Toshiba RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL User Manual

FILE NO. A09-010

SERVICE MANUAL

AIR-CONDITIONER

SPLIT TYPE

OUTDOOR UNIT

<SUPER DIGITAL INVERTER>

RAV-SP180AT2-UL RAV-SP240AT2-UL RAV-SP300AT2-UL RAV-SP360AT2-UL RAV-SP420AT2-UL

(2 HP)

(3 HP)

(4 HP)

(4, 5 HP)

(5 HP)

R410A

PRINTED IN JAPAN, Dec., 2009 ToMo

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.

– 2 –

CONTENTS

SAFETY CAUTION ............................................................................................			4
1.	SPECIFICATIONS ......................................................................................		9
	1-1.	Outdoor Unit........................................................................................................	9
	1-2.	Operation Characteristic Curve.......................................................................	10
2.	CONSTRUCTION VIEWS (EXTERNAL VIEWS).......................................		12
	2-1.	Outdoor Unit......................................................................................................	12
3.	SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ..............................		15
	3-1.	Indoor Unit.........................................................................................................	15
	3-2.	Outdoor Unit......................................................................................................	16
4.	WIRING DIAGRAM ...................................................................................		19
	4-1.	Outdoor Unit......................................................................................................	19
5.	SPECIFICATIONS OF ELECTRICAL PARTS ..........................................		22
	5-1.	Outdoor Unit (Parts Ratings) ...........................................................................	22
6.	REFRIGERANT R410A ............................................................................		23
	6-1.	Safety During Installation/Servicing ...............................................................	23
	6-2.	Refrigerant Piping Installation.......................................................................	23
	6-3.	Tools ..................................................................................................................	27
	6-4.	Recharging of Refrigerant................................................................................	27
	6-5.	Brazing of Pipes................................................................................................	28
7.	CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS ...........		30
	7-1.	Print Circuit Board <MCC-1571> .....................................................................	30
	7-2.	Outline of Main Controls ..................................................................................	32
8.	TROUBLESHOOTING ..............................................................................		45
	8-1.	Summary of Troubleshooting...........................................................................	45
	8-2.	Troubleshooting ................................................................................................	47
9.	REPLACEMENT OF SERVICE P.C. BOARD............................................		73
	9-1.	Outdoor Unit......................................................................................................	73
10.	SETUP AT LOCAL SITE AND OTHERS ..................................................		74
	10-1.	Outdoor Unit......................................................................................................	74
11.	DETACHMENTS .......................................................................................		82
	11-1.	Outdoor Unit.....................................................................................................	82
12.	EXPLODED VIEWS AND PARTS LIST ..................................................		106
	12-1.	Outdoor Unit....................................................................................................	106

– 3 –

SAFETY CAUTION

The important contents concerned to the safety are described on the product itself and on this Service Manual.

Please read this Service Manual after understanding the described items thoroughly in the following contents (Indications/Illustrated marks), and keep them.

[Explanation of indications]

Indication	Explanation
DANGER	Indicates contents assumed that an imminent danger causing a death or serious injury of
	the repair engineers and the third parties when an incorrect work has been executed.

Indicates possibilities assumed that a danger causing a death or serious injury of the WARNING repair engineers, the third parties, and the users due to troubles of the product after work

when an incorrect work has been executed.

Indicates contents assumed that an injury or property damage ( ) may be caused on the CAUTION repair engineers, the third parties, and the users due to troubles of the product after work

when an incorrect work has been executed.

Property damage : Enlarged damage concerned to property, furniture, and domestic animal/pet

[Explanation of illustrated marks]

Mark	Explanation

Indicates prohibited items (Forbidden items to do)

The sentences near an illustrated mark describe the concrete prohibited contents.

Indicates mandatory items (Compulsory items to do)

The sentences near an illustrated mark describe the concrete mandatory contents.

Indicates cautions (Including danger/warning)

The sentences or illustration near or in an illustrated mark describe the concrete cautious contents.

[Confirmation of warning label on the main unit]

Confirm that labels are indicated on the specified positions (Refer to the Parts disassembly diagram (Outdoor unit).)

If removing the label during parts replace, stick it as the original.

DANGER

	Turn “OFF” the breaker before removing the front panel and cabinet, otherwise an electric
	shock is caused by high voltage resulted in a death or injury.
	During operation, a high voltage with 400V or higher of circuit ( ) at secondary circuit of the
	high-voltage transformer is applied.
Turn off breaker.	If touching a high voltage with the naked hands or body, an electric shock is caused even if using an
	electric insulator.
	: For details, refer to the electric wiring diagram.

		When removing the front panel or cabinet, execute short-circuit and discharge between
		high-voltage capacitor terminals.
	Execute discharge	If discharge is not executed, an electric shock is caused by high voltage resulted in a death or injury.
		After turning off the breaker, high voltage also keeps to apply to the high-voltage capacitor.
	between terminals.

Do not turn on the breaker under condition that the front panel and cabinet are removed.

An electric shock is caused by high voltage resulted in a death or injury.

Prohibition

– 4 –

WARNING

		Before troubleshooting or repair work, check the earth wire is connected to the earth
		terminals of the main unit, otherwise an electric shock is caused when a leak occurs.
	Check earth wires.	If the earth wire is not correctly connected, contact an electric engineer for rework.
		Do not modify the products.
		Do not also disassemble or modify the parts. It may cause a fire, electric shock or injury.
	Prohibition of modification.
		For spare parts, use those specified ( ).
		If unspecified parts are used, a fire or electric shock may be caused.
	Use specified parts.	: For details, refer to the parts list.
		Before troubleshooting or repair work, do not bring a third party (a child, etc.) except
		the repair engineers close to the equipment.
	Do not bring a child	It causes an injury with tools or disassembled parts.
		Please inform the users so that the third party (a child, etc.) does not approach the equipment.
	close to the equipment.
		Connect the cut-off lead wires with crimp contact, etc, put the closed end side
		upward and then apply a water-cut method, otherwise a leak or production of fire is
		caused at the users’ side.
	Insulating measures

When repairing the refrigerating cycle, take the following measures.

1)Be attentive to fire around the cycle. When using a gas stove, etc, be sure to put out fire before work; otherwise the oil mixed with refrigerant gas may catch fire.

	2) Do not use a welder in the closed room.
No fire	When using it without ventilation, carbon monoxide poisoning may be caused.

3)Do not bring inflammables close to the refrigerant cycle, otherwise fire of the welder may catch the inflammables.

