Toshiba RAV-SM566KRT-TR, RAV-SM806KRT-TR, RAV-SM806KRT-E User Manual

FILE NO. SVM-12004

SERVICE MANUAL

AIR-CONDITIONER

SPLIT TYPE

INDOOR UNIT

High Wall Type

RAV-SM566KRT-E, RAV-SM806KRT-E RAV-SM566KRT-TR, RAV-SM806KRT-TR

R410A

FILE NO. SVM-12004

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.

CONTENTS

SAFETY CAUTION ............................................................................................			3
1.	SPECIFICATIONS ....................................................................................		12
	1-1. High Wall Type .................................................................................................................		12
2.	CONSTRUCTION VIEWS (EXTERNAL VIEWS).......................................		13
3.	SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ..............................		15
4.	WIRING DIAGRAM ...................................................................................		16
5.	SPECIFICATIONS OF ELECTRICAL PARTS ..........................................		17
6.	REFRIGERANT R410A ............................................................................		18
	6-1.	Safety During Installation/Servicing .............................................................................	18
	6-2.	Refrigerant Piping Installation ....................................................................................	18
	6-3.	Tools ................................................................................................................................	22
	6-4.	Recharging of Refrigerant .............................................................................................	23
	6-5.	Brazing of Pipes .............................................................................................................	24
7.	INDOOR CONTROL CIRCUIT ..................................................................		26
	7-1.	Indoor Controller Block Diagram .................................................................................	26
	7-2. Control Specifications ..................................................................................................		28
	7-3. Indoor Print Circuit Board (High Wall Type) .................................................................		40
8.	TROUBLESHOOTING ..............................................................................		42
	8-1.	Summary of Troubleshooting .......................................................................................	42
	8-2.	Troubleshooting ............................................................................................................	44
9.	REPLACEMENT OF SERVICE P.C. BOARD............................................		60
10.	SETUP AT LOCAL SITE AND OTHERS ..................................................		66
11.	ADDRESS SETUP....................................................................................		83
	11-1.	Address Setup Procedure .............................................................................................	83
	11-2.	Address Setup & Group/Twin/Triple Control ...............................................................	84
	11-3.	Address Setting .............................................................................................................	86
12.	DETACHMENTS .......................................................................................		88
13.	EXPLODED VIEWS AND PARTS LIST ....................................................		95
14. APPENDIX (Lite-vision plus remote controller Installation manual) .....			97

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Original instruction

FILE NO. SVM-12004

Generic Denomination: Air Conditioner

Definition of Qualified Installer or Qualified Service Person

Agent	Qualifications and knowledge which the agent must have

– 3 –

FILE NO. SVM-12004

Definition of Protective Gear

Work undertaken	Protective gear worn

[Explanation of indications]

Indication

Explanation

DANGER

WARNING

CAUTION

[Explanation of illustrated marks]

Mark	Explanation

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FILE NO. SVM-12004

Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit]

Warning indication

Description

WARNING

ELECTRICAL SHOCK HAZARD

WARNING

CAUTION

CAUTION

CAUTION

BURST HAZARD

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FILE NO. SVM-12004

Precautions for safety

DANGER

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FILE NO. SVM-12004

WARNING

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FILE NO. SVM-12004

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FILE NO. SVM-12004

Ω

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FILE NO. SVM-12004

Explanations given to user

Relocation

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FILE NO. SVM-12004

Declaration of Conformity

NOTE

Specifications

	Model	Sound power level (dBA)		Weight (kg)
		Cooling	Heating	Main unit (Ceiling panel)

