Toshiba RAV-103TUH-PE User manual

FILE No. A90-9611
SERVICE MANUAL
AIR CONDITIONER
SPLIT TYPE
2 WAY CASSETTE TYPE, HEATPUMP
RAV-103TUH-PE
RAV-133TUH-PE/RAV-132AH-PE
RAV-163TUH-PE/RAV-162AH-PE
Printed in UK Dec 1996
s

-2-
• Operating conditions of units are as follows:
Note 1 : Cooling Capacity is based on the following temperature conditions:
Indoor air inlet temperature 27°C DB, 19°C WB.
Outdoor air inlet temperature 35°C DB.
Note 2: Heating Capacity is based on the following temperature conditions:
Indoor air inlet temperature 20°C DB.
Outdoor air inlet temperature 7°C DB, 6°C WB.
Note 3: For details on the Remote Controller and Control Circuits
refer to Service Manual A90-9503.
OUTDOOR TEMPERATURE -2 TO 43°C (COOL)
-10 TO 21°C (HEAT)
ROOM TEMPERATURE 18 TO 32°C (COOL)
15 TO 29°C (HEAT)
ROOM HUMIDITY LESS THAN 80% (COOL)
CONTENTS
1. SPECIFICATION....................................................................................................................................................3
2. CONSTRUCTION VIEWS......................................................................................................................................6
3. WIRING DIAGRAM................................................................................................................................................8
4. SPECIFICATIONS OF ELECTRICAL PARTS........................................................................................................10
5. INTERFACE PCB.................................................................................................................................................12
6. REFRIGERANT PIPING DIAGRAM......................................................................................................................13
7. PERFORMANCE CHARACTER............................................................................................................................15
8. EXPLODED VIEWS AND PARTS LISTS...............................................................................................................17
SUMMARY
• The units referred to within this manual conform with the protection requirements of Directives 89/336/EEC
Electromagnetic Compatibility and 73/23/EEC Low Voltage.

-3-
MODEL
Power source
ITEM
Starting current
Power consumption
Running current
Power factor
Operating noise (SPL) (High, Med, Low)
Refrigerant
Phase
Hz
V
kW
%
A
A
dB(A)
Name of refrigerant
Interconnection
pipe
Larger side size
Coupler style
Smaller side size
Coupler style
mm
mm
Condensate drain pipe diameter
Appearance colour
Dimensions
Net weight
Heat exchanger type
Indoor fan type
Air volume
Fan motor output
Appearance colour
CEILING PANEL Model
Height
Width
Depth
mm
mm
mm
kg
m3/h
Net weight
Height
Depth
mm
mm
mm
kg
Dimensions Width
Air filter
Specifications are subject to change without notice.
RAV-103TUH-PE
1
220-240
50
0.07
93
0.33
0.6
R-22
Ø12.7
Flare
Ø6.4
Flare
Ø25.5(OD)
mm Grey (zinc galvanized steel
+ Thermal insulator)
RBC-U133PG(W)-PE
Silky white (Munsell 2.9Y8.9/0.8)
25
1050
550
4.5
Washable
Finned tube
Transverse flow fan
550
7 x 2
190
910
480
23
W
40/36/34
1.SPECIFICATION

