Toshiba RAV-SM562MUT-E, RAV-SM452MUT-E User Manual

SERVICE MANUAL

AIR-CONDITIONER

SPLIT TYPE

<DIGITAL INVERTER>

FILE NO. A06-005

Revised: Jun, 2008

INDOOR UNIT

RAV-SM402MUT-E
RAV-SM452MUT-E
RAV-SM562MUT-E

This Service Manual describes contents of the new indoor unit.
For the outdoor unit, refer to the Service Manual with FILE NO. A05-001 and A07-003.

R410A

PRINTED IN JAPAN, Jun, 2008 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 ser vice person, and not for the customer.

CONTENTS

1. SPECIFICATIONS ...................................................................................... 4

1-1. Indoor Unit........................................................................................................... 4

1-2. Outdoor Unit........................................................................................................ 9

1-3. Operation Characteristic Curve....................................................................... 11

1-4. Capacity Variation Ratio According to Temperature ...................................... 13

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) ...................................... 14

2-1. Indoor Unit......................................................................................................... 14

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM .............................. 17

3-1. Indoor Unit......................................................................................................... 17

3-2. Outdoor Unit...................................................................................................... 18

4. WIRING DIAGRAM................................................................................... 21

4-1. Indoor Unit......................................................................................................... 21

5. SPECIFICATIONS OF ELECTRICAL PARTS .......................................... 23

5-1. Indoor Unit......................................................................................................... 23

6. REFRIGERANT R410A............................................................................ 24

6-1. Safety During Installation/Servicing ............................................................... 24

6-2. Refrigerant Piping Installation....................................................................... 24

6-3. Tools .................................................................................................................. 28

6-4. Recharging of Refrigerant................................................................................ 29

6-5. Brazing of Pipes................................................................................................ 30

6-6. Tolerance of Pipe Length and Pipe Head........................................................ 32

6-7. Additional Refrigerant Amount........................................................................ 34

6-8. Piping Materials and Sizes............................................................................... 36

6-9. Branch Pipe....................................................................................................... 37

6-10. Distributor ......................................................................................................... 37

– 2 –

7. CONTROL BLOCK DIAGRAM................................................................. 38

7-1. Indoor Control Cir cuit....................................................................................... 38

7-2. Control Specifications...................................................................................... 39

7-3. Indoor Print Circuit Board................................................................................ 46

8. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS........... 47

8-1. Indoor Control Cir cuit....................................................................................... 47

9. TROUBLESHOOTING.............................................................................. 49

9-1. Summary of Troubleshooting........................................................................... 49

9-2. Check Code List................................................................................................ 51

9-3. Error Mode Detected by LED on Outdoor P.C. Board .................................... 54

9-4. Troubleshooting Pr ocedure for Each Check Code......................................... 55

10. REPLACEMENT OF SERVICE INDOOR P.C. BOARD ............................ 71

11. SETUP AT LOCAL SITE AND OTHERS.................................................. 75

11-1. Indoor Unit......................................................................................................... 75

11-2. Setup at Local Site / Others ............................................................................. 82

11-3. How to Set up Central Control Address Number ........................................... 86

12. ADDRESS SETUP.................................................................................... 87

12-1. Address Setup Procedure................................................................................ 87

12-2. Address Setup & Group Control...................................................................... 88

12-3. Address Setup (Manual Setting from Remote Controller)............................. 91

12-4. Confirmation of Indoor Unit No. Position ....................................................... 92

13. DETACHMENTS ....................................................................................... 93

13-1. Indoor Unit......................................................................................................... 93

14. EXPLODED VIEWS AND PARTS LIST.................................................. 101

14-1. Ceiling Panel ................................................................................................... 101

14-2. Compact 4-way Air Discharge Cassette Type............................................... 102

– 3 –

1. SPECIFICATIONS

1-1. Indoor Unit

1-1-1. 4-Way Air Discharge Cassette Type

<Single type>

Model

Cooling capacity (kW)
Heating capacity (kW)
Pow er supply

Electrical
characteristics

Appearance

Outer
dimension

Total weight

Heat exchanger

Fan unit Standard air flow H/M/L (m³/min.)

