Toshiba Air Conditioner Rav Sp800at E User Manual

FILE NO. A03-013  
SERVICE MANUAL  
<OWNER’S MANUAL/INSTALLATION MANUAL>  
SPLIT TYPE  
RAV-SP1100UT-E  
RAV-SP560AT-E, RAV-SP800AT-E  
RAV-SP1100AT-E, RAV-SP1400AT-E  
R410A  
The type of all the indoor units described in this Service Manual is a new model, RAV-SP1100UT-E only.  
For the other indoor units to be combined, refer to the Service Manuals for the following models.  
Indoor unit  
Service Manual No.  
A02-013  
A02-013  
A03-003  
A03-007  
A03-007  
A03-007  
A03-007  
A03-015  
A03-015  
A03-015  
A03-015  
A02-013  
A02-013  
RAV-SM560UT-E  
RAV-SM800UT-E  
RAV-SM1400UT-E  
RAV-SM561BT-E  
RAV-SM801BT-E  
RAV-SM1101BT-E  
RAV-SM1401BT-E  
RAV-SM561CT-E  
RAV-SM801CT-E  
RAV-SM1101CT-E  
RAV-SM1401CT-E  
RAV-SM560KRT-E  
RAV-SM800KRT-E  
4-way Air Discharge Cassette type  
Concealed Duct type  
Under Ceiling type  
High wall type  
PRINTED IN JAPAN, Feb.,2004 ToMo  
Indoor Unit (4-Way Air Discharge Cassette Type) ––––––––––––––––––––––––  
RAV-SP1100UT-E  
OWNWE’S MANUAL  
ACCESSORIES (SOLD SEPARATELY) ...............................4  
PRECAUTIONS FOR SAFETY ............................................4  
PARTS NAME .......................................................................6  
PARTS NAME OF REMOTE CONTROLLER .......................7  
CORRECT USAGE ...............................................................9  
AUTOMATIC OPERATION (Auto Changeover) ................10  
ADJUSTMENT OF WIND DIRECTIONd ............................11  
TIMER OPERATION ...........................................................12  
MAINTENANCE..................................................................14  
AIR CONDITIONER OPERATIONS AND PERFORMANCE ...15  
RE-INSTALLATION ............................................................16  
TROUBLES AND CAUSES ................................................16  
INSTALLATION MANUAL  
Accessory parts and Parts to be procured locally ........18 5 ELECTRICALWORK...................................................30  
1 PRECAUTIONS FOR SAFETY....................................19 6 TEST RUN ...................................................................33  
2 SELECTION OF INSTALLATION PLACE ...................21 7 TROUBLESHOOTING .................................................34  
3 DRAIN PIPINGWORK .................................................26 8 MAINTENANCE...........................................................35  
4 REFRIGERANT PIPING AND EVACUATING..............28  
Outdoor Unit –––––––––––––––––––––––––––––––––––––––––––––––––––––––––  
RAV-SP560AT-E, RAV-SP800AT-E  
INSTALLATION MANUAL  
1 PRECAUTIONS FOR SAFETY....................................36 5 EVACUATING...............................................................45  
2 ACCESSORY AND REFRIGERANT ...........................37 6 ELECTRICALWORK...................................................47  
3 SELECTION OF INSTALLATION ................................38 7 FINAL INSTALLATION CHECKS ................................48  
4 REFRIGERANT PIPING ..............................................43  
RAV-SP1100AT-E, RAV-SP1400AT-E  
INSTALLATION MANUAL  
1 PRECAUTIONS FOR SAFETY....................................50 5 EVACUATING...............................................................58  
2 ACCESSORY AND REFRIGERANT ...........................51 6 ELECTRICALWORK...................................................60  
3 SELECTION OF INSTALLATION ................................52 7 FINAL INSTALLATION CHECKS ................................61  
4 REFRIGERANT PIPING ..............................................56  
Accessories ––––––––––––––––––––––––––––––––––––––––––––––––––––  
OWNER’S MANUAL  
REMOTE CONTROLLER FOR AIR CONDITIONER (SPLITTYPE)  
<WirelessType>  
WEEKLYTIMER FOR AIR CONDITIONER (SPLITTYPE)  
<ProgramWeeklyTimerType>  
REMOTE CONTROLLER FOR AIR CONDITIONER  
<Simple OperationType>  
TCB-AX21U (W)-E.......................................... 63  
RBC-EXW21E................................................. 72  
RBC-AS21E .................................................... 78  
INSTALLATION MANUAL  
Standard Remote Controller  
Simple Remote Controller  
ProgramWeeklyTimer  
Remote sensor  
Remote ControllerWireless Kit  
RBC-AMT21E ................................................. 81  
RBC-AS21E .................................................... 82  
RBC-EXW21E................................................. 83  
TCB-TC21LE .................................................. 84  
TCB-AX21U (W)-E.......................................... 85  
Network Adapter for Air Conditioner  
(Use for Indoor Unit Only)  
TCB-PCNT20E ............................................... 86  
1
PRECAUTIONS FOR SAFETY  
• Ensure that all Local, National and International regulations are satisfied.  
• Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.  
• The precautions described below include the important items regarding safety. Observe them without fail.  
• After the installation work, perform a trial operation to check for any problem.  
Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.  
Turn off the main power supply switch (or breaker) before the unit maintenance.  
• Ask the customer to keep the Installation Manual together with the Owner’s Manual.  
CAUTION  
New Refrigerant Air Conditioner Installation  
• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DE-  
STROY OZONE LAYER.  
The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure  
is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil  
has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or  
refrigerating oil does not enter the refrigerating cycle.  
To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging  
port of the main unit and installation tools are charged from those for the conventional refrigerant.  
Accordingly the exclusive tools are required for the new refrigerant (R410A).  
For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust  
does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance  
force and impurity in it.  
CAUTION  
To Disconnect the Appliance from Main Power Supply.  
This appliance must be connected to the main power supply by means of a switch with a contact separation of  
at least 3 mm.  
The installation fuse (25A D type  
) must be used for the power supply line of this conditioner.  
WARNING  
• Ask an authorized dealer or qualified installation professional to install/maintain the air condi-  
tioner.  
Inappropriate installation may result in water leakage, electric shock or fire.  
Turn off the main power supply switch or breaker before attempting any electrical work.  
Make sure all power switches are off. Failure to do so may cause electric shock.  
• Connect the connecting cable correctly.  
If the connecting cable is connected in a wrong way, electric parts may be damaged.  
• When moving the air conditioner for the installation into another place, be very careful not to  
enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.  
If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnor-  
mally high and it may resultingly causes pipe burst and injuries on persons.  
• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety  
interlock switches.  
• Exposure of unit to water or other moisture before installation may cause short-circuit of  
electrical parts.  
Do not store it in a wet basement or expose to rain or water.  
• After unpacking the unit, examine it carefully if there are possible damage.  
• Do not install in a place that might increase the vibration of the unit.  
• To avoid personal injury (with sharp edges), be careful when handling parts.  
• Perform installation work properly according to the Installation Manual.  
Inappropriate installation may result in water leakage, electric shock or fire.  
36  
• When the air conditioner is installed in a small room, provide appropriate measures to ensure  
that the concentration of refrigerant leakage occur in the room does not exceed the critical  
level.  
• Install the air conditioner securely in a location where the base can sustain the weight adequately.  
• Perform the specified installation work to guard against an earthquake.  
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.  
• If refrigerant gas has leaked during the installation work, ventilate the room immediately.  
If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.  
• After the installation work, confirm that refrigerant gas does not leak.  
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas  
might generate.  
• Electrical work must be performed by a qualified electrician in accordance with the Installation  
Manual. Make sure the air conditioner uses an exclusive power supply.  
An insufficient power supply capacity or inappropriate installation may cause fire.  
• Use the specified cables for wiring connect the terminals securely fix. To prevent external  
forces applied to the terminals from affecting the terminals.  
• Be sure to provide grounding.  
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.  
• Conform to the regulations of the local electric company when wiring the power supply.  
