Toshiba RAV-SM560XT-E User manual

FILE NO. SVM-03021
SERVICE MANUAL
AIR-CONDITIONER
UNDER CEILING / CONSOLE TYPE
RAV-SM560XT-E / RAV-SM560AT-E
RAV-SM800XT-E / RAV-SM800AT-E
Sep., 2003
R410A

CONTENTS
1. SPECIFICATIONS............................................................................................................. 1
2. CONSTRUCTION VIEWS ................................................................................................. 4
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ...................................................... 7
4. WIRING DIAGRAM ........................................................................................................... 9
5. SPECIFICATION OF ELECTRICAL PARTS .................................................................. 12
6. REFRIGERANT R410A .................................................................................................. 13
7. CONTROL BLOCK DIAGRAM.......................................................................................21
8. OPERATION DESCRIPTION..........................................................................................22
9. INSTALLATION PROCEDURE....................................................................................... 27
10. TROUBLESHOOTING CHART ...................................................................................... 46
11. DETACHMENTS .............................................................................................................60
12. EXPLODED VIEWS AND PARTS LIST.......................................................................... 80

– 1 –
1. SPECIFICATIONS
1-1. Indoor Unit
Model name RAV-SM560XT-E RAV-SM800XT-E
Cooling Heating Average Cooling Heating Average
Standard capacity (Note 1) kW 5.0 5.6 6.7 8.0
(1.5 – 5.6) (1.5 – 6.3) (2.2 – 8.0) (2.2 – 9.0)
Heating low temp.capacity (Note 1) (kW) 4.9 5.8
Energy consumption effect ratio (Cooling) 2.67 [D] 3.29 [C] 2.98 2.46 [E] 3.00 [D] 2.73
Power supply 1 phase 220 – 240V 50Hz
Running current (A) 8.95 – 8.20 8.13 – 7.46 13.15 – 12.06 12.91 – 11.84
Power consumption (kW) 1.87 1.7 2.72 2.67
(Low temp.) (kW) 2.18 2.29
Power factor (%) 95 95 94 94
Main unit Pure white
Appearance Ceiling panel Model –––
(Sold separately) Panel color –––
Height (mm) 633
Main unit Width (mm) 1093
Outer Depth (mm) 208
dimension Height (mm) –––
Width (mm) –––
Depth (mm) –––
Total weight Main unit (kg) 23
Ceiling panel –––
Heat exchanger Finned tube
Fan Multi blade fan
Fan unit Standard air flow High (Mid./Low) (m3/h) 800 (680/580) 900(750/550)
Motor (W) 50
Air filter Washable filter
Controller (Sold separately) Wireless remote control
Gas side (mm) ∅12.7 (1/2”) ∅15.9 (5/8”)
Dimensions pipe Liquid side (mm) ∅6.4 (1/4”) ∅9.5 (3/8”)
Drain port (Nominal dia.) 25 (Polyvinyl chloride tube)
Sound level High (Mid./Low) (Note 2) (dB•A) 43 39 36 46 42 37
Electrical
characteristics
Note 1 : The cooling capacities and electrical characteristics are measured under the conditions specified by JIS B 8616
based on the reference piping length 7.5 m with 0 meter height.
Note 2 : The sound level is measured in an anechoic chamber in accordance with JIS B8616.Normally, the values
measured in the actual operating environment become larger than the indicated values due to the effects of
external sound.
Note : Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB
Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB
Ceiling panel
(Sold separately)

• Operation characteristic curve
<Cooling> <Heating>
• Capacity variation ratio according to temperature
<Cooling> <Heating>
0020
15
40 60 70 80 100
2
4
6
8
10
12
14
Compressor speed (rps)
Current (A)
• Conditions
Indoor : DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
230V
RAV-SM560XT-E
0020
15
40 60 80 90 100
2
4
6
8
10
12
14
Compressor speed (rps)
Current (A)
RAV-SM800XT-E
RAV-SM560XT-E
• Conditions
Indoor : DB20˚C
Outdoor : DB7˚C/WB6˚C
Air flow : High
Pipe length : 7.5m
230V
50
55
60
65
70
75
80
85
90
95
100
105
32 33 34 35 36 37 38 39 40 41 42 43
Outsoor temp. (˚C)
Capacity ratio (%)
• Conditions
Indoor : DB27˚C/WB19˚C
Indoor air flow : High
Pipe length : 7.5m 0
10
20
30
40
50
60
70
80
90
100
110
120
-14-12-10-8-6-4-20246810
Outsoor temp. (˚C)
Capacity ratio (%)
• Conditions
Indoor : DB20˚C
Indoor air flow : High
Pipe length : 7.5m
RAV-SM800XT-E
–2–