Air filter
Controller (Sold separately)

Connecting pipe Liquid side (mm)

Sound pressure level H/M/L (dB•A)
Sound power level H/M/L (dB•A)

Indoor unit RA V­Outdoor unit RA V-

Running current (A)
Power consumption (kW)

Cooling

Heating

Main unit
Ceiling panel

(Sold separately)

Main unit Width (mm)

Ceiling panel
(Sold separately)

Main unit (kg)
Ceiling panel (Sold separately) (kg)

Fan

Motor (W)

Power factor (%)
EER
Energy efficiency class ∗
Energy rating ∗∗
Running current (A)
Power consumption (kW)
Power factor (%)
COP
Energy efficiency class ∗
Energy rating ∗∗

Model
Panel color
Height (mm)

Depth (mm)
Height (mm)
Width (mm)
Depth (mm)

Gas side (mm)

Drain port (mm)

SM402MUT-E SM452MUT-E SM562MUT-E

SP404A T(Z, ZG)-E SP454AT(Z, ZG)-E SP562AT(Z, ZG)-E

3.6 4.0 5.0

4.0 4.5 5.6
1 phase 230V (220 – 240V) 50Hz

5.05 – 4.63 5.82 – 5.33 6.6 – 7.15

1.00 1.19 1.53
90 93 97

3.60 3.36 3.27

AAA

5.0 4.5 4.5

4.79 – 4.39 5.67 – 5.20 6.62 – 7.21

0.97 1.16 1.54
92 93 97

4.12 3.88 3.64

AAA

5.5 5.0 4.5
Zinc hot dipping steel plate

RBC-UM11PG (W)-E

Moon-white (Muncel 2.5GY 9.0/0.5)

268
575
575

27
700
700

17

3

Finned tube

Turbo fan

11.0 / 9.2 / 7.8 13.3 / 11.2 / 9.1
60

Long life filter

Remote controller

12.7

6.4

VP25
40 / 36 / 31 43 / 39 / 34
55 / 51 / 46 58 / 54 / 49

– 4 –

∗ : IEC standard, ∗∗ : AS standard

<Single type>

Model

Cooling capacity (kW)
Heating capacity (kW)
Pow er supply

Electrical
characteristics

Indoor unit RA V­Outdoor unit RA V-

Running current (A)
Power consumption (kW)
Power factor (%)

Cooling

EER
Energy efficiency class ∗
Energy rating ∗∗
Running current (A)
Power consumption (kW)
Power factor (%)

Heating

COP
Energy efficiency class ∗
Energy rating ∗∗

SM562MUT-E SM562MUT-E

SM562AT-E SM563AT-E

5.0 5.0

5.6 5.6
1 phase 230V (220 – 240V) 50Hz

7.02 – 7.75 7.02 – 7.75

1.61 1.61
95 95

3.11 3.11

BB

4.0 4.0

7.04 – 7.72 7.04 – 7.72

1.61 1.61
95 95

3.48 3.48

BB

4.5 4.5

Main unit

Appearance

Outer
dimension

Total weight

Heat exchanger

Fan unit Standard air flow H/M/L (m³/min.)

Air filter
Controller (Sold separately)

Ceiling panel
(Sold separately)

Main unit Width (mm)

Ceiling panel
(Sold separately)

Main unit (kg)
Ceiling panel (Sold separately) (kg)

Fan

Motor (W)

Model

Panel color

Height (mm)

Depth (mm)
Height (mm)
Width (mm)
Depth (mm)

Zinc hot dipping steel plate

RBC-UM11PG (W)-E

Moon-white

(Muncel 2.5GY 9.0/0.5)

268
575
575

27
700
700

17

3

Finned tube

Turbo fan

13.3 / 11.2 / 9.1
60

Long life filter

Remote controller
Sound pressure level H/M/L (dB•A)
Sound power level H/M/L (dB•A)

Gas side (mm)

Connecting pipe Liquid side (mm)

Drain port (mm)

– 5 –

12.7

6.4

VP25
43 / 39 / 34
58 / 54 / 49

∗ : IEC standard, ∗∗ : AS standard

<Twin type>

Indoor unit 1 RA V- SM562MUT -E SM562MUT-E

Model Indoor unit 2 RA V- SM562MUT -E SM562MUT-E

Outdoor unit RAV- SP1102AT(Z, ZG)-E SP1104AT(Z, ZG)-E

Cooling capacity (kW) 10.0 10.0
Heating capacity (kW) 11.2 11.2

Indoor unit

Po w er supply 1 phase 230V (220 – 240V) 50Hz

Running current (A) 10.31 – 11.24 12.51 – 11.47
Pow er consumption (kW) 2.4 2.67

Cooling

Electrical
characteristics

Heating

Fan Turbo fan

Fan unit Standard air flow H/M/L (m³/min.) 13.3 / 11.2 / 9.1

Motor (W) 60
Sound pressure level H/M/L (dB•A) 43 / 39 / 34
Sound power lev el H/M/L (dB•A) 58 / 54 / 49

Po w er supply 1 phase 230V (220 – 240V) 50Hz

Pow er factor (%) 97 97
EER 4.17 3.75
Energy efficiency class ∗ AA
Energy rating ∗∗ ——
Running current (A) 10.95 – 11.95 12.51 – 11.47
Pow er consumption (kW) 2.55 2.67
Pow er factor (%) 97 97
COP 4.39 4.19
Energy efficiency class ∗ AA
Energy rating ∗∗ ——

