Toshiba RAV-SM562XT-E SERVICE MANUAL
FILE NO. SVM-06012
SERVICE MANUAL
AIR-CONDITIONER
UNDER CEILING / CONSOLE TYPE
RAV-SM562XT-E / RAV-SM562AT-E
AV-SM802XT-E / RAV-SM802AT-E
R
R410A
April, 2006
FILE NO. SVM-06012
CONTENTS
1. SPECIFICATIONS............................................................................................................. 1
2. CONSTRUCTION VIEWS ................................................................................................. 3
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ...................................................... 4
4. WIRING DIAGRAM ........................................................................................................... 5
5. SPECIFICATION OF ELECTRICAL PARTS .................................................................... 6
6. REFRIGERANT R410A .................................................................................................... 7
7. CONTROL BLOCK DIAGRAM ....................................................................................... 15
8. OPERATION DESCRIPTION.......................................................................................... 16
9. TROUBLESHOOTING CHART ...................................................................................... 21
10. DETACHMENTS ............................................................................................................ 27
11. EXPLODED VIEWS AND PARTS LIST ...................................................................... 32
Note :
This Service Manual describes explanation for the Under Ceiling 1 console type indoor unit.
For the combined outdoor unit, refer to the following Service Manual.
Outdoor unit Model name SVM to be referred
RAV-SMXX0AT-E A03-007
RAV-SPXXXAT-E A03-014
RAV-SMXX1AT-E A05-001
RAV-SMXX2AT-E A05-018
1-1. Indoor Unit (Flexi Type)
FILE NO. SVM-06012
1. SPECIFICATIONS
Model
Cooling capacity
Heating capacity
Power supply
Electrical
characteristics
Appearance
Outer
dimension
Total weight
Heat exchanger Finned tube
Fan unit Standard air flow (m3/h) 14.0 / 12.0 / 10.0 18.5 / 13.5 / 10.7
Air filter Attached main unit
Controller Attached main unit (WH-H2UE)
Dimensions pipe
Sound level (dB¥A)
Sound power level
Indoor unit
Outdoor unit
(kW)
(kW)
Cooling
Heating
Running current (A)
Power consumption
Power factor
EER
Energy efficiency class *
Energy rating *
Running current
Power consumption
Power factor
COP
Energy efficiency class *
Energy rating *
(kW)
(%)
(W/W)
(A) 8.13-7.46 12.91-11.84
(kW)
(%)
(W/W)
Main unit
Ceiling panel
(Sold separately)
Main unit
Ceiling panel
(Sold separately)
Main unit (kg)
Ceiling panel
Fan Centrifugal Centrifugal
Motor (W) 50
Gas side (mm) 12.7 15.9
Liquid side (mm) 6.4 9.5
Drain port
Model -
Panel color -
Height (mm)
Width (mm)
Depth (mm)
Height (mm)
Width (mm)
Depth (mm)
(kg)
H/M/L
(mm)
H/M/L
H/M/L
(dB¥A)
RAV-SM562XT-E RAV-SM802XT-E
RAV-SM562AT-E RAV-SM802AT-E
5.0
5.6
1 phase 230V (220-240V) 50Hz
8.95-8.20 13.15-12.06
1.87 2.72
95 94
2.67
D E
2.5 1.5
1.70
95
3.29 3.00
C
3.0
Pure white
208
1093
633 633
-
-
-
23
-
VP16
43 / 39 / 36 46 / 42 / 37
58 / 54 / 51 61 / 57 / 52
* IEC standard
** AS standard
6.7
8.0
2.46
2.67
94
D
2.5
208
1093
-
-
-
23
-
50
– 1 –
• Operation characteristic curve
<Cooling> <Heating>
14
FILE NO. SVM-06012
12
RAV-SM802XT-E
10
8
6
Current (A)
4
2
0
15
020
RAV-SM562XT-E
• Conditions
Indoor : DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
230V
40 60 70 80 100
Compressor speed (rps)
14
12
10
8
Current (A)
6
4
2
0
15
020
RAV-SM802XT-E
RAV-SM562XT-E
• Conditions
Indoor : DB20˚C
Outdoor : DB7˚C/WB6˚C
Air flow : High
Pipe length : 7.5m
230V
40 60 80 90 100
Compressor speed (rps)
• Capacity variation ratio according to temperature
<Cooling> <Heating>
105
100
95
90
120
110
100
90
80
85
70
80
60
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
50
40
Capacity ratio (%)
30
20
10
0
-14-12-10-8-6-4-20246810
Outsoor temp. (˚C)
• Conditions
Indoor : DB20˚C
Indoor air flow : High
Pipe length : 7.5m
Outsoor temp. (˚C)
– 2 –
2-1. Indoor Unit
FILE NO. SVM-06012
2. CONSTRUCTION VIEWS
Front panel
1093
208
633
Knock out system
Grille air inlet
Back body
For stud bolt
(Ø8 – Ø10)
For stud bolt (Ø6)
200 Min
330165
1093
1015
742
450
20 20
Ø74
UNDER CEILING & CONSOLE INSTALLATION
– 3 –
Installation plate
Mount plate
M10 Suspention bolt
633
460
70 Min
Wireless remote control
Knock out system
160
57 18
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM
3-1. RAV-SM562XT-E / RAV-SM802XT-E
FILE NO. SVM-06012
Indoor unit
TCJ
sensor
Air heat exchanger
TC sensor
Model
RAV-SM
562XT-E
802XT-E
Outer diameter of refrigerant pipe
Gas side ∅A Liquid side ∅ B
12.7 mm 6.4 mm
15.9 mm 9.5 mm
Refrigerant pipe
at liquid side
Outer dia. ∅B
Packed valve
Outer dia. ∅B
Note :
This Service Mamual describes explanation for the Under Ceiling 1 console type indoor unit.
