Toshiba RAV-SM1401CT-E User Manual

FILE NO. A03-016

SERVICE MANUAL

UNDER CEILING TYPE (INDOOR UNIT)

RAV-SM561CT-E

RAV-SM801CT-E
RAV-SM1101CT-E
RAV-SM1401CT-E

R410A

PRINTED IN JAPAN, Feb.,2004 ToMo

CONTENTS

1. SPECIFICATIONS................................................................................................ 3

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) ................................................. 7

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM .........................................8

4. WIRING DIAGRAM .............................................................................................. 9

5. SPECIFICATIONS OF ELECTRICAL PAR T S ................................................... 10

6. REFRIGERANT R410A ..................................................................................... 11

7. INDOOR UNIT CONTROL ................................................................................. 19

8. TROUBLESHOOTING ....................................................................................... 28

9. REPLACEMENT OF SERVICE INDOOR P.C. BOARD ..................................... 50

10. SETUP AT LOCAL SITE AND OTHERS ........................................................... 54

11. ADDRESS SETUP ............................................................................................. 64

12. DETACHMENTS................................................................................................. 68

13. EXPLODED VIEWS AND PARTS LIST ............................................................. 73

NOTE :

This Service Manual describes explanation for the Under Ceiling type indoor unit.
For the combined outdoor unit, refer to the following Service Manual.

Outdoor unit Model name SVM to be referred
RAV-SMXXXAT-E A03-007
RAV-SPXXXAT-E A03-014

1. SPECIFICATIONS

1-1. Under Ceiling Type (Indoor Unit)

Model name

Standard capacity (Note 1) (kW)

Energy consumption effect ratio (Cooling)

Power supply

Electrical
characteristics

Appearance Main unit

Outer
dimension

Total weight Main unit (kg)

Running current (A)

Power consumption (kW)

Power factor (%)

Height (mm)

Main unit Width (mm)

Depth (mm)

RAV-SM561CT-E RAV-SM801CT-E

Cooling Heating Average Cooling Heating Average

5.0 5.6 7.0 8.0

(1.5 – 5.6) (1.5 – 6.3) (2.2 – 8.0) (2.2 – 9.0)

2.75 [D] 3.41 [B] 3.08 2.77 [D] 3.24 [C] 3.01

1 phase 230V (220 – 240V) 50Hz

8.71–7.98 7.85–7.19 12.23–11.21 11.94–10.95

1.82 1.64 2.53 2.47

95 95 94 94

Shine white

210 210

680 680

910 1180

20 25

Heat exchanger

Soundproof/Heat-insulating material

Fan

Fan unit Standard air flow High (Mid./Low) (m³/h)

Motor (W)

Air filter

Controller (Sold separately)

Gas side (mm)

Connecting
pipe

Sound level High (Mid./Low) (Note 2) (dB•A)

Liquid side (mm)

Drain port (Nominal dia.)

Inflammable polyethylene foam

840 1140

60 60

Ø12.7 (1/2”) Ø15.9 (5/8”)

Ø6.4 (1/4”) Ø9.5 (3/8”)

36 33 30 38 36 33

Finned tubu

Multi-blade fan

Attached main unit

RBC-AMT21E

25 (Polyvinyl chloride tube)

Note 1 : The cooling and heating capacities and electrical characteristics are measured under the conditions specified by JIS B

8616 based on the reference piping 7.5m.

Note 2 : The sound level is measured in an anechoic chamber in accordance with JIS B8616. Normally, the values measured in

the actual operating environment become larger than the indicated values due to the effects of external sound.

Note : Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB

Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB

3

Model name

RAV-SM1101CT-E RAV-SM1401CT-E

Cooling Heating Average Cooling Heating Averag e

Standard capacity (Note 1) (kW)

Energy consumption effect ratio (Cooling)

Power supply

Electrical
characteristics

Appearance Main unit

Outer
dimension

Total weight Main unit (kg)

Heat exchanger

Soundproof/Heat-insulating material

Running current (A)

Power consumption (kW)

Power factor (%)

Height (mm)

Main unit Width (mm)

Depth (mm)

10.0 11.2 12.3 14.0

(2.2 – 11.2) (2.2 – 12.5) (3.0 – 13.2) (3.0 – 16.0)

2.85 [C] 3.50 [B] 3.18 2.72 [D] 3.38 [C] 3.05

1 phase 230V (220 – 240V) 50Hz

16.2–14.9 14.84–13.61 21.18–19.40 19.40–17.78

3.51 3.20 4.52 4.14

98 98 97 97

Shine white

210

680

1595

42

Finned tubu

Inflammable polyethylene foam

Fan

Fan unit Standard air flow High (Mid./Low) (m³/h)

Motor (W)

Air filter

Controller (Sold separately)

Gas side (mm)

Connecting
pipe

Sound level High (Mid./Low) (Note 2) (dB•A)

Liquid side (mm)

Drain port (Nominal dia.)