Outdoor unit

Standard length (m) 7.5

Min. length (m) 5 3
Outer
dimension

Fan unit Standard air flow volume (m³/min.) 125 101

Connecting
pipe

Sound pressure level Cooling/Heating (dB•A) 49 / 51 49 / 50
Sound power lev el Cooling/Heating (dB•A) 66 / 68 66 / 67

Max. total length (m) 50

Height

difference

Fan Propeller fan

Motor (W) 63 + 63 100 + 100

Gas side

Liquid side

Outdoor lower (m) 30
Outdoor higher (m) 30

Main (mm) 15.9
Sub (mm) 12.7
Main (mm) 9.5
Sub (mm) 6.4

∗ : EC standard, ∗∗ : AS standard

– 6 –

<Twin type>

Indoor unit 1 RA V- SM562MUT -E SM562MUT-E
Model Indoor unit 2 RA V- SM562MUT -E SM562MUT-E

Outdoor unit RA V- SM1102AT-E SM1103AT-E

Cooling capacity (kW) 10.0 10.0
Heating capacity (kW) 11.2 11.2

Indoor unit

Po w er supply 1 phase 230V (220 – 240V) 50Hz

Running current (A) 14.96 – 16.32 14.96 – 16.32
Pow er consumption (kW) 3.52 3.52

Cooling

Electrical
characteristics

Heating

Fan Turbo fan
Fan unit Standard air flow H/M/L (m³/min.) 13.3 / 11.2 / 9.1

Motor (W) 60
Sound pressure level H/M/L (dB•A) 43 / 39 / 34
Sound power lev el H/M/L (dB•A) 58 / 54 / 49

Po w er supply 1 phase 230V (220 – 240V) 50Hz

Pow er factor (%) 98 98
EER 2.84 2.84
Energy efficiency class ∗ CC
Energy rating ∗∗ ——
Running current (A) 13.35 – 14.56 13.35 – 14.56
Pow er consumption (kW) 3.14 3.14
Pow er factor (%) 98 98
COP 3.57 3.57
Energy efficiency class ∗ BB
Energy rating ∗∗ ——

Outdoor unit

Standard length (m) 7.5

Min. length (m) 5.0
Outer
dimension

Fan unit Standard air flow volume (m³/min.) 75

Connecting
pipe

Sound pressure level Cooling/Heating (dB•A) 53 / 54
Sound power lev el Cooling/Heating (dB•A) 70 / 71

Max. total length (m) 50

Height

difference

Fan Propeller fan

Motor (W) 100 63

Gas side

Liquid side

Outdoor lower (m) 30
Outdoor higher (m) 30

Main (mm) 15.9
Sub (mm) 12.7
Main (mm) 9.5
Sub (mm) 6.4

∗ : IEC standard, ∗∗ : AS standard

– 7 –

<Triple type>

Indoor unit 1 RAV-SM562MUT-E

Model

Cooling capacity (kW) 14.0
Heating capacity (kW) 16.0

Power supply 1 phase 230V (220 – 240V) 50Hz

Electrical
characteristics

Indoor unit 2 RAV-SM562MUT-E
Indoor unit 3 RAV-SM562MUT-E
Outdoor unit RAV-SM1603AT-E

Indoor unit

Running current (A) 23.88 – 21.89
Power consumption (kW) 4.99

Cooling Power factor (%) 95

EER 2.81
Energy efficiency class ∗ C
Running current (A) 22.44 – 20.57
Power consumption (kW) 4.69

Heating Power factor (%) 95

COP 3.41
Energy efficiency class ∗ B

Fan Turbo fan

Fan unit Standard air flow H/M/L (m³/min.) 13.3 / 11.2 / 9.1

Motor (W) 60
Sound pressure level H/M/L (dB•A) 43 / 39 / 34
Sound power level H/M/L (dB•A) 58 / 54 / 49

Outdoor unit

Power supply 1 phase 230V (220 – 240V) 50Hz

Standard length (m) 7.5

Min. length (m) 5.0
Outer dimension Max. total length (m) 50

Height

difference

Fan Propeller fan
Fan unit Standard air flow volume (m³/min.) 103

Motor (W) 100 + 100

Gas side
Connecting pipe

Liquid side

Outdoor lower (m) 30
Outdoor higher (m) 30

Main (mm) 15.9
Sub (mm) 12.7
Main (mm) 9.5

Sub (mm) 6.4
Sound pressure level Cooling/Heating (dB•A) 51 / 53
Sound power level Cooling/Heating (dB•A) 68 / 70

– 8 –

∗ : IEC standard

1-2. Outdoor Unit

<Super Digital Inverter>

Model name Outdoor unit RAV-SP

Power supply

Type

Compressor Motor (kW)

Pole

Refrigerant charged (kg)

Refrigerant control

Standard length (m)

Max. total length (m)

