Toshiba RAV-SM1400UT-E, RAV-SM1100UT-E User Manual

FILE NO. A03-002

SERVICE MANUAL

<OWNERS MANUAL/INSTALLATION MANUAL>

SPLIT TYPE

RAV-SM1100AT-E/RAV-SM1400AT-E

RAV-SM1100UT-E/RAV-SM1400UT-E

R410A

PRINTED IN JAPAN, Aug., 2003 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

RAV-SM1100AT-E

RAV-SM1400AT-E

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.

RAV-SM1100AT-E

RAV-SM1400AT-E

ACCESSORIES

Outdoor Unit –––––––––––––––––––––––– RAV-SM1100AT-E/RAV-SM1400AT-E

INSTALLATION MANUAL

PRECAUTIONS FOR SAFETY.................................... 1

ACCESSORY AND REFRIGERANT ........................... 3

SELECTION OF INSTALLATION ................................ 3

REFRIGERANT PIPING .............................................. 7

EVACUATING............................................................... 9

ELECTRICAL WORK ................................................. 11

FINAL INSTALLATION CHECKS .............................. 12

Indoor Unit ––––––––––––––––––––––– RAV-SM1100UT-E/RAV-SM1400UT-E

4-Way Air Discharge Cassette Type OWNER’S MANUAL

RAV-SM1100AT-E

RAV-SM1400AT-E

ACCESSORIES (SOLD SEPARATELY) ........................... 14

PRECAUTIONS FOR SAFETY ........................................ 14

PARTS NAME ................................................................... 16

PARTS NAME OF REMOTE CONTROLLER ................... 17

CORRECT USAGE ........................................................... 19

AUTOMATIC OPERATION (Auto Changeover) .............. 20

ADJUSTMENT OF WIND DIRECTIONd .......................... 21

TIMER OPERATION ......................................................... 22

MAINTENANCE ................................................................ 24

AIR CONDITIONER OPERATIONS AND PERFORMANCE . 25

RE-INSTALLATION .......................................................... 26

TROUBLES AND CAUSES .............................................. 26

4-Way Air Discharge Cassette Type INSTALLATION MANUAL

Accessory parts and Parts to be procured locally ...... 28

PRECAUTIONS FOR SAFETY.................................. 29

SELECTION OF INSTALLATION PLACE ................. 31

DRAIN PIPING WORK ............................................... 36

REFRIGERANT PIPING ............................................ 38

EVACUATING............................................................. 39

ELECTRICAL WORK ................................................. 41

TEST RUN ................................................................. 44

TROUBLESHOOTING ............................................... 45

MAINTENANCE ......................................................... 46

Accessories –––––––––––––––––––––––––––––––––––––––––––––––––––––

OWNER’S MANUAL

RAV-SM1100AT-E

RAV-SM1400AT-E

REMOTE CONTROLLER FOR AIR CONDITIONER (SPLIT TYPE)

<Wireless Type> TCB-AX21U (W)-E ............................................................ 48

WEEKLY TIMER FOR AIR CONDITIONER (SPLIT TYPE)

<Program Weekly Timer Type> RBC-EXW21E ................................................................... 56

REMOTE CONTROLLER FOR AIR CONDITIONER

<Simple Operation Type> RBC-AS21E ...................................................................... 62

INSTALLATION MANUAL

Ceiling Panel RBC-U21PG (W)-E ............................................................ 65

Standard Remote Controller RBC-AMT21E .................................................................... 67

Simple Remote Controller RBC-AS21E ...................................................................... 68

Program Weekly Timer RBC-EXW21E ................................................................... 69

Remote sensor TCB-TC21LE .....................................................................70

Drain-up Kit for Concealed Duct Type Indoor Unit TCB-DP11BE .................................................................... 71

Remote Controller Wireless Kit TCB-AX21U (W)-E ............................................................ 72

Network Adapter for Air Conditioner (Use for Indoor Unit Only)

TCB-PCNT20E .................................................................. 73

ACCESSORIES

• Ensure that all Local, National and International regulations are satisfied.

• Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.

• The precautions described below include the important items regarding safety. Observe them without fail.

• After the installation work, perform a trial operation to check for any problem. Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.

• Turn off the main power supply switch (or breaker) before the unit maintenance.

RAV-SM1100AT-E

RAV-SM1400AT-E

• Ask the customer to keep the Installation Manual together with the Owner’s Manual.

PRECAUTIONS FOR SAFETY

CAUTION New Refrigerant Air Conditioner Installation

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DE-

STROY OZONE LAYER.

The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle.

To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging port of the main unit and installation tools are charged from those for the conventional refrigerant.

Accordingly the exclusive tools are required for the new refrigerant (R410A). For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust

does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance force and impurity in it.

CAUTION To Disconnect the Appliance from Main Power Supply.

This appliance must be connected to the main power supply by means of a switch with a contact separation of at least 3 mm.

