FILE NO. SVM-06012
SERVICE MANUAL
AIR-CONDITIONER
UNDER CEILING / CONSOLE TYPE
RAV-SM562XT-E / RAV-SM562AT-E
RAV-SM802XT-E / RAV-SM802AT-E
R410A
April, 2006
FILE NO. SVM-06012
1. SPECIFICATIONS
1-1. Indoor Unit (Flexi Type)
Indoor unit
Model
RAV-SM562XT-E
RAV-SM562AT-E
RAV-SM802XT-E
Outdoor unit
RAV-SM802AT-E
(kW)
(kW)
5.0
6.7
8.0
Cooling capacity
5.6
Heating capacity
Power supply
1 phase 230V (220-240V) 50Hz
8.95-8.20
1.87
13.15-12.06
2.72
Running current
(A)
(kW)
(%)
Cooling
Electrical
characteristics
Power consumption
Power factor
95
2.67
94
2.46
EER
(W/W)
D
E
1.5
Energy efficiency class *
Energy rating *
Running current
2.5
Heating
(A)
(kW)
(%)
8.13-7.46
1.70
12.91-11.84
2.67
Power consumption
Power factor
COP
94
95
3.29
3.00
D
(W/W)
C
Energy efficiency class *
Energy rating *
Main unit
2.5
3.0
Appearance
Pure white
Model
-
-
Ceiling panel
(Sold separately)
Panel color
Height
Width
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(kg)
Main unit
Outer
208
208
dimension
1093
1093
633
Depth
633
Ceiling panel
Height
Width
-
-
-
-
(Sold separately)
-
-
Depth
Total weight
Heat exchanger
Fan unit
Main unit
23
-
23
-
Ceiling panel
(kg)
Finned tube
Fan
Standard air flow
Centrifugal
14.0 / 12.0 / 10.0
50
Centrifugal
18.5 / 13.5 / 10.7
50
(m3/h)
(W)
H/M/L
Motor
Air filter
Attached main unit
Controller
Attached main unit (WH-H2UE)
Gas side
(mm)
(mm)
12.7
6.4
15.9
9.5
Dimensions pipe
Liquid side
Drain port
(mm)
VP16
Sound level
(dB¥A)
H/M/L
H/M/L
43 / 39 / 36
58 / 54 / 51
46 / 42 / 37
61 / 57 / 52
Sound power level
(dB¥A)
* IEC standard
** AS standard
– 1 –
FILE NO. SVM-06012
• Operation characteristic curve
<Cooling>
<Heating>
14
14
12
10
12
RAV-SM802XT-E
RAV-SM802XT-E
10
8
8
6
6
RAV-SM562XT-E
4
2
0
RAV-SM562XT-E
• Conditions
Indoor : DB20˚C
Outdoor : DB7˚C/WB6˚C
Air flow : High
Pipe length : 7.5m
230V
4
2
• Conditions
Indoor : DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow : High
Pipe length : 7.5m
230V
0
0
0
15 20
40
60 70 80
100
1520
40
60
80 90 100
Compressor speed (rps)
Compressor speed (rps)
• Capacity variation ratio according to temperature
<Cooling>
<Heating>
120
110
100
90
80
70
60
50
40
30
20
10
0
105
100
95
90
85
80
75
70
65
60
• Conditions
• Conditions
Indoor : DB27˚C/WB19˚C
Indoor : DB20˚C
55
Indoor air flow : High
Pipe length : 7.5m
Indoor air flow : High
Pipe length : 7.5m
50
-14 -12 -10 -8 -6 -4 -2
0
2
4
6
8
10
32 33 34 35 36 37 38 39 40 41 42 43
Outsoor temp. (˚C)
Outsoor temp. (˚C)
– 2 –
FILE NO. SVM-06012
2. CONSTRUCTION VIEWS
2-1. Indoor Unit
Front panel
208
1093
Knock out system
Grille air inlet
Back body
200 Min
1093
1015
742
For stud bolt
Installation plate
Mount plate
(Ø8 – Ø10)
For stud bolt (Ø6)
450
20
20
M10 Suspention bolt
74
Ø
57
Wireless remote control
Knock out system
18
UNDER CEILING & CONSOLE INSTALLATION
– 3 –
FILE NO. SVM-06012
3. SYSTEMATIC REFRIGERATING CYCLE DIAGRAM
3-1. RAV-SM562XT-E / RAV-SM802XT-E
Indoor unit
TCJ
sensor
Air heat exchanger
TC sensor
Refrigerant pipe
at liquid side
Outer dia. ∅B
Refrigerant pipe
at gas side
Outer dia. ∅A
Outer diameter of refrigerant pipe
Model
Gas side ∅A
12.7 mm
Liquid side ∅B
6.4 mm
RAV-SM
562XT-E
802XT-E
Max
30m
15.9 mm
9.5 mm
Packed valve
Packed valve
Outer dia. ∅B
Outer dia. ∅A
Outdoor unit
Note :
This Service Mamual describes explanation for the Under Ceiling 1 console type indoor unit.
For the combined outdoor unit, refer to the following Service Manual.