		Check the used refrigerant name and use tools and materials of the parts which
		match with it.
		For the products which use R410A refrigerant, the refrigerant name is indicated at a
		position on the outdoor unit where is easy to see. To prevent miss-charging, the route of the
		service port is changed from one of the former R22.
		For an air conditioner which uses R410A, never use other refrigerant than R410A.
		For an air conditioner which uses other refrigerant (R22, etc.), never use R410A.
		If different types of refrigerant are mixed, abnormal high pressure generates in the
		refrigerating cycle and an injury due to breakage may be caused.
		Do not charge refrigerant additionally.
		If charging refrigerant additionally when refrigerant gas leaks, the refrigerant composition in
		the refrigerating cycle changes resulted in change of air conditioner characteristics or
		refrigerant over the specified standard amount is charged and an abnormal high pressure is
		applied to the inside of the refrigerating cycle resulted in cause of breakage or injury.
		Therefore if the refrigerant gas leaks, recover the refrigerant in the air conditioner, execute
	Refrigerant	vacuuming, and then newly recharge the specified amount of liquid refrigerant.
		In this time, never charge the refrigerant over the specified amount.
		When recharging the refrigerant in the refrigerating cycle, do not mix the refrigerant
		or air other than R410A into the specified refrigerant.
		If air or others is mixed with the refrigerant, abnormal high pressure generates in the
		refrigerating cycle resulted in cause of injury due to breakage.
		After installation work, check the refrigerant gas does not leak.
		If the refrigerant gas leaks in the room, poisonous gas generates when gas touches to fire
		such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.
		Never recover the refrigerant into the outdoor unit.
		When the equipment is moved or repaired, be sure to recover the refrigerant with
		recovering device. The refrigerant cannot be recovered in the outdoor unit; otherwise a
		serious accident such as breakage or injury is caused.
		After repair work, surely assemble the disassembled parts, and connect and lead the
		removed wires as before. Perform the work so that the cabinet or panel does not
		catch the inner wires.
	Assembly/Cabling	If incorrect assembly or incorrect wire connection was done, a disaster such as a leak or
		fire is caused at user’s side.

– 5 –

WARNING

		After the work has finished, be sure to use an insulation tester set (500V Megger) to
		check the resistance is 2MΩ or more between the charge section and the non-charge
		metal section (Earth position).
	Insulator check	If the resistance value is low, a disaster such as a leak or electric shock is caused at user’s
		side.
		When the refrigerant gas leaks during work, execute ventilation.
		If the refrigerant gas touches to a fire, poisonous gas generates.
		A case of leakage of the refrigerant and the closed room full with gas is dangerous because
	Ventilation	a shortage of oxygen occurs. Be sure to execute ventilation.
		When checking the circuit inevitably under condition of the power-ON, use rubber
		gloves and others not to touch to the charging section.
		If touching to the charging section, an electric shock may be caused.
	Be attentive to
	electric shock
		When the refrigerant gas leaks, find up the leaked position and repair it surely.
		If the leaked position cannot be found up and the repair work is interrupted, pump-down
		and tighten the service valve, otherwise the refrigerant gas may leak into the room.
		The poisonous gas generates when gas touches to fire such as fan heater, stove or cocking
		stove though the refrigerant gas itself is innocuous.
		When installing equipment which includes a large amount of charged refrigerant
		such as a multi air conditioner in a sub-room, it is necessary that the density does
		not the limit even if the refrigerant leaks.
	Compulsion	If the refrigerant leaks and exceeds the limit density, an accident of shortage of oxygen is
		caused.
		For the installation/moving/reinstallation work, follow to the Installation Manual.
		If an incorrect installation is done, a trouble of the refrigerating cycle, water leak, electric
		shock or fire is caused.
		After repair work has finished, check there is no trouble.
		If check is not executed, a fire, electric shock or injury may be caused.
		For a check, turn off the power breaker.
	Check after repair
		After repair work (installation of front panel and cabinet) has finished, execute a test
		run to check there is no generation of smoke or abnormal sound.
		If check is not executed, a fire or an electric shock is caused.
		Before test run, install the front panel and cabinet.

Check the following items after reinstallation.

Check after reinstallation	1)	The earth wire is correctly connected.
	2)	The power cord is not caught in the product.
	3)	There is no inclination or unsteadiness and the installation is stable.
		If check is not executed, a fire, an electric shock or an injury is caused.

CAUTION

	Be sure to put on the gloves ( ) and a long sleeved shirt:
	otherwise an injury may be caused with the parts, etc.
Put on gloves	( ) Heavy gloves such as work gloves
	When the power was turned on, start to work after the equipment has been
	sufficiently cooled.
Cooling check	As temperature of the compressor pipes and others became high due to cooling/heating
	operation, a burn may be caused.

– 6 –

• New Refrigerant (R410A)

This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer.

1. Safety Caution Concerned to New Refrigerant

The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of refrigerant, the refrigerating oil has been also changed.

Therefore, be sure that water, dust, the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with new refrigerant during installation work or service work.

If an incorrect work or incorrect service is performed, there is a possibility to cause a serious accident. Use the tools and materials exclusive to R410A to purpose a safe work.

2.Cautions on Installation/Service

1)Do not mix the other refrigerant or refrigerating oil.

For the tools exclusive to R410A, shapes of all the joints including the service port differ from those of the former refrigerant in order to prevent mixture of them.

2)As the use pressure of the new refrigerant is high, use material thickness of the pipe and tools which are specified for R410A.

3)In the installation time, use clean pipe materials and work with great attention so that water and others do not mix in because pipes are affected by impurities such as water, oxide scales, oil, etc.

Use the clean pipes.

Be sure to brazing with flowing nitrogen gas. (Never use gas other than nitrogen gas.)

4)For the earth protection, use a vacuum pump for air purge.

5)R410A refrigerant is azeotropic mixture type refrigerant.

Therefore use liquid type to charge the refrigerant. (If using gas for charging, composition of the refrigerant changes and then characteristics of the air conditioner change.)

3.Pipe Materials

For the refrigerant pipes, copper pipe and joints are mainly used.

It is necessary to select the most appropriate pipes to conform to the standard.

Use clean material in which impurities adhere inside of pipe or joint to a minimum.

1) Copper pipe

<Piping>

The pipe thickness, flare finishing size, flare nut and others differ according to a refrigerant type.

When using a long copper pipe for R410A, it is recommended to select “Copper or copper-base pipe without seam” and one with bonded oil amount 0.0001 lbs / 32’ 10” (40 mg / 10 m) or less.

Also do not use crushed, deformed, discolored (especially inside) pipes. (Impurities cause clogging of expansion valves and capillary tubes.)

<Flare nut>

Use the flare nuts which are attached to the air conditioner unit.

2)Joint

The flare joint and socket joint are used for joints of the copper pipe.

The joints are rarely used for installation of the air conditioner. However clear impurities when using them.

–7 –

4.Tools

1.Required Tools for R410A

Mixing of different types 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		Conventional air
				air conditioner installation		conditioner installation
	No.	Used tool	Usage
				Existence of	Whether conven-	Whether conventional
				new equipment	tional equipment
						equipment can be used
				for R410A	can be used
	Q	Flare tool	Pipe flaring	Yes	*(Note)	Yes
	R	Copper pipe gauge for	Flaring by conventional	Yes	*(Note)	*(Note)
		adjusting projection margin	flare tool
	S	Torque wrench	Tightening of flare nut	Yes	No	No
	T	Gauge manifold	Evacuating, refrigerant	Yes	No	No
	U	Charge hose	charge, run check, etc.
	V	Vacuum pump adapter	Vacuum evacuating	Yes	No	Yes
	W	Electronic balance for	Refrigerant charge	Yes	Yes	Yes
		refrigerant charging
	X	Refrigerant cylinder	Refrigerant charge	Yes	No	No
	Y	Leakage detector	Gas leakage check	Yes	No	Yes

NOTE

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.

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. Use vacuum pump by attaching vacuum pump adapter.