The installation fuse (25A D type ) must be used for the power supply line of this conditioner.

WARNING

• Ask an authorized dealer or qualified installation professional to install/maintain the air

conditioner.

Inappropriate installation may result in water leakage, electric shock or fire.

• Turn off the main power supply switch or breaker before attempting any electrical work.

Make sure all power switches are off. Failure to do so may cause electric shock.

• Connect the connecting cable correctly.

If the connecting cable is connected in a wrong way, electric parts may be damaged.

• When moving the air conditioner for the installation into another place, be very careful not

to enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.

If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnormally high and it may resultingly causes pipe burst and injuries on persons.

• Do not modify this unit by removing any of the safety guards or by by-passing any of the

safety interlock switches.

• Exposure of unit to water or other moisture before installation may cause a short-circuit of

electrical parts.

Do not store it in a wet basement or expose to rain or water.

• After unpacking the unit, examine it carefully if there are possible damage.

• Do not install in a place that might increase the vibration of the unit.

• To avoid personal injury (with sharp edges), be careful when handling parts.

• Perform installation work properly according to the Installation Manual.

Inappropriate installation may result in water leakage, electric shock or fire.

• When the air conditioner is installed in a small room, provide appropriate measures to

ensure that the concentration of refrigerant leakage occur in the room does not exceed the critical level.

• Install the air conditioner securely in a location where the base can sustain the weight

adequately.

• Perform the specified installation work to guard against an earthquake.

If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.

• If refrigerant gas has leaked during the installation work, ventilate the room immediately.

If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.

• After the installation work, confirm that refrigerant gas does not leak.

If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas might generate.

• Electrical work must be performed by a qualified electrician in accordance with the Installa-

tion Manual. Make sure the air conditioner uses an exclusive power supply.

An insufficient power supply capacity or inappropriate installation may cause fire.

• Use the specified cables for wiring connect the terminals securely fix. To prevent external

forces applied to the terminals from affecting the terminals.

RAV-SM1100AT-E

RAV-SM1400AT-E

• Be sure to provide grounding.

Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.

• Conform to the regulations of the local electric company when wiring the power supply.

Inappropriate grounding may cause electric shock.

• Do not install the air conditioner in a location subject to a risk of exposure to a combustible

gas.

If a combustible gas leaks, and stays around the unit, a fire may occur.

Required tools for installation work

1) Philips screw driver

2) Hole core drill (65 mm)

3) Spanner

4) Pipe cutter

5) Knife

6) Reamer

7) Gas leak detector

8) Tape measure

9) Thermometer

10) Mega-tester

11) Electro circuit tester

12) Hexagonal wrench

13) Flare tool

14) Pipe bender

15) Level vial

16) Metal saw

R410A (Special requirement)

17) Gauge manifold (Charge hose : R410A special requirement)

18) Vacuum pump (Charge hose : R410A special requirement)

19) Torque wrench 1/4 (17 mm) 16 N•m (1.6 kgf•m) 3/8 (22 mm) 42 N•m (4.2 kgf•m) 1/2 (26 mm) 55 N•m (5.5 kgf•m) 5/8 (15.9 mm) 120 N•m (12.0 kgf•m)

20) Copper pipe gauge adjusting projection margin

21) Vacuum pump adapter

RAV-SM1100AT-E

ACCESSORY AND REFRIGERANT

Accessory and Installation Parts Refrigerant Piping

• Piping kit used for the conventional refrigerant cannot be used.

• Use copper pipe with 0.8 mm or more thickness for Ø9.5 mm.

Use copper pipe with 1.0 mm or more thickness for

Ø15.9 mm.

• Flare nut and flare works are also different from those

of the conventional refrigerant. Take out the flare nut attached to the main unit of the air conditioner, and use it.

RAV-SM1400AT-E

Outdoor unit Installation manual x 1

Drain nipple

Waterproof rubber cap

Protective bush

Guard material for passage part

SELECTION OF INSTALLATION

Before installation

Be careful to the following items before installation.

Length of refrigerant pipe

connected to

indoor/outdoor unit

20m or shorter

21m to 50m

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 20m, add 40g/m of refrigerant and the maximum total length of pipe is 50m. (Max. amount of additional refrigerant is 1200g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor.

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 40g of refrigerant for every 1m of pipe which exceeds 20m.

Item

Air purge

• For air purge, use a vacuum pump.

• Do not use refrigerant charged in the outdoor unit for

air purge. (The refrigerant for air purge is not contained in the outdoor unit.)

Electrical cabling

• Be sure to fix the power cables and indoor/outdoor connecting cables with clamps so that they do not contact with the cabinet, etc.

Installation Place

500

or more

150

or more

Necessary Space for Installation

• A place which provides a specified space around the outdoor unit.

• A place where the operation noise and discharged air are not given to your neighbors.

• A place that is not exposed to a strong wind.

• A place that does not block a passage.