1620 1980

120 120

41 38 35 43 40 37

Multi-blade fan

Attached main unit

RBC-AMT21E

Ø15.9 (5/8”)

Ø9.5 (3/8”)

25 (Polyvinyl chloride tube)

Note 1 : The cooling and heating capacities and electrical characteristics are measured under the conditions specified by JIS B

8616 based on the reference piping 7.5m.

Note 2 : The sound level is measured in an anechoic chamber in accordance with JIS B8616. Normally, the values measured in

the actual operating environment become larger than the indicated values due to the effects of external sound.

Note : Rated conditions Cooling : Indoor air temperature 27°C DB/19°C WB, Outdoor air temperature 35°C DB

Heating : Indoor air temperature 20°C DB, Outdoor air temperature 7°C DB/6°C WB

4

1-2. Operation Characteristic Curve

RAV-SM561CT-E

RAV-SM561CT-E

RAV-SM561CT-E / SM801CT-E
<Cooling> <Heating>

14

12

RAV-SM801CT-E

RAV-SM801CT-E

10

8

6

Current (A)

4

2

0

15

020

RAV-SM561CT-E

RAV-SM561CT-E

• Conditions
Indoor : DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
220V

40 60 70 80 100

Compressor speed (rps)

16

14

12

10

8

Current (A)

6

4

2

0

15

020

RAV-SM801CT-E

RAV-SM801CT-E

RAV-SM561CT-E

RAV-SM561CT-E

• Conditions
Indoor : DB20˚C
Outdoor : DB7˚C/WB6˚C
Air flow : High
Pipe length : 7.5m
220V

40 60 80 90 100

Compressor speed (rps)

RAV-SM1101CT-E
<Cooling> <Heating>

20

18

16

RAV-SM1101CT-E

14

12

10

Current (A)

8

6

4

2

0

0 204060

RAV-SM1101CT-E

• Conditions
Indoor : DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
230V

80 100 120

20

18

16

14

12

10

Current (A)

8

6

4

2

0

0204060

RAV-SM1101CT-E

RAV-SM1101CT-E

• Conditions
Indoor : DB20˚C
Outdoor : DB7˚C/WB6˚C
Air flow : High
Pipe length : 7.5m
230V

80 100 120

Compressor speed (rps)

Compressor speed (rps)

5

RAV-SM1401CT-E
<Cooling> <Heating>

22
20

18

RAV-SM1401CT-E RAV-SM1401CT-E

16

RAV-SM1401CT-E RAV-SM1401CT-E

14
12
10

Current (A)

8
6

• Conditions

4
2
0

020406080

Indoor : DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
230V

Compressor speed (rps)

22
20

18
16
14
12
10

Current (A)

8
6

• Conditions

4
2
0

020406080

Indoor : DB20˚C
Outdoor : DB7˚C/WB6˚C
Air flow : High
Pipe length : 7.5m
230V

Compressor speed (rps)

1-3. Capacity Variation Ratio According to Temperature

<Cooling> <Heating>

105
100

95
90
85
80
75
70

Capacity ratio (%)

65
60
55

• Conditions
Indoor : DB27˚C/WB19˚C
Indoor air flow : High
Pipe length : 7.5m

50

32 33 34 35 36 37 38 39 40 41 42 43

Outsoor temp. (˚C)

120
110
100

90
80
70
60
50

Capacity ratio (%)

40
30
20
10

0

-14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10

• Conditions
Indoor : DB20˚C
Indoor air flow : High
Pipe length : 7.5m

Outsoor temp. (˚C)

6

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

2-1. Under Ceiling Type (Indoor Unit)

RAV-SM561CT-E / SM801CT-E / SM1101CT-E / SM1401CT-E

128
84

170320

(Hanging position)

Hanging bolt

50

Within

Upper pipe draw-out port (Knockout hole)

Power supply cable take-in port (Knockout)

Remote controller cable take- in port
(Knockout hole)

53

Left drain size

B (Hanging position)

Refrigerant pipe (Gas side ØD)

Ceiling surface

Unit

Refrigerant pipe
(Liquid side ØC)

A

216

110

70

75 97

76

50

130

680

Drain pipe connecting port

146

145

Pipe hole on wall (Ø100 hole)

210

167

105

347

262

135 84

Outside air take-in port
(Duct sold separately)(Knockout hole Ø92)

Pipe draw-out port (Knockout hole)

Drain port VP20
(Inner dia. Ø26, hose attached)

114

41

200 (Liquid pipe)

216 (Gas pipe)