Inter Additional refrigerant charge
connecting pipe under long piping connector

Height
difference

Height (mm)

Outer dimension Width (mm)

Outdoor lower (m)

Outdoor higher (m)

562A T(Z)(ZG)-E 802AT(Z)(ZG)-E 1104AT(Z)(ZG)-E 1404AT(Z)(ZG)-E

1 phase 230V (220 – 240V) 50Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

2 2 3.75 3.75

4444

1.5 2.1 3.1 3.1

Pulse motor valve

7.5 7.5 7.5 7.5

50 50 75 75

20g/m 40g/m 40g/m 40g/m

(21m to 50m) (31m to 50m) (31m to 75m) (31m to 75m)

30 30 30 30

30 30 30 30

795 795 1340 1340

900 900 900 900

Depth (mm)

Appearance

Total weight (kg)

Heat exchanger

Fan

Fan unit Standard air flow (m³/h)

Motor (W)

Gas side (mm)

Connecting pipe

Liquid side (mm)

Sound pressure level Cooling/Heating (dB•A)

Sound power level Cooling/Heating (dB•A)

Outside air temperature, Cooling (°C)

Outside air temperature, Heating (°C)

320 320 320 320

Silky shade (Muncel 1Y8.5/0.5)

55 62 93 93

Finned tube

Propeller fan

57 57 101 103

63 63 100 + 100 100 + 100

12.7 15.9 15.9 15.9

6.4 9.5 9.5 9.5

46 / 47 47 / 49 49 / 50 51 / 52

63 / 64 64 / 66 66 / 67 68 / 69

43 to –15°C

15 to –15°C 15 to –20°C

– 9 –

Model name Outdoor unit

RAV-SP404AT(Z)(ZG)-E RAV-SP454AT(Z)(ZG)-E

Power supply

Type

Compressor Motor (kW)

Pole

Refrigerant charged (kg)

Refrigerant control

Standard length (m)

Max. total length (m)

Inter Additional refrigerant charge
connecting pipe under long piping connector

Height
difference

Height (mm)

Outer dimension Width (mm)

Depth (mm)

Outdoor lower (m)

Outdoor higher (m)

1 phase 230V (220 – 240V) 50Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

1.1 1.1

44

1.0 1.0

Pulse motor valve

7.5 7.5

30 30

20g/m (21m to 30m)

30 30

30 30

550 550

780 780

290 290

Appearance

Total weight (kg)

Heat exchanger

Fan

Fan unit Standard air flow (m³/h)

Motor (W)

Gas side (mm)

Connecting pipe

Liquid side (mm)

Sound pressure level Cooling/Heating (dB•A)

Sound power level Cooling/Heating (dB•A)

Outside air temperature, Cooling (°C)

Outside air temperature, Heating (°C)

Silky shade (Muncel 1Y8.5/0.5)

40 40

Finned tube

Propeller fan

40 40

43 43

12.7 12.7

6.4 6.4

45 / 47 45 / 47

62 / 64 62 / 64

43 to –15°C

15 to –15°C

– 10 –

1-3. Operation Characteristic Curve

<Digital Inverter>

RAV-SM562MUT-E / RAV -SM562AT-E

<Cooling> <Heating>

10

8

6

4

Current (A)

2

0

0

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

20 40 60 70 80 100

Compressor speed (rps)

10

8

6

4

Current (A)

• Conditions
Indoor : DB20˚C

2

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

0

0 2040608090100

Compressor speed (rps)

<Super Digital Inverter>

RAV-SM562MUT-E / RAV -SP562AT-E

<Cooling> <Heating>

10

12

10

8

8

6

6

Current (A)

Current (A)

4

• Conditions
Indoor : DB27˚C/WB19˚C

2

Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
230V

0

0 20406050 70 80 100

4

2

0

0 204060 908070 100

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

Compressor speed (rps) Compressor speed (rps)

– 11 –

<Super Digital Inverter>

SP40

SP40

SP45

SP45

RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E
RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E

<Cooling> <Heating>

14

12

SP45

10

8

6

Current (A)

4

2

0

0 20 405060708090100

SP45

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

SP40

SP40

Compressor speed (rps)

16

14

SP45

12

10

8

SP40

SP40

SP45

Current (A)

6

4

2

0

0 2040608090100120

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

Compressor speed (rps)

– 12 –

1-4. Capacity Variation Ratio According to Temperature

RAV-SP404AT-E, RAV-SP404ATZ-E, RAV-SP404ATZG-E
RAV-SP454AT-E, RAV-SP454ATZ-E, RAV-SP454ATZG-E

<Cooling> <Heating>

105
100

95
90
85
80
75
70

Capacity ratio (%)

65
60
55
50

32 33 34 35 36 37 38 39

Outdoor temp. (˚C)

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

40

41 42 43

120
110
100

90
80
70
60
50

Capacity ratio (%)

