Page 1: Indoor Unit
Revised : Nov. 2006 SERVICE MANUAL/INTEGRATION AIR-CONDITIONER SPLIT TYPE INDOOR UNIT <DIGITAL INVERTER> RAV-SM562UT-E RAV-SM562BT-E RAV-SM562CT-E RAV-SM802UT-E RAV-SM802BT-E RAV-SM802CT-E RAV-SM1102UT-E RAV-SM1102BT-E RAV-SM1102CT-E RAV-SM1402UT-E RAV-SM1402BT-E RAV-SM1402CT-E <SUPER DIGITAL INVERTER> RAV-SP1102UT-E • Service Manual for RAV-SM[[[KRT and RAV-SM[[[XT contact the Sales company or Dealer.
Page 2: Table Of Contents
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.
Page 3 7. REFRIGERANT R410A ................51 7-1. Safety During Installation/Servicing ............... 51 7-2. Refrigerant Piping Installation ............... 51 7-3. Tools ........................55 7-4. Recharging of Refrigerant................55 7-5. Brazing of Pipes....................56 8. CONTROL BLOCK DIAGRAM ..............58 8-1. Indoor Control Circuit ..................58 8-2.
Page 4: Safety Caution
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 Explanation...
Page 5 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. Check earth wires.
Page 6 WARNING After the work has finished, be sure to use an insulation tester set (500V mugger) to check the resistance is 2MΩ Ω Ω Ω Ω 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 Insulator check side.
Page 7: Safety Caution Concerned To New Refrigerant
• 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.
Page 8 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.
Page 9: Specifications
1. SPECIFICATIONS 1-1. Indoor Unit 1-1-1. 4-Way Air Discharge Cassette Type <Digital Inverter> Indoor unit RAV- SM562UT-E SM802UT-E SM1102UT-E SM1402UT-E Model Outdoor unit RAV- SM562AT-E SM802AT-E SM1102AT-E SM1402AT-E Cooling capacity (kW) 10.0 12.3 Heating capacity (kW) 11.2 14.0 Power supply 1 phase 230V (220 –...
Page 10 <Super Digital Inverter> Indoor unit RAV- SM562UT-E SM802UT-E SM1102UT-E SM1402UT-E Model Outdoor unit RAV- SP562AT-E SP802AT-E SP1102AT-E SP1402AT-E Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current 7.17 – 6.57 8.95 –...
Page 11: Concealed Duct Type
1-1-2. Concealed Duct Type <Digital Inverter> Indoor unit RAV- SM562BT-E SM802BT-E SM1102BT-E SM1402BT-E Model Outdoor unit RAV- SM562AT-E SM802AT-E SM1102AT-E SM1402AT-E Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current 8.99 –...
Page 12 <Super Digital Inverter> Indoor unit RAV- SM562BT-E SM802BT-E SM1102BT-E SM1402BT-E Model Outdoor unit RAV- SP562AT-E SP802AT-E SP1102AT-E SP1402AT-E Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current 6.51 – 5.97 9.74 –...
Page 13: Under Ceiling Type
1-1-3. Under Ceiling Type <Digital Inverter> Indoor unit RAV- SM562CT-E SM802CT-E SM1102CT-E SM1402CT-E Model Outdoor unit RAV- SM562AT-E SM802AT-E SM1102AT-E SM1402AT-E Cooling capacity (kW) 10.0 12.3 Heating capacity (kW) 11.2 14.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current 8.71 –...
Page 14 <Super Digital Inverter> Indoor unit RAV- SM562CT-E SM802CT-E SM1102CT-E SM1402CT-E Model Outdoor unit RAV- SP562AT-E SP802AT-E SP1102AT-E SP1402AT-E Cooling capacity (kW) 10.0 12.5 Heating capacity (kW) 11.2 14.0 Power supply 1 phase 230V (220 – 240V) 50Hz Running current 6.61 – 6.06 9.47 –...
Page 15 1-1-4. Twin Type <Digital Inverter> Type 4-Way Air Cassette Concealed Duct Under Ceiling Indoor unit 1 RAV- SM562UT-E SM802UT-E SM562BT-E SM802BT-E SM562CT-E SM802CT-E Model Indoor unit 2 RAV- SM562UT-E SM802UT-E SM562BT-E SM802BT-E SM562CT-E SM802CT-E Outdoor unit RAV- SM1102AT-E SM1402AT-E SM1102AT-E SM1402AT-E SM1102AT-E SM1402AT-E Cooling capacity (kW) 10.0...
Page 16 <Super Digital Inverter> Type 4-Way Air Cassette Concealed Duct Under Ceiling Indoor unit 1 RAV- SM562UT-E SM802UT-E SM562BT-E SM802BT-E SM562CT-E SM802CT-E Model Indoor unit 2 RAV- SM562UT-E SM802UT-E SM562BT-E SM802BT-E SM562CT-E SM802CT-E Outdoor unit RAV- SP1102AT-E SP1402AT-E SP1102AT-E SP1402AT-E SP1102AT-E SP1402AT-E Cooling capacity (kW) 10.0...
Page 17: Outdoor Unit
1-2. Outdoor Unit <Digital Inverter> Model name RAV- SM562AT-E SM802AT-E SM1102AT-E SM1402AT-E 1 phase 230V (220 – 240V) Power supply 50Hz (Power exclusive to outdoor is required.) Type Hermetic compressor Compressor Motor (kW) Pole Refrigerant charged (kg) Refrigerant control Pulse motor valve Standard length Min.
Page 18 <Super Digital Inverter> Model name RAV- SP562AT-E SP802AT-E SP1102AT-E SP1402AT-E 1 phase 230V (220 – 240V) Power supply 50Hz (Power exclusive to outdoor is required.) Type Hermetic compressor Compressor Motor (kW) 3.75 3.75 Pole Refrigerant charged (kg) 2.95 2.95 Refrigerant control Pulse motor valve Standard length Min.
Page 19: Operation Characteristic Curve
1-3. Operation Characteristic Curve • Operation characteristic curve <Digital Inverter> RAV-SM562AT-E, RAV-SM802AT-E <Cooling> <Heating> RAV-SM802AT-E RAV-SM802AT-E RAV-SM802AT-E RAV-SM802AT-E RAV-SM562AT-E RAV-SM562AT-E RAV-SM562AT-E RAV-SM562AT-E • Conditions • Conditions Indoor : DB27˚C/WB19˚C Indoor : DB20˚C Outdoor : DB35˚C Outdoor : DB7˚C/WB6˚C Air flow : High Air flow : High Pipe length : 7.5m Pipe length : 7.5m...
Page 20 • Operation characteristic curve <Super Digital Inverter> RAV-SP562AT-E, RAV-SP802AT-E <Cooling> <Heating> RAV-SP802AT-E RAV-SP802AT-E RAV-SP802AT-E RAV-SP802AT-E RAV-SP562AT-E RAV-SP562AT-E RAV-SP562AT-E RAV-SP562AT-E • Conditions • Conditions Indoor : DB27˚C/WB19˚C Indoor : DB20˚C Outdoor : DB35˚C Outdoor : DB7˚C/WB6˚C Air flow : High Air flow : High Pipe length : 7.5m Pipe length : 7.5m 230V...
Page 21 • Capacity variation ratio according to temperature RAV-SM562AT-E, RAV-SM802AT-E, RAV-SM1102AT-E, RAV-SM1402AT-E RAV-SP562AT-E, RAV-SP802AT-E, RAV-SP1102AT-E, RAV-SP1402AT-E <Cooling> <Heating> • Conditions • Conditions Indoor : DB20˚C Indoor : DB27˚C/WB19˚C Indoor air flow : High Indoor air flow : High Pipe length : 7.5m Pipe length : 7.5m 32 33 34 35 36 37 38 39 40 41 42 43 -14 -12 -10 -8 -6 -4 -2 0...
Page 22: Air Ducting Work
2. AIR DUCTING WORK 2-1. Static Pressure Characteristics of Each Model RAV-SM562BT-E, RAV-SM802BT-E, RAV-SM1102BT-E, RAV-SM1402BT-E Fig. 1 RAV-SM562BT-E (Round duct) Fig. 3 RAV-SM802BT-E (Round duct) Standard air volume 780m³/h Standard air volume 1140m³/h 1000 1140 1200 1300 Air volume m³/h Air volume m³/h Fig.
Page 23 Fig. 5 RAV-SM1102BT-E (Round duct) Fig. 7 RAV-SM1402BT-E (Round duct) Standard air volume 1620m³/h Standard air volume 1980m³/h 1620 1980 1200 2000 1200 1800 2200 2400 Air volume m³/h Air volume m³/h Fig. 6 RAV-SM1102BT-E (Square duct) Fig. 8 RAV-SM1402BT-E (Square duct) Standard air volume 1620m³/h Standard air volume 1980m³/h 1200...
Page 24: Construction Views (External Views)
3. CONSTRUCTION VIEWS (EXTERNAL VIEWS) 3-1. Indoor Unit 3-1-1. 4-Way Air Discharge Cassette Type RAV-SM562UT-E, RAV-SM802UT-E 860 to 910 Recommended external size Check port ¨ 450) Check port ¨ 450) Standing 850 or less Surface Standing under ceiling Cable draw-in port...
Page 25 RAV-SM1102UT-E, RAV-SM1402UT-E, RAV-SP1102UT-E 860 to 910 Recommended external size Check port ¨ 450) Check port ¨ SM1102UT Ø12.7 Ø15.9 450) SM1402UT Ø12.7 Ø15.9 SP1102UT Ø9.5 Ø15.9 Standing 850 or less Standing 640 or less Ceiling bottom surface Take-in port of pipes Surface under ceiling Drain pipe...
Page 26 3-1-2. Concealed Duct Type RAV-SM562BT-E, RAV-SM802BT-E, RAV-SM1102BT-E, RAV-SM1402BT-E Refrigerant pipe connecting port Drain pipe connecting port (Gas side ØF) for vinyl chloride pipe (Inner dia. 32, VP. 25) Hanging bolt 4-M10 screw Discharge port flange (Arranged locally) N-Ø200 Main unit dimension 800 Hanging bolt pitch B Hanging bolt pitch 700 59 Main unit dimension A...
Page 27 3-1-3. Under Ceiling Type RAV-SM562CT-E, RAV-SM802CT-E, RAV-SM1102CT-E, RAV-SM1402CT-E Upper pipe draw-out port (Knockout hole) Power supply cable take-in port (Knockout) Pipe draw-out port (Knockout hole) Remote controller cable take- in port Drain port VP20 (Knockout hole) (Inner dia. Ø26, hose attached) Refrigerant pipe Left drain size (Liquid side ØC)
Page 28: Outdoor Unit
3-2. Outdoor Unit RAV-SM562AT-E, RAV-SM802AT-E Drain hole Drain hole (Ø25) (2-Ø20 × 88 long hole) 2-Ø11-14 U-shape hole A legs (For Ø8-Ø10 anchor bolts) Connecting pipe port Gas flare side RAV-SM562AT-E: Ø12.7 RAV-SM802AT-E: Ø15.9 Connecting pipe port Liquid flare side RAV-SM562AT-E: Ø6.4 RAV-SM802AT-E: Ø9.5 8-Ø6 hole...
Page 29 RAV-SM1102AT-E, RAV-SM1402AT-E / RAV-SP562AT-E, RAV-SP802AT-E Knockout (For draining) Drain hole (Ø20 × 88 Burring hole) Drain hole (Ø25 Burring hole) Installation bolt hole (Ø12 × 17 U-shape holes) Suction Part B port Suction Details of B part Knockout port (For draining) Details of A part Discharge port...
