<SUPER DIGITAL INVERTER>
RAV-SP562AT-ERAV-SP802AT-ERAV-SP1102AT-E RAV-SP1402AT-E
R410A
PRINTED IN JAPAN, Mar.,2007 ToMo
ADOPTION OF NEW REFRIGERANT
This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional
refrigerant R22 in order to prevent destruction of the ozone layer.
WARNING
Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to
have a service person do it. Do not attempt it yourself. The cleaning diagram for the air filter is there for the
service person, and not for the customer.
NOTE
A direct current motor is adopted for indoor fan motor in the Concealed Duct Standard Type air conditioner.
Caused from its characteristics, a current limit works on the direct current motor. When replacing the highperformance filter or when opening the service board, be sure to stop the fan. If an above action is executed
during the fan operation, the protective control works to stop the unit operation, and the check code “P12”
may be issued. However it is not a trouble. When the desired operation has finished, be sure to reset the
system to clear “P12” error code using the leak breaker of the indoor unit. Then push the operation stop
button of the remote controller to return to the usual operation.
15-3. Replacement of Main Parts (Sold Separately).............................................. 181
16. CORD HEATER INSTALLATION WORK ................................................ 183
16-1. Required parts for installation work (Recommendation) ............................ 183
16-2. Base Plate ....................................................................................................... 192
– 3 –
SAFETY CAUTION
The important contents concerned to the safety are described on the product itself and on this Service Manual.
Please read this Service Manual after understanding the described items thoroughly in the following contents
(Indications/Illustrated marks), and keep them.
[Explanation of indications]
Indication
DANGER
WARNING
CAUTION
∗ Property damage : Enlarged damage concerned to property, furniture, and domestic animal/pet
Indicates contents assumed that an imminent danger causing a death or serious injury of
the repair engineers and the third parties when an incorrect work has been executed.
Indicates possibilities assumed that a danger causing a death or serious injury of the
repair engineers, the third parties, and the users due to troubles of the product after work
when an incorrect work has been executed.
Indicates contents assumed that an injury or property damage ( ∗) may be caused on the
repair engineers, the third parties, and the users due to troubles of the product after work
when an incorrect work has been executed.
Explanation
[Explanation of illustrated marks]
MarkExplanation
Indicates prohibited items (Forbidden items to do)
The sentences near an illustrated mark describe the concrete prohibited contents.
Indicates mandatory items (Compulsory items to do)
The sentences near an illustrated mark describe the concrete mandatory contents.
Indicates cautions (Including danger/warning)
The sentences or illustration near or in an illustrated mark describe the concrete cautious contents.
[Confirmation of warning label on the main unit]
Confirm that labels are indicated on the specified positions
(Refer to the Parts disassembly diagram (Outdoor unit).)
If removing the label during parts replace, stick it as the original.
DANGER
Turn “OFF” the breaker before removing the front panel and cabinet, otherwise an electric
shock is caused by high voltage resulted in a death or injury.
During operation, a high voltage with 400V or higher of circuit (∗) at secondary circuit of the highvoltage transformer is applied.
Tur n off breaker.
Execute discharge
between terminals.
Prohibition
If touching a high voltage with the naked hands or body, an electric shock is caused even if using an
electric insulator.
∗ : For details, refer to the electric wiring diagram.
When removing the front panel or cabinet, execute short-circuit and discharge between highvoltage capacitor terminals.
If discharge is not executed, an electric shock is caused by high voltage resulted in a death or injury.
After turning off the breaker, high voltage also keeps to apply to the high-voltage capacitor.
Do not turn on the breaker under condition that the front panel and cabinet are removed.
An electric shock is caused by high voltage resulted in a death or injury.
– 4 –
Check earth wires.
Prohibition of modification.
Use specified parts.
Do not bring a child
close to the equipment.
Insulating measures
No fire
WARNING
Before troubleshooting or repair work, check the earth wire is connected to the earth
terminals of the main unit, otherwise an electric shock is caused when a leak occurs.
If the earth wire is not correctly connected, contact an electric engineer for rework.
Do not modify the products.
Do not also disassemble or modify the parts. It may cause a fire, electric shock or injury.
For spare parts, use those specified (
If unspecified parts are used, a fire or electric shock may be caused.
∗: For details, refer to the parts list.
Before troubleshooting or repair work, do not bring a third party (a child, etc.) except
the repair engineers close to the equipment.
It causes an injury with tools or disassembled parts.
Please inform the users so that the third party (a child, etc.) does not approach the equipment.
