Toshiba RAV-SM801AT-E, RAV-SM1401AT-E, RAV-SM561AT-E, RAV-SM1101AT-E SERVICE MANUAL

SERVICE MANUAL

SPLIT TYPE

<NEW DIGITAL INVERTER>

FILE NO. A05-001

OUTDOOR UNIT

RAV-SM561AT-E

RAV-SM801AT-E
RAV-SM1101AT-E
RAV-SM1401AT-E

INDOOR UNIT

This Service Manual describes contents of the new outdoor unit.
For the indoor unit, ref er to the Service Manual with FILE NO. A03-003F.

R410A

PRINTED IN JAPAN, Apr.,2005 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 prev ent destruction of the oz one layer.

WARNING

Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to
have a service person do it. Do not attempt it yourself. The cleaning diagram for the air filter is there for the
service person, and not for the customer.

CONTENTS

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

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)............................................................. 5

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

4. WIRING DIAGRAM ....................................................................................................... 11

5. SPECIFICATIONS OF ELECTRICAL PARTS............................................................... 12

6. REFRIGERANT R410A................................................................................................. 13

6-1. Safety During Installation/Servicing................................................................................ 13

6-2. Refrigerant Piping Installation ....................................................................................... 13

6-3. Tools ...................................................................................................................................17

6-4. Recharging of Refrigerant ................................................................................................18

6-5. Brazing of Pipes ................................................................................................................19

7. CONTROL SPECIFICATIONS ...................................................................................... 21

7-1. Outdoor Controls ..............................................................................................................21

7-2. Outline of Main Controls...................................................................................................24

8. TROUBLESHOOTING .................................................................................................. 29

8-1. Summary of Troubleshooting ........................................................................................... 29

8-2. Check Code List ................................................................................................................31

8-3. Error Mode Judgment by LED Display of Outdoor Unit ................................................ 34

8-4. Contents of Error Display.................................................................................................35

8-5. Troubleshooting Procedure for Each Check Code.........................................................36

8-5. Other Function...................................................................................................................57

9. DETACHMENTS............................................................................................................ 58

10. EXPLODED VIEWS AND PARTS LIST ........................................................................ 73

– 2 –

RAV-SM561AT-E, RAV-SM801AT-E

1. SPECIFICATIONS

Model name

Appearance

Power supply

Type

Compressor Motor (kW)

Pole
Refrigerant charged (kg)
Refrigerant control

Standard length

Max. total length (m)
Pipe Over 20m

Outdoor lower (m)

Height difference

Outdoor higher (m)

Height (mm)
Outer dimension Width (mm)

RAV-SM561AT-E RAV-SM801AT-E

Silky shade (Muncel 1Y8.5/0.5)

1 phase 230 V (220 – 240 V) 50 Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

1.1 1.6
4 poles

R410A 1.0 R410A 1.7

Pulse motor valve

20 (without additional charge)

30

Add 20 g/m (Max. 200 g) Add 40 g/m (Max. 400 g)

30

30
550
780

Depth (mm)
Total weight (kg)
Heat exchanger

Fan
Fan unit Standard air flow High (m³/h)

Motor (W)

Connecting pipe

Protection device

Sound level High (Mid./Low)
(Note 2) (Cooling/Heating)

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions speciied 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

Gas side (mm)

Liquid side (mm)

(dB•A)

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

38 42

2400 2700

Ø12.7 (1/2”) Ø15.9 (5/8”)

Ø6.4 (1/4”) Ø9.5 (3/8”)

Discharge temp. sensor

Over-current sensor

Compressor thermo.