1-2.Outdoor Unit
Note 1 : The sound level is measured in an anechoic chamber in accordance with JIS B8616.Normally, the values measured in
the actual operating environment become larger than the indicated values due to the effects of external sound.
Note 2 : Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB
Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB
Model name
Appearance
Power supply
Type
Compressor Motor (kW)
Pole
Refrigerant charged (kg)
Refrigerant control
Standard length
Max. total length (m)
Pipe Over 20m
Height difference Outdoor lower (m)
Outdoor higher (m)
Outer Height (mm)
Width (mm)
dimension Depth (mm)
Total weight (kg)
Heat exchanger
Fan
Fan unit Standard air flow High (m³/h)
Motor (W)
Connecting Gas side (mm)
pipe Liquid side (mm)
Protection device
Sound level High (Mid./Low) (dB•A)
(Note 2) (Cooling/Heating)
RAV-SM560AT-E RAV-SM800AT-E
Silky shade (Muncel 1Y8.5/0.5)
1 phase 230V (220 – 240V) 50Hz
(Power exclusive to outdoor is required.)
Hermetic compressor
1.1 1.6
4 poles
R410A 0.9 R410A 1.5
Pulse motor valve
20 (without additional charge)
30 50
Add 20g/m (Max. 200g) Add 40g/m (Max. 1200g)
15
30
595 795
780 780
270 270
35 55
Finned tube
Propeller fan
2400 3400
43 63
Ø12.7 (1/2”) Ø15.9 (5/8”)
Ø6.4 (1/4”) Ø9.5 (3/8”)
Discharge temp. sensor
Over-current sensor
Compressor thermo.
46/48 48/50
– 3 –

2. CONSTRUCTIONVIEWS
2-1. Indoor Unit
Front panel
Knock out system
For stud bolt
(Ø8 – Ø10)
For stud bolt (Ø6)
Grille air inlet
Back body
Installation plate
Mount plate
M10 Suspention bolt
Wireless remote control
Knock out system
200 Min 1093
1015
742
450
20 20
330165
Ø74
70 Min 633
460
57 18
160
633
208
1093
UNDER CEILING & CONSOLE INSTALLATION
– 4 –

2-2.Outdoor Unit (RAV-SM560AT-E)
Drain hole (Ø25) Drain hole (2-Ø20 x 88 long hole)
83
30
600
780
115.3 125
97
30
21 76
308
(Long hole pitch
For anchor bolt)
153 150
11
302
Ø6 hole pitch
2927031 330
A legs
B legs
Space required for service
Protective net mounting hole
(4-Ø4 embossing)
43 707 30
60
475
Refrigerant pipe connecting port
(Ø12.7 flare at gas side) Refrigerant pipe connecting port
(Ø6.4 flare at liquid side)
31
31 134
23
115.3
49.5
25 220
147
500 (Fan center dividing)
90.6
132
598 593 521 21
(49.3)
Discharge guard Discharge guide mounting hole
(4-Ø4 embossing)
500 (Fan center dividing)
Protective net mounting hole
(2-Ø4 embossing)
21
216
Charge port
Earth
terminal
Valve cover
365
600
2-Ø11 x 14 U-shape holes
(For Ø8–Ø10 anchor bolt) Suction port
Discharge
port
Discharge
port
(Minimum
distance up to wall)
2-Ø11 x 14 long hole
(For Ø8–Ø10 anchor bolt)
500
or more
150
or more
300
or more
150 or more
600
308 11
308 302
11
302
52
36
52
36
R15 2-Ø6 hole
Product
external line
Product
external
line
Ø11 x 14 U-shape hole
Ø11 x 14 U-
shape holes 2-Ø6 hole
R15
600
Details of A legs Details of B legs
– 5 –

2-3.Outdoor Unit (RAV-SM800AT-E)
365 17.517.5
21
21
40 70
29 90 191 20
40
39 47
43
43
95
300150
6026
Knockout
(For draining)
Knockout
(For draining)
Drain hole (Ø20 x 88 burring hole)
Drain hole (Ø25 burring hole)
Part A
Part B
(Long hole pitch for anchor bolt)
Suction
port
Suction
port
Discharge
port
Z
1
2
6760
264
565 101
154
900
2760
96
307
300
314
Handles
(Both sides)
Refrigerant pipe connecting port
(Ø9.5 flare at liquid side)
Refrigerant pipe connecting port
(Ø15.9 flare at gas side)
Discharge guide
mounting hole
(4-Ø4 embossing)
1
1
2
2
795
85
165
60 80
25
60 90
32028
400
161
58
46
30 45
27
Space required for service
365
600
2-Ø12 x 17 U-shape holes
(For Ø8–Ø10 anchor bolt)
Suction port
Discharge
port
Discharge
port
(Minimum
distance up to wall)
2-Ø12 x 17 long hole
(For Ø8–Ø10 anchor bolt)
500
or more
150
or more
150
or more
150 or more
58 7
86 7
Knockout for lower piping
Z views
17.5
4040
17.5
Installation bolt hole
(Ø12 x 17 U-shape holes)
Installation bolt hole
(Ø12 x 17 U-shape holes)
Details of B part
Details of A part
– 6 –

