Toshiba RAV-SP1100UT-E User manual

FILE NO. A03-013
SERVICE MANUAL
<OWNERS MANUAL/INSTALLATION MANUAL>
SPLIT TYPE
RAV-SP1100UT-E
RAV-SP560AT-E, RAV-SP800AT-E
RAV-SP1100AT-E,RAV-SP1400AT-E
PRINTED IN JAPAN, Feb.,2004 ToMo
4-way Air Discharge Cassette type
Concealed Duct type
Under Ceiling type
High wall type
Indoor unit
RAV-SM560UT-E
RAV-SM800UT-E
RAV-SM1400UT-E
RAV-SM561BT-E
RAV-SM801BT-E
RAV-SM1101BT-E
RAV-SM1401BT-E
RAV-SM561CT-E
RAV-SM801CT-E
RAV-SM1101CT-E
RAV-SM1401CT-E
RAV-SM560KRT-E
RAV-SM800KRT-E
Service Manual No.
A02-013
A02-013
A03-003
A03-007
A03-007
A03-007
A03-007
A03-015
A03-015
A03-015
A03-015
A02-013
A02-013
R410A
The type of all the indoor units described in this Service Manual is a new model, RAV-SP1100UT-E only.
For the other indoor units to be combined, refer to the Service Manuals for the following models.

– 2 –
ADOPTION OF NEW REFRIGERANT
This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional
refrigerant R22 in order to prevent destruction of the ozone layer.
WARNING
Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have
a service person do it.Do not attempt it yourself.The cleaning diagram for the air filter is there for the service
person, and not for the customer.

Accessories ––––––––––––––––––––––––––––––––––––––––––––––––––––
OWNER’S MANUAL
REMOTE CONTROLLER FOR AIR CONDITIONER (SPLITTYPE)
<WirelessType> TCB-AX21U (W)-E.......................................... 63
WEEKLYTIMER FOR AIR CONDITIONER (SPLITTYPE)
<ProgramWeeklyTimerType> RBC-EXW21E................................................. 72
REMOTE CONTROLLER FOR AIR CONDITIONER
<Simple OperationType> RBC-AS21E.................................................... 78
INSTALLATION MANUAL
Standard Remote Controller RBC-AMT21E ................................................. 81
Simple Remote Controller RBC-AS21E.................................................... 82
ProgramWeeklyTimer RBC-EXW21E................................................. 83
Remote sensor TCB-TC21LE .................................................. 84
Remote ControllerWireless Kit TCB-AX21U (W)-E.......................................... 85
Network Adapter for Air Conditioner
(Use for Indoor Unit Only) TCB-PCNT20E ............................................... 86
Indoor Unit (4-Way Air Discharge CassetteType) ––––––––––––––––––––––––
RAV-SP1100UT-E
OWNWE’S MANUAL
ACCESSORIES (SOLD SEPARATELY)...............................4
PRECAUTIONS FOR SAFETY ............................................4
PARTS NAME .......................................................................6
PARTS NAME OF REMOTE CONTROLLER.......................7
CORRECT USAGE...............................................................9
AUTOMATIC OPERATION (Auto Changeover) ................10
ADJUSTMENT OFWIND DIRECTIONd ............................11
TIMER OPERATION ...........................................................12
MAINTENANCE..................................................................14
AIR CONDITIONER OPERATIONS AND PERFORMANCE ...15
RE-INSTALLATION ............................................................16
TROUBLES AND CAUSES ................................................16
INSTALLATION MANUAL
Accessory parts and Parts to be procured locally ........18
1 PRECAUTIONS FOR SAFETY....................................19
2 SELECTION OF INSTALLATION PLACE ...................21
3 DRAIN PIPINGWORK.................................................26
4 REFRIGERANT PIPING AND EVACUATING..............28
5 ELECTRICALWORK...................................................30
6 TEST RUN ...................................................................33
7 TROUBLESHOOTING .................................................34
8 MAINTENANCE...........................................................35
Outdoor Unit –––––––––––––––––––––––––––––––––––––––––––––––––––––––––
RAV-SP560AT-E, RAV-SP800AT-E
INSTALLATION MANUAL
1 PRECAUTIONS FOR SAFETY....................................36
2 ACCESSORY AND REFRIGERANT ...........................37
3 SELECTION OF INSTALLATION ................................38
4 REFRIGERANT PIPING ..............................................43
5 EVACUATING...............................................................45
6 ELECTRICALWORK...................................................47
7 FINAL INSTALLATION CHECKS ................................48
RAV-SP1100AT-E, RAV-SP1400AT-E
INSTALLATION MANUAL
1 PRECAUTIONS FOR SAFETY....................................50
2 ACCESSORY AND REFRIGERANT ...........................51
3 SELECTION OF INSTALLATION ................................52
4 REFRIGERANT PIPING ..............................................56
5 EVACUATING...............................................................58
6 ELECTRICALWORK...................................................60
7 FINAL INSTALLATION CHECKS ................................61
RAV-SP1100UT-E
RAV-SP560AT-E RAV-SP800AT-E
RAV-SP1100AT-E RAV-SP1400AT-E
ACCESSORIES