Outdoor unit Model name
RAV-SMXX0AT-E
SVM to be referred
A03-007
RAV-SPXXXAT-E
RAV-SMXX1AT-E
RAV-SMXX2AT-E
A03-014
A05-001
A05-018
Cooling
Heating
– 4 –
FILE NO. SVM-06012
4. WIRING DIAGRAM
Indoor Unit
HEAT
EXCHANGER
SENSOR
(TCJ)
SWITCH PCB
MCC-1428B
CN101
1 2 3
FOR FLOAT SWITCH
1 2
1 2
(OPTION)
When you use float
switch you should cut J401
1 2 3
1 2 3
CN402
1 2
CN100
CN05
IC03
CN03
1 2
THERMO
SENSOR
(TA)
BLK
BLK
J401
2 2
1 1
WHI
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
10 10
10 10
9 9
8 8
7 7
6 6
5 5
4 4
3 3
2 2
1 1
CN13
POWER
DC12V
9 9
8 8
7 7
6 6
5 5
4 4
3 3
2 2
1 1
CN25
BLK
BLK
SUPPLY
CIRCUIT
HEAT
2 2
1 1
CN01
4
DC5V
EXCHANGER
SENSOR
(TC)
C02
DB01
1
R506
CR502
1 1
2 2
3 3
4 4
5 5
CN10
CR501
R01
WHI
WHI
1 1
2 2
3 3
4 4
5 5
6 6
C01
RY501
RED
BLK
RED
BLK
BRW
RED
ORN
YEL
PNK
BLU
1 1
2 2
3 3
4 4
5 5
6 6
CN07
5
C501
MCC-1428A
3 3
2 2
1 1
3 3
2 2
1 1
BLU
PUR
GRY
BRW
GRY
YEL
C15
IC04
R405
CR401
CN11
FAN-MOTOR
RY401
LOUVER
MOTOR
100”C
R507
R09
3
2
1
FOR DRAIN PUMP
(OPTION)
R21
CN401
FUSE
250VAC
R22
3
SG01
F01
T6.3A
P04
CN23
CN30
CN31
BLK
GRN&YEL
INDOOR
TERMINAL
INDOOR
UNIT
2
1 2 3
BLOCK
OUTDOOR
UNIT
SIMPLE CHECK POINTS FOR DIAGNOSING FAULTS
Color
Identification
BRW : BROWN
RED : RED
Check items
Diagnosis result
OPERATION Check to see if OPERATION indicator goes on and off when the main switch
1
2
3
4
5
or breaker is turned on.
indicator
WHI : WHITE
YEL : YELLOW
BLU : BLUE
BLK : BLACK
GRY : GRAY
Check the power supply voltage between 1 - 2 (Refer to the name plate.)
Chack the fluctuate voltage between 2 - 3 (DC15 to 60V)
Terminal
block
Fuse
6.3A
Check to see if the fuse blows out. (Check the varistor. : R22, R21)
PNK : PINK
ORN : ORANGE
GRN&YEL : GREEN&
YELLOW
Check the voltage at the No.8 pin on CN13 connector of the infrared receiver.
(Check the transformer and the power supply circuit of the rated voltage.)
DC 5V
GRN : GREEN
PUR : PURPLE
Check the voltage at the brown lead of the louver motor.
(Check the transformer and the power supply circuit of the rated voltage.)
DC 12V
– 5 –
FILE NO. SVM-06012
5. SPECIFICATION OF ELECTRICAL PARTS
Indoor Unit
No.
Parts name
Fan motor (for indoor)
Grille motor
Type
Specifications
Output (Rated) 50 W, 220 – 240 V
DC 12 V
1
2
3
4
5
AFP-220-50-4A
MP35EA
Thermo. sensor (TA-sensor)
550 mm
10 kΩ at 25°C
Heat exchanger sensor (TC-sensor)
Heat exchanger sensor (TCJ-sensor)
∅6 mm, 500 mm
∅6 mm, 500 mm
10 kΩ at 25°C
10 kΩ at 25°C
– 6 –
FILE NO. SVM-06012
6. REFRIGERANT R410A
This air conditioner adopts the new refrigerant HFC
(5) After completion of installation work, check to
(R410A) which does not damage the ozone layer.
make sure that there is no refrigeration gas
leakage.
If the refrigerant gas leaks into the room, coming
into contact with fire in the fan-driven heater,
space heater, etc., a poisonous gas may occur.
The working pressure of the new refrigerant R410A is
1.6 times higher than conventional refrigerant (R22).
The refrigerating oil is also changed in accordance
with change of refrigerant, so be careful that water,
dust, and existing refrigerant or refrigerating oil are not (6) When an air conditioning system charged with a
entered in the refrigerant cycle of the air conditioner
using the new refrigerant during installation work or
servicing time.
large volume of refrigerant is installed in a small
room, it is necessary to exercise care so that,
even when refrigerant leaks, its concentration
does not exceed the marginal level.
If the refrigerant gas leakage occurs and its
concentration exceeds the marginal level, an
oxygen starvation accident may result.
The next section describes the precautions for air
conditioner using the new refrigerant. Conforming to
contents of the next section together with the general
cautions included in this manual, perform the correct
and safe work.
(7) Be sure to carry out installation or removal
according to the installation manual.
Improper installation may cause refrigeration
trouble, water leakage, electric shock, fire, etc.
6-1. Safety During Installation/Servicing
As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may cause
a serious trouble. By using tools and materials exclu-
sive for R410A, it is necessary to carry out installation/
servicing safely while taking the following precautions
into consideration.
(8) Unauthorized modifications to the air conditioner
may be dangerous. If a breakdown occurs please
call a qualified air conditioner technician or
electrician.