46 / 48 48 / 50

290

Finned tube

Propeller fan

43

– 3 –

RAV-SM1101AT-E, RAV-SM1401AT-E

Model name

Appearance

Power supply

Type
Compressor Motor (kW)

Pole
Refrigerant charged (kg)
Refrigerant control

Standard length

Max. total length (m)
Pipe Over 20m

Outdoor lower (m)

Height difference

Outdoor higher (m)

Height (mm)
Outer dimension Width (mm)

RAV-SM1101AT-E RAV-SM1401AT-E

Silky shade (Muncel 1Y8.5/0.5)

1 phase 230 V (220 – 240 V) 50 Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

2.5 3.0
4 poles

R410A 2.8

Pulse motor valve

30 (without additional charge)

50

Add 40 g/m (Max. 800 g)

30

30
795
780

Depth (mm)
Total weight (kg)
Heat exchanger

Fan
Fan unit Standard air flow High (m³/h)

Motor (W)

Connecting pipe

Protection device

Sound level High (Mid./Low)
(Note 2) (Cooling/Heating)

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions speciied 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

Gas side (mm)

Liquid side (mm)

Discharge temp. sensor

Over-current sensor

Compressor thermo.

(dB•A)

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

320

77

Finned tube

Propeller fan

4500

100

Ø15.9 (5/8”)

Ø9.5 (3/8”)

53 / 54

– 4 –

RAV-SM561AT-E

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

Drain hole (Ø25)

Drain hole
(2-Ø20 × 88 long hole)

A legs

60

600

108 125

30

54

90

2-Ø11-14 U-hole
(For Ø8–Ø10 anchor bolts)

Connecting pipe port
(Flare Ø12.7 at gas side)

69.5 147

320

306

hole pitch)

(Anchor bolt long

21

550

290

Ø6 hole pitch

B legs

449

483

30

20

483 257

108

Connecting pipe port
(Flare Ø6.4 at liquid side)

8-Ø6 hole
(For fixing outdoor unit)

2-Ø11 × 14 long hole
(For Ø8–Ø10 anchor bolts)

157 79

25 31 143
22

54

137

93

21

145

8

32

52

35 6

Guard for air discharge

600

54

R15

38
11

2-Ø6 hole

Product

320

R5.5

Details of A legs Details of B legs

external line

320

38
54

Product
external line

2-Ø6 hole

R15
R5.5

600

500

780

4-Ø4.5 embossing (Ø4 STS used)
(For mounting air direction guide)

Space required for service

2-Ø11 × 14 U-shape holes
(For Ø8–Ø10 anchor bolt)

Suction
port

320

150 or more

500
or more

71

342

Charge port

Anchor bolt mounting dimension

600

Suction port

150

or more

Discharge
port

300
or more

(Minimum
distance up to wall)

2-Ø11 × 14 long hole
(For Ø8–Ø10 anchor bolt)

Earth
terminal

– 5 –

RAV-SM801AT-E

Drain hole
(2-Ø20 × 88 long hole)

A legs

60

600

108 125

Drain hole (Ø25)

30

54

90

2-Ø11–14 U-hole
(For Ø8–Ø10 anchor bolts)

Connecting pipe port
(Flare Ø15.9 at gas side)

69.5 147

320

306

hole pitch)

(Anchor bolt long

21

550

290

Ø6 hole pitch

B legs

449

483

30

20

483 257

108

Connecting pipe port
(Flare Ø9.5 at liquid side)

8-Ø6 hole
(For fixing outdoor unit)

2-Ø11 × 14 long hole
(For Ø8–Ø10 anchor bolts)

157 79

25 31 143
22

54

137

93

21

145

8

32

52

35 6

Guard for air discharge

600

54

R15

38
11

2-Ø6 hole

Product

320

R5.5

Details of A legs Details of B legs

external line

320

38
54

Product
external line

2-Ø6 hole

R15
R5.5

600

500

780

4-Ø4.5 embossing (Ø4 STS used)
(For mounting air direction guide)

Space required for service

2-Ø11 × 14 U-shape holes
(For Ø8–Ø10 anchor bolt)

Suction
port

320

150 or more

500
or more

71

342

Charge port

Anchor bolt mounting dimension

600

Suction port

150

or more

Discharge
port

300
or more

(Minimum
distance up to wall)

2-Ø11 × 14 long hole
(For Ø8–Ø10 anchor bolt)

Earth
terminal

– 6 –

RAV-SM1101AT-E, RAV-SM1401AT-E

Knockout
(For draining)