• When the outdoor unit is installed in an elevated

position, be sure to secure its feet.

• There must be sufficient space for carrying in the unit.

• A place where the drain water does not make any problem.

CAUTION

1. Install the outdoor unit at a place where dis-

charge air is not blocked.

2. When an outdoor unit is installed in a place that

is always exposed to a strong wind like a coast or on a high storey of a building, secure a normal fan operation by using a duct or a wind shield.

3. When installing the outdoor unit in a place that is

constantly exposed to a strong wind such as the upper stairs or rooftop of a building, apply the windproof measures referring to the following examples.

1) Install the unit so that its discharge port faces to the wall of the building. Keep a distance 500 mm or more between the unit and the wall surface.

500

Obstacle at rear side

1. Single unit installation

2. Obstacles at both right and left sides.

200

or more

150

or more

The height of the obstacle should be lower than the height of the outdoor unit.

300

or more

3. Serial installation of two or more units

150

or more

The height of the obstacle should be lower than the height of the outdoor unit.

300

or more

300

or more

150

300

or more

200 or more

RAV-SM1100AT-E

RAV-SM1400AT-E

2) Supposing the wind direction during the operation season of the air conditioner, install the unit so that the discharge port is set at right angle to the wind direction.

Strong wind

4. Installation in the following places may result in some troubles. Do not install the unit in such places below.

• A place full of machine oil.

• A place full of sulphuric gas.

• A place where high-frequency radio waves are

likely to be generated as from audio quipment, welders, and medical equipment.

Obstacle at front side

1. Single unitIn installation

2. Serial installation of two or more units

500

1000

or more

15 or less

SELECTION OF INSTALLATION

1000

RAV-SM1100AT-E

or more

RAV-SM1400AT-E

1000

or more

Obstacles at both front and rear sides

Open the upper side and both right and left sides. The height of obstacle at both front and rear side, should be lower than the height of the outdoor unit.

1. Single unit installation

150

or more

Installation of Outdoor Unit

• Before installation, check strength and horizontality of the base so that abnormal sound does not generate.

• According to the following base diagram, fix the base firmly with the anchor bolts. (Anchor bolt, nut: M10 x 4 pairs)

600150 150

430

Drain hole

365

400

Knockout hole

Set the out margin of the anchor bolt to 15mm or less.

Drain nipple mounting hole

1000

or more

2. Serial installation of two or more units

200

or more

300

or more

300

or more

1000

or more

Serial installation at front and rear sides

Open the upper side and both right and left sides. The height of obstacle at both front and rear sides should be lower than the height of the outdoor unit.

• In case of drainning through the drain hose, attach the following drain nipple and the waterproof rubber cap, and use the drain hose (Inner diam.: 16mm) sold on the market. And also seal the screws securely with silicone material, etc. so that water does not drop down. Some conditions may cause dewing or dripping of water.

Drain nipple Waterproof rubber cap

Knockout hole

Open

Waterproof rubber cap

Drain nipple

1000

or more

300

or more

1500

or more

2000

or more

200

or more

• When there is a possibility of freezing of drain at the cold district or a snowfall area, be careful for drainage ability of drain. The drainage ability increases when a knockout hole on the base plate is opened. (Open the knockout hole to outside using a screwdriver, etc.)

Optional Installation Parts (Local Procure)

Knockout of Pipe Cover

Parts name

Refrigerant piping

Liquid side : Ø9.5 mm Gas side : Ø15.9 mm

Pipe insulating material

(polyethylene foam, 6 mm thick)

Putty, PVC tapes

Refrigerant Piping Connection

CAUTION

TAKE NOTICE THESE IMPORTANT 4 POINTS BELOW FOR PIPING WORK

1. Keep dust and moisture away from inside the connecting pipes.

2. Tightly connect the connection between pipes and the unit.

3. Evacuate the air in the connecting pipes using VACUUM PUMP.

4. Check gas leak at connected points.

Liquid side

Outer diameter Thickness

Ø9.5 0.8

Outer diameter Thickness

Gas side

Ø15.9 1.0

Q’ty

Each one

Rear direction

Pipe cover

Side direction

Front direction

Down direction

Knockout procedure

• The indoor/outdoor connecting pipes can be connected to 4 directions.

Take off the knockout part of the pipe cover in which pipes or wires pass through the base plate.

• As shown in the figure, do not remove the pipe cover from the cabinet so that the knockout hole can be easily punched. To knock out, it is easily taken off by hands by punching a position at the lower side of 3 connected parts with screwdriver along the guide line.

• After marking the knockout hole, remove the burr and mount the attached protective bush and guard material for pass-through part in order to protect pipes and wires.

For Reference

If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, draining of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.

It is recommended to procure an anti-freeze heater locally for a safety installation of the air conditioner.

For details, contact the dealer.

After connecting the pipes, be sure to mount the pipe cover. The pipe cover is easily mounted by cutting off the slit at the lower part of the pipe cover.

