250V
FUSE, 10A, 250V
BUSHING
COLLAR
SUPPORTER, ASSY

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