Improper repair’s may result in water leakage,
electric shock and fire, etc.
(1) Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.
6-2. Refrigerant Piping Installation
If other refrigerant than R410A is mixed, pressure 6-2-1. Piping materials and joints used
in the refrigeration cycle becomes abnormally
For the refrigerant piping installation, copper pipes and
high, and it may cause personal injury, etc. by a
joints are mainly used. Copper pipes and joints suit-
rupture.
able for the refrigerant must be chosen and installed.
(2) Confirm the used refrigerant name, and use tools
and materials exclusive for the refrigerant R410A.
The refrigerant name R410A is indicated on the
visible place of the outdoor unit of the air condi-
tioner using R410A as refrigerant. To prevent
mischarging, the diameter of the service port
differs from that of R22
Furthermore, it is necessary to use clean copper pipes
and joints whose interior surfaces are less affected by
contaminants.
(1) Copper pipes
It is necessary to use seamless copper pipes
which are made of either copper or copper alloy
and it is desirable that the amount of residual oil is
less than 40 mg/10 m. Do not use copper pipes
having a collapsed, deformed or discolored
portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube
may become blocked with contaminants.
As an air conditioner using R410A incurs pressure
higher than when using R22, it is necessary to
choose adequate materials.
(3) If a refrigeration gas leakage occurs during
installation/servicing, be sure to ventilate fully.
If the refrigerant gas comes into contact with fire,
a poisonous gas may occur.
(4) When installing or removing an air conditioner,
do not allow air or moisture to remain in the
refrigeration cycle. Otherwise, pressure in the
refrigeration cycle may become abnormally high
so that a rupture of personal injury may be
caused.
Thicknesses of copper pipes used with R410A are
as shown in Table 6-2-1. Never use copper pipes
thinner than 0.8 mm even when it is available on
the market.
– 7 –
FILE NO. SVM-06012
Table 6-2-1 Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter
Outer diameter (mm)
R410A
0.80
R22
0.80
0.80
0.80
1.00
1/4
3/8
1/2
5/8
6.35
9.52
0.80
12.70
15.88
0.80
1.00
(2) Joints
b) Socket joints
For copper pipes, flare joints or socket joints are
used. Prior to use, be sure to remove all
contaminants.
Socket joints are such that they are brazed for
connections, and used mainly for thick pipings
whose diameter is larger than 20 mm.
Thicknesses of socket joints are as shown in
Table 6-2-2.
a) Flare joints
Flare joints used to connect the copper pipes
cannot be used for pipings whose outer
diameter exceeds 20 mm. In such a case,
socket joints can be used.
Sizes of flare pipe ends, flare joint ends and
flare nuts are as shown in Tables 6-2-3 to 6-2-6
below.
Table 6-2-2 Minimum thicknesses of socket joints
Reference outer diameter of
Minimum joint thickness
(mm)
Nominal diameter
copper pipe jointed (mm)
1/4
3/8
1/2
5/8
6.35
9.52
0.50
0.60
0.70
0.80
12.70
15.88
6-2-1. Processing of piping materials
d) Flare processing
Make certain that a clamp bar and copper pipe
have been cleaned.
By means of the clamp bar, perform the flare
processing correctly.
Use either a flare tool for R410A or conven-
tional flare tool.
Flare processing dimensions differ according to
the type of flare tool. When using a conven-
tional flare tool, be sure to secure “dimension A”
by using a gauge for size adjustment.
When performing the refrigerant piping installation,
care should be taken to ensure that water or dust does
not enter the pipe interior, that no other oil other than
lubricating oils used in the installed air conditioner is
used, and that refrigerant does not leak. When using
lubricating oils in the piping processing, use such
lubricating oils whose water content has been removed.
When stored, be sure to seal the container with an
airtight cap or any other cover.
(1) Flare Processing procedures and precautions
a) Cutting the pipe
∅D
A
By means of a pipe cutter, slowly cut the pipe
so that it is not deformed.
b) Removing burrs and chips
If the flared section has chips or burrs,
refrigerant leakage may occur. Carefully
remove all burrs and clean the cut surface
before installation.