Page 30 RAV-SP1102AT-E, RAV-SP1402AT-E Knockout (Drain) Drain hole (Ø20 x 88) Suction Drain hole (Ø25) port B legs A legs Suction Knockout (Drain) port Discharge port Refrigerant pipe connecting port (Ø9.5 flare at liquid side) Refrigerant pipe connecting port (Ø15.9 flare at gas side) Discharge guide mounting port (8-Ø3 embossing)
Page 31: Systematic Refrigerating Cycle Diagram
Revised : Nov. 2006 4. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM 4-1. Indoor Unit/Outdoor Unit RAV-SM562UT-E, RAV-SM562BT-E, RAV-SM562CT-E / RAV-SM562AT-E Indoor unit sensor Air heat exchanger TC sensor Outer diameter of refrigerant pipe Gas side ØA Liquid side ØB 12.7mm 6.4mm Refrigerant pipe...
Page 32 Revised : Nov. 2006 RAV-SM802UT-E, RAV-SM802BT-E, RAV-SM802CT-E / RAV-SM802AT-E Indoor unit sensor Air heat exchanger TC sensor Outer diameter of refrigerant pipe Gas side ØA Liquid side ØB 15.9mm 9.5mm Refrigerant pipe Refrigerant pipe at gas side at liquid side Ø15.9 Ø9.5 Packet valve...
Page 33 RAV-SM1102UT-E, RAV-SM1102BT-E, RAV-SM1102CT-E / RAV-SM1102AT-E Indoor unit Distributor TCJ sensor (Strainer incorporated) Outer diameter of refrigerant pipe Strainer Gas side ØA Liquid side ØB Air heat exchanger 15.9mm 9.5mm TC sensor Refrigerant pipe Refrigerant pipe at gas side at liquid side Ø15.9 Ø9.5 Packet valve...
Page 34 RAV-SM1402UT-E, RAV-SM1402BT-E, RAV-SM1402CT-E / RAV-SM1402AT-E Indoor unit Distributor TCJ sensor (Strainer incorporated) Outer diameter of refrigerant pipe Strainer Gas side A Liquid side B Air heat exchanger 15.9mm 9.5mm TC sensor Refrigerant pipe Refrigerant pipe at gas side at liquid side 15.9 Packet valve Packet valve...
Page 35 Revised : Nov. 2006 RAV-SM562UT-E, RAV-SM562BT-E, RAV-SM562CT-E / RAV-SP562AT-E Indoor unit sensor Air heat exchanger TC sensor Outer diameter of refrigerant pipe * The refrigerating cycle of the indoor units differs according to Gas side ØA Liquid side ØB the models to be combined. For the refrigerating cycles of the other indoor units, refer to the corresponding Service Manuals 12.7mm...
Page 36 Revised : Nov. 2006 RAV-SM802UT-E, RAV-SM802BT-E, RAV-SM802CT-E / RAV-SP802AT-E Indoor unit sensor Air heat exchanger TC sensor Outer diameter of refrigerant pipe * The refrigerating cycle of the indoor units differs according to Gas side ØA Liquid side ØB the models to be combined. For the refrigerating cycles of the other indoor units, refer to the corresponding Service Manuals 15.9mm 9.5mm...
Page 37 RAV-SM1102UT-E, RAV-SM1102BT-E, RAV-SM1102CT-E / RAV-SP1102AT-E Indoor unit Distributor TCJ sensor (Strainer incorporated) Strainer Air heat exchanger TC sensor * The refrigerating cycle of the indoor units differs according to Outer diameter of refrigerant pipe the models to be combined. For the refrigerating cycles of the Gas side ØA Liquid side ØB other indoor units, refer to the corresponding Service Manuals...
Page 38 RAV-SM1402UT-E, RAV-SM1402BT-E, RAV-SM1402CT-E / RAV-SP1402AT-E Indoor unit Distributor TCJ sensor (Strainer incorporated) Strainer Air heat exchanger TC sensor * The refrigerating cycle of the indoor units differs according to Outer diameter of refrigerant pipe the models to be combined. For the refrigerating cycles of the Gas side ØA Liquid side ØB other indoor units, refer to the corresponding Service Manuals...
Page 39: Wiring Diagram
5. WIRING DIAGRAM 5-1. Indoor Unit 5-1-1. 4-Way Air Discharge Cassette Type RAV-SM562UT-E, RAV-SM802UT-E, RAV-SM1102UT-E, RAV-SM1402UT-E, RAV-SP1102UT-E Connection interface (option) (EXCT) 1 2 3 CN50 CN51 CN34 (WHI) (RED) CN104 CN102 CN101 CN80 CN73 CN70 (RED) (YEL) (RED) (BLK) (GRN)
Page 40 5-1-2. Concealed Duct Type RAV-SM562BT-E, RAV-SM802BT-E, RAV-SM1102BT-E, RAV-SM1402BT-E (EXCT) Connection interface (option) 1 2 3 CN50 CN51 CN104 CN102 CN101 CN80 CN73 CN70 (WHI) (RED) (YEL) (RED) (BLK) (GRN) (RED) (WHI) CN34 MCC-1402 P.C. (RED) Board Control P.C. Board for CN40 Indoor Unit (BLU)
Page 41 5-1-3. Under Ceiling Type RAV-SM562CT-E, RAV-SM802CT-E, RAV-SM1102CT-E, RAV-SM1402CT-E (EXCT) Connection interface (option) 1 2 3 CN50 CN51 CN104 CN102 CN101 CN80 CN73 CN70 (WHI) (RED) (YEL) (RED) (BLK) (GRN) (RED) (WHI) CN34 MCC-1402 P.C. (RED) Board Control P.C. Board for CN40 Indoor Unit (BLU)
Page 42: Outdoor Unit (Wiring Diagram)
Compressor CN300 Q200~205 Q300~305 P .C. Board IGBT MOS-FET (MCC-5009) R221 R321 Fan motor R220 R320 CN700 R219 R319 Pulse motor valve CAUTION : HIGH VOLTAGE Fuse Varistor T3.15A The high voltage circuit is AC250V incorporated. DB01 CN603 Be careful to do the check service, as the electric shock may be Surge (Suction pipe...
Page 43 Reactor Reactor Color Identification BLACK WHITE BLUE BROWN ORANGE GRAY YELLOW PINK PURPLE F01 Fuse RY01 CN01 T25A, 250V~ CN09 RED Fuse CN02 T25A, 250V~ CN10 WHI P .C. board CN11 BLK Power factor (MCC-1438) W V U control CN03 CN13 CN05 CN06...
Page 44 Reactor Reactor Color Identification BLACK WHITE BLUE BROWN ORANGE GRAY YELLOW PINK PURPLE F01 Fuse RY01 CN01 T25A, 250V~ CN20 RED Fuse CN02 T25A, 250V~ CN21 WHI P .C. board CN22 BLK Power factor (MCC-1438) W V U control CN03 CN13 CN05 CN06...
Page 45 Reactor Reactor Color Identification BLACK WHITE BLUE BROWN ORANGE GRAY YELLOW PINK PURPLE F01 Fuse RY01 CN01 T25A, 250V~ CN09 RED Fuse CN02 T25A, 250V~ CN10 WHI P .C. board CN11 BLK Power factor (MCC-1438) W V U control CN03 CN13 CN05 CN06...
Page 46: Specifications Of Electrical Parts
6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit 6-1-1. 4-Way Air Discharge Cassette Type RAV-SM562UT-E, RAV-SM802UT-E Parts name Type Specifications Fan motor (for indoor) SWF-230-60-1 Output (Rated) 60 W, 220–240 V Thermo. sensor (TA-sensor) 155 mm 10 kΩ at 25°C Heat exchanger sensor (TCJ-sensor) Ø6 mm, 1200 mm...
Page 47 6-1-2. Concealed Duct Type RAV-SM562BT-E, RAV-SM802BT-E, RAV-SM1102BT-E, RAV-SM1402BT-E Parts name Type Specifications Fan motor (SM802BT-E) ICF-280-120-1 Output (Rated) 120 W, 220–240 V Fan motor ICF-280-120-2 Output (Rated) 120 W, 220–240 V (SM562BT-E/SM1102BT-E/SM1402BT-E) Thermo. sensor (TA-sensor) 618 mm 10 kΩ at 25°C Heat exchanger sensor (TCJ-sensor) Ø6 mm, 1200 mm 10 kΩ...
Page 48: Outdoor Unit
6-2. Outdoor Unit RAV-SM562AT-E Parts name Type Specifications Fan motor ICF-140-43 Output (Rated) 43 W Compressor DA150A1F-20F 3 phase, 4P, 1100 W Reactor CH-57 10 mH, 16A Outdoor temp. sensor (To-sensor) — 10 kΩ at 25°C Heat exchanger sensor (Te-sensor) —...
Page 49 RAV-SM1402AT-E Parts name Type Specifications Fan motor ICF-280-100-1R Output (Rated) 100 W Compressor DA420A3F-21M 3 phase, 4P , 3500 W Reactor CH-62 6 mH, 18.5 A Outdoor temp. sensor (To-sensor) — 10 kΩ at 25°C Heat exchanger sensor (Te-sensor) — 10 kΩ...
Page 50: Accessory Separate Soldparts
RAV-SM562CT-E, RAV-SM802CT-E, RAV-SM1102CT-E, RAV-SM1402CT-E Parts name Type Specifications Float switch FS-0218-106 Drain pump motor ADP-1406 or ADP-1415 RBC-U21PG (W) E2 (Ceiling panel) RAV-SM562UT-E, RAV-SM802UT-E, RAV-SM1102UT-E, RAV-SM1402UT-E, RAV-SP1102UT-E Parts name Type Specifications Motor-louver MP24GA DC 12 V TCB-DP11E2 (Drain up pump)
Page 51: Refrigerant R410A
7. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC 6. When an air conditioning system charged with a (R410A) which does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, The working pressure of the new refrigerant R410A even when refrigerant leaks, its concentration is 1.6 times higher than conventional refrigerant...
Page 52 Table 7-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A 0.80 0.80 0.80 0.80 12.7 0.80 0.80 15.9 1.00 1.00 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.
Page 53 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. ØD Flare processing dimensions differ according to the type of flare tool.
Page 54 Table 7-2-6 Flare and flare nut dimensions for R22 Dimension (mm) Nominal Outer diameter Thickness Flare nut width diameter (mm) (mm) (mm) 13.0 13.5 12.7 16.2 16.0 12.9 15.9 19.4 19.0 16.0 19.0 23.3 24.0 19.2 Fig. 7-2-2 Relations between flare nut and flare seal surface 2.
Page 55: Tools
7-3. Tools 7-3-1. Required Tools Refer to the “4. Tools” (Page 8) 7-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment.
Page 56: Brazing Of Pipes
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.