Connect the cut-off lead cables with crimp contact, etc, put the closed end side
upward and then apply a water-cut method, otherwise a leak or production of fire is
caused at the users’ side.
When repairing the refrigerating cycle, take the following measures.
1) Be attentive to fire around the cycle. When using a gas stove, etc, be sure to put out fire
before work; otherwise the oil mixed with refrigerant gas may catch fire.
2) Do not use a welder in the closed room. When using it without ventilation, carbon
monoxide poisoning may be caused.
3) Do not bring inflammables close to the refrigerant cycle, otherwise fire of the welder may
catch the inflammables.
∗∗
∗).
∗∗
Refrigerant
Check the used refrigerant name and use tools and materials of the parts which
match with it.
For the products which use R410A refrigerant, the refrigerant name is indicated at a
position on the outdoor unit where is easy to see. To prevent miss-charging, the route of the
service port is changed from one of the former R22.
For an air conditioner which uses R410A, never use other refrigerant than R410A.
For an air conditioner which uses other refrigerant (R22, etc.), never use R410A.
If different types of refrigerant are mixed, abnormal high pressure generates in the refrigerating cycle and an injury due to breakage may be caused.
Do not charge refrigerant additionally.
If charging refrigerant additionally when refrigerant gas leaks, the refrigerant composition in
the refrigerating cycle changes resulted in change of air conditioner characteristics or
refrigerant over the specified standard amount is charged and an abnormal high pressure is
applied to the inside of the refrigerating cycle resulted in cause of breakage or injury.
Therefore if the refrigerant gas leaks, recover the refrigerant in the air conditioner, execute
vacuuming, and then newly recharge the specified amount of liquid refrigerant. In this time,
never charge the refrigerant over the specified amount.
When recharging the refrigerant in the refrigerating cycle, do not mix the refrigerant
or air other than R410A into the specified refrigerant.
If air or others is mixed with the refrigerant, abnormal high pressure generates in the
refrigerating cycle resulted in cause of injury due to breakage.
After installation work, check the refrigerant gas does not leak.
If the refrigerant gas leaks in the room, poisonous gas generates when gas touches to fire
such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.
Never recover the refrigerant into the outdoor unit.
When the equipment is moved or repaired, be sure to recover the refrigerant with recovering device. The refrigerant cannot be recovered in the outdoor unit; otherwise a serious
accident such as breakage or injury is caused.
Assembly/Cabling
After repair work, surely assemble the disassembled parts, and connect and lead the
removed cables as before. Perform the work so that the cabinet or panel does not
catch the inner cables.
If incorrect assembly or incorrect cable connection was done, a disaster such as a leak or
fire is caused at user’s side.
– 5 –
WARNING
Insulator check
Ventilation
Be attentive to
electric shock
Compulsion
After the work has finished, be sure to use an insulation tester set (500V mugger) to
check the resistance is 2M
metal section (Earth position).
If the resistance value is low, a disaster such as a leak or electric shock is caused at user’s
side.
When the refrigerant gas leaks during work, execute ventilation.
If the refrigerant gas touches to a fire, poisonous gas generates. A case of leakage of the
refrigerant and the closed room full with gas is dangerous because a shortage of oxygen
occurs. Be sure to execute ventilation.
When checking the circuit inevitably under condition of the power-ON, use rubber
gloves and others not to touch to the charging section.
If touching to the charging section, an electric shock may be caused.
When the refrigerant gas leaks, find up the leaked position and repair it surely.
If the leaked position cannot be found up and the repair work is interrupted, pump-down
and tighten the service valve, otherwise the refrigerant gas may leak into the room.
The poisonous gas generates when gas touches to fire such as fan heater, stove or cocking
stove though the refrigerant gas itself is innocuous.
When installing equipment which includes a large amount of charged refrigerant such
as a multi air conditioner in a sub-room, it is necessary that the density does not the
limit even if the refrigerant leaks.
If the refrigerant leaks and exceeds the limit density, an accident of shortage of oxygen is
caused.
For the installation/moving/reinstallation work, follow to the Installation Manual.
If an incorrect installation is done, a trouble of the refrigerating cycle, water leak, electric
shock or fire is caused.
ΩΩ
Ω or more between the charge section and the non-charge
ΩΩ
Check after rerair
Check after reinstallation
Put on gloves
Cooling check
After repair work has finished, check there is no trouble.
If check is not executed, a fire, electric shock or injury may be caused. For a check, turn off
the power breaker.
After repair work (installation of front panel and cabinet) has finished, execute a test
run to check there is no generation of smoke or abnormal sound.