36
1 PRECAUTIONS FOR SAFETY
• Ensure that all Local, National and International regulations are satisfied.
• Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.
• The precautions described below include the important items regarding safety. Observe them without fail.
• After the installation work, perform a trial operation to check for any problem.
Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.
• Turn off the main power supply switch (or breaker) before the unit maintenance.
• Ask the customer to keep the Installation Manual together with the Owner’s Manual.
CAUTION New Refrigerant Air Conditioner Installation
• THIS AIR CONDITIONER ADOPTSTHE NEW HFC REFRIGERANT (R410A)WHICH DOES NOT DE-
STROY OZONE LAYER.
The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure
is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil
has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or
refrigerating oil does not enter the refrigerating cycle.
To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging
port of the main unit and installation tools are charged from those for the conventional refrigerant.
Accordingly the exclusive tools are required for the new refrigerant (R410A).
For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust
does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance
force and impurity in it.
CAUTION To Disconnect the Appliance from Main Power Supply.
This appliance must be connected to the main power supply by means of a switch with a contact separation of
at least 3 mm.
The installation fuse (25A D type ) must be used for the power supply line of this conditioner.
WARNING
• Ask an authorized dealer or qualified installation professional to install/maintain the air condi-
tioner.
Inappropriate installation may result in water leakage, electric shock or fire.
• Turn off the main power supply switch or breaker before attempting any electrical work.
Make sure all power switches are off. Failure to do so may cause electric shock.
• Connect the connecting cable correctly.
If the connecting cable is connected in a wrong way, electric parts may be damaged.
• When moving the air conditioner for the installation into another place, be very careful not to
enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.
If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnor-
mally high and it may resultingly causes pipe burst and injuries on persons.
• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety
interlock switches.
• Exposure of unit to water or other moisture before installation may cause short-circuit of
electrical parts.
Do not store it in a wet basement or expose to rain or water.
• After unpacking the unit, examine it carefully if there are possible damage.
• Do not install in a place that might increase the vibration of the unit.
• To avoid personal injury (with sharp edges), be careful when handling parts.
• Perform installation work properly according to the Installation Manual.
Inappropriate installation may result in water leakage, electric shock or fire.