Remote controller cable take- in port

Power supply cable take-in port (Knockout hole)

Remote controller cable take- in port

90

32

(Knockout hole)

92

Drain left pipe draw-out port (Knockout hole)

32

171

Wireless sensor
mounting section

250 or more250 or more

Model name A B C D
561CT
801CT
1101CT to 1401CT

910
1180
1595

855
1125
1540

Ø6.4 Ø12.7

Ø9.5 Ø15.9

500 or more

7

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Under Ceiling Type

RAV-SM561CT-E / SM801CT-E / SM1101CT-E / SM1401CT-E

RAV-SM
561CT-E
801CT-E

1101CT-E
1401CT-E

Outer diameter of refrigerant pipeModel

Gas side ØA Liquid side ØB

12.7 mm 6.4 mm

15.9 mm 9.5 mm

TC sensor

Indoor unit

TCJ

sensor

Air heat exchanger

Refrigerant pipe
at gas side
Outer dia. ØA

Pd PsPacked valve

Packed valve
Outer dia. ØA

Refrigerant pipe
at liquid side
Outer dia. ØB

Outer dia. ØB

Outdoor unit

NOTE :

The refrigerating cycle differs according to the combined outdoor units.
For the cycle diagram, cycle pressure , etc., refer to the following Service Manual.

RAV -SMXXXXAT-E : A03-007
RAV -SPXXXXAT-E : A03-014

Cooling
Heating

8

4. WIRING DIAGRAM

4-1. Under Ceiling Type (Indoor Unit)

RAV-SM561CT-E / SM801CT-E / SM1101CT-E / SM1401CT-E

LM

FM

TA

1 2
1 2

CN104

(YEL)

CN34

FS

(RED)

3 3

2 2

1 1

CN33
(WHI)

5

5

5

5

4

4

3

3

2

2

1

1

4

4

3

3

2

2

1

1

1 2
1 2

CN102

(RED)

TCJ

1 2
1 2

CN101

(BLK)

TC

1 2 3

CN80

(GRN)

(EXCT)

1 2

CN73

(RED)

MCC-1402

Control P.C. Board for

Indoor Unit

DC20V
DC15V
DC12V
DC7V

Power
supply

1 2

CN70
(WHI)

5
4

CN620

3

(BLU)

2
1

6
5

CN60

4

(WHI)

3
2
1

CN32

2

(WHI)

1

(FAN DRIVE)

circuit

6
5
4

CN61
(YEL)

3
2
1

5
4

CN50

3

(WHI)

2
1

3

CN309

2

(YEL)

1

3

3

2 2

1 1

CN41
(BLU)

BLK
BLK

BLK

WHI

Wireless Remote

BLK

B
A

WHI

CN001

2 2

(WHI)

1 1

Adapter for

Controller

CN1

2 2

(WHI)

1 1

Wired Remote

Controller

CN333

(WHI)

5 5

4 4

3 3

2 2

1 1

CN334

(WHI)

1 1

2 2
3 3

4 4
5 5

CN68
(BLU)

Motor

drive

circuit

RY
302

1 233 1 2 3
1 2

RY
303

CN304

(GRY)

Fuse
F302
T3.15A
250V~

CN67
(BLK)

Capacitor

+ –

~~

Fuse
F301
250V~
T6.3A

1 233
1 2

WHI BLK

RED

445

P301

5

BLK

1 2

CN66
(WHI)

FM

TA

TC

TCJ

LM
DP

FS

RY302

DP

NOTE

: Fan motor
: Indoor temp. sensor
: Temp. sensor
: Temp. sensor
: Louver motor
: Drain pump motor
: Float switch
: Drain control relay

RED

WHI

321

Indoor unit
earth screw

321

Outdoor unit
earth screw

Serial

NL

signal

Single phase 220V, 50Hz

9

Closed-end
connector

1 233
1 2

Reactor

Color

Identification

BLACK

:

BLK

BLUE

:

BLU

RED

:

RED

GRAY

:

GRY

PINK

:

PNK

GREEN

:

GRN

WHITE

:

WHI

BROWN

:

BRW

ORANGE

:

ORN

YELLOW

:

YEL

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Under Ceiling Type (Indoor Unit)

RAV-SM561CT-E / SM801CT-E / SM1101CT-E / SM1401CT-E

No.

1

Fan motor (SM501CT-E)

2

Fan motor (SM801CT-E)

3

Fan motor (SM1101CT-E/SM1401CT-E)

4

Thermo. sensor (TA-sensor)

5

Heat exchanger sensor (TCJ-sensor)

6

Heat exchanger sensor (TC-sensor)

7

Louver motor

8

Reactor

Parts name

5-2. Accessory Separate Soldparts

TCB-DP22CE (Drain up kit)

No.