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FILE NO. SVM-12004

1. SPECIFICATIONS

1-1. High-wall type

	Model	Indoor unit	RAV-SM			566KRT-E(TR)	806KRT-E(TR)	566KRT-E(TR)	806KRT-E(TR)
		Outdoor unit	RAV-			SP564AT(Z)(ZG)-E	SP804AT(Z)(ZG)-E	SM563AT-E	SM803AT-E
	Cooling Capacity		(kW)			5.0	7.1	5.0	6.7
	Heating Capacity		(kW)			5.6	8.0	5.6	8.0
	Power Supply						1 phase 230V (220-240V) 50Hz
			Running current		(A)	6.74-6.18	10.71-9.82	7.77-7.12	11.18-10.25
			Power consumption (kW)			1.44	2.21	1.66	2.37
		Cooling	Power factor		(%)	99	96	98	99
			EER			3.47	3.21	3.01	2.83
			Energy efficiency class			A	A	B	C
	Electrical		Energy rating			-	-	-	-
			Running current		(A)	6.98-6.40	11.02-10.10	7.60-6.96	11.88-10.89
	Characteristics
			Power consumption (kW)			1.50	2.34	1.64	2.49
		Heating	Power factor		(%)	99	96	98	99
			COP			3.73	3.42	3.41	3.21
			Energy efficiency class			A	B	B	C
			Energy rating			-	-	-	-
		Maximum current			(A)	13.4	20.4	12.3	14.4
	Appearance	Main unit					Moon white
			Height		(mm)	320	320	320	320
	Outer dimension	Main unit	Width		(mm)	1050	1050	1050	1050
			Depth		(mm)	228	228	228	228
	Total weight	Main unit			(kg)	12	12	12	12
	Heat exchanger						Finned tube
		Fan					Cross flow fan
	Fan unit	Standard air flow	H/M/L	(m3/min.)		14.0/12.5/11.0	17.0/12.5/11.0	14.0/12.5/11.0	17.0/12.5/11.0
		Motor			(W)	30	30	30	30
	Air filter						Standard filter attached
	Controller (packed with inndoor unit)						WH-L11SE
	Controller (sold separately)						RBC-AMT32E,AS21E2,AMS41E,AMS51E
	Sound pressure level		H/M/L		(dB A)	42/39/36	47/41/36	42/39/36	47/41/36
	Sound power level		H/M/L		(dB A)	57/54/51	62/56/51	57/54/51	62/56/51
			Gas side		(mm)	12.7	15.9	12.7	15.9
	Connecting pipe		Liquid side		(mm)	6.4	9.5	6.4	9.5
			Drain port		(mm)		VP16
								IEC Standard AS Standard

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FILE NO. SVM-12004

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

2-1. 4-Way Air Discharge Cassette Type

RAV-SM566KRT-E(TR)

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FILE NO. SVM-12004

RAV-SM806KRT-E(TR)

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FILE NO. SVM-12004

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

High Wall Type

• Single type (Combination of 1 indoor unit and 1 outdoor unit)

TCJ sensor

Air heat exchanger

TC sensor

Dimension table

	Indoor unit	Outer diameter of refrigerant pipe (In (mm))
		Gas side ØA	Liquid side ØB
	SM56 type	12.7	6.4
	SM80 type	15.9	9.5

– 15 –

– 16 –

													BLK				LM
																	M
																											FM
		Earth										CN22
																																													BLU
		SCREW
TB01															1	2	3	4	5	6			1	3	4	5	6					1		2		1	2	3	4	5			CN40	1	BLU
																CN33(WHI)								CN210(WHI)								CN44(BRW)					CN50(WHI)						(BLU) 2
			CN67							U																																		1	BLK
			(BLK)															+																									CN41
			RED	1																																							(BLU)	2	BLK
		Earth
																												POWER																3
		SCREW	WHI															+
				3														-										SUPPLY
																												CIRCUIT															CN100	1
			BLK	5														-																										2
																																											(BRW)	3
POWER SUPPLY							CN213(WHI)																																					1	A	B
220-240V 1		50Hz		1	2	3	4	5	6	7	8	9	10																														CN101
220V	1	60Hz
																																											(BLU) 2
OUTDOOR UNIT(SINGLE PHASE)
														1
														2	CN309																												CN103	1	WIRED REMOTE
															(YEL)																														CONTROLLER
														3			Control P.C. board for indoor unit																										(GRN)	2
		Earth												1	CN32										(MCC-1510)																		(YEL)	1
														2	(WHI)																													2
			1	2	3	4	5	6	7	8	9	10 11																															CN102
		SCREW		INFRARED RAYS RECEIVE
				AND INDICATION PARTS																																								1
						(MCC-5044)							CN80(GRN)						CN82(BLU)							CN81(BLK)					CN61(YEL)							CN60(WHI)					CN104
													1	2	3			1	2	3	4	5	6		1	2	3	4	5	1	2	3	4	5	6		1	2	3	4	5	6	(WHI) 2
POWER SUPPLY													PNL/EMG																										OPTION

380-415V 3N 50Hz

380V 3N 60Hz

OUTDOOR UNIT (3-PHASE)

