Toshiba RAV-SM802KRT-E User Manual

FILE NO.SVM-05053-1

SERVICE MANUAL

HI WALL TYPE (INDOOR UNIT)

RAV-SM562KRT-E

RAV-SM802KRT-E

R410A

Rev. Mar, 2006

CONTENTS

1. SPECIFICATIONS................................................................................................ 2

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS) ................................................. 4

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM ......................................... 5

4. WIRING DIAGRAM .............................................................................................. 6

5. SPECIFICATIONS OF ELECTRICAL PARTS ..................................................... 7

6. REFRIGERANT R410A ....................................................................................... 8

7. INDOOR UNIT CONTROL ................................................................................. 16

8. TROUBLESHOOTING ....................................................................................... 27

9. HOW TO REPLACEMENT OF SERVICE INDOOR P.C. BOARD....................... 50

10. SETUP AT LOCAL SITE AND O THERS ........................................................... 54

11. ADDRESS SETUP ............................................................................................. 71

12. EXPLODED VIEWS AND PARTS LIST.............................................................. 76

NOTE :

This Service Manual describes explanation for the Under Ceiling type indoor unit.
For the combined outdoor unit, refer to the following Service Manual.

Outdoor unit Model name SVM to be referred
RAV-SMXX0AT-E A03-007
RAV-SPXXXAT-E A03-014

RAV-SMXX1AT-E A05-001

– 1 –

1-1. High-Wall Type (Indoor Unit)

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

Power consumption (kW)

(Low temp.) (kW)

Power factor (%)

Main unit

Ceiling Panel

(Sold separately)

Main unit Width (mm)

Model

Panel color

Height (mm)

RAV-SM562KRT-E RAV-SM802KRT-E

Cooling Heating Average Cooling Heating Average

5.1 5.6 6.7 8

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

4.9 5.8

2.93 [D] 3.29 [C] 3.11 2.46 [E] 3.00 [D] 3.24

1 phase 230V (220 – 240V) 50Hz

8.33–7.63 8.138–7.46 13.15–12.05 12.91–11.84

1.74 1.7 2.72 2.67

1.95 2.21

95 95 94 94

Pure white

——

——

298

998

Outer
dimension

Ceiling panel

(Sold separately)

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

Main unit (kg)

Ceiling panel

Fan

Motor (W)

Gas side (mm)

Liquid side (mm)

Drain port (Nominal dia.)

Depth (mm)

Height (mm)

Width (mm)

Depth (mm)

221

——

——

——

12

——

Finned tubu

Inflammable polyethylene foam Foamed polyethylen

Turbo fan

840 1110

30

Attached main unit

Wired remote controller RBC-AMT21E

Ø12.7 (1/2”) Ø15.9 (5/8”)

Ø6.4 (1/4”) Ø9.5 (3/8”)

25 (Polyvinyl chloride tube)

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

45 41 36 45 41 36

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

on the reference piping. The reference piping consists of 3 m of main piping and 2 m of branch piping connected with 0
meter height.

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 –

Operation characteristic curve

<Cooling> <Heating>

14

12

RAV-SM802KRT-E

10

8

6

Current (A)

4

2

0

0201540 60 70 80 100

RAV-SM562KRT-E

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

Compressor speed (rps)

16

14

12

10

8

Current (A)

6

4

2

0

15

020

RAV-SM802KRT-E

RAV-SM562KRT-E

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

40 60 80 90 100

Compressor speed (rps)

•Capacity variation ratioaccor ding to temperature
<Cooling> <Heating>

105

100

95

90

120

110

100

90

80

85

70

80

60

75

70

Capacity ratio (%)

65

60

55

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

50

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

50

40

Capacity ratio (%)

30

20

10

0

-14-12-10-8-6-4-20246810

Outsoor temp. (°C)

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

Outsoor temp. (°C)

– 3 –

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

High-Wall Type
RAV-SM562KRT-E/RAV-SM802KRT-E

75

7

51

Knock out system

Back body

Front panel

Grille inlet

298

Air inlet

Air outlet

998

75

56

220

Knock out system

50

50

75

8

Connection pipe (0.39 m)

(For SM802 : Flare ∅15.88)
(For SM562 : Flare ∅12.7)

55 or more

Outline of indoor unit

298

Minimum distance

to ceiling

∅65



100

20

48

998

763.5

450

Installation
Plate outline

Drain hose (0.54 m)

