Toshiba RAV-SP1400UT-E, RAV-SP1100AT-E, RAV-SP1100UT-E, RAV-SP560AT-E, RAV-SP800AT-E User Manual

FILE NO. A03-013

SERVICE MANUAL

<OWNERS MANUAL/INSTALLATION MANUAL>

SPLIT TYPE

RAV-SP1100UT-E

RAV-SP560AT-E, RAV-SP800AT-E

RAV-SP1100AT-E, RAV-SP1400AT-E

R410A

The type of all the indoor units described in this Service Manual is a new model, RAV-SP1100UT-E only. For the other indoor units to be combined, refer to the Service Manuals for the following models.

4-way Air Discharge Cassette type

Concealed Duct type

Under Ceiling type

High wall type

Indoor unit RAV-SM560UT-E RAV-SM800UT-E RAV-SM1400UT-E RAV-SM561BT-E RAV-SM801BT-E RAV-SM1101BT-E RAV-SM1401BT-E RAV-SM561CT-E RAV-SM801CT-E RAV-SM1101CT-E RAV-SM1401CT-E RAV-SM560KRT-E RAV-SM800KRT-E

Service Manual No.

A02-013 A02-013 A03-003 A03-007 A03-007 A03-007 A03-007 A03-015 A03-015 A03-015 A03-015 A02-013 A02-013

PRINTED IN JAPAN, Feb.,2004 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 ha ve 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.

– 2 –

Indoor Unit (4-Way Air Discharge Cassette Type) ––––––––––––––––––––––––

RAV-SP1100UT-E O WNWE’S MANUAL

ACCESSORIES (SOLD SEPARATELY) ............................... 4

PRECAUTIONS FOR SAFETY ............................................4

PARTS NAME .......................................................................6

PARTS NAME OF REMOTE CONTROLLER.......................7

CORRECT USAGE...............................................................9

AUTOMATIC OPERATION (Auto Changeover) ................10

ADJUSTMENT OF WIND DIRECTIONd ............................11

TIMER OPERATION ...........................................................12

MAINTENANCE..................................................................14

AIR CONDITIONER OPERATIONS AND PERFORMANCE

RE-INSTALLATION ............................................................16

TROUBLES AND CAUSES................................................16

...15

INSTALLATION MANUAL

Accessory parts and Parts to be procured locally ........ 18

PRECAUTIONS FOR SAFETY....................................19

SELECTION OF INSTALLATION PLACE ...................21

DRAIN PIPING WORK ................................................. 26

REFRIGERANT PIPING AND EVACUATING ..............28

ELECTRICAL WORK...................................................30

TEST RUN ...................................................................33

TROUBLESHOOTING.................................................34

MAINTENANCE...........................................................35

Outdoor Unit –––––––––––––––––––––––––––––––––––––––––––––––––––––––––

RAV-SP560AT-E, RAV-SP800AT-E INSTALLATION MANUAL

PRECAUTIONS FOR SAFETY....................................36

ACCESSORY AND REFRIGERANT ...........................37

SELECTION OF INSTALLATION ................................38

REFRIGERANT PIPING ..............................................43

EVACUATING...............................................................45

ELECTRICAL WORK...................................................47

FINAL INSTALLATION CHECKS................................48

RAV-SP1100UT-E

RAV-SP560AT-E

RAV-SP800AT-E

RAV-SP1100AT-E, RAV-SP1400AT-E INSTALLATION MANUAL

PRECAUTIONS FOR SAFETY....................................50

ACCESSORY AND REFRIGERANT ...........................51

SELECTION OF INSTALLATION ................................52

REFRIGERANT PIPING ..............................................56

EVACUATING...............................................................58

ELECTRICAL WORK...................................................60

FINAL INSTALLATION CHECKS................................61

Accessories ––––––––––––––––––––––––––––––––––––––––––––––––––––

O WNER’S MANUAL

REMOTE CONTR OLLER FOR AIR CONDITIONER (SPLIT TYPE)

<Wireless Type> TCB-AX21U (W)-E.......................................... 63

WEEKLY TIMER FOR AIR CONDITIONER (SPLIT TYPE)

<Program W eekly Timer T ype> RBC-EXW21E................................................. 72

REMOTE CONTROLLER FOR AIR CONDITIONER

<Simple Operation Type> RBC-AS21E.................................................... 78

INSTALLATION MANUAL

Standard Remote Controller RBC-AMT21E ................................................. 81

Simple Remote Controller RBC-AS21E.................................................... 82

Program W eekly Timer RBC-EXW21E................................................. 83

Remote sensor TCB-TC21LE .................................................. 84

Remote Controller Wireless Kit TCB-AX21U (W)-E.......................................... 85

Network Adapter for Air Conditioner

(Use for Indoor Unit Only) TCB-PCNT20E ............................................... 86

RAV-SP1100AT-E

RAV-SP1400AT-E

ACCESSORIES

• Ensure that all Local, National and International regulations are satisfied.

• Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.

• The precautions described below include the important items regarding safety. Observe them without fail.

• After the installation work, perform a trial operation to check for any prob lem. Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.

• Turn off the main power supply switch (or breaker) before the unit maintenance.

• Ask the customer to keep the Installation Manual together with the Owner’s Manual.

PRECAUTIONS FOR SAFETY

CAUTION New Refrigerant Air Conditioner Installation

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DE-

STROY OZONE LAYER.

The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle.

To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging port of the main unit and installation tools are charged from those for the conventional refrigerant.

Accordingly the exclusive tools are required for the new refrigerant (R410A). For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust

does not enter. Moreover, do not use the existing piping because there are prob lems with pressure-resistance force and impurity in it.

CAUTION To Disconnect the Appliance from Main Power Supply.

This appliance must be connected to the main power supply by means of a switch with a contact separation of at least 3 mm.

The installation fuse (25A D type ) must be used for the power supply line of this conditioner.

WARNING

• Ask an authorized dealer or qualified installation professional to install/maintain the air condi-

tioner.

Inappropriate installation may result in water leakage, electric shock or fire.

• Turn off the main power supply switch or breaker before attempting any electrical work.

Make sure all power switches are off. Failure to do so may cause electric shock.

• Connect the connecting cable correctly.

If the connecting cable is connected in a wrong way, electric parts may be damaged.

• When moving the air conditioner for the installation into another place, be very careful not to

enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.

If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnormally high and it may resultingly causes pipe burst and injuries on persons.

• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety

interlock switches.

• Exposure of unit to water or other moisture before installation may cause short-circuit of

electrical parts.

Do not store it in a wet basement or expose to rain or water.

• After unpacking the unit, examine it carefully if there are possible damage.

• Do not install in a place that might increase the vibration of the unit.

• To avoid personal injury (with sharp edges), be careful when handling parts.

• Perform installation work properly according to the Installation Manual.

Inappropriate installation may result in water leakage, electric shock or fire.

• When the air conditioner is installed in a small room, provide appropriate measures to ensure

that the concentration of refrigerant leakage occur in the room does not exceed the critical level.

• Install the air conditioner securely in a location where the base can sustain the weight adequately.

• Perform the specified installation work to guard against an earthquake.

If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.

• If refrigerant gas has leaked during the installation work, ventilate the room immediately.

If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.

• After the installation work, confirm that refrigerant gas does not leak.

If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas might generate.

• Electrical work must be performed by a qualified electrician in accordance with the Installation

Manual. Make sure the air conditioner uses an exclusive power supply.

An insufficient power supply capacity or inappropriate installation may cause fire.

• Use the specified cables for wiring connect the terminals securely fix. To prevent external

forces applied to the terminals from affecting the terminals.

• Be sure to provide grounding.

Do not connect ground wires to gas pipes, water pipes, lightning rods or g round wires for telephone cables.

• Conform to the regulations of the local electric company when wiring the power supply.

Inappropriate grounding may cause electric shock.

• Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.

If a combustible gas leaks, and stays around the unit, a fire may occur.

Required tools for installation work

1) Philips screwdriver

2) Hole core drill (65 mm)

3) Spanner

4) Pipe cutter

5) Knife

6) Reamer

7) Gas leak detector

8) Tape measure

9) Thermometer

10) Mega-tester

ACCESSORY AND REFRIGERANT

11) Electro circuit tester

12) Hexagonal wrench

13) Flare tool

14) Pipe bender

15) Level vial

16) Metal saw

R410A (Special requirement)

17) Gauge manifold (Charge hose : R410A special requirement)

18) Vacuum pump (Charge hose : R410A special requirement)

19) Torque wrench 1/4 (17 mm) 16 N•m (1.6 kgf•m) 3/8 (22 mm) 42 N•m (4.2 kgf•m) 1/2 (26 mm) 55 N•m (5.5 kgf•m) 5/8 (15.9 mm) 120 N•m (12.0 kgf•m)

20) Copper pipe gauge adjusting projection margin

21) Vacuum pump adapter

Accessory and Installation Parts Refrigerant Piping

• Piping kit used for the conventional refrigerant cannot be used.