Inappropriate grounding may cause electric shock.  
• Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.  
If a combustible gas leaks, and stays around the unit, a fire may occur.  
Required tools for installation work  
R410A (Special requirement)  
1) Philips screwdriver  
2) Hole core drill (65 mm)  
3) Spanner  
4) Pipe cutter  
5) Knife  
17) Gauge manifold  
(Charge hose : R410A special requirement)  
18) Vacuum pump  
(Charge hose : R410A special requirement)  
19) Torque wrench  
1/4 (17 mm) 16 Nm (1.6 kgfm)  
3/8 (22 mm) 42 Nm (4.2 kgfm)  
1/2 (26 mm) 55 Nm (5.5 kgfm)  
5/8 (15.9 mm) 120 Nm (12.0 kgfm)  
20) Copper pipe gauge adjusting projection margin  
11) Electro circuit tester  
12) Hexagonal wrench  
13) Flare tool  
14) Pipe bender  
15) Level vial  
6) Reamer  
16) Metal saw  
7) Gas leak detector  
8) Tape measure  
9) Thermometer  
10) Mega-tester  
21) Vacuum pump adapter  
2
ACCESSORY AND REFRIGERANT  
Accessory and Installation Parts  
Refrigerant Piping  
Piping kit used for the conventional refrigerant cannot be  
used.  
1
3
4
Use copper pipe with 0.8 mm or more thickness for Ø6.4,  
Ø9.5, Ø12.7.  
Outdoor unit  
Protective bush  
Installation manual x 1  
(For SM800, SP560, SP800)  
Use copper pipe with 1.0 mm or more thickness for Ø15.9.  
Drain nipple  
Flare nut and flare works are also different from those of  
the conventional refrigerant. Take out the flare nut at-  
tached to the main unit of the air conditioner, and use it.  
2
Guard material for  
passage part  
(For SM800, SP560, SP800)  
Waterproof rubber cap  
37  
3
SELECTION OF INSTALLATION  
<SP560AT-E>  
CAUTION  
Length of refrigerant pipe  
<SP560AT-E, SP800AT-E only>  
connected to  
Item  
indoor/outdoor unit  
When using an air conditioner under low outside  
temperature condition (Outside temp.:5°C or  
lower) with COOL mode, prepare a duct or wind  
shield so that it is not affected by the wind.  
Addition of refrigerant is  
20m or shorter  
unnecessary at the local site.  
<Addition of refrigerant>  
Add 20g of refrigerant for every  
1m of pipe which exceeds 20m.  
21m to 50m  
*
<Example>  
* Caution at addition of refrigerant  
Suction hood (Side)  
Discharge hood  
Suction hood  
(Rear side)  
When the total length of refrigerant pipe exceeds  
20m, add 20g/m of refrigerant and the maximum total  
length of pipe is 50m.  
Discharge  
(Max. amount of additional refrigerant is 600g.)  
Discharge guide  
Fin  
Charge the refrigerant accurately. Overcharge may  
cause a serious trouble of compressor.  
Fin  
Suction  
Suction  
<SP800AT-E>  
Length of refrigerant pipe  
connected to  
Item  
indoor/outdoor unit  
Before installation  
Addition of refrigerant is  
unnecessary at the local site.  
30m or shorter  
Be careful to the following items before installation.  
<Addition of refrigerant>  
Add 40g of refrigerant for every  
1m of pipe which exceeds 30m.  
31m to 50m  
*
Length of refrigerant pipe  
* Caution at addition of refrigerant  
<SM560AT-E>  
When the total length of refrigerant pipe exceeds  
30m, add 40g/m of refrigerant and the maximum total  
length of pipe is 50m.  
Length of refrigerant pipe  
connected to  
Item  
indoor/outdoor unit  
(Max. amount of additional refrigerant is 800g.)  
Addition of refrigerant is  
20m or shorter  
unnecessary at the local site.  
Charge the refrigerant accurately. Overcharge may  
cause a serious trouble of compressor.  
<Addition of refrigerant>  
Add 20g of refrigerant for every  
1m of pipe which exceeds 20m.  
21m to 30m  
*
* Caution at addition of refrigerant  
Air purge  
When the total length of refrigerant pipe exceeds  
20m, add 20g/m of refrigerant and the maximum total  
length of pipe is 30m.  
For air purge, use a vacuum pump.  
Do not use refrigerant charged in the outdoor unit for  
air purge. (The refrigerant for air purge is not con-  
tained in the outdoor unit.)  
(Max. amount of additional refrigerant is 200g.)  
Charge the refrigerant accurately. Overcharge may  
cause a serious trouble of compressor.  
<SM800AT-E>  
Electrical cabling  
Length of refrigerant pipe  
Be sure to fix the power cables and indoor/outdoor  
connecting cables with clamps so that they do not  
contact with the cabinet, etc.  
connected to  
Item  
indoor/outdoor unit  
Addition of refrigerant is  
unnecessary at the local site.  
20m or shorter  
<Addition of refrigerant>  
Add 40g of refrigerant for every  
1m of pipe which exceeds 20m.  
21m to 50m  
*
* Caution at addition of refrigerant  
When the total length of refrigerant pipe exceeds  
20m, add 40g/m of refrigerant and the maximum total  
length of pipe is 50m.  
(Max. amount of additional refrigerant is 1200g.)  
Charge the refrigerant accurately. Overcharge may  
cause a serious trouble of compressor.  
38  
Installation Place  
Necessary Space for Installation  
Obstacle at rear side  
A place which provides a specified space around the  
outdoor unit.  
A place where the operation noise and discharged air  
are not given to your neighbors.  
<Upper side is free>  
1. Single unit installation  
A place that is not exposed to a strong wind.  
A place that does not block a passage.  
When the outdoor unit is installed in an elevated  
position, be sure to secure its feet.  
There must be sufficient space for carrying in the  
unit.  
2. Obstacles at both right and left sides.  
A place where the drain water does not make any  
The height of the  
obstacle should be  
lower than the height  
of the outdoor unit.  
problem.  
CAUTION  
150  
or more  
300  
or more  
1. Install the outdoor unit at a place where dis-  
charge air is not blocked.  
3. Serial installation of two or more units  
2. When an outdoor unit is installed in a place that  
is always exposed to a strong wind like a coast  
or on a high story of a building, secure a normal  
fan operation by using a duct or a wind shield.  
3. When installing the outdoor unit in a place that is  
constantly exposed to a strong wind such as the  
upper stairs or rooftop of a building, apply the  
windproof measures referring to the following  
examples.  
150  
or more  
300  
or more  
300  
or more  
300  
or more  
The height of the obstacle should be lower  
than the height of the outdoor unit.  
1) Install the unit so that its  
discharge port faces to the  
wall of the building. Keep a  
distance 500 mm or more  
between the unit and the  
wall surface.  
<Obstacle also at the upper side>  
150  
or more  
2) Supposing the wind direction during the  
operation season of the air conditioner, install  
the unit so that the discharge port is set at  
right angle to the wind direction.  
Obstacle at front side  
Strong  
wind  
<Upper side is free>  
Strong  
wind  
1. Single unit installation  
4. Installation in the following places may result in  
some troubles. Do not install the unit in such  
places below.  
2. Serial installation of two or more units  
A place full of machine oil.  
A place full of sulfuric gas.  
A place where high-frequency radio waves are  
likely to be generated as from audio equip-  
ment, welders, and medical equipment.  
39  
3
SELECTION OF INSTALLATION  
<Obstacle also at the upper side>  
Installation of Outdoor Unit  
Before installation, check strength and horizontality of  
the base so that abnormal sound does not generate.  
1000  
or more  
According to the following base diagram, fix the base  
firmly with the anchor bolts.  
(Anchor bolt, nut: M10 x 4 pairs)  
<SM560AT-E>  
90  
600  
115  
90  
Obstacles at both front and rear sides  
Open the upper side and both right and left sides.  
The height of obstacle at both front and rear side,  
should be lower than the height of the outdoor unit.  