Connection pipe (0.49 m)
(Flare ∅6.35)

20

10

100

57

Wireless remote control

(For stud bolt ∅6)

(For stud bolt ∅8 -∅10)

29

41

55

5555



∅6

40

5

160

18

48

– 4 –

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Hi Wall type

RAV-SM562KRT-E/SM802KRT-E

Outer diameter of refrig erant pipeModel

RAV-SM
562KRT-E
802KRT-E

Gas side ØA Liquid side ØB

12.7 mm 6.4 mm

15.9 mm

9.5 mm

Indoor unit

TCJ

sensor

Air heat exchanger

TC sensor

Refrigerant pipe
at gas side
Outer dia. ØA

Pd PsPacked valve

Packed valve
Outer dia. ØA

Refrigerant pipe
at liquid side
Outer dia. ØB

Outer dia. ØB

Outdoor unit

NOTE :

The refrigerating cycle differs according to the combined outdoor units.
For the cycle diagram, cycle pressure, etc., refer to the following Service Manual.

RAV-SMXXX0AT-E : A03-007
RAV-SPXXXXAT-E : A03-014

RAV-SMXXX1AT-E : A05-001

– 5 –

Cooling
Heating

4-1. Hi Wall type (Indoor unit)

RAV-SM562KRT-E/SM802KRT-E

ＬＯＵＶＥＲ
ＭＯＴＯＲ

BLK

F

S

ＣＮ２２

Ｆ３０１ ＦＵＳＥ

Ｔ３．１５Ａ ２５０Ｖ〜

１

１

３

３

５

５

ＣＮ６７
（ＢＬＫ）

ＣＮ２１３（ＷＨＩ）

9

５ ８７６

６ ７ ８５

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

６ ７ ８５

５ ８７６

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

10
10

9

ＷＨＩ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵ
9

10

9

10

ＣＮ８０
（ＧＲＮ）

１ ２ ３

ＣＮ８２
（ＢＬＵ）

１

４２ ３

１

３２ ４

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

ＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵＢＬＵ

１

３２ ４

１

４２ ３

ＩＮＦＲＡＲＥＤ ＲＡＹＳ ＲＥＣＥＩＶＥ

ＡＮＤ ＩＮＤＩＣＡＴＩＯＮ ＰＡＲＴＳ

（ＭＣＣ−８１９）

ＰＮＬ/ＥＭＧ

4. WIRING DIAGRAM

ＴＥＲＭＩＮＡＬ

２ １４５ ３

ＲＥＤ

ＢＬＫ

１

３４

１

ＣＮ６１
（ＹＥＬ）

５３ ４ ６２１
５３ ４ ６２

３ ４２

ＢＬＯＣＫ

U3

U4

ＢＬＵ

ＢＬＵ

１１２

２

ＣＮ４０
（ＢＬＵ）

ＰＯＷＥＲ
ＳＵＰＰＬＹ
ＣＩＲＣＵＩＴ

ＣＮ６０
（ＷＨＩ）

２ ５４３１ ６

ＯＰＴＩＯＮ

FAN
MOTOR

ＹＥＬ

ＷＨＩ

ＢＲＷ

ＲＥＤ

ＯＲＮ

ＢＬＵ

ＹＥＬ

ＰＮＫ

ＢＬＵ

１３ ２
１２３

ＣＮ２１０
（ＷＨＩ）

５５６６

４ ３

６ ５

４

５６

４

ＣＮ３３
（ＷＨＩ）

（ＭＣＣ−１５１０）

ControlP.Cboard
forindoorunit

ＣＮ８１
（ＢＬＫ）

６３２１ ４ ５

４ ５１ ２ ３

１

１

HA

ＢＵＳ

ＥＭＧ

１ ２

ＣＮ４４
(ＢＲＷ)