Page 57 2. Characteristics required for flux 7-5-3. Brazing • Activated temperature of flux coincides with the As brazing work requires sophisticated techniques, brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is hard to carbonize.
Page 58: Control Block Diagram
8. CONTROL BLOCK DIAGRAM 8-1. Indoor Control Circuit Main (Sub) master remote controller Weekly timer *1 Connection Interface is attached to master unit. Display Function setup Function setup (In case of group control operation) driver *2 Weekly timer is not connectable to Display Display the sub remote controller.
Page 59: Control Specifications
8-2. Control Specifications Item Outline of specifications Remarks When power 1) Distinction of outdoor units supply is reset When the power supply is reset, the outdoors are distinguished, and control is exchanged according to the distinguished result. 2) Setting of speed of the indoor fan/setting whether to adjust air direction or not.
Page 60 Item Outline of specifications Remarks Room 1) Adjustment range Remote controller setup tem- temperature perature (°C) control COOL/ Heating Auto operation operation Wired type 18 to 29 18 to 29 18 to 29 Wireless type 18 to 30 16 to 30 17 to 27 : Only for 4-way air discharge cassette type and Under ceiling type...
Page 61 Item Outline of specifications Remarks <HEAT> Air speed Ta (˚C) selection (Continued) L(L) (-0.5) –1.0 L(H) H(H) (+0.5) +1.0 (HH) (+1.0) +2.0 (+1.5) +3.0 (HH) (+2.0) +4.0 Value in the parentheses indicates one when thermostat of the remote controller works. Value without parentheses indicates one when thermostat of the body works.
Page 62 Item Outline of specifications Remarks <HEAT> Air speed selection (Continued) Ta (˚C) L(L) (-0.5) –1.0 L(H) H(H) (+0.5) +1.0 (HH) (+1.0) +2.0 (+1.5) +3.0 (HH) (+2.0) +4.0 Value in the parentheses indicates one when thermostat of the remote controller works. Value without parentheses indicates one when thermostat of the body works.
Page 63 Item Outline of specifications Remarks Freeze 1) The cooling operation (including Dry operation) is Tcj : Indoor heat ex- preventive performed as follows based on the detected tempera- changer sensor control ture of Tc sensor or Tcj sensor. temperature (Low When [J] zone is detected for 6 minutes (Following temperature figure), the commanded frequency is decreased from...
Page 64 Item Outline of specifications Remarks Drain pump control 1) In cooling operation (including Dry operation), the drain pump is usually operated. 2) If the float switch operates while drain pump operates, the compressor stops, the drain pump continues the operation, and a check code is output.
Page 65 Item Outline of specifications Remarks <In case of wired remote controller> Frequency fixed operation 1. When pushing [CHECK] button for 4 seconds or more, (Test run) [TEST] is displayed on the display screen and the mode enters in Test run mode. 2.
Page 66 Item Outline of specifications Remarks Central control 1) Setting at the central controller side enables to select mode selection the contents which can be operated on the remote controller at indoor unit side. 2) RBC-AMT31 [Last push priority] : (No display) The operation contents can be selected from both remote controller and central controller of the indoor unit side, and the operation is performed with the...
Page 67 Revised : Nov. 2006 Item Outline of specifications Remarks Max. frequency 1) This control is operated by selecting [AUTO] operation cut control mode. 2) COOL operation mode: the frequency is controlled according to the following figure if To < 28°C. Ta(˚C) Normal control Max.
Page 68: Indoor Print Circuit Board
Microcomputer operation LED Filter/Option error input EEPROM Connection interface DC fan output Indoor/Outdoor inter-unit cable Optional power supply Remote controller power supply LED DC fan return Drain pump output Float SW Fan output TCJ sensor EXCT HA (T10) TA sensor Remote controller inter-unit cable Used for DISP...
Page 69: Circuit Configuration And Control Specifications
Revised : Nov. 2006 9. CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 9-1. Indoor Control Circuit 9-1-1. Outline of Main Controls (This content is same 9-2-2. of Outdoor Content) RAV-SM562AT-E, RAV-SM802AT-E, RAV-SM1102AT-E, RAV-SM1402AT-E 1. Pulse Motor Valve (P.M.V.) control 1) PMV is controlled with 50 to 500 pulses during operation, respectively. 2) In cooling operation, P .M.V.
Page 70: Outdoor Controls
9-1-2. Indoor P.C. Board Optional Connector Specifications Connector Function Specifications Remarks Option output CN60 DC12V (COM) Defrost output ON during defrost operation of outdoor unit Thermo. ON output ON during Real thermo-ON (Comp ON) Cooling output ON when operation mode is in cooling system (COOL, DRY, COOL in AUTO cooling/heating) Heating output ON when operation mode is in heating system...
Page 71 F01, 02, 25A fuse P.C. board earth lead DB02: (Black) High power factor diode Q404: High power factor circuit IGBT C12, 13, 14 C12, 13, 14 electrolytic capacitor electrolytic capacitor F03: 3.15A fuse F03: 3.15A fuse DB01: DB01: Single-phase rectifier diode Single-phase rectifier diode L-phase power supply lead (Black)
Page 72 Model selection jumpers Refrigerant recovery Switch (Available only service P.C. board) SW802 J800 to J803 Dip switch Case thermo. switch Communication signal SW801 P.M.V. CN702 CN500 (To MCC-1438) EEPROM-IC CN800 IC801 TD sensor CN600 Serial signal TO sensor (To terminal block) CN601 CN02 TE sensor...
Page 73 Model selection jumpers Refrigerant recovery Switch (Available only service P.C. board) SW802 J800 to J803 EEPROM-IC Dip switch for service Case thermo. switch Communication signal IC801 SW801 P.M.V. CN702 CN500 (To MCC-1438) CN800 TD sensor CN600 Serial signal (To terminal block) TO sensor CN02 CN601...
Page 74 Reactor connector DC15V output Communication signal AC output (To MCC-1531) (To MCC-1531) (To MCC-1531) CN05 CN06 CN13 IGBT TH sensor (Compressor drive device) CN600 Earth ground CN03 DC320V output (To MCC-1531) CN04 Compressor output CN09, CN10, CN11 Mains (Neutral) input CN02 Mains (Live) input CN01...
Page 75 9-2-2. Outline of Main Controls 1. Pulse Modulating V alve (PMV ) control 1) For PMV with 50 to 500 pulses during operation, respectively. 2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor.
Page 76 4. Outdoor fan control Allocations of fan tap revolutions [rpm] SM562 SM802 SM1102 SM1402 1) Cooling fan control The outdoor fan is controlled by TE, TD, and TO sensors and also revolution frequency of the opera- tion. The outdoor is controlled by every 1 tap of DC fan control (15 taps). Only during 60 seconds after the operation has started, the fan is fixed with the maximum fan tap which corresponds to the zone in the following table.
Page 77 2) Heating fan control The outdoor fan is controlled by TE sensor, TO sensor and the operation frequency. (From Min. W1 to Max. are controlled according to the following table.) During 3 minutes after start-up, the fan is fixed with the maximum fan tap corresponding to TE [˚C] zone in the following table.
Page 78 6. Defrost control In heating operation, defrost operation is performed when TE sensor temperature satisfies any condition in A zone to D zone. The defrost operation is immediately finished if TE sensor temperature has become 12°C or more, or it also is finished when condition of 7°C <...
Page 79: Troubleshooting
10. TROUBLESHOOTING 10-1. Summary of Troubleshooting <W ired remote controller type> 1. Before troubleshooting 1) Required tools/instruments – • screwdrivers, spanners, radio cutting pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal.
Page 80 <W ireless remote controller type> (For 4-way air discharge cassette type only models) 1. Before troubleshooting 1) Required tools/instruments – • screwdrivers, spanners, radio cutting pliers, nippers, etc. • Tester, thermometer, pressure gauge, etc. 2) Confirmation points before check a) The following operations are normal. 1.
Page 81: Check Code List
10-2. Check Code List Error mode detected by indoor and outdoor units ¥ ¡ : Flash, : Go on, : Go off Wireless sensor Wired remote Diagnostic function lamp display controller Judgment and measures Status of air Cause of operation Condition Operation Timer Ready Check code...
Page 82 ¥ ¡ : Flash, : Go on, : Go off Wireless sensor Wired remote Diagnostic function lamp display controller Judgment and measures Status of air Cause of operation Condition Operation Timer Ready Check code conditioner ¥ ¥ Unset indoor capacity Stop Displayed when 1.
