Toshiba RAV-SM801BT-E, RAV-SM1400AT-E, RAV-SM1100AT-E, RAV-SM561BT-E, RAV-SM1401BT-E User Manual

SERVICE MANUAL

RAV-SM561BT-E/RAV-SM560AT-E

FILE NO. A03-007

SPLIT TYPE

RAV-SM801BT-E/RAV-SM800AT-E
RAV-SM1101BT-E/RAV-SM1100AT-E
RAV-SM1401BT-E/RAV-SM1400AT-E

R410A

PRINTED IN JAPAN, Feb.,2004 ToMo

CONTENTS

1. SPECIFICATIONS................................................................................................ 1

2. AIR DUCTING WORK..........................................................................................7

3. CONSTRUCTION VIEWS (EXTERNAL VIEWS) ................................................. 9

4. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM .......................................13

5. WIRING DIAGRAM ............................................................................................ 17

6. SPECIFICATIONS OF ELECTRICAL PAR T S ................................................... 21

7. REFRIGERANT R410A ..................................................................................... 23

8. INDOOR UNIT CONTROL ................................................................................. 31

9. OUTDOOR CONTROL ...................................................................................... 40

10. TROUBLESHOOTING ....................................................................................... 47

11. REPLACEMENT OF SERVICE INDOOR P.C. BOARD ..................................... 70

12. SETUP AT LOCAL SITE AND OTHERS ........................................................... 74

13. ADDRESS SETUP ............................................................................................. 84

14. DETACHMENTS................................................................................................. 88

15. EXPLODED VIEWS AND PARTS LIST ........................................................... 114

1-1. Indoor Unit

Concealed Duct Type

1. SPECIFICATIONS

Model name

Standard capacity (Note 1) (kW)

Heating low temp. capacity (Note 1) (kW)
Energy consumption effect ratio (Cooling)

Power supply
Running current (A)

Electrical
characteristics

Appearance

Outer
dimension

Power consumption (kW)
(Low temp.) (kW)
Power factor (%)
Main unit

Ceiling Panel
(Sold separately)

Main unit Width (mm)

Ceiling panel
(Sold separately)

Model
Panel color
Height (mm)

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

RAV-SM561BT-E RAV-SM801BT-E

Cooling Heating Average Cooling Heating Average

5.0 5.6 7.1 8.0

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

4.6 6.2

2.81 [C] 3.27 [C] 3.04 2.81 [C] 3.32 [C] 3.07
1 phase 230V (220 – 240V) 50Hz

8.99–8.24 8.18–7.50 12.25–11.21 11.65–10.68

1.78 1.71 2.53 2.41

1.98 2.86

95 95 94 94

Zinc hot dipping steel plate

——

——
320 320
700 1000
800 800

——

——

——

Total weight

Heat exchanger
Soundproof/Heat-insulating material

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

Air filter
Controller (Sold separately)

Connecting
pipe

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

Main unit (kg)
Ceiling panel

Fan

Motor (W)

Gas side (mm)
Liquid side (mm)
Drain port (Nominal dia.)

42 39 36 43 40 37

30 39

——

Finned tubu

Inflammable polyethylene foam

Multi-blade fan
840 1140
120 120

Attached main unit

RBC-AMT21E

Ø12.7 (1/2”) Ø15.9 (5/8”)

Ø6.4 (1/4”) Ø9.5 (3/8”)

25 (Polyvinyl chloride tube)

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions specified by JIS B 8616 based

on the reference piping 7.5m.

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

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

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

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

1

Model name

Standard capacity (Note 1) (kW)

RAV-SM1101BT-E RAV-SM1401BT-E

Cooling Heating Average Cooling Heating Averag e

10.0 11.2 12.5 14.0

(2.2 – 11.2) (2.2 – 12.5) (3.0 – 13.2) (3.0 – 16.0)
Heating low temp. capacity (Note 1) (kW)
Energy consumption effect ratio (Cooling)

Power supply
Running current (A)

Electrical
characteristics

Appearance

Outer
dimension

Power consumption (kW)
(Low temp.) (kW)
Power factor (%)
Main unit

Ceiling Panel
(Sold separately)

Main unit Width (mm)

Ceiling panel
(Sold separately)

Model
Panel color
Height (mm)

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

8.7 11.8

2.81 [C] 3.57 [B] 3.19 2.83 [C] 3.47 [B] 3.15
1 phase 230V (220 – 240V) 50Hz

16.5–15.1 14.6–13.4 20.7–19.0 18.9–17.3

3.56 3.14 4.42 4.03

3.50 4.18

98 98 97 97

Zinc hot dipping steel plate

——
——

320

1340

800
——
——
——

Total weight

Heat exchanger
Soundproof/Heat-insulating material

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

Air filter
Controller (Sold separately)

Connecting
pipe

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

Main unit (kg)
Ceiling panel

Fan

Motor (W)

Gas side (mm)
Liquid side (mm)
Drain port (Nominal dia.)

42 39 36 44 41 38

54 54

——

Finned tubu

Inflammable polyethylene foam

Multi-blade fan

1620 1980

120 120

Attached main unit

RBC-AMT21E

Ø15.9 (5/8”)

Ø9.5 (3/8”)

25 (Polyvinyl chloride tube)

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions specified by JIS B 8616 based

on the reference piping 7.5m.