37
•When the air conditioner is installed in a small room, provide appropriate measures to ensure
that the concentration of refrigerant leakage occur in the room does not exceed the critical
level.
•Install the air conditioner securely in a location where the base can sustain the weight adequately.
•Perform the specified installation work to guard against an earthquake.
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.
•If refrigerant gas has leaked during the installation work, ventilate the room immediately.
If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.
•After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas
might generate.
•Electrical work must be performed by a qualified electrician in accordance with the Installation
Manual. Make sure the air conditioner uses an exclusive power supply.
An insufficient power supply capacity or inappropriate installation may cause fire.
•Use the specified cables for wiring connect the terminals securely fix. To prevent external
forces applied to the terminals from affecting the terminals.
•Be sure to provide grounding.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.
•Conform to the regulations of the local electric company when wiring the power supply.
Inappropriate grounding may cause electric shock.
•Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.
If a combustible gas leaks, and stays around the unit, a fire may occur.
Required tools for installation work
1) Philips screwdriver
2) Hole core drill (65 mm)
3) Spanner
4) Pipe cutter
5) Knife
6) Reamer
7) Gas leak detector
8) Tape measure
9) Thermometer
10) Mega-tester
R410A (Special requirement)
17) Gauge manifold
(Charge hose : R410A special requirement)
18) Vacuum pump
(Charge hose : R410A special requirement)
19) Torque wrench
1/4 (17 mm) 16 N•m (1.6 kgf•m)
3/8 (22 mm) 42 N•m (4.2 kgf•m)
1/2 (26 mm) 55 N•m (5.5 kgf•m)
5/8 (15.9 mm) 120 N•m (12.0 kgf•m)
20) Copper pipe gauge adjusting projection margin
21) Vacuum pump adapter
11) Electro circuit tester
12) Hexagonal wrench
13) Flare tool
14) Pipe bender
15) Level vial
16) Metal saw
2 ACCESSORY AND REFRIGERANT
Accessory and Installation Parts Refrigerant Piping
•Piping kit used for the conventional refrigerant cannot be
used.
•Use copper pipe with 0.8 mm or more thickness for Ø6.4,
Ø9.5, Ø12.7.
Use copper pipe with 1.0 mm or more thickness for Ø15.9.
•Flare nut and flare works are also different from those of
the conventional refrigerant. Take out the flare nut at-
tached to the main unit of the air conditioner, and use it.
Outdoor unit
Installation manual x 1
1
2
3
4
Drain nipple
Waterproof rubber cap
Protective bush
(For SM800, SP560, SP800)
Guard material for
passage part
(For SM800, SP560, SP800)
RAV-SP560AT-E RAV-SP800AT-E

38
3 SELECTION OF INSTALLATION
Length of refrigerant pipe
connected to
indoor/outdoor unit
20m or shorter
*21m to 30m
<SP560AT-E>
*Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds
20m, add 20g/m of refrigerant and the maximum total
length of pipe is 50m.
(Max.amount of additional refrigerant is 600g.)
Charge the refrigerant accurately.Overcharge may
cause a serious trouble of compressor.
<SP800AT-E>
* Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds
20m, add 20g/m of refrigerant and the maximum total
length of pipe is 30m.
(Max.amount of additional refrigerant is 200g.)
Charge the refrigerant accurately.Overcharge may
cause a serious trouble of compressor.
<SM800AT-E>
Length of refrigerant pipe
connected to
indoor/outdoor unit
20m or shorter
*21m to 50m
Item
Addition of refrigerant is
unnecessary at the local site.
<Addition of refrigerant>
Add 20g of refrigerant for every
1m of pipe which exceeds 20m.
CAUTION
<SP560AT-E, SP800AT-E only>
When using an air conditioner under low outside
temperature condition (Outside temp.:–5°C or
lower) with COOL mode, prepare a duct or wind
shield so that it is not affected by the wind.
<Example>
Item
Addition of refrigerant is
unnecessary at the local site.
<Addition of refrigerant>
Add 20g of refrigerant for every
1m of pipe which exceeds 20m.
Length of refrigerant pipe
connected to
indoor/outdoor unit
20m or shorter
*21m to 50m
Item
Addition of refrigerant is
unnecessary at the local site.
<Addition of refrigerant>
Add 40g of refrigerant for every
1m of pipe which exceeds 20m.
* Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds
20m, add 40g/m of refrigerant and the maximum total
length of pipe is 50m.
(Max.amount of additional refrigerant is 1200g.)
Charge the refrigerant accurately.Overcharge may
cause a serious trouble of compressor.
Length of refrigerant pipe
connected to
indoor/outdoor unit
30m or shorter
*31m to 50m
Item
Addition of refrigerant is
unnecessary at the local site.
<Addition of refrigerant>
Add 40g of refrigerant for every
1m of pipe which exceeds 30m.
* Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds
30m, add 40g/m of refrigerant and the maximum total
length of pipe is 50m.
(Max.amount of additional refrigerant is 800g.)
Charge the refrigerant accurately.Overcharge may
cause a serious trouble of compressor.
Air purge
•For air purge, use a vacuum pump.
•Do not use refrigerant charged in the outdoor unit for
air purge.(The refrigerant for air purge is not con-
tained in the outdoor unit.)
Electrical cabling
•Be sure to fix the power cables and indoor/outdoor
connecting cables with clamps so that they do not
contact with the cabinet, etc.
Before installation
Be careful to the following items before installation.
Length of refrigerant pipe
<SM560AT-E>
Discharge guide
Suction
Suction hood (Side)
Discharge hood
Fin
Suction hood
(Rear side)
Suction
Fin
Discharge