SELECTION OF INSTALLATION

How to remove the front panel

1. Remove screws of the front panel.

2. Pull the front panel downward. Removing the front panel, the electric parts appear at

the front side.

• The metal pipes are attachable to the piping holes. If the size of the used power pipe does not match with the hole, adjust the hole size to match with pipe size.

• Be sure to fix the power cable and indoor/outdoor connecting cable with bundling band sold on the market so that they do not make contact with the compressor and discharge pipe. (Temperature of the compressor and discharge pipe becomes high.)

REFRIGERANT PIPING

Pipe Forming/End Positioning

Flaring

1. Cut the pipe with a pipe cutter.

In order to avoid the force applied to on the connecting section, be sure to fix the cables to the cord clamps provided on the pipe valve fixing plate and the electric parts box.

Electric parts box

Cord clamp

* In case of flaring for R410A with the conventional

flare tool, pull it out approx. 0.5 mm more than that of R22 to adjust to the specified flare size. The copper pipe gauge is useful for adjusting projection margin size.

Front panel

Pipe valve fixing plate

Piping hole

90˚

2. Insert a flare nut into the pipe, and flare the pipe.

As the flaring sizes of R410A differ from those of refrigerant R22, the flare tools newly manufactured for R410A are recommended. However, the conventional tools can be used by adjusting projection margin of the copper pipe.

Obliquity Roughness Warp

• Flaring size : A (Unit : mm)

Outer dia. of copper pipe

6.4

9.5

12.7

15.9

R410A R22

9.1 9.0

13.2 13.0

16.6 16.2

19.7 19.4

- 0.4

• Projection margin in flaring : B (Unit : mm)

Rigid (Clutch type)

Outer dia. of copper

pipe

6.4

9.5

12.7

15.9

Imperial (Wing nut type)

Outer dia. of copper pipe

R410A tool used

R410A R22

0 to 0.5

6.4

9.5

12.7

15.9

(Same as left)

Conventional tool used

R410A R22

1.0 to 1.5 0.5 to 1.0

R410A R22

1.5 to 2.0 1.0 to 1.5

2.0 to 2.5 1.5 to 2.0

Tightening of Connecting Part

(Unit: N•m)

Outer dia. of copper pipe

6.4 mm (diam.)

9.5 mm (diam.)

12.7 mm (diam.)

15.9 mm (diam.)

Flare at indoor unit side

• Align the centers of the connecting pipes and tighten the flare nut strong as far as possible with your fingers.

Then fix the nut with a spanner and tighten it with torque wrench as shown in the figure.

Tightening torque

14 to 18 (1.4 to 1.8 kgf•m)

33 to 42 (3.3 to 4.2 kgf•m)

50 to 62 (5.0 to 6.2 kgf•m)

63 to 77 (6.3 to 7.7 kgf•m)

Flare at outdoor unit side

REQUIREMENT

1. Do not put the spanner on the cap. The valve may be broken.

2. If applying excessive torque, the nut may be broken according to some installation conditions.

• After the installation work, be sure to check gas leak of connecting part of the pipes with nitrogen.

Cover

Half union or packed valve Flare nut

Externally threaded side

Fix with spanner.

Tighten with torque wrench.

Internally threaded side

• As shown in the figure, be sure to use a double spanner to loosen or tighten the flare nut of the valve at gas side. If using a single spanner, the nut cannot be tightened with necessary tightening torque.

On the contrary, use a single spanner to loosen or tighten the flare nut of the valve at liquid side.

Cover

Cap

Piping valve

Loosened

Tightened

• Pressure of R410A is higher than that of R22 (Approx. 1.6 times). Therefore, using a torque wrench, tighten the flare pipe connecting sections which connect the indoor/outdoor units at the specified tightening torque. Incomplete connections may cause not only a gas leak, but also a trouble of the refrigeration cycle.

Do not apply refrigerating machine oil to the flared surface.

Flare nut

Valve at gas side

EVACUATING

Air Purge

This air conditioner can be installed up to the connecting pipe length and height difference in the following table.

Max. connecting

pipe length (m)

With respect to the preservation of terrestrial environment, adopt “Vacuum pump” for air purge (Evacuate air in the connecting pipes) when installing the unit.

• Do not discharge the refrigerant gas to the atmosphere to preserve the terrestrial environment.

• Use a vacuum pump to discharge the air (nitrogen, etc.) remained in the set. If the air remains, the capacity

may decrease.

For the vacuum pump, be sure to use one with backflow preventer so that the oil in the pump does not backflow into the pipe of the air conditioner when the pump stops. (If oil in the vacuum pump is put in an air conditioner including R410A, it may cause trouble on the refrigeration cycle.)

Outdoor unit at upper side Outdoor unit at lower side

Height difference (m)

30 15

Hexagonal wrench size

4 mm

Vacuum pump

As shown in the right figure, connect the charge hose after the manifold valve are closed completely.