2)	Torque wrench	8)	Spanner or Monkey wrench
3)	Pipe cutter	9)	Hole core drill
4)	Reamer	10)	Hexagon wrench (Opposite side 4mm)
5)	Pipe benderr	11)	Tape measure
6)	Level vial	12)	Metal saw
7)	Screwdriver (+, –)

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

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

– 8 –

1. SPECIFICATIONS

1-1. Outdoor Unit

<Super Digital Inverter>

Size					018	024	030		036		042
Outdoor model				RAV-	SP180AT2-UL	SP240AT2-UL	SP300AT2-UL	SP360AT2-UL			SP420AT2-UL
			Outdoor Min - Max DB 1	(°F)			23 to 109.4
		Cooling	Indoor Min - Max DB	(°F)			69.8 to 89.6
Operating
			Indoor Min - Max WB	(°F)			59 to 75.2
range
			Outdoor WB Min - Max	(°F)			–4 to 59
		Heating
			Indoor DB Min - Max	(°F)			59 to 86
		Standard Piping Length		(ft.)			25
		Min. Piping Length		(ft.)	16’ 5”	16’ 5”	9’ 8”		9’ 8”		9’ 8”
		Max. Piping Length		(ft.)	164’ 1”	164’ 1”	246’ 1”		246’ 1”		246’ 1”
		Lift	(Outdoor below Indoor)	(ft.)			98’ 5”
Piping
		Lift	(Outdoor above Indoor)	(ft.)			98’ 5”
		Gas Pipe	(Size / connection type)		1/2”	5/8”	5/8”		5/8”		5/8”
		Liquid Pipe	(Size / connection type)		1/4”	3/8”	3/8”		3/8”		3/8”
		Additional refrigerant charge			0.22 oz / ft	0.43 oz / ft			0.43 oz / ft
		under long piping connection			(65’7”ft to164’1”ft)	(98’5”ft to 164’1”ft)	(98’5”ft to 246’1”ft)
		Voltage				208 V / 230 V-1-60 Hz
Electrical		Maximum Running Current Amps		(A)	17	24	24		24		24
		Fuse Rating 2			30	40	40		40		40
		Type				Hermetic compressor
Compressor		Motor		(kw)	1.1	2	3.75		3.75		3.75
		Pole			4	4	4		4		4
			Height	(in.)	21.7	35.0	52.8		52.8		52.8
		Dimensions	Width	(in.)	30.7	35.4	35.4		35.4		35.4
			Length	(in.)	11.4	12.6	12.6		12.6		12.6
Outdoor		Weight -Gross / Net		(lbs.)	98 / 105	144.5 / 157	211.5 / 226		211.5 / 226		211.5 / 226
		Refrigerant charged			3.1	4.6	6.8		6.8		6.8
		Appearance	(Munsell symbol)			Silky shade (Muncel 1Y8.5/0.5)
		Sound Pressure		(dBa)	48 / 49	49 / 50	50 / 51		52 / 52		52 / 52

1 When installed a duct or wind shield so that it is not affected by the wind. The minimum outside temperature will be 5°F

2 UL value

– 9 –

1-2. Operation Characteristic CurveRAV*

• Operation characteristic curve <Super Digital Inverter>

RAV-SP180AT2-UL

<Cooling>

	10
	9
	8		RAV-SP180CT, KRT-UL
	7
(A)	6
Current	5
	4
						RAV-SP180UT-UL
	3
						• Conditions
	2					Indoor	: DB 80.6˚F (27˚C)/
							WB 66.2˚F (19˚C)
						Outdoor : DB 95˚F (35˚C)
	1					Air flow	: High
						Pipe length : 295.3” (7.5m)
						230V
	0
			10	20	30	40	50	60	70	80
	0

<Heating>

	16
	14
			RAV-SP180CT, KRT-UL
	12
	10
(A)
Current	8
	6								RAV-SP180UT-UL
	4
									• Conditions
									Indoor	: DB 68˚F (20˚C)
									Outdoor : DB 44.6˚F (7˚C)/
											WB 42.8˚F (6˚C)
	2								Air flow : High
									Pipe length : 295.3” (7.5m)
									230V
	0
			10	20	30	40	50		60	70	80	90 100 110 120
	0

Compressor speed (rps)

RAV-SP240AT2-UL

<Cooling>

	13
	12
	11		RAV-SP240CT, KRT-UL
	10
	9
(A)	8
	7
Current
	6					RAV-SP240UT-UL
	5
	4
	3					• Conditions
						Indoor	: DB 80.6˚F (27˚C)/
							WB 66.2˚F (19˚C)
	2					Outdoor : DB 95˚F (35˚C)
						Air flow	: High
	1					Pipe length : 295.3” (7.5m)
						230V
	0
			10	20	30	40	50	60	70	80
	0

Compressor speed (rps)

Compressor speed (rps)

<Heating>

	22
	20
		RAV-SP240CT, KRT-UL
	18
	16
	14
(A)	12
Current
	10		RAV-SP240UT-UL
	8
	6
			• Conditions
			Indoor : DB 68˚F (20˚C)
	4		Outdoor : DB 44.6˚F (7˚C)/
			WB 42.8˚F (6˚C)
			Air flow : High
	2		Pipe length : 295.3” (7.5m)
			230V

0

0 10 20 30 40 50 60 70 80 90 100 110 120

Compressor speed (rps)

– 10 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL
<Cooling>						<Heating>
	22						22
	20						20
	18	RAV-SP360AT2-UL,					18	RAV-SP300AT2-UL
		RAV-SP420AT2-UL
	16						16
	14						14
(A)	12					(A)	12
Current						Current
	10						10		RAV-SP360AT2-UL,
									RAV-SP420AT2-UL
	8		RAV-SP300AT2-UL				8
	6		• Conditions				6		• Conditions
	4		Indoor	: DB 80.6˚F (27˚C)/			4		Indoor	: DB 68˚F (20˚C)
				WB 66.2˚F (19˚C)					Outdoor : DB 44.6˚F (7˚C)/
			Outdoor : DB 95˚F (35˚C)							WB 42.8˚F (6˚C)
	2		Air flow	: High			2		Air flow	: High
			Pipe length : 295.3” (7.5m)						Pipe length : 295.3” (7.5m)
			230V						230V
	0	20	40	60	80		0	20	40	60	80
	0						0

Compressor speed (rps)

Compressor speed (rps)

• Capacity variation ratio according to temperature

RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL
<Cooling>													<Heating>
	105													120
	100													110
	95													100
	90													90
(%)	85												(%)	80
														70
ratio	80												ratio
														60
Capacity													Capacity
	75													50
	70													40
	65													30
	60					• Conditions								20
						Indoor : DB 80.6˚F (27˚C)/															• Conditions
	55							WB 66.2˚F (19˚C)													Indoor		: DB 68˚F (20˚C)
						Indoor air flow : High								10							Indoor air flow : High
						Pipe length : 295.3” (7.5m)															Pipe length : 295.3” (7.5m)
	50								104					0
	89.6	91.4	93.2	95	96.8	98.6	100.4 102.2			105.8 107.6 109.4				–4	–0.4	3.2	6.8	10.4	14	17.6 21.2 24.8 28.4				32	35.6 39.2 42.8 46.4				50
	(32)	(33)	(34)	(35)	(36)	(37)	(38)	(39)	(40)	(41)	(42)	(43)		(–20)(–18)(–16)(–14)(–12)(–10) (–8)							(–6)	(–4)	(–2)	(0)	(2)	(4)	(6)	(8)	(10)