ＤＣ１５Ｖ
ＤＣ ０Ｖ

ＤＣ１２Ｖ
ＤＣ７Ｖ

２１ ５４３

ＣＮ５０
（ＷＨＩ）

３

ＣＮ４１

２
１

（ＢＬＵ）

１

ＣＮ１００

２

（ＢＲＷ）

３
１

ＣＮ１０１
（ＢＬＵ）

１

ＣＮ１０３

２

（ＧＲＮ）

１

ＣＮ１０２

２

（ＹＥＬ）

１

ＣＮ１０４

２

（ＷＨＩ）

３
２
１

２１２

１
２

１
２

ＢＬＫ
ＢＬＫ

ＢＬＫ
ＢＬＫ

ＢＬＫ
ＢＬＫ

ＢＬＫ
ＢＬＫ

ＴＥＲＭＩＮＡＬ
ＢＬＯＣＫ

Ｂ
Ａ

ＨＥＡＴ
ＥＸＣＨＡＮＧＥＲ
ＳＥＮＳＯＲ
（ＴＣ）

ＨＥＡＴ
ＥＸＣＨＡＮＧＥＲ
ＳＥＮＳＯＲ
（ＴＣＪ）

ＴＨＥＲＭＯ
ＳＥＮＳＯＲ
（ＴＡ）

WHI

BLK

1

2

1

2

ＣＮ１(WHI)



WIERDREMOTE
CONTROLLER

NOTE

: Fan motor

FM

: Indoor temp. sensor

TA

: Temp. sensor

TC

: Temp. sensor

TCJ

: Louver motor

LM

WHI BLK

RED

321

321

Serial

NL

signal

Single phase 220V, 50Hz

– 6 –

Indoor unit
earth screw

Outdoor unit
earth screw

Color

Identification

BLACK

:

BLK

BLUE

:

BLU

RED

:

RED

GRAY

:

GRY

PINK

:

PNK

GREEN

:

GRN

WHITE

:

WHI

BROWN

:

BRW

ORANGE

:

ORN

YELLOW

:

YEL

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor Unit

High-Wall Type
RAV-SM562KRT-E/RAV-SM802KRT-E

No.

1

Fan motor (for indoor)

2

Grille motor

3

Thermo. sensor (TA-sensor)

4

Heat exchanger sensor (TC-sensor)

5

Heat exchanger sensor (TCJ-sensor)

Parts name

Type

ICF340-30-X

MF-340-30-X

MP35EA12

268 mm
Ø6 mm, 400 mm

Ø6 mm, 400 mm

Specifications

Output (Rated) 30 W, 220–240 V

10 kW at 25°C
10 kW at 25°C

– 7 –

6. REFRIGERANT R410A

This air conditioner adopts the new refrigerant HFC
(R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410A
is 1.6 times higher than conventional refrigerant
(R22). The refrigerating oil is also changed in
accordance with change of refrigerant, so be careful
that water, dust, and existing refrigerant or refrigerat­ing oil are not entered in the refrigerant cycle of the
air conditioner using the new refrigerant during
installation work or servicing time.

The next section describes the precautions for air
conditioner using the new refrigerant. Conforming to
contents of the next section together with the
general cautions included in this manual, perform
the correct and safe work.

6-1. Safety During Installation/Servicing

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

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

conditioner which is designed to operate with
R410A.

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

(2) Confirm the used refrigerant name, and use

tools and materials exclusive for the refrigerant
R410A.

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

(3) If a refrigeration gas leakage occurs during

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

a poisonous gas may occur.

(4) When installing or removing an air conditioner,

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

(5) After completion of installation work, check to

make sure that there is no refrigeration gas
leakage.

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

(6) When an air conditioning system charged with a

large volume of refrigerant is installed in a small
room, it is necessary to exercise care so that,
even when refrigerant leaks, its 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 repairÕs 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.

– 8 –

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 for 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 burrs and clean the cut surface
before installation.

– 9 –

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 "dimen­sion 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

– 10 –

Flare nut

width (mm)

17

22

26

29

Table 6-2-6 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

°

to 46

°

45

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 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 6-2-7
shows reference values.

NOTE:

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

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)

– 11 –

42 (420)

55 (550)

65 (650)

6-3. Tools

6-3-1. Required Tools

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

1

Copper pipe gauge for

adjusting projection

2

margin

3

Torque wrench

Gauge manifold

4

Charge hose

5

Vacuum pump adapter

6

Electronic balance for

7

refrigerant charging

Refrigerant cylinder

8

Leakage detector

9

Charging cylinder

10

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

Ye s

Ye s

Ye s

Ye s

Ye s

Ye s

Ye s
Ye s

(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 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

– 12 –

6-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the
following steps.

Recover the refrigerant, and check no refrigerant
remains in the equipment.

Connect the charge hose to packed valve service
port at the outdoor unit's gas side.

