Toshiba RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL User Manual

SERVICE MANUAL

AIR-CONDITIONER

SPLIT TYPE

FILE NO. A09-010

OUTDOOR UNIT

RAV-SP180AT2-UL (2 HP) RAV-SP240AT2-UL (3 HP) RAV-SP300AT2-UL (4 HP) RAV-SP360AT2-UL (4, 5 HP) RAV-SP420AT2-UL (5 HP)

R410A

PRINTED IN JAPAN, Dec., 2009 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.

– 2 –

CONTENTS

SAFETY CAUTION ............................................................................................ 4

1. SPECIFICATIONS ...................................................................................... 9

1-1. Outdoor Unit........................................................................................................ 9

1-2. Operation Characteristic Curve ....................................................................... 10

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)....................................... 12

2-1. Outdoor Unit...................................................................................................... 12

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM .............................. 15

3-1. Indoor Unit......................................................................................................... 15

3-2. Outdoor Unit...................................................................................................... 16

4. WIRING DIAGRAM ................................................................................... 19

4-1. Outdoor Unit...................................................................................................... 19

5. SPECIFICATIONS OF ELECTRICAL PARTS .......................................... 22

5-1. Outdoor Unit (Parts Ratings) ........................................................................... 22

6. REFRIGERANT R410A ............................................................................ 23

6-1. Safety During Installation/Servicing ............................................................... 23

6-2. Refrigerant Piping Installation ....................................................................... 23

6-3. Tools .................................................................................................................. 27

6-4. Recharging of Refrigerant................................................................................ 27

6-5. Brazing of Pipes................................................................................................ 28

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS ........... 30

7-1. Print Circuit Board <MCC-1571> ..................................................................... 30

7-2. Outline of Main Controls .................................................................................. 32

8. TROUBLESHOOTING .............................................................................. 45

8-1. Summary of Troubleshooting........................................................................... 45

8-2. Troubleshooting ................................................................................................ 47

9. REPLACEMENT OF SERVICE P.C. BOARD............................................ 73

9-1. Outdoor Unit...................................................................................................... 73

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

10-1. Outdoor Unit...................................................................................................... 74

11. DETACHMENTS ....................................................................................... 82

11-1. Outdoor Unit..................................................................................................... 82

12. EXPLODED VIEWS AND PARTS LIST .................................................. 106

12-1. Outdoor Unit.................................................................................................... 106

– 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]

Mark Explanation

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 high-voltage transformer is applied.

Turn 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 high-voltage 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 wires 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 wires as before. Perform the work so that the cabinet or panel does not catch the inner wires.

If incorrect assembly or incorrect wire connection was done, a disaster such as a leak or fire is caused at user’s side.

– 5 –

Insulator check

Ventilation

Be attentive to

electric shock

Compulsion

WARNING

After the work has finished, be sure to use an insulation tester set (500V Megger) to check the resistance is 2MΩ or more between the charge section and the non-charge 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.

Check after repair

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 earth 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 the gloves (∗) and a long sleeved shirt: otherwise 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.

– 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 prevent 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

The pipe thickness, flare finishing size, flare nut and others differ according to a refrigerant type.

When using a long copper pipe for R410A, it is recommended to select “Copper or copper-base pipe without seam” and one with bonded oil amount 0.0001 lbs / 32’ 10” (40 mg / 10 m) or less.

Also do not use crushed, deformed, discolored (especially inside) pipes. (Impurities cause clogging of expansion valves and capillary tubes.)

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 Tools 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

Vacuum pump adapter

Electronic balance for

refrigerant charging

Refrigerant cylinder

Leakage detector

Used tool

NOTE

Usage

Pipe flaring

Flaring by conventional flare tool

Tightening of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating

Refrigerant charge

Gas leakage check

air conditioner installation

R410A

Existence of Whether conven-

new equipment tional equipment

for R410A can be used

Yes *(Note)

Ye s N o

Ye s Ye s

Ye s N o

Conventional air

conditioner installation

Whether conventional

equipment can be used

Ye s

*(Note)

Ye s

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.

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 8) Spanner or Monkey wrench

3) Pipe cutter 9) Hole core drill

4) Reamer 10) Hexagon wrench (Opposite side 4mm)

5) Pipe benderr 11) Tape measure

6) Level vial 12) Metal saw

7) Screwdriver (+, –)

Also prepare the following equipments for other installation method and run check.

1) Clamp meter 3) Insulation resistance tester (Megger)

2) Thermometer 4) Electroscope

– 8 –

1-1. Outdoor Unit

1. SPECIFICATIONS

Size

Outdoor model RAV-

Outdoor Min - Max DB ∗1 (°F)

Cooling Indoor Min - Max DB (°F)

Operating range

Piping

Heating

Standard Piping Length (ft.)

Min. Piping Length (ft.)

Max. Piping Length (ft.)

Lift (Outdoor below Indoor) (ft.)

Lift (Outdoor above Indoor) (ft.)