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

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

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

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

2

1-2. Outdoor Unit

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)
Outdoor higher (m)

Outer
dimension

Height difference

Height (mm)

Width (mm)

Depth (mm)

RAV-SM560AT-E RAV-SM800AT-E

Silky shade (Muncel 1Y8.5/0.5)

1 phase 230V (220 – 240V) 50Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

1.1 1.6
8 poles

R410A 0.9 R410A 1.5

Pulse motor valve

20 (without additional charge)

30 50

Add 20g/m (Max. 200g) Add 40g/m (Max. 1200g)

30

50
595 795
780 780
270 270

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)

Gas side (mm)
Liquid side (mm)

(dB•A)

35 55

Finned tube

Propeller fan

2400 3400

43 63

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 45/50

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions specified by JIS B 8616 based

on the reference piping 7.5m.

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

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

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

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

3

Model name

RAV-SM1100AT-E RAV-SM1400AT-E

Appearance

Power supply

Type

Compressor Motor (kW)

Pole
Refrigerant charged (kg)
Refrigerant control

Standard length

Max. total length (m)
Pipe Over 20m

Height difference

Height (mm)
Outer

dimension

Total weight (kg)

Width (mm)

Depth (mm)

Outdoor lower (m)
Outdoor higher (m)

Silky shade (Muncel 1Y8.5/0.5)

1 phase 230V (220 – 240V) 50Hz

(Power exclusive to outdoor is required.)

Hermetic compressor

2.0 3.75
8 poles

R410A 2.1 R410A 2.3

Pulse motor valve

20 (without additional charge)

50

Add 40g/m (Max. 1200g)

15
30

1340

900
320

75 85

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)

Gas side (mm)
Liquid side (mm)

(dB•A)

6800 7500

63 + 43 63 + 63

53/54 53/54

Finned tube

2 Propeller fans

Ø15.9 (5/8”)

Ø9.5 (3/8”)

Discharge temp. sensor

Over-current sensor

Compressor thermo.

Note 1 : The cooling capacities and electrical characteristics are measured under the conditions specified by JIS B 8616 based

on the reference piping 7.5m.

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

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

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

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

4

1-3. Operation Characteristic Curve

RAV-SM561BT-E / SM801BT-E
<Cooling> <Heating>

14

12

RAV-SM801BT-E

10

8

6

Current (A)

4

2

0

15

020

RAV-SM561BT-E

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

40 60 70 80 100

Compressor speed (rps)

16

14

12

10

8

Current (A)

6

4

2

0

15

020

RAV-SM801BT-E

RAV-SM561BT-E

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

40 60 80 90 100

Compressor speed (rps)

RAV-SM1101BT-E
<Cooling> <Heating>

20

18

16

14

12

10

Current (A)

8

6

4

2

0

0 204060

RAV-SM1100UT-ERAV-SM1101BT-E

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

80 100 120

20

18

16

14

12

10

Current (A)

8

6

4

2

0

0204060

RAV-SM1100UT-ERAV-SM1101BT-E

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

80 100 120

Compressor speed (rps)

Compressor speed (rps)

5

RAV-SM1401BT-E
<Cooling> <Heating>

22
20

18
16

RAV-SM1400UT-E

14
12
10

Current (A)

8
6

• Conditions

4
2
0

020406080

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

Compressor speed (rps)

22
20

18
16

RAV-SM1400UT-ERAV-SM1401BT-E RAV-SM1401BT-E

14
12
10

Current (A)

8
6

• Conditions

4
2
0

020406080

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

Compressor speed (rps)

1-4. Capacity Variation Ratio According to Temperature

<Cooling> <Heating>

105
100

95
90
85
80
75
70

Capacity ratio (%)

65
60
55

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

50

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

Outsoor temp. (˚C)

120
110
100

90
80
70
60
50

Capacity ratio (%)

40
30
20
10

0

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

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

Outsoor temp. (˚C)

6

2. AIR DUCTING WORK

2-1. Static Pressure Characteristics of Each Model

Fig. 1 RAV-SM561BT-E (Round duct)

140

120

100

Usable limit

80

60

Static pressure (Pa)

40

Air volume limit (Min.)

20

Standard air volume 780m³/h

High static pressure 2H tap

High static pressure 1H tap

Standard H tap

Low static pressure H tap

Standard L tap

140

120

100

Static pressure (Pa)

Air volume limit (Max.)

Fig. 3 RAV-SM801BT-E (Round duct)

Standard air volume 1140m³/h

High static pressure 2H tap

Usable limit

80

60

40

20

Air volume limit (Min.)

High static pressure 1H tap

Standard H tap

Low static pressure H tap

Standard L tap

Air volume limit (Max.)

0

500 700 780 900

Air volume m³/h

Fig. 2 RAV-SM561BT-E (Square duct)

140

120

108
100

80

60

Usable limit

Static pressure (Pa)

40

Air volume limit (Min.)

20

Standard air volume 780m³/h

High static pressure 2H tap

High static pressure 1H tap

Standard H tap

Low static pressure H tap

Standard L tap

Static pressure (Pa)

Air volume limit (Max.)

0
800

1000

Air volume m³/h

Fig. 4 RAV-SM801BT-E (Square duct)

140

120

100

80

60

40

20

Usable lim

Air volume limit (Min.)