Attach the connecting port of the charge hose with a projection to push the valve core (setting pin) to the charge port of the set.

Open handle Low fully.

Turn ON the vacuum pump (*1)

Loosen the flare nut of the packed valve (Gas side) a little to check the air passes through. (*2)

Tighten the flare nut again.

Execute vacuuming until the compound pressure gauge indicates –101kPa (–76cmHg). (*1)

Close handle Low completely.

Turn OFF the vacuum pump.

Leave the vacuum pump as it is for 1 or 2 minutes, and check the indicator of the compound pressure gauge does not return.

Open fully the valve stem or the valve handle. (First, at liquid side, then gas side)

Disconnect the charge hose from the charge port.

Tighten valve and caps of the charge port surely.

Compound pressure gauge

–101kPa

(–76cmHg)

Handle Lo

Charge hose (For R410A only)

Service port (Valve core (Setting pin))

Pressure gauge

Manifold valve

Handle Hi (Keep fully closed)

Charge hose (For R410A only)

Vacuum pump adapter for counter-flow prevention (For R410A only)

Handle position

Closed completely

Handle

Opened fully

Packed valve at gas side

How to open the valve

Charge port

How to close the valve

Vacuum

pump

Valve unit

Handle Pull out the handle and using cutting pliers, etc. turn it counterclockwise by 90˚. (Open fully)

Flare nut

*1. Use the vacuum pump, vacuum pump adapters,

and gauge manifold referring to the manuals attached to each tool before using them. For the vacuum pump, check oil is filled up to the specified line of the oil gauge.

*2. While the air is purged, check again that the

connecting port of charge hose, which has a projection to push the valve core, is firmly connected to the charge port.

Valve handling precautions

• Open the valve stem or the handle until it strikes

the stopper. It is unnecessary to apply further force.

• Securely tighten the cap with a torque wrench.

• Cap tightening torque

14 to 18N•m (1.4 to 1.8kgf•m)

33 to 42N•m (3.3 to 4.2kgf•m)

20 to 25N•m (2.0 to 2.5kgf•m)

14 to 18N•m (1.4 to 1.8kgf•m)

Valve size

Charge port

Ø6.4

Ø9.5

Ø12.7

Ø15.9

Charge port

Valve unit

Push in handle and turn clockwise by 90˚.

(Close fully)

Flare nut

ELECTRICAL WORK

For the air conditioner that has no power cable, connect a power cable as mentioned below.

Model RAV-

Power supply

Maximum running current

Installation fuse rating

Power cable

SM1100AT-E SM1400AT-E

220 – 240 V

Single phase 50 Hz

22.0 A 22.8 A

25 A (D type )

H07 RN-F or 245 IEC 66

(2.5 mm2 or more)

CAUTION

• Wrong wiring may cause a burn-out to some electrical parts.

• Be sure to use the cord clamps attached to the product.

• Do not damage or scratch the conductive core and inner insulator of power and inter-connecting cables when peeling them.

• Be sure to comply with local regulations of the cable from outdoor unit to indoor unit. (wire size and cabling method etc.)

• Use the power and Inter-connecting cables with specified thickness, specified type and protective devices required.

Stripping length power cord and connecting cable

10 10

40 30

10 10

50 40

Earth line Earth line

Power cable

Connecting cable

123

(mm)

CAUTION

• The installation fuse (25A D type ) must be used for the power supply line of this air conditioner.

• Incorrect/incomplete wiring might cause an electrical fire or smoke.

• Prepare the exclusive power supply for the air conditioner.

• This product can be connected to the mains.

Connection to the fixed wiring : A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring.

How to wire

1. Connect the connecting cable to the terminal as identified with their respective numbers on the terminal block of indoor and outdoor unit. H07 RN-F or 245 IEC 66 (1.0 mm2 or more)

2. When connecting the connecting cable to the outdoor unit terminal, prevent water coming in the outdoor unit.

3. Insulate the unsheathed cords (conductors) with electrical insulation tape. Process them so that they do not touch any electrical or metal parts.

4. For inter connecting cable, do not use a wire jointed to another on the way.

Use wires long enough to cover the entire length.

Power supply

terminal block

Earth screw

To Indoor unit

terminal block

123

Connecting cablePower cable

FINAL INSTALLATION CHECKS

Check and Test Operation

For R410A, use the leak detector exclusively manufactured for HFC refrigerant (R410A, R134a, etc.). The conventional leak detector for HCFC refrigerant (R22, etc.) cannot be used because its sensitivity for HFC

refrigerant lowers to approx. 1/40.

• Pressure of R410A is approx. 1.6 times higher than that of R22.

If installation work is incompletely finished, a gas leakage may occur when pressure rises during operation. Therefore, be sure to test the piping connections for leakage.