Gas Pipe (Size / connection type)

Liquid Pipe (Size / connection type)

Additional refrigerant charge under long piping connection

Indoor Min - Max WB (°F)

Outdoor WB Min - Max (°F)

Indoor DB Min - Max (°F)

018 024 030 036 042

SP180AT2-UL SP240AT2-UL SP300AT2-UL SP360AT2-UL SP420AT2-UL

23 to 109.4

69.8 to 89.6

59 to 75.2

–4 to 59

59 to 86

16’ 5” 16’ 5” 9’ 8” 9’ 8” 9’ 8”

164’ 1” 164’ 1” 246’ 1” 246’ 1” 246’ 1”

98’ 5”

1/2” 5/8” 5/8” 5/8” 5/8”

1/4” 3/8” 3/8” 3/8” 3/8”

0.22 oz / ft 0.43 oz / ft 0.43 oz / ft

(65’7”ft to164’1”ft) (98’5”ft to 164’1”ft) (98’5”ft to 246’1”ft)

Voltage

Electrical Maximum Running Current Amps (A)

Fuse Rating ∗2

Type

Compressor Motor (kw)

Pole

Height (in.)

Dimensions Width (in.)

Length (in.)

Outdoor Weight -Gross / Net (lbs.)

Refrigerant charged

Appearance (Munsell symbol)

Sound Pressure (dBa)

17 24 24 24 24

30 40 40 40 40

1.1 2 3.75 3.75 3.75

44444

21.7 35.0 52.8 52.8 52.8

30.7 35.4 35.4 35.4 35.4

11.4 12.6 12.6 12.6 12.6

98 / 105 144.5 / 157 211.5 / 226 211.5 / 226 211.5 / 226

3.1 4.6 6.8 6.8 6.8

48 / 49 49 / 50 50 / 51 52 / 52 52 / 52

208 V / 230 V-1-60 Hz

Hermetic compressor

Silky shade (Muncel 1Y8.5/0.5)

∗1 When installed a duct or wind shield so that it is not affected by the wind.

The minimum outside temperature will be 5°F

∗2 UL value

– 9 –

1-2. Operation Characteristic CurveRAV*

RAV-SP240CT, KRT-UL

RAV-SP240UT-UL

RAV-SP180CT, KRT-UL

RAV-SP180UT-UL

• Operation characteristic curve <Super Digital Inverter>

RAV-SP180AT2-UL

RAV-SP180CT, KRT-UL

RAV-SP180CT, KRT-UL RAV-SP180CT, KRT-UL

Current (A)

RAV-SP180UT-UL

• Conditions

02010 30 40 50 60 70 80

Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Outdoor : DB 95˚F (35˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

Compressor speed (rps)

RAV-SP180CT, KRT-UL

Current (A)

0203010 40 50 60 70 80 90 100 110 120

Compressor speed (rps)

RAV-SP180UT-UL

• Conditions Indoor : DB 68˚F (20˚C) Outdoor : DB 44.6˚F (7˚C)/ WB 42.8˚F (6˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

RAV-SP240AT2-UL

RAV-SP240CT, KRT-UL

Current (A)

RAV-SP240UT-UL

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Outdoor : DB 95˚F (35˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

Current (A)

RAV-SP240CT, KRT-UL

RAV-SP240UT-UL

• Conditions Indoor : DB 68˚F (20˚C) Outdoor : DB 44.6˚F (7˚C)/ WB 42.8˚F (6˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

02010 30 40 50 60 70 80

Compressor speed (rps)

– 10 –

0 203040506070809010011012010

Compressor speed (rps)

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

RAV-SP300AT2-UL

RAV-SP360AT2-UL, RAV-SP420AT2-UL

RAV-SP300AT2-UL

RAV-SP360AT2-UL, RAV-SP420AT2-UL

RAV-SP360AT2-UL,

RAV-SP420AT2-UL

Current (A)

020406080

RAV-SP300AT2-UL

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Outdoor : DB 95˚F (35˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

Compressor speed (rps)

RAV-SP300AT2-UL

RAV-SP360AT2-UL,

Current (A)

RAV-SP360AT2-UL,

RAV-SP420AT2-UL

• Conditions

020406080

Indoor : DB 68˚F (20˚C) Outdoor : DB 44.6˚F (7˚C)/ WB 42.8˚F (6˚C) Air flow : High Pipe length : 295.3” (7.5m) 230V

Compressor speed (rps)

• Capacity variation ratio according to temperature

RAV-SP180AT2-UL, RAV-SP240AT2-UL, RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

105

100

Capacity ratio (%)

89.6 (32)

91.4

93.2

(33)

(34)95(35)

• Conditions Indoor : DB 80.6˚F (27˚C)/ WB 66.2˚F (19˚C) Indoor air flow : High Pipe length :

96.8

98.6

(36)

(37)

100.4 (38)

295.3” (7.5m)

104

102.2 (40)

(39)

105.8 (41)

107.6 (42)

109.4 (43)

120

110

100

Capacity ratio (%)

–4

(–20)

–0.4

(–18)

3.2

(–16)

(–14)

• Conditions Indoor : DB 68˚F (20˚C) Indoor air flow : High Pipe length :

6.8

10.4

17.6

21.2

(–8)

(–6)

24.8 (–4)

(–12)14(–10)

28.4 (–2)32(0)

295.3” (7.5m)

35.6

39.2

(2)

(4)

42.8 (6)

46.4 (8)50(10)

Outdoor temp. ˚F (˚C)