Fig. 6-2-1 Flare processing dimensions
c) Insertion of flare nut
– 8 –
FILE NO. SVM-06012
Table 6-2-3 Dimensions related to flare processing for R410A
A (mm)
Conventional flare tool
Outer
diameter
(mm)
Nominal
diameter
Thickness
(mm)
Flare tool for R410A
clutch type
Clutch type
1.0 to 1.5
1.0 to 1.5
1.0 to 1.5
1.0 to 1.5
Wing nut type
1.5 to 2.0
1/4
3/8
1/2
5/8
6.35
9.52
0.8
0.8
0.8
1.0
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
1.5 to 2.0
12.70
15.88
2.0 to 2.5
2.0 to 2.5
Table 6-2-4 Dimensions related to flare processing for R22
A (mm)
Outer
diameter
(mm)
Nominal
diameter
Thickness
(mm)
Conventional flare tool
Flare tool for R22
clutch type
Clutch type
0.5 to 1.0
0.5 to 1.0
0.5 to 1.0
0.5 to 1.0
Wing nut type
1.0 to 1.5
1/4
3/8
1/2
5/8
6.35
9.52
0.8
0.8
0.8
1.0
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
1.0 to 1.5
12.70
15.88
1.5 to 2.0
1.5 to 2.0
Table 6-2-5 Flare and flare nut dimensions for R410A
Outer
diameter
(mm)
Flare nut
width
(mm)
Dimension (mm)
Thickness
Nominal
diameter
(mm)
A
B
C
D
1/4
3/8
1/2
5/8
6.35
9.52
0.8
0.8
0.8
1.0
9.1
9.2
6.5
13
20
23
25
17
22
26
29
13.2
16.6
19.7
13.5
16.0
19.0
9.7
12.70
15.88
12.9
16.0
Table 6-2-6 Flare and flare nut dimensions for R22
Outer
diameter
(mm)
Flare nut
width
(mm)
Dimension (mm)
Thickness
Nominal
diameter
(mm)
A
B
C
D
1/4
3/8
1/2
5/8
3/4
6.35
9.52
0.8
0.8
0.8
1.0
1.0
9.0
9.2
6.5
13
20
20
23
34
17
22
24
27
36
13.0
16.2
19.4
23.3
13.5
16.0
19.0
24.0
9.7
12.70
15.88
19.05
12.9
16.0
19.2
– 9 –
FILE NO. SVM-06012
°
to 46
°
45
43
°
to 45
°
Fig. 6-2-2 Relations between flare nut and flare seal surface
(2) Flare connecting procedures and precautions
When it is strong, the flare nut may crack and
may be made non-removable. When choosing
the tightening torque, comply with values
designated by manufacturers. Table 6-2-7
shows reference values.
a) Make sure that the flare and union portions do
not have any scar or dust, etc.
b) Correctly align the processed flare surface with
the union axis.
Note:
c) Tighten the flare with designated torque by
means of a torque wrench. The tightening
torque for R410A is the same as that for
conventional R22. Incidentally, when the torque
is weak, the gas leakage may occur.
When applying oil to the flare surface, be sure to use
oil designated by the manufacturer. If any other oil is
used, the lubricating oils may deteriorate and cause
the compressor to burn out.
Table 6-2-7 Tightening torque of flare for R410A [Reference values]
Tightening torque of torque
wrenches available on the market
N·m (kgf·m)
Nominal
diameter
Outer diameter
(mm)
Tightening torque
N·m (kgf·cm)
1/4
3/8
1/2
5/8
6.35
9.52
14 to 18 (140 to 180)
33 to 42 (330 to 420)
50 to 62 (500 to 620)
63 to 77 (630 to 770)
16 (160), 18 (180)
42 (420)
12.70
15.88
55 (550)
65 (650)
– 10 –
FILE NO. SVM-06012
6-3.Tools
6-3-1. Required tools
The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to
prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and
opposite side dimension of flare nut (For ∅12.70 copper pipe) of the refrigerant piping are lengthened.
The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge,
clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.
(1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))
(2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)
(3) Tools commonly used for R410A and for conventional refrigerant (R22)
The table below shows the tools exclusive for R410A and their interchangeability.
Tools exclusive for R410A (The following tools for R410A are required.)
Tools whose specifications are changed for R410A and their interchangeability
R410A air conditioner
installation
Conventional air
conditioner installation
No.
Used tool
Usage
Existence of
new equipment conventional
Whether
Whether new equipment
can be used with
for R410A
equipment can
be used
conventional refrigerant
1
2
Flare tool
Copper pipe gauge
Pipe flaring
Flaring by
Yes
*(Note 1)
for adjusting projection conventional flare
Yes
*(Note 1)
*(Note 1)
margin
tool
Connection of
flare nut
3
4
Torque wrench
Yes
Yes
Evacuating,
refrigerant charge,
run check, etc.
Gauge manifold
Charge hose
5
6
Vacuum pump adapter Vacuum evacuating
Yes
Yes
Electronic balance for
Refrigerant charge
refrigerant charging
7
8
9
!
Refrigerant cylinder
Leakage detector
Charging cylinder
Refrigerant charge
Gas leakage check
Refrigerant charge
Yes
Yes
(Note 2)
(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection
margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.
(Note 2) Charging cylinder for R410A is being currently developed.
General tools (Conventional tools can be used.)
In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as
the general tools.
(1) Vacuum pump
(4) Reamer
(5) Pipe bender
(9) Hole core drill (∅65)
(10) Hexagon wrench
(Opposite side 4 mm)
(11) Tape measure
(12) Metal saw
Use vacuum pump by
attaching vacuum pump adapter. (6) Level vial
(2) Torque wrench
(3) Pipe cutter
(7) Screwdriver (+, –)
(8) Spanner of Monkey wrench
Also prepare the following equipments for other installation method and run check.
(1) Clamp meter
(2) Thermometer
(3) Insulation resistance tester
(4) Electroscope
– 11 –
FILE NO. SVM-06012
6-4. Recharging of Refrigerant
When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the
following steps.
Recover the refrigerant, and check no refrigerant
remains in the equipment.
When the compound gauge’s pointer has indi-
cated -0.1 Mpa (-76 cmHg), place the handle Low
in the fully closed position, and turn off the
Connect the charge hose to packed valve service
port at the outdoor unit’s gas side.
vacuum pump’s power switch.
Keep the status as it is for 1 to 2 minutes, and
ensure that the compound gauge’s pointer does
not return.
Connect the charge hose of the vacuum pump
adapter.
Open fully both packed valves at liquid and gas
Set the refrigerant cylinder to the electronic
sides.
balance, connect the connecting hose to the
cylinder and the connecting port of the electronic
balance, and charge liquid refrigerant.