<Standard installation>  
Ø28 Drain hole  
1. Single unit installation  
<SM800AT-E, SP560AT-E, SP800AT-E>  
150  
600  
150  
430  
Drain hole  
Drain nipple mounting hole  
Knockout hole  
2. Serial installation of two or more units  
Set the out margin of the anchor bolt to 15mm or less.  
15 or less  
300  
or more  
300  
or more  
In case of draining through the drain hose, attach the  
following drain nipple and the waterproof rubber cap,  
and use the drain hose (Inner diam.: 16mm) sold on  
the market. And also seal the screws securely with  
silicone material, etc. so that water does not drop  
down. Some conditions may cause dewing or drip-  
ping of water.  
Serial installation at front and rear sides  
Open the upper side and both right and left sides.  
The height of obstacle at both front and rear sides  
should be lower than the height of the outdoor unit.  
<Standard installation>  
1000  
or more  
300  
or more  
1500  
or more  
2000  
or more  
200  
or more  
Drain nipple  
Waterproof rubber cap  
40  
<SM560AT-E>  
Refrigerant Piping Connection  
CAUTION  
TAKE NOTICE THESE IMPORTANT  
Waterproof rubber cap  
4 POINTS BELOW FOR PIPING WORK  
1. Keep dust and moisture away from inside the  
connecting pipes.  
2. Tightly connect the connection between pipes  
and the unit.  
Base plate  
3. Evacuate the air in the connecting pipes using  
VACUUM PUMP.  
Drain nipple  
4. Check gas leak at connected points.  
<SM800AT-E, SP560AT-E, SP800AT-E>  
<Piping connection>  
Knockout hole  
Capacity  
rank  
Liquid side  
Gas side  
Outer  
Outer  
Thickness  
0.8  
Thickness  
RAV-  
diameter  
diameter  
Open  
Waterproof rubber cap  
Drain nipple  
SM560  
SP560  
Ø6.4  
Ø12.7  
0.8  
SM800  
SP800  
Ø9.5  
0.8  
Ø15.9  
1.0  
When there is a possibility of freezing of drain at the  
cold district or a snowfall area, be careful for drainage  
ability of drain.The drainage ability increases when a  
knockout hole on the base plate is opened. (Open the  
knockout hole to outside using a screwdriver, etc.)  
For Reference  
If a heating operation would be continuously performed  
for a long time under the condition that the outdoor  
temperature is 0°C or lower, draining of defrosted water  
may be difficult due to freezing of the bottom plate,  
resulting in a trouble of the cabinet or fan.  
Optional Installation Parts  
(Local Procure)  
Parts name  
Refrigerant piping  
Q’ty  
It is recommended to procure an anti-freeze heater  
locally for a safety installation of the air conditioner.  
A
Liquid side : Ø6.35 mm or Ø9.52 mm  
Each one  
For details, contact the dealer.  
Gas side : Ø12.7 mm or Ø15.9 mm  
Pipe insulating material  
(polyethylene foam, 6 mm thick)  
B
C
1
Putty, PVC tapes  
Each one  
41  
3
SELECTION OF INSTALLATION  
How to remove the front panel  
Knockout of Pipe Cover  
1. Remove screws of the front panel.  
2. Pull the front panel downward.  
<SM800AT-E, SP560AT-E, SP800AT-E>  
Removing the front panel, the electric parts appear at  
the front side.  
The metal pipes are attachable to the piping holes.  
If the size of the used power pipe does not match  
with the hole, adjust the hole size to match with pipe  
size.  
Rear direction  
Pipe cover  
Be sure to fix the power cable and indoor/outdoor  
connecting cable with bundling band sold on the  
market so that they do not make contact with the  
compressor and discharge pipe.  
(Temperature of the compressor and discharge pipe  
becomes high.)  
Side direction  
Front direction  
Down direction  
In order to avoid the force applied to on the connect-  
ing section, be sure to fix the cables to the cord  
clamps provided on the pipe valve fixing plate and the  
electric parts box.  
Knockout procedure  
The indoor/outdoor connecting pipes can be con-  
nected to 4 directions.  
Electric parts box  
Front panel  
Take off the knockout part of the pipe cover in which  
pipes or wires pass through the base plate.  
As shown in the figure, do not remove the pipe cover  
from the cabinet so that the knockout hole can be  
easily punched.To knock out, it is easily taken off by  
hands by punching a position at the lower side of 3  
connected parts with screwdriver along the guideline.  
Pipe valve  
fixing plate  
Piping  
hole  
After marking the knockout hole, remove the burr and  
mount the attached protective bush and guard  
material for pass-through part in order to protect  
pipes and wires.  
Cord clamp  
After connecting the pipes, be sure to mount the pipe  
cover. The pipe cover is easily mounted by cutting off  
the slit at the lower part of the pipe cover.  
42  
4
REFRIGERANT PIPING  
• Flaring size : A (Unit : mm)  
Pipe Forming/End Positioning  
+0  
0.4  
<SM560AT-E>  
A
-
Outer diam. of copper pipe  
Forming of pipe  
R410A  
R22  
9.0  
Form the pipe along with a marked line of the cabinet.  
End positioning of pipe  
6.35  
9.52  
12.7  
15.9  
9.1  
13.2  
16.6  
19.7  
13.0  
16.2  
19.4  
Match the ends of both pipes at a distance of  
85 mm apart from the marked line.  
* In case of flaring for R410A with the conventional  
flare tool, pull it out approx. 0.5 mm more than that of  
R22 to adjust to the specified flare size. The copper  
pipe gauge is useful for adjusting projection margin  
size.  
A
Marked line  
• Projection margin in flaring : B (Unit : mm)  
Rigid (Clutch type)  
Flaring  
1. Cut the pipe with a pipe cutter.  
Outer diam.  
of copper  
pipe  
R410A tool used  
R410A R22  
Conventional tool used  
R410A R22  
6.35  
9.52  
12.7  
15.9  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
90˚  
Obliquity Roughness  
Warp  
Imperial (Wing nut type)  
2. Insert a flare nut into the pipe, and flare the pipe.  
Outer diam. of  
copper pipe  
R410A  
R22  
As the flaring sizes of R410A differ from those of  
refrigerant R22, the flare tools newly manufactured  
for R410A are recommended.  
However, the conventional tools can be used by  
adjusting projection margin of the copper  
6.35  
9.52  
12.7  
15.9  
1.5 to 2.0  
1.5 to 2.0  
2.0 to 2.5  
2.0 to 2.5  
1.0 to 1.5  
1.0 to 1.5  
1.5 to 2.0  
1.5 to 2.0  
pipe.  
B
43  
4
REFRIGERANT PIPING  
Tightening of Connecting Part  
REQUIREMENT  
(Unit: Nm)  
1. Do not put the spanner on the cap. The valve  
may be broken.  
Outer diam. of copper pipe  
6.35mm (diam.)  
Tightening torque  
2. If applying excessive torque, the nut may be  
broken according to some installation conditions.  
14 to 18 (1.4 to 1.8kgfm)  
33 to 42 (3.3 to 4.2kgfm)  
50 to 62 (5.0 to 6.2kgfm)  
68 to 82 (6.8 to 8.2kgfm)  
9.52mm (diam.)  
12.7mm (diam.)  
After the installation work, be sure to check gas leak  
of connecting part of the pipes with nitrogen.  
15.9mm (diam.)  
Flare at  
indoor unit side  
Cover  
Flare at  
outdoor unit side  
Align the centers of the connecting pipes and tighten  
the flare nut strong as far as possible with your  
fingers.  
Then fix the nut with a spanner and tighten it with  
torque wrench as shown in the figure.  
Half union or packed valve  
Flare nut  
Pressure of R410A is higher than that of R22  
(Approx. 1.6 times).Therefore, using a torque  
wrench, tighten the flare pipe connecting sections  
which connect the indoor/outdoor units at the speci-  
fied tightening torque. Incomplete connections may  
cause not only a gas leak, but also a trouble of the  
refrigeration cycle.  
Externally  
threaded side  
Internally  
threaded side  
Fix with spanner.  