– 11 –

2. CONSTRUCTION VIEWS (EXTERNAL VIEWS)

2-1. Outdoor Unit

RAV-SP180AT2-UL

(Minimum

11.8” (300)

or more

distance

up to wall)

2-Ø0.4” (11)×0.6” (14) U-shape holes

(For Ø0.3” (8)-0.4” (10) anchor bolts)

Space required for service

2.1” (54)

3.5” (90)

Suction port

23.6” (600)

5.9” (150)

2-Ø0.4” (11)-0.6” (14)

U-shape hole

1.2” (30)

Discharge port

or more

5.9” (150)

or more

(For Ø0.3” (8)-0.4” (10)

anchor bolts)

Discharge port

19.7” (500)

or more

12.6” (320)

8-Ø0.2” (6) hole

(For fixing outdoor unit)

2-Ø0.4” (11)×0.6” (14) long hole

(For Ø0.3” (8)-0.4” (10) anchor bolts)

2-Ø0.4” (11)×0.6” (14) long hole

(For Ø0.3” (8)-0.4” (10) anchor bolts)

0.6” (16)

3.1” (79)

6.2” (157)

10” (255)

0.8” (21)

5.7” (145)

Refrigerant pipe

connecting port

(Ø0.6” (6.4) flare at liquid side)

6.1” (155)

2” (53)

Refrigerant pipe

connecting port

(Ø0.5” (12.7) flare at gas side)

13.5” (342)

Charge port

5.6” (141)

3.5” (88)

1” (26)

0.9” (22)

Discharge guide mounting hole

(4-Ø1.8” (4.5) embossing)

23.6” (600)

A legs

4.3” (108) 4.9” (125)

Drain hole(Ø1” (25))

2.4” (60)

Drain hole

(2-Ø0.7” (20)×3.5” (88) long hole)

11.4” (290)

Ø0.2” (6) hole pitch

12” (306)

1.2” (30)

For anchor bolt) (Long hole pitch

12.6” (320)

B legs

4.3” (108)

19.1” (486)

0.8” (21)

5.8” (147)

2.8” (70)

30.7” (780)

19.7” (500) 2.7” (69)

R0.6” (15)

2-Ø0.3” (6) hole

Prpduct

external line

23.6” (600)

Discharge guard

Ø0.4” (11)×0.6” (14)

U-shape hole

12.6” (320)

1.5” (38)

17.7” (449)2” (51)

0.2” (5)

19.1” (486)1.3” (33)

21.7” (550)

1.3” (32)

0.3” (8)

R0.6” (15)

23.6” (600)

2.1” (54)

2-Ø0.2” (6) hole

Product

external line

Ø0.4” (11)×0.6” (14)

U-shape hole

Details of B legs

Details of A legs

12.6” (320)

2.1” (54)

1.5” (38)

0.4” (11)

– 12 –

RAV-SP240AT2-UL

NoteName

Refrigerant piping

Conduit hole Ø0.9” (22) hole

0.5” (12)

Mounting bolt hole

(Ø0.5” (12)×0.7” (17) U-shape hole)

Details of B legs

1.6” (40)

2.2” (55) 3.7” (95)

Drain hole

(Ø1.0” (25) burring hole)

2.4” (60)7.9” (200)

B legs

35.0” (890)

0.5” (12) 2.5” (64)

1.0"(24)

2.3” (58)

0.7” (18)

2.2” (56)

15.7” (400)

3.9” (99)

Mounting bolt hole

(Ø0.5” (12)×0.7” (17) long hole)

Details of A legs

1.6” (40)

12.6” (320)

1.2” (30) 2

2.0” (50)3.4” (85)

5.1” (130)

0.3” (7)2.6” (65)

10.0” (255)

2.1” (54)

1.9” (48)

1.5” (39)15.1” (383) 2.8” (70)

Refrigerant pipe

connecting port

Ø0.4” (9.5) flare

at liquid side

Refrigerant pipe

connecting port

Ø0.6” (15.9) flare

at gas side

9.7” (247)

Z views

3.3” (83) 0.3” (7)

6.7” (170)

1.3” (34)

A legs

15.0” (380)

port

Air inlet

port

Air inlet

1.8” (46)

5.9” (150)

35.4” (900)

2.0” (52) 21.7” (550)

Knockout for downward piping

7” (178) 7” (178) 7” (178)

12.9” (327)

21.0” (534)

22.9” (581)

(165)

6.5”

2.4” (60)

5.8” (148)

2.7” (68) 20.4” (518)

3.0” (75)

Air outlet

port

23.6” (600) 3.8” (96)

2.9” (74) 4.7” (118) 5.0” (128)

0.7” (17.5) 14.4” (365) 0.7” (17.5)

Mounting hole

sold separately

5-drain hole

Ø0.8” (20)×3.5” (88)

burring hole

(12-Ø0.1” (3) emboss)

– 13 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

NoteName

Mounting bolt hole

Refrigerant piping

Conduit hole Ø0.9” (22) hole

0.5” (12)

(Ø0.5” (12)×0.7” (17) U-shape hole)

Details of B legs

1.6” (40)

12.6” (320)

52.8” (1340)

2.2” (55) 3.7” (95)

0.5” (12) 2.5” (64)

1.0” (24)

2.3” (58)

15.7” (400)