When the compound gauge's pointer has indicated

- 0.1 Mpa (- 76 cmHg), place the handle Low in the
fully closed position, and turn off the vacuum pump's
power switch.

Connect the charge hose of the vacuum pump
adapter.

Open fully both packed valves at liquid and gas
sides.

Place the handle of the gauge manifold Low in the
fully opened position, and turn on the vacuum pump's
power switch. Then, evacuating the refrigerant in the
cycle.

Never charge refrigerant exceeding the specified amount.

1.

If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

2.

Do not carry out additional charging.

3.

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)

– 13 –

(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

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

6-5. Brazing of Pipes

6-5-1. Materials for Brazing

(1) Silver brazing filler

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

Fig. 6-4-2

Electronic

balance

Siphon

Phosphor bronze brazing filler tends to react

1.

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.

2.

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

1.By removing the oxide film and any foreign
matter on the metal surface, it assists the flow
of brazing filler.

2.In the brazing process, it prevents the metal
surface from being oxidized.

3.By reducing the brazing filler's surface tension,
the brazing filler adheres better to the treated
metal.

– 14 –

(2) Characteristics required for flux

Nitrogen gas

cylinder

Pipe

Flow meter

M

Stop valve

From Nitrogen cylinder

Nitrogen
gas

Rubber plug

Nitrogen gas

cylinder

Pipe

Flow meter

M

Stop valve

From Nitrogen cylinder

Nitrogen
gas

Rubber plug

1.Activated temperature of flux coincides with
the brazing temperature.

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

3.It is easy to remove slag after brazing.

4.The corrosive action to the treated metal and
brazing filler is minimum.

5.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 brazing 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.

(4) Piping materials for brazing and used braz-

ing filler/flux

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

1.

Attach a reducing valve and a flow-meter to
the Nitrogen gas cylinder.

2.

Use a copper pipe to direct the piping mate­rial, and attach a flow-meter to the cylinder.

Apply a seal onto the clearance between the

3.

piping material and inserted copper pipe for
Nitrogen in order to prevent backflow of the
Nitrogen gas.

4.

When the Nitrogen gas is flowing, be sure to
keep the piping end open.

5.

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.

6.

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.

7.

Copper - Copper

Copper - Iron

1.

2.

3.

4.

Piping

material

Iron - Iron

Used brazing

filler

Phosphor copper

Silver

Silver

Used

flux

Do not use

Paste flux

Vapor flux

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.

Fig. 6-5-1 Prevention of oxidation during brazing

– 15 –

7-1. Indoor Control Circuit

7. INDOOR UNIT CONTROL

Max. 8 units are connectable.*1

*1 When group and twin combination.
main remote controller shal be connected
follower indoor unit

*2 Weekly timer is not connectable to the
sub remote controller.

Indoor unit

#1 Header unit

Indoor control P.C. board (MCC-1510)

Central control

remote controller

(Sold separatrly)

Reciver and Display P.C board

(MCC-819)

Reciver unit

Display LED

U3

U4

Main (Sub) master remote controller

(Wired)

Display

LCD

Display

LED

DC20V
DC12V

DC5V

Buzzer

CPU

Remote

controller

communication

circuit

Central control

communication

circuit

Driver

Function setup

Key switch

CN2 CN1

DC5V

Power circuit

Sold separatrly Sold separatrly

AB

Remote

controller

communication

circuit

CPU

Driver

H8/3039

Weekly timer

Display

LCD

2

*

Powe r

circuit

EEPROM

TA sensor

TC sensor

TCJ sensor

LCD

driver

CPU

DC5V

Secondary

battery

Follower unit

AB

#2

Same as

the left

Function setup

Key switch

#3

AB

Same as

the left

Louver

motor

Indoor

fan

motor

DC280V

Power
circuit

DC15V

Outdoor unit

Fan motor

control

circuit

123

3

12

Outside
output

Run

Warning

Ready

Thermo. ON

Cool
Heat

Fan

AC

synchronous

signal input

circuit

Serial
send/

receive

circuit

HA

Wireless

remote

signal

Setting
(A/B)

123

Outdoor

unit

123

Outdoor

unit

– 16 –

INDOOR UNIT CONTROL CIRCUIT (Continued)

7-2. Control Specifications

NO.