If check is not executed, a fire or an electric shock is caused. Before test run, install the
front panel and cabinet.
Check the following items after reinstallation.
1) The ear th wire is correctly connected.
2) The power cord is not caught in the product.
3) There is no inclination or unsteadiness and the installation is stable.
If check is not executed, a fire, an electric shock or an injury is caused.
CAUTION
Be sure to put on gloves (
If not putting on gloves, an injury may be caused with the parts, etc.
(∗) Heavy gloves such as work gloves
When the power was turned on, start to work after the equipment has been
sufficiently cooled.
As temperature of the compressor pipes and others became high due to cooling/heating
operation, a burn may be caused.
∗∗
∗) during repair work.
∗∗
– 6 –
•New Refrigerant (R410A)
This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer.
1. Safety Caution Concerned to New Refrigerant
The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of
refrigerant, the refrigerating oil has been also changed. Therefore, be sure that water, dust, the former
refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the air conditioner with
new refrigerant during installation work or service work. If an incorrect work or incorrect service is performed, there is a possibility to cause a serious accident. Use the tools and materials exclusive to R410A to
purpose a safe work.
2. Cautions on Installation/Service
1) Do not mix the other refrigerant or refrigerating oil.
For the tools exclusive to R410A, shapes of all the joints including the service port differ from those of the
former refrigerant in order to prev ent mixture of them.
2) As the use pressure of the new refrigerant is high, use material thickness of the pipe and tools which are
specified for R410A.
3) In the installation time, use clean pipe materials and work with great attention so that water and others do
not mix in because pipes are affected by impurities such as water, oxide scales, oil, etc. Use the clean
pipes.
Be sure to brazing with flowing nitrogen gas. (Never use gas other than nitrogen gas.)
4) For the earth protection, use a vacuum pump for air purge.
5) R410A refrigerant is azeotropic mixture type refrigerant. Therefore use liquid type to charge the refrigerant. (If using gas for charging, composition of the refrigerant changes and then characteristics of the air
conditioner change.)
3. Pipe Materials
For the refrigerant pipes, copper pipe and joints are mainly used. It is necessary to select the most appropriate pipes to conform to the standard. Use clean material in which impurities adhere inside of pipe or joint to a
minimum.
1) Copper pipe
<Piping>
The pipe thickness, flare finishing size , flare nut and others differ according to a refrigerant type.
When us#ing a long copper pipe for R410A, it is recommended to select “Copper or copper-base pipe
without seam” and one with bonded oil amount 40mg/10m or less. Also do not use crushed, deformed,
discolored (especially inside) pipes. (Impurities cause clogging of expansion valves and capillary tubes.)
<Flare nut>
Use the flare nuts which are attached to the air conditioner unit.
2) Joint
The flare joint and socket joint are used for joints of the copper pipe. The joints are rarely used for installation of the air conditioner. However clear impurities when using them.
– 7 –
4. Tools
1. Required T ools for R410A
Mixing of different types 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.
Flare tool
Copper pipe gauge for
adjusting projection margin
Torque wrench
Gauge manifold
Charge hose
V acuum pump adapter
Electronic balance for
refrigerant charging
Refrigerant cylinder
Leakage detector
Charging cylinder
Used tool
Usage
Pipe flaring
Flaring by conventional
flare tool
Connection of flare nut
Evacuating, refrigerant
charge, run check, etc.
V acuum evacuating
Refrigerant charge
Refrigerant charge
Gas leakage check
Refrigerant charge
air conditioner installation
R410A
Existence ofWhether convennew equipment tional equipment
for R410Acan be used
Yes*(Note 1)
Yes*(Note 1)
YesNo
YesNo
YesNo
YesYes
YesNo
YesNo
(Note 2)No
Conventional air
conditioner installation
Whether conventional
equipment can be used
Yes
*(Note 1)
No
No
Yes
Yes
No
Yes
No
(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projec-
tion 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 ser ve 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
7) Screwdriver (+, –)
8) Spanner or Monkey wrench
9) Hole core drill
10) Hexagon wrench (Opposite side 4mm)
11) Tape measure
12) Metal saw
5) Pipe bender
6) Level vial
Also prepare the following equipments for other installation method and run check.