For the combined outdoor unit, refer to the following Service Manual.
Outdoor unit Model name SVM to be referred
RAV-SMXX0AT-E A03-007
RAV-SPXXXAT-E A03-014
RAV-SMXX1AT-E A05-001
RAV-SMXX2AT-E A05-018
Outdoor unit
Refrigerant pipe
at gas side
Outer dia. ∅A
Packed valve
Outer dia. ∅A
Max
30m
– 4 –
Cooling
Heating
Indoor Unit
1
AND INDICATION PARTS
INFRARED RAYS RECEIVE
LOUVER
MOTOR
10
10
9
8
7
6
5
4
3
2
1
CN25
FILE NO. SVM-06012
4. WIRING DIAGRAM
HEAT
SWITCH PCB
MCC-1428B
CN101
CN100
WHI
10
10
BLU
9
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BRW
RED
ORN
YEL
PNK
BLU
8
7
6
5
4
3
2
1
CN13
1
2
3
4
5
CN07
9
8
7
6
5
4
3
2
1
1
2
3
4
5
66
R507
R09
R22
SG01
9
8
7
6
5
4
3
2
1
4
5
IC04
21 3
WHI
GRY
21 3
21
250VAC
GRY
3
DB01
R01
FUSE
F01
T6.3A
FOR FLOAT SWITCH
(OPTION)
When you use float
switch you should cut J401
CN402
POWER
SUPPLY
CIRCUIT
C02
C01
C15
R21
3
EXCHANGER
SENSOR
21
J401
DC12V
DC5V
CR502
RY501
MCC-1428A
R405
RY401
(TCJ)
CN05
IC03
CR501
C501
CR401
21
21
CN03
21
2
121
2
121
CN01
R506
1
1
2
2
3
3
4
4
5
5
CN10
3
3
2
2
1
1
CN11
3
FOR DRAIN PUMP
2
1
CN401
BLK
BLK
BLK
BLK
WHI
RED
BLK
BRW
GRY
YEL
(OPTION)
1
1
2
2
3
3
4
4
5
5
66
3
3
2
2
1
1
THERMO
SENSOR
(TA)
HEAT
EXCHANGER
SENSOR
(TC)
WHI
RED
BLK
BLU
PUR
GRY
FAN-MOTOR
100”C
Check items
OPERATION
1
indicator
Terminal
2
block
Fuse
3
6.3A
DC 5V
4
DC 12V
5
BLK
P04
CN30
2
BLK
CN31
WHI
21
RED
INDOOR
TERMINAL
3
BLOCK
CN23
GRN&YEL
SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS
Diagnosis result
Check to see if OPERATION indicator goes on and off when the main switch
or breaker is turned on.
Check the power supply voltage between 1 - 2 (Refer to the name plate.)
Chack the fluctuate voltage between 2 - 3 (DC15 to 60V)
Check to see if the fuse blows out. (Check the varistor. : R22, R21)
Check the voltage at the No.8 pin on CN13 connector of the infrared receiver.
(Check the transformer and the power supply circuit of the rated voltage.)
Check the voltage at the brown lead of the louver motor.
(Check the transformer and the power supply circuit of the rated voltage.)