– 7 –
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM
3-1.RAV-SM560XT-E / RAV-SM560AT-E
Pressure Pipe surface temperature (°C)
(MPa) Discharge Suction Indoor heat Outdoor heat Indoor
exchanger exchanger fan
Pd Ps (TD) (TS) (TC) (TE) Indoor Outdoor
Standard 3.1 0.9 85 13 10 47 74 HIGH 27/19 35/–
Cooling Overload 3.8 1.0 96 13 12 60 71 HIGH 32/24 43/–
Low load 0.9 0.5 25 7 10 5 28 LOW 18/15.5 –5/–
Standard 2.8 0.6 87 3 46 1 87 HIGH 20/– 7/6
Heating Overload 3.3 1.1 78 22 55 16 55 LOW 30.– 24/18
Low load 1.7 0.2 110 –20 26 –22 110 HIGH 0 –20/(70%)
Indoor/Outdoor
temp. conditions
(DB/WB) (°C)
Compressor
revolutions
per second
(rps)
*
* 4 poles are provided to this compressor.
The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.
Indoor unit
Outdoor unit
TCJ
sensor
Air heat exchanger
Strainer
TC sensor
Refrigerant pipe
at liquid side
Outer dia. ∅B
Refrigerant pipe
at gas side
Outer dia. ∅A
Packed valve
Outer dia. ∅BPacked valve Outer dia. ∅A
Max
30m
TS sensor
TD sensor
TO sensor
TE
sensor
Distributor
4-way valve
(VT7101D)
Muffler
∅19 x L160
Rotary compressor
(DA130A1F-23F)
Heat exchanger
∅8 multiple thread
ripple 1 row 22 stages
FP1.3 flat fin
PMV
(SKV-18D26)
R410A 0.9 kg
Cooling
Heating
Outer diameter of refrigerant pipe
Gas side ∅A Liquid side ∅B
6.4 mm 12.7 mm

– 8 –
3-2.RAV-SM800XT-E / RAV-SM800AT-E
Indoor unit
Outdoor unit
TCJ
sensor
Air heat exchanger
Strainer
Strainer
TC sensor
Refrigerant pipe
at liquid side
Outer dia. ∅B
Refrigerant pipe
at gas side
Outer dia. ∅A
Packed valve
Outer dia. ∅BPacked valve Outer dia. ∅A
Max
50m
TS sensor
Accumulator
(1500cc)
TD sensor
TO sensor
TE
sensor
4-way valve
(STF-0213Z)
∅25 x L160
Rotary compressor
(DA220A2F-20L)
Heat exchanger∅8
1 row 30 stages
FP1.3 flat fin
Modulating (PMV)
(SKV-18D26)
Capillary
∅3 x ∅2
x L530
∅25 x L210
Muffler
R410A 1.5 kg
Cooling
Heating
PsPd
Pressure Pipe surface temperature (°C)
(MPa) Discharge Suction Indoor heat Outdoor heat Indoor
exchanger exchanger fan
Pd Ps (TD) (TS) (TC) (TE) Indoor Outdoor
Standard 3.3 0.9 89 8 8 40 64 HIGH 27/19 35/–
Cooling Overload 3.7 1.1 87 17 14 46 45 HIGH 32/24 43/–
Low load 1.0 0.8 22 2 1 1 24 LOW 18/15.5 –5/–
Standard 3.3 0.6 93 0 54 0 70 HIGH 20/– 7/6
Heating Overload 3.1 1.1 75 20 52 15 24 LOW 30.– 24/18
Low load 2.0 0.2 90 –26 25 –25 90 HIGH 0 –20/(70%)
Indoor/Outdoor
temp. conditions
(DB/WB) (°C)
Compressor
revolutions
per second
(rps)
*
* 4 poles are provided to this compressor.
The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.
Outer diameter of refrigerant pipe
Gas side ∅A Liquid side ∅B
9.5 mm 15.9 mm