1) Clamp meter
2) Thermometer
3) IInsulation resistance tester
4) Electroscope
– 8 –
1. SPECIFICATIONS
1-1. Indoor Unit
1-1-1. 4-Way Air Discharge Cassette Type
<Digital Inverter>
Revised : Mar. 2007
Model
Cooling capacity(kW)
Heating capacity(kW)
Po w er supply
Cooling
Electrical
characteristics
Heating
Main unit
Appearance
Outer
dimension
Total weight
Heat exchanger
Fan unitStandard air flow H/M/L(m³/min)
Air filter
Controller (Sold separately)
Connecting pipeLiquid side(mm)
Sound pressure levelH/M/L(dB•A)
Sound power levelH/M/L(dB•A)
Ceiling panel
(Sold separately)
Main unitWidth(mm)
Ceiling panel
(Sold separately)
Main unit(kg)
Ceiling panel (Sold separately)(kg)
Fan
Motor(W)
Indoor unitRA VOutdoor unitRA V-
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
EER(W/W)
Energy efficiency class *
Energy rating **
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
COP(W/W)
Energy efficiency class *
Energy rating **
Cooling capacity(kW)
Heating capacity(kW)
Po w er supply
Cooling
Electrical
characteristics
Heating
Indoor unitRA VOutdoor unitRA V-
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
EER(W/W)
Energy efficiency class *
Energy rating **
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
COP(W/W)
Energy efficiency class *
Energy rating **
Cooling capacity(kW)
Heating capacity(kW)
Po w er supply
Cooling
Electrical
characteristics
Heating
Main unit
Appearance
Outer
dimension
Total weight
Heat exchanger
Fan unitStandard air flow H/M/L(m³/min)
Air filterTCB-
Controller (Sold separately)
Connecting pipeLiquid side(mm)
Sound pressure levelH/M/L(dB•A)
Sound power levelH/M/L(dB•A)
Ceiling panel
(Sold separately)
Main unitWidth(mm)
Ceiling panel
(Sold separately)
Main unit(kg)
Ceiling panel (Sold separately)(kg)
Fan
Motor(W)
Indoor unitRA VOutdoor unitRA V-
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
EER(W/W)
Energy efficiency class *
Energy rating **
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
COP(W/W)
Energy efficiency class *
Energy rating **
Cooling capacity(kW)
Heating capacity(kW)
Po w er supply
Cooling
Electrical
characteristics
Heating
Main unit
Appearance
Outer
dimension
Total weight
Heat exchanger
Fan unitStandard air flow H/M/L(m³/min)
Air filterTCB-
Controller (Sold separately)
Connecting pipeLiquid side(mm)
Sound pressure levelH/M/L(dB•A)
Sound power levelH/M/L(dB•A)
Ceiling panel
(Sold separately)
Main unitWidth(mm)
Ceiling panel
(Sold separately)
Main unit(kg)
Ceiling panel (Sold separately)(kg)
Fan
Motor(W)
Indoor unitRA VOutdoor unitRA V-
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
EER(W/W)
Energy efficiency class *
Energy rating **
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
COP(W/W)
Energy efficiency class *
Energy rating **
Cooling capacity(kW)
Heating capacity(kW)
Po w er supply
Cooling
Electrical
characteristics
Heating
Main unit
Appearance
Outer
dimension
Total weight
Heat exchanger
Fan unitStandard air flow H/M/L(m³/min)
Air filter
Controller (Sold separately)
Connecting pipeLiquid side(mm)
Sound pressure levelH/M/L(dB•A)
Sound power levelH/M/L(dB•A)
Ceiling panel
(Sold separately)
Main unitWidth(mm)
Ceiling panel
(Sold separately)
Main unit(kg)
Ceiling panel (Sold separately)(kg)
Fan
Motor(W)
Indoor unitRA VOutdoor unitRA V-
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
EER(W/W)
Energy efficiency class *
Energy rating **
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
COP(W/W)
Energy efficiency class *
Energy rating **
Cooling capacity(kW)
Heating capacity(kW)
Po w er supply
Cooling
Electrical
characteristics
Heating
Indoor unitRA VOutdoor unitRA V-
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
EER(W/W)
Energy efficiency class *
Energy rating **
Running current(A)
Po w er consumption(kW)
Po w er factor(%)
COP(W/W)
Energy efficiency class *
Energy rating **
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
ABCDEFGHJKMNO
RAV-SM562BT
RAV-SM802BT
RAV-SM1102BT
RAV-SM1402BT
700 766 690 750 78012.76.425228028012410
10001066 9901050108015.99.525258029023410
1350141613401400143015.99.525293031034410
NOTE 1 :
For maintenance of the equipment, be sure to install
a check port A at the position as shown below.
NOTE 2 :
Using the drain up kit sold separately, drain-up by 300 (mm)
from drain pipe draw-out port of the main unit is necessary.
The drain-up over 300mm or more is impossible.