Outdoor unit Installation manual x 1

Drain nipple

Waterproof rubber cap

Protective bush

(For SM800, SP560, SP800)

Guard material for passage part

(For SM800, SP560, SP800)

• Use copper pipe with 0.8 mm or more thickness for Ø6.4, Ø9.5, Ø12.7.

Use copper pipe with 1.0 mm or more thickness for Ø15.9.

• Flare nut and flare works are also different from those of

the conventional refriger ant. Take out the flare nut attached to the main unit of the air conditioner, and use it.

RAV-SP560AT-E

RAV-SP800AT-E

SELECTION OF INSTALLATION

CAUTION

<SP560AT-E, SP800AT-E only>

When using an air conditioner under low outside temperature condition (Outside temp.:–5°C or lower) with COOL mode, prepare a duct or wind shield so that it is not affected by the wind.

Suction hood (Side)

Suction hood (Rear side)

Discharge guide

Fin

Suction

Before installation

Be careful to the following items before installation.

Length of refrigerant pipe

<SM560AT-E>

Length of refrigerant pipe

connected to

indoor/outdoor unit

20m or shorter

21m to 30m

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 20m, add 20g/m of refrigerant and the maximum total length of pipe is 30m. (Max. amount of additional refrigerant is 200g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor .

Discharge hood

Discharge

Fin

Suction

Item

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 20g of refrigerant for every 1m of pipe which exceeds 20m.

<SP560AT-E>

Length of refrigerant pipe

connected to

indoor/outdoor unit

20m or shorter

21m to 50m

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 20g of refrigerant for every 1m of pipe which exceeds 20m.

Item

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 20m, add 20g/m of refrigerant and the maximum total length of pipe is 50m. (Max. amount of additional refrigerant is 600g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor .

<SP800AT-E>

Length of refrigerant pipe

connected to

indoor/outdoor unit

30m or shorter

31m to 50m

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 40g of refrigerant for every 1m of pipe which exceeds 30m.

Item

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 30m, add 40g/m of refrigerant and the maximum total length of pipe is 50m. (Max. amount of additional refrigerant is 800g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor .

Air purge

• For air purge, use a vacuum pump.

• Do not use refrigerant charged in the outdoor unit for

air purge. (The refrigerant for air purge is not contained in the outdoor unit.)

<SM800AT-E>

Length of refrigerant pipe

connected to

indoor/outdoor unit

20m or shorter

21m to 50m

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 40g of refrigerant for every 1m of pipe which exceeds 20m.

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 20m, add 40g/m of refrigerant and the maximum total length of pipe is 50m. (Max. amount of additional refrigerant is 1200g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor .

Item

Electrical cabling

• Be sure to fix the power cables and indoor/outdoor connecting cables with clamps so that they do not contact with the cabinet, etc.

500

or more

150

or more

Installation Place

Necessary Space for Installation

• A place which provides a specified space around the outdoor unit.

• A place where the operation noise and discharged air are not given to your neighbors .

• A place that is not exposed to a strong wind.

• A place that does not block a passage.

• When the outdoor unit is installed in an elev ated

position, be sure to secure its feet.

• There must be sufficient space for carrying in the unit.

• A place where the drain water does not make an y problem.

CAUTION

1. Install the outdoor unit at a place where dis-

charge air is not blocked.

2. When an outdoor unit is installed in a place that

is always exposed to a strong wind like a coast or on a high story of a building, secure a normal fan operation b y using a duct or a wind shield.

3. When installing the outdoor unit in a place that is

constantly exposed to a strong wind such as the upper stairs or rooftop of a building, apply the windproof measures referring to the follo wing examples.

1) Install the unit so that its discharge port faces to the wall of the building. Keep a distance 500 mm or more between the unit and the wall surface .

500

Obstacle at rear side

1. Single unit installation

2. Obstacles at both right and left sides.

200

or more

150

or more

The height of the obstacle should be lower than the height of the outdoor unit.

300

or more

3. Serial installation of two or more units

150

or more

The height of the obstacle should be lower than the height of the outdoor unit.

300

or more

300

or more

150

300

or more

200 or more

2) Supposing the wind direction during the operation season of the air conditioner, install the unit so that the discharge port is set at right angle to the wind direction.

Strong wind

4. Installation in the following places may result in some troubles. Do not install the unit in such places below.

• A place full of machine oil.

• A place full of sulfuric gas.

• A place where high-frequency radio waves are

likely to be generated as from audio equipment, welders, and medical equipment.