Place the handle of the gauge manifold Low in
the fully opened position, and turn on the vacuum
pump’s power switch. Then, evacuating the
refrigerant in the cycle.
(For refrigerant charging, see the figure below.)
1 Never charge refrigerant exceeding the specified amount.
2 If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.
3 Do not carry out additional charging.
When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the
refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the
specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high
pressure, and may cause a rupture or personal injury.
(Liquid side)
(INDOOR unit)
(OUTDOOR unit)
Opened
Closed
(Gas side)
Refrigerant cylinder
(With siphon pipe)
Check valve
Open/Close valve
for charging
Service port
Electronic balance for refrigerant charging
Fig. 6-4-1 Configuration of refrigerant charging
– 12 –
FILE NO. SVM-06012
1 Be sure to make setting so that liquid can be charged.
2 When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.
It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant.
Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the
cylinder upside down if cylinder is not equipped with siphon.
[Cylinder with siphon]
[Cylinder without siphon]
Gauge manifold
Gauge manifold
OUTDOOR unit
OUTDOOR unit
c y l i n d e r
R e f r i g e r a n t
Refrigerant
cylinder
Electronic
balance
Electronic
balance
Siphon
R410A refrigerant is HFC mixed refrigerant.
Therefore, if it is charged with gas, the composition
of the charged refrigerant changes and the
characteristics of the equipment varies.
Fig. 6-4-2
6-5. Brazing of Pipes
1 Phosphor bronze brazing filler tends to react
with sulfur and produce a fragile compound
water solution, which may cause a gas leakage.
Therefore, use any other type of brazing filler at
a hot spring resort, etc., and coat the surface
with a paint.
6-5-1. Materials for brazing
(1) Silver brazing filler
Silver brazing filler is an alloy mainly composed of
silver and copper. It is used to join iron, copper or
copper alloy, and is relatively expensive though it
excels in solderability.
2 When performing brazing again at time of
servicing, use the same type of brazing filler.
(2) Phosphor bronze brazing filler
Phosphor bronze brazing filler is generally used to
join copper or copper alloy.
6-5-2. Flux
(1) Reason why flux is necessary
• By removing the oxide film and any foreign
matter on the metal surface, it assists the flow of
brazing filler.
(3) Low temperature brazing filler
Low temperature brazing filler is generally called
solder, and is an alloy of tin and lead. Since it is
weak in adhesive strength, do not use it for
refrigerant pipes.
• In the brazing process, it prevents the metal
surface from being oxidized.
• By reducing the brazing filler’s surface tension,
the brazing filler adheres better to the treated
metal.
– 13 –
FILE NO. SVM-06012
(2) Characteristics required for flux
• Activated temperature of flux coincides with the
brazing temperature.
6-5-3. Brazing
As brazing work requires sophisticated techniques,
experiences based upon a theoretical knowledge, it
must be performed by a person qualified.
In order to prevent the oxide film from occurring in the
pipe interior during brazing, it is effective to proceed
with brazing while letting dry Nitrogen gas (N2) flow.
• Due to a wide effective temperature range, flux
is hard to carbonize.
• It is easy to remove slag after brazing.
• The corrosive action to the treated metal and
brazing filler is minimum.
• It excels in coating performance and is harmless
to the human body.
Never use gas other than Nitrogen gas.
(1) Brazing method to prevent oxidation
1 Attach a reducing valve and a flow-meter to the
Nitrogen gas cylinder.
As the flux works in a complicated manner as
described above, it is necessary to select an
adequate type of flux according to the type and
shape of treated metal, type of brazing filler and
brazing method, etc.
2 Use a copper pipe to direct the piping material,
and attach a flow-meter to the cylinder.
3 Apply a seal into the clearance between the
piping material and inserted copper pipe for
Nitrogen in order to prevent backflow of the
Nitrogen gas.
(3) Types of flux
• Noncorrosive flux
Generally, it is a compound of borax and boric
acid.
It is effective in case where the brazing
temperature is higher than 800°C.
4 When the Nitrogen gas is flowing, be sure to
keep the piping end open.
5 Adjust the flow rate of Nitrogen gas so that it is
lower than 0.05 m3/Hr or 0.02 Mpa (0.2 kgf/
cm2) by means of the reducing valve.
6 After performing the steps above, keep the
Nitrogen gas flowing until the pipe cools down
to a certain extent (temperature at which pipes
are touchable with hands).
• Activated flux
Most of fluxes generally used for silver brazing
are this type.
It features an increased oxide film removing
capability due to the addition of compounds
such as potassium fluoride, potassium chloride
and sodium fluoride to the borax-boric acid
compound.
7 Remove the flux completely after brazing.
(4) Piping materials for brazing and used brazing
filler/flux
M
Flow meter
Piping
material
Used brazing
filler
Used
flux
Stop valve
Copper - Copper Phosphor copper
Do not use
Paste flux
Vapor flux
Nitrogen gas
cylinder
Copper - Iron
Iron - Iron
Silver
Silver
From Nitrogen cylinder
1 Do not enter flux into the refrigeration cycle.
2 When chlorine contained in the flux remains
within the pipe, the lubricating oil deteriorates.
Therefore, use a flux which does not contain
chloring.
3 When adding water to the flux, use water which
does not contain chlorine (e.g. distilled water or
ion-exchange water).