Color
Identification
BRW
RED
WHI
YEL
BLU
BLK
GRY
PNK
ORN
GRN&YEL
GRN
PUR
:
:
:
:
:
:
:
:
:
:
:
:
BROWN
RED
WHITE
YELLOW
BLUE
BLACK
GRAY
PINK
ORANGE
GREEN&
YELLOW
GREEN
PURPLE
SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS
Diagnosis result
Check to see if OPERATION indicator goes on and off when the main switch
or breaker is turned on.
Check the power supply voltage between 1 - 2 (Refer to the name plate.)
Chack the fluctuate voltage between 2 - 3 (DC15 to 60V)
Check to see if the fuse blows out. (Check the varistor. : R22, R21)
Check the voltage at the No.8 pin on CN13 connector of the infrared receiver.
(Check the transformer and the power supply circuit of the rated voltage.)
Check the voltage at the brown lead of the louver motor.
(Check the transformer and the power supply circuit of the rated voltage.)
Check items
OPERATION
indicator
Terminal
block
Fuse
6.3A
DC 5V
DC 12V
1
2
3
4
5
1
2
21
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
INFRARED RAYS RECEIVE
AND INDICATION PARTS
SWITCH PCB
MCC-1428B
BRW
RED
ORN
YEL
PNK
BLU
BLU
WHI
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
CN13
CN07
CN100 CN402 J401
C01
R01
DB01
C02
DC12V IC03
C501
R405
R21
R22
SG01 F01
T6.3A
FUSE
250VAC
R09
R507
CR401
RY401
R506
CR502
RY501
CR501
CN05 CN03
CN01
CN10
CN11
CN401
CN23
FOR FLOAT SWITCH
(OPTION)
When you use float
switch you should cut J401
HEAT
EXCHANGER
SENSOR
(TCJ)
THERMO
SENSOR
(TA)
HEAT
EXCHANGER
SENSOR
(TC)
CN101
CN25
1
2
4
5
3
3
21 3
21 3
21 3
WHI
GRY GRY
WHI
RED
WHI
RED
BLK
BLK
BLK
BLK
BLK
BLK
BLK
BLK CN30
P04 CN31
WHI RED
BRW
POWER
SUPPLY
CIRCUIT
C15
IC04
DC5V
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
66
5
4
3
2
1
5
4
3
2
1
66
GRY
YEL
BLU
PUR
GRY
100”C
FAN-MOTOR
FOR DRAIN PUMP
(OPTION)
MCC-1428A
INDOOR
UNIT
LOUVER
MOTOR
OUTDOOR
UNIT
GRN&YEL
INDOOR
TERMINAL
BLOCK
1
21 2
1
21 2
21
21
21
21
4. WIRING DIAGRAM
4-1. Indoor Unit
– 9 –

4-2. Outdoor Unit (RAV-SM560AT-E)
SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS
Diagnosis result
TERMINAL BLOCK
There is no supply voltage
(AC220 to 240V) between L - N , 1 - 2
There is no voltage (DC15 to 25V) 2 - 3
Power supply and connecting
cable check
Check
items
FUSE
T25A 250V to fuse (F01) blown
T3.15A 250V to fuse (F04) blown
Converter module (DB01) and
electrolytic capacitor (C12 to C14) check
IGBT module (Q200) check
Fan motor check
ELECTROLYTIC CAPACITOR VOLTAGE (C12, C13, C14)
DC320V not available between
+ – terminal of electrolytic capacitor T25A fuse (F01) check P.C.board and converter
module (DB01) check
INVERTER OUTPUT (Inverter and compressor connector out of position)
(Please confirm within six minutes after instructing in the drive.)
Voltage between each line of inverter side
conector pins are not equal. IGBT module and P.C. board check
CM
PMV
FM
TE
TD
TO
TS
IGBT
DB01
CT
Q300
: Compressor
: Pulse modulating valve
: Fan motor
: Heat exchanger Temp. Sensor
: Discharge Temp.Sensor
: Outdoor Temp.Sensor
: Suction Temp.Sensor
: Insulated Gate Bipolar Transistor
: Converter module
: Curreut Transformer
: Fan motor driver module
NOTE
Color Identification
BLK
BLU
RED
GRY
PNK
GRN
:
:
:
:
:
:
BLACK
BLUE
RED
GRAY
PINK
GREEN
WHI
BRW
ORN
YEL
PUR
:
:
:
:
:
WHITE
BROWN
ORANGE
YELLOW
PURPLE
P10
ORN
BRW
BZ BY BX EW BW EV BV EU BU
BLU
P09
P19P20
CT
C12
C13
C14
REACTOR
THERMOSTAT
FOR
COMPRESSOR
P08 P07
CN500
CN600 TE
TD
TO
TS
CN601
CN602
CN603
CN701
CN703
F01
P06 BLK
FUSE
T25A
250V~
P.C. BOARD
(MCC-813)
VARISTOR
SURGE
ABSORBER
RELAY
P02
P11
P12
P13
P14
CN300
Q300
CN301
P03
P01
ORN WHI
PUR
BLK
FAN MOTOR
REACTOR
POWER
SUPPLY
220 to 240
50Hz
TO
INDOOR
UNIT
P17 P18
RED WHI BLK
YEL
PNK
GRY
FM
BLK
YEL
RED
ORN
RED
GRY
1
2
3
4
3
4
2
2
1
PULSE
MODULATING
VALVE
PMV
COIL FOR
4-WAY VALVE
N
L
3
2
1
+
–
+
–
+
–
POWER
RELAY
ELECTRONIC
STARTER
F04
FUSE
T3. 15A
250V~
DB01
Q200 CONVERTER
MODULE
IGBT MODULE
GEA
~
–
~
+
COMPRESSOR
RED WHI BLK
P21 P22 P23
CM
WHITE (S) BLACK (C)
RED (R)
TERMINAL OF COMPRESSOR
The sign in ( ) is displayed
in the terminalcover
11 22
11 22
11
33 22
11
33 22
11
33 22
44
66 55
11
33 22
2 1
2 1
2 1
2 1
2 1
2
3
3 1
2 1
2 1
2 1
2 1
3
3
2 1
21
4 3
43
5
5
– 10 –