40
30
20
10

0

-14-16-18-20 -12-10 -8 -6 -4 -2 0 2 4 6 8 10

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

Outdoor temp. (˚C)

RAV-SP562A T-E, RAV-SM563AT-E

<Cooling> <Heating>

105
100

95
90
85
80
75
70

Capacity ratio (%)

65
60
55
50

32 33 34 35 36 37 38 39

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

40

41 42 43

120
110
100

90
80
70
60
50

Capacity ratio (%)

40
30
20
10

0

Outdoor temp. (˚C)

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

-14-16-18-20 -12-10 -8 -6 -4 -2 0 2 4 6 8 10

Outdoor temp. (˚C)

– 13 –

2-1. Indoor Unit

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

200

1000 or more

15 or more15 or more

1000 or more

Obustacle

1000 or more

Space required for

installation and servicing

149

175

207

64

Bottom face
of ceiling

145.5

93

Knockout for flesh
air intake Ø100

70

105

595 to 660 Ceiling open dimension

142 64

29

700 Panel external dimension

595 to 660 Ceiling open dimension

525 Hanging bolt pitch

368.5

Check port

( 450)

Check port

( 450)

200

Check port

( 450)

Drain-up standing-up size

Indoor unit

627.5

or less

Stand-up

Bottom face
of ceiling

Stand-up

850 or less

Note)

595 to 660 Ceiling open dimension

As ABS is used for the drain discharge port of the main unit,
the vinyl chlor paste cannot be used.

Use the flexible hose (Band fix) included in the package.

• Wired remote controller
(RBC-AMT32E)

Drain discharge port

Hanging bolt
M10 or W3/8
local arrange

120

268 27

220.5

145.5
134

63

120

16

Bottom face
of ceiling

Ceiling panel

200

235

105235

Ø162

For branch duct knockout
square hole Ø150

Bottom face of ceiling

575 Unit external dimension

Electric parts box

320.5

575 Unit external dimension

– 14 –

Ø162

256

177

148

510 Hanging bolt pitch

700 Panel external dimension

595 to 660 Ceiling open dimension

Refrigerant pipe
(Liquid) Ø6.4

For branch ductt
knockout square
hole Ø150

Refrigerant pipe
(Gas) Ø12.7

214 105

97.5 42

139.5

190.5

120

142

21

158

Wiring
connection
port

55

9310570

RBC-TWP30E2, RBC-TWP50E2 (Simultaneous Twin)

Inner diameter Ø C

B

Inner

diameter Ø D

Model (RBC-)

TWP30E2

TWP50E2

Liquid side
Gas side
Liquid side
Gas side

Inner

diameter Ø D

A

ABCD

36 14 Ø9.5 Ø6.4
43 23 Ø15.9 Ø12.7
34 14 Ø9.5 Ø9.5
44 21 Ø15.9 Ø15.9

– 15 –

RBC-TRP100E (Simultaneous Triple)

<Gas side>

Header assembly

300

Inner diameter Ø25.4Inner diameter Ø12.7

<Liquid side>

Branch pipe assembly

35

80 80100

Inner diameter
Ø15.9

100

80 80100

Inner diameter
Ø9.52

Insulator

Gas side socket Liquid side socket

Ø15.9

28

10

Ø12.7

Ø15.9

(External

diameter)

46

12

6

24

Ø25.4

(External

diameter)

Ø6.4

Ø9.5

(External

diameter)

100

Ø9.5

9

26

Ø12.7

(External

diameter)

3 pcs. 3 pcs.1 pc. 1 pc.

– 16 –

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Indoor Unit

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

Distributor
(Strainer
incorporated)

TC sensor

Refrigerant pipe
at liquid side
Outer diameter Ø6.4

Heating time
Cooling time

• Twin type (Combination of two indoor units and one outdoor unit)

RAV-SM562MUT-E RAV-SM562MUT-E

Distributor
(Strainer
incorporated)

TC sensor

Indoor A unit

TCJ sensor

Air heat

exchanger

Distributor
(Strainer
incorporated)

TC sensor

Indoor unit

TCJ sensor

Air heat

exchanger

Refrigerant pipe
at gas side
Outer diameter Ø12.7

To outdoor unitTo outdoor unit

Indoor B unit

TCJ sensor

Air heat

exchanger

Refrigerant pipe
at liquid side
Outer diameter Ø6.4

Branch pipe

Refrigerant pipeat liquid side
Outer diameter Ø9.5

To outdoor unit

Refrigerant pipe
at gas side
Outer diameter Ø12.7

Refrigerant pipe
at liquid side
Outer diameter Ø6.4

Refrigerant pipeat gas side

Outer diameter Ø15.9
Heating time
Cooling time

• Triple type (Combination of three indoor units and one outdoor unit)