21

Suction
port

365 17.517.5

40 70

(Long hole pitch

for anchor bolt)

21

565 101

Drain hole (Ø20 × 88 Burring hole)

29 90 191 20

Suction
port

43

Knockout
(For draining)

6026

Discharge
port

300150

900

314

Drain hole (Ø25 Burring hole)

Part B

40

39

Part A

43

95

Handles
(Both sides)

Refrigerant pipe connecting port
(Ø9.5 Flare at liquid side)

Refrigerant pipe connecting port
(Ø15.9 Flare at gas side)

47

Installation bolt hole
(Ø12 × 17 U-shape holes)

17.5
4040

Details of B part

Details of A part

17.5

Installation bolt hole
(Ø12 × 17 U-shape holes)

2

Discharge guide
mounting hole
(4-Ø4 Embossing)

1

60 90

58

27

161

32028

400

6760

264

154

1

300

264

Z

307

2760

96

Knockout for lower piping

86 7

7
58

Z views

Space required for service

795

2

46

25

85

2

165

60 80

30 45

1

2-Ø12 × 17 U-shape holes
(For Ø8–Ø10 Anchor bolt)

150
or more

365

500
or more

Suction port

150

or more

Discharge
port

600

150
or more

Discharge
port

(Minimum
distance up to wall)

2-Ø12 × 17 long hole
(For Ø8–Ø10 Anchor bolt)

– 7 –

RAV-SM561AT-E

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

12.7mm 6.4mm

3. REFRIGERATING CYCLE DIAGRAM

Indoor unit

TCJ

sensor

Air heat exchanger

TC sensor

TS sensor

TD sensor

Rotary compressor

(DA150A1F-20F)

2-step muffler

Ø19.05 × 200L

4-way valve

(STF-0108Z)

Muffler

Ø19 × L160

Refrigerant pipe
at gas side
Ø12.7
Packed valve

Packed valve
Outer dia. ØA

TO sensor

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

Outdoor unit

TE
sensor

Distributor

Refrigerant pipe
at liquid side
Ø6.4
Packed valve

Min.

5m
Packed valve
Outer dia. ØB

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

Strainer

Max.
30m

Cooling
Heating

Pressure

(MPa) (kg/cm²G)

Pd P s Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Over load

Low load

4 poles are provided to this compressor.

*

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

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

Outdoor heat

Compressor

revolutions per

second (rps)

*

70
70
50
97
95
98

Indoor

fan

HIGH
HIGH

LOW
HIGH
HIGH
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/

The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.

– 8 –

(70%)

RAV-SM801AT-E

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

15.9mm 9.5mm

Indoor unit

TCJ

sensor

Air heat exchanger

TC sensor

TS

sensor

Accumulator

(1000cc)

compressor

(DA150A1F-20F)

TD

sensor

Rotary

2-step
muffler

Ø25 × 200L

4-way valve

(STF-0213Z)

Refrigerant pipe
at gas side
Ø15.9
Packed valve

Packed valve
Outer dia. ØA

TO sensor

Heat exchanger
Ø8 ripple,
2 rows, 20 steps
FP1.3, flat fin

Outdoor unit

TE
sensor

Distributor

Refrigerant pipe
at liquid side
Ø9.5
Packed valve

Min.
5m

Packed valve
Outer dia. ØB

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

Strainer

Max.
50m

PsPd

Cooling
Heating

Pressure

(MPa) (kg/cm²G)

Pd P s Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Over load

Low load

4 poles are provided to this compressor.

*

3.28 0.86 33.4 8.8

3.59 1.00 33.6 10.2

1.85 0.83 18.9 8.5

2.53 0.62 25.8 6.3

3.42 1.07 34.9 10.9

1.99 0.23 20.3 2.3

Discharge Suction

Pipe surface temperature (°C)

Indoor heat

exchanger exchanger

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

84 11 10 45
82 17 16 51
42 8 6 23
75 3 42 2
80 20 54 17
89 –19 34 –18

Outdoor heat

Compressor

revolutions per

second (rps)

*

83
76
35
95
50

120

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/

The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.