Drain hole

(Ø1.0” (25) burring hole)

2.4” (60)7.9” (200)

15.0” (380)

B legs

port

Air inlet

port

Air inlet

Mounting bolt hole

(Ø0.5” (12)×0.7” (17) long hole)

0.7”(18)

Details of A legs

1.6” (40)

1.2” (30)

2.0” (50)3.4” (85)

5.1” (130)2.2” (56)

3.9” (99)

0.3” (7)2.6” (65)

2.1” (54)

1.9” (48)

1.5” (39)15.1” (383) 2.8” (70)

Refrigerant pipe

connecting port

Ø0.4” (9.5) flare

at liquid side

Refrigerant pipe

connecting port

Ø0.6” (15.9) flare

at gas side

24.1” (613)

23.8” (605)

Z views

6.7” (170)

1.3” (34)

3.3” (83) 0.3” (7)

A legs

(178)

1.8” (46)

3.0” (75)

Air outlet

port

23.6” (600) 3.8” (96)

35.4” (900)

”

(178) 7 ”

(178) 7 ” 7

12.9” (327)

Knockout for downward piping

5.9” (150)

2.9” (74) 4.6” (118) 5.0” (128)

2.0” (52) 21.7” (550)

0.7” (17.5) 14.4” (365) 0.7” (17.5)

2.9” (74)

4.8” (121)

22.9” (581) 22.9” (581)

21.0” (534) 21.0” (534)

25.8” (655)

2.4” (60)

2.7” (68) 20.4” (518)

2.7” (70)

3.3” (85)

14.2” (360)

5-drain hole

Ø0.8” (20)×3.5” (88)

burring hole

– 14 –

Mounting hole

sold separately

(24-Ø0.1” (3) emboss)

3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM

3-1. Indoor Unit

• Single type (Combination of 1 indoor unit and 1 outdoor unit)

Dimension table

Indoor unit

RAV-SP180AT2-UL

Distributor (Strainer incorporated)

TC sensor

Refrigerant pipe at liquid side (Outer dia : ØB)

To outdoor unit

(Indoor unit)

TCJ sensor

Air heat

exchanger

Gas side ØA Liquid side ØB

Strainer

Heating Cooling

Refrigerant pipe at gas side (Outer dia : ØA)

To outdoor unit

Outer diameter of refrigerant pipe

1/2” (12.7) 1/4” (6.4)

RAV-SP240, 300, 360, 420AT2-UL

5/8” (15.9) 3/8” (9.5)

– 15 –

3-2. Outdoor Unit

RAV-SP180AT2-UL

sensor

Accumulator

(1L)

sensor

Rotary compressor

(DA150A1F-21F)

4-way valve

(STF-0213Z)

Muffler

Ø19.05 × 160L

TO sensor

Heat exchanger

Ø8 ripple, 2 rows, 20 stages

FP1.3, flat fin

PMV (Pulse Motor Valve) (CAM-B30YGTF-2)

TE sensor

Distributor

2-step muffler

Ø25 × 200L

Muffler

Ø31.75 × 200L

Strainer

Refrigerant pipe at liquid side Ø6.4 Packed valve

Refrigerant pipe at gas side Ø12.7 Packed valve

In cooling operation In heating operation

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

416.2 145.0 2.87 1.00

517.7 159.5 3.57 1.10

248.0 110.2 1.71 0.76

327.7 98.6 2.26 0.68

471.3 165.3 3.25 1.14

290.0 36.3 2.00 0.25

Pipe surface temperature °F (°C)

Discharge Suction

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

161.6 60.8 55.4 107.6 (72) (16) (13) (42)

190.4 68 66.2 125.6 (88) (20) (19) (52)

113.0 53.6 44.6 55.4 (45) (12) ( 7) (13)

150.8 42.8 98.6 37.4 (66) ( 6) (37) ( 3)

172.4 68.0 127.4 60.8 (78) (20) (53) (16)

172.4 –0.4 93.2 –0.4 (78) (–18) (34) (–18)

Indoor heat Outdoor heat

exchanger exchanger

Compressor

drive revolution

frequency

(rps)

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F °C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68/– 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

– 16 –

RAV-SP240AT2-UL

Muffler

Accumulator

Sub-ass’y

Accumulator

(1.8L)

Rotary compressor

(DA220A2F-22L)

In cooling operation In heating operation

TS sensor

sensor

Muffler

4-way valve

(STF-0218G)

Ø25 × L180

Ø25 × L210

TO sensor TL sensor

Heat exchanger

Ø8, 2 rows, 34 stages

FP1.45, flat fin

Strainer

PMV

(Pulse Motor Valve)

(CAM-B30YGTF-2)

Ø2 × Ø3 × 600L

Ø2 × Ø3 × 550L

Strainer

Ø2 × Ø3 × 450L

TE sensor

Ø2 × Ø3 × 450L

Capillary

Refrigerant pipe at liquid side Ø9.5 Packed valve

Refrigerant pipe at gas side Ø15.9 Ball valve

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

404.6 129.1 2.79 0.89

511.9 155.2 3.53 1.07

248.0 104.4 1.71 0.72

384.3 98.6 2.65 0.68

464.0 161.0 3.2 1.11

337.9 30.5 2.33 0.21

Pipe surface temperature °F (°C)