• Check gas leakage at the flare nut connections, valve stem cap connections and service port cap fittings with a

leak detector or soap water.

CAUTION

When the remote controller is used for the first time, it accepts an operation approx. 5 minutes after the power supply has been turned on.

It is not a trouble, but is because the setup of the remote controller is being checked. For the second power-ON time and after, approx. 1 munute is required to start the operation by the remote controller.

Useful Functions

In addition to the code checking by remote controller of the indoor unit, troubles of the outdoor unit can be diagnosed by LED indications on the cycle control P.C. board of the outdoor unit. Utilize them for various checks. For the check by remote controller of the indoor unit, refer to the Installation Manual of the indoor unit. Before a check, confirm each bit of the DIP switch is set to OFF position.

LED indication and code checking

Cycle control P.C. board

LED indication

D800 ¡ : Red

¡ : Yellow

D801

¡ : Yellow

D802

¡ : Yellow

D803

¥ : Rapid flash

l : Go off

¡ : Go on

LED indication

D800 D801 D802 D803

¡¡

¡¡¡

¡¡

¥ l

l ¥ l

¥¥

¥ l ¥

lll

¡¡

Self-Diagnosis by LED Indication

Cause

Heat exchanger sensor (TE) error

Suction sensor (TS) error

Discharge sensor (TD) error

High-pressure protection error

Outdoor temperature sensor (TO) error

DC outside fan error

Communication error between IPDU (Abnormal stop)

High-pressure release operation

Discharge temp. error

EEPROM error

Communication error between IPDU (No abnormal stop)

G-Tr short-circuit protection

Detect circuit error

Current sensor error

Comp. lock error

Comp. break down

FINAL INSTALLATION CHECKS

Installation/Servicing Tools

In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged accidentally, service port diameter of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads per inch)

• In order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of

opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)

Changes in the product and components

New tools for R410A

Gauge manifold

Charge hose

Electronic balance for refrigerant charging

Torque wrench (nominal diam. 1/2, 5/8)

Applicable to R22 model

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Changes

As pressure is high, it is impossible to measure by means of conventional gauge. In order to prevent any other refrigerant from being charged, each port diameter is changed.

In order to increase pressure resisting strength, hose materials and port size are changed (to 1/2 UNF 20 threads per inch). When purchasing a charge hose, be sure to check the port size.

As pressure is high and gasification speed is fast, it is difficult to read the indicated value by means of charging cylinder, as air bubbles occur.

The size of opposite sides of flare nuts have been increased. Incidentally, a common wrench is used for nominal diameters 1/4 and 3/8.

Flare tool (clutch type)

Gauge for projection adjustment

Vacuum pump adapter

Gas leakage detector

• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the

U,S.’s ARI specified rose color (ARI color code: PMS 507).

• Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to

the charge hose’s port size.

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By increasing the clamp bar’s receiving hole, strength of spring in the tool has been improved.

Used when flare is made with using conventional flare tool.

Connected to the conventional vacuum pump. It is necessary to use an adapter to prevent vacuum pump oil from flowing back to the charge hose. The charge hose connecting part has two ports-one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R410A a sludge may occur and damage the equipment.

Exclusive for HFC refrigerant.

ACCESSORIES (SOLD SEPARATELY)

Remote controller Standard 4-way cassette panel optional parts

PRECAUTIONS FOR SAFETY

WARNING

WARNINGS ABOUT INSTALLATION

• Make sure to ask the qualified installation professional in electric work to install the air conditioner. If the air conditioner is inappropriate installed by yourself, it may cause water leak, electric shock, fire, and so on.

• Be sure to provide grounding. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.

RAV-SM1100AT-E

RAV-SM1400AT-E

CAUTION

TO DISCONNECT THE APPLIANCE FROM THE MAINS SUPPLY

This appliance must be connected to the mains by means of a switch with a contact separation of at least 3 mm.

The installation fuse (25A D type ) must be used for the power supply line of this conditioner.

WARNINGS ABOUR OPERATION

• 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.

• Avoid cooling the room too strong or exposing the human body to cool breeze for a long time as it is bad for the health.

• When you notice something abnormal with the air conditioner (smells like something scorching, poor cooling, etc.), immediately turn off the main switch, the circuit breaker, from the mains to stop the air conditioner, and contact the dealer. If the air conditioner is continuously operated with something abnormal, it may cause machine failure, electric shock, fire, and so on.

WARNINGS ABOUT MOVEMENT AND REPAIR

• Do not move or repair any unit by yourself. Since there is high voltage inside the unit, you may get electric shock when removing the cover and main unit.

• Whenever the air conditioner needs repair, make sure to ask the dealer to do it. If it is repaired imperfectly, it may cause electric shock or fire.

• When moving the air conditioner for re-installing at another place, ask the dealer to do it. If it is imperfectly installed, it may cause electric shock or fire.

RAV-SM1100AT-E

CAUTION

CAUTIONS ABOUT INSTALLATION

• Be sure to confirm the following cautions.