1

Float switch

2

Drain pump motor

Parts name

Type

SWF-280-60-1
SWF-280-60-2

SWF-280-120-2

258 mm

Ø6 mm, 1200 mm
Ø6 mm, 1200 mm

MP24GA1

CH-43-2Z-K

Type

FS-0218-106

ADP-1406 or ADP-1415

Specifications

Output (Rated) 60 W, 220–240 V
Output (Rated) 120 W, 220–240 V
Output (Rated) 120 W, 220–240 V
10 kΩ at 25°C
10 kΩ at 25°C
10 kΩ at 25°C
DC 15 V
10 mH, 1 A

Specifications

10

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 exclusiv e 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 exclusiv e 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’s may result in water leakage,
electric shock and fire, etc.

6-2. Refrigerant Piping Installation

6-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes
and joints are mainly used. Copper pipes and joints
suitable for the refrigerant must be chosen and
installed. Furthermore, it is necessary to use clean
copper pipes and joints whose interior surfaces are
less affected by contaminants.

(1) Copper Pipes

It is necessary to use seamless copper pipes
which are made of either copper or copper alloy
and it is desirable that the amount of residual oil
is less than 40 mg/10 m. Do not use copper
pipes having a collapsed, deformed or discol­ored portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube
may become blocked with contaminants.

As an air conditioner using R410A incurs
pressure higher than when using R22, it is
necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A
are as shown in Table 6-2-1. Never use copper
pipes thinner than 0.8 mm even when it is
available on the market.

11

Table 6-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter

1/4
3/8
1/2
5/8

(2) Joints

For copper pipes, flare joints or socket joints are
used. Prior to use, be sure to remove all con­taminants.

a) Flare Joints

Flare joints used to connect the copper pipes
cannot be used for pipings whose outer
diameter exceeds 20 mm. In such a case,
socket joints can be used.

Sizes of flare pipe ends, flare joint ends and
flare nuts are as shown in Tables 6-2-3 to 6­2-6 below .

Outer diameter (mm)

6.35

9.52

12.70

15.88

R410A R22

0.80 0.80

0.80 0.80

0.80 0.80

1.00 1.00

b) Socket Joints

Socket joints are such that they are brazed
for connections, and used mainly f or thick
pipings whose diameter is larger than 20 mm.
Thicknesses of socket joints are as shown in
Table 6-2-2.

Table 6-2-2 Minimum thicknesses of socket joints

Nominal diameter

1/4
3/8
1/2
5/8

Reference outer diameter of

copper pipe jointed (mm)

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.

6.35

9.52

12.70

15.88

Minimum joint thickness

(mm)

0.50

0.60

0.70

0.80

(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 b urrs and clean the cut surface
before installation.

12

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.

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

Flare processing dimensions differ according
to the type of flare tool. When using a con­ventional flare tool, be sure to secure “dimen-
sion A” by using a gauge for size adjustment.

ØD

A

Fig. 6-2-1 Flare processing dimensions

Nominal

diameter

1/4
3/8
1/2
5/8

Nominal

diameter

1/4
3/8

Outer

diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

0.8

0.8

1.0

Flare tool for

R410A clutch type

0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5

Table 6-2-4 Dimensions related to flare processing for R22

Outer

diameter

(mm)

6.35

9.52

Thickness

(mm)

0.8

0.8

Flare tool for

R22 clutch type

0 to 0.5
0 to 0.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

1.0 to 1.5 1.5 to 2.0

1.0 to 1.5 1.5 to 2.0

1.0 to 1.5 2.0 to 2.5

1.0 to 1.5 2.0 to 2.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

0.5 to 1.0 1.0 to 1.5

0.5 to 1.0 1.0 to 1.5
1/2
5/8

Nominal

diameter

1/4
3/8
1/2
5/8

12.70

15.88

Table 6-2-5 Flare and flare nut dimensions for R410A

Outer diameter

(mm)

6.35

9.52

12.70
15,88

0.8

1.0

Thickness

(mm)

0.8

0.8

0.8

1.0

0 to 0.5
0 to 0.5

0.5 to 1.0 1.5 to 2.0

0.5 to 1.0 1.5 to 2.0

Dimension (mm)

ABCD

9.1 9.2 6.5 13

13.2 13.5 9.7 20

16.6 16.0 12.9 23

19.7 19.0 16.0 25

13

Flare nut

width (mm)

17
22
26
29

Table 6-2-6 Flare and flare nut dimensions for R22

Nominal Outer diameter Thickness

diameter (mm) (mm)

1/4 6.35 0.8
3/8 9.52 0.8
1/2 12.70 0.8
5/8 15.88 1.0
3/4 19.05 1.0

45˚to 46˚

B A

Dimension (mm)

ABCD

9.0 9.2 6.5 13

13.0 13.5 9.7 20

16.2 16.0 12.9 20

19.4 19.0 16.0 23

23.3 24.0 19.2 34

D

C

43˚to 45˚

Flare nut width

(mm)

17
22
24
27
36

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.