Standard air volume 1140m³/h

High static pressure 2H tap

it

High static pressure 1H tap

Standard H tap

Low static pressure H tap

Standard L tap

12001140 1300

Air volume limit (Max.)

0
500 700 780 900

Air volume m³/h

0
800

1000

12001140 1300

Air volume m³/h

7

0

Fig. 5 RAV-SM1101BT-E (Round duct)

Fig. 7 RAV-SM1401BT-E (Round duct)

140

120

Standard air volume 1620m³/h

140

120

Standard air volume 1980m³/h

High static pressure 2H tap

High static pressure 2H tap

100

100

Usable limit

High static pressure 1H tap

80

60

Standard H tap

Static pressure (Pa)

40

Air volume limit (Min.)

20

0
1200

Low static pressure H tap

Standard L tap

1620

Air volume limit (Max.)

2000

80

60

Static pressure (Pa)

40

20

0
1200 1800

Air volume m³/h

Usable limit

Air volume limit (Min.)

High static pressure 1H tap

Standard H tap

Low static pressure H tap

Standard L tap

1980

Air volume m³/h

Air volume limit (Max.)

2200 2400

Fig. 6 RAV-SM1101BT-E (Square duct)

140

120

Usable limit

100

80

60

Static pressure (Pa)

40

Air volume limit (Min.)

20

Low static pressure H tap

Standard air volume 1620m³/h

High static pressure 2H tap

High static pressure 1H tap

Standard H tap

Standard L tap

Air volume limit (Max.)

Fig. 8 RAV-SM1401BT-E (Square duct)

140

120

100

80

60

Usable limit

Static pressure (Pa)

40

Air volume limit (Min.)

20

Standard air volume 1980m³/h

High static pressure 2H tap

High static pressure 1H tap

Standard H tap

Low static pressure H tap

Standard L tap

Air volume limit (Max.)

0
1200

1620

Air volume m³/h

2000

0
1200 1800

1980

2200 240

Air volume hm³/h

8

3. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

3-1. Indoor Unit
3-1-1. Concealed Duct Type

RAV-SM561BT-E / SM801BT-E / SM1101BT-E / SM1401BT-E

129

110

Knock-out hole Ø125
(Air take-in port)

6-Ø4 T apping screw
undersized hole Ø160

Discharge port flange
N-Ø200

60 to 260
9

Suction port canvas
(Separate sold)

Refrigerant pipe connecting port
(Gas side ØF)

Hanging bolt pitch B

Main unit dimension A

J = M x K H

C

Ceiling open size D

Panel external dimension E

Hanging bolt
4-M10 screw
(Arranged locally)

44
49

Refrigerant pipe
connecting port
(Liquid side ØG)

Drain pipe connecting port
for vinyl chloride pipe
(Inner dia. 32, VP. 25)

75

Main unit dimension 800

Hanging bolt pitch 700

50

131

50

Ø26 Power supply,
remote controller
cable take-out port

638

498

393

41

196

243

Panel C.L

410

Ceiling open size

470

Panel external
dimension 500

5941

174

Suction port
flange
(Separate sold)

Suction port
panel
(Separate sold)

320

• Dimension

RAV-SM561BT

RAV-SM801BT

RAV-SM1101, 1401BT

ABCDEFGHJ KMN

700 766 690 750 780 12.7 6.4 252 280 280 1 2
1000 1066 990 1050 1080 15.9 9.5 252 580 290 2 3
1350 1416 1340 1400 1430 15.9 9.5 252 930 310 2 4

NOTE :

For maintenance of the equipment,
be sure to install a check port A at
the position as shown below.

Plane view of main unit

(Pipe side)

Discharge side

Check port A

300

100

450

9

3-2. Outdoor Unit

RAV-SM560AT-E

49.5

521 21

25 220

308

302

Ø6 Hole pitch

for anchor bolt)

(Long hole pitch

147

Drain hole (Ø25)

83

A legs

150

11

30

76

153

B legs

Discharge guard

(49.3)

598

593

500 (Fan center dividing)

500 (Fan center dividing)

Protective net mounting hole
(2-Ø4 Embossing)

Drain hole (2-Ø20 x 88 long hole)

600

115.3 125

30

21

780

115.3

Discharge guide mounting hole
(4-Ø4 Embossing)

97

2927031

330

21

31
23

132

90.6

Charge port

216

Valve cover

31 134

43 707 30

Protective net mounting hole
(4-Ø4 Embossing)

Refrigerant pipe connecting port
(Ø12.7 Flare at gas side)

600

52
36

R15

302

308 11

Ø11 x 14 U-shape hole

Details of A legs Details of B legs

2-Ø6 hole

Product
external line

Ø11 x 14 U­shape holes

308

302

11

36
52

Refrigerant pipe connecting port
(Ø6.4 Flare at liquid side)

Space required for service

2-Ø6 hole

Product
external
line

R15

600

2-Ø11 x 14 U-shape holes
(For Ø8–Ø10 Anchor bolt)

150
or more

365

500
or more

60

475

Suction port

150

or more

Discharge
port

600

300
or more

Discharge
port

(Minimum
distance up to wall)

2-Ø11 x 14 long hole
(For Ø8–Ø10 Anchor bolt)