Outdoor temp. ˚F (˚C)

Outdoor temp. ˚F (˚C)

– 11 –

– 12 –

			A legs		23.6” (600)	1.2”(30)	3.5” (90)	Space required for service
				(60)2.4”
		Drain hole			Drain hole(Ø1” (25))			2-Ø0.4” (11)×0.6” (14) U-shape holes
					4.3” (108) 4.9” (125)		2.1” (54)	(For Ø0.3” (8)-0.4” (10) anchor bolts)
(2-Ø0.7” (20)×3.5” (88) long hole)										23.6” (600)
							2-Ø0.4” (11)-0.6” (14)
										Suction port
	(320)12.6”	hole(Longpitch anchorForbolt) (306)12” (6)Ø0.2”hole pitch	(290)11.4”				8-Ø0.2” (6) hole	12.6”(320)	19.7” (500)
										Discharge port
							U-shape hole			5.9” (150)
							(For Ø0.3” (8)-0.4” (10)			or more	11.8” (300)
							anchor bolts)		5.9” (150)		or more
									or more	Discharge port	(Minimum
											distance
											up to wall)
							(For fixing outdoor unit)		or more	2-Ø0.4” (11)×0.6” (14) long hole
						(16)
		1.2” (30)					2-Ø0.4” (11)×0.6” (14) long hole			(For Ø0.3” (8)-0.4” (10) anchor bolts)
				B legs
	0.8”(21)	0.2”(5)				0.6”	(For Ø0.3” (8)-0.4” (10) anchor bolts)
2.8” (70) 5.8” (147)					19.1” (486)		10” (255)		6.2” (157)	3.1” (79)
					4.3” (108)
										0.8” (21)

		21.7” (550)	19.1” (486)	17.7” (449)
		0.3” (8)	(33)1.3”	(51)2”
					1.3” (32)		19.7” (500)
							30.7” (780)
							Discharge guard
		23.6” (600)			(320)	Ø0.4” (11)×0.6” (14)
						U-shape hole
2.1” (54)
		R0.6” (15)			12.6”		Prpduct
1.5” (38)
							external line
0.4” (11)		2-Ø0.2” (6) hole					2-Ø0.3” (6) hole
(320)					1.5” (38)
		Product					R0.6” (15)
					2.1” (54)
12.6”		external line					23.6” (600)
	Ø0.4” (11)×0.6” (14)
	U-shape hole
	Details of A legs					Details of B legs

0.9” (22)

1” (26)

Charge port

5.6” (141)

2.7” (69)	(88)
	3.5”

Discharge guide mounting hole (4-Ø1.8” (4.5) embossing)

5.7” (145)

6.1” (155)

Refrigerant pipe connecting port

(Ø0.6” (6.4) flare at liquid side)

2” (53)

13.5” (342)

Refrigerant pipe connecting port

(Ø0.5” (12.7) flare at gas side)

-RAV	.1-2
UL-SP180AT2	Unit Outdoor	.2
		VIEWS) (EXTERNAL VIEWS CONSTRUCTION

RAV-SP240AT2-UL

Note		Ø0.9” (22) hole
Name	Refrigerant piping	Conduit hole
	1	2

Drain hole	(Ø1.0” (25) burring hole)	B legs
	2.4” (60)
15.0” (380)	7.9” (200)	Air inlet port

(128)	0”.5
.(175)	7”.0

0.5” (12)

1”.2(54)

(48)9”.1

(170)7”.6 (34) 3”.1

(46)8”.1

3.0” (75)

inlet	port
Air

(118)7”.4

(365)4”.14

Mounting bolt hole (Ø0.5” (12)×0.7” (17) U-shape hole)

Details of B legs

6”.1(40)
Mounting bolt hole	(Ø0.5” (12)×0.7” (17) long hole)	Details of A legs
6”.1(40)
	1.5” (39)	3.8” (96)
A legs	2.8” (70)	(600)
Air outlet port	15.1” (383)	23.6”

		5.9” (150)
	9”.2(74)	(88)
	7”.0.(175)
		5-drain hole Ø0.8” (20)×3.5” burring hole

12.6” (320)
	1.2” (30)
Refrigerant pipe connecting port Ø0.4” (9.5) flare at liquid side	Refrigerant pipe connecting port

35.4” (900)	(550)
	21.7”
	2.0” (52)

						2.5” (64)
		1	7”.3(95)	2”.2(55)		(12)
						0.5”
	0”.35(890)
				.10"(24)
				2.3” (58)			15.7” (400)
	2	1		0.7” (18)	3.9” (99)
	flare		0”.2(50)	4”.3(85)
			1”.5(130)	2”.2(56)
	(15.9)Ø0.6” sidegasat						(7)0.3”
								3”.0(7)
			0”.10(255)
			7”.9(247)
				Z			(83)
							3.3”
					7” (178)
					7” (178) 7” (178)	20.4” (518)	12.9” (327)
	0”.21(534)			(165)	(60)	(68)
					2.4”	2.7”	holeMounting separatelysold emboss)(3)Ø0.1”-(12
				5”.6
	9”.22(581)			8”.5(148)

(65) 6”.2 viewsZ

forKnockout pipingdownward

– 13 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Note		Ø0.9” (22) hole
Name	Refrigerant piping	Conduit hole
	1	2

Drain hole	(Ø1.0” (25) burring hole)	B legs
	2.4” (60)
15.0” (380)	7.9” (200)	Air inlet port

0”.5(128) 7”.0.(175)

		Mounting bolt hole (Ø0.5” (12)×0.7” (17) U-shape hole)	Details of B legs
(12)	6”.1(40)
0.5”
		Mounting bolt hole (Ø0.5” (12)×0.7” (17) long hole)
			Details of A legs	(96)3.8”		12.6” (320)		pipeRefrigerant portconnecting flare(15.9)Ø0.6” sidegasat
9”.1(48)	6”.1(40)		(39)1.5”				pipeRefrigerant portconnecting flare(9.5)Ø0.4” sideliquidat
1”.2(54)
7”.6(170)		legs	(70)
3”.1(34)		A	15.1”(383) 2.8”	23.6” (600)		35.4” (900) 21.7”(550)
3.0”(75)
		Airoutlet port			(150)
8”.1(46)
inlet port					5.9”		(52)
Air							2.0”
6”.4(118)		9”.2(74)					9”.22(581)
4”.14(365)		7”.0.(175)			5-drain hole Ø0.8” (20)×3.5” (88)		0”.21(534)
							burring hole

1	7”.3(95)

8”.52(1340)

1.2” (30)	2	1
		(50)	0”.2
		(130)	1”.5
		1”.24(613)
		8”.23(605)

9”.2(74)
8”.4(121)	9”.22(581)
	0”.21(534)
8”.25(655)	2”.14(360)

		2.5” (64)
		(12)
2”.2(55)		0.5”
0”.1(24)
2.3” (58)		15.7” (400)
0.7”(18)	3.9” (99)
4”.3(85)

(56)2”.2

(7)3”.0

		0.3” (7)
Z		3.3” (83)
7” (178)
7” (178) 7” (178)	20.4” (518)	12.9” (327)
2.4” (60)	2.7” (68)
	7”.2(70)
	3”.3(85)
	Mounting hole	sold separately (24-Ø0.1” (3) emboss)