Pipe
Nitrogen
gas
Rubber plug
Fig. 6-5-1 Prevention of oxidation during brazing
4 Remove the flux after brazing.
– 14 –
FILE NO. SVM-06012
7. CONTROL BLOCK DIAGRAM
Indoor Unit Control Panel
M.C.U.
8 MHz
Heat Exchanger Sensor (TCJ)
Heat Exchanger Sensor (TC)
Temperature Sensor
Hi POWER
Display
Functions
• Louver Control
FILTER Sign
Display
• 3-minute Delay at Restart for Compressor
• Motor Revolution Control
PRE DEF.
Sign Display
Infrared Rays Signal Receiver
• Processing
(Temperature Processing)
TIMER
Display
Initiallizing Circuit
Infrared
• Timer
Rays
OPERATION
Display
Clock Frequence
Oscillator Circuit
36.7 kHz
• Drain Pump ON/OFF
• Serial Signal Communication
Indoor Fan
Motor
Power Supply
Circuit
Louver ON/OFF Signal
Louver Driver
Remote
Control
Louver Motor
Serial Signal
Transmitter/
Receiver
Noise Filter
Relay
RY401
Float
Switch
Drain
Pump
From Outdoor Unit
Serial Signal Communication
REMOTE CONTROL
Infrared Rays
Remote Control
Operation (START/STOP)
Operation Mode Selection
AUTO, COOL, DRY, HEAT, FAN ONLY
Temperature Setting
Fan Speed Selection
ON TIMER Setting
OFF TIMER Setting
Louver Auto Swing
Louver Direction Setting
ECO
Hi power
Filter Reset
– 15 –
FILE NO. SVM-06012
8. OPERATION DESCRIPTION
8-1. When power supply is reset
8-3. Air volume control
(1) Distinction of outdoor units
(1) Operation with [HIGH (H)], [MED (M)], [LOW (L)],
or [AUTO] mode is performed by the command
from the remote control.
When the power supply is reset, the outdoors are
distinguished, and control is exchanged according
to the distinguished result.
(2) When [FAN] button is set to AUTO, the indoor fan
motor operates as shown in Fig. 8-3-1, Fig. 8-3-2
and Table 8-3-1.
(2) Setting of the indoor fan speed
Based on EEPROM data, rspeed of the indoor fan
is selected.
<COOL>
Remarks: Air speed
°C
8-2. Operation mode selection
+3
M+
(1) Based on the operation mode selecting command
from the remote control, the operation mode is
selected.
+2.5
*1
+2
*1
+1.5
Table 8-2-1
*1
+1
Remote control
Outline of control
command
+0.5
Preset
temp.
0
STOP
FAN
Air conditioner stops.
Fan operation
−0.5
COOL
DRY
Cooling operation
Dry operation
NOTE :
*1: The values marked with *1 are calculated and
controlled by the difference in motor speed
between M+ and L–.
HEAT
AUTO
Heating operation
Automatic operation
Fig. 8-3-1
(2) Automatic Operation
• The air conditioner selects and operates in one
of the operating modes of cooling, heating or
fan only, depending on the room temperature.
• If the AUTO mode is uncomfortable, you can
select the desired conditions manually.
Table 8-2-2
Room temperature in operation
Operating condition
Cooling
Performs the cooling operation at a temperature 1°C
The set temperature +1°C or higher
operation
higher than the setting.
(in case that the room is hot)
Fan only
operation
Performs the fan only operation (low speed) while
monitoring the room temperature. When the room
temperature changes, the air conditioner will select the
cooling or heating mode.
The set temperature –1°C to +1°C
Heating
Performs the heating operation at a temperature 1°C
The set temperature –1°C or lower
operation
lower than the setting.
(in case that the room is cold)
– 16 –
FILE NO. SVM-06012
<HEAT>
8-4. Cool air discharge preventive control
In heating operation, the indoor heat exchanger
restricts revolving speed of the fan motor to prevent a
cold draft. The upper limit of the revolving speed is
shown in Fig. 8-4-1 and Table 8-4-1.
°C
0
Preset
temp.
L
−0.5
−1
−1.5
−2
*1
*2
Manual
(One of
5 steps)
+
M
AUTO
*4
46
45
34
33
−5.0
−5.5
L−H
H
33
32
21
20
[FAN AUTO]
(Up to
setting
speed)
SUL*3
NOTE :
*2 A+4 A+4
SUL*1
Stop
*1, *2 : The values marked with *1 and *2 are
calculated and controlled by the difference in
motor speed between M+ and L.
A−8 A−8
*6
*5
Fig. 8-3-2
NOTES :
*1: The fan stops for 2 minutes after thermostat-OFF.
Table 8-3-1
*2: A is 24°C when the preset temperature is 24°C or
more and A is the preset temperature when it is
under 24°C.
RAV-SM562XT-E
RAV-SM802XT-E
MODEL
Cooling
Motor speed Air flow level Motor speed Air flow level
(rpm)
1060
950
(m3/h)
800
690
580
830
730
600
(rpm)
1190
1010
850
(m3/h)
900
750
650
980
800
650
HIGH
MED
LOW
HIGH
MED
LOW
*3: SUL means Super Ultra Low.
and
*4: Calculated from difference in motor speed
between SUL and HIGH.