Tighten with torque wrench.  
As shown in the figure, be sure to use a double  
spanner to loosen or tighten the flare nut of the valve  
at gas side. If using a single spanner, the nut cannot  
be tightened with necessary tightening torque.  
Do not apply refrigerating machine oil to  
the flared surface.  
On the contrary, use a single spanner to loosen or  
tighten the flare nut of the valve at liquid side.  
Cover  
Cap  
Piping valve  
Loosened  
Tightened  
Flare nut  
SM800 type valve at gas side  
44  
5
EVACUATING  
Air Purge  
This air conditioner can be installed up to the connecting pipe length and height difference in the following table.  
Height difference (m)  
Max. connecting  
pipe length (m)  
Hexagonal  
wrench size  
Capacity rank  
Outdoor unit at upper side Outdoor unit at lower side  
SM560 type  
30  
50  
30  
30  
15  
15  
4mm  
SM800, SP560, SP800 type  
With respect to the preservation of terrestrial environment, adopt Vacuum pumpfor air purge (Evacuate air in  
the connecting pipes) when installing the unit.  
Do not discharge the refrigerant gas to the atmosphere to preserve the terrestrial environment.  
Use a vacuum pump to discharge the air (nitrogen, etc.) remained in the set. If the air remains, the capacity  
may decrease.  
For the vacuum pump, be sure to use one with backflow preventer so that the oil in the pump does not backflow  
into the pipe of the air conditioner when the pump stops. (If oil in the vacuum pump is put in an air conditioner  
including R410A, it may cause trouble on the refrigeration cycle.)  
Vacuum pump  
As shown in the right figure, connect the charge hose after the manifold valve are closed completely.  
Attach the connecting port of the charge hose with a projection to push the valve core (setting pin) to the charge port of the set.  
Open the handle Low fully.  
Turn ON the vacuum pump (*1)  
Loosen the flare nut of the packed valve (Gas side) a little to check the air passes through. (*2)  
Tighten the flare nut again.  
Execute vacuuming until the compound pressure gauge indicates 101kPa (76cmHg). (*1)  
Close handle Low completely.  
Turn OFF the vacuum pump.  
Leave the vacuum pump as it is for 1 or 2 minutes, and check the indicator of the compound pressure gauge does not return.  
Open fully the valve stem or the valve handle. (First, at liquid side, then gas side)  
Disconnect the charge hose from the charge port.  
Tighten valve and caps of the charge port surely.  
45  
5
EVACUATING  
<SM560AT-E>  
How to open the valve  
Compound pressure gauge  
Pressure gauge  
Valve unit  
101kPa  
(76cmHg)  
Manifold valve  
Handle Lo  
Handle Hi  
(Keep fully closed)  
Handle  
Pull out the handle and  
using cutting pliers, etc.  
turn it counterclockwise  
by 90˚. (Open fully)  
Charge hose  
(For R410A only)  
Charge hose  
(For R410A only)  
Vacuum pump adapter  
for counter-flow prevention  
(For R410A only)  
Charge port  
Flare nut  
Valve unit  
Vacuum  
pump  
Packed valve (Gas side)  
Service port (Valve core (Setting pin))  
Push in handle.  
Flare nut  
Valve unit  
Stopper  
Charge cap  
Charge port  
Flare nut  
Charge port  
Valve rod  
Handle position  
<SM800AT-E, SP560AT-E, SP800AT-E>  
Compound pressure gauge  
Pressure gauge  
101kPa  
(76cmHg)  
Handle  
Manifold valve  
Handle Lo  
Handle Hi  
Closed completely  
Opened fully  
(Keep fully closed)  
Charge hose  
(For R410A only)  
*1. Use the vacuum pump, vacuum pump adapters,  
and gauge manifold referring to the manuals  
attached to each tool before using them. For the  
vacuum pump, check oil is filled up to the specified  
line of the oil gauge.  
Charge hose  
(For R410A only)  
Service port  
(Valve core (Setting pin))  
Vacuum pump adapter  
for counter-flow prevention  
(For R410A only)  
*2. While the air is purged, check again that the  
connecting port of charge hose, which has a  
projection to push the valve core, is firmly con-  
nected to the charge port.  
Vacuum  
pump  
Packed valve at gas side  
Valve handling precautions  
Open the valve stem or the handle until it strikes  
the stopper. It is unnecessary to apply further  
force.  
Ø6.4  
14 to 18Nm (1.4 to 1.8kgfm)  
Ø9.5  
33 to 42Nm (3.3 to 4.2kgfm)  
Valve size  
Ø12.7 33 to 42Nm (3.3 to 4.2kgfm)  
Ø15.9 20 to 25Nm (2.0 to 2.5kgfm)  
14 to 18Nm (1.4 to 1.8kgfm)  
Securely tighten the cap with a torque wrench.  
Cap tightening torque  
Charge port  
46  
6
ELECTRICAL WORK  
For the air conditioner that has no power cable, connect  
a power cable as mentioned below.  
How to wire  
1. Connect the connecting cable to the terminal as  
identified with their respective numbers on the  
terminal block of indoor and outdoor unit.  
SM800AT-E  
Model RAV-  
SM560AT-E SP560AT-E  
H07 RN-F or 245 IEC 66 (1.0 mm2 or more)  
SP800AT-E  
2. When connecting the connecting cable to the  
outdoor unit terminal, prevent water coming in the  
outdoor unit.  
220 240 V  
Single phase 50 Hz  
Power supply  
Maximum running current  
Installation fuse rating  
12A  
15A  
3. Insulate the unsheathed cords (conductors) with  
electrical insulation tape. Process them so that they  
do not touch any electrical or metal parts.  
25 A (D type  
)
H07 RN-F or 245 IEC 66  
(2.5 mm2 or more)  
Power cable  
4. For inter connecting cable, do not use a wire jointed  
to another on the way.  
Use wires long enough to cover the entire length.  
CAUTION  
Terminal block  
Wrong wiring may cause a burnout to some  
electrical parts.  
1
2
3
L
N
Be sure to use the cord clamps attached to the  
product.  
Do not damage or scratch the conductive core  
and inner insulator of power and inter-connecting  
cables when peeling them.  
Screw  
Power cable  
Connecting  
cable  
Be sure to comply with local regulations of the  
cable from outdoor unit to indoor unit.  
(wire size and cabling method etc.)  
Use the power and Inter-connecting cables with  
specified thickness, specified type and protective  
devices required.  
Stripping length power cord and connecting cable  
10  
10  
1 2 3  
L
N
10  
10  
<SM560AT-E>  
How to remove the valve cover  
40  
40  
30  
30  
1. Remove screws of the valve cover.  
2. Pull the valve cover downward to remove it.  
Earth line Earth line  
(mm)  
Connecting  
cable  
Power cable  
Valve cover  
CAUTION  
Piping cover  
The installation fuse (25A D type  
) must  
be used for the power supply line of this air  
conditioner.  
Cord clamp  
Incorrect/incomplete wiring might cause an  
electrical fire or smoke.  
Indoor/outdoor  
connecting cables  
Prepare the exclusive power supply for the air  
conditioner.  
Power cable  
This product can be connected to the mains.  
Connection to the fixed wiring :  
A switch which disconnects all poles and has a  
contact separation of at least 3 mm must be  
incorporated in the fixed wiring.  
47  
7
FINAL INSTALLATION CHECKS  
Check and Test Operation  
Valve cover  
For R410A, use the leak detector exclusively manufactured for  
HFC refrigerant (R410A, R134a, etc.).  
Piping  
cover  
The conventional leak detector for HCFC refrigerant (R22,  
etc.) cannot be used because its sensitivity for HFC refrigerant  
lowers to approx. 1/40.  
*
Flare nut  
connections  
(Indoor unit)  
Pressure of R410A is approx. 1.6 times higher than that of  
R22.  
If installation work is incompletely finished, a gas leakage may  
occur when pressure rises during operation.  
Therefore, be sure to test the piping connections for leakage.  