1

Control at
power-on reset

Operation mode

2

switching

Item

Overview of specifications

(1) Identification of outdoor unit

Identifies outdoor unit at power-on reset, and switches control
according to the identification result.

(2)

Setting of indoor unit fan speed and adjustment of air flow direction
Switches indoor unit fan speed, setting of air flow direction
adjustment, etc. based on EEPROM data.

(1) Switches operation mode according to mode select instruction

from remote controller.

R/C instructions

OFF

FAN

COOL

DRY
HEAT
AUTO

Turns OFF air conditioner
“Fan only” operation
Cooling operation
Dehumidifying operation
Heating operation

• Selects COOL or HEAT mode

Outline of control

automatically according to Ta, Ts, and To.

• The first operation is as follows according
to Ta. (COOL thermo sensor continues
OFF (FAN mode with set fan speed) within
the range of Ts +α-1<Ta< Ts +α+1.)

COOL
operation

FAN mode with
set fan speed

Ta

( )

+1.0

Ts+

Remarks

The “PREPARING” lamp
lights during initial setting
(model recognition) after
power-on reset.
Fan speed, adjustment of
air flow direction

Ta : Room temperature
Ts : Set temperature
To : Outside air temperature

Room temperature

3

control

-1.0

HEAT
operation

• α is corrected according to outside air
temperature.

Outside air temp. Corrected value (α)

No To 0 K

>

To

24°C -1 K

=

>

24>To

18°C 0 K

=

To<18°C +1 K

Abnormal To 0 K

(2) Operation instruction permission mode

HEAT and AUTO modes are not available for COOL only models.
When instruction is issued from wireless remote controller in the
HEAT or AUTO mode, it is indicated by a reception sound “pi, pi”
and by alternate blinking of “TIMER” and “PREPARING” lamps. To
cancel this alternate blinking, issue an instruction of mode other
than HEAT or AUTO.

(1) Adjustment range Remote controller set temperature (°C)

COOL/DRY HEAT AUTO

Wired type 18 - 29 18 - 29 18 - 29

Wireless type 17 - 30 17 - 30 17 - 30

* When use of remote controller sensor is set (with DN32), even

when sensor value is within the above range in HEAT or AUTO
mode, the thermo sensor turns OFF when Ta sensor value
exceeds 35 °C.

k=deg

– 17 –

NO.

Room temperature

3

control

Capacity auto

4

control

(GA control)

Item

Overview of specifications

(2) The set temperature for HEAT operation can be corrected by code

No. 06.

Set data 0246

Correction of set temp. +0°C +2°C +4°C +6°C

Factory setting

Set data 2

* When use of remote controller sensor is set (with DN32), no

correction is performed.

(1) Issues instruction of operating frequency to outdoor unit according

to the difference between Ta and Ts.

(2) COOL operation

Calculates room temp. difference between Ta and Ts as well as
room temp. variation every 90 seconds to find correction value of
specified operating frequency and to correct the current operating
frequency.
Ta(n)–Ts(n) : Room temp. difference n : Number of detection times
Ta(n-1)–Ta(n) : Room temp. variation n–1 : Number of detection times

(90 seconds before)

(3) HEAT operation

Calculates room temp. difference between Ta and Ts as well as
room temp. variation every 60 seconds to find correction value of
specified operating frequency and to correct the current operating
frequency.
Ts(n)–Ts(n) : Room temp. difference n : Number of detection times
Ta(n)–Ta(n_1) : Room temp. variation n–1 : Number of detection times

(60 seconds before)

(4) DRY operation

The frequency correction control is the same as that for COOL
operation.
However, the maximum frequency is limited to S6 or so.

Note) When LOW fan speed is set, the maximum frequency is

limited to SB or so.

Remarks

Heat intake temperature
shift
(When unit’s temperature
sensor is used)

COOL/HEAT/

5

AUTO control

(1) Switching between COOL and HEAT is determined based on the

following control.

Ta

(˚C)

+1.5

Tsc

or

Tsh

COOL

(COOL ON)

(COOL OFF)

-1.5

After 10 minutes pass from
thermo sensor OFF,
operation mode changes
from HEAT (thermo sensor
OFF) to COOL if Ta exceeds
Tsh +1.5.

( ) shows an example of

HEAT

COOL ON/OFF.

After 10 minutes pass from
thermo sensor OFF,
operation mode changes
from COOL (thermo sensor
OFF) to HEAT if Ta lowers
below Tsc -1.5.