(65) 6”.2 viewsZ

forKnockout pipingdownward

– 14 –

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Indoor Unit

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

(Indoor unit)

Distributor

(Strainer incorporated)

TCJ sensor

Strainer

Air heat

exchanger TC sensor

Heating Cooling

Refrigerant pipe at liquid side (Outer dia : ØB)

Refrigerant pipe at gas side (Outer dia : ØA)

To outdoor unit

To outdoor unit

Dimension table

Indoor unit		Outer diameter of refrigerant pipe
		Gas side ØA	Liquid side ØB
RAV-SP180AT2-UL		1/2” (12.7)	1/4” (6.4)
RAV-SP240, 300, 360, 420AT2-UL		5/8” (15.9)	3/8” (9.5)

– 15 –

3-2. Outdoor Unit

RAV-SP180AT2-UL

		TO sensor	PMV
			(Pulse Motor Valve)
			(CAM-B30YGTF-2)
TS	TD
sensor	sensor
			TE sensor
	4-way valve			Muffler
				Ø31.75 × 200L
	(STF-0213Z)
	Muffler	Heat exchanger
	Ø19.05 × 160L
		Ø8 ripple, 2 rows, 20 stages
		FP1.3, flat fin	Distributor	Strainer
Accumulator				Refrigerant pipe
(1L)
Rotary compressor				at liquid side Ø6.4

	(DA150A1F-21F)	Packed valve
		Refrigerant pipe
		at gas side Ø12.7
		Packed valve
		2-step muffler
		Ø25 × 200L
		In cooling operation
		In heating operation

				Pressure			Pipe surface temperature °F (°C)				Compressor		Indoor/Outdoor
			(psi)		(MPa)		Discharge	Suction	Indoor heat	Outdoor heat	drive revolution	Indoor	temp. conditions
													(DB/WB) °F °C)
									exchanger	exchanger	frequency	fan
											(rps)
			Pd	Ps	Pd	Ps	(TD)	(TS)	(TC)	(TE)			Indoor	Outdoor
		Standard	416.2	145.0	2.87	1.00	161.6	60.8	55.4	107.6	58	HIGH	80.6/66.2	95/–
							(72)	(16)	(13)	(42)			(27/19)	(35/–)
	Cooling	Overload	517.7	159.5	3.57	1.10	190.4	68	66.2	125.6	65	HIGH	89.6/75.2	109.4/–
							(88)	(20)	(19)	(52)			(32/24)	(43/–)
		Low load	248.0	110.2	1.71	0.76	113.0	53.6	44.6	55.4	30	LOW	64.4/59.9	23/–
							(45)	(12)	( 7)	(13)			(18/15.5)	(–5/–)
		Standard	327.7	98.6	2.26	0.68	150.8	42.8	98.6	37.4	64	HIGH	68/–	44.6/42.8
							(66)	( 6)	(37)	( 3)			(20/–)	(7/6)
	Heating	Overload	471.3	165.3	3.25	1.14	172.4	68.0	127.4	60.8	30	LOW	86/–	75.2/64.4
							(78)	(20)	(53)	(16)			(30/–)	(24/18)
		Low load	290.0	36.3	2.00	0.25	172.4	–0.4	93.2	–0.4	88	HIGH	59/–	5/–
							(78)	(–18)	(34)	(–18)			(15/–)	(–15/–)

– 16 –

RAV-SP240AT2-UL

	TS sensor			PMV
		TO sensor	TL sensor
				(Pulse Motor Valve)
				(CAM-B30YGTF-2)
				Ø2 × Ø3 × 600L
	TD
	sensor			Ø2 × Ø3 × 550L
	Accumulator			Strainer
	Sub-ass’y			Ø2 × Ø3 × 450L
	4-way valve			TE sensor
	(STF-0218G)
				Ø2 × Ø3
				× 450L
	Muffler			Capillary
		Heat exchanger		Refrigerant pipe
	Ø25 × L180	Ø8, 2 rows, 34 stages
				at liquid side Ø9.5
		FP1.45, flat fin
				Packed valve
	Accumulator
	(1.8L)
	Rotary compressor Ø25 × L210
	(DA220A2F-22L)			Refrigerant pipe
				at gas side Ø15.9

		Strainer	Ball valve
In cooling operation
In heating operation

			Pressure				Pipe surface temperature °F (°C)				Compressor		Indoor/Outdoor
		(psi)		(MPa)		Discharge		Suction	Indoor heat	Outdoor heat	drive revolution	Indoor	temp. conditions
													(DB/WB) °F °C)
									exchanger	exchanger	frequency	fan
											(rps)
		Pd	Ps	Pd	Ps	(TD)		(TS)	(TC)	(TE)			Indoor	Outdoor
	Standard	404.6	129.1	2.79	0.89	158.0		55.4	51.8	102.2	58.2	HIGH	80.6/66.2	95/–
						(70)		(13)	(11)	(39)			(27/19)	(35/–)
Cooling	Overload	511.9	155.2	3.53	1.07	177.8		62.6	57.2	118.4	65.0	HIGH	89.6/75.2	109.4/–
						(81)		(17)	(14)	(48)			(32/24)	(43/–)
	Low load	248.0	104.4	1.71	0.72	107.6		44.6	37.4	64.4	30.0	LOW	64.4/59.9	23/–
						(42)		( 7)	( 3)	(18)			(18/15.5)	(–5/–)
	Standard	384.3	98.6	2.65	0.68	165.2		39.2	111.2	37.4	61.5	HIGH	68	44.6/42.8
						(74)		( 4)	(44)	( 3)			(20/–)	(7/6)
Heating	Overload	464.0	161.0	3.2	1.11	168.8		66.2	125.6	59	28.0	LOW	86/–	75.2/64.4
						(76)		(19)	(52)	(15)			(30/–)	(24/18)
	Low load	337.9	30.5	2.33	0.21	199.4		–0.4	87.8	–4	99.6	HIGH	59/–	5/–
						(93)		(–18)	(31)	(–20)			(15/–)	(–15/–)

– 17 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

	TS sensor	TO sensor
			PMV
		TL sensor
			Strainer
	Check joint		TE sensor	Capillary
	Cooling: High pressure
				Ø4 ×Ø3 (6 pcs.)
	Heating: Low pressure
		Heat exchanger	Distributor	Refrigerant pipe
	TD sensor	Ø8, 2 rows, 52 stages
		FP1.45, flat fin		at liquid side Ø9.5
				Packed valve
		In cooling operation
		In heating operation		Refrigerant pipe
			Strainer	at gas side Ø15.9
				Ball valve
	Muffler		Cooling: Low pressure
		Ø25 × L180	Heating: High pressure
	Ø25 × L210
Accumulator	Rotary compressor
(2500cc)	(DA422A3F-25M)