-4-
MODEL
ITEM RAV-133TUH-PE
3.6
kW
kW 4.2Heatingcapacity
Coolingcapacity
1
50 HEATINGCOOLING
2.1 2.2
Power source
Powerconsumption
Power factor 89 89
Runningcurrent 10.3 10.7
Starting current
Operating noise (SPL)
Refrigerant
60
40/36/34
R-22
1.2
35
Refrigerantcontrol
Interconnectionpipe
Ø12.7
Flare
Ø 6.4
Flare
7.5
Hz
Phase
kW
%
A
A
dB(A)
dB(A)
kg
g/m
mm
m
Indoor unit (High, Med, Low)
Outdoor unit
Name of refrigerant
Charge volume
Add. volume (20-30m)
Larger side size
Coupler style
Smaller side size
Coupler style
Standard length
Maximum length
(of one way) *1 m 30
If indoor unit higher m 15
If outdoor unit higher m 30
Condensate drain pipe diameter mm
INDOOR UNIT Model RAV-133TUH-PE
Appearancecolour Grey (zinc galvanized steel + thermal insulator)
Capillary tube & Expansion valve
50
Dimensions Height mm 190
910
Width mm
Depth mm 480
Net weight kg 23
Heat exchanger type Finned tube
Indoor fan type Transverse flow fan
Air volume m3/h 700
Fan motor output W7x2
Air filter Washable
OUTDOOR UNIT Model RAV-132AH-PE
Appearancecolour Bronze white (Munsell 6Y7.5/1)
Dimensions Width mm
Depth mm
Height mm 740
880
310
Net weight kg 61
Ø 25.5 (OD)
Outdoor fan type Propellerfan
Air flow volume m3/h 2,700
Fan motor output W39
PH230X3-4LS
Compressor Model
1.5
Protective device High pressure switch, Fuse, Crankcase heater, Overload relay, Bimetal thermostat
mm
220-240
Finned tube
Appearancecolour Silky white (Munsell 2.9Y8.9/0.8)
Dimensions Width mm
Depth mm
Height mm 25
1050
550
Net weight kg 4.5
Washable
CEILING PANEL Model
Air filter
Specifications are subject to change without notice.
* Note 1 : These mean actual length.
RBC-U133PG(W)-PE
Heat exchanger type
Output kW
V
Maximum height difference

-5-
ITEM MODEL
Coolingcapacity kW
kW 4.5 5.0
Power source V
50
Powerconsumption kW
Power factor %
Runningcurrent A
Starting current
Operating
noise (SPL) Indoor unit (high/med/low) 41/37/35
50
R-22
35
Outdoor unit
Refrigerant
Name of refrigerant
Charge volume kg
Add. volume (20-30m) g/m Capillary tube & Expansion valve
Interconnection
pipe
Larger side size mm ø 12.7
Flare
mm ø 6.4
Coupler style Flare
Standard length m 7.5
Maximum length
(of one way) *1 m30
15m
m30
Condensate drain pipe diameter ø 25.5(OD)
RAV-163TUH-PE
Appearancecolour Grey (zinc galvanized steel + thermal insulator)
Dimensions Height
mm
mm 190
Width mm 910
Depth mm 480
Net weight kg 23
Heat exchanger type Finned tube
Transverse flow fan
750
Fan motor output 7 x 2
Air filter
Refrigerantcontrol
880
310
61
Finned tube
Propellerfan
2,700
39
Dimensions Height mm
Width mm
Depth mm
Heat exchanger type
Net weight
Outdoor fan type
Air flow volume
Fan motor output
Compressor Model
Output
A
kg
m3/h
kW
W
Hz
Bronze white (Munsell 6Y7.5/1)
740
INDOOR UNIT Model
Heatingcapacity
Smaller side size
Coupler style
Phase
Indoor fan type
Air volume
OUTDOOR UNIT Model
Appearancecolour
W
m3/h
Washable
1.6
RAV-163TUH-PE
1
220-240
COOLING
90
11.1
2.3 HEATING
2.2
90
10.6
60
RAV-162AH-PE
PH250X3-4LS
1.5
Protective device
CEILING PANEL Model
Appearancecolour
Dimensions Height
Width
Depth
mm
mm
mm
Net weight
Air filter
Specifications are subject to change without notice.
* Note 1 : These mean actual length.
High pressure switch, Fuse, Crankcase heater, Overload relay, Bimetal thermostat
RBC-U133PG(W)-PE
Silky white (Munsell 2.9Y8.9/0.8)
25
550
Washable
4.5
1050
If outdoor unit higher
If indoor unit higher
Maximum height difference
kg
dB (A)
dB (A)

-6-
2. CONSTRUCTION VIEWS
2.1 Indoor unit
RAV-103TUH-PE
RAV-133TUH-PE
RAV-163TUH-PE
Space required for service and installation
(Unit: mm)
550
View A
200
Ceiling opening 510
Panelouterdimension550
Hang bolt pitch 480
410
20
40
40
Hang bolt pitch 930
Ceilingopening1010
Panelouterdimension1050
73
131
96
186
267
170
156
140
190
1050
840
130
480
190
Long hole
Remote controller
600
Minimum Minimum
600
Minimum
70 70 Refrigerant piping joint
( Gas ∅ 12.7)
Wiring connection
840 110
90
66
20
40
60
290
Hanger bolt (4- M10) Refrigerant piping joint
( Liquid ∅ 6.4)
25
600
A
12.5
83.5
2-4.5 x 9L
120
Drain pipe joint (outer ∅ 25.5)