39
500
Strong
wind
Strong
wind
2) Supposing the wind direction during the
operation season of the air conditioner, install
the unit so that the discharge port is set at
right angle to the wind direction.
4. Installation in the following places may result in
some troubles.Do not install the unit in such
places below.
•A place full of machine oil.
•A place full of sulfuric gas.
•A place where high-frequency radio waves are
likely to be generated as from audio equip-
ment, welders, and medical equipment.
150
or more 300 or more 300 or more 300 or more
200 or more
The height of the obstacle should be lower
than the height of the outdoor unit.
1000
or more
Necessary Space for Installation
Obstacle at rear side
<Upper side is free>
1. Single unit installation
150
or more
150
or more 300 or more
200
or more
The height of the
obstacle should be
lower than the height
of the outdoor unit.
500
or more
150
or more
500
or more
2. Obstacles at both right and left sides.
3. Serial installation of two or more units
<Obstacle also at the upper side>
Obstacle at front side
<Upper side is free>
1. Single unit installation
2. Serial installation of two or more units
Installation Place
•A place which provides a specified space around the
outdoor unit.
•A place where the operation noise and discharged air
are not given to your neighbors.
•A place that is not exposed to a strong wind.
•A place that does not block a passage.
•When the outdoor unit is installed in an elevated
position, be sure to secure its feet.
•There must be sufficient space for carrying in the
unit.
•A place where the drain water does not make any
problem.
CAUTION
1. Install the outdoor unit at a place where dis-
charge air is not blocked.
2. When an outdoor unit is installed in a place that
is always exposed to a strong wind like a coast
or on a high story of a building, secure a normal
fan operation by using a duct or a wind shield.
3. When installing the outdoor unit in a place that is
constantly exposed to a strong wind such as the
upper stairs or rooftop of a building, apply the
windproof measures referring to the following
examples.
1) Install the unit so that its
discharge port faces to the
wall of the building. Keep a
distance 500 mm or more
between the unit and the
wall surface.

40
1000
or more 300 or more 1500 or more 2000 or more 200 or more
300
or more
300
or more
1000
or more 200
or more
1000
or more
1000
or more
1000
or more 150
or more
<Obstacle also at the upper side>
Obstacles at both front and rear sides
Open the upper side and both right and left sides.
The height of obstacle at both front and rear side,
should be lower than the height of the outdoor unit.
<Standard installation>
1. Single unit installation
2. Serial installation of two or more units
Serial installation at front and rear sides
Open the upper side and both right and left sides.
The height of obstacle at both front and rear sides
should be lower than the height of the outdoor unit.
<Standard installation>
600
115
90 90
310
76
330
Ø28 Drain hole
600150 150
430
365
40
400
Drain hole
Knockout hole Drain nipple mounting hole
Drain nipple Waterproof rubber cap
Installation of Outdoor Unit
•Before installation, check strength and horizontality of
the base so that abnormal sound does not generate.
•According to the following base diagram, fix the base
firmly with the anchor bolts.
(Anchor bolt, nut:M10 x 4 pairs)
<SM560AT-E>
15 or less
<SM800AT-E, SP560AT-E, SP800AT-E>
Set the out margin of the anchor bolt to 15mm or less.
•In case of draining through the drain hose, attach the
following drain nipple and the waterproof rubber cap,
and use the drain hose (Inner diam.:16mm) sold on
the market.And also seal the screws securely with
silicone material, etc. so that water does not drop
down.Some conditions may cause dewing or drip-
ping of water.
3 SELECTION OF INSTALLATION