Type Wall High .1-4

DIAGRAM WIRING .4

12004-SVM .NO FILE

FILE NO. SVM-12004

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-3. High Wall Type

No.	Parts Name	Type	Specications
1	Fan motor (for indoor)	ICF-340-U30-1	Output (Rated) 30W, 340V DC
		ICF-340-30X
		MF-340-30X
2	Grille motor	MP24Z3T	Output (Rated) 1W, 16 poles DC
3	Thermo. Sensor (TA sensor)	318mm	10kΩ at 25°C
4	Heat exchanger sensor (TC sensor)	Ø6,800mm	10kΩ at 25°C
5	Heat exchanger sensor (TCJ sensor)	Ø6,800mm	10kΩ at 25°C

n Name of Each Part

Air outlet / Louver

Change the direction of the air to be discharged according to cool/heat mode.

Air inlet grille

Air in the room is sucked from here.

Air filter	Earth screw
Removes dirt or dust.	Earth screws are provided
(Provided in the air inlet grille)	in the electric parts box.

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FILE NO. SVM-12004

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. SafetyDuringInstallation/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 exclusive 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 conditioner 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 or personal injury may be caused.

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 fandriven 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 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 suitable 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.

– 18 –

				FILE NO. SVM-12004
	Table 6-2-1 Thicknesses 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

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 in Tables 6-2-3 to 6-2-6 below.

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.

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

6-2-2. 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 than lubricating oils used in the installed air-water heat pump 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

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FILE NO. SVM-12004

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 conventional flare tool.

Flare processing dimensions differ according to the type of flare tool.

When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

ØD

A

Fig. 6-2-1 Flare processing dimensions

Table 6-2-3 Dimensions related to flare processing for R410A

		Outer				A (mm)
	Nominal		Thickness
		diameter			Flare tool for R410A	Conventional flare tool
	diameter		(mm)
		(mm)
					clutch type	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 6-2-4 Dimensions related to flare processing for R22
		Outer				A (mm)
	Nominal		Thickness
		diameter			Flare tool for R22	Conventional flare tool
	diameter		(mm)
		(mm)
					clutch type	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 6-2-5 Flare and flare nut dimensions for R410A

Nominal	Outer diameter	Thickness		Dimension (mm)					Flare nut width
diameter	(mm)	(mm)	A		B	C		D	(mm)
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

– 20 –

																									FILE NO. SVM-12004
		Table 6-2-6 Flare and flare nut dimensions for R22
Nominal	Outer diameter								Thickness									Dimension (mm)												Flare nut width
diameter		(mm)									(mm)						A		B	C					D					(mm)
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							19.7			19.0	16.0					23					27
3/4	19.05								1.0							23.3			24.0	19.2					34					36
			46˚
		to
		45˚
							B			A													C			D

				43˚	to
					45˚

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 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.

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.

Table 6-2-7 Tightening torque of flare for R410A [Reference values]

	Nominal	Outer diameter	Tighteningtorque	Tightening torque of torque
				wrenches available on the market
	diameter	(mm)	N•m (kgf•cm)
				N•m (kgf•cm)
	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)

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FILE NO. SVM-12004

6-3. Tools

6-3-1. RequiredTools

The service port diameter of packed valve of the outdoor unit in the air-water heat pump 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 Ø12.7 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		Conventionalair-water
			air-water heat pump installation			heatpumpinstallation
No.	Used tool	Usage
			Existence of		Whether conventional	Whether new equipment
			new equipment		equipment can be	can be used with
			for R410A		used	conventional refrigerant
1	Flare tool	Pipe flaring	Yes		(Note 1)	¡
2	Copper pipe gauge for	Flaring by	Yes		(Note 1)	(Note 1)
	adjusting projection margin	conventional flare tool
3	Torque wrench	Connection of flare nut	Yes		×	×
4	Gauge manifold	Evacuating, refrigerant	Yes		×	×
5	Charge hose	charge, run check, etc.
6	Vacuum pump adapter	Vacuum evacuating	Yes		×	¡
7	Electronic balance for	Refrigerant charge	Yes		×	¡
	refrigerant charging
8	Refrigerant cylinder	Refrigerant charge	Yes		×	×
9	Leakage detector	Gas leakage check	Yes		×	¡
10	Charging cylinder	Refrigerant charge	(Note 2)		×	×

(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	7)	Screwdriver (+, –)
	Use vacuum pump by attaching vacuum pump adapter.	8)	Spanner or Monkey wrench
2)	Torque wrench	9)	Hole core drill (Ø65)
3)	Pipe cutter	10)	Hexagon wrench (Opposite side 4mm)
4)	Reamer	11)	Tape measure
5)	Pipe bender	12)	Metal saw
6)	Level vial

Also prepare the following equipments for other installation method and run check.