Obstacle at front side

1. Single unit installation

2. Serial installation of two or more units

500

1000

or more

15 or less

SELECTION OF INSTALLATION

1000

or more

1000

or more

Obstacles at both front and rear sides

Open the upper side and both right and left sides. The height of obstacle at both front and rear side, should be lower than the height of the outdoor unit.

1. Single unit installation

150

or more

1000

or more

Installation of Outdoor Unit

• Before installation, check strength and horizontality of the base so that abnormal sound does not generate.

• According to the following base diagram, fix the base firmly with the anchor bolts. (Anchor bolt, nut: M10 x 4 pairs)

<SM560AT-E>

90 90

310

330

<SM800AT-E, SP560AT-E, SP800AT-E>

600

115

Ø28 Drain hole

600150 150

430

Drain hole

2. Serial installation of two or more units

200

or more

300

or more

300

or more

1000

or more

Serial installation at front and rear sides

Open the upper side and both right and left sides. The height of obstacle at both front and rear sides should be lower than the height of the outdoor unit.

400

365

Knockout hole

Drain nipple mounting hole

Set the out margin of the anchor bolt to 15mm or less.

• In case of draining through the drain hose, attach the following dr ain nipple and the waterproof rubber cap, and use the drain hose (Inner diam.: 16mm) sold on the market. And also seal the screws securely with silicone material, etc. so that w ater does not drop down. Some conditions may cause dewing or dripping of water.

1000

or more

300

or more

1500

or more

2000

or more

200

or more

Drain nipple Waterproof rubber cap

<SM560AT-E>

Refrigerant Piping Connection

CAUTION

Waterproof rubber cap

Base plate

Drain nipple

<SM800AT-E, SP560AT-E, SP800AT-E>

Knockout hole

Open

Waterproof rubber cap

Drain nipple

• When there is a possibility of freezing of drain at the cold district or a snowfall area, be careful for drainage ability of drain. The drainage ability increases when a knockout hole on the base plate is opened. (Open the knockout hole to outside using a screwdriver, etc.)

TAKE NOTICE THESE IMPORTANT 4 POINTS BELOW FOR PIPING WORK

1. Keep dust and moisture away from inside the connecting pipes.

2. Tightly connect the connection between pipes and the unit.

3. Evacuate the air in the connecting pipes using VACUUM PUMP.

4. Check gas leak at connected points.

Capacity

rank

RAV-

SM560

SP560

SM800

SP800

Liquid side

Outer

diameter

Ø6.4 0.8

Ø9.5 0.8

Thickness

Gas side

Outer

diameter

Ø12.7 0.8

Ø15.9 1.0

Thickness

For Reference

Optional Installation Parts (Local Procure)

Parts name

Refrigerant piping

Liquid side : Ø6.35 mm or Ø9.52 mm Gas side : Ø12.7 mm or Ø15.9 mm

Pipe insulating material

(polyethylene foam, 6 mm thick)

Putty, PVC tapes

Q’ty

Each one

If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, draining of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.

It is recommended to procure an anti-freeze heater locally for a safety installation of the air conditioner .

For details, contact the dealer.

SELECTION OF INSTALLATION

Knockout of Pipe Cover

<SM800AT-E, SP560AT-E, SP800AT-E>

Rear direction

Pipe cover

Side direction

Front direction

Down direction

Knockout procedure

• The indoor/outdoor connecting pipes can be connected to 4 directions.

Take off the knock out part of the pipe cover in which pipes or wires pass through the base plate.

• As shown in the figure, do not remove the pipe cover from the cabinet so that the knockout hole can be easily punched. To knock out, it is easily taken off by hands by punching a position at the lower side of 3 connected parts with screwdriver along the guideline.

• After marking the knockout hole, remove the burr and mount the attached protective bush and guard material for pass-through part in order to protect pipes and wires.

How to remove the front panel

1. Remove screws of the front panel.

2. Pull the front panel downward.

Removing the front panel, the electric parts appear at the front side.

• The metal pipes are attachable to the piping holes. If the size of the used power pipe does not match with the hole, adjust the hole size to match with pipe size.

• Be sure to fix the power cable and indoor/outdoor connecting cable with bundling band sold on the market so that they do not mak e contact with the compressor and discharge pipe. (Temperature of the compressor and discharge pipe becomes high.)

In order to avoid the force applied to on the connecting section, be sure to fix the cables to the cord clamps provided on the pipe valve fixing plate and the electric parts box.

Electric parts box

Front panel

Pipe valve fixing plate

Piping hole

Cord clamp

After connecting the pipes, be sure to mount the pipe cover. The pipe cover is easily mounted by cutting off the slit at the lower part of the pipe cover.

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