– 5 –
INDOOR
UNIT
OUTDOOR
UNIT
Identification
BRW
RED
GRY
PNK
ORN
GRN&YEL
GRN
PUR
Color
WHI
YEL
BLU
BLK
BROWN
:
RED
:
WHITE
:
YELLOW
:
BLUE
:
BLACK
:
GRAY
:
PINK
:
ORANGE
:
GREEN&
:
YELLOW
GREEN
:
PURPLE
:
FILE NO. SVM-06012
5. SPECIFICATION OF ELECTRICAL PARTS
Indoor Unit
No. Parts name Type Specifications
1 Fan motor (for indoor) AFP-220-50-4A Output (Rated) 50 W, 220 – 240 V
2 Grille motor MP35EA DC 12 V
3 Thermo. sensor (TA-sensor) 550 mm 10 kΩ at 25°C
4 Heat exchanger sensor (TC-sensor) ∅6 mm, 500 mm 10 kΩ at 25°C
5 Heat exchanger sensor (TCJ-sensor) ∅6 mm, 500 mm 10 kΩ at 25°C
– 6 –
6. REFRIGERANT R410A
FILE NO. SVM-06012
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 of 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.
– 7 –
FILE NO. SVM-06012
Table 6-2-1 Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter Outer diameter (mm) R410A R22
1/4 6.35 0.80 0.80
3/8 9.52 0.80 0.80
1/2 12.70 0.80 0.80
5/8 15.88 1.00 1.00
(2) Joints
For copper pipes, flare joints or socket joints are
used. Prior to use, be sure to remove all
contaminants.
a) Flare joints
Flare joints used to connect the copper pipes
cannot be used for pipings whose outer
diameter exceeds 20 mm. In such a case,
socket joints can be used.
Sizes of flare pipe ends, flare joint ends and
flare nuts are as shown in Tables 6-2-3 to 6-2-6
below.
Table 6-2-2 Minimum thicknesses of socket joints
Nominal diameter
Reference outer diameter of Minimum joint thickness
1/4 6.35 0.50
3/8 9.52 0.60
1/2 12.70 0.70
5/8 15.88 0.80
b) Socket joints
Socket joints are such that they are brazed for
connections, and used mainly for thick pipings
whose diameter is larger than 20 mm.
Thicknesses of socket joints are as shown in
Table 6-2-2.
copper pipe jointed (mm) (mm)
6-2-1. 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, slo wly cut the pipe
so that it is not deformed.
b) Removing burrs and chips
If the flared section has chips or burrs,
refrigerant leakage may occur. Carefully
remove all burrs and clean the cut surface
before installation.
c) Insertion of flare nut
– 8 –
d) Flare processing
Make certain that a clamp bar and copper pipe
have been cleaned.
By means of the clamp bar, perform the flare
processing correctly.
Use either a flare tool for R410A or conventional flare tool.
Flare processing dimensions differ according to
the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A”
by using a gauge for size adjustment.
∅D
A
Fig. 6-2-1 Flare processing dimensions
FILE NO. SVM-06012
Table 6-2-3 Dimensions related to flare processing for R410A
Nominal
diameter
1/4 6.35 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0
3/8 9.52 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0
1/2 12.70 0.8 0 to 0.5 1.0 to 1.5 2.0 to 2.5
5/8 15.88 1.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5
Nominal
diameter
1/4 6.35 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5
3/8 9.52 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5
1/2 12.70 0.8 0 to 0.5 0.5 to 1.0 1.5 to 2.0
Outer
diameter
(mm)
Table 6-2-4 Dimensions related to flare processing for R22
Outer
diameter
(mm)
Thickness
(mm)
Thickness
(mm)
Flare tool for R410A
clutch type
Flare tool for R22
clutch type
A (mm)
Conventional flare tool
Clutch type Wing nut type
A (mm)
Conventional flare tool
Clutch type Wing nut type
5/8 15.88 1.0 0 to 0.5 0.5 to 1.0 1.5 to 2.0
Table 6-2-5 Flare and flare nut dimensions for R410A
Nominal
diameter
1/4 6.35 0.8 9.1 9.2 6.5 13 17
3/8 9.52 0.8 13.2 13.5 9.7 20 22
1/2 12.70 0.8 16.6 16.0 12.9 23 26
5/8 15.88 1.0 19.7 19.0 16.0 25 29
Nominal
diameter
1/4 6.35 0.8 9.0 9.2 6.5 13 17
Outer
diameter
(mm)
Outer
diameter
(mm)
Thickness
(mm)
Table 6-2-6 Flare and flare nut dimensions for R22
Thickness
(mm)
ABCD
ABCD
Dimension (mm)
Dimension (mm)
Flare nut
width
(mm)
Flare nut
width
(mm)
3/8 9.52 0.8 13.0 13.5 9.7 20 22
1/2 12.70 0.8 16.2 16.0 12.9 20 24
5/8 15.88 1.0 19.4 19.0 16.0 23 27
3/4 19.05 1.0 23.3 24.0 19.2 34 36
– 9 –
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