RAV-SP300AT2-UL

			Pressure				Pipe surface temperature °F (°C)					Compressor		Indoor/Outdoor
		(psi)		(MPa)		Discharge		Suction	Indoor heat	Outdoor heat		drive revolution	Indoor	temp. conditions
									exchanger	exchanger		frequency	fan	(DB/WB) °F (°C)
		Pd	Ps	Pd	Ps	(TD)		(TS)	(TC)	(TL)	(TE)	(rps)		Indoor	Outdoor
	Standard	372.7	143.6	2.57	0.99	150.8		57.2	53.6	111.2	104.0	38	HIGH	80.6/66.2	95/–
						(66)		(14)	(12)	(44)	(38)			(27/19)	(35/–)
Cooling	Overload	478.5	158.1	3.30	1.09	172.4		48.2	55.4	120.2	109.4	53	HIGH	89.6/75.2	109.4/–
						(78)		( 9)	(13)	(49)	(43)			(32/24)	(43/–)
	Low load	252.3	108.8	1.74	0.75	114.8		44.6	41.0	89.6	77.0	21	LOW	64.4/59.9	23/–
						(46)		( 7)	( 5)	(32)	(25)			(18/15.5)	(–5/–)
	Standard	336.4	105.9	2.32	0.73	149.0		37.4	102.2	35.6	37.4	43	HIGH	68/–	44.6/42.8
						(65)		( 3)	(39)	( 2)	( 3)			(20/–)	(7/6)
Heating	Overload	466.9	169.7	3.22	1.17	163.4		66.2	129.2	57.2	59.0	26	LOW	86/–	75.2/64.4
						(73)		(19)	(54)	(14)	(15)			(30/–)	(24/18)
	Low load	314.7	43.5	2.17	0.30	188.6		5	100.4	6.8	8.6	71	HIGH	59/–	5/–
						(87)		(–15)	(38)	(–14)	(–13)			(15/–)	(–15/–)

This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp meter becomes 2 times of No. of compressor revolutions (rps).

RAV-SP360AT2-UL, RAV-SP420AT2-UL

			Pressure				Pipe surface temperature °F (°C)					Compressor		Indoor/Outdoor
		(psi)		(MPa)		Discharge		Suction	Indoor heat	Outdoor heat		drive revolution	Indoor	temp. conditions
									exchanger	exchanger		frequency	fan	(DB/WB) °F (°C)
		Pd	Ps	Pd	Ps	(TD)		(TS)	(TC)	(TL)	(TE)	(rps)		Indoor	Outdoor
	Standard	394.4	130.5	2.72	0.90	163.4		53.6	50	114.8	100.4	51	HIGH	80.6/66.2	95/–
						(73)		(12)	(10)	(46)	(38)			(27/19)	(35/–)
Cooling	Overload	484.3	155.2	3.34	1.07	176.0		48.2	55.4	123.8	113.0	55	HIGH	89.6/75.2	109.4/–
						(80)		( 9)	(13)	(51)	(45)			(32/24)	(43/–)
	Low load	253.8	110.2	1.75	0.76	116.6		46.4	42.8	91.4	77.0	21	LOW	64.4/59.9	23/–
						(47)		( 8)	( 6)	(33)	(25)			(18/15.5)	(–5/–)
	Standard	375.6	100.1	2.59	0.69	167		37.4	109.4	35.6	35.6	53	HIGH	68/–	44.6/42.8
						(45)		( 3)	(43)	( 2)	( 2)			(20/–)	(7/6)
Heating	Overload	453.9	152.3	3.13	1.05	161.6		60.8	127.4	53.6	55.4	26	LOW	86/–	75.2/64.4
						(72)		(16)	(53)	(12)	(13)			(30/–)	(24/18)
	Low load	348.0	30.45	2.40	0.21	206.6		–7.6	107.6	–2.2	–0.4	90	HIGH	59/–	5/–
						(97)		(–22)	(42)	(–19)	(–18)			(15/–)	(–15/–)

This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp meter becomes 2 times of No. of compressor revolutions (rps).

–18 –

4. WIRING DIAGRAM

4-1. Outdoor Unit

RAV-SP180AT2-UL

ORN

49C

CN500

2

2

3 3

1

1

BLK

1

1

P.C. Board

HP SW

Compressor

(MCC-5009)

3 3

1 1 RED

P04

1 1

CM

2 2

WHI

P05

CN300

BLK

3 3

BLK

P06

3

3

Q200~205

Q300~305

2

2

WHI

FM

IGBT

MOS-FET

1

1

RED

P25

R221

R321

Fan motor

YEL

P24

R220

R320

6

6

P23

5

YEL

P22

R219

R319

4

4

PMV

P21

CN700

3

3

BRN

P20

2

2

Pulse

L03

C13

1

1

P35

motor valve

YEL

P34

DB01

3

3

P19

CN603

2

F03

1

1

ORN

P18

Power

Fuse, T3.15A

TS

relay

AC250V

(Suction pipe temp. sensor)

C12

C14

2

2

Varistor

CN602

1

1

CT

TO

DB02

L1

(Outdoor temp. sensor)

Relay

3

3

Reactor

Surge

CN601

2

P11

absorber

2

2

P08

1

1

1 1

TD

Varistor

(Discharge pipe temp. sensor)

F01

Q404

Fuse, T25A

CN600

2

2

AC250V

P33

P32

CN701

P7

P03

P10

P02

CN806

1

1

TE

1

2

3

1

3

1

2

3

4

5

(Condenser pipe temp. sensor)

CN605

P31

P30

BLK

ORN

BLK

WHI

BLK

1 2 3

PUR

2 1

1

3

For optional

RED

WHI

BLK

P.C. Board

Color

2

1

1 2 3

Reactor

Identification

Coil for

BLK : BLACK

1 2 3

Reactor

4-way valve

GRN/YEL

BLU : BLUE

SW802

WHI

RED

WHI

RED : RED

MCC-1530

GRY : GRAY

PNK : PINK

Sub P.C. Board

L1 L2

S

L1

L2

GRN : GREEN

WHI : WHITE

BRN : BROWN

High voltage

ORN : ORANGE

YEL : YELLOW

CAUTION : HIGH VOLTAGE

PUR : PURPLE

To indoor

Power supply

The high voltage circuit is incorporated.

208/230-1-60

NOTE

Be careful to do the check service, as the

CM

: Compressor

electric shock may be caused in case of

touching parts on the P.C. board by hand.

PMV

: Pulse Motor Valve

FM

: Fan Motor

TE

: Heat Exchanger Temp. Sensor

The 4-way valve coil is turned on while the cooling operation

TD

: Discharge Temp. Sensor

TO

: Outdoor Temp. Sensor

1.

indicates the terminal block.

TS

: Suction Temp. Sensor

IGBT

: Insulated Gate Bipolar Transistor

Alphanumeric characters in the cycle indicate the terminal No.

DB

: Rectifier

2. The two-dot chain line indicates the wiring procured locally.

CT

: Curreut Transformer

3.

indicates the P.C. board.