– 9 –

(70%)

RAV-SM1101AT-E, RAV-SM1401AT-E

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

15.9mm 9.5mm

Strainer

Indoor unit

TCJ sensor

Air heat exchanger

SM801BT-E /
SM800AT-E, SM800UT-E,
SM800BT-E, SM800KRT-E

Distributor
(Strainer incorporated)

TC sensor

Accumulator

(2500cc)

compressor

(DA420A3F – 21M)

RAV-SM1101AT-E

Cooling: Low pressure

TS sensor

TD sensor

4-way valve

(STF-0213Z)

Muffler

Ø25 × L210

Rotary

Ø25 × L180

Refrigerant pipe
at gas side
Ø15.9
Ball valve

Ball valve
Outer dia. ØA

Outdoor unit

Strainer

TO sensor

TE
sensor

Heat exchanger
Outer side Ø8, 2 rows, 20 steps

FP1.3, flat fin
Inner side Ø9.52, 1 row, 30 steps

FP1.5, flat fin

Refrigerant pipe
at liquid side
Ø9.5
Packed valve

Packed valve
Outer dia. ØB

PMV
(Pulse Motor Valve)
(UKV-25D22)

Distributor

Min.
5m

Strainer

Max.
50m

Cooling
Heating

Standard

Cooling Overload

Low load
Standard

Heating Over load

Low load

Pressure

(MPa) (kg/cm²G)

Pd P s Pd Ps

3.44 0.92 35.1 9.4

3.73 1.18 38.1 12.0

1.49 0.70 15.2 7.1

2.80 0.61 28.6 6.2

3.43 1.08 35.0 11.0

2.20 0.25 22.4 2.6

Discharge Suction

Pipe surface temperature (°C)

Indoor heat Outdoor heat
exchanger exchanger

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

82 8 10 39
82 15 17 48
398322
80 0 46 1
82 14 55 13
76 –19 36 –16

revolutions per

Compressor
second (rps)

*

47
42
30
48
24
55

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/––10/

RAV-SM1401AT-E

Pressure

(MPa) (kg/cm²G)

Pd P s Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Over load

Low load

4 poles are provided to this compressor.

*

3.52 0.85 35.9 8.7

3.78 1.12 38.6 11.4

1.51 0.71 15.4 7.2

2.88 0.60 29.4 6.1

3.41 1.08 34.8 11.0

2.35 0.24 24.0 2.4

Discharge Suction

Pipe surface temperature (°C)

Indoor heat Outdoor heat
exchanger exchanger

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

878939
84 15 17 47
407323
85 1 47 1
81 14 54 13
80 –19 40 –16

revolutions per

Compressor
second (rps)

*

54
45
30
61
24
73

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/––10/

The compressor frequency (Hz) measured with a clamp meter is 2 times of revolutions (rps) of the compressor.

(70%)

(70%)

– 10 –

RAV-SM561AT-E, RAV-SM801AT-E

4. WIRING DIAGRAM

Compressor

Reactor

YEL

YEL

BRW

YEL

RED
WHI
BLK

P25

P23

P21

P35

P34

P19

P18
P11

P08

P04
P05
P06

P24

P22

P20

Q404

Q200~205
IGBT

R221

P.C. Board
(MCC-5009)

R220

R219

F03

C13L03

Fuse

T3.15A

AC250V

C12 C14

Power relay

DB02

CT

Relay

P32

CN701 P7

P33 P31 P30 BLK

PUR

Reactor

Surge absorber

Coil for
4-way valve

Varistor

L01

Varistor

F01 Fuse
T25A, AC250V

To
indoor unit

P10

Power supply
220-240V~,
50Hz

CN300

CN700

P02P03
WHIBLKORN

CN603

CN602

CN601

CN600

BLK
WHI
RED

Fan motor

Pulse motor valve

TS

(Suction pipe
Temp. sensor)

TO

(Outdoor

Temp. sensor)