-7-
2.2 Outdoor unit
RAV-132AH-PE
RAV-162AH-PE
(2-(20 x 60) slots)
Hole for drain
(2-ø19 hole)
(Liquid side ∅ 6.4)
(Gas side ∅ 12.7)
Refrigerant piping joint
Anchor bolt hole
Blow out guide
mountinghole
(4-ø3 embosses)
(Space for wiring
andpiping)
Outlet
(Space for wiring
andpiping)
Space required for service
When installed with the
outlet faced to the wall side
When installed with the
inlet faced to the wall side
(Unit: mm)
(4-(12x18)slots) Air outlet
(Both sides)
Carryinghandle Electric parts
box Terminal cover
Refrigerant piping joint
Knock - out hole for drain
Earth screw (M6)

-8-
Shows terminal block and figures show terminal numbers. Broken lines show wiring at site. Do not operate the units with magnetic contactor pushed in.
Symbol Name Symbol Name FM Fan motor 43 Relay RC Running capacitor RY01~RY14 Relay TR Transformer SM01,02 Stepper motor TA Sensor CS Float switch TC Sensor DM Drain motor F Fuse (PCB) F3 Fuse (Interface PCB)
3.1 RAV-103TUH-PE
RAV-133TUH-PE
RAV-163TUH-PE
( )
RY01
output
Earth Screw
F2
Indoor unit Outdoor unit
(1 Phase model)
Remote Controller CS
43 CN10
(PUMP)
TR
RY01
RY14
CN01
(TRANS)
CN12
REMOCON UL L M H
TA
CN04
(TA)
CN05
(TC)
CN07 (FAN) TC
RY11
WHI
FM
CN09(LOUVER)
(L1) (N)
CN03
(SERIAL)
CN11
(FLOAT)
43
DM
F
Power Supply 220/240V 50Hz
Spark Killer
FM
01 02
BLU BLU
ORN
WHI
RED
RC02
RC01
SM
SM
01
02
TR
INTERFACE
PCB
3. WIRING DIAGRAM
ORN
BLK
BLK
RED
WHI WHI
YEL
YEL RED
YEL BLU ORN BLK
RED
F3
RY04 RY03 RY02

-9-
TR
3.2 RAV-132AH-PE
RAV-162AH-PE
Power Supply 220/240V 50Hz CH
Earth
Screw
Earth
RY07
F
1. Shows terminal block and figures show terminal numbers.
Broken lines show wiring at site.
Don't operate the units with magnetic contactor pushed.
CM
RCC
52C
TE
TL
BLK
TD
BLK
WHI
63H
52C
F2
Indoor unit
Outdoor unit
26HD
Wave
Control
Circuit
20SR20SF
Symbol Name Symbo Name Symbol Name
20SF Solenoid Coil (4 Way Valve) CM Compressor F2 Fuse (T5A)
RY05, 07 Relay 52C Magnetic Contactor 63H High Pressure Switch
51C Overload Relay FMo Fan Motor (Out door) CH Crank Case Heater
20SR Solenoid Coil (2 Way Valve) TL Sensor FFuse (on PCB)
RCc Running Capacitor (Compressor) TE Sensor TR Transformer
RCo Running Capacitor (Fan motor) 26HD Bimetal Thermostat TD Sensor
WHI
FM
0
RED
BLK
RED
BLU
BLK WHI WHI
RY05
RED
GRY
RED
RCO
51C