Diagnosis result
TERMINAL BLOCK
There is no supply voltage
(AC220 to 240V) between L - N , 1 - 2
There is no voltage (DC15 to 25V) 2 - 3 Connecting cable check
1
2
3
4
FUSE
25A fuse (F01) blown, 15A fuse (F02) blown
3.15A fuse (F04) blown,
T5A fuse (F300) blown (SUB P.C. board)
T3.15A fuse (F01) blown (SUB P.C. board)
Converter module (DB01) and electrolytic
capacitor (C10 to C13) check IGBT
module (Q200) check, Fan motor check
SUB P.C. board check
ELECTROLYTIC CAPACITOR VOLTAGE (C10, C11, C12, C13)
DC320V not available between
+ terminal of electrolytic capacitor 25A fuse (F01) check P.C. board and coverter
module (DB01) check
INVERTER OUTPUT (CN09, CN10, CN11)
(Please confirm within six minutes after instructing in the drive.)
Voltage between each line of inverterside
conector pins are not equal. IGBT module and P.C. board check
Color Identification
BLK
BLU
RED
GRY
PNK
GRN
:
:
:
:
:
:
BLACK
BLUE
RED
GRAY
PINK
GREEN
WHI
BRN
ORN
YEL
PUR
:
:
:
:
:
WHITE
BROWN
ORANGE
YELLOW
PURPLE
3
2
1
3
2
1
2
12 1
5
4
1
5
4
3
2
3
21
3
1
3
1
6
5
4
3
2
1
6
5
4
3
2
1
ORN
ORN
VARISTOR
T02
CT
G
E
A
~
~
+
DB01
Converter
module
SURGE
ABSORBER
PHOTO COUPLER
P.C. BOARD
(MCC-1359)
SUB
P.C. BOARD
(MCC-1398)
F01
FUSE
T3.15A
F01
FUSE
25A
CN01
CN02
P12
P09
P11
P13
P19
P18
P17
P20
P10
RY01
R05
R06
CN04
CN800
CN302
CN06
CN05
CN04
C13
CN03
CN02CN01
CN702
THERMOSTAT
FOR
COMPRESSOR
CN500
CN700
CN300
CN301
BLKWHIRED
ORN
BRN
BZ
BY
BX
EW
BW
EV
BV
EU
BU
CN09
CN10
CN11
CN600 TD
3
2
1
3
1
GRN
CN604 TE
2
12 1
BLK
WHI
RED
Compressor
FAN MOTOR
4-WAY VALVE COIL
CN601 TO
2
12 1
CN605 TS
2
12 1
3
1
3
1
3
1
3
1
BLU
YEL
2
12 12 12 1
ORN
2
12 12 12 1
PNK
RED
3 3 3 3
BLU
4 4 4 4
WHI
5 5 5 5
BLK
CN13
2
12 12 12 1
RED
3 3 3 3
4 4 4 4
WHI
5 5 5 5
BLK
Fan
circuit
CM
FM
PMV
T03
CT
T04
CT
Q200
IGBT
POWER SUPPLY CIRCUIT
(FOR P.C. BOARD)
module
C12
C11
C10
+
3
1
F02
FUSE
15A
F04
FUSE
3.15A
F300
FUSE
T5A
2
12 1
REACTOR
POWER
RELAY
P08
P15
P14
2
12 1
REACTOR
REACTOR
RED
TO
INDOOR
UNIT
POWER
SUPPLY
220-240V
~50Hz
GRY
WHI L N2 31
231 231
BLU
YEL
WHITE(S) BLACK(C)
RED(R)
TERMINAL OF COMPRESSOR
The sign in ( )
is displayed
in the terminal
cover
2
2
2
1
2
3
2
4
Check
items
4-3. Outdoor Unit (RAV-SM800AT-E)
SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS
– 11 –