• Certainly lay the drain hose for perfect draining. Bad drainage may cause flooding in the house and getting furniture wet.

• Make sure to connect the air conditioner to an exclusive power supply of the rated voltage, otherwise the unit may break down or cause a fire.

• Do not install the unit in a place where inflammable gas may leak. If inflammable gas accumulates around the unit, it may cause a fire.

CAUTIONS ABOUT OPERATION

• Carefully read this manual before starting the air conditioner. There are many important things to keep in mind for daily operation.

• Do not use this air conditioner for special purpose such as preserving food, precision instruments, art objects, breeding animals, growing potted plants, etc.

• Avoid exposing potted plants and animals to the wind of the air conditioner, since it badly affects the health and growth of them.

• When the air conditioner is operated with a combustion appliance in the same place, be careful of ventilation to let fresh air enter the room. Poor ventilation causes oxygen shortage.

RAV-SM1400AT-E

• Do not place any combustion appliance in a place where it is directly exposed to the wind of air conditioner, otherwise it may cause imperfect combustion.

• When the air conditioner is used in a closed room, be careful of sufficient ventilation of the room. Poor ventilation causes oxygen shortage.

• Do not touch any switches with wet finger, otherwise you may get an electric shock.

• If the air conditioner won’t be used for a considerably long time, turn off the main switch or the circuit breaker, for safety.

• Check the concrete blocks, etc. of the base of the outdoor unit occasionally. If the base is left damaged or deteriorated, the unit may topple over and inflict an injury to a person as the worst case.

• Do not put anything on the outdoor unit nor step onto it. If you do so, it may not only topple over the unit but also injure yourself.

• To make the air conditioner operate in its original performance, operate it within the range of the operating temperature specified in the instructions. Otherwise it may cause a malfunction, or water leak from the unit.

• Prevent any liquid from falling into the remote controller. Do not spill juice, water or any kind of liquid.

PARTS NAME

Indoor unit

Button

Button to open/close the suction port

Air filter

Removes dust or trash. (Provided on the suction port.)

Earth screw

Provided in the electric parts box

Discharge flap of discharge port

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

Suction air port

The air in the room is sucked in from this port.

RAV-SM1100AT-E

RAV-SM1400AT-E

Outdoor unit

Air inlet (Side and rear)

Air outlet

Projection of air filter

Remote controller

REMOTE CONTROLLER

Pipes and electric wires

PARTS NAME OF REMOTE CONTROLLER

Display section

In the display example, all indicators are displayed for the explanation.

In reality only, the selected contents are indicated.

• When turning on the leak breaker at the first time, [SET

DATA] flashes on the display part of the remote controller.

While this display is flashing, the model is being automatically confirmed. Accordingly, wait for a while after [SET DATA] display has disappeared, and then use the remote controller.

SET DATA

SETTING

SET

TEST

CODE No.

UNIT No.

R.C. No.

UNIT

Display section

Operation section

RAV-SM1100AT-E

RAV-SM1400AT-E

SET DATA display

Displayed during setup of the timer.

Operation mode select display

The selected operation mode is displayed.

CHECK display

Displayed while the protective device works or a trouble occurs.

Timer time display

Time of the timer is displayed. (When a trouble occurs, the check code is displayed.)

Timer SETIN setup display

When pushing the Timer SETIN button, the display of the timer is selected in order of [OFF]

→ [OFF] repeat OFF timer → [ON] → No display.

Filter display

If “FILTER ” is displayed, clean the air filter.

TEST run display

Displayed during a test run.

Flap position display

Displays flap position.

SET DATA

SETTING

TEST

UNIT No.

R.C. No.

CODE No.

SWING display

Displayed during up/down movement of the flap.

Set up temperature display

The selected set up temp. is displayed.

Remote controller sensor display

Displayed while the sensor of the remote controller is used.

PRE-HEAT display

Displayed when the heating operation starts or defrost operation is carried out.

While this indication is displayed, the indoor fan stops or the mode enters in LOW.

No function display

Displayed if there is no function even if the button is pushed.

Air volume select display

The selected air volume mode is displayed.

(AUTO) (HIGH) (MED.) (LOW)

11 13

Operation section

Push each button to select a desired operation.

• The details of the operation needs to be set up once, afterward, the air conditioner can be used by pushing

button only.

Air volume select button

Selects the desired air volume mode.

Timer set button

TIMER SET button is used when the timer is set up.

Check button

The CHECK button is used for the check operation. During normal operation, do not use this button.

Fan button

FAN button is used when a fan which is sold on the market or etc. is connected.

• If “No function” is displayed on the remote controller when pushing the FAN button, a fan is not connected.

SET

UNIT

When the button is pushed, the operation starts, and it stops by pushing the button again.

When the operation has stopped, the operation lamp and all the displays disappear.

Operation select button

Selects desired operation mode.