Check points  
of outdoor unit  
Check gas leakage at the flare nut connections, valve stem  
cap connections and service port cap fittings with a leak  
detector or soap water.  
CAUTION  
When the remote controller is used for the first time, it accepts an operation approx. 5 minutes after the power  
supply has been turned on.  
It is not a trouble, but is because the setup of the remote controller is being checked.  
For the second power-ON time and after, approx. 1 minute is required to start the operation by the remote controller.  
Useful Functions  
(SM800AT-E, SP560AT-E, SP800AT-E)  
Self-Diagnosis by LED Indication  
In addition to the code checking by remote controller of the indoor unit, troubles of the outdoor unit can be diag-  
nosed by LED indications on the cycle control P.C. board of the outdoor unit. Utilize them for various checks.  
For the check by remote controller of the indoor unit, refer to the Installation Manual of the indoor unit.  
Before a check, confirm each bit of the DIP switch is set to OFF position.  
LED indication and code checking  
Cycle control P.C. board  
LED indication  
LED indication  
Cause  
D800 D801 D802 D803  
Heat exchanger sensor (TE) error  
Suction sensor (TS) error  
¡
l
¡
l
l
¡
¡
l
l
¡
l
¥
l
¥
l
¥
l
l
¡
¡
¡
¡
l
¡
¡
¡
l
l
¥
¥
l
l
l
¡
l
l
l
¡
l
l
¡
l
¡
l
l
l
¥
¥
l
l
l
¡
l
l
¡
¡
l
¡
¡
l
l
l
l
l
Discharge sensor (TD) error  
High-pressure protection error  
Outdoor temperature sensor (TO) error  
DC outside fan error  
D800 ¡ : Red  
D801 ¡ :Yellow  
D802 ¡ :Yellow  
D803 ¡ :Yellow  
Communication error between IPDU (Abnormal stop)  
High-pressure release operation  
Discharge temp. error  
¥ : Rapid flash  
l : Go off  
EEPROM error  
Communication error between IPDU (No abnormal stop)  
G-Tr short-circuit protection  
Detect circuit error  
¡ : Go on  
Current sensor error  
Comp. lock error  
Comp. break down  
48  
Installation/ServicingTools  
Changes in the product and components  
In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged acciden-  
tally, service port diameter of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads  
per inch)  
In order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of  
opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)  
New tools for R410A  
New tools for R410A  
Applicable to R22 model  
Changes  
As pressure is high, it is impossible to measure by means of conventional  
gauge. In order to prevent any other refrigerant from being charged, each  
port diameter is changed.  
Gauge manifold  
×
In order to increase pressure resisting strength, hose materials and port  
size are changed (to 1/2 UNF 20 threads per inch).  
When purchasing a charge hose, be sure to check the port size.  
Charge hose  
×
Electronic balance  
for refrigerant charging  
As pressure is high and gasification speed is fast, it is difficult to read the  
indicated value by means of charging cylinder, as air bubbles occur.  
¡
Torque wrench  
The sizes of opposite sides of flare nuts have been increased. Inciden-  
tally, a common wrench is used for nominal diameters 1/4 and 3/8.  
×
¡
(nominal diam. 1/2, 5/8)  
Flare tool  
(clutch type)  
By increasing the clamp bars receiving hole, strength of spring in the tool  
has been improved.  
Gauge for projection adjustment  
Used when flare is made with using conventional flare tool.  
Connected to the conventional vacuum pump. It is necessary to use an  
adapter to prevent vacuum pump oil from flowing back to the charge hose.  
The charge hose connecting part has two ports - one for conventional  
refrigerant (7/16 UNF 20 threads per inch) and the other for R410A. If the  
vacuum pump oil (mineral) mixes with R410A, sludge may occur and  
damage the equipment.  
Vacuum pump adapter  
¡
Gas leakage detector  
X
Exclusive for HFC refrigerant.  
×
Incidentally, the refrigerant cylindercomes with the refrigerant designation (R410A) and protector coating in the  
U.S.s ARI specified rose color (ARI color code: PMS 507).  
Also, the charge port and packing for refrigerant cylinderrequire 1/2 UNF 20 threads per inch corresponding to  
the charge hoses port size.  
49  
1
PRECAUTIONS FOR SAFETY  
• Ensure that all Local, National and International regulations are satisfied.  
• Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.  
• The precautions described below include the important items regarding safety. Observe them without fail.  
• After the installation work, perform a trial operation to check for any problem.  
Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.  
Turn off the main power supply switch (or breaker) before the unit maintenance.  
• Ask the customer to keep the Installation Manual together with the Owner’s Manual.  
CAUTION  
New Refrigerant Air Conditioner Installation  
• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DE-  
STROY OZONE LAYER.  
The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure  
is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil  
has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or  
refrigerating oil does not enter the refrigerating cycle.  
To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging  
port of the main unit and installation tools are charged from those for the conventional refrigerant.  
Accordingly the exclusive tools are required for the new refrigerant (R410A).  
For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust  
does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance  
force and impurity in it.  
CAUTION  
To Disconnect the Appliance from Main Power Supply.  
This appliance must be connected to the main power supply by means of a switch with a contact separation of  
at least 3 mm.  
The installation fuse (25A D type  
) must be used for the power supply line of this conditioner.  
WARNING  
• Ask an authorized dealer or qualified installation professional to install/maintain the air condi-  
tioner.  
Inappropriate installation may result in water leakage, electric shock or fire.  
Turn off the main power supply switch or breaker before attempting any electrical work.  
Make sure all power switches are off. Failure to do so may cause electric shock.  
• Connect the connecting cable correctly.  
If the connecting cable is connected in a wrong way, electric parts may be damaged.  
• When moving the air conditioner for the installation into another place, be very careful not to  
enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.  
If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnor-  
mally high and it may resultingly causes pipe burst and injuries on persons.  
• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety  
interlock switches.  
• Exposure of unit to water or other moisture before installation may cause a short-circuit of  
electrical parts.  
Do not store it in a wet basement or expose to rain or water.  
• After unpacking the unit, examine it carefully if there are possible damage.  
• Do not install in a place that might increase the vibration of the unit.  
• To avoid personal injury (with sharp edges), be careful when handling parts.  
• Perform installation work properly according to the Installation Manual.  
Inappropriate installation may result in water leakage, electric shock or fire.  
50  
• When the air conditioner is installed in a small room, provide appropriate measures to ensure  
that the concentration of refrigerant leakage occur in the room does not exceed the critical  
level.  
• Install the air conditioner securely in a location where the base can sustain the weight adequately.  
• Perform the specified installation work to guard against an earthquake.  
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.  
• If refrigerant gas has leaked during the installation work, ventilate the room immediately.  
If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.  
• After the installation work, confirm that refrigerant gas does not leak.  
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas  
might generate.  
• Electrical work must be performed by a qualified electrician in accordance with the Installation  
Manual. Make sure the air conditioner uses an exclusive power supply.  
An insufficient power supply capacity or inappropriate installation may cause fire.  
• Use the specified cables for wiring connect the terminals securely fix. To prevent external  
forces applied to the terminals from affecting the terminals.  
• Be sure to provide grounding.  
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.  
• Conform to the regulations of the local electric company when wiring the power supply.  
Inappropriate grounding may cause electric shock.  
• Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.  
If a combustible gas leaks, and stays around the unit, a fire may occur.  
Required tools for installation work  
R410A (Special requirement)  
17) Gauge manifold  
(Charge hose : R410A special requirement)  
18) Vacuum pump  
(Charge hose : R410A special requirement)  
19) Torque wrench  
1/4 (17 mm) 16 Nm (1.6 kgfm)  
3/8 (22 mm) 42 Nm (4.2 kgfm)  
1/2 (26 mm) 55 Nm (5.5 kgfm)  
5/8 (15.9 mm) 120 Nm (12.0 kgfm)  
20) Copper pipe gauge adjusting projection margin  
10) Mega-tester  
11) Electro circuit tester  
12) Hexagonal wrench  
13) Flare tool  
14) Pipe bender  
15) Level vial  
1) Philips screw driver  
2) Hole core drill (65 mm)  
3) Spanner  
4) Pipe cutter  
5) Knife  
6) Reamer  
7) Gas leak detector  
8) Tape measure  
9) Thermometer  
16) Metal saw  
21) Vacuum pump adapter  
2
ACCESSORY AND REFRIGERANT  
Accessory and Installation Parts  
Refrigerant Piping  
Piping kit used for the conventional refrigerant cannot be  
used.  