10

RAV-SM800AT-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 x 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)

2

47

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

17.5
4040

Details of B part

Details of A part

17.5

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

Discharge guide
mounting hole
(4-Ø4 Embossing)

1

60 90

58

27

161

32028

400

264

6760

154

2760

300

Z

307

96

1

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 x 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 x 17 long hole
(For Ø8–Ø10 Anchor bolt)

11

RAV-SM1100AT-E / SM1400AT-E

Knockout (Drain)

70 21

Suction
port

365 17.517.5

21 40

350 625

Drain hole (Ø20 x 88)

9029

191 20

Suction
port

Drain hole (Ø25)

B legs

A legs

43

Knockout (Drain)

Discharge port

60 4326

50

600

40

108

40

54

900

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

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

28

706

715

67

154

60 27

z

95

314 307 400

60

60 90

27

161

58

320

89

1340

25

46

8060

165

32 45

Mounting bolt hole
(Ø12 x 17 Long hole)

40

Details of A legs Details of B legs

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

150
or more

365

Mounting bolt hole
(Ø12 x 17 U-shape hole)

20

40

86 7

Z view

58 7

Space required for service

600

Suction port

150

or more

Discharge
port

500
or more

Discharge
port

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

12

150
or more

(Minimum
distance up to wall)

12

4. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

4-1. Indoor Unit/Outdoor Unit

RAV-SM561BT-E

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

12.7mm 6.4mm

Indoor unit

TCJ

sensor

Air heat exchanger

TC sensor

TS sensor

TD sensor

Rotary compressor

(DA130A1F-23F)

4-way valve

(VT7101D)

Muffler

Ø19 × L160

Refrigerant pipe
at gas side
Outer dia. ØA

Pd PsPacked valve

Packed valve
Outer dia. ØA

Outdoor unit

Refrigerant pipe
at liquid side
Outer dia. ØB

Outer dia. ØB

PMV
(SKV-18D26)

TO sensor

Strainer

TE
sensor

Heat exchanger
Ø8 multiple thread
ripple 1 row 22 stages
FP1.3 flat fin

Distributor

Max.
30m

R410A 0.9 kg

Cooling
Heating

Pressure

(MPa) (kg/cm²G)

Pd Ps Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

4 poles are provided to this compressor.

*

3.1 0.9 31.9 8.9

3.6 1.0 37.1 10.4

0.9 0.7 9.1 7.1

2.3 0.6 23.6 6.2

3.3 1.2 33.2 11.8

1.7 0.2 16.4 1.8

Discharge Suction

Pipe surface temperature (°C)

Indoor heat

exchanger exchanger

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

85 15 10 50
93 20 15 57
20735
71 1 39 3
78 20 54 19

110 –20 26 –22

Outdoor heat

Compressor

revolutions per

second (rps)

*

74
72
28
84
47

110

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/

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

13

(70%)

RAV-SM801BT-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

Accumulator
(1500cc)

TS sensor

TD sensor

Muffler

Ø25 × L160

Rotary compressor

(DA220A2F-20L)

Refrigerant pipe
at gas side
Outer dia. ØA

Pd Ps

Packed valve
Outer dia. ØA

Outdoor unit

Strainer

Refrigerant pipe
at liquid side
Outer dia. ØB

Packed valve
Outer dia. ØB

Modulating (PMV)
(SKV-18D26)

TO sensor

Strainer

4-way valve

(STF-0213Z)

TE
sensor

Capillary

Ø3×Ø2×

Ø25 × L210

Heat exchanger Ø8

L530

1 row 30 stages
FP1.3 flat fin

Max.
50m

R410A 1.5 kg

Cooling
Heating

Pressure

(MPa) (kg/cm²G)

Pd Ps Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

4 poles are provided to this compressor.

*

3.3 0.9 33.4 8.8

3.7 1.1 37.8 11.4

1.0 0.8 10.0 7.9

2.5 0.6 25.8 6.3

3.4 1.1 34.7 11.5

2.0 0.2 20.3 2.3

Discharge Suction

Pipe surface temperature (°C)

Indoor heat Outdoor heat

exchanger exchanger

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

86 11 9 44
90 21 18 54
19448
67 6 42 2
85 23 55 16
89 –16 34 –18

Compressor

revolutions per

second (rps)

*

64
52
27
65
31
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/––20/

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

14

(70%)

RAV-SM1001BT-E

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

15.9mm 9.5mm

Strainer

Indoor unit

TCJ sensor

Air heat exchanger

Distributor
(Strainer incorporated)

TC sensor

Accumulator

(2500cc)

(DA220A2F – 20L)

TD sensor

Rotary

compressor

TS sensor

(STF-0213Z)

Muffler

4-way valve

Ø25 × L210
Ø25 × L180

Refrigerant pipe
at gas side
Outer dia. ØA

Ball valve
Outer dia. ØA

Strainer

Check joint

TO sensor

Heat exchanger Ø8
1 row 52 stages
FP1.3 flat fin

Outdoor unit

TE sensor

Refrigerant pipe
at liquid side
Outer dia. ØB

Max.
50m

Packed valve
Outer dia. ØB

PMV
(UKV-25D22)

Strainer

Distributor

R410A 2.1kg

Cooling
Heating

Pressure

(MPa)

Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

4 poles are provided to this compressor.