-10-
4.2.RAV-163TUH-PE
No. PARTS NAME TYPE SPECIFICATIONS
1Indoor unit fan motor (x2) PAF-230-7-4 Output (Rated) 7W, 4 pole, 1 phase, 230V, 50Hz
2Running capacitor for
indoor fan motor (x2) EVM45M504UF AC 450V, 0.5µF
3Transformer (Indoor unit) ST-9586 AC187~264V
4Stepper motor (x2) MP35EA2 DC12V, 80mNm
5Relay LY2F AC 240V, 2ab
6Drain pump PCD-4N230TF-7 AC230V, 0.2A
7Float switch FS-085-003E AC230V, 0.5A
8Sensor for room
temperature Maximum input 38mA °C 15 20 25 30 40
16.1 12.6 10.0 8.0 5.2
9Indoor unit sensor for
heat- exchanger
temperature. DTN-C103J40 Maximum input
34mA °C –12 025 50
62.29 32.82 10.0 3.59
4.1RAV-103TUH-PE,RAV-133TUH-PE
No. PARTS NAME TYPE SPECIFICATIONS
1Indoor unit fan motor (x2) PAF-230-7-4 Output (Rated) 7W, 4 pole, 1 phase, 230V, 50Hz
2Runnin
g
capacitor for indoor
fan motor (x2) EEP2H105HQA105 AC 500V, 1.0µF
3Transformer (Indoor unit) ST-9586 AC187~264V
4Stepper motor (x2) MP35EA2 DC12V, 80mNm
5Rela
y
LY2F AC 240V, 2ab
6Drain pump PCD-4N230TF-7 AC230V, 0.2A
7Float switch FS-085-003E AC230V, 0.5A
8Sensor for room temperature Maximum input
38mA °C 15 20 25 30 40
16.1 12.6 10.0 8.0 5.2
9Indoor unit sensor for heat-
exchan
g
er temperature. DTN-C103J40 Maximum input
34mA °C –12 025 50
62.29 32.82 10.0 3.59
KΩ
KΩ
KΩ
4. SPECIFICATION OF ELECTRICAL PARTS
KΩ

-11-
No. PARTS NAME TYPE SPECIFICATIONS
1Compressor PH250X3-4LS Output (Rated) 1.5 kW, 2 pole, 220/240V, 1 phase, 50Hz
2Outdoor unit fan motor SMF-230-39N-2 Output (Rated) 39W, 6 pole, 230V, 1 phase, 50Hz
3Running capacitor for outdoor
fan motor EEP2G405HQA114 AC 400V, 4 µF
4Magnetic contactor FMca-1S AC 220-240V, 50Hz
5High pressure switch ACB-2TBO4W Tripping pressure 30kg/cm²G
Resetting pressure 23kg/cm²G
6Solenoid coil for four-way valve CHV-AC240V AC 220-240V
7Crankcase heater AC 240V, 28W
8Sensor for defrosting Maximum input
15.5mA
°C –12 10
67.5 21.3
9Fuse T5A
10 Sensor for cooling operation in low
ambient temperature Maximum input 15.5mA
°C –12 10
67.5 21.3
11 Solenoid coil for two-way valve NEV AC 240V AC 220-240V, 50Hz
12 Running capacitor for compressor MT-44MP456W AC 440V 45µF
13 Transformer
(Outdoor unit) FT-67 AC 187-264V
14 Overload relay OL-177GM15 AC 240V, Tripping temp: 165°C, Resetting temp: 80°C
15 Bimetal thermostat CS-7 Tripping temp: 110°C, Resetting temp 90°C
4.3 RAV-132AH-PE
No. PARTS NAME TYPE SPECIFICATIONS
1Compressor PH230X3-4LS Output (Rated) 1.5 kW, 2 pole, 220/240V, 1 phase, 50Hz
2Outdoor unit fan motor SMF-230-39N-2 Output (Rated) 39W, 6 pole, 230V, 1 phase, 50Hz
3Running capacitor for outdoor
fan motor EEP2G405HQA114 AC 400V, 4 µF
4Magnetic contactor FMca-1S AC 220-240V, 50Hz
5High pressure switch ACB-2TBO4W Tripping pressure 30kg/cm²G
Resetting pressure 23kg/cm²G
6Solenoid coil for four-way valve CHV-AC240V AC 220-240V
7Crankcase heater AC 240V, 28W
8Sensor for defrosting Maximum input
15.5mA
°C –12 10
67.5 21.3
9Fuse T5A
10 Sensor for cooling operation in low
ambient temperature Maximum input 15.5mA
°C –12 10
67.5 21.3
11 Solenoid coil for two-way valve NEV AC 240V AC 220-240V, 50Hz
12 Running capacitor for compressor MT-44MP456W AC 440V 45µF
13 Transformer
(Outdoor unit) FT-67 AC 187-264V
14 Overload relay OL-177GM15 AC 240V, Tripping temp: 165°C, Resetting temp: 80°C
15 Bimetal thermostat CS-7 Tripping temp: 110°C, Resetting temp 90°C
KΩ
KΩ
4.4 RAV-162AH-PE
KΩ
KΩ

-12-
5. INTERFACE PCB FOR LOUVER OPERATION
An additional PCB, referred to as the Interface PCB, is fitted to this unit to operate the dc stepper motors,
which drive the louvers. The power supply to the interface PCB is via relay RY11 on the indoor PCB.