Fan only
800
1120
970
1300
1070
860
Heating
Fig. 8-4-1 Cold draft preventing control
820
*5 and *6:
LOW+MED
2
LOW+ =
MED+ =
Table 8-4-1
MED+HIGH
2
Fan
speed
*5
*6
Starting period
Stabilized period
AUTO
• Up until 12 minutes
passed after starting
the unit
• From 12 to 25 minutes
passed after starting
the unit and room
temperature is 3°C
lower than preset
temperature
• From 12 to 25 minutes
passed after starting
the unit and room
temperature is
between preset
temperature and 3°C
lower than preset
temperature
• 25 minutes or more
passed after starting
the unit
Manual • Room temperature
(L – H) < Preset temperature
–4°C
• Room temperature
Preset temperature
–3.5°C
– 17 –
FILE NO. SVM-06012
8-5. Freeze preventive control (Low
temperature release)
8-7. Louver control
(1) Vertical air flow louver
Position of veritcal air flow louver is automatically
controlled according to the operation mode.
Besides, position of vertical air flow louver can be
arbitrarily set by pressing [FIX] button.
The louver position which is set by [FIX] button is
stored in the microcomputer, and the louver is
automatically set at the stored position for the next
operation.
The cooling operation (including Dry operation) is
performed as follows based on the detected
temperature of Tc sensor or Tcj sensor.
When [J] zone is detected for T1 minutes (Following
figure), the commanded frequency is decreased from
the real operation frequency. After then the
commanded frequency changes every 2 minutes while
operation is performed in [J] zone.
(2) Swing
T1
If [SWING] button is pressed when the indoor unit
is in operation, the vertical air flow louver starts
swinging. When [SWING] button is pressed, it
stops swinging.
Normal
1 minute
In [K] zone, time counting is interrupted and the
operation is held.
8-8. Filter sign display
When [I] zone is detected, the timer is cleared and the
operation returns to the normal operation.
(1) The operation time of the indoor fan is calculated,
the filter lamp (Orange) on the display part of the
main unit goes on when the specified time (240H)
has passed. When a wired remote controller is
connected, the filter reset signal is sent to the
remote controller, and also it is displayed on LCD
of the wired remote control.
(°C)
7
6
5
A
I
K
J
(2) When the filter reset signal has been received
from the wired remote control after [FILTER] lamp
has gone on or when the filter check button
(Temporary button) is pushed, time of the
calculation timer is cleared. In this case, the
measurement time is reset if the specified time
has passed, and display on LCD and the display
on the main unit disappear.
Fig. 8-5-1
In heating operation, the freeze-preventive control
works if 4-way valve is not exchanged and the
condition is satisfied.
Remarks:
Remarks:
[FILTER] goes on
Tcj : Indoor heat exchanger sensor temperature
8-6. High-temp release control
The heating operation is performed as follows based
on the detected temperature of Tc sensor.
•
When [M] zone is detected, the commanded
frequency is decreased from the real operation
frequency. After then the commanded frequency
changes every 30 seconds while operation is
performed in [M] zone.
•
•
In [N] zone, the commanded frequency is held.
When [L] zone is detected, the commanded
frequency is returned to the original value by
approx. 6Hz every 60 seconds.
Tc (°C)
55 A
M
N
52
48 B
L
Fig. 8-6-1
– 18 –
FILE NO. SVM-06012
8-9-1. How to set auto restart function
8-9. Auto Restart Function
To set the auto restart function, proceed as follows:
The power supply to the unit must be on; the function
will not set if the power is off.
Push the [TEMPORARY] button located in the center
of the front panel continuously for three seconds.
The unit receives the signal and beeps three times.
The unit then restarts operating automatically in the
event of power supply being accidentally shut down.
The indoor unit is equipped with an automatic
restarting function which allows the unit to restart
operating with the set operating conditions in the event
of power supply being accidentally shut down. The
operation will resume without warning three minutes
after power is restored.
This function is not set to work when shipped from the
factory. Therefore it is necessary to set it to work.
When the unit is on standby (Not operating)
Operation
Motions
Push [TEMPORARY] button for more
than three seconds.
The unit is on standby.
The unit starts to operate.
The green lamp is on.
After approx. three seconds,
0
The unit beeps three times
and continues to operate.
The lamp changes from
green to orange.
3S
Hi POWER FILTER
PRE.D
TEMPORARY
button
If the unit is not required to operate at this time, push [TEMPORARY]
button once more or use the remote control to turn it off.
When the unit is in operation
Operation
Motions
Push [TEMPORARY] button for more
than three seconds.
The unit is in operation.
The unit stops operating.
The green lamp is on.
The green lamp is turned off.
After approx. three seconds,
The unit beeps three times.
0
3S
Hi POWER FILTER
PRE.D
TEMPORARY
button
If the unit is required to operate at this time, push [TEMPORARY]
button once more or use the remote control to turn it on.
•
•
•
While this function is being set, if the unit is in
operation, the orange lamp is on.
This function can not be set if the timer operation
has been selected.
When the unit is turned on by this function, the
louver will not swing even though it was swinging
automatically before shutting down.
•
While the filter check lamp is on, the
TEMPORARY button has the function of filter
reset button.
– 19 –
FILE NO. SVM-06012
8-9-2. How to cancel auto restart function
To cancel auto restart function, proceed as follows:
Repeat the setting prodedure: the unit receives the
signal and beeps three times.
The unit will be required to be turned on with the
remote control after the main power supply is turned
off.
When the unit is on standby (Not operating)
Operation
Motions
Push [TEMPORARY] button for more
than three seconds.