*

3.3 0.9

3.0 1.0

1.0 0.8

2.5 0.6

3.3 1.1

1.8 0.2

Discharge Suction

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

88 10 8 38
88 14 14 46
30 8 8 3
90 4 50 2
83 17 54 13
80 –23 29 –20

Pipe surface temperature (°C)

Indoor heat

exchanger exchanger

Outdoor heat

Compressor

revolutions per

second (rps)

*

92
74
27
86
52

100

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/

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

15

(70%)

RAV-SM1401BT-E

Outer diameter of refrigerant pipe

Gas side ØA Liquid side ØB

15.9mm 9.5mm

Strainer

Indoor unit

TCJ sensor

Air heat exchanger

Distributor
(Strainer incorporated)

TC sensor

Accumulator

(2500cc)

(DA420A3F – 21M)

TD sensor

Rotary

compressor

TS sensor

(STF-0213Z)

Muffler

4-way valve

Ø25 × L210
Ø25 × L180

Refrigerant pipe
at gas side
Outer dia. ØA

Ball valve
Outer dia. ØA

Strainer

Check joint

TO sensor

Heat exchanger Ø8
1 row 52 stages
FP1.3 flat fin

Outdoor unit

TE sensor

Refrigerant pipe
at liquid side
Outer dia. ØB

Max.
50m

Packed valve
Outer dia. ØB

PMV
(UKV-25D22)

Strainer

Distributor

R410A 2.3kg

Cooling
Heating

Pressure

(MPa)

Pd Ps

Standard

Cooling Overload

Low load
Standard

Heating Overload

Low load

4 poles are provided to this compressor.

*

3.3 0.9

3.5 1.0

1.7 0.8

3.0 0.6

3.4 1.1

2.0 0.2

Discharge Suction

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

84 11 10 40
87 7 15 54
44 8 4 8
79 2 44 2
78 21 54 17
82 –21 36 –18

Pipe surface temperature (°C)

Indoor heat

exchanger exchanger

Outdoor heat

Compressor

revolutions per

second (rps)

*

56
54
27
60
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/––20/

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

16

(70%)

5. WIRING DIAGRAM

5-1. Indoor Unit

RAV-SM561BT-E / SM801BT-E / SM1101BT-E / SM1401BT-E

FM

FS

CN34

(RED)

3 3

2 2

1 1

CN33
(WHI)

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)

5
4
3
2
1

TA

1 2
1 2

CN104

(YEL)

1 2
1 2

CN102

(RED)

Control P.C. Board for

Motor

drive

circuit

RY
302

1 233 1 2 3
1 2

RY
303

CN304

(GRY)

TCJ

1 2
1 2

CN101

(BLK)

TC

MCC-1402

Indoor Unit

Fuse
F302
T3.15A
250V~

Fuse
F301
250V~
T6.3A

CN67
(BLK)

RED

Capacitor

1 2 3

CN80

(GRN)

DC20V
DC15V
DC12V
DC7V

Power

supply

circuit

+ –

~~

1 233
1 2

WHI BLK

5

445

P301

BLK

(EXCT)

1 2

CN73

(RED)

CN66
(WHI)

1 2

1 2

CN70
(WHI)

5
4

CN620

3

(BLU)

2
1

6
5

CN60

4

(WHI)

3
2
1

CN32

2

(WHI)

1

(FAN DRIVE)

6
5
4

CN61
(YEL)

3
2
1

5
4

CN50

3

(WHI)

2
1

3

CN309

2

(YEL)

1

BLK

3

3

2 2

BLK

1 1

CN41
(BLU)

BLK

B
A

WHI

2 2
1 1

CN1

(WHI)

Wired Remote

Controller

FM

TA

TC

TCJ

DP

FS

RY302

DP

NOTE

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

RED

WHI

321

Indoor unit
earth screw

321

Outdoor unit
earth screw

Serial

NL

signal

Single phase 220V, 50Hz

17

Closed-end
connector

1 233
1 2

Reactor

Color

Identification

BLACK

:

BLK

BLUE

:

BLU

RED

:

RED

GRAY

:

GRY

PINK

:

PNK

GREEN

:

GRN

WHITE

:

WHI

BROWN

:

BRW

ORANGE

:

ORN

YELLOW

:

YEL

5-2. Outdoor Unit

RAV-SM560AT-E

Q200

BLU

P17 P18

P21

P22

P23

RED

WHI

BLK

2 1

4

233 1

CM

COMPRESSOR

CN301

IGBT MODULE

BZBYBXEWBWEVBVEUBU

P.C. BOARD

(MCC-813)

5
5

GRY

4 3

PNK

2 1

YEL

3
3

BLK

2 1
2 1

WHI

RED

2 1

4 3

FM

FAN MOTOR

Q300

CN300

BRW

P19P20

P14

PUR

REACTOR

DB01

CONVERTER
MODULE

~

~

–

+

ELECTRONIC
STARTER

–
–
–

F04
FUSE
T3. 15A
250V~

P13

P12

2 1
2 1

+
+
+

P11

C12
C13
C14

2

GEA

P10

POWER

RELAY

3

P02

1

TO
INDOOR
UNIT

REACTOR

ORN

P09

P08 P07

CT

FUSE
T25A
250V~

P03

ORN

WHI

2

3

L

POWER
SUPPLY
220V
50Hz

2 1
2 1

RELAY

VARISTOR

F01

P01

BLK

N

~

CN500

2 1
2 1

CN600

CN601

CN602

CN603

CN701

P06

SURGE
ABSORBER

2

WHITE (S)