41
Waterproof rubber cap
Base plate
Drain nipple
Knockout hole
Waterproof rubber cap Open
Drain nipple
<SM560AT-E>
<SM800AT-E, SP560AT-E, SP800AT-E>
•When there is a possibility of freezing of drain at the
cold district or a snowfall area, be careful for drainage
ability of drain.The drainage ability increases when a
knockout hole on the base plate is opened.(Open the
knockout hole to outside using a screwdriver, etc.)
Optional Installation Parts
(Local Procure)
Refrigerant Piping Connection
CAUTION
TAKE NOTICETHESE IMPORTANT
4 POINTS BELOW FOR PIPINGWORK
1. Keep dust and moisture away from inside the
connecting pipes.
2. Tightly connect the connection between pipes
and the unit.
3. Evacuate the air in the connecting pipes using
VACUUM PUMP.
4. Check gas leak at connected points.
<Piping connection>
A
B
C
Parts name
Refrigerant piping
Liquid side : Ø6.35 mm or Ø9.52 mm
Gas side : Ø12.7 mm or Ø15.9 mm
Pipe insulating material
(polyethylene foam, 6 mm thick)
Putty, PVC tapes
Q’ty
Each one
1
Each one
Capacity
rank
RAV-
SM560
SP560
SM800
SP800
Liquid side
Outer Thickness
diameter
Ø6.4 0.8
Ø9.5 0.8
Gas side
Outer Thickness
diameter
Ø12.7 0.8
Ø15.9 1.0
For Reference
If a heating operation would be continuously performed
for a long time under the condition that the outdoor
temperature is 0°C or lower, draining of defrosted water
may be difficult due to freezing of the bottom plate,
resulting in a trouble of the cabinet or fan.
It is recommended to procure an anti-freeze heater
locally for a safety installation of the air conditioner.
For details, contact the dealer.

42
Knockout of Pipe Cover
<SM800AT-E, SP560AT-E, SP800AT-E>
Front direction
Rear direction
Pipe cover
Side direction
Down direction
Knockout procedure
•The indoor/outdoor connecting pipes can be con-
nected to 4 directions.
Take off the knockout part of the pipe cover in which
pipes or wires pass through the base plate.
•As shown in the figure, do not remove the pipe cover
from the cabinet so that the knockout hole can be
easily punched.To knock out, it is easily taken off by
hands by punching a position at the lower side of 3
connected parts with screwdriver along the guideline.
•After marking the knockout hole, remove the burr and
mount the attached protective bush and guard
material for pass-through part in order to protect
pipes and wires.
After connecting the pipes, be sure to mount the pipe
cover.The pipe cover is easily mounted by cutting off
the slit at the lower part of the pipe cover.
How to remove the front panel
1. Remove screws of the front panel.
2. Pull the front panel downward.
Removing the front panel, the electric parts appear at
the front side.
•The metal pipes are attachable to the piping holes.
If the size of the used power pipe does not match
with the hole, adjust the hole size to match with pipe
size.
•Be sure to fix the power cable and indoor/outdoor
connecting cable with bundling band sold on the
market so that they do not make contact with the
compressor and discharge pipe.
(Temperature of the compressor and discharge pipe
becomes high.)
In order to avoid the force applied to on the connect-
ing section, be sure to fix the cables to the cord
clamps provided on the pipe valve fixing plate and the
electric parts box.
Cord clamp
Electric parts box Front panel
Pipe valve
fixing plate
Piping
hole
3 SELECTION OF INSTALLATION