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

Nominal Outer diameter Tightening torque

diameter (mm) N•m (kgf•cm)

1/4 6.35 14 to 18 (140 to 180)

When it is strong, the flare nut may crack and
may be made non-removable. When choosing
the tightening torque, comply with values
designated by manufacturers. Table 6-2-7
shows reference v alues.

NOTE:

When applying oil to the flare surface, be sure to use
oil designated by the manufacturer. If any other oil is
used, the lubricating oils may deteriorate and cause
the compressor to burn out.

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

16 (160), 18 (180)
3/8 9.52 33 to 42 (330 to 420)
1/2 12.70 50 to 62 (500 to 620)
5/8 15.88 63 to 77 (630 to 770)

14

42 (420)
55 (550)
65 (650)

6-3. Tools

6-3-1. Required T ools

The service port diameter of packed v alve of the outdoor unit in the air conditioner using R410A is changed to
prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and
opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge,
clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

(1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))
(2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)
(3) Tools commonly used for R410A and for conventional refrigerant (R22)
The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

No. Used tool

Flare tool



Copper pipe gauge for
adjusting projection



margin
Torque wrench



Gauge manifold



Charge hose



Vacuum pump adapter



Electronic balance for



refrigerant charging
Refrigerant cylinder



Leakage detector



Charging cylinder



Usage

Pipe flaring
Flaring by conventional

flare tool

Connection of flare nut

Evacuating, refrigerant
charge, run check, etc.

Vacuum evacuating
Refrigerant charge
Refrigerant charge

Gas leakage check
Refrigerant charge

air conditioner installation

Existence of Whether conven­new equipment tional equipment
for R410A can be used

Yes

Yes

Yes

Yes

Yes
Yes

Yes
Yes

(Note 2)

R410A

(Note 1)

*

(Note 1)

*

X
X

X
X
X

X
X

Conventional air

conditioner installation

Whether new equipment
can be used with
conventional refrigerant

¡

(Note 1)

*

X
X

¡

¡

X

¡

X

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection

margin is necessary. For this adjustment, a copper pipe gauge , etc. are necessary.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary
as the general tools.

(1) Vacuum pump

Use vacuum pump by

attaching vacuum pump adapter.
(2) Torque wrench
(3) Pipe cutter

(4) Reamer
(5) Pipe bender
(6) Level vial
(7) Screwdriver (+, –)
(8) Spanner or Monkey wrench

(9) Hole core drill (Ø65)
(10) Hexagon wrench

(Opposite side 4mm)
(11) Tape measure
(12) Metal saw

Also prepare the following equipments for other installation method and run check.
(1) Clamp meter
(2) Thermometer

(3) Insulation resistance tester
(4) Electroscope

15

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.

When the compound gauge’s pointer has indicated
–0.1 Mpa (–76 cmHg), place the handle Low in the
fully closed position, and turn off the vacuum pump’s
power switch.

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.

Nev er charge refrigerant exceeding the specified amount.



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



Do not carry out additional charging.



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.)

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)

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

Electronic balance for refrigerant charging

Fig. 6-4-1 Configuration of refrigerant charging

(Liquid side)

(Gas side)

16

(OUTDOOR unit)

Opened

Closed

Service port

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



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

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Electronic

balance

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.

6-5. Brazing of Pipes

6-5-1. Materials for Brazing

(1) Silver brazing filler

Silver brazing filler is an alloy mainly composed
of silver and copper. It is used to join iron,
copper or copper alloy, and is relatively expen­sive though it excels in solderability.

(2) Phosphor bronze brazing filler

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

(3) Low temperature brazing filler

Low temperature brazing filler is generally called
solder, and is an alloy of tin and lead. Since it is
weak in adhesive strength, do not use it for
refrigerant pipes.

Fig. 6-4-2

Electronic

balance

Siphon

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.

When performing brazing again at time of



servicing, use the same type of brazing filler.

6-5-2. Flux

(1) Reason why flux is necessary

• By removing the oxide film and any f oreign
matter on the metal surface, it assists the flo w
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.

17

(2) Characteristics required for flux

Nitrogen gas

cylinder

Pipe

Flow meter

M

Stop valve

From Nitrogen cylinder

Nitrogen
gas

Rubber plug

• Activated temperature of flux coincides with
the brazing temperature.

• Due to a wide effective temperature r ange, 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 br azing tem­perature is higher than 800°C.