Page 83 Error mode detected by remote controller ¥ ¡ : Flash, : Go on, : Go off Wireless sensor Diagnostic function Wired remote controller lamp display Judgment and measures Status of Cause of operation Condition Operation Timer Ready Check code air conditioner No communication with master indoor unit Stop —...
Page 84: Error Mode Detected By Led On Outdoor P.c. Board
10-3. Error Mode Detected by LED on Outdoor P.C. Board RAV-SM562AT-E, RAV-SM802AT-E, RAV-SM1102AT-E, RAV-SM1402AT-E RAV-SP562AT-E, RAV-SP802AT-E, RAV-SP1102AT-E, RAV-SP1402AT-E <SW801: LED display in bit 1, bit 2 OFF> • When multiple errors are detected, the latest error is displayed. ¡ • When LED display is (Go on), there is the main cause of trouble on the objective part of control at CDB side and the unit stops.
Page 85: Troubleshooting Procedure For Each Check Code
10-4. Troubleshooting Procedure for Each Check Code 10-4-1. Check Code [E01 error] Correct inter-unit cable of remote controller. Is inter-unit cable of A and B normal? Is there no disconnection Correct connection of connector. or contact error of connector on harness Check circuit cables.
Page 86 [E04 error] Does outdoor unit operate? Is setup of group address correct? Check item code [14]. Are 1, 2, 3 inter-unit cables normal? Correct inter-unit cable. Are connections from connectors of inter-terminal blocks (1, 2, 3) Correct connection of connector. of indoor/outdoor units normal? Check indoor P.C.
Page 87 [E10 error] Check indoor control P.C. board (MCC-1402). Defect Replace [E18 error] Correct inter-unit cable of remote controller. Is inter-unit cable of A and B normal? Is there no disconnection Correct connection of connector. or contact error of connector on harness Check circuit cables.
Page 88 [L20 error] Correct cable connection Are cable connections to communication line U3, U4 normal? Are not multiple same central Correct central control network address. control network addresses connected? Check central controller (including connection interface) indoor P.C. board. Defect → Replace. [L30 error] Check indoor P.C.
Page 89 [P12 error] <Only for 4-way air discharge cassette type models> Turn off the power. Are not there connections errors or Correct connection of connector. disconnection on connectors CN333 and CN334 of indoor unit P.C. board (MCC-1402)? Remove connectors CN333 and CN334 of indoor unit P.C.
Page 90 [P22 error] Are connections of CN301 and CN300 of P.C. board correct? Does the fan rotate without trouble CN301, CN303 when handling the fan with hands under condition of removing CN301 and CN300 from P.C. board? The status that the resistance values between leads below are 50 to 80 W for 40 W motor (ICF-140-40) and 25 to 55 W for 60 W motor (ICF-140-60-1) is normal.
Page 91 [P19 error] Is voltage applied Is operation of to 4-way valve coil terminal 4-way valve normal? in heating operation? Is flow of refrigerant ® Check 4-way valve by electron expansion Defect Replace valve normal? Check and replace electron expansion Is circuit cable normal? valve.
Page 92 [F01 error] Is connection of TCJ sensor connector Correct connection of connector. (Indoor P.C. board CN102) normal? Are characteristics of Replace TCJ sensor. TCJ sensor resistance value normal? * Refer to Characteristics-2. Check indoor P.C. board ® (MCC-1402). Defect Replace [P26 error] Improve the power supply line.
Page 93 [P29 error] Check and correct circuit cabling Are connections of cable/connector normal? such as cabling to compressor. Is compressor normal? ® Compressor error Replace Is not earthed? ® Is not winding shorted? Compressor error Replace (Is resistance between windings 0.6 to 1.2 ®...
Page 94 [F06 error] Are connections of Correct connection of connector. TE/TS sensor connectors of CDB CN604/CN605 normal? * (For RAV-SM562AT-E, CN600 TE sensor and CN603 TS sensor) Are characteristics of TE/TS sensor Replace TE and TS sensors. resistance values normal? ® Check CDB.
Page 95 [L29 error] Are connections of Correct connection of connector. CDB CN800 and CDB IPDU CN06 connectors normal? Check cabling between IPDU Was the error just after Are cabling/connector normal? power ON determined? and CDB and connector. ® IPDU P.C. board error Defect Replace Improve and eliminate the cause.
Page 96 [P03 error] Is protective control such as Are connections of Correct the cabling and discharge temprelease control normal? cable/connector normal? connection of connector. ® Check parts. Defect Replace Check and correct the charged Is charged refrigerant amount normal? refrigerant amount. Improve and delete the cause Is not abnormal overload? Are characteristics of...
Page 97 [P04 error] Is high-voltage protective operation by TE sensor normal? Is connection of cabling Correct connection of cabling connector. connector normal? ® Check TE sensor. Defect Replace Does cooling outdoor fan normally operate? Is connection of Correct connection of connector normal? connector.
Page 98 [C06 error] (Central controller) Correct communication line. Is U3, U4 communication line normal? Are connections between connectors CN51 of connection interface P.C. board Correct connection of connector. and connectors CN51 of indoor P.C. board normal? Check connections of A, B terminal blocks. Is A, B communication line normal? Correct communication line of remote controller.
Page 99 [E03 error] (Master indoor unit) [E03 error] is detected when the indoor unit cannot receive a signal sent from the main remote controller (and central controller). In this case, check the communication cables of the remote controllers A and B, the central control system X and Y.
Page 100 10-4-2. Relational Graph of Temperature Sensor Resistance Value and Temperature TA sensor TC, TCJ sensor Caracteristics-2 Caracteristics-1 Resistance Resistance –10 Temperature [˚C] Temperature [˚C] TE, TO, TS sensor Caracteristics-3 Resistance Resistance (10˚C or higher) (10˚C or lower) Temperature [˚C] TD sensor Caracteristics-4 Resistance Resistance...
Page 101: Replacement Of Service Indoor P.c. Board
11. REPLACEMENT OF SERVICE INDOOR P.C. BOARD [Requirement when replacing the service indoor P.C. board assembly] In the non-volatile memory (Hereinafter said EEPROM, IC10) installed on the indoor P .C. board before replace- ment, the type and capacity code exclusive to the corresponding model have been stored at shipment from the factory and the important setup data such as system/indoor/group address set in (AUTO/MANUAL) mode or setting of high ceiling selection have been stored at installation time.
Page 102 H1 Readout of the setup data from EEPROM (Data in EEPROM contents, which have been changed at the local site, are read out together with data in EEPROM set at shipment from the factory.) TEST 1. Push , and buttons of the remote controller at the same time for 4 seconds or more. (Corresponded with No.
Page 103 r3 Writing of the setup contents to EEPROM (The contents of EEPROM installed on the service P .C. board have been set up at shipment from the factory.) TEST 1. Push , and buttons of the remote controller at the same time for 4 seconds or more. (Corresponded with No.
Page 104 Memorandum for setup contents (Item code table (Example)) Item Memo At shipment Filter sign lighting time According to type Dirty state of filter 0000: Standard Central control address 0099: Unfixed Heating suction temp shift 0002: +2°C (Floor type: 0) Cooling only 0000: Shared for cooling/heating Type According to model type...
Page 105: Setup At Local Site And Others
12. SETUP AT LOCAL SITE AND OTHERS 12-1. Indoor Unit 12-1-1. Test Run Setup on Remote Controller RAV-SM562UT-E, RAV-SM802UT-E, RAV-SM562BT-E, RAV-SM802BT-E <Wired remote controller> TEST 1. When pushing button on the remote controller for 4 seconds or more, “TEST” is displayed on LC display.
Page 106 (Except 4-way Air Discharge Cassette Type and Under Ceiling Type) Remove a screw which fixes the serial olate of the receiver part on the wireless remote con- troller. Remove the nameplate of the reciver section by inserting a minus screwdriver, etc. into the notch at the bottom of the plate, and set the Dip switch to [TEST RUN ON].
Page 107 <In case of wireless remote controller> Procedure Description Turn on power of the air conditioner. The operation is not accepted for 5 minutes when power has been turned on at first time after installation, and 1 minute when power has been turned on at the next time and after. After the specified time has passed, perform a test operation.