TD

(Discharge pipe

Temp. sensor)

TE

(Condensor pipe

Temp. sensor)

RAV-SM1101AT-E, RAV-SM1401AT-E

1 2

1 2

1 2

1 2

GRY

WHI

WHI

GRY

P09

P08

P12

F01 Fuse
T25A, 250V~

CN01

RED

CN02

WHI

CN03

BLK

PNK

CN02

WHI

Power supply

BLK

1 1
3 3
5 5

PMV

RED

WHI

BLK

RED

321 NL

220V~240V~,50Hz

To indoor unit

ReactorReactor

P13

531

CN13

531

RED

BLK

531

CN01

RED

531

53 41 2
5663 41 2

Pulse motor
valve

CN702

WHI

RED
BLK

Power factor

control

1 2

CN05

1 2

ORN

1 2
1 2

CN301

WHI

Fan motor

WHI

CN04

~

+

~
~

P29 RED

P24 BRW

P21 ORG

RY01

P.C. Board
(MCC-1438)

PNK

RED

WHI

SUB P.C. Board
(MCC-1531)

31 2
31 2

BLK

WHI

RED

YEL

FM

BLU

–

WHI

PNK

53 41 2
53 41 2

GRY

P28 BLK

53 41 2

CN06

53 41 2

RED

BLK

53 41 2

CN800

53 41 2

CN300

WHI

3 3
1 1

RED

1
1

YEL

113

CN03

WHI

Optional
P.C.Board
MCC-1522

53 41 2
53 41 2

53 41 2
53 41 2

3

CN04

3

BLU

3

CN804

BLU

WHI

ORN

49C

112

112

P19

2

TH

2

ORN

BLUYEL

P20

P17

CN600

BLK

TS TE TO

113

CN605

WHI

CN700 YEL

RED

3 3
1 1

RED

CN500

BLU

3

P18

20SF

112

CN604

WHI

2

CN09 RED

CN10 WHI

CN11 BLK

IGBT Module

TD

112

113

2

CN600

CN601

WHI

WHI

7 85 63 41 2

CN801

Coil for 4-way valve

WV U

CM

Compressor

3

– 11 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

RAV-SM561AT-E, RAV-SM801AT-E

No.

1

Fan motor

2

Compressor

3

Reactor

4

Outdoor temp. sensor (To-sensor)

5

Heat exchanger sensor (Te-sensor)

6

Suction temp. sensor (Ts-sensor)

7

Discharge temp. sensor (Td-sensor)

8

Fuse (Switching power (Protect))

9

Fuse (Inverter, input (Current protect)

10

4-way valve solenoid coil

11

Compressor thermo. (Protection)

Parts name

RAV-SM1101AT-E, RAV-SM1401AT-E

No.

1

Fan motor

Parts name

Type

ICF-140-43-4

DA150A1F-20F

CH-57

—
—
—
—

VHV-01AJ503C1

US-622

Type

ICF-280-100-1

Specifications

Output (Rated) 43 W
3 phase, 4P, 1100 W
10 mH, 16A
10 kΩ at 25°C
10 kΩ at 25°C
10 kΩ at 25°C
50 kΩ at 25°C
T3.15 A, AC 250 V
25 A, AC 250 V

ON : 90 ± 5°C, OFF : 125 ± 4°C

Specifications

Output (Rated) 100 W

2

Compressor

3

Reactor

4

Outdoor temp. sensor (To-sensor)

5

Heat exchanger sensor (Te-sensor)

6

Suction temp. sensor (Ts-sensor)

7

Discharge temp. sensor (Td-sensor)

8

Fuse (Switching power (Protect))

9

Fuse (Inverter, input (Current protect))

10

4-way valve solenoid coil

11

Compressor thermo. (Protection)

DA420A3F-21M

CH-56-2Z-T

—
—
—
—

VHV-01AJ503C1

US-622

3 phase, 4P, 3750 W
6 mH, 18.5 A
10 kΩ at 25°C
10 kΩ at 25°C
10 kΩ at 25°C
50 kΩ at 25°C
T3.15 A, AC 250 V
25 A, AC 250 V

ON : 90 ± 5°C, OFF : 125 ± 4°C

– 12 –

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 remo ving 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, chec k 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.