(2) The GA control after determination of operation mode follows the

description in No. 4.

(3) The room temperature control and temperature correction follow

the descriptions in No. 3 and No. 15.

Tsc : COOL set temp.
Tshc : HEAT set temp. +

room temp. control/
correction

– 18 –

INDOOR UNIT CONTROL CIRCUIT (Continued)

NO.

6

Fan speed control

Item

Overview of specifications

(1) A fan speed HH (quick high), H (high), L (low) or AUTO is selected

according to the instruction from remote controller for FAN mode
operation.

(2) Fan speed is switched according to the difference between Ta and

Ts in the AUTO mode.

[Cooling]

Ta (˚C)

+3.0

+2.5

+2.0

+1.5

+1.0

+0.5

Tsc

-0.5

HH
(HH)

H+(HH)

H(HH)

L+(H+)

L(H)

L(H)

L(L+)

A

B

C

D

E

F

G

• The fan speed control is the same for temperature setting by remote
controller or the unit.

• Once fan speed is changed, it remains unchanged for 3 minutes
unless different fan speed is selected by instruction.

• At the beginning of cooling, a falling gradient (higher fan speed) is
selected.

• When the temperature difference between Ta and Ts is on a
threshold line, fan speed does not change.

• ( ): Auto cooling

Remarks

HH>H+>H>
L+>L>UL

Wireless type allows HH,
H+, H, L+, L, and AUTO.

HH

H+

H

L+

L

[Heating]

Ta (˚C)

(-0.5)

(0)

(+0.5)

(+1.0)

(+1.5)

(+2.0)

-1.0

Tsh

+1.0

+2.0

+3.0

+4.0

L( L+)

L+(H)

H(H+)

H+
(HH)

HH
(HH)

E

D

C

B

A

( ): Temperature setting by remote controller
Other than ( ): Temperature setting by unit

• Once fan speed is changed, it remains unchanged for one minute
unless different fan speed is selected by instruction.

• At the beginning of heating, a rising gradient (higher fan speed) is
selected.

• When the temperature difference between Ta and Ts is on a
threshold line, fan speed does not change.

• ( ): Auto heating

• Fan speed is switched to a higher level when Tc reaches 60 °C.

Tc : Indoor unit heat

exchange sensor
temp.

– 19 –

NO.

6

Fan speed control

Item

COOL

HH
H+

H

L+

L

UL

Overview of specifications

HEAT

HH

AP40-56

1220

AP63

1180

H+

H

1140
1120
1060

L+

L

1060

990
940

UL

500

1360
1300
1240
1200
1120
1120
1020

970
500

Remarks

AP71-80

1480
1340
1320
1300
1200
1200
1100
1040

500

7

Cool air prevention
control

(3) When thermo sensor turns OFF during heating, the fan speed

mode becomes UL (weak).

(4) When Ta is 25 °C or above at the beginning of HEAT operation or

when canceling defrost mode, H or HH mode continues for one
minute from the time when Tc enters zone E shown in the figure in
No.7 below.

(5) The HH fan speed for auto cooling/heating is set to a speed higher

than that for normal cooling/heating. However, it varies depending
on the temperature difference of Tc during auto heating.

Tc

(˚C)

47

HH+

42

HH

(1) Performs indoor unit fan control in the HEAT mode according to

the Tc (or Tcj) sensor detect temperature. The maximum speed is
limited as shown below.

Tc
Tcj

(˚C)

36

34

32

30

24

20

HH

H

L

UL

OFF

Shifts Tc control value by +6 °C
during defrosting. However, zone
B is regarded as zone C after 6
minutes pass from the startup of
compressor.

Zone E

Zone D

Zone C
Zone B

Zone A

“HEAT PREPARING”
indication

Fan speed select setting
by remote controller takes
precedence in zones D
and E.
“HEAT PREPARING” is
indicated in zones A and
B.

– 20 –

INDOOR UNIT CONTROL CIRCUIT (Continued)

NO.

8

Freezing
prevention control
(low-temp.
release)

9

High-temp. release
control

Item

Overview of specifications

(1) Performs the following operation control in the COOL or DRY

mode according to the Tc (or Tcj) sensor detect temperature.
When zone J in the figure below is detected for 6 minutes, the
specified operating frequency is decreased from the actual
operating frequency, and the specified operating frequency is
changed every 30 seconds in zone J.
Timer count stops and is maintained in zone K.
Timer count is cleared to restore normal operation when zone I is
detected.
If the specified operating frequency becomes SO due to
continuation of zone J, return temperature A is raised from 5 to
12 °C, and operation with L fan speed continues until zone I is
detected.