Page 108 Item No. (DN) table (Selection of function) Item Description At shipment Filter sign lighting 0000 : None 0002 for D.I. and S.D.I. time 0002 : 2500H (4-Way/Duct/Ceiling Type) models Dirty state of filter 0000 : Standard 0001 : High degree of dirt 0000 : Standard (Half of standard time) Central control...
Page 109 12-1-2. Cabling and Setting of Remote Controller Control 2-remote controller control <Wireless remote controller> (Controlled by two remote controllers) How to set wireless remote controller to sub One or multiple indoor units are controlled by two remote controller remote controllers. Change OFF of Bit [3: Remote controller Sub/ (Max.
Page 110 12-1-3. Monitor Function of Remote Controller Switch n Call of sensor temperature display <Contents> Each sensor temperature of the remote controller, indoor unit, and outdoor unit can become known by calling the service monitor mode from the remote controller. <Procedure> TEST Push buttons simultaneously for 4 seconds or more to call th e service monitor mode.
Page 111: Group Control Operation
n Calling of error h istory <Contents> The error contents in the past can be called. <Procedure> DATA UNIT No. TEST Push buttons simultaneously for 4 R.C. seconds or more to call th e service ch eck mode. TEMP. ON / OFF Service Check goes on, the item code TIMER SET MODE...
Page 112: Setup At Local Site / Others
12-2. Setup at Local Site / Oth ers Model name: TCB-PCNT30TLE2 12-2-1. TCC-LINK Adapter (For TCC-LINK Central Control) 1. Function This model is an optional P .C. board to connect the indoor unit to TCC-LINK (Central controller). 2. Microprocessor Block Diagram Indoor unit Central controller...
Page 113: Wiring Specifications
4. Wiring Specifications • Use 2-core with no polar wire. No. of wires Size • Match the length of wire to wire length of the central Up to 1000m: twisted wire 1.25mm control system. Up to 2000m: twisted wire 2.0mm If mixed in the system, the wire length is lengthened with all indoor/outdoor inter-unit wire length at side.
Page 114: How To Set Up Central Control Address Number
6. External View of P.C. Board Terminator (SW01) 7. Address Setup In addition to set up the central control address, it is necessary to change the indoor unit number. (Line/Indoor/Group address). For details, refer to TCC-LINK Adapter Installation Manual. 12-3. How to set up central control address number When connecting the indoor unit to the central control remote controller using TCC-LINK adapter, it is neces- sary to set up the central control address number.
Page 115: Address Setup
13. ADDRESS SETUP 13-1. Address Setup <Address setup procedure> When an outdoor unit and an indoor unit are connected, or when an outdoor unit is connected to each indoor unit respectively in the group operation even if multiple refrigerant lines are provided, the automatic address setup completes with power-ON of the outdoor unit.
Page 116: Address Setup & Group Control
13-2. Address Setup & Group Control <Terminology > Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64) Group address : 0 = Individual (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The representative of multiple indoor units in group operation sends/receives signals to/from the remote controllers and sub indoor units.
Page 117: Address Setup
13-3. Address Setup In case th at addresses of th e indoor units will be determined prior to piping work after cabling work (Manual setting from remote controller) <Address setup procedure> • Set an indoor unit per a remote controller. (Example of 2-lines cabling) (Real line: Cabling, Broken line: Refrigerant pipe) •...
Page 118 n Confirmation of indoor unit No. position 1. To k now th e indoor unit addresses th ough position of th e indoor unit body is recognized • In case of individual operation (Wired remote controller : indoor unit = 1 : 1) (Follow to the procedure during operation) <Procedure>...
Page 119: Detachments
14. DETACHMENTS 14-1. Indoor Unit 14-1-1. 4-Way Air Discharge Cassette Type RAV-SM562UT-E, RAV-SM802UT-E, RAV-SM1102UT-E, RAV-SM1402UT-E RAV-SP1102UT-E Part name Procedure Remarks Suction grille REQUIREMENT Never forget to put on the gloves at disassembling work, otherwise an injury will be caused.
Page 120 Part name Procedure Remarks ƒ 1. Detachment Adjust corner 1) Perform work of item 1. of 2) Remove screws at 4 corners of the suction port. (Ø4 × 10, 4 pcs.) 3) Push the knob outward and remove the Scre Screw Screw...
Page 121 Part name Procedure Remarks … 1. Detachment Control P .C. board 1) Perform works of items 1 of and 1 of ‚ 2) Remove connectors which are con- nected from the control P .C. board to other parts. CN33 : Louver motor (5P: White) CN34 : Float switch (3P: Red) Card-edge spacer Card-edge spacer...
Page 122 Part name Procedure Remarks † 1. Detachment Fan motor 1) Perform works of items 1 of and 1 of ‚ Screws fixing electric parts box Screws fixing electric parts box 2) Remove clamps of the lead wires connected to the following connectors of the control P .C.
Page 123 Part name Procedure Remarks ‡ 1. Detachment Drain pan ‚ 1) Perform works of items 1 of , 1 of ƒ „ and 1 of 2) Remove clamps of the lead wires con- nected to the following connectors of the control P .C.
Page 124 Part name Procedure Remarks ˆ 1. Detachment Drain pump ‚ assembly 1) Perform works of items 1 of , 1 of Slide to hose side. Slide to hose side. ƒ „ ‡ 1 of , 1 of and 1 of 2) Picking the hose band, slide it from pump connecting part to remove the drain hose.
Page 125 Part name Procedure Remarks ‰ 1. Detachment Heat exchanger 1) Recover refrigerant gas. 2) Remove refrigerant pipe at the indoor unit side. Fixing screws Fixing screws 3) Perform works of items 1 of , 1 of ‚ ƒ „ ‡...
Page 126 <Replacement of Distributor Assembly> RAV-SM562UT-E 1. Cutting of Capillary Tube A capillary tube ( 023 : Inner diameter 2mm, Length 1000mm) is brazed to a distributor assembly. Cut and divide the tube to each length as shown below. Ref No.
Page 127 RAV-SM802UT-E 1. Cutting of Capillary Tube A capillary tube ( 025 026 : Inner diameter 2mm, Length 1000mm) is brazed to a distributor assembly. Cut and divide the tube to each length as shown below. Ref No. No. of capillary tubes Cutting 100mm : 1 pc.
Page 128 14-1-2. Concealed Duct Type RAV-SM562BT-E, RAV-SM802BT-E, RAV-SM1102BT-E, RAV-SM1402BT-E Be sure to turn off the power supply or circuit breaker before disassembling work Part name Procedure Remarks Electrical parts 1. Remove the air filter. Screws (Fixing electrical parts cover and box) 2.
Page 129 Part name Procedure Remarks ƒ Fan motor 1. Remove the Multi blade fan. Fan motor holder Fan motor 2. Remove the hexagon head screw of fixing fan motor holder. 3. Remove the fan motor holder (2 positions). 3 -2 Screws 3 -3 (Fixing fan motor holder) „...
Page 130 Part name Procedure Remarks † Drain pump 1. Remove the drain pan and float switch. Drain pump Drain pump holder 2. Remove the set screws (3 positions) of fixing drain pump plate and main unit. 3. Remove the set screws (3 positions) of fixing drain pump plate and drain pump.
Page 131 14-1-3. Under Ceiling Type RAV-SM562CT-E, RAV-SM802CT-E, RAV-SM1102CT-E, RAV-SM1402CT-E Be sure to turn off the power supply or circuit breaker before disassembling work Part name Procedure Remarks Suction grille 1. Slide the suction grille fixing Pull out suction grille knobs (2 positions) toward the while pushing hook.
Page 132 Part name Procedure Remarks „ Multi blade fan 1. Remove the suction grille. Screws motor 2. Remove the connector of the fan (Fixing reinforcing bar and main unit) motor from P .C. board. 3. (SM802, SM1102, SM1402CT-E only) Remove the set screw (1 position) to fixing and reinforcing bar.
Page 133 Part name Procedure Remarks … Drain pan 1. Take down the main unit and then treat Screws the drain pan on the floor. (Fixing lower plate and main unit) 2. Remove the both side panels and suction grilles. 3. (SM802, SM1102, SM1402CT-E only) Remove the set screw (1 position) to fixing and reinforcing bar.
Page 134 Part name Procedure Remarks ˆ Horizontal 1. Push the louver holder toward arrow louver direction of right figure, and pull out the center shaft (SM562, SM802 : 1 position, SM1102, SM1402 : 2 positions) from louver holder. 2. Pull off the left and right chaft of horizontal louver.
Page 135: Outdoor Unit