– 13 –

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.

– 14 –

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

– 15 –

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

(mm)

0.8

0.8

0.8

1.0

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

diameter

Outer diameter

(mm)

Tightening torque

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.

N•m (kgf•cm)

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.

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

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

6.35

9.52

12.70

15.88

14 to 18 (140 to 180)
33 to 42 (330 to 420)
50 to 62 (500 to 620)
63 to 77 (630 to 770)

– 16 –

16 (160), 18 (180)

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
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
new equipment
for R410A

Yes

Yes

Yes

Yes

Yes
Yes

Yes
Yes

(Note 2)

R410A

Whether conven­tional equipment
can be used

NO GOOD

NO GOOD

NO GOOD
NO GOOD

NO GOOD
NO GOOD
NO GOOD

*(Note 1)

*(Note 1)

Conventional air

conditioner installation

Whether new equipment
can be used with
conventional refrigerant

OK

*(Note 1)

NO GOOD

NO GOOD

OK
OK

NO GOOD

OK

NO GOOD

(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

– 17 –

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)

– 18 –

(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

Electronic

balance

Siphon

R410A refrigerant is HFC mixed refrigerant.
Therefore, if it is charged with gas , the composi­tion of the charged refrigerant changes and the
characteristics of the equipment varies.

Fig. 6-4-2

6-5. Brazing of Pipes

6-5-1. Materials for Brazing

(1) Silver brazing filler

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

(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 gener ally called solder, and is an alloy of tin and lead. Since it is weak in
adhesive strength, do not use it for refriger ant pipes.

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 an y 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.

– 19 –

Nitrogen gas

cylinder

Pipe

Flow meter

M

Stop valve

From Nitrogen cylinder

Nitrogen
gas

Rubber plug

(2) Characteristics required for flux

• Activated temperature of flux coincides with
the brazing temperature.

• Due to a wide effective temperature range, flux
is hard to carbonize.

• It is easy to remove slag after brazing.

• The corrosive action to the treated metal and

brazing filler is minimum.

• It excels in coating performance and is harm­less to the human body.

As the flux works in a complicated manner as
described above, it is necessary to select an
adequate type of flux according to the type and
shape of treated metal, type of brazing filler and
brazing method, etc.

(3) Types of flux

• Noncorrosive flux

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

It is effective in case where the 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.

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.



(4) Piping materials for brazing and used

brazing filler/flux

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.

Circuit Configuration and Control Specifications

– 20 –

7-1. Outdoor Controls

7-1-1. Print Circuit Board

<Viewed from parts of P.C board>

RAV-SM561AT-E, RAV-SM801AT-E

<MCC-5009>

F01, 02, 25A fuse P.C. board earth lead

L-phase power supply lead
(Black)

N-phase power supply lead
(White)

Serial lead (Orange)
Reactor lead connector

(White)
CN701:

4-way valve connector

– 21 –

RY701:
4-way valve relay

(Black)

C12, 13, 14

C12, 13, 14

electrolytic capacitor

electrolytic capacitor

DB02:
High power factor diode

Q404:
High power factor circuit IGBT

F03: 3.15A fuse

F03: 3.15A fuse

DB01:

DB01:

Single-phase rectifier diode

Single-phase rectifier diode

7. CONTROL SPECIFICATIONS

CN300:
Fan motor connector

CN602:
Outdoor temperature
(TO) sensor connector

CN806:
Optional connector

CN600:
Heat exchange temperature
(TE) sensor connector

CN603:
Suction temperature
(TS) sensor connector

CN601:
Discharge temperature
(TD) sensor connector

CN700:
PMV connector

CN500:
Case thermo
connector

CN605:
Sub SW board connector

Fan drive circuit
Q300 to Q305:
FET (QTY: 6P)