Tc(˚C)

I5

2

J

A

K

If 4-way valve cannot be switched during heating and the following
conditions become true, freezing prevention control is performed.
(However, zone J entering control temperature is changed from 2
to -5 °C.)
[Conditions]
The following A or B becomes true after 5 minutes pass from
operation start.

<

A Tcn
B Tcn<Tc(n–1)–1 and Tcn

Tc(n–1)–5

=

<

Ta<5°C

=

(1) Performs the following operation control in the HEAT mode

according to the Tc (or Tcj) sensor detect temperature.

•

When zone M is detected, the specified operating frequency is
decreased from the actual operating frequency, and the specified
operating frequency is changed every 30 seconds in zone M.

• The specified operating frequency is maintained in zone N.

• When zone L is detected, the specified operating frequency is
returned by approx. 6 Hz every 60 seconds.

Factory setting

Control temp. (°C)

AB

Tc
Tcj

(˚C)

A

56 (54) 52 (52)

B

L

Remarks

Tcj : Indoor unit heat

exchange sensor
temp.

Tcn :

Tc after 5 minutes
from operation start

Tc (n-1):

Tc at operation start

This control is disabled for
twin follower indoor units.

M

N

Note) At the beginning of operation or when Tc (or Tcj) lowers below

30 °C after operation start, values (54) and (52) in the table are
used as control temperature.

10 Runs indoor unit fan in L (low) mode for about 30 seconds after HEAT

Residual heat
removal

operation stops to remove residual heat.

– 21 –

Even when the thermo is
set to OFF, the control is
implemented in the same
way.

NO.

11

Item

Flap control

Overview of specifications

(1) During the first operation after power on, flap position is controlled

automatically according to operation mode (COOL/HEAT).

Cooling Heating

Remarks

Louver angle: 0 °C (full
close)

Full close

45°

103°

(2) When louver position is controlled by remote controller, the unit’s

microcomputer memorizes the position for use in the next
operation.

* The memorized louver position is cleared when power is turned

off, and returns to the state of (1) above.

(3) Flap position setting

• Flap position can be set within the range below.

COOL/DRY HEAT/FAN

• Flap position can be set collectively or individually in the group
twin or triple operation mode. (Wireless remote controller allows
individual setting only.)

(4) Swing setting

• Flap moves within the range below.

All operation modes

• Flap swing range can be set collectively or individually in the
group twin or triple operation mode. (Setting by wireless remote
controller is disabled when the main remote controller is used.)

(5) When air conditioner operation stops, flap closes automatically. It

keeps its position in the event of an alarm.
(6) Flap tilts upward automatically during preparation for heating.
(7) In the twin or triple operation mode selected by wireless remote

controller, swing setting interlocks with the header indoor unit. If

this setting is transmitted from a follower indoor unit, operation

does not change with a reception sound “pi, pi, pi” if operation

mode differs between header unit and follower unit.

0°

Alarm : A code number

(except F08 and
L31) appears on
the remote
controller and the
indoor unit stops.

– 22 –

INDOOR UNIT CONTROL CIRCUIT (Continued)

NO.

12

Item

HA control

Overview of specifications

(1) When connected to a remote control system (tele-control or

remote on/off interface), operation ON/OFF can be controlled by

the HA signal input.
(2) Outputs operation ON/OFF status to the HA output terminal.
(3) HA signal input/output specifications conform to the JEMA

standard.

Remarks

A connector (separately
available) is required
when using the HA
terminal CH61 for remote
ON/OFF control.

When group operation is
in use, connect the
connector to either header
or follower indoor unit.

13

Filter sign
indication
(unavailable for
wireless type)

(1) Transmits filter replacement signal to remote controller for

indication on the LCD when accumulated operation hours of

indoor unit fan exceeds the specified time (150 hours).

(2) Clears accumulation timer upon receiving the filter reset signal

from remote controller. At this time, when the specified time has

already passed, the accumulated time is reset and the filter sign

disappears from the LCD.

“FILTER” lamp ON

– 23 –