Discharge Suction Indoor heat Outdoor heat

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

158.0 55.4 51.8 102.2 (70) (13) (11) (39)

177.8 62.6 57.2 118.4 (81) (17) (14) (48)

107.6 44.6 37.4 64.4 (42) ( 7) ( 3) (18)

165.2 39.2 111.2 37.4 (74) ( 4) (44) ( 3)

168.8 66.2 125.6 59 (76) (19) (52) (15)

199.4 –0.4 87.8 –4 (93) (–18) (31) (–20)

exchanger exchanger

Compressor

drive revolution

frequency

(rps)

58.2

65.0

30.0

61.5

28.0

99.6

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F °C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

– 17 –

Muffler

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Accumulator

(2500cc)

TS sensor

Check joint

Cooling: High pressure Heating: Low pressure

TD sensor

Rotary compressor

(DA422A3F-25M)

Muffler

Ø25 × L210

TO sensor

TL sensor

Heat exchanger

Ø8, 2 rows, 52 stages

FP1.45, flat fin

In cooling operation In heating operation

Ø25 × L180

TE sensor

Distributor

Strainer

PMV

Strainer

Capillary Ø4 ×Ø3 (6 pcs.)

Refrigerant pipe at liquid side Ø9.5 Packed valve

Refrigerant pipe at gas side Ø15.9 Ball valve

Cooling: Low pressure Heating: High pressure

RAV-SP300AT2-UL

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

372.7 143.6 2.57 0.99

478.5 158.1 3.30 1.09

252.3 108.8 1.74 0.75

336.4 105.9 2.32 0.73

466.9 169.7 3.22 1.17

314.7 43.5 2.17 0.30

Pipe surface temperature °F (°C)

Discharge Suction

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

150.8 57.2 53.6 111.2 104.0 (66) (14) (12) (44) (38)

172.4 48.2 55.4 120.2 109.4 (78) ( 9) (13) (49) (43)

114.8 44.6 41.0 89.6 77.0 (46) ( 7) ( 5) (32) (25)

149.0 37.4 102.2 35.6 37.4 (65) ( 3) (39) ( 2) ( 3)

163.4 66.2 129.2 57.2 59.0 (73) (19) (54) (14) (15)

188.6 5 100.4 6.8 8.6 (87) (–15) (38) (–14) (–13)

Indoor heat Outdoor heat

exchanger exchanger

Compressor

drive revolution

frequency

(rps)

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F (°C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68/– 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

∗ This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp

meter becomes 2 times of No. of compressor revolutions (rps).

RAV-SP360AT2-UL, RAV-SP420AT2-UL

Standard

Cooling Overload

Low load

Standard

Heating Overload

Low load

Pressure

(psi) (MPa)

Pd Ps Pd Ps

394.4 130.5 2.72 0.90

484.3 155.2 3.34 1.07

253.8 110.2 1.75 0.76

375.6 100.1 2.59 0.69

453.9 152.3 3.13 1.05

348.0 30.45 2.40 0.21

Pipe surface temperature °F (°C)

Discharge Suction

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

163.4 53.6 50 114.8 100.4 (73) (12) (10) (46) (38)

176.0 48.2 55.4 123.8 113.0 (80) ( 9) (13) (51) (45)

116.6 46.4 42.8 91.4 77.0 (47) ( 8) ( 6) (33) (25)

167 37.4 109.4 35.6 35.6 (45) ( 3) (43) ( 2) ( 2)

161.6 60.8 127.4 53.6 55.4 (72) (16) (53) (12) (13)

206.6 –7.6 107.6 –2.2 –0.4 (97) (–22) (42) (–19) (–18)

Indoor heat Outdoor heat

exchanger exchanger

Compressor

drive revolution

frequency

(rps)

Indoor

fan

HIGH

LOW

HIGH

LOW

HIGH

Indoor/Outdoor

temp. conditions

(DB/WB) °F (°C)

Indoor Outdoor

80.6/66.2 95/– (27/19) (35/–)

89.6/75.2 109.4/– (32/24) (43/–)

64.4/59.9 23/–

(18/15.5) (–5/–)

68/– 44.6/42.8

(20/–) (7/6)

86/– 75.2/64.4

(30/–) (24/18)

59/– 5/–

(15/–) (–15/–)

∗ This compressor has 4-pole motor. The value when compressor frequency (Hz) is measured by a clamp

meter becomes 2 times of No. of compressor revolutions (rps).

– 18 –

4-1. Outdoor Unit

RAV-SP180AT2-UL

4. WIRING DIAGRAM

P.C. Board

Compressor

YEL

BRN

YEL

ORN

Reactor

121

212 3 3

P25 P24 P23 P22 P21 P20

P35 P34

P19 P18

P11 P08

RED WHI

BLK

CN605

BLK

P04 P05 P06

RED

DB01

Q404

22113

WHI

BLK

Powe r

relay

DB02

P32 CN701

P31 P30

PUR

22113

SW802

MCC-1530

Sub P.C. Board

CAUTION : HIGH VOLTAGE

The high voltage circuit is incorporated. Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand.