– 12 –
5-2. Outdoor Unit (RAV-SM560AT-E)
5. SPECIFICATION OF ELECTRICAL PARTS
5-1. Indoor Unit
No. Parts name Type Specifications
1 Fan motor (for indoor) AFP-220-50-4A Output (Rated) 50 W, 220 – 240 V
2 Grille motor MP35EA12 DC 12 V
3 Thermo.sensor (TA-sensor) 550 mm 10 kΩat 25°C
4 Heat exchanger sensor (TC-sensor) ∅6 mm, 500 mm 10 kΩat 25°C
5 Heat exchanger sensor (TCJ-sensor) ∅6 mm, 500 mm 10 kΩat 25°C
No. Parts name Type Specifications
1 Fan motor ICF-140-43-1 Output (Rated) 40 W
2 Compressor DA130A1F-23F 3 phase, 4P, 1100 W
3 Reactor CH-57 1=10 mH, 16A
4 Outdoor temp. sensor (To-sensor) — 10 kΩat 25°C
5 Heat exchanger sensor (Te-sensor) — 10 kΩat 25°C
6 Suction temp. sensor (Ts-sensor) — 10 kΩat 25°C
7 Discharge temp. sensor (Td-sensor) — 50 kΩat 25°C
8 Fuse (Switching power (Protect)) — T3.15 A, AC 250 V
9 Fuse (Inverter, input (Current protect) — 25 A, AC 250 V
10 4-way valve solenoid coil STF-0108G
11 Compressor thermo.(Protection) US-622 ON : 90 ± 5°C, OFF : 125 ± 4°C
5-3. Outdoor Unit (RAV-SM800AT-E)
No. Parts name Type Specifications
1 Fan motor ICF-140-63-1 Output (Rated) 63 W, 220 – 240 V
2 Compressor DA220A2F-20L 3 phase, 4P, 1600 W
3 Reactor CH-47
4 Outdoor temp. sensor (To-sensor) — 10 kΩat 25°C
5 Heat exchanger sensor (Te-sensor) — 10 kΩat 25°C
6 Suction temp. sensor (Ts-sensor) — 10 kΩat 25°C
7 Discharge temp. sensor (Td-sensor) — 50 kΩat 25°C
8 Fuse (Switching power (Protect)) — T3.15 A, AC 250 V
9 Fuse (Inverter, input (Current protect) — 25 A, AC 250 V
10 4-way valve solenoid coil DKV-M0ZS743B0
11 Compressor thermo.(Protection) US-622 ON : 90 ± 5°C, OFF : 125 ± 4°C

– 13 –
(5) After completion of installation work, check to
make sure that there is no refrigeration gas
leakage.
If the refrigerant gas leaks into the room, coming
into contact with fire in the fan-driven heater,
space heater, etc., a poisonous gas may occur.
(6) When an air conditioning system charged with a
large volume of refrigerant is installed in a small
room, it is necessary to exercise care so that,
even when refrigerant leaks, its concentration
does not exceed the marginal level.
If the refrigerant gas leakage occurs and its
concentration exceeds the marginal level, an
oxygen starvation accident may result.
(7) Be sure to carry out installation or removal
according to the installation manual.
Improper installation may cause refrigeration
trouble, water leakage, electric shock, fire, etc.
(8) Unauthorized modifications to the air conditioner
may be dangerous.If a breakdown occurs please
call a qualified air conditioner technician or
electrician.
Improper repair’s may result in water leakage,
electric shock and fire, etc.
6-2. Refrigerant Piping Installation
6-2-1. Piping materials and joints used
For the refrigerant piping installation, copper pipes and
joints are mainly used. Copper pipes and joints suit-
able for the refrigerant must be chosen and installed.
Furthermore, it is necessary to use clean copper pipes
and joints whose interior surfaces are less affected by
contaminants.
(1) Copper pipes
It is necessary to use seamless copper pipes
which are made of either copper or copper alloy
and it is desirable that the amount of residual oil is
less than 40 mg/10 m. Do not use copper pipes
having a collapsed, deformed or discolored
portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube
may become blocked with contaminants.
As an air conditioner using R410A incurs pressure
higher than when using R22, it is necessary to
choose adequate materials.
Thicknesses of copper pipes used with R410A are
as shown in Table 6-2-1.Never use copper pipes
thinner than 0.8 mm even when it is available on
the market.
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 R410A is
1.6 times higher than conventional refrigerant (R22).
The refrigerating oil is also changed in accordance
with change of refrigerant, so be careful that water,
dust, and existing refrigerant or refrigerating oil are not
entered in the refrigerant cycle of the air conditioner
using the new refrigerant during installation work or
servicing time.
The next section describes the precautions for air
conditioner using the new refrigerant.Conforming to
contents of the next section together with the general
cautions included in this manual, perform the correct
and safe work.
6-1. Safety During Installation/Servicing
As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may cause
a serious trouble.By using tools and materials exclu-
sive for R410A, it is necessary to carry out installation/
servicing safely while taking the following precautions
into consideration.
(1) Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.
If other refrigerant than R410A is mixed, pressure
in the refrigeration cycle becomes abnormally
high, and it may cause personal injury, etc. by a
rupture.
(2) Confirm the used refrigerant name, and use tools
and materials exclusive for the refrigerant R410A.
The refrigerant name R410A is indicated on the
visible place of the outdoor unit of the air condi-
tioner using R410A as refrigerant.To prevent
mischarging, the diameter of the service port
differs from that of R22
(3) If a refrigeration gas leakage occurs during
installation/servicing, be sure to ventilate fully.
If the refrigerant gas comes into contact with fire,
a poisonous gas may occur.
(4) When installing or removing an air conditioner,
do not allow air or moisture to remain in the
refrigeration cycle.Otherwise, pressure in the
refrigeration cycle may become abnormally high
so that a rupture of personal injury may be
caused.