1

THERMOSTAT
FOR
COMPRESSOR

TE

11
22

TD

11

22

33

TO

11
22

TS

11

22

33
11

22

33

COIL FOR

11
22
33
44
55
66

BLK
YEL
RED
ORN

RED

GRY

4-WAY VALVE

PMV

PULSE
MODULATING
VALVE

BLACK (C)

RED (R)

BLK

CN703

TERMINAL OF COMPRESSOR

The sign in ( ) is displayed
in the terminal cover

Check

items

1

2

3

4

SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS

Diagnosis result

TERMINAL BLOCK
There is no supply voltage

(AC220V) between L - N , 1 - 2
There is no voltage (DC15 to 25V) 2 - 3

FUSE
T25A 250V to fuse (F01) blown

T3.15A 250V to fuse (F04) blown

ELECTROLYTIC CAPACITOR VOLTAGE (C12, C13, C14)
DC320V not available between

+ – terminal of electrolytic capacitor

INVERTER OUTPUT (Inverter and compressor connector out of position)
(Please confirm within six minutes after instructing in the drive.)
Voltage between each line of in v erter side
connector pins are not equal.

Power supply and connecting
cable check

Converter module (DB01) and
electrolytic capacitor (C12 to C14) check
IGBT module (Q200) check
Fan motor check

T25A fuse (F01) check
P.C. board and converter
module (DB01) check

IGBT module and
P.C. board check

18

Color Identification

BLK
BLU
RED
GRY
PNK
GRN

BLACK

:

BLUE

:

RED

:

GRAY

:

PINK

:

GREEN

:

WHI
BRW
ORN
YEL
PUR

NOTE

: Compressor

CM

: Pulse modulating valve

PMV

: Fan motor

FM

: Heat exchanger Temp. Sensor

TE

: Discharge Temp. Sensor

TD

: Outdoor Temp. Sensor

TO

: Suction Temp. Sensor

TS

: Insulated Gate Bipolar Transistor

IGBT

: Converter module

DB01

: Curreut Transformer

CT

: Fan motor driver module

Q300

:

WHITE

:

BROWN

:

ORANGE

:

YELLOW

:

PURPLE

RAV-SM800AT-E

THERMOST AT
FOR
COMPRESSOR

ORN

212

ORN

4-WA Y V ALVE COIL

313

1

FAN MOTOR

5
4

FM

1
3

2
1

6
5

PMV

SUB
P.C. BO ARD
(MCC-1398)

4
3
2
1

SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS

CN500

1

3

CN700

1

5
4

CN300

3
232
1

3

CN301

2
1

6
5
4

CN702

3
2
1

PHOTO COUPLER

CN02

2

2

Fan

circuit

CN302

F300
FUSE
T5A

CN800

2 31
2 31

COMPRESSOR

212

CN604

CN605

CN600

CN601

CN04

CN01

F01
FUSE
T3.15A

1

212

GRN

1

3

2

131
212

1

313

1

5 5 5 5
4 4 4 4
3 3 3 3
212

1

212

1

5 5 5 5

4 4 4 4

3 3 3 3

212

1

GRY
WHI

BLU
YEL

BLK
WHI

BLU
RED
PNK

ORN

BLK

WHI
RED

RED

1

CM

TE

TS

TD

TO

REACTOR

TO

INDOOR

UNIT

313

212

212

212

L N2 31

POWER
SUPPL Y

220V

50Hz

RED
WHI

BLK

POWER SUPPLY CIRCUIT
(FOR P.C. BOARD)

F04
FUSE

3.15A

CN04

1

CN06

P.C. BO ARD

1

(MCC-1359)

CN05

1

1

CN13

F01
FUSE

2

25A

~

WHITE(S)

+

BU
EU
BV
EV
BW
EW
BX
BY
BZ

CN09
CN10
CN11

T03
CT

T04
CT

4

–

2

P20

P10
P11

P13
P12

P09
P08

P15
P14

CN03
BLKWHIRED

P19
P18
P17

G
E
A

~

–

~
+

REACTOR

212

REACTOR

212

RED(R)

C13

3

C12
C11
C10

POWER
RELA Y

RY01

R05
R06

T02
CT

VARIST OR

CN02CN01

TERMINAL OF COMPRESSOR

F02

2

FUSE
15A

SURGE
ABSORBER

BLACK(C)

IGBT

MODULE

Q200

YEL
BLU

CONVERTER

MODULE

DB01

ORN

1

1

BRN

The sign in ( )
is displayed
in the terminal
cover

Check

items

1

2

3

4

Diagnosis result

TERMINAL BLOCK
There is no supply voltage

(AC220V) between L - N , 1 - 2
There is no voltage (DC15 to 25V) 2 - 3

FUSE
25A fuse (F01) blown, 15A fuse (F02) blown

3.15A fuse (F04) blown,
T5A fuse (F300) blown (SUB P.C. board)
T3.15A fuse (F01) blown (SUB P.C. board)

ELECTROLYTIC CAPACITOR VOLTAGE (C10, C11, C12, C13)
DC320V not available between

+ – terminal of electrolytic capacitor

INVERTER OUTPUT (CN09, CN10, CN11)
(Please confirm within six minutes after instructing in the drive.)
Voltage between each line of in v erterside
connector pins are not equal.