1
3
4
Use copper pipe with 0.8 mm or more thickness for Ø9.5.  
Outdoor unit  
Use copper pipe with 1.0 mm or more thickness for  
Ø15.9.  
Installation manual x 1  
Protective bush  
Drain nipple  
Flare nut and flare works are also different from those of  
the conventional refrigerant. Take out the flare nut  
attached to the main unit of the air conditioner, and use it.  
2
Guard material for  
passage part  
Waterproof rubber cap  
51  
3
SELECTION OF INSTALLATION  
CAUTION  
<SP1100AT-E, SP1400AT-E only>  
When using an air conditioner under low outside temperature condition (Outside temp.:5°C or lower) with  
COOL mode, prepare a duct or wind shield so that it is not affected by the wind.  
<Example>  
Discharge upward/downward  
or leftward is also available.  
(
)
Suction hood (Side)  
Discharge hood  
Suction hood (Rear side)  
Use it at location  
where a side wind  
drives thickly  
Discharge  
Fin  
Fin  
Suction  
Suction  
<SP1100AT-E, SP1400AT-E>  
Before installation  
Length of refrigerant pipe  
connected to  
Be careful to the following items before installation.  
Item  
indoor/outdoor unit  
Addition of refrigerant is  
unnecessary at the local site.  
Length of refrigerant pipe  
<SM1100AT-E, SM1400AT-E>  
Length of refrigerant pipe  
30m or shorter  
<Addition of refrigerant>  
Add 40g of refrigerant for every  
1m of pipe which exceeds 30m.  
31m to 70m  
*
connected to  
Item  
indoor/outdoor unit  
* Caution at addition of refrigerant  
When the total length of refrigerant pipe exceeds  
30m, add 40g/m of refrigerant and the maximum total  
length of pipe is 70m.  
Addition of refrigerant is  
unnecessary at the local site.  
20m or shorter  
<Addition of refrigerant>  
Add 40g of refrigerant for every  
1m of pipe which exceeds 20m.  
(Max. amount of additional refrigerant is 1600g.)  
21m to 50m  
*
Charge the refrigerant accurately. Overcharge may  
cause a serious trouble of compressor.  
* Caution at addition of refrigerant  
When the total length of refrigerant pipe exceeds  
20m, add 40g/m of refrigerant and the maximum total  
length of pipe is 50m.  
Air purge  
For air purge, use a vacuum pump.  
(Max. amount of additional refrigerant is 1200g.)  
Do not use refrigerant charged in the outdoor unit for  
air purge. (The refrigerant for air purge is not con-  
tained in the outdoor unit.)  
Charge the refrigerant accurately. Overcharge may  
cause a serious trouble of compressor.  
Electrical cabling  
Be sure to fix the power cables and indoor/outdoor  
connecting cables with clamps so that they do not  
contact with the cabinet, etc.  
52  
Installation Place  
Necessary Space for Installation  
Obstacle at rear side  
A place which provides a specified space around the  
outdoor unit.  
A place where the operation noise and discharged air  
are not given to your neighbors.  
<Upper side is free>  
1. Single unit installation  
A place that is not exposed to a strong wind.  
A place that does not block a passage.  
When the outdoor unit is installed in an elevated  
position, be sure to secure its feet.  
There must be sufficient space for carrying in the  
unit.  
2. Obstacles at both right and left sides.  
A place where the drain water does not make any  
The height of the  
obstacle should be  
lower than the height  
of the outdoor unit.  
problem.  
CAUTION  
150  
or more  
300  
or more  
1. Install the outdoor unit at a place where dis-  
charge air is not blocked.  
3. Serial installation of two or more units  
2. When an outdoor unit is installed in a place that  
is always exposed to a strong wind like a coast  
or on a high storey of a building, secure a  
normal fan operation by using a duct or a wind  
shield.  
3. When installing the outdoor unit in a place that is  
constantly exposed to a strong wind such as the  
upper stairs or rooftop of a building, apply the  
windproof measures referring to the following  
examples.  
150  
or more  
300  
or more  
300  
or more  
300  
or more  
The height of the obstacle should be lower  
than the height of the outdoor unit.  
1) Install the unit so that its  
discharge port faces to the  
wall of the building. Keep a  
distance 500 mm or more  
between the unit and the  
wall surface.  
<Obstacle also at the upper side>  
150  
or more  
2) Supposing the wind direction during the  
operation season of the air conditioner, install  
the unit so that the discharge port is set at  
right angle to the wind direction.  
Obstacle at front side  
Strong  
wind  
<Upper side is free>  
Strong  
wind  
1. Single unitIn installation  
4. Installation in the following places may result in  
some troubles. Do not install the unit in such  
places below.  
2. Serial installation of two or more units  
A place full of machine oil.  
A place full of sulphuric gas.  
A place where high-frequency radio waves are  
likely to be generated as from audio quipment,  
welders, and medical equipment.  
53  
3
SELECTION OF INSTALLATION  
<Obstacle also at the upper side>  
Installation of Outdoor Unit  
Before installation, check strength and horizontality of  
the base so that abnormal sound does not generate.  
1000  
or more  
According to the following base diagram, fix the base  
firmly with the anchor bolts.  
(Anchor bolt, nut: M10 x 4 pairs)  
150  
600  
150  
430  
Obstacles at both front and rear sides  
Drain hole  
Open the upper side and both right and left sides.  
The height of obstacle at both front and rear side,  
should be lower than the height of the outdoor unit.  
Drain nipple mounting hole  
Knockout hole  
<Standard installation>  
1. Single unit installation  
Set the out margin of the anchor bolt to 15mm or less.  
15 or less  
In case of drainning through the drain hose, attach  
the following drain nipple and the waterproof rubber  
cap, and use the drain hose (Inner diam.: 16mm) sold  
on the market. And also seal the screws securely with  
silicone material, etc. so that water does not drop  
down. Some conditions may cause dewing or drip-  
ping of water.  
2. Serial installation of two or more units  
300  
or more  
300  
or more  
Drain nipple  
Waterproof rubber cap  
Knockout hole  
Serial installation at front and rear sides  
Open the upper side and both right and left sides.  
The height of obstacle at both front and rear sides  
should be lower than the height of the outdoor unit.  
<Standard installation>  
Open  
Waterproof rubber cap  
Drain nipple  
When there is a possibility of freezing of drain at the  
cold district or a snowfall area, be careful for drainage  
ability of drain.The drainage ability increases when a  
knockout hole on the base plate is opened. (Open the  
knockout hole to outside using a screwdriver, etc.)  
1000  
or more  
300  
or more  
1500  
or more  
2000  
or more  
200  
or more  
54  
Optional Installation Parts  
(Local Procure)  
Knockout of Pipe Cover  
Parts name  
Q’ty  
Refrigerant piping  
Liquid side : Ø9.5 mm  
Gas side : Ø15.9 mm  
A
Each one  
Pipe insulating material  
(polyethylene foam, 6 mm thick)  
B
C
1
Rear direction  
Putty, PVC tapes  
Each one  
Pipe cover  
Side direction  
Front direction  
Down direction  
Refrigerant Piping Connection  
CAUTION  
TAKE NOTICE THESE IMPORTANT  
4 POINTS BELOW FOR PIPING WORK  
Knockout procedure  
1. Keep dust and moisture away from inside the  
connecting pipes.  
The indoor/outdoor connecting pipes can be con-  
nected to 4 directions.  
2. Tightly connect the connection between pipes  
and the unit.  
Take off the knockout part of the pipe cover in which  
pipes or wires pass through the base plate.  