The 4-way valve coil is turned on while the cooling operation

1. indicates the terminal block. Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

Reactor

(MCC-5009)

Q200~205

IGBT

R221

R220

R219

L03 C13

C12

Relay

113

112

Coil for

4-way valve

Q300~305 MOS-FET

R321

R320

R319

C14

Surge

absorber

P7 P03 P10 P02 CN806P33

BLK

Reactor

High voltage

To indoor Power supply

F03

Fuse, T3.15A

AC250V

Varistor

F01

Fuse, T25A

AC250V

ORN

WHI

1 2 3 4 5

BLK

WHI

GRN/YEL

WHI

RED

L2L1L2L1

208/230-1-60

ORN

CN500

CN300

121

232 1 1

BLK

WHI

RED

Fan motor

6 5 4 4

CN700

3 232 1 1

CN603

3 2

motor valve

1 1

(Suction pipe temp. sensor)

CN602

CN601

2 2 1 1

(Outdoor temp. sensor)

3 2 1 1

(Discharge pipe temp. sensor)

CN600

212 1

(Condenser pipe temp. sensor)

For optional

P.C. Board

NOTE

CM : Compressor PMV : Pulse Motor Valve FM : Fan Motor TE : Heat Exchanger Temp. Sensor TD : Discharge Temp. Sensor TO : Outdoor Temp. Sensor TS : Suction Temp. Sensor IGBT : Insulated Gate Bipolar Transistor DB : Rectifier CT : Curreut Transformer 49C : Compressor Case Thermostat HP SW : High pressure switch

49C

1 1

HP SW

1 1

PMV

Pulse

Color

Identification

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY PNK : PINK GRN : GREEN WHI : WHITE BRN : BROWN ORN : ORANGE YEL : YELLOW PUR : PURPLE

– 19 –

RAV-SP240AT2-UL

Reactor Reactor

(GRY) (GRY) (WHI) U(WHI)

(RED) (WHI) (BLK)

V W

HP SW

49C

1 1 2 2

1 1

3 3

1 1 2 2

1 2 3 4 5 6

CN300

(WHI)

CN609

(BLU)

CN690

(RED)

CN610

(YEL)

CN604

(WHI)

CN603

(WHI)

CN602

(YEL)

CN601

(WHI)

P04 P05 P06 P07

SW804 SW801 SW800

2 3 4

Control P.C. Board

SW803

SW802

2 3 4

2 3 41

MCC-1571

RY704

CN201 CN202CN200

L/F

Fuse, F01

T25A, 250V~

(BLK)

P09

Fuse, F03

T10A, 250V~

1 1

CN600

3 3

CN710

(WHI)

1 2 3 4 5 6 1 2 3

1 341 4

CN704

CN701

(WHI)

1 4

CN04 (WHI)

1 7

(BLU)

20SFPMW

(GRY)

Earth

screw

Symbol

CM FM

PMV

TD TS TE

20SF

49C

HP SW

L/F

Compressor Fan Motor Pulse Motor Valve Pipe temp. sensor (Discharge) Pipe temp. sensor (Suction) Heat exchanger sensor 1 Heat exchanger sensor 2 Outside temp. sensor 4-way valve coil Compressor case thermostat High pressure switch Relay Line Filter

Parts name

High voltage

Outdoor unit

Indoor unit

Earth

screw

1. indicates the terminal block. Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

L1L

3 5

(WHI)

(RED)

716

(RED) (WHI)

(BLK)

Earth screw

Power supply 208/230-1-60

Identification

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY WHI : WHITE YEL : YELLOW

P02P01

Color

– 20 –

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

Reactor

(GRY) (GRY) (WHI) U(WHI)

Reactor

(RED) (WHI) (BLK)

V W

FM01

FM02

HP SW

49C

1 1 2 2

1 1

3 3

1 1 2 2

1 2 3 4 5 6

CN400

(WHI)

CN300

(WHI)

CN609

(BLU)

CN690

(RED)

CN610

(YEL)

CN604

(WHI)

CN603

(WHI)

CN602

(YEL)

CN601

(WHI)

P04 P05 P06 P07

SW804 SW801 SW800

2 3 4

Control P.C. Board

SW803

SW802

2 3 4

2 3 41

MCC-1570

RY704

CN201 CN202CN200

L/F

Fuse, F01

T25A, 250V~

(BLK)

P09

Fuse, F03

T10A, 250V~

1 1

CN600

Symbol

FM01, 02

PMV

TD TS TE TL TO

20SF

49C

HP SW

L/F

(WHI)

Parts name

(WHI)

1 2 3 4 5 6 1 2 3

3 3

CN710

CN704

(BLU)

1 341 4

Outdoor unit

Indoor unit

CN701

(WHI)

1 4

20SFPMW

screw

CN04 (WHI)

1 7

(GRY)

Earth

High voltage

Earth

1. indicates the terminal block. Alphanumeric characters in the cycle indicate the terminal No.

2. The two-dot chain line indicates the wiring procured locally.

3. indicates the P.C. board.

4. For the indoor unit circuit, refer to the wiring diagram of the indoor unit.

L1L

3 5

(WHI)

(RED)

716

(RED) (WHI)

(BLK)

Earth screw

Power supply 208/230-1-60

Identification

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY WHI : WHITE YEL : YELLOW

P02P01

Color

– 21 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Outdoor Unit (Parts Ratings)

RAV-SP180AT2-UL

No.