• Activated flux

Most of fluxes generally used for silver brazing
are this type.
It features an increased oxide film removing
capability due to the addition of compounds
such as potassium fluoride, potassium chloride
and sodium fluoride to the borax-boric acid
compound.

(4) Piping materials for brazing and used braz-

ing filler/flux

6-5-3. Brazing

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

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

Never use gas other than Nitrogen gas.

(1) Brazing method to prevent oxidation

Attach a reducing valve and a flow-meter to



the Nitrogen gas cylinder.
Use a copper pipe to direct the piping mate-



rial, and attach a flow-meter to the cylinder.
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.

When the Nitrogen gas is flowing, be sure to



keep the piping end open.
Adjust the flow rate of Nitrogen gas so that it



is lower than 0.05 m³/Hr or 0.02 MPa (0.2kgf/
cm²) by means of the reducing valve.

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).

Remove the flux completely after brazing.



Copper - Copper

Copper - Iron








Piping

material

Iron - Iron

Do not enter flux into the refrigeration cycle.
When chlorine contained in the flux remains

within the pipe, the lubricating oil deteriorates.
Therefore, use a flux which does not contain
chlorine.

When adding water to the flux, use water
which does not contain chlorine (e.g. distilled
water or ion-exchange water).

Remove the flux after brazing.

Used brazing

filler

Phosphor copper

Silver

Silver

Used

flux

Do not use

Paste flux

Vapor flux

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

18

7-1. Indoor Control Cir cuit

7. INDOOR UNIT CONTROL

Max. 8 units are connectable.*1
*1 Max. 7 units when network adapters

are attached
*2 Network adapters are attached to only

one unit.
*3 Weekly timer is not connectable to the

sub remote controller.

Central control

remote controller

(Sold separatrly)

Indoor unit

#1

Network adapter
(Sold separatrly)

X

Y

Network adapter
P.C. board
(MCC-1401)

AI NET

communication

circuit

DC5V

Power circuit

Transformer

Remote
controller
communication
circuit

CPU

H8/3687

Switch setup

Louver

motor

Drain
pump

Indoor

fan

motor

Indoor control P.C. board (MCC-1402)

DC280V

Main (Sub) master remote controller

Display

LCD

CPU

Remote

controller

communication

circuit

Humidifier

relay output

Heater relay

output

control

circuit

Function setup

Key switch

DC5V

Power circuit

Sold separatrly Sold separatrly

Driver

Outside
output

Run

Warning

Ready

Thermo. ON

Cool

Heat

Fan

Power
circuit

Display

LED

DC20V
DC12V

DC5V

CPU
TMP88CH
47FG
(TMP88PH
47FG)

Fan motor

AB

Remote

controller

communication

circuit

CPU

H8/3039

AC

synchronous

signal input

circuit

CN2 CN1

3

*

Serial
send/

receive

circuit

Weekly timer

Display

LCD

DC5V

Power
circuit

EEPROM

TA sensor
TC sensor
TCJ sensor

Float input

Secondary

LCD

driver

CPU

battery

#2

AB

Same as

the left

*

123

Function setup

Key switch

#3

AB

Same as

the left

2

123

2

*

123
123

Outdoor unit

19

communication

Power

circuit

DC5V

Buzzer

Receive circuit

Wireless remote controller kit

Sensor P.C. board (MCC-1504)

Remote

controller

circuit

CPU

Temporary

operation SW

Display LED

Function

setup SW

Outdoor

unit

Outdoor

unit

7-2. Control Specifications

No.

1

When power
supply is reset

2

Operation mode
selection

Item

Outline of specifications

1) Distinction of outdoor units
When the power supply is reset, the outdoors are

distinguished, and control is exchanged according to
the distinguished result.

2) Setting of speed of the indoor fan/setting weather to
adjust air direction or unit.

3) Based on EEPROM data, speed of the indoor fan or
setting whether to adjust air direction or not is se­lected.

1) Based on the operation mode selecting command
from the remote controller, the operation mode is
selected.

Remote controller

command

STOP

FAN

COOL

DRY
HEAT
AUTO

Ta
(˚C)

+1.5

Tsc

or Tsh

-1.5

COOL

Outline of control

Air conditioner stops.
Fan operation
Cooling operation
Dry operation
Heating operation

• COOL/HEAT operation mode
is automatically selected by Ta
and Ts for operation.

(COOL ON)

(COOL OFF)

HEAT

Remarks

Air speed/
Air direction adjustment

Ta : Room temperature
Ts : Setup temperature
Tsc : Setup temperature in

cooling operation

Tsh: Setup temperature

+ Room temperature
control temperature
compensation

1) Judge the selection of COOL/HEAT mode as shown
in the figure above.