1)	Clamp meter	3)	Insulation resistance tester
2)	Thermometer	4)	Electroscope

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FILE NO. SVM-12004

6-4. RechargingofRefrigerant

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 to 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 indicated –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.)

CAUTION

1.Never charge refrigerant exceeding the specified amount.

2.If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3.Do 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.

(INDOOR unit)

(Liquid side)

(OUTDOOR unit)

Opened

(Gas side)

Refrigerant cylinder (With siphon pipe)

Check valve

Closed

Open/Close valve for charging

Service port

Electronic balance for refrigerant charging

Fig. 6-4-1 Configuration of refrigerant charging

– 23 –

FILE NO. SVM-12004

1.Be sure to make setting so that liquid can be charged.

2.When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant.

Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ]	[ Cylinder without siphon ]
Gauge manifold	Gauge manifold
OUTDOOR unit	OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

cylinder Refrigerant

Electronic

balance

Siphon

R410A refrigerant is HFC mixed refrigerant.

Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

Fig. 6-4-2

6-5. Brazing of Pipes

6-5-1. Materials for Brazing

1.Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper.

It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

2.Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

3.Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead.

Since it is weak in adhesive strength, do not use it for refrigerant pipes.

1.Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage.

Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2.When performing brazing again at time of servicing, use the same type of brazing filler.

6-5-2. Flux

1.Reason why flux is necessary

•By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

•In the brazing process, it prevents the metal surface from being oxidized.

•By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal.

–24 –

2.Characteristicsrequiredforflux

•Activated temperature of flux coincides with the brazing temperature.

•Due to a wide effective temperature range, flux is hard to carbonize.

•It is easy to remove slag after brazing.

•The corrosive action to the treated metal and brazing filler is minimum.

•It excels in coating performance and is harmless to the human body.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

3.Types of flux

•Noncorrosiveflux

Generally, it is a compound of borax and boric acid. It is effective in case where the brazing temperature is higher than 800°C.

•Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

4.Piping materials for brazing and used brazing filler/flux

Piping material	Used brazing filler	Used flux
Copper - Copper	Phosphor copper	Do not use
Copper - Iron	Silver	Paste flux
Iron - Iron	Silver	Vapor flux

1.Do not enter flux into the refrigeration cycle.

2.When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates.

Therefore, use a flux which does not contain chlorine.

3.When adding water to the flux, use water which does not contain chlorine

(e.g. distilled water or ion-exchange water).

4.Remove the flux after brazing.

FILE NO. SVM-12004

6-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitrogen gas.

1.Brazing method to prevent oxidation

1)Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2)Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3)Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4)When the Nitrogen gas is flowing, be sure to keep the piping end open.

5)Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 MPa (0.2kgf/cm2) by means of the reducing valve.

6)After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7)Remove the flux completely after brazing.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe Nitrogen gas

Rubber plug

Fig. 6-5-1 Prevention of oxidation during brazing

– 25 –

FILE NO. SVM-12004

7. INDOOR UNIT CONTROL

7-1. IndoorControllerblockdiagram

7-1-1. Connection of wired remote controller

Wired (Simple) header remote controller (wired)

Central remote controller

Display LCD		Function setup	Display	LCD driver
			LCD
Display LED	CPU	Key switch
		CN2
					Function setup
		CN1		CPU
		DC5V			Key switch
Remote controller		Power circuit	DC5V
communication circuit
		2
			Power	Secondary
		Sold separately	circuit	battery	Sold separately

Central control

remote controller

Indoor unit

(Sold separately)

Follower unit

#2 A

B #3 A

#1 Header unit

U3

U4

A

B

B

Indoor control P.C. board

(MCC-1510)

Central control

communication circuit

DC20V

Remote controller

communication circuit

DC12V

EEPROM

Receiver and

Display P.C. board

DC5V

TA sensor

(MCC-5044)