12V12V

GNDGND

IC800: MCU

IC800: MCU

J800 to 803, 806
Model switch jumper line

5V5V

Comp. lead
(Red) (White) (Black)

Comp. drive circuit
Q200 to Q205: IGBT (QTY: 6P)
IC200: Drive IG (QTY: 1P)

RAV-SM1101AT-E, RAV-SM1401AT-E

<IPDU : MCC-1438>

Reactor connector DC15V output

IGBT
(Compressor drive device)

Compressor output

– 22 –

CN09, CN10, CN11

Rectifier

(To MCC-1531)
CN05

Communication signal
(To MCC-1531)
CN06

AC output
(To MCC-1531)
CN13

TH sensor
CN600

Earth ground
CN03

DC320V output
(To MCC-1531)
CN04

Mains (Neutral) input
CN02

Mains (Live) input
CN01

Rectifier connectors
P29 (Red), P28 (Black),
P21 (Orange), P24 (Brown)

Reactor Connector Capacitor

<CDB : MCC-1531>

Refrigerant recovery Switch
SW802

Dip switch

EEPROM-IC
IC801

Serial signal
(To terminal block)
CN02

AC input
(To MCC-1438)
CN01

SW801 P.M.V. CN702

– 23 –

4-way valve
CN700

Model selection jumpers
(Available only service P.C. board)
J800 to J803

Case thermo. switch
CN500

Communication signal
(To MCC-1438)
CN800

TD sensor
CN600

TO sensor
CN601

TE sensor
CN604

TS sensor
CN605

Optional connector
CN804

Fan motor revolution
CN300

DC15V input
(To MCC-1438)
CN04

Fan motor output
CN301

DC320V input
(To MCC-1438)
CN03

7-2. Outline of Main Controls

a
b

c

d

e

TD [˚C]

Error stop ("P03" display with 4 times of error counts)

As command is

Frequency down

Frequency holding

Frequency slow-up
(Up to command)

1. Pulse Modulating Valve (PMV) control

1) For PMV with 50 to 500 pulses during operation, respectively.

2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC
sensor.

3) In heating operation, PMV is controlled with the temperature difference betw een TS sensor and TE
sensor.

4) For the temperature difference in items 2) and 3), 1 to 5K is aimed as the target in both cooling and
heating operations.

5) When the cycle excessively rose in both cooling and heating operations, PMV is controlled by TD sensor.
The aimed value is usually 103°C for SM561, SM801 and 92°C for SM1101, SM1401 in both cooling and
heating operations.

REQUIREMENT

A sensor trouble may cause a liquid back-flow or abnormal overheat resulting in excessive shortening of the
compressor life. In a case of trouble on the compressor, be sure to check there is no error in the resistance
value an the refrigerating cycle of each sensor after repair and then start the operation.

2. Discharge temperature release control

1) This function controls the operation frequency, that
is, lowers the operation frequency when the
discharge temperature has not lower or the
discharge temperature has rapidly risen during
PMV control. It subdivides the frequency control up
to a unit of 0.6 Hz to stabilize the cycle.

2) When the discharge temperature is detected in an
abnormal stop zone, the unit stops the compressor
and restarts after 2 minutes 30 seconds. The error
counter is cleared when it has continued the
operation for 10 minutes.
If the abnormal stop zone has been detected by 4
times without clearing of counter, an error “P03” is
displayed.

* The cause is considered as excessively little

amount of refrigerant, defective PMV, or clogging
of cycle.

[°C]

abcde

SM561, SM801

SM1101, SM1401

117 107 103 100 93
111 106 100 95 90

3. Current release control

The output frequency and the output voltage are
controlled by AC current value detected by T02 on the
outdoor P.C. board so that input current of the inverter
does not exceed the specified value.

Objective model

11 value [A]

SM561

COOL H E AT

10.1 12.0

SM801

COOL H E AT

12.2 14.0

SM1101

COOL HEAT

18.9 19.7

– 24 –

Current [A]

I1

I1–0.5

SM1401

COOL HEAT

19.7 19.7

Frequency down

Hold

Hold

Normal operation