14-2. Outdoor Unit RAV-SM562AT-E Part name Procedure Remarks Common procedure CAUTION Valve Never forget to put on the gloves at cover working time, otherwise an injury will be caused by the parts, etc. 1. Detachment 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner.
Page 136 Part name Procedure Remarks ‚ 1. Detachment Front cabinet Motor support 1) Perform work of item 1 of 2) Remove screws (ST1T Ø4 × 10L, 2 pcs.) of the front cabinet and the inverter cover. 3) Take off screws of the front cabinet and the bottom plate.
Page 137 Part name Procedure Remarks ƒ 1. Detachment Inverter Screws assembly 1) Perform work of item 1 of 2) Take off screws of the upper part of the front cabinet. • If removing the inverter cover under this Front cabinet condition, P.C.
Page 138 Part name Procedure Remarks „ Control P .C. 1) Disconnect lead wires and connectors board assembly connected from the control P .C. board assembly to other parts. 1. Lead wires Take off earth screws. • Connection with the power terminal block: 3 wires (Black, White, Orange) •...
Page 139 Part name Procedure Remarks … ‚ ƒ Rear cabinet 1) Perform works of items 1 of 2) Take off fixed screws for the bottom plate. (ST1T Ø4 × 10L, 3 pcs.) 3) Take off fixed screws for the heat ex- changer.
Page 140 Part name Procedure Remarks ‡ Compressor 1) Perform works of items 1 of ‚ ƒ „ … Partition plate 2) Discharge refrigerant gas. 3) Remove the partition plate. (ST1T Ø4 × 10L, 2 pcs.) 4) Remove the noise-insulator. 5) Remove the terminal covers of the compressor, and disconnect lead wires of the compressor and the compressor thermo assembly from...
Page 141 Part name Procedure Remarks ‰ 1. Detachment Pulse Modulating ‚ Valve (P.M.V.) coil 1) Perform works of items Positioning extrusion PMV body 2) Release the coil from the concavity by turning it, and remove coil from the P .M.V. 2.
Page 142 RAV-SP562AT-E, RAV-SP802AT-E Part name Procedure Remarks Common procedure CAUTION Never forget to put on the gloves at working time, otherwise an injury will be caused by the parts, etc. Front cabinet 1. Detachment 1) Stop operation of the air conditioner, and also turn off switch of the breaker.
Page 143 Part name Procedure Remarks ‚ 1. Detachment Discharge port cabinet 1) Perform work of item 1 of Side cabinet 2) Take off screws (ST1T Ø4 × 10L, 3 pcs.) of discharge port cabinet for the partition plate. 3) Take off screws (ST1T Ø4 × 10L, 2 pcs.) Inverter of discharge port cabinet for the bottom plate.
Page 144 Part name Procedure Remarks „ Inverter 1) Perform works of items of 1) to 5) of assembly 2) Take off screw (ST1T Ø4 × 10L, 1 pc.) of Screw the upper left part of the inverter cover. • If removing the inverter cover under this Inverter assembly condition, P.C.
Page 145 Part name Procedure Remarks „ Inverter 7) Remove connectors which are connected assembly from the cycle P .C. board to other parts. (Continued) CN600: TD sensor (3P: White) CN601: TO sensor (2P: White) CN604: TE sensor (2P: White) *Note 1) Inverter box (Metal sheet) CN605: TS sensor (3P: White) *(Note 1) CN301: Outdoor fan (3P: White) *(Note 1)
Page 146 Part name Procedure Remarks † „ … IPDU P .C. 1) Perform the works in board 2) Remove the connectors and the lead wires which are connected from IPDU P .C. board to the other parts. 1. Connector CN04 : Connection with cycle P .C. board (3P: White) *(Note 1) CN05 : Connection with cycle P .C.
Page 147 Part name Procedure Remarks ‡ Fan motor 1) Perform works of items 1) to 5), 7) of 2) Remove the flange nut fixing the fan Flange motor and the propeller fan. • Loosen the flange nut by turning clock- wise.
Page 148 Part name Procedure Remarks ˆ ‚ ƒ „ Compressor 1) Perform works of items , and 2) Evacuate refrigerant gas. Motor base 3) Disconnect the connector for fan motor from the inverter. 4) Take off screws fixing the motor base to the bottom plate.
Page 149 Part name Procedure Remarks ‰ „ Reactor 1) Perform works of items 1 of 2) Take off screws fixing the reactor. Partition plate (Ø4 x 10L , 2 pcs. per one reactor. Screws An outdoor unit has two reactors on the partition plate.) Reactor Š...
Page 150 Part name Procedure Remarks 1. Detachment Fan guard Discharge ‚ 1) Perform works of items 1 of port cabinet 2) Remove the air flow cabinet, and put it down so that the fan guard side directs Bell mouth downward. Perform work on a corrugated card- board, cloth, etc.
Page 151 RAV-SP1102AT-E, RAV-SP1402AT-E Part name Procedure Remarks Common procedure REQUIREMENT Front panel Before works, put on gloves, otherwise an injury may be caused by parts, etc. 1. Detachment 1) Stop operation of the air conditioner, and turn off switch of the breaker. 2) Remove the front panel.
Page 152 Part name Procedure Remarks ‚ 1. Detachment Air-outlet cabinet Heat exchanger Air-outlet cabinet 1) Perform the work in 1 of 2) Take off screws for the air-outlet cabinet and the partition plate. (ST1T Ø4 × 10, 3 pcs.) 3) Take off screws for the air-outlet cabinet and the base plate.
Page 153 Part name Procedure Remarks „ ƒ Inverter 1) Perform the works in 1 of Inverter assembly Cycle P.C. board assembly 2) Remove connectors which are connected from the cycle P .C. board to other parts. CN600: TD sensor (3P: White) CN601: TO sensor (2P: White) CN604: TE sensor (2P: White) *(Note 1) CN605: TS sensor (3P: White) *(Note 1)
Page 154 Part name Procedure Remarks … ƒ Cycle P .C. board 1) Perform the works in 1 of Cycle control P.C. board assembly 2) Remove connectors and lead wires which are connected from the cycle P .C. board to other parts. 1.
Page 155 Part name Procedure Remarks † „ … IPDU P .C. board 1) Perform the works in Screw Screw 2) Take off screws of the inverter assembly to separate the inverter assembly. (M4 × 8, 4 pcs) 3) Remove the connectors and the lead wires which are connected from IPDU P .C.
Page 156 Part name Procedure Remarks ‡ ‚ Fan motor 1) Perform the works in 1 of and 1 of Flange nut Flange nut Loosen by Loosen by 2) Take off flange nut fixing the fan motor turning clockwise turning clockwise. kwise.
Page 157 Part name Procedure Remarks ˆ Compressor 1) Recover refrigerant gas. ƒ 2) Perform the works in 1 of and in 3) Remove the piping panel (Front). Take off screws of the piping panel (Front) and the base plate. (ST1T Ø4 × 10, 2 pcs) Take off screws of the piping panel (Front) and the piping panel (Rear).
Page 158 Part name Procedure Remarks Š 1. Detachment Fan guard ‚ 1) Perform the works in 1 of and in 1 of Air-outlet cabinet REQUIREMENT Bell-mouth To prevent damage on the products, treat component on a corrugated paper, cloth, etc. Screws (2 pcs) Remove...
Page 159 Part name Procedure Remarks „ Reactor 1) Perform works of items Partition board Reactor NOTE) The same two reactors are installed to this outdoor unit though each installation place is different. One is attached to a partition board, and the other is attached to an electric parts box.
Page 160: Exploded Views And Parts List
15-1. Indoor Unit 15-1-1. 4-Way Air Discharge Cassette Type RAV-SM562UT-E, RAV-SM802UT-E 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2...
Page 161 Location Part Description 43160565 Terminal Block, 3P , 20A 43050425 Sensor, TC (F6) 43050426 Sensor, TA 43160568 Terminal Block, 2P , 1A, AC30V 4316V280 P .C. Board Ass’y, MMC-1402 – 161 –...
Page 162 Revised : Nov. 2006 RAV-SP1102UT-E 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 230, 231,...
Page 163 Location Part Description 43160565 Terminal Block, 3P , 20A 43050425 Sensor, TC (F6) 43050426 Sensor, TA 43160568 Terminal Block, 2P , 1A, AC30V 4316V280 P .C. Board Ass’y, MMC-1402 – 163 –...
Page 164 Revised : Nov. 2006 RAV-SM1102UT-E, RAV-SM1402UT-E 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 229, 230,...
Page 165 Location Part Description 43160565 Terminal Block, 3P , 20A 43050425 Sensor, TC (F6) 43050426 Sensor, TA 43160568 Terminal Block, 2P , 1A, AC30V 4316V280 P .C. Board Ass’y, MMC-1402 – 165 –...
Page 166 RBC-U21PG (W) - E2 Location Part Location Part Description Description 43409164 Panel, PS-HI100 43407116 Grille, Catch, ABS 43480010 Air Filter, ABS 43409168 Grille, Air, Inlet 43407120 Outlet, Air Form, PS-F 43409182 Cover, Panel Ass’y, PS-HI100 4302C063 Motor, Louver, MP24Z 43407123 Fix, Motor, ABS 43409173 Louver, ABS...
Page 167 Revised : Nov. 2006 15-1-2. Concealed Duct Type RAV-SM562BT-E 3, 902, 905 4, 6, 906 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8...