49C

: Compressor Case Thermostat

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

HP SW : High pressure switch

– 19 –

RAV-SP240AT2-UL

			CM
Reactor	Reactor	(RED)	(WHI)	(BLK)

			(GRY)	(GRY)	(WHI)	(WHI)	U	V	W
	1	1	P04 P05		P06 P07		CN200	CN201	CN202
FM	2	2	CN300
			(WHI)
	3	3
49C
	1	1	CN609
	2	2	(BLU)
HP	SW		SW804 SW801 SW800
	1	1	CN690	4
	2	2	(RED)	3
		1		2
			ON	1
		2
		3	CN610
		4	(YEL)		Control P.C. Board
		5	SW803
		6				MCC-1571

	TL	1	1	CN604
		2	2	(WHI)
		1	1	CN603
	TD		2
				(WHI)
		3	3
	TO	1	1	CN602
		2	2	(YEL)
	TE	1	1	CN601
		2	2	(WHI)

	4
	3
	2
ON	1
	4
	3
	2
ON	1

SW802

L/F

Fuse, F01

T25A, 250V~

P09

	Fuse, F03
RY704	T10A, 250V~

(BLK)

	1	1	CN600
	TS	2		CN701	CN04
			(WHI)
	3	3		(WHI)	(WHI)

CN710	1	2	3	4	5	6	1	3	1	4	1	3	5	7
(WHI)	1	2	3	4		6	CN704		1	4	1	3	5	7
							(BLU)			(GRY)		(WHI)	(RED)	(BLK)
			PMW						20SF
									Earth
									screw

L1

L2

S

Symbol

Parts name

CM

Compressor

FM

Fan Motor

Outdoor unit

High voltage

PMV

Pulse Motor Valve

TD

Pipe temp. sensor (Discharge)

Indoor unit

TS

Pipe temp. sensor (Suction)

S

TE

Heat exchanger sensor 1

L1

L2

TL

Heat exchanger sensor 2

Earth

TO

Outside temp. sensor

screw

20SF

4-way valve coil

49C

Compressor case thermostat

HP SW

High pressure switch

RY

Relay

L/F

Line Filter

1. indicates the terminal block.

Alphanumeric characters in the cycle indicate the terminal No.

2.The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4.For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

P01 P02

(RED) (WHI)

Earth screw

L1 L2

Power supply 208/230-1-60

Color

Identification

BLK : BLACK

BLU : BLUE

RED : RED

GRY : GRAY

WHI : WHITE

YEL : YELLOW

– 20 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

FM01

FM02

49C

HP SW

TL

TD

TO

TE

CM

Reactor (RED) (WHI) (BLK)

Reactor			(GRY)	(GRY)	(WHI)	(WHI)	U	V	W
1	1		P04 P05		P06 P07		CN200	CN201	CN202
2	2	CN400
		(WHI)
3	3
1	1	CN300
2	2
		(WHI)
3	3
1	1	CN609
2	2	(BLU)
			SW804 SW801 SW800
1	1	CN690		4
2	2	(RED)		3
	1			2
			ON	1
	2
	3	CN610
	4	(YEL)			Control P.C. Board
	5		SW803
	6					MCC-1570

11 CN604

22 (WHI)

	1	1	CN603
		2
			(WHI)
	3	3

11 CN602

22 (YEL)

	4
	3
	2
ON	1
	4
	3
	2
ON	1

L/F

Fuse, F01

T25A, 250V~

P09

1	1	CN601	SW802		Fuse, F03
				RY704	T10A, 250V~
2	2	(WHI)

(BLK)

1	1	CN600
TS	2					CN704				CN701		CN04
		(WHI)
3	3						(BLU)			(WHI)		(WHI)
CN710		1	2	3	4	5	6	1	3	1	4	1	3	5	7
(WHI)		1	2	3	4		6			1	4	1	3	5	7

PMW	20SF	(GRY)	(WHI)	(RED)	(BLK)

Symbol

Parts name

Earth

CM

Compressor

screw

FM01, 02

Fan Motor

L1

L2

S

PMV

Pulse Motor Valve

TD

Pipe temp. sensor (Discharge)

TS

Pipe temp. sensor (Suction)

High voltage

TE

Heat exchanger sensor 1

Outdoor unit

TL

Heat exchanger sensor 2

TO

Outside temp. sensor

Indoor unit

20SF

4-way valve coil

S

L1

L2

49C

Compressor case thermostat

Earth

HP SW

High pressure switch

screw

RY

Relay

L/F

Line Filter

1. indicates the terminal block.

Alphanumeric characters in the cycle indicate the terminal No.

2.The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4.For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

P01 P02

(RED) (WHI)

Earth screw

L1 L2

Power supply 208/230-1-60

Color

Identification

BLK : BLACK

BLU : BLUE

RED : RED

GRY : GRAY

WHI : WHITE

YEL : YELLOW

– 21 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Outdoor Unit (Parts Ratings)

RAV-SP180AT2-UL

	No.	Parts name	Type	Specifications
	1	Fan motor	ICF-140-43-4R	Output (Rated) 43 W
	2	Compressor	DA150A1F-21F	3 phase, 4P, 1100 W
	3	Reactor	CH-57	10mH, 16A
	4	Outdoor temp. sensor (To sensor)	—	10 kΩ at 77°F (25°C)
	5	Heat exchanger sensor (Te sensor)	—	10 kΩ at 77°F (25°C)
	6	Suction temp. sensor (Ts sensor)	—	10 kΩ at 77°F (25°C)
	7	Discharge temp. sensor (Td sensor)	—	50 kΩ at 77°F (25°C)
	8	Fuse (Switching power (Protect))	—	T3.15 A, AC 250 V
	9	Fuse (Inverter, input (Current protect))	—	AC 240 V, 25 A
	10	4-way valve solenoid coil	STF-01AJ502E1	—
	11	Compressor thermo. (Protection)	US-622	OFF : 257 ± 39.2°F (125 ± 4°C),
				ON : 194 ± 41°F (90 ± 5°C)
	12	Coil (Pulse Motor Valve)	CAM-MD12TF-12	—
				OFF : 601.8 + 0
	13	Pressure switch	ACB-4UB82W	– 29 psi 4.15 + 0
				4.15 – 0.2 MPa
				ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

RAV-SP240AT2-UL

	No.	Parts name	Type	Specifications
	1	Compressor	DA220A2F-22L	—
	2	Outdoor fan motor	ICF-280-A60-1	Output 60 W
	3	Reactor	CH-56	5.8 mH, 18.5 A
	4	4-way valve coil	VHV-01AP552B1	AC200 – 240 V
	5	PMV coil	CAM-MD12TF-15	DC12 V
	6	P.C. board	MCC-1571	AC208 / 230 V
	7	Fuse (Mounted on P.C. board)	—	AC250 V, 25 A
	8	Fuse (Mounted on P.C. board)	—	AC250 V, 10 A
	9	Fuse (Mounted on P.C. board)	—	AC250 V, 3.15 A
	10	Outdoor temp. sensor (TO sensor)	—	10 kΩ at 77°F (25°C)
	11	Heat exchanger sensor (Te sensor)	—	10 kΩ at 77°F (25°C)
	12	Discharge temp. sensor (Td sensor)	—	50 kΩ at 77°F (25°C)
	13	Heat exchanger Temp sensor (Ts sensor)	—	10 kΩ at 77°F (25°C)
	14	Compressor thermo. (Protection)	US-622	OFF : 257 ± 39.2°F (125 ± 4°C),
				ON : 194 ± 41°F (90 ± 5°C)
				OFF : 601.8 + 0
	15	Pressure switch	ACB-4UB82W	601.8 – 29 psi 4.15 + 0.2 MPa
				601.8 – 29 psi 4.15 – 0.2 MPa
				ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