Fan motor

Compressor

Reactor

Outdoor temp. sensor (To sensor)

Heat exchanger sensor (Te sensor)

Suction temp. sensor (Ts sensor)

Discharge temp. sensor (Td sensor)

Fuse (Switching power (Protect))

Fuse (Inverter, input (Current protect))

4-way valve solenoid coil

Compressor thermo. (Protection)

Coil (Pulse Motor Valve)

Pressure switch

Parts name

RAV-SP240AT2-UL

No.

Compressor

Outdoor fan motor

Reactor

4-way valve coil

PMV coil

P.C. board

Fuse (Mounted on P.C. board)

Outdoor temp. sensor (TO sensor)

Heat exchanger sensor (Te sensor)

Discharge temp. sensor (Td sensor)

Heat exchanger Temp sensor (Ts sensor)

Compressor thermo. (Protection)

Pressure switch

Parts name

Type

ICF-140-43-4R

DA150A1F-21F

CH-57

— — — — — —

STF-01AJ502E1

US-622

CAM-MD12TF-12

ACB-4UB82W

Type

DA220A2F-22L

ICF-280-A60-1

CH-56

VHV-01AP552B1

CAM-MD12TF-15

MCC-1571

— — — — — — —

US-622

ACB-4UB82W

Specifications

Output (Rated) 43 W 3 phase, 4P, 1100 W 10mH, 16A 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 50 kΩ at 77°F (25°C) T3.15 A, AC 250 V AC 240 V, 25 A

—

OFF : 257 ± 39.2°F (125 ± 4°C), ON : 194 ± 41°F (90 ± 5°C)

—

OFF : 601.8 + 0

601.8 – 29 psi ⎛4.15 + 0.2 MPa⎞

601.8 – 29 psi ⎝4.15 – 0.2 MPa⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

Specifications

—

Output 60 W

5.8 mH, 18.5 A AC200 – 240 V DC12 V AC208 / 230 V AC250 V, 25 A AC250 V, 10 A AC250 V, 3.15 A 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 50 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C) OFF : 601.8 + 0

601.8 – 29 psi ⎛4.15 + 0.2 MPa⎞

601.8 – 29 psi ⎝4.15 – 0.2 MPa⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

RAV-SP300AT2-UL, RAV-SP360AT2-UL, RAV-SP420AT2-UL

No.

Compressor

Outdoor fan motor

Reactor

4-way valve coil

PMV coil

P.C. board

Fuse (Mounted on P.C. board)

Outdoor temp. sensor (TO sensor)

Heat exchanger sensor (Te sensor)

Discharge temp. sensor (Td sensor)

Heat exchanger mid. Temp sensor (TL sensor)

Compressor thermo. (Protection)

Pressure switch

Parts name

Type

DA422A3F-25M

ICF-280-A100-1

CH-62

VHV-01AP552B1

UKV-A038

MCC-1571

— — — — — — —

US-622

ACB-4UB82W

– 22 –

Specifications

—

Output 100W

5.7mH, 18.5A AC240V DC12V AC208 / 230 V AC250V, 25A AC250V, 10A AC250V, 3.15A 10 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) 50 kΩ at 77°F (25°C) 10 kΩ at 77°F (25°C) OFF : 257 ± 39.2°F (125 ± 4°C),

ON : 194 ± 41°F (90 ± 5°C) OFF : 601.8 + 0

601.8 – 29 psi ⎛4.15 + 0.2 MPa⎞

601.8 – 29 psi ⎝4.15 – 0.2 MPa⎠

ON : 464 ± 26 psi (3.2 ± 0.2 MPa)

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 repair 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 0.0001 lbs / 32’ 10” (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 0.03” (0.8 mm) even when it is available on the market.

– 23 –

Table 6-2-1 Thicknesses of annealed copper pipes

Thickness (In (mm))

Outer diameter (In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

1. 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 6-2-5 below.

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 0.79” (20 mm). Thicknesses of socket joints are as shown in Table 6-2-2.

Table 6-2-2 Minimum thicknesses of socket joints

R410A R22

0.03” (0.80) 0.03” (0.80)

0.04” (1.00) 0.04” (1.00)

Reference outer diameter of copper pipe jointed

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Minimum joint thickness

(In (mm))

0.02” (0.50)

0.02” (0.60)

0.03” (0.70)

0.03” (0.80)

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.

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.

– 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.

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.

Table 6-2-3 Dimensions related to flare processing for R410A / R22

Outer diameter

(In (mm))

Thickness

(In (mm))

Flare tool for

R410A, R22clutch type

ØD

Fig. 6-2-1 Flare processing dimensions

A (In (mm))

Conventional flare tool (R410A)

Clutch type Wing nut type

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

0.03” (0.8)

0.04” (1.0)

0 – 0.02” (0 – 0.5)

0.04” – 0.06” (1.0 – 1.5) 0.06” – 0.08” (1.5 – 2.0)

0.04” – 0.06” (1.0 – 1.5) 0.08” – 0.10” (2.0 – 2.5)

Table 6-2-4 Flare and flare nut dimensions for R410A

Thickness

(In (mm))

0.03” (0.8)

0.04” (1.0)