RAV-SM562MUT-E

Distributor
(Strainer
incorporated)

TC sensor

Refrigerant pipe
at liquid side
Outer diameter
Ø6.4

Indoor A unit

TCJ sensor

exchanger

Air heat

Refrigerant pipe
at gas side
Outer diameter
Ø12.7

RAV-SM562MUT-E

Distributor
(Strainer
incorporated)

TC sensor

Refrigerant pipe
at liquid side
Outer diameter
Ø6.4

Indoor B unit

TCJ sensor

exchanger

Air heat

Refrigerant pipe
at gas side
Outer diameter
Ø12.7

RAV-SM562MUT-E

Distributor
(Strainer
incorporated)

TC sensor

Refrigerant pipe
at liquid side
Outer diameter
Ø6.4

Refrigerant pipe
at gas side
Outer diameter Ø12.7

Branch pipe

To outdoor unit

Indoor C unit

TCJ sensor

Air heat

exchanger

Refrigerant pipe
at gas side
Outer diameter
Ø12.7

Refrigerant
pipeat liquid side
Outer diameter Ø9.5

To outdoor unit

Distributor

Heating time
Cooling time

– 17 –

Distributor

Refrigerant
pipeat gas side
Outer diameter Ø15.9

To outdoor unit

3-2. Outdoor Unit

RAV-SM562MUT-E / RAV -SP562AT-E

Accumulator
(1500cc)

TS sensor

TD sensor

Muffler

Ø25 × L160

Rotary compressor

(DA220A2F-20L)

Packed valve
Outer dia. Ø12.7

Strainer

4-way valve

(STF-0213Z)

Ø25 × L210

TO sensor

Heat exchangerØ8
1 row 30 stages
FP1.3 flat fin

Outdoor unit

TE

sensor

Packed valve
Outer dia. Ø6.4

Modulating
(PMV)
(SKV-18D26)

Capillary
Ø3×Ø2×
L530

PsPd

Strainer

R410A 1.5 kg

Cooling
Heating

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

Pressure

(MPa)

Pd Ps

2.71 1.03

3.48 1.16

1.92 0.74

2.22 0.72

3.47 1.16

1.79 0.25

Pipe surface temperature (°C)

Discharge Suction

(TD) (TS) (TC) (TE)

75 15 10 38
81 20 16 51
34 5 2 11
62 6 38 2
81 20 55 15
71 –16 30 –18

Indoor heat Outdoor heat

exchanger exchanger

Compressor

revolutions per

second (rps)

∗∗

∗

∗∗

43
44
24
41
41
70

Indoor

fan

HIGH
HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) (°C)

Indoor Outdoor

27/19 35/–
32/24 43/–

18/15.5 –5/–

20/– 7/6
30/– 24/18
15/–

–20/(70%)

∗ 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 –

RAV-SM562MUT-E / RAV -SM562AT-E

TS sensor

TD sensor

Rotary compressor

(DA150A1F-20F)

2-step muffler

Ø19 .05 × 200L

4-way valve

(STF-0108Z)

Muffler

Ø19 × L160

Packed valve
Outer dia. Ø12.7

TO sensor

TE

sensor

Heat exchanger Ø8 ripple,
2 rows, 14 steps
FP1.3 flat fin

Outdoor unit

Packed valve
Outer dia. Ø6.4

PMV
(Pulse Motor Valve)
(CAM-B30YGTF-1)

Strainer

Distributor

R410A 1.0 kg

Cooling
Heating

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

Pressure

(MPa) (kg/cm²G)

Pd Ps Pd Ps

3.50 0.97 35.7 9.9

3.90 1.08 39.8 11.0

1.90 0.70 19.4 7.1

2.31 0.61 13.6 6.2

2.86 0.89 29.2 9.1

1.86 0.25 19.0 2.6

Discharge Suction

Pipe surface temperature (°C)

Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TE)

85 14 12 48
93 26 17 54
48 7 5 30
87 5 40 1
86 17 47 11
69 –14 31 –15

Compressor

revolutions per

second (rps)

∗∗

∗

∗∗

70
70
50
97
95
98

Indoor

fan

HIGH
HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) (°C)

Indoor Outdoor

27/19 35/–
32/24 43/–

18/15.5 –5/–

20/– 7/6
28/– 24/18
15/–

–10/(70%)

∗ 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).