	No.	Parts name	Type	Specifications
	1	Compressor	DA422A3F-25M	—
	2	Outdoor fan motor	ICF-280-A100-1	Output 100W
	3	Reactor	CH-62	5.7mH, 18.5A
	4	4-way valve coil	VHV-01AP552B1	AC240V
	5	PMV coil	UKV-A038	DC12V
	6	P.C. board	MCC-1571	AC208 / 230 V
	7	Fuse (Mounted on P.C. board)	—	AC250V, 25A
	8	Fuse (Mounted on P.C. board)	—	AC250V, 10A
	9	Fuse (Mounted on P.C. board)	—	AC250V, 3.15A
	10	Outdoor temp. sensor (TO sensor)	—	10 kΩ at 77°F (25°C)
	11	Heat exchanger sensor (Te sensor)	—	10 kΩ at 77°F (25°C)
	12	Discharge temp. sensor (Td sensor)	—	50 kΩ at 77°F (25°C)
	13	Heat exchanger mid. Temp sensor (TL sensor)	—	10 kΩ at 77°F (25°C)
	14	Compressor thermo. (Protection)	US-622	OFF : 257 ± 39.2°F (125 ± 4°C),
				ON : 194 ± 41°F (90 ± 5°C)
				OFF : 601.8 + 0
	15	Pressure switch	ACB-4UB82W	601.8 – 29 psi 4.15 + 0.2 MPa
				601.8 – 29 psi 4.15 – 0.2 MPa
				ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

– 22 –

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 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 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 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 0.0001 lbs / 32’ 10” (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 0.03” (0.8 mm) even when it is available on the market.

– 23 –

Table 6-2-1 Thicknesses of annealed copper pipes

		Thickness (In (mm))
Outer diameter (In (mm))		R410A	R22
1/4”	(6.4)	0.03” (0.80)	0.03” (0.80)
3/8”	(9.5)	0.03” (0.80)	0.03” (0.80)
1/2” (12.7)		0.03” (0.80)	0.03” (0.80)
5/8” (15.9)		0.04” (1.00)	0.04” (1.00)

1.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 6-2-5 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 0.79” (20 mm). Thicknesses of socket joints are as shown in Table 6-2-2.

Table 6-2-2 Minimum thicknesses of socket joints

Reference outer diameter of copper pipe jointed		Minimum joint thickness
(In (mm))		(In (mm))
1/4”	(6.4)	0.02” (0.50)
3/8”	(9.5)	0.02” (0.60)
1/2” (12.7)		0.03” (0.70)
5/8” (15.9)		0.03” (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 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.

– 24 –

c)Insertion of Flare Nut

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 / R22
					A (In (mm))
Outer diameter		Thickness
				Flare tool for	Conventional flare tool (R410A)
(In (mm))		(In (mm))
				R410A, R22clutch type	Clutch type	Wing nut type
1/4”	(6.4)	0.03” (0.8)		0 – 0.02” (0 – 0.5)	0.04” – 0.06” (1.0 – 1.5)	0.06” – 0.08” (1.5 – 2.0)
3/8”	(9.5)	0.03” (0.8)		0 – 0.02” (0 – 0.5)	0.04” – 0.06” (1.0 – 1.5)	0.06” – 0.08” (1.5 – 2.0)
1/2” (12.7)		0.03” (0.8)		0 – 0.02” (0 – 0.5)	0.04” – 0.06” (1.0 – 1.5)	0.08” – 0.10” (2.0 – 2.5)
5/8” (15.9)		0.04” (1.0)		0 – 0.02” (0 – 0.5)	0.04” – 0.06” (1.0 – 1.5)	0.08” – 0.10” (2.0 – 2.5)

Table 6-2-4 Flare and flare nut dimensions for R410A

Outer diameter		Thickness				Dimension (In (mm))				Flare nut width
(In (mm))		(In (mm))	A		B		C		D	(In (mm))
1/4”	(6.4)	0.03” (0.8)	0.36”	(9.1)	0.36”	(9.2)	0.26”	(6.5)	0.51” (13)	0.67” (17)
3/8”	(9.5)	0.03” (0.8)	0.52” (13.2)		0.53” (13.5)		0.38”	(9.7)	0.79” (20)	0.87” (22)
1/2” (12.7)		0.03” (0.8)	0.65” (16.6)		0.63” (16.0)		0.51” (12.9)		0.91” (23)	1.02” (26)
5/8” (15.9)		0.04” (1.0)	0.78” (19.7)		0.75” (19.0)		0.63” (16.0)		0.98” (25)	1.14” (29)

		Table 6-2-5		Flare and flare nut dimensions for R22
Outer diameter		Thickness				Dimension (In (mm))				Flare nut width
(In (mm))		(In (mm))	A		B		C		D	(In (mm))
1/4”	(6.4)	0.03” (0.8)	0.36”	(9.1)	0.36”	(9.2)	0.26”	(6.5)	0.51” (13)	0.67” (17)
3/8”	(9.5)	0.03” (0.8)	0.51” (13.0)		0.53” (13.5)		0.38”	(9.7)	0.79” (20)	0.87” (22)
1/2” (12.7)		0.03” (0.8)	0.64” (16.2)		0.63” (16.0)		0.51” (12.9)		0.79” (20)	0.94” (24)
5/8” (15.9)		0.04” (1.0)	0.76” (19.4)		0.75” (19.0)		0.63” (16.0)		0.91” (23)	1.06” (27)
3/4” (19.0)		0.04” (1.0)	0.92” (23.3)		0.94” (24.0)		0.76” (19.2)		1.34” (34)	1.42” (36)

– 25 –

46˚ 45˚to

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

Outer diameter (In (mm))		Tightening torque (ft • lbs (N • m))
1/4”	(6.4)	10 – 13 (14 – 18)
3/8”	(9.5)	24 – 31 (33 – 42)
1/2” (12.7)		37 – 46 (50 – 62)
5/8” (15.9)		50 – 60 (68 – 82)

– 26 –

6-3. Tools

6-3-1. Required Tools

Refer to the “4.Tools” (Page 8)

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 indicated –101 kpa (–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.)

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

– 27 –

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.

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.

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.

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.

– 28 –

2.Characteristics required for flux

•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

•Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 1,472°F (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	Used brazing	Used
material	filler	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.

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 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 2.9 psi (0.02 MPa) 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

– 29 –

– 30 –

F01, 02, 25A fuse	Lead wire for grounding
	(Black)

L-phase power supply lead (Black)

N-phase power supply lead (White)

Serial lead (Orange)

Reactor lead connector (White)

CN701:

4-way valve connector

RY701:

4-way valve relay

CN300:

Fan motor connector

CN602:

Outdoor temperature (TO) sensor connector

CN806:

Optional connector

	CN600:
	Heat exchange temperature
	(TE) sensor connector
	CN603:
	Suction temperature
	(TS) sensor connector
	CN601:	CN500:
	Discharge temperature
		Case thermo. or
	(TD) sensor connector
		High pressure SW

C12, 13, 14 electrolytic capacitor

12V

5V

GND

IC800: MCU

Fan drive circuit

Q300 to Q305: FET (QTY: 6P)

CN700:	CN605:
PMV connector	Sub SW board connector

DB02:	UL-SP180AT2RAV-	5009><MCC-	CircuitPrint.17-
High power factor diode
Q404:
High power factor circuit IGBT
F03: 3.15A fuse
DB01:
Single-phase rectifier diode			Board

Comp. lead

(Red) (White) (Black)

Comp. drive circuit

Q200 to Q205: IGBT (QTY: 6P)

IC200: Drive IC (QTY: 1P)

SPECIFICATIONS CONTROL AND CONFIGURATION CIRCUIT .7