ABCD

0.36” (9.1) 0.36” (9.2) 0.26” (6.5) 0.51” (13)

0.52” (13.2) 0.53” (13.5) 0.38” (9.7) 0.79” (20)

0.65” (16.6) 0.63” (16.0) 0.51” (12.9) 0.91” (23)

0.78” (19.7) 0.75” (19.0) 0.63” (16.0) 0.98” (25)

Dimension (In (mm))

Flare nut width

(In (mm))

0.67” (17)

0.87” (22)

1.02” (26)

1.14” (29)

Outer diameter

(In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

3/4” (19.0)

Table 6-2-5 Flare and flare nut dimensions for R22

Thickness

(In (mm))

0.03” (0.8)

0.04” (1.0)

Dimension (In (mm))

ABCD

0.36” (9.1) 0.36” (9.2) 0.26” (6.5) 0.51” (13)

0.51” (13.0) 0.53” (13.5) 0.38” (9.7) 0.79” (20)

0.64” (16.2) 0.63” (16.0) 0.51” (12.9) 0.79” (20)

0.76” (19.4) 0.75” (19.0) 0.63” (16.0) 0.91” (23)

0.92” (23.3) 0.94” (24.0) 0.76” (19.2) 1.34” (34)

– 25 –

Flare nut width

(In (mm))

0.67” (17)

0.87” (22)

0.94” (24)

1.06” (27)

1.42” (36)

45˚to 46˚

B A

43˚to 45˚

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.

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 6-2-6 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.

Table 6-2-6 Tightening torque of flare for R410A [Reference values]

Outer diameter (In (mm))

1/4” (6.4)

3/8” (9.5)

1/2” (12.7)

5/8” (15.9)

Tightening torque (ft • lbs (N • m))

10 – 13 (14 – 18)

24 – 31 (33 – 42)

37 – 46 (50 – 62)

50 – 60 (68 – 82)

– 26 –

6-3. Tools

6-3-1. Required Tools

Refer to the “4. Tools” (Page 8)

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 –101 kpa (–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.

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.)

1) Never charge refrigerant exceeding the specified amount.

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

3) Do not carry out additional charging.

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)

(Liquid side)

(OUTDOOR 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

Opened

(Gas side)

Closed

Service port

– 27 –

1) Be sure to make setting so that liquid can be charged.

2) 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 ]

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Gauge manifold

OUTDOOR unit

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.

Fig. 6-4-2

Electronic

balance

Siphon

1) Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2) When performing brazing again at time of servicing, use the same type of brazing filler.

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.

6-5-2. Flux

1. Reason why flux is necessary

• By removing the oxide film and any foreign

matter on the metal surface, it assists the flow of brazing filler.

• In the brazing process, it prevents the metal

surface from being oxidized.

• By reducing the brazing filler's surface tension,

the brazing filler adheres better to the treated metal.

– 28 –

2. Characteristics required for flux

• Activated temperature of flux coincides with the brazing temperature.

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

• It is easy to remove slag after brazing.

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

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

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

3. Types of flux

• Noncorrosive flux

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

It is effective in case where the brazing temperature is higher than 1,472°F (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 brazing 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 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.

3) Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

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 2.9 psi (0.02 MPa) 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).

7) Remove the flux completely after brazing.

Piping

material

Copper - Copper

Copper - Iron

Iron - Iron

1) Do not enter flux into the refrigeration cycle.

2) When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates.

Therefore, use a flux which does not contain chlorine.

3) When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

4) Remove the flux after brazing.

Used brazing

filler

Phosphor copper

Silver

Used

flux

Do not use

Paste flux

Vapor flux

Flow meter

Stop valve

Nitrogen gas

cylinder

From Nitrogen cylinder

Pipe

Nitrogen gas

Rubber plug

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

– 29 –

DB01:

Single-phase rectifier diode

F03: 3.15A fuse

C12, 13, 14

electrolytic capacitor

12V

GND

IC800: MCU

7. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS

7-1. Print Circuit Board

<MCC-5009>

RAV-SP180AT2-UL

DB01:

Single-phase rectifier diode

DB01:

Single-phase rectifier diode

F03: 3.15A fuse

Comp. lead

(Red) (White) (Black)

Comp. drive circuit

Q200 to Q205: IGBT (QTY: 6P)

IC200: Drive IC (QTY: 1P)

DB02:

High power factor diode

Q404:

High power factor circuit IGBT

GND

12V

C12, 13, 14

electrolytic capacitor

C12, 13, 14

electrolytic capacitor

(Black)

12V

IC800: MCU

Fan drive circuit

Q300 to Q305: FET (QTY: 6P)

CN605:

Sub SW board connector

CN500:

Case thermo. or

High pressure SW

F01, 02, 25A fuse Lead wire for grounding

L-phase power supply lead

(Black)

N-phase power supply lead

(White)

Serial lead (Orange)

Reactor lead connector

(White)

CN300:

CN701:

4-way valve connector

RY701:

Fan motor connector

4-way valve relay

– 30 –

CN602:

Outdoor temperature

(TO) sensor connector

CN806:

Optional connector

CN600:

Heat exchange temperature

(TE) sensor connector

CN603:

Suction temperature

(TS) sensor connector

CN601:

Discharge temperature

(TD) sensor connector

CN700:

PMV connector

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