Same as

Same as

the left

the left

Display LED

CPU

TC sensor

Driver

H8/3039

TCJ sensor

Receiver unit

Buzzer

HA

Driver

Wireless remote

signal setting

(A/B)

Louver

Outside

motor

Serial send/

output

receive circuit

2

3

2

3

Run/

1

1

Alarm/

Ready/

AC

Indoor

Fan motor

Thermo. ON/

synchronous

fan motor

control circuit

COOL/HEAT/

Power circuit

FAN

signal input circuit

DC280V

DC15V

1

2

3

Outdoor

Outdoor

unit

unit

1

2

3

Max. 8 units are connectable. 1

1 When group and twin combination.

Main remote controller shal be connected follower indoor unit.

2 Weekly timer is not connectable to the sub remote controller.

Outdoor unit

– 26 –

FILE NO. SVM-12004

7-1-2. Connection of Wireless Remote Controller

Central control

remote controller

Indoor unit

(Sold separately)

Follower unit

#2 A

B #3 A

#1 Header unit

U3

U4

A

B

B

	Indoor control P.C. board
	(MCC-1510)	Central control
		communication circuit
	DC20V		Remote controller
			communication circuit
	DC12V		EEPROM
Receiver and
Display P.C. board	DC5V		TA sensor
(MCC-5044)				Same as
			Same as
			the left	the left
Display LED			TC sensor
			CPU
		Driver	H8/3039
Receiver unit			TCJ sensor
	Buzzer		HA
		Driver
			Wireless remote
			signal setting
			(A/B)

Louver

Outside

motor

Serial send/

output

receive circuit

Run/

1

2

3

1

2

3

Warning/

Defrost/

AC

Indoor

Fan motor

Thermo. ON/

synchronous

fan motor

control circuit

COOL/HEAT/

Power circuit

FAN

signal input circuit

DC280V

	DC15V			×
	L1 L2 S				Outdoor	Outdoor
					unit	unit

	L1 L2 S
Max. 8 units are connectable. 1
1 When group combination, wired remote controller shall be
connected to the follower indoor unit.	Outdoor unit

– 27 –

FILE NO. SVM-12004

7-2. Control Specifications (High Wall Type)

No.

Item

Outline of specifications

Remarks

1

When power

1)

Distinction of outdoor unit

supply is reset

When the power supply is reset, the outdoors are distin-

guished and the control is selected according to the

distinguished result.

2)

Setting of indoor fan speed and existence of air direction

adjustment

Based on EEPROM data, select setting of the indoor fan

Fan speed (rpm)/

speed and the existence of air direction adjustment.

Air direction adjustment

2

Operation

1)

Based on the operation mode selecting command from the

mode selection

remote controller, the operation mode is selected.

Remote controller

Control outline

command

STOP

Air conditioner stops.

FAN

Fan operation

COOL

Cooling operation

DRY

Dry operation

HEAT

Heating operation

Ta: Room temp.

AUTO

• COOL/HEAT operation mode is

automatically selected by Ta, Ts

Ts: Setup temp.

and To for operation.

To: Outside temp.

• The operation is performed as

shown in the following figure

according to Ta value at the first

time only. (In the range of Ts +

α –1 < Ta < Ts + α

+ 1, Cooling

thermo. OFF (Fan)/Setup air

volume operation continues.)

Cooling

1.0

operation

Cooling thermo. OFF (Fan)

Ta

˚C Ts + α

• Setup air volume

–1.0

Heating

operation

• α is corrected according to the outside temperature.

Outside temp.

Correction value (α)

K = deg

No To

0K

To ≥ 24°C

–1K

24°C > To ≥ 18°C

0K

To < 18°C

+1K

To error

0K

3

Room temp.

1)

Adjustment range: Remote controller setup temperature °C

control

COOL/DRY

HEAT

AUTO

Wired type

18°C to 29°C

Wireless type

17°C to 30°C

When use of remote sensor is set (with DN32), even when sensor value is within

the above range in HEAT or AUTO mode, the thermo. sensor turns OFF when Ta

sensor value exceeds 35°C.