– 14 –
Table 6-2-1Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter Outer diameter (mm) R410A R22
1/4 6.35 0.80 0.80
3/8 9.52 0.80 0.80
1/2 12.70 0.80 0.80
5/8 15.88 1.00 1.00
b) Socket joints
Socket joints are such that they are brazed for
connections, and used mainly for thick pipings
whose diameter is larger than 20 mm.
Thicknesses of socket joints are as shown in
Table 6-2-2.
(2) 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 exceeds 20 mm. In such a case,
socket joints can be used.
Sizes of flare pipe ends, flare joint ends and
flare nuts are as shown inTables 6-2-3 to 6-2-6
below.
Table 6-2-2 Minimum thicknesses of socket joints
Nominal diameter Reference outer diameter of Minimum joint thickness
copper pipe jointed (mm) (mm)
1/4 6.35 0.50
3/8 9.52 0.60
1/2 12.70 0.70
5/8 15.88 0.80
d) Flare processing
Make certain 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 conven-
tional flare tool.
Flare processing dimensions differ according to
the type of flare tool.When using a conven-
tional flare tool, be sure to secure “dimension A”
by using a gauge for size adjustment.
Fig. 6-2-1 Flare processing dimensions
6-2-1. Processing of piping materials
When performing the refrigerant piping installation,
care should be taken to ensure that water or dust does
not enter the pipe interior, that no other oil other than
lubricating oils used in the installed air conditioner is
used, and that refrigerant does not leak.When using
lubricating oils in the piping processing, use such
lubricating oils whose water content has been removed.
When stored, be sure to seal the container with an
airtight cap or any other cover.
(1) Flare Processing procedures and precautions
a) Cutting the pipe
By means of a pipe cutter, slowly cut the pipe
so that it is not deformed.
b) Removing burrs and chips
If the flared section has chips or burrs,
refrigerant leakage may occur.Carefully
remove all burrs and clean the cut surface
before installation.
c) Insertion of flare nut
∅DA

– 15 –
A (mm)
Conventional flare tool
Clutch type Wing nut type
1/4 6.35 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0
3/8 9.52 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0
1/2 12.70 0.8 0 to 0.5 1.0 to 1.5 2.0 to 2.5
5/8 15.88 1.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5
Table 6-2-3 Dimensions related to flare processing for R410A
Nominal
diameter
Outer
diameter
(mm)
Thickness
(mm) Flare tool for R410A
clutch type
A (mm)
Conventional flare tool
Clutch type Wing nut type
1/4 6.35 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5
3/8 9.52 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5
1/2 12.70 0.8 0 to 0.5 0.5 to 1.0 1.5 to 2.0
5/8 15.88 1.0 0 to 0.5 0.5 to 1.0 1.5 to 2.0
Table 6-2-4 Dimensions related to flare processing for R22
Nominal
diameter
Outer
diameter
(mm)
Thickness
(mm) Flare tool for R22
clutch type
Dimension (mm)
ABCD
1/4 6.35 0.8 9.1 9.2 6.5 13 17
3/8 9.52 0.8 13.2 13.5 9.7 20 22
1/2 12.70 0.8 16.6 16.0 12.9 23 26
5/8 15.88 1.0 19.7 19.0 16.0 25 29
Table 6-2-5 Flare and flare nut dimensions for R410A
Nominal
diameter
Outer
diameter
(mm)
Thickness
(mm)
Flare nut
width
(mm)
Dimension (mm)
ABCD
1/4 6.35 0.8 9.0 9.2 6.5 13 17
3/8 9.52 0.8 13.0 13.5 9.7 20 22
1/2 12.70 0.8 16.2 16.0 12.9 20 24
5/8 15.88 1.0 19.4 19.0 16.0 23 27
3/4 19.05 1.0 23.3 24.0 19.2 34 36
Table 6-2-6 Flare and flare nut dimensions for R22
Nominal
diameter
Outer
diameter
(mm)
Flare nut
width
(mm)
Thickness
(mm)

