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
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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
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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
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• 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 N•m (1.6 kgf•m)
3/8 (22 mm) 42 N•m (4.2 kgf•m)
1/2 (26 mm) 55 N•m (5.5 kgf•m)
5/8 (15.9 mm) 120 N•m (12.0 kgf•m)
20) Copper pipe gauge adjusting projection margin
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
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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
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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
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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
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<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
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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
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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
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4
REFRIGERANT PIPING
Tightening of Connecting Part
REQUIREMENT
(Unit: N•m)
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 1.8kgf•m)
33 to 42 (3.3 to 4.2kgf•m)
50 to 62 (5.0 to 6.2kgf•m)
68 to 82 (6.8 to 8.2kgf•m)
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
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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 pump” for 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
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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 18N•m (1.4 to 1.8kgf•m)
Ø9.5
33 to 42N•m (3.3 to 4.2kgf•m)
Valve size
Ø12.7 33 to 42N•m (3.3 to 4.2kgf•m)
Ø15.9 20 to 25N•m (2.0 to 2.5kgf•m)
14 to 18N•m (1.4 to 1.8kgf•m)
• Securely tighten the cap with a torque wrench.
• Cap tightening torque
Charge port
46
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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
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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
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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 bar’s 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 cylinder” comes 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 cylinder” require 1/2 UNF 20 threads per inch corresponding to
the charge hose’s port size.
49
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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
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• 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 N•m (1.6 kgf•m)
3/8 (22 mm) 42 N•m (4.2 kgf•m)
1/2 (26 mm) 55 N•m (5.5 kgf•m)
5/8 (15.9 mm) 120 N•m (12.0 kgf•m)
20) Copper pipe gauge adjusting projection margin
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
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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
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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.
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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
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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
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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
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4
REFRIGERANT PIPING
Tightening of Connecting Part
REQUIREMENT
(Unit: N•m)
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 kgf•m)
33 to 42 (3.3 to 4.2 kgf•m)
50 to 62 (5.0 to 6.2 kgf•m)
68 to 82 (6.8 to 8.2 kgf•m)
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
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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 pump” for 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
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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 18N•m (1.4 to 1.8kgf•m)
Ø9.5
33 to 42N•m (3.3 to 4.2kgf•m)
Valve size
Ø12.7 33 to 42N•m (3.3 to 4.2kgf•m)
Ø15.9 20 to 25N•m (2.0 to 2.5kgf•m)
14 to 18N•m (1.4 to 1.8kgf•m)
Charge port
Push in handle.
Charge port
Flare nut
59
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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
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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
¡
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
¡ : 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
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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 bar’s 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 cylinder” comes 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 cylinder” require 1/2 UNF 20 threads per inch corresponding to
the charge hose’s port size.
62
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