– 19 –

RAV-SM402MUT-E / RAV -SP404AT-E
RAV-SM454MUT-E / RAV -SP454AT-E

TS sensor

TD sensor

(STF-0108Z)

Rotary compressor

(DA150A1F-20F)

2-step muffler

Ø19.05 × 200L

4-way valve

Muffler

Ø19 × L160

Packed valve
Outer dia. Ø12.7

TO sensor

TE

sensor

Heat exchanger Ø8 ripple,
2 rows, 14 steps
FP1.3 flat fin

Packed valve
Outer dia. Ø6.4

PMV
(Pulse Motor Valve)
(CAM-B30YGTF-2)

Strainer

Distributor

R410A 1.0 kg

Cooling
Heating

RAV-SP404AT-E

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

Pressure

(MPa) (kg/cm²g)

Pd Ps Pd Ps

2.68 0.94 27.3 9.6

3.23 1.16 32.9 11.8

1.34 0.70 13.7 7.1

2.38 0.70 24.3 7.1

3.39 1.03 34.6 10.5

1.95 0.26 19.9 2.7

Discharge Suction

Pipe surface temperature (°C)

Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TE)

61 12 11 43
77 14 15 50
36 4 2 8
65 7 39 4
83 20 54 16
90 –17 32 –19

Compressor

drive revolution

frequency

(rps)

47
50
44
49
49
90

Indoor

fan

HIGH
HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) (°C)

Indoor Outdoor

27/19 35/–
32/24 43/–

18/15.5 –5/–

20/– 7/6
30/– 24/18
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).

RAV-SP454AT-E

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

Pressure

(MPa) (kg/cm²g)

Pd Ps Pd Ps

2.81 0.89 28.7 9.1

3.24 1.16 33.0 11.8

1.34 0.70 13.7 7.1

2.53 0.68 25.8 6.9

3.39 1.03 34.6 10.5

2.00 0.25 20.4 2.6

Discharge Suction

Pipe surface temperature (°C)

Indoor heat Outdoor heat

exchanger exchanger

(TD) (TS) (TC) (TE)

68 11 10 41
78 14 15 51
36 4 2 8
70 7 41 4
83 20 54 16
92 –17 33 –19

Compressor

drive revolution

frequency

(rps)

53
53
44
56
49
98

Indoor

fan

HIGH
HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) (°C)

Indoor Outdoor

27/19 35/–
32/24 43/–

18/15.5 –5/–

20/– 7/6
30/– 24/18
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).

– 20 –

4. WIRING DIAGRAM

4-1. Indoor Unit

4-1-1. Compact 4-way Cassette Type

1 2
1 2

CN104

(YEL)

Control P.C. Board for

RY
302

1 233 1 2 3
1 2

LM1

LM2

5 5
4 4
3 3
2 2
1 1

5 5
4 4
3 3
2 2
1 1

5 5
4 4
3 3
2 2
1 1

FM

FS

CN34

(RED)

3 3

2 2

1 1

CN33
(WHI)

5 5
4 4
3 3
2 2
1 1

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)

TA

TCJ

1 2
1 2

CN102

(RED)

1 2
1 2

CN101

(BLK)

MCC-1402

Indoor Unit

Fuse
F302
T3.15A
250V~

Motor

drive

circuit

RY
303

CN304
(GRY)

Fuse
F301
250V~
T6.3A

CN67
(BLK)

TC

1 2 3

CN80

(GRN)

Power

supply

circuit

+–

~~

1 233
1 2

WHI BLK

RED

DC20V
DC15V
DC12V
DC7V

5

445

(EXCT)

1 2

CN73

(RED)

P301

BLK

1 2

CN70
(WHI)

1 2

CN66
(WHI)

Connection interface (option)

CN50
(WHI)

(FAN DRIVE)

5

5

4

4

3

3

2

2

1

1

6
5

CN60

4

(WHI)

3
2
1

CN32

2

(WHI)

1

6
5
4

CN61
(YEL)

3
2
1

3

CN309

2

(YEL)

1

3

3

2 2

1 1

CN41
(BLU)

BLK

WHI

CN51
(RED)

5

5

4

4

P.C.

3

3

Board

2

2

1

1

1 2
1 2

Terminal for

central remote

controller

B
A

CN40
(BLU)

U4U3

BLK

WHI

2 2
1 1

CN001
(WHI)

Adapter for

Wireless Remote

Controller

BLK

B
A

WHI

Wired Renote

Controller

FM

TA

TC

TCJ

LM1,LM2

DP

FS

RY302

NOTE

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

DP

Single phase
220 to 240V
50Hz

– 21 –

321

Indoor unit
earth screw

321

Outdoor unit
earth screw

Serial

NL

signal

Color

Identification

BLACK

:

BLK

BLUE

:

BLU

RED

:

RED

GRAY

:

GRY

PINK

:

PNK

GREEN

:

GRN

WHITE

:

WHI

BROWN

:

BRN

ORANGE

:

ORN

YELLOW

:

YEL

• Single type • Twin type

Power supply 220-240V

Single phase 50Hz

L
N

Wired remote controller

• Triple type

Outdoor unit

123

123

Indoor

B

A

AB

unit

Power supply 220-240V

Single phase 50Hz

L

N

Wired remote controller

Outdoor unit

123

123

Indoor unit

No.1 (Master)