When 10 minutes passed after thermostat had
been turned off, the heating operation (Thermo
OFF) is exchanged to cooling operation if Tsh
exceeds +1.5 or more.

(COOL OFF) and (COOL ON) in the figure indicate
an example.

When 10 minutes passed after thermostat had
been turned off, the cooling operation (Thermo
OFF) is exchanged to heating operation if Tsc
exceeds –1.5 or less.

2) For the automatic capacity control after judgment of
COOL/HEAT, refer to item 4.

3) For the temperature correction of room temperature
control in automatic heating operation, refer to item 3.

20

No.

3

Item

Room
temperature
control

Outline of specifications

1) Adjustment range Remote controller setup tem­perature (°C)

Wired type
Wireless type

COOL/DRY

18 to 29
18 to 30

Heating operation

18 to 29
16 to 30

Remarks

Auto operation

18 to 29
17 to 27

4

Automatic
capacity control

5

Air speed
selection

2) Using the item code 06, the setup temperature in
heating operation can be compensated.

Setup data
Setup temp. compensation

0246

+0°C+2°C+4°C+6°C

Setting at shipment

Setup data 2

1) Based on the difference between Ta and Ts, the
operation frequency is instructed to the outdoor unit.

1) Operation with (HH), (H), (L), or
[AUTO] mode is performed by the
command from the remote controller .

2) When the air speed mode [AUTO] is
selected, the air speed varies by the
difference between T a and Ts.

Ta (˚C)
+3.0

+2.5
+2.0

<COOL>

+1.5
+1.0

+0.5

Tsc

-0.5

Shift of suction tempera­ture in heating operation

HH > H > L > LL

HH
(HH)

H (HH)
H (HH)

L(H)
L(H)

L(H)
L(L)

A

B
C
D

E

F
G

F1
F2
F3
F4
F5
F6
F7
F8
F9
FA
FB
FC
FD

Standard

COOL HEAT

HH

HH

H+ H+

H

H

L+

L+ L

L

LL LL

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

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

• When cooling operation has started, the air speed selects a downward slope, that
is, the high position.

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

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

Type 1

COOL HEAT

HH HH

H+

H+

H

H

L+

L+ L

L

LL LL

Type 2

COOL HEAT

HH HH

H+ H+

H

H

L+

L+ L

L

LL LL

Type 3

COOL HEAT

HH HH

H+,H H+,H

L+ L+

LL

LL LL

Type 7

COOL HEAT

HH

HH H+,H

H+,H

L+

L+ L

L

LL LL

SM561

1120
1080
1000
970
930
910
860
820
800
780
760
740
550

SM801

1140
1080
1040
990
950
940
900
880
860
830
800
780
550

SM1101

1220
1180
1120
1060
1020

980

940
910
880
850
820
790
580

SM1401

1300
1220
1180
1140
1100
1060
1020
970
940
930
880
850
580

21

No.

5

Item

Air speed
selection
(Continued)

Outline of specifications

<HEAT>

Ta (˚C)

L(L)

(-0.5)

(0)

(+0.5)

–1.0

Tsh

+1.0

L(H)
H(H)

H

E

D

(HH)

(+1.0)
(+1.5)

(+2.0)

+2.0
+3.0

+4.0

HH

(HH)

C

B
A

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

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

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

• When heating operation has started, the air speed
selects a upward slope, that is, the high position.

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

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

• In Tc ≥ 60°C, the air speed increases by 1 step.

3) In heating operation, the mode changes to [UL] if

thermostat is turned off.

4) If T a ≥ 25°C when heating operation has started and

when defrost operation has been cleared, it oper­ates with HIGH (H) mode or (HH) for 1 minute from
when Tc has entered in E zone of cool air discharge
preventive control (Item 6).

5) In automatic cooling/heating operation, the revolu-

tion frequency of [HH] is set larger than that in the
standard cooling/heating operation. However the
revolution frequency is restricted in the automatic
heating operation as shown in the following figure.

Remarks

[PRE-HEAT] display

Tc

(˚C)

47

42

F5 F4

F5

6 Cool air

discharge
preventive
control

1) In heating operation, the indoor fan is controlled based

on the detected temperature of Tc sensor or Tcj sensor.
As shown below, the upper limit of the revolution
frequency is determined.

Tc

(˚C)

Tcj

32
30
28
26

20
16

HH

H

UL

OFF

L

E zone
D zone

C zone
B zone

A zone

22

In D or E zone, the priority
is given to setup of air
volume exchange .

In A and B zones,
[PRE-HEAT] is displayed.

No.

7

Freeze preven­tive control
(Low tempera­ture release)

Item

Outline of specifications

1) The cooling operation (including Dry operation) is

performed as follows based on the detected tempera­ture of Tc sensor or Tcj sensor.