Page 168 Revised : Nov. 2006 RAV-SM802BT-E 6, 7, 8 3, 904, 905 901, 902, 903 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8...
Page 169 Revised : Nov. 2006 RAV-SM1102BT-E, RAV-SM1402BT-E 6, 7, 8 3, 904, 905 901, 902, 903 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8...
Page 170 RAV-SM562BT-E, RAV-SM802BT-E, RAV-SM1102BT-E, RAV-SM1402BT-E Location Part Location Part Description Description 43160565 Terminal Block, 3P , 20A 43160568 Terminal Block, 2P 4316V281 P .C. Board Ass’y, MMC-1402 43158193 Reactor 43050425 Sensor, TC (F6) 43155203 Capacitor 43050426 Sensor, TA – 170 –...
Page 171 Revised : Nov. 2006 15-1-3. Under Ceiling Type RAV-SM562CT-E, RAV-SM802CT-E, RAV-SM1102CT-E, RAV-SM1402CT-E 44, 45, 46 1, 2, 3 22, 23, 24 36, 37, 38,39, 54, 55 33, 34, 35,53, 56, 57 7, 8, 9 4, 5, 6 27, 28 (1101, 1401CT-E) (1101, 1401CT-E) 12, 13 43 41...
Page 172 (SM1102CT, SM1402CT) 43121746 Driver Ass’y, Horizontal L 43122084 Case, Fan, Lower Louver 43160556 Lead, Louver Horizontal 43122085 Case, Fan, Upper 43108016 Mark TOSHIBA 43180314 Air Filter (SM562CT, SM1102CT, SM1402CT) 43162049 Bushing, 50DIA 43180315 Air Filter (SM802CT, 43162050 Bushing, 56DIA SM1102CT, SM1402CT)
Page 173 Location Part Location Part Description Description 43050425 Sensor, TC (F6) 43160568 Terminal Block, 2P 43160565 Terminal Block, 3P , 20A 4316V280 P .C. Board Ass’y, MMC-1402 43050426 Sensor, TA 43155203 Capacitor 43158193 Reactor – 173 –...
Page 174: Outdoor Unit
15-2. Outdoor Unit RAVSM562AT-E, RAV-SM802AT-E Location Part Location Part Description Description 43147195 Bonnet, 1/2 IN (SM562AT-E) 43005657 Cabinet, Front 43194029 Bonnet (SM802AT-E) 43005642 Cabinet, Upper 43047401 Bonnet, 3/8 IN (SM802AT-E) 43005658 Cabinet, Side, Right 43046444 Valve, 4-Way, STF-0108Z 43005634 Cabinet, Side, Left (SM562AT-E) 4301V035 Guard, Fan...
Page 175 Revised : Nov. 2006 Location Part Location Part Description Description 43150319 Sensor Ass’y, Service 4316V293 P .C. Board, Ass’y, SW, MCC-1530 43050425 Sensor Ass’y, Service 4316V284 P .C. Board, Ass’y, MCC-5009 43062228 Base, P .C. Board 43160571 Fuse Holder, 15A, 250V 43160566 Terminal Block, 6P , 20A –...
Page 176 Revised : Nov. 2006 RAV-SM1102AT-E, RAV-SM1402AT-E Location Part Location Part Description Description 43005635 Cabinet, Air Outled 43149324 Rubber, Cushion, EPDM 43100350 Cabinet, Front, Ass’y 43046445 Valve, 4-WAY, STF-0213Z 43100349 Cabinet, Side, Ass’y 43046443 Coil, Solenoid, VHV-01AJ502E1 43005643 Panel, Upper 43146634 Valve, Pulse, Modulating 43191633 Guard, Fin...
Page 177 Location Part Location Part Description Description 43150319 Sensor Ass’y, Service 4316V283 P .C. Board, Ass’y, CDB, MCC-1531 43050425 Sensor Ass’y, Service 4316V291 P .C. Board Ass’y, IPDU, 43160565 Terminal Block, 3P , 20A MCC-1438 43131052 Rectifier 43150320 Sensor Ass’y, Service 43160567 Terminal Block, 3P , 30A 43160571...
Page 178 RAV-SP562AT-E, RAV-SP802AT-E 21,22 34 24 16,17 Location Part Location Part Description Description 43146695 Valve, Pulse, Modulating, 43100348 Cabinet, Air Outlet CAMB30YGTF-2 43100350 Cabinet, Front Ass’y 43100349 Cabinet, Side Ass’y 43046450 Coil, PMV, CAM-MD12TF-8 43100351 Panel, Upper 43048066 Accumulator Ass’y 43005489 Guard, Fin 43046392 Valve, Packed, 6.35...
Page 179 INVERTER COVER TE Sensor (Ø6) TS Sensor (Ø6) TO Sensor (Ø6) TD Sensor (Ø4) INVERTER BOX Location Part Location Part Description Description 43150319 Sensor, TD (F4) 4316V292 P .C. Board Ass’y, IPDU, MCC-1438 43050425 Sensor, TC (F6) 43160571 Fuse Holder, 15A, 250V 43160566 Terminal Block, 6P , 20A 43131052...
Page 180 RAV-SP1102AT-E, RAV-SP1402AT-E Inverter 23 9 26,27 23,24 28,29 Location Part Location Part Description Description 43148170 Accumulator Ass’y, 2.5L 43100343 Base Ass’y 4314Q020 Strainer 43041787 Compressor Ass’y, DA420A3F-21M 4302C069 Motor, Fan, ICF-140-63-2R 43049739 Cushion, Rubber 43047669 Nut, Flange 43097212 43120213 Fan, Propeller, PJ491, AS-G 43050407 Thermostat, Bimetal 43122065...
Page 181 702 TD SENSOR 701 TC SENSOR (F6) R501 R500 CN600 IC800 CN601 CN604 CN800 CN12 CN04 CN03 703 SENSOR ASS’Y RY01 Location Part Location Part Description Description 43050425 Sensor Ass’y, Service 4316V283 P .C. Board Ass’y, IPDU, MCC-1531 (SP1102AT) 43150319 Sensor Ass’y, Service 4316V291 P .C.
Page 182: Replacement Of Main Parts (Sold Separately)
15-3. Replacement of Main Parts (Sold Separately) 15-3-1. Drain up Kit TCB-DP22CE2 Part name Procedure Remarks Drain pan 1. Remove the Drain up kit from the main Screws unit. (Fixing drain pan and main unit) 2. Remove the set screws (2 positions) and drain pan.
Page 183 15-3-2. Wireless Remote Control Kit RBC-AX22CE2 Part name Procedure Remarks P .C. board 1. Remove the signal receiving unit from main unit. 2. Remove the set screw (1 position) and P .C. board cover. 3. Remove the p.c. board. 1 -2 Screw P.C.
Page 184: Cord Heater Installation Work
16. CORD HEATER INSTALLATION WORK This is on installation for 2 HP and 3 HP Products (RAV-SM562AT-E, RAV-SM802AT-E, RAV-SP562AT-E, RAV-SP802AT-E). In case of 4 HP or 5 HP , refer to this installation as reference. 1. Required parts for installation work (Recommendation) The above products conform to RoHS (2002/95/EC).
Page 185 Part name Q’ty Specifications/Vendor Remarks Power cord 2-cores x 0.75mm² or more, H05RN-F Procured locally Thermostat Material: SGCC-Z08, Board thickness: 0.8t Procured locally fixing plate (Drawing attached) PVC tube Inside diameter Ø8 x outside diameter Ø11 x 70 mm Procured locally Shield tube Inside diameter Ø18 x outside diameter Ø26 x 70 mm Procured locally...
Page 186 3. Cord heater installation wiring diagram Fuse Thermostat Cord heater * Be sure to connect the fuse and the thermostat to LIVE side of the cord heater. Outdoor unit Earth leakage circuit breaker Power supply for air conditioner Earth leakage circuit breaker Power supply for cord heater NOTE: Separate the cord heater power from the air conditioner power, and connect it to its exclusive breaker.
Page 187 4. Cord heater installation work procedure Photo / Explanatory diagram Procedure Remove each cabinet, inverter assembly, motor base assembly, and partition board assembly. * Do not damage the electric parts such as cables, connectors, etc. while this work. Remove the upper cabinet and the valve cover. Upper cabinet Related parts / Screws list Used screw...
Page 188 Photo / Explanatory diagram Procedure Remove the motor base assembly, partition plate assembly and the sound insulation board. Motor base assembly Related parts / Screws list Partition plate Used screw assembly Part name Screw type Quantity Motor base assembly Ø4 × 8 (Including motor and fan) Partition plate assembly Sound...
Page 189 Revised : Nov. 2006 Photo / Explanatory diagram Procedure Cord heater installation work Drill a hole on the outdoor unit base plate, and fix the cord heater to the outdoor unit base plate using P-shape clamp. Connect the cord heater cables. Using a motor drill, etc., drill Ø3.2 holes on the outdoor unit base plate.
Page 190 Photo / Explanatory diagram Procedure Rework the side cabinet (L) to remove part of it. Side cabinet (L) The area to be removed is indicated by the shaded lines in the left figure. After removing part of the side cabinet (L), deburr the edges of the side cabinet (L).
Page 191 Photo / Explanatory diagram Procedure Assembly Return a set of the refrigeration cycle assembly into the outdoor unit base plate and reassemble sound insulation board, partition plate assembly, fan motor assembly, and side cabinet (R/L) as original. Fix the thermostat fixing plate to the side cabinet (R), built in the inverter assembly, and then connect various cables.
Page 192 5. Drawing of thermostat fixing plate 2-Ø3.4 burring hole (Upward) 3-Ø3.4 burring hole (Downward) Material: SGCC-Z08, Thickness: 0.8t – 192 –...
Page 193: Appendix
Revised : Nov. 2006 APPENDIX 1. RAV-SM562AT-E, RAV-SM802AT-E APPENDIX-1...
Page 194: Rav-Sm1102At-E, Rav-Sm1402At-E, Rav-Sp562At-E, Rav-Sp802At-E, Rav-Sp1102At-E, Rav-Sp1402At-E
Revised : Nov. 2006 2. RAV-SM1102AT-E, RAV-SM1402AT-E, RAV-SP562AT-E, RAV-SP802AT-E, RAV-SP1102AT-E, RAV-SP1402AT-E 10.5 APPENDIX-2...
Page 195 WARNINGS ON REFRIGERANT LEAKAGE Important Check of Concentration Limit NOTE 2 : The room in which the air conditioner is to be installed requires a design that in the event of The standards for minimum room volume are as follows. refrigerant gas leaking out, its concentration will not (1) No partition (shaded portion) exceed a set limit.