Set up temperature button

Adjusts the room temperature.

Set the desired set temperature by pushing

button

or .

RAV-SM1100AT-E

RAV-SM1400AT-E

Filter reset button

Resets (Erases) “FILTER ” display.

UNIT and AUTO flap button

(No function)

UNIT

Operation lamp

Lamp is lit during the operation. Lamp is off when stopped.

Although it flashes when operating the protection device or abnormal time.

OPTION :

Remote controller sensor

Usually the TEMP. sensor of the indoor unit senses the temperature. The temperature on the surrounding of the remote controller can also be sensed. For details, contact the dealer from which you have purchased the air conditioner.

CORRECT USAGE

When you use the air conditioner for the first time or when you change the SET DATA value, follow the procedure below. From the next time, the operation displayed on the remote controller will start by pushing the

button only.

Preparation

Turn on the main power switch and/or the leakage breaker.

• When the power supply is turned on, a partition line is displayed on the display part of the remote controller.

After the power supply is turned on, the remote controller does not accept an operation for approx. 1 minute,

but it is not a failure.

REQUIREMENT

• While using the air conditioner, operate it only with button without turning off the main power switch and the leak breaker.

UNIT

SET

Push button.

The operation lamp goes on, and the operation starts.

Select an operation mode with the “MODE” button.

One push of the button, and the display changes in the order shown on the right.

• In HEAT mode, if the room temperature reaches to the set temperature, the outdoor unit stops and the air flow becomes LOW and the air volume decreases.

• In the defrost mode, the fan stops so that cool air is not discharged and PRE-DEF is displayed.

Select air volume with “FAN ” button.

One push of the button, and the display changes in the order shown on the right.

• When air volume is “AUTO ”, air volume differs according to the room temperature.

• In DRY mode, “AUTO ” is displayed and the air volume is LOW.

• In heating operation, if the room temperature is not heated sufficiently with VOLUME “LOW ” opera-

tion, select “MED. ” or “HIGH ” operation.

AUTO HEAT DRY COOL FAN

AUTO

LOW MED. HIGH

Determine the set up temperature by pushing the “TEMP. ” or “TEMP. ” button.

Stop

Push button.

The operation lamp goes off, and the operation stops.

AUTOMATIC OPERATION (Auto Changeover)

When you set the air conditioner in mode or switch over from AUTO operation because of some settings change, it will automatically select either cooling, heating, or fan only operation depending on the indoor temperature.

Start

Push this button to start the air conditioner.

Mode select button (MODE)

Select Auto.

Temperature button

Set the desired temperature.

• In case of cooling, start the operation after approx. 1 minute.

• In case of heating, the operation mode is selected in accordance with the room temperature and operation

starts after approximately 3 to 5 minutes.

• When you select the Auto mode, it is unnecessary to set the fan speed. The FAN speed display will show AUTO and the fan speed will be automatically controlled.

• After the heating operation has stopped, FAN operation may continue for approx. 30 seconds.

• When the room temperature reaches the set temperature and the outdoor unit stops, the supper low wind is

discharged and the air volume decreases excessively. During defrost operation, the fan stops so that cool air is not discharged and “HEAT READY” is displayed.

• If the Auto mode is uncomfortable, you can select the desired conditions manually.

button

NOTE

When restarting the operation after stop

• When restarting the operation immediately after stop, the air conditioner does not operate for approx. 3

minutes to protect the machine.

Stop

Push button.

Push this button again to stop the air conditioner.

ADJUSTMENT OF WIND DIRECTIONd

• When the air conditioner stops, the flap (adjustment plate of up/down wind direction) directs downward automatically.

• When the heating operation is in READY states, the flap (adjustment plate of up/down wind direction) directs upward. The swinging starts after HEAT READY status cleared, SWING is displayed on the remote controller even if the heating operation is in READY status.

How to set up the wind direction

Push during operation.

The wind direction changes for every push of the button.

In HEAT operation

Direct the flap (adjustment plate of up/down wind direction) downward. If directing at upward, hot air may not come to the foot.

Initial setup

In COOL/DRY operation

Direct the flap (adjustment plate of up/down wind direction) upward. If directing it downward, the dew may from on the surface of the air discharge port and may drop down.

Initial setup

How to start swinging

Push , set the flap (adjustment plate of up/down wind direction) direction to the lowest position, and then push

again.

SWING is displayed and the up/down wind direction is automatically selected.

How to stop swinging

Push SWING/WIND again while the flap is swinging.

• The flap stops at a position when you push. After then, if pushing , the wind direction descends from the highest position.

• In COOL/DRY operation, the flap does not stop as it directs downward. If stopping the flap as it directs downward during swing operation, it stops after moving to the 3 position from the highest position.

UNIT

SET

In FAN operation

Initial setup

Display when stopping the swing

In all modes

Series of operation

Fan/Heat operation

Cool/Dry operation

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