– 16 –
(2) Flare connecting procedures and precautions
a) Make sure that the flare and union portions do
not have any scar or dust, etc.
b) Correctly align the processed flare surface with
the union axis.
c) Tighten the flare with designated torque by
means of a torque wrench.The tightening
torque for R410A is the same as that for
conventional R22.Incidentally, when the torque
is weak, the gas leakage may occur.
Fig. 6-2-2 Relations between flare nut and flare seal surface
When it is strong, the flare nut may crack and
may be made non-removable.When choosing
the tightening torque, comply with values
designated by manufacturers.Table 6-2-7
shows reference values.
Note:
When applying oil to the flare surface, be sure to use
oil designated by the manufacturer. If any other oil is
used, the lubricating oils may deteriorate and cause
the compressor to burn out.
Tightening torque of torque
Nominal Outer diameter Tightening torque wrenches available on the market
diameter (mm) N·m (kgf·cm) N·m (kgf·m)
1/4 6.35 14 to 18 (140 to 180) 16 (160), 18 (180)
3/8 9.52 33 to 42 (330 to 420) 42 (420)
1/2 12.70 50 to 62 (500 to 620) 55 (550)
5/8 15.88 63 to 77 (630 to 770) 65 (650)
Table 6-2-7Tightening torque of flare for R410A [Reference values]
45°to 46°
43°to 45°

– 17 –
6-3.Tools
6-3-1. Required tools
The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to
prevent mixing of other refrigerant.To reinforce the pressure-resisting strength, flare processing dimensions and
opposite side dimension of flare nut (For ∅12.70 copper pipe) of the refrigerant piping are lengthened.
The used refrigerating oil is changed, and mixing 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 conventional refrigerant (R22))
(2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)
(3) Tools commonly used for R410A and for conventional refrigerant (R22)
The table below shows the tools exclusive for R410A and their interchangeability.
Tools exclusive for R410A (The following tools for R410A are required.)
Tools whose specifications are changed for R410A and their interchangeability
R410A air conditioner Conventional air
installation conditioner installation
No. Used tool Usage Existence of Whether Whether new equipment
new equipment conventional can be used with
for R410A equipment can conventional refrigerant
be used
1Flare tool Pipe flaring Yes *(Note 1)
2Copper pipe gauge Flaring by
for adjusting projection conventional flare Yes *(Note 1) *(Note 1)
margin tool
3Torque wrench Connection of Yes
flare nut
4Gauge manifold
5Charge hose
6Vacuum pump adapter Vacuum evacuating Yes
7Electronic balance for Refrigerant charge Yes
refrigerant charging
8Refrigerant cylinder Refrigerant charge Yes
9Leakage detector Gas leakage check Yes
!Charging cylinder Refrigerant charge (Note 2)
Evacuating,
refrigerant charge, Yes
run check, etc.
(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection
margin is necessary.For this adjustment, a copper pipe gauge, etc. are necessary.
(Note 2) Charging cylinder for R410A is being currently developed.
General tools (Conventional tools can be used.)
In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as
the general tools.
(1) Vacuum pump (4) Reamer (9) Hole core drill (∅65)
Use vacuum pump by (5) Pipe bender (10) Hexagon wrench
attaching vacuum pump adapter. (6) Level vial (Opposite side 4 mm)
(2) Torque wrench (7) Screwdriver (+, –) (11) Tape measure
(3) Pipe cutter (8) Spanner of Monkey wrench (12) Metal saw
Also prepare the following equipments for other installation method and run check.
(1) Clamp meter (3) Insulation resistance tester
(2) Thermometer (4) Electroscope

– 18 –
6-4. Recharging of Refrigerant
When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the
following steps.
Recover the refrigerant, and check no refrigerant
remains in the equipment.
Connect the charge hose to packed valve service
port at the outdoor unit’s gas side.
Connect the charge hose of the vacuum pump
adapter.
Open fully both packed valves at liquid and gas
sides.
Place the handle of the gauge manifold Low in
the fully opened position, and turn on the vacuum
pump’s power switch.Then, evacuating the
refrigerant in the cycle.
When the compound gauge’s pointer has indi-
cated -0.1 Mpa (-76 cmHg), place the handle Low
in the fully closed position, and turn off the
vacuum pump’s power switch.
Keep the status as it is for 1 to 2 minutes, and
ensure that the compound gauge’s pointer does
not return.
Set the refrigerant cylinder to the electronic
balance, connect the connecting hose to the
cylinder and the connecting port of the electronic
balance, and charge liquid refrigerant.
(For refrigerant charging, see the figure below.)
1Never charge refrigerant exceeding the specified amount.
2If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.
3Do not carry out additional charging.
When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the
refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the
specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high
pressure, and may cause a rupture or personal injury.
Fig. 6-4-1 Configuration of refrigerant charging
(INDOOR unit) (Liquid side)
(OUTDOOR unit)
Opened
(Gas side)
Closed
Service port
Electronic balance for refrigerant charging
Check valve
Open/Close valve
for charging
Refrigerant cylinder
(With siphon pipe)