– 28 –

											FILE NO. SVM-12004
No.	Item		Outline of specifications								Remarks
3	Room temp.	2) Using the CODE No. 06, the setup temperature in heating									Shift of suction
	control		operation can be corrected.								temperature in heating
	(Continued)										operation

Setting at shipment

SET DATA	3

4 Automatic	1)	Based on the difference between Ta and Ts, the operation frequency is instructed to
capacity control		the outdoor unit.
(GA control)	2)	Cooling operation
		Every 90 seconds, the room temperature difference between temperature detected by
		Ta and Ts and the varied room temperature value are calculated to obtain the
		correction value of the frequency command and then the present frequency command
		is corrected.
		Ta (n) – Ts (n)	: Room temp. difference
		n	: Counts of detection
		Ta (n-1) – Ts (n) : Varied room temp. value
		n – 1	: Counts of detection of 90 seconds before

3)Heating operation

Every 1 minute (60 sec.), the room temperature difference between temperature detected by Ta and Ts and the varied room temperature value are calculated to obtain the correction value of the frequency command and then the present frequency command is corrected.

		Ts (n) – Ta (n)	: Room temp. difference
		n	: Counts of detection
		Ta (n) – Ta (n – 1) : Varied room temp. value
		n – 1	: Counts of detection of 1 minute before
	4)	Dry operation
		The frequency correction control is same as those of the cooling operation.
		However the maximum frequency is limited to approximately “S6”.
	Note) When LOW is set up, the maximum frequency is limited to approximately “SB”.
5 Automatic	1)	The judgment of selecting COOL/HEAT is carried out as
cooling/heating		shown below. When +1.5°C exceeds against Tsh							Tsc: Setup temp. in
control		10 minutes and after thermo.-OFF, heating operation
									cooling operation
		(Thermo. OFF) exchanges to cooling operation.
									Tsh: Setup temp. in
		Description in the parentheses shows an example of
									heating operation
		cooling ON/OFF.
									+ temp. correction
									of room temp. control
		˚C		Cooling
		+1.5
							(Cooling ON)
		Tsc or Tsh
						(Cooling OFF)
		–1.5
						Heating

When –1.5°C lowers against Tsc 10 minutes and after thermo. OFF, cooling operation (Thermo. OFF) exchanges to heating operation.

2)For the automatic capacity control after judgment of cooling/heating, see Item 4.

3)For temperature correction of room temp. control in automatic heating, see Item 3.

– 29 –

			FILE NO. SVM-12004
No.	Item	Outline of specifications	Remarks
6	Fan speed control	1) Operation with (HH), (H), (L) or [AUTO] mode is carried	HH > H+ > H > L+ > L >
		out by the command from the remote controller.	UL

2)	When the fan speed mode [AUTO] is selected, the fan
	speed varies by the difference between Ta and Ts.			Wireless type allows HH,
<COOL>				H+, H, L+, L and AUTO.
				[HH]
	Ta ˚C		A	[H+]
	+3.0
				[H]
		HH	B
	+2.5
		(HH)	C	[L+]
	+2.0
				[L]
		H+ (HH)	D
	+1.5
		H (HH)
	+1.0
		L+ (H+)	E
	+0.5
		L (H)
	Tsc
		L (H)	F
	–0.5
		L (L+)	G

•Controlling operation in case when thermo of remote controller works is same as a case when thermo of the body works.

•If the fan speed has been changed once, it is not changed for 3 minutes. However when the air volume is exchanged, the fan speed changes.

•When cooling operation has started, select a downward slope for the fan speed, that is, the high position.

•If the temperature is just on the difference boundary, the fan speed does not change.

•Mode in the parentheses indicates one in automatic cooling operation.

<HEAT>

	Ta ˚C	L (L+)
	(–0.5) –1.0
		L+ (H)	E
	(0) Tsh
		H (H+)
	(+0.5) +1.0
			D
		H+
	(+1.0) +2.0	(HH)
			C
	(+1.5) +3.0	HH
		(HH)	B
	(+2.0) +4.0
			A

Value in the parentheses indicates one when thermostat of the remote controller works.

Value without parentheses indicates one when thermostat of the body works.

•If the fan speed has been changed once, it is not changed for 1 minute. However when the fan speed I exchanged, the fan speed changes.

•When heating operation has started, select an upward slope for the fan speed, that is, the high position.

•If the temperature is just on the difference boundary, the fan speed does not change.

• Mode in the parentheses indicates one in automatic	Tc: Indoor heat
heating operation.	exchanger sensor
• In Tc ≥ 60°C, the fan speed increases by 1 step.	temperature

– 30 –