Connecting cable check

Converter module (DB01) and electrolytic
capacitor (C10 to C13) check
IGBT module (Q200) check, Fan motor check
SUB P.C. board chec k

25A fuse (F01) check
P.C. board and coverter
module (DB01) check

IGBT module and
P.C. board check

19

Color Identification

BLACK

:

BLK
BLU
RED
GRY
PNK
GRN

BLUE

:

RED

:

GRAY

:

PINK

:

GREEN

:

WHI
BRN
ORN
YEL
PUR

:

WHITE

:

BROWN

:

ORANGE

:

YELLOW

:

PURPLE

RAV-SM1100AT-E / RAV-SM1400AT-E

RED

ORN

REACTOR

REACTOR

~
+

3 3

212

3 3

212

BLU

YEL

~

1

1

BLK

–

~

GRY
GRY

BRN

WHI
WHI

RED

CN09 CN10 CN11

IGBT MODULE

P18
P17

P20
P19

RY01

P29
P28

P24

P21

+
~

F02

P13

P12
P09

P08

FUSE

250V~
T25A

T02 CT

T25A
250V~
F01
FUSE

CN01 CN02 CN03

WHI

BLK

TH

212

SWITCHING
REGURATOR

F04

250V~

FUSE

T3.15A

P.C. BOARD
(MCC-1438)

–

~

COMPRESSOR

CM

CN600

1

TO

TE

TS

TD

3 3

212

CN04 CN03

5 5 5 5
4 4 4 4
3 3 3 3
212

CN06

22
121

CN05 CN04

5 5 5 5

4 4 4 4

3 3 3 3

212

CN13 CN01

BLK

1

1

1

BLU
YEL

BLK
WHI

BLU
RED
PNK

CN800

ORN

BLK

WHI
RED

212

212

3 3

212

3 3

212

3 3

212

212

2

1

212

CN606

2

T5A

1

2

2

1

1

CN500

1

1

1

1

1

1

1

CN601

CN604

CN605

CN600

250V~

FUSE
F300

SUB P.C. BOARD
(MCC-1398)

SERIAL
COMMUNICATION

CIRCUIT
T3.15A
250V~

F01 FUSE

1

RY700

4-WAY
VALVE

BLK
BLU
RED
GRY
PNK
GRN

ORN
ORN

FUN
CIRCUIT

FUN
CIRCUIT

2 31
2 31

GRN/YEL

Color Identification

BLACK

:

BLUE

:

RED

:

GRAY

:

PINK

:

GREEN

:

2 31
2 31

WHI

CN02CN700

GRY

WHI
BRN
ORN
YEL
PUR
GRN/YEL : GREEN&YELLO W

THERMOSTAT

CN300

5 5
4 4
3 3
212

1

CN301

3 3
212

CN302

5 5
4 4
3 3
212

CN303

3 3
212

CN702

6
5
4
3
2
1

FM01 FAN MOTOR

1

1

FM02 FAN MOTOR

1

6
5
4

PMV

3
2
1

WHI

:

WHITE

:

BROWN

:

ORANGE

:

YELLOW

:

PURPLE

RED

GRYWHI

321NL

WHI

RED

20

POWER SUPPLY

220V

50Hz

~

TO INDOOR UNIT

6. SPECIFICATIONS OF ELECTRICAL PARTS

6-1. Indoor Unit

RAV-SM561BT-E / SM801BT-E / SM1101BT-E / SM1401BT-E

No.

1

Fan motor (SM801BT-E)
Fan motor

2

(SM561BT-E/SM1101BT-E/SM1401BT-E)

3

Thermo. sensor (TA-sensor)

4

Heat exchanger sensor (TCJ-sensor)

5

Heat exchanger sensor (TC-sensor)

6

Float switch

7

Drain pump motor

8

Reactor

6-2. Outdoor Unit

RAV-SM560AT-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

Parts name

Type

ICF-280-120-1
ICF-280-120-2

258 mm

Ø6 mm, 1200 mm
Ø6 mm, 1200 mm

FS-0218-106

ADP-1406

CH-43-2Z-K

Type

ICF-140-43-1

DA130A1F-23F

CH-57

—
—
—
—

STF-0108G

US-622

Specifications

Output (Rated) 120 W, 220–240 V
Output (Rated) 120 W, 220–240 V

10 kΩ at 25°C
10 kΩ at 25°C
10 kΩ at 25°C

10 mH, 1 A

Specifications

Output (Rated) 40 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

RAV-SM800AT-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

Type

ICF-140-63-1 or ICF-140-63-2

DA220A2F-20L

CH-47

—
—
—
—

DKV-M0ZS743B0

US-622

21

Specifications

Output (Rated) 63 W
3 phase, 4P, 1600 W
8 mH, 16 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

RAV-SM1100AT-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)

RAV-SM1400AT-E

No.