3. Evacuate the air in the connecting pipes using  
VACUUM PUMP.  
As shown in the figure, do not remove the pipe cover  
from the cabinet so that the knockout hole can be  
easily punched.To knock out, it is easily taken off by  
hands by punching a position at the lower side of 3  
connected parts with screwdriver along the guide  
line.  
4. Check gas leak at connected points.  
<Piping connection>  
After marking the knockout hole, remove the burr and  
mount the attached protective bush and guard  
material for pass-through part in order to protect  
pipes and wires.  
Liquid side  
Gas side  
Outer diameter Thickness Outer diameter Thickness  
Ø9.5  
0.8  
Ø15.9  
1.0  
After connecting the pipes, be sure to mount the pipe  
cover. The pipe cover is easily mounted by cutting off  
the slit at the lower part of the pipe cover.  
For Reference  
If a heating operation would be continuously performed  
for a long time under the condition that the outdoor  
temperature is 0°C or lower, draining of defrosted water  
may be difficult due to freezing of the bottom plate,  
resulting in a trouble of the cabinet or fan.  
It is recommended to procure an anti-freeze heater  
locally for a safety installation of the air conditioner.  
For details, contact the dealer.  
55  
3
SELECTION OF INSTALLATION  
In order to avoid the force applied to on the connect-  
ing section, be sure to fix the cables to the cord  
clamps provided on the pipe valve fixing plate and the  
electric parts box.  
How to remove the front panel  
1. Remove screws of the front panel.  
2. Pull the front panel downward.  
Front panel  
Electric parts box  
Removing the front panel, the electric parts appear at  
the front side.  
The metal pipes are attachable to the piping holes.  
If the size of the used power pipe does not match  
with the hole, adjust the hole size to match with pipe  
size.  
Terminal  
plate  
Be sure to fix the power cable and indoor/outdoor  
connecting cable with bundling band sold on the  
market so that they do not make contact with the  
compressor and discharge pipe.  
(Temperature of the compressor and discharge pipe  
becomes high.)  
Piping  
hole  
Cord clamp  
4
REFRIGERANT PIPING  
* In case of flaring for R410A with the conventional  
flare tool, pull it out approx. 0.5 mm more than that of  
R22 to adjust to the specified flare size. The copper  
pipe gauge is useful for adjusting projection margin  
Pipe Forming/End Positioning  
Flaring  
size.  
1. Cut the pipe with a pipe cutter.  
A
90˚  
Obliquity Roughness  
Warp  
• Projection margin in flaring : B (Unit : mm)  
Rigid (Clutch type)  
2. Insert a flare nut into the pipe, and flare the pipe.  
As the flaring sizes of R410A differ from those of  
refrigerant R22, the flare tools newly manufactured  
for R410A are recommended.  
However, the conventional  
tools can be used by adjusting  
projection margin of the copper  
pipe.  
Outer dia.  
of copper  
pipe  
R410A tool used  
R410A R22  
Conventional tool used  
R410A R22  
B
6.4  
9.5  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
0 to 0.5 (Same as left) 1.0 to 1.5 0.5 to 1.0  
12.7  
15.9  
• Flaring size : A (Unit : mm)  
Imperial (Wing nut type)  
+0  
A
-
0.4  
Outer dia. of copper pipe  
R410A  
9.1  
R22  
9.0  
Outer dia. of copper pipe  
R410A  
R22  
6.4  
9.5  
6.4  
9.5  
1.5 to 2.0  
1.5 to 2.0  
2.0 to 2.5  
2.0 to 2.5  
1.0 to 1.5  
1.0 to 1.5  
1.5 to 2.0  
1.5 to 2.0  
13.2  
16.6  
19.7  
13.0  
16.2  
19.4  
12.7  
15.9  
12.7  
15.9  
56  
4
REFRIGERANT PIPING  
Tightening of Connecting Part  
REQUIREMENT  
(Unit: Nm)  
1. Do not put the spanner on the cap. The valve  
may be broken.  
Outer dia. of copper pipe  
6.4 mm (diam.)  
Tightening torque  
2. If applying excessive torque, the nut may be  
broken according to some installation conditions.  
14 to 18 (1.4 to 1.8 kgfm)  
33 to 42 (3.3 to 4.2 kgfm)  
50 to 62 (5.0 to 6.2 kgfm)  
68 to 82 (6.8 to 8.2 kgfm)  
9.5 mm (diam.)  
12.7 mm (diam.)  
15.9 mm (diam.)  
After the installation work, be sure to check gas leak  
of connecting part of the pipes with nitrogen.  
Flare at  
indoor unit side  
Cover  
Flare at  
outdoor unit side  
Align the centers of the connecting pipes and tighten  
the flare nut strong as far as possible with your  
fingers.  
Then fix the nut with a spanner and tighten it with  
torque wrench as shown in the figure.  
Pressure of R410A is higher than that of R22  
(Approx. 1.6 times).Therefore, using a torque  
wrench, tighten the flare pipe connecting sections  
which connect the indoor/outdoor units at the speci-  
fied tightening torque. Incomplete connections may  
cause not only a gas leak, but also a trouble of the  
refrigeration cycle.  
Half union or packed valve  
Flare nut  
Externally  
threaded side  
Internally  
threaded side  
Fix with spanner.  
Tighten with torque wrench.  
Do not apply refrigerating machine oil to  
the flared surface.  
As shown in the figure, be sure to use a double  
spanner to loosen or tighten the flare nut of the valve  
at gas side. If using a single spanner, the nut cannot  
be tightened with necessary tightening torque.  
On the contrary, use a single spanner to loosen or  
tighten the flare nut of the valve at liquid side.  
Cover  
Cap  
Piping valve  
Loosened  
Tightened  
Flare nut  
Valve at gas side  
57  
5
EVACUATING  
Air Purge  
This air conditioner can be installed up to the connecting pipe length and height difference in the following table.  
Height difference (m)  
Max. connecting  
pipe length (m)  
Hexagonal  
wrench size  
Capacity rank  
Outdoor unit at upper side Outdoor unit at lower side  
SM1100, SM1400 type  
SP1100, SP1400 type  
50  
70  
30  
30  
15  
15  
4mm  
With respect to the preservation of terrestrial environment, adopt Vacuum pumpfor air purge (Evacuate air in  
the connecting pipes) when installing the unit.  
Do not discharge the refrigerant gas to the atmosphere to preserve the terrestrial environment.  
Use a vacuum pump to discharge the air (nitrogen, etc.) remained in the set. If the air remains, the capacity  
may decrease.  
For the vacuum pump, be sure to use one with backflow preventer so that the oil in the pump does not backflow  
into the pipe of the air conditioner when the pump stops. (If oil in the vacuum pump is put in an air conditioner  
including R410A, it may cause trouble on the refrigeration cycle.)  
Vacuum pump  
As shown in the right figure, connect the charge hose after the manifold valve are closed completely.  
Attach the connecting port of the charge hose with a projection to push the valve core (setting pin) to the charge port of the set.  
Open handle Low fully.  
Turn ON the vacuum pump (*1)  
Loosen the flare nut of the packed valve (Gas side) a little to check the air passes through. (*2)  
Tighten the flare nut again.  
Execute vacuuming until the compound pressure gauge indicates 101kPa (76cmHg). (*1)  
Close handle Low completely.  
Turn OFF the vacuum pump.  
Leave the vacuum pump as it is for 1 or 2 minutes, and check the indicator of the compound pressure gauge does not return.  
Open fully the valve stem or the valve handle. (First, at liquid side, then gas side)  
Disconnect the charge hose from the charge port.  
Tighten valve and caps of the charge port surely.  
58  
Compound pressure gauge  
Pressure gauge  
Handle position  
101kPa  
(76cmHg)  
Manifold valve  
Handle Lo  
Handle Hi  
(Keep fully closed)  
Charge hose  
(For R410A only)  
Charge hose  
(For R410A only)  
Service port  
(Valve core (Setting pin))  
Handle  
Vacuum pump adapter  
for counter-flow prevention  
(For R410A only)  
Closed completely  
Opened fully  
Vacuum  
pump  
*1. Use the vacuum pump, vacuum pump adapters,  
and gauge manifold referring to the manuals  
attached to each tool before using them. For the  
vacuum pump, check oil is filled up to the specified  
line of the oil gauge.  