B

A

AB

Earth
screw

123

Indoor unit
No.2 (Sub)

AB

Power supply 220-240V

Single phase 50Hz

L
N

Earth

screw

Wired remote controller

Outdoor unit

123

123

Indoor unit

No.1 (Header)

B

A

Earth

AB

screw

Earth
screw

Earth
screw

123

Indoor unit

No.2 (Follower)

AB

Earth

screw

Earth

screw

Earth

screw

123

Indoor unit

No.3 (Follower)

AB

Notes)

1. : indicates a terminal block

2. Broken line and chain line indicate wiring at local site.

3. For the inner wiring diagram of the outdoor unit and the indoor unit, refer to the wiring diagram of each model.

4. There is no polarity. It is no problem that the remote controller is connected to the indoor unit ter minal block A
and B reversely.

5. When using a wireless remote controller, connection of the remote controller to A and B terminal blocks are
unnecessary. (Wire connection between indoor unit No.1 and No.2 is necessary.)

– 22 –

5-1. Indoor Unit

5. SPECIFICATIONS OF ELECTRICAL PARTS

No.

1

Fan motor (for indoor)

2

Thermo. sensor (TA-sensor)

3

Heat exchanger sensor (TCJ-sensor)

4

Heat exchanger sensor (TC-sensor)

5

Float switch

6

Drain pump motor

Parts name

Type

SWF-230-60-1R

155 mm

Ø6 mm, 1200 mm

Ø6 mm, 1200 mm

FS-0218-106

ADP-1406

Specifications

Output (Rated) 60 W, 220–240 V

10 kΩ at 25°C

10 kΩ at 25°C

10 kΩ at 25°C

– 23 –

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 concentr ation
does not exceed the marginal le vel.

If the refrigerant gas leakage occurs and its
concentration exceeds the marginal le vel, an
oxygen starvation accident ma y 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 m ust 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.

– 24 –

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 6-2-6 below .

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thic k pipings whose
diameter is larger than 20 mm.

Thicknesses of sock et joints are as shown in Table 6-2-2.

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

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)

6.35

9.52

12.70

15.88

Minimum joint thickness

(mm)

0.50

0.60

0.70

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.

– 25 –

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

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

Flare processing dimensions differ according
to the type of flare tool. When using a conven­tional flare tool, be sure to secure “dimension
A” b y using a gauge for size adjustment.

Fig. 6-2-1 Flare pr ocessing dimensions

Flare tool for

R410A clutch type

ØD

A

A (mm)

Conventional flare tool

Clutch type Wing nut type

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

Nominal

diameter

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

6.35

9.52

12.70

15.88

0.8

0.8

0.8

1.0

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)

Thickness

(mm)

Flare tool for

R22 clutch type

6.35

9.52

12.70

15.88

0.8

0.8

0.8

1.0

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

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

0.5 to 1.0 1.5 to 2.0

0.5 to 1.0 1.5 to 2.0

Nominal

diameter

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

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

Outer diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

0.8

0.8

1.0

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

– 26 –

Flare nut

width (mm)

17
22
26
29

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

Nominal

diameter

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

Outer diameter

(mm)

6.35

9.52

12.70

15.88

19.05

Thickness

45˚to 46˚

(mm)

0.8

0.8

0.8

1.0

1.0

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.
When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening

torque, comply with values designated b y manufacturers. Table 6-2-7 shows reference values.

Note)

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

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

Nominal

diameter

1/4

Outer diameter

(mm)

6.35

Tightening torque

N•m (kgf•cm)

14 to 18 (140 to 180)

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

16 (160), 18 (180)
3/8
1/2
5/8

9.52

12.70

15.88

33 to 42 (330 to 420)
50 to 62 (500 to 620)
63 to 77 (630 to 770)

– 27 –

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

6-3. Tools

6-3-1. Required T ools

The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to
prev ent 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 con ventional refrigerant (R22)

3) Tools commonly used for R410A and f or 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
V acuum 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.
V acuum evacuating

Refrigerant charge

Refrigerant charge
Gas leakage check
Refrigerant charge

air conditioner installation

Existence of
new equipment
for R410A

Yes

Yes

Yes

Yes

Yes
Yes

Yes
Yes

(Note 2)

R410A

Whether conven­tional equipment
can be used

*(Note 1)

*(Note 1)

×
×

×
×

×
×
×

Conventional air

conditioner installation

Whether new equipment
can be used with
conventional refrigerant

¡

*(Note 1)

×
×

¡

¡

×

¡

×

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) V acuum 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

– 28 –

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.

Never 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)

– 29 –

(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 ]

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Gauge manifold

OUTDOOR unit

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 allo y 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.

Fig. 6-4-2

6-5-2. Flux

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.

3) Low temperature brazing filler

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

1) 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.

– 30 –