-13-
Cooling
Heating
6. REFRIGERANT PIPING DIAGRAM
Refrigerant pipe (Smaller side)
ø6.4mm (1/4 " )
Strainer
Heat exchanger
Indoor unit
Distributor strainer
capillarytube
IDø1.5 x 300 l x 2P
Refrigerant pipe (Larger side)
ø12.7mm (1/2 " )
6.1 Indoor unit
RAV-103TUH-PE

-14-
Cooling
Heating
Packedvalve
Packedvalve
Strainer
Capillarytube
ø2.4 x 500 L x 1P
Checkvalve
Refrigerantpipe(Smallerside)
ø6.4mm(1/4 " )
Strainer
Heatexchanger
Indoorunit
Distributor
Strainer
Refrigerantpipe(Larger side)
ø12.7mm(1/2 " )
6.2 Indoor unit
RAV-133TUH-PE
RAV-163TUH-PE
Distributorstrainer
capillarytube
Low pressure High pressure
P1
P2
Cooling Heating
High pressure Low pressure
LinePressure
RAV-133TUH-P
RAV-163TUH-P IDφ 2.2x200 L x2P IDφ 1.5x200 L x2P RAV-132AH-PE RAV-162AH-PE
BYPASS
CAPILLARY
INDOORUNIT OUTDOOR UNIT
MODEL CAPILLARY MODEL MAIN
CAPILLARY
IDφ 2.4x500 L x1P IDφ 0.8x1000 L x1P
Compressor
Accumulator
2-way
valve
Expansion
valve
Dryer
Checkjoint
TEsensor
TLsensor Heatexchanger
Four-wayvalve
Highpressureswitch
Outdoorunit
BypassCapillarytube
ø0.8 x 1000 L x 1P
Outdoor unit
RAV-132AH-PE
RAV-162AH-PE

-15-
Ambient Temp. (Dry Bulb) (oC)
Capacity Ratio (%)
Ambient Temp. (Wet Bulb) (oC)
Room Temp. (Wet Bulb) (oC)
Room Temp. (Dry Bulb) (oC)
7. PERFORMANCE CHARACTER
7.1 Cooling capacity
7.2 Heating capacity
-2 ~
Capacity Ratio (%)
RAV-132AH-PE
2.88
3.06
3.24
3.42
3.60
3.78
3.96
4.14
4.32
RAV-162AH-PE
3.60
3.82
4.05
4.28
4.50
4.73
4.95
5.18
5.40
RAV-132AH-PE
5.04
4.83
4.62
4.41
4.20
3.99
3.78
3.57
3.36
3.15
2.94
2.73
2.52
2.31
RAV-162AH-PE
6.00
5.75
5.50
5.25
5.00
4.75
4.50
4.25
4.00
3.75
3.50
3.25
3.00
2.75
(KW)
(KW)

-16-
7.3 Cooling capacity
RAV-132AH-PE
RAV-162AH-PE
Indoor Unit
Outdoor Unit
Heating Capacity Ratio
Piping Length (m)
Cooling Capacity Ratio
Piping Length (m)
Outdoor Unit Height H (m)
Outdoor Unit Height H (m)
7.4 Piping length/additional refrigerant volume
45 5
0.95
Recharge quantity (kg)
30
1.55
25
1.35
Additional amount of refrigerant
at installation site (kg)
40 50 20
1.20
20
Filled at
factory
Piping length
less than (m)
Model
30
30
RAV-132AH-PE
lThe amount of refrigerant put into the outdoor unit at the factory is equivalent to that which fills up 20m length of refrigerant pipe.
lIf the length of refrigerant pipe is 20m or less, addition of refrigerant at the installation site is unnecessary. If the length of the pipe
exceeds 20m, add the refrigerant R-22.
lOvercharge or undercharge of refrigerant in the outdoor unit will cause malfunction of the compressor. The prescribed amount of
the replenishment of the refrigerant is shown in the table above.
The permissible amount of refrigerant is the prescribed amount ±50g.
Filled at
factory
RAV-162AH-PE
35
30
0.35
25
0.15
0.15 0.35
10
1.05
15
1.10
1.35 1.45 1.50 1.60 1.75 1.95