1

Fan motor

2

Compressor

Parts name

Parts name

Type

ICF-140-63-2
ICF-140-43-2

DA220A2F-20L

CH-56

—
—
—
—

VHV-01AJ502E1

US-622

Type

ICF-140-63-2

DA420A3F-21M

Specifications

Output (Rated) 63 W
Output (Rated) 43 W
3 phase, 4P, 2000 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
AC 220 – 240 V
ON : 90 ± 5°C, OFF : 125 ± 4°C

Specifications

Output (Rated) 63 W
3 phase, 4P, 3500 W

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)

CH-56

—
—
—
—

VHV-01AJ502E1

US-622

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
AC 220 V
ON : 90 ± 5°C, OFF : 125 ± 4°C

22

7. 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.

7-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may
cause a serious trouble. By using tools and materi­als exclusiv e for R410A, it is necessary to carry out
installation/servicing safely while taking the following
precautions into consideration.

(1) Never use refrigerant other than R410A in an air

conditioner which is designed to operate with
R410A.

If other refrigerant than R410A is mixed, pres­sure in the refrigeration cycle becomes abnor­mally high, and it may cause personal injury, etc.
by a rupture.

(2) Confirm the used refrigerant name, and use

tools and materials exclusiv e for the refrigerant
R410A.

The refrigerant name R410A is indicated on the
visible place of the outdoor unit of the air condi­tioner using R410A as refrigerant. To prevent
mischarging, the diameter of the service port
differs from that of R22.

(3) If a refrigeration gas leakage occurs during

installation/servicing, be sure to ventilate fully.
If the refrigerant gas comes into contact with fire,

a poisonous gas may occur.

(4) When installing or removing an air conditioner,

do not allow air or moisture to remain in the
refrigeration cycle. Otherwise, pressure in the
refrigeration cycle may become abnormally high
so that a rupture or personal injury may be
caused.

(5) After completion of installation work, check to

make sure that there is no refrigeration gas
leakage.

If the refrigerant gas leaks into the room, coming
into contact with fire in the fan-driven heater,
space heater, etc., a poisonous gas may occur.

(6) When an air conditioning system charged with a

large volume of refrigerant is installed in a small
room, it is necessary to exercise care so that,
even when refrigerant leaks , its concentration
does not exceed the marginal level.

If the refrigerant gas leakage occurs and its
concentration exceeds the marginal level, an
oxygen starvation accident may result.

(7) Be sure to carry out installation or removal

according to the installation manual.
Improper installation may cause refrigeration

trouble, water leakage, electric shock, fire, etc.

(8) Unauthorized modifications to the air conditioner

may be dangerous. If a breakdown occurs
please call a qualified air conditioner technician
or electrician.

Improper repair’s may result in water leakage,
electric shock and fire, etc.

7-2. Refrigerant Piping Installation

7-2-1. 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 7-2-1. Never use copper
pipes thinner than 0.8 mm even when it is
available on the market.

23

Table 7-2-1 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 7-2-3 to 7­2-6 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 7-2-2.

Table 7-2-2 Minimum thicknesses of socket joints

Nominal diameter

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

Reference outer diameter of

copper pipe jointed (mm)

7-2-2. 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.

24

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 7-2-3 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. 7-2-1 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 7-2-4 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 7-2-5 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

25

Flare nut

width (mm)

17
22
26
29

Table 7-2-6 Flare and flare nut dimensions for R22

Nominal Outer diameter Thickness

diameter (mm) (mm)

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

45˚to 46˚

B A

Dimension (mm)

ABCD

9.0 9.2 6.5 13

13.0 13.5 9.7 20

16.2 16.0 12.9 20

19.4 19.0 16.0 23

23.3 24.0 19.2 34

C

43˚to 45˚

Flare nut width

(mm)

17
22
24
27
36

D

Fig. 7-2-2 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 7-2-7 Tightening torque of flare for R410A [Reference values]

Nominal Outer diameter Tightening torque

diameter (mm) N•m (kgf•cm)

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

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

NOTE:

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

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

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

26

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

7-3. Tools

7-3-1. Required T ools

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

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

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

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

Tools whose specifications are changed for R410A and their interchangeability

No. Used tool

Flare tool



Copper pipe gauge for
adjusting projection



margin
Torque wrench



Gauge manifold



Charge hose



Vacuum pump adapter



Electronic balance for



refrigerant charging
Refrigerant cylinder



Leakage detector



Charging cylinder



Usage

Pipe flaring
Flaring by conventional

flare tool

Connection of flare nut

Evacuating, refrigerant
charge, run check, etc.

Vacuum evacuating
Refrigerant charge
Refrigerant charge

Gas leakage check
Refrigerant charge

air conditioner installation

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

Yes

Yes

Yes

Yes

Yes
Yes

Yes
Yes

(Note 2)

R410A

(Note 1)

*

(Note 1)

*

X
X

X
X
X

X
X

Conventional air

conditioner installation

Whether new equipment
can be used with
conventional refrigerant

¡

(Note 1)

*

X
X

¡

¡

X

¡

X

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

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

(Note 2) Charging cylinder for R410A is being currently dev e loped.

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

27

7-4. 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. 7-4-1 Configuration of refrigerant charging

(Liquid side)

(Gas side)

28

(OUTDOOR unit)

Opened

Closed

Service port