Toshiba RAV-SM562UT-E Service Manual/Integration

Safety Caution

1 Specifications

Indoor Unit

Outdoor Unit

Operation Characteristic Curve

2 Air Ducting Work

Static Pressure Characteristics of each Model

3 Construction Views (External Views)

Indoor Unit

Outdoor Unit

4 Systematic Refrigerating Cycle Diagram

Indoor Unit/Outdoor Unit

5 Wiring Diagram

Indoor Unit

Outdoor Unit (Wiring Diagram)

6 Specifications of Electrical Parts

Indoor Unit

Outdoor Unit

Accessory Separate Soldparts

7 Refrigerant R410A

8 Control Block Diagram

9 Circuit Configuration and Control Specifications

10 Troubleshooting

11 Replacement of Service Indoor P.C. Board

12 Setup at Local Site and Others

13 Address Setup

14 Detachments

15 Exploded Views and Parts List

16 Cord Heater Installation Work

Appendix

Rav-Sm562At-E, Rav-Sm802At-E

Rav-Sm1102At-E, Rav-Sm1402At-E, Rav-Sp562At-E, Rav-Sp802At-E, Rav-Sp1102At-E, Rav-Sp1402At-E

Quick Links

INDOOR UNIT

Troubleshooting

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Summary of Contents for Toshiba RAV-SM562UT-E

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