When [J] zone is detected for 6 minutes (Following
figure), the commanded frequency is decreased from
the real operation frequency. After then the commanded
frequency changes every 30 seconds while operation is
performed in [J] zone.

In [K] zone, time counting is interrupted and the opera­tion is held.

When [I] zone is detected, the timer is cleared and the
operation returns to the normal operation.

If the commanded frequency becomes S0 because the
operation continues in [J] zone, the return temperature
A is raised from 5°C to 12°C until [I] zone is detected
and the indoor fan operates with [M] mode.

(˚C)

5

I

A

K

Remarks

Tcj : Indoor heat ex-

changer sensor
temperature

[M] mode :
Air speed selection

8

High-temp
release control

2

J

In heating operation, the freeze-prev entive control
works if 4-way valve is not exchanged and the condition
is satisfied. (However the temperature for J zone
dashing control is changed from 2°C to –5°C.)

1) The heating operation is performed as follows based on

the detected temperature of Tc sensor or Tcj sensor.

• When [M] zone is detected, the commanded fre­quency is decreased from the real operation fre­quency. After then the commanded frequency
changes every 30 seconds while operation is per­formed in [M] zone.

• In [N] zone, the commanded frequency is held.

• When [L] zone is detected, the commanded fre-

quency is returned to the original value by approx.
6Hz every 60 seconds.

Setup at
shipment

Control temp (°C)

AB

56 (54) 52 (52)

Tcj

(˚C)Tc

A

B

L

M
N

NOTE :

When the operation has started or when Tc or Tcj became
lower than 30°C after start of the operation, temperature is
controlled between values in parentheses of A and B.

Same when thermostat is
turned off.

9 Drain pump

control
When, the

drain up kit
(sold sepa­rately) is
mounted.

1) In cooling operation (including Dry operation), the drain
pump is usually operated.

2) If the float switch operates while drain pump operates,
the compressor stops, the drain pump continues the
operation, and a check code is output.

3) If the float switch operates while drain pump stops, the
compressor stops and the drain pump operates. If the
float switch keeps operating for approx. 4 minutes, a
check code is output. Check code [P10]

23

No.

10

11

Item

DAfter-heat
elimination

Frequency
fixed
operation
(Test run)

Outline of specifications

Remarks

When heating operation stops, the indoor fan operates with LOW
mode for approx. 30 seconds.

<In case of wired remote controller>

1. When pushing [CHECK] button for 4 seconds or more, [TEST] is displayed on the
display screen and the mode enters in Test run mode.

2. Push [ON/OFF] button.

3. Using [MODE] button, change the mode from [COOL] to [HEAT].

• Do not use other mode than [COOL]/[HEAT] mode.

• During test run operation, the temperature cannot be adjusted.

• An error is detected as usual.

• A frequency fixed operation is performed.

4. After the test run, push [ON/OFF] button to stop the operation. (Display in the display
part is same as the procedure in item 1).)

5. Push [CHECK] button to clear the test run mode.
([TEST] display in the display part disappears and the status returns to the normal stop
status.)

<In case of wireless remote controller>

1. Turn off the power of the set.
Remove the adjuster with sensors from the ceiling panel.

2. Turn Bit [1: TEST] of sensor P.C. board switch [S003] from OFF to ON.
Turn on the power of the set.

3. Push [ON/OFF] button of the wireless remote controller and set the operation mode to
[COOL] or [HEAT] using [MODE] button.
(During test run operation, all the display lamps of wireless remote controller sensors
flash.)

• Do not use other mode than [COOL]/[HEAT] mode.

• An error is detected as usual.

• A frequency fixed operation is performed.

4. After the test run, push [ON/OFF] button to stop the operation.

5. Turn off the power of the set.
Turn Bit [1: TEST] of sensor P.C. board switch [S003] from ON to OFF.
Mount the adjuster with sensors to the ceiling panel.

12

Central
control
mode
selection

1) Setting at the central controller side enables to select the
contents which can be operated on the remote controller at
indoor unit side.

2) RBC-AMT21

[Last push priority] :

The operation contents can be selected from both remote
controller and central controller of the indoor unit side, and the
operation is performed with the contents selected at the last.

[Center] :

Start/Stop operation only can be handled on the remote control­ler at indoor unit side.

[Operation Prohibited] :

It cannot be operated on the remote controller at indoor unit
side. (Stop status is held.)

24

(No display)

[CENTER] goes on.

[CENTER] goes on.

In a case of wireless
type, the display lamp
does not change.
However, contents which
can be operated are
same.

The status set in [CEN­TER]/[Operation Prohib­ited] mode is notified with
the receiving sound “Pi,
Pi, Pi, Pi, Pi” (5 times).