Location Part No Description
No
214 43039240 Canoe Clip
215 43A72001 Drain Pan
216 43A88004 Manual
217 43155086 Spark Killer
218 43A69008 Interface PC Board
219 37555721 Capacitor, Metal Film (RAV-103/133TUH-PE)
219 43155100 Capacitor, Metal Film (RAV-163TUH-PE)
220 43A69002 PC Board
221 43A58002 Transformer
222 43154141 Relay
223 43A62001 Cover, Remote Controller
224 43A69004 Remote Controller
225 43A50002 Sensor (TC)
226 43150118 Sensor (TA)
-17-
Location Part No Description
No
201 43A22001 Casing Assembly
202 43020288 Fan
203 43151217 Float Switch
204 43A70003 Pump Assembly
205 43020253 Bearing
206 43071019 Drain Connection
207 43070164 Drain Hose
208 43A60002 3 P Terminal
209 43A60001 4 P Terminal
210 43A21014 Fan Motor
211 43019604 Sensor Fix Plate
212 43A22002 Casing Outlet
213 43A44012 Heat Exchanger (RAV-103TUH-PE)
213 43A44010 Heat Exchanger (RAV-133TUH-PE)
213 43A44011 Heat Exchanger (RAV-163TUH-PE)
8. EXPLODED VIEWS AND PARTS LIST
8.1 Indoor unit
RAV-103TUH-PE
RAV-133TUH-PE
RAV-163TUH-PE

-18-
8.2 CEILING PANEL
RBC-U133PG(W)-PE
Location Part Description
number Number
1 43080392 Filter
2 43007108 Plate connect (long)
3 43009504 ASM-Grille-Out
4 43007107 Bushing
5 43007109 Plate connect (short)
Location Part Description
number Number
6 43009503 Grille-L-R
7 43007124 Supportplate
8 43009499 ASM-Grille-Out
9 43A26001 ASM-Motor
10 43007125 Supportplate
1
1
3
10
5
4
7
6
4
7
9
55
2
2
74
28
28
4

-19-
8.3 Outdoor unit
RAV-132AH-PE
RAV-162AH-PE
Location
No. Part No. Description
25 43041837 Compressor, AC220/240V,
50Hz, PH230X3-4LS (RAV-132AH-PE)
25 43041845 Compressor, AC220/240V,
50Hz, PH250X3-4LS (RAV-162AH-PE)
26 43146454 Packed Valve (1/4")
27 43146406 Packed Valve (1/2")
28 43147321 Check Joint
29 43146424 Expansion Valve
30 43046198 Coil, 2-Way Valve
31 43146283 1-Way Valve
33 43A58003 Transformer, Power
34 43046151 Valve, 2-Way
35 43193043 Spring
36 43A50001 Sensor, Cond. Out (TL)
37 43150196 Sensor, Heat Exch. (TE)
38 43146418 Valve 4-Way
39 43157167 Heater, Crankcase
41 43146459 Capillary Tube
42 44246235 Capillary Tube
43 43150122 Thermostat, Bimetal
44 43107215 Holder, Sensor (TL)
Location
No. Part No. Description
143120156 Fan, Propeller
243A21003 Motor, Fan, AC230V, 50Hz
343A43001 Condenser
443149212 Base, Spring, A
543149198 Spring, Buffer
643049132 Base, Spring, B
743A69003 PC Board
843A49001 Switch, High-Pressure
943060479 Terminal, 4P
10 43A60003 Terminal, 2P
11 43A60001 Terminal, 4P
12 43152334 Magnetic Contactor
13 43054286 Relay, Overload
14 43A19001 Guard, Fan
15 43119368 Hanger
16 43A46004 Solenoid Coil
17 43162027 Cover, Electric Parts
18 43155115 Capacitor, Plastic Film, 45MFD, 440V
20 43107215 Holder, Sensor (TE)
22 43148105 Accumulator
23 43145082 Dryer
24 43155080 Capacitor, Electrolytic

-1-