Packed valve at gas side  
*2. While the air is purged, check again that the  
connecting port of charge hose, which has a  
projection to push the valve core, is firmly con-  
nected to the charge port.  
How to open the valve  
Valve unit  
Valve handling precautions  
Open the valve stem or the handle until it strikes  
the stopper. It is unnecessary to apply further  
force.  
Handle  
Pull out the handle and  
using cutting pliers, etc.  
turn it counterclockwise  
by 90˚. (Open fully)  
Securely tighten the cap with a torque wrench.  
Charge port  
Cap tightening torque  
Flare nut  
Valve unit  
Ø6.4  
14 to 18Nm (1.4 to 1.8kgfm)  
Ø9.5  
33 to 42Nm (3.3 to 4.2kgfm)  
Valve size  
Ø12.7 33 to 42Nm (3.3 to 4.2kgfm)  
Ø15.9 20 to 25Nm (2.0 to 2.5kgfm)  
14 to 18Nm (1.4 to 1.8kgfm)  
Charge port  
Push in handle.  
Charge port  
Flare nut  
59  
6
ELECTRICAL WORK  
For the air conditioner that has no power cable, connect  
a power cable as mentioned below.  
Stripping length power cord and connecting cable  
SM1400AT-E  
SM1100AT-E SP1100AT-E  
SP1400AT-E  
Model RAV-  
10  
10  
1 2 3  
L
N
10  
10  
220 240 V  
Single phase 50 Hz  
Power supply  
50  
40  
40  
30  
Maximum running current  
Installation fuse rating  
22.0 A  
22.8 A  
25 A (D type  
)
Earth line Earth line  
(mm)  
H07 RN-F or 245 IEC 66  
(2.5 mm2 or more)  
Connecting  
cable  
Power cable  
Power cable  
CAUTION  
CAUTION  
The installation fuse (25A D type  
be used for the power supply line of this air  
conditioner.  
Incorrect/incomplete wiring might cause an  
electrical fire or smoke.  
Prepare the exclusive power supply for the air  
conditioner.  
) must  
Wrong wiring may cause a burn-out to some  
electrical parts.  
Be sure to use the cord clamps attached to the  
product.  
Do not damage or scratch the conductive core  
and inner insulator of power and inter-connecting  
cables when peeling them.  
This product can be connected to the mains.  
Be sure to comply with local regulations of the  
cable from outdoor unit to indoor unit.  
(wire size and cabling method etc.)  
Connection to the fixed wiring :  
A switch which disconnects all poles and has a  
contact separation of at least 3 mm must be  
incorporated in the fixed wiring.  
Use the power and Inter-connecting cables with  
specified thickness, specified type and protective  
devices required.  
How to wire  
1. Connect the connecting cable to the terminal as  
identified with their respective numbers on the  
terminal block of indoor and outdoor unit.  
H07 RN-F or 245 IEC 66 (1.0 mm2 or more)  
2. When connecting the connecting cable to the  
outdoor unit terminal, prevent water coming in the  
outdoor unit.  
3. Insulate the unsheathed cords (conductors) with  
electrical insulation tape. Process them so that they  
do not touch any electrical or metal parts.  
4. For inter connecting cable, do not use a wire jointed  
to another on the way.  
Use wires long enough to cover the entire length.  
Power supply  
terminal block  
To Indoor unit  
terminal block  
1
2
3
L
N
Earth screw  
Power cable  
Connecting cable  
60  
7
FINAL INSTALLATION CHECKS  
Check and Test Operation  
For R410A, use the leak detector exclusively manufactured for HFC refrigerant (R410A, R134a, etc.).  
The conventional leak detector for HCFC refrigerant (R22, etc.) cannot be used because its sensitivity for HFC  
refrigerant lowers to approx. 1/40.  
*
Pressure of R410A is approx. 1.6 times higher than that of R22.  
If installation work is incompletely finished, a gas leakage may occur when pressure rises during operation.  
Therefore, be sure to test the piping connections for leakage.  
Check gas leakage at the flare nut connections, valve stem cap connections and service port cap fittings with a  
leak detector or soap water.  
CAUTION  
When the remote controller is used for the first time, it accepts an operation approx. 5 minutes after the power  
supply has been turned on.  
It is not a trouble, but is because the setup of the remote controller is being checked.  
For the second power-ON time and after, approx. 1 munute is required to start the operation by the remote controller.  
Useful Functions  
Self-Diagnosis by LED Indication  
In addition to the code checking by remote controller of the indoor unit, troubles of the outdoor unit can be diag-  
nosed by LED indications on the cycle control P.C. board of the outdoor unit. Utilize them for various checks.  
For the check by remote controller of the indoor unit, refer to the Installation Manual of the indoor unit.  
Before a check, confirm each bit of the DIP switch SW800 is set to OFF position.  
LED indication and code checking  
Cycle control P.C. board  
LED indication  
LED indication  
Cause  
D800 D801 D802 D803  
Heat exchanger sensor (TE) error  
Suction sensor (TS) error  
¡
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l
¥
l
¥
l
¥
l
l
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l
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l
l
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Discharge sensor (TD) error  
High-pressure protection error  
Outdoor temperature sensor (TO) error  
DC outside fan error  
D800 ¡ : Red  
D801 ¡ :Yellow  
D802 ¡ :Yellow  
D803 ¡ :Yellow  
Communication error between IPDU (Abnormal stop)  
High-pressure release operation  
Discharge temp. error  
¥ : Rapid flash  
l : Go off  
¡ : Go on  
EEPROM error  
Communication error between IPDU (No abnormal stop)  
G-Tr short-circuit protection  
Detect circuit error  
Current sensor error  
Comp. lock error  
Comp. break down  
61  
7
FINAL INSTALLATION CHECKS  
Installation/ServicingTools  
Changes in the product and components  
In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged acciden-  
tally, service port diameter of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads  
per inch)  
In order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of  
opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)  
New tools for R410A  
New tools for R410A  
Applicable to R22 model  
Changes  
As pressure is high, it is impossible to measure by means of conventional  
gauge. In order to prevent any other refrigerant from being charged, each  
port diameter is changed.  
Gauge manifold  
×
In order to increase pressure resisting strength, hose materials and port  
size are changed (to 1/2 UNF 20 threads per inch).  
When purchasing a charge hose, be sure to check the port size.  
Charge hose  
×
Electronic balance  
for refrigerant charging  
As pressure is high and gasification speed is fast, it is difficult to read the  
indicated value by means of charging cylinder, as air bubbles occur.  
¡
Torque wrench  
(nominal diam. 1/2, 5/8)  
The size of opposite sides of flare nuts have been increased. Incidentally,  
a common wrench is used for nominal diameters 1/4 and 3/8.  
×
¡
Flare tool  
(clutch type)  
By increasing the clamp bars receiving hole, strength of spring in the tool  
has been improved.  
Gauge for projection adjustment  
Used when flare is made with using conventional flare tool.  
Connected to the conventional vacuum pump. It is necessary to use an  
adapter to prevent vacuum pump oil from flowing back to the charge hose.  
The charge hose connecting part has two ports-one for conventional  
refrigerant (7/16 UNF 20 threads per inch) and one for R410A.  
If the vacuum pump oil (mineral) mixes with R410A a sludge may occur  
and damage the equipment.  
Vacuum pump adapter  
¡
Gas leakage detector  
Exclusive for HFC refrigerant.  
×
Incidentally, the refrigerant cylindercomes with the refrigerant designation (R410A) and protector coating in the  
U,S.s ARI specified rose color (ARI color code: PMS 507).  
Also, the charge port and packing for refrigerant cylinderrequire 1/2 UNF 20 threads per inch corresponding to  
the charge hoses port size.  
62  

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