The unit is on standby.
The unit starts to operate.
The orange lamp is on.
After approx. three seconds,
0
The unit beeps three times
and continues to operate.
The lamp changes from
orange to green.
3S
Hi POWER FILTER
PRE.D
TEMPORARY
button
If the unit is not required to operate at this time, push [TEMPORARY]
button once more or use the remote control to turn it off.
When the unit is in operation
Operation
Motions
Push [TEMPORARY] button for more
than three seconds.
The unit is in operation.
The unit stops operating.
The orange lamp is on.
The orange lamp is turned off.
After approx. three seconds,
The unit beeps three times.
0
3S
Hi POWER FILTER
PRE.D
TEMPORARY
button
If the unit is required to operate at this time, push [TEMPORARY]
button once more or use the remote control to turn it on.
•
While this function is being set, if the unit is in
operation, the orange lamp is on.
8-10. Filter Check Lamp
When the elapsed time reaches 1000 hours, the filter
check lamp indicates. After cleaning the filters, turn off
the filter check lamp.
8-9-3. Power failure during timer operation
When the unit is in Timer operation, if it is turned off
because of power failure, the timer operation is
cancelled. Therefore, set the timer operation again.
8-10-1. How to turn off filter check lamp
(1) Press [FILTER] button on the remote control.
(2) Push [TEMPORARY] button on the indoor unit.
Note:
If [TEMPORARY] button is pushed while the filter
check lamp is not indicating, the indoor unit will start
the Automatic Operation.
– 20 –
FILE NO. SVM-06012
9.TROUBLESHOOTING
9-1-2. Troubleshooting procedure
9-1. Summary of Troubleshooting
When a trouble occurred, check the parts along with
the following procedure.
9-1-1. Before troubleshooting
(1) Required tools/instruments
• e and d screwdrivers, spanners, radio
cutting pliers, nippers, etc.
Trouble
→
Confirmation of check code by service mode
• Tester, thermometer, pressure gauge, etc.
(2) Confirmation points before check
1 The following operations are normal.
a) Compressor does not operate.
• Is not 3-minutes delay (3 minutes after
compressor OFF)?
→
Check defective position and parts.
NOTE :
For cause of a trouble, power conditions or malfunc-
tion/erroneous diagnosis of microcomputer due to
outer noise is considered except the items to be
checked. If there is any noise source, change the
cables of the signal line to shield cables.
• Does not thermostat turn off?
• Does not timer operate during fan
operation?
• Is not outside high-temperature operation
controlled in heating operation?
b) Indoor fan does not rotate.
• Does not cool air discharge preventive
control work in heating operation?
c) Outdoor fan does not rotate or air volume
changes.
9-1-3. Outline of Judgment
A primary judgment to detect cause of error exists on
the indoor unit or outdoor unit is performed in the
following procedure.
<Judgment by flashing display on the indoor
unit display part>
• Does not high-temperature release opera-
tion control work in heating operation?
• Does not outside low-temperature opera-
tion control work in cooling operation?
• Is not defrost operation performed?
d) ON/OFF operation cannot be performed from
remote control.
The indoor unit monitors operating status of the air
conditioner, and if a protective circuit works, contents
of the self-diagnosis are displayed with a block
restricted to the following cases on the indoor unit
display part (Sensor).
• Is not forced operation performed?
• Is not the control operation performed from
outside/remote side?
2 Did you return the cabling to the initial
positions?
3 Are connecting cables between indoor unit and
receiving unit correct?
Table 9-1-1
Remote
control code
Block display
Contents of self-diagnosis
Check code
––
00
01
02
03
––
Operation lamp display flashes. (1Hz)
Operation lamp display flashes. (5Hz)
Operation/timer lamp displays flash. (5Hz)
Operation/defrost lamp displays flash. (5Hz)
Operation/timer/defrost lamp displays flash. (5Hz)
––
Power failure (In power ON)
Indoor P.C. board
––
0b to 0F, 11, 12, b5, b6
04
Inter-unit cables/transmission system
Outdoor P.C. board
Cycle system, etc.
14 to 19, 1A, 1C
1d, 1E, 1F, 21
1b, 8b
––
– 21 –
FILE NO. SVM-06012
9-2. Self-Diagnosis by Remote Control
(Check Code)
(1) If the lamps are indicated as shown 00 to 03 in
Table 9-1-1, exchanger the self-diagnosis by the
remote control.
(2) When the remote control is set to the service
mode, the indoor controller diagnoses the
operation condition and indicate the information of
the self-diagnosis on the display of the remote
control with the check codes. If a fault is detected,
all lamps on the indoor unit will blink at 5 Hz and it
will beep for 10 seconds (Pi, Pi, Pi....). The timer
lamp usually blinks (5 Hz) during the self-diagnosis.
9-2-1. How to use remote control in service mode
(1) Press [CHECK] button with a tip of pencil to set the
remote control to the service mode.
• “00” is indicated on the display of the remote
control.
SET
CLR
RESET CLOCK CHECK
• The timer lamp on the indoor unit blinks
continuously. (5 times per 1 sec.)
(2) Press [TIMER 8] button.
If there is no fault with a code, the indoor unit will
beep once (Pi) and the display of the remote
control will change as follows:
AUTOA
00
01
02 1d
1E
22
• Check the unit with all 35 check codes (00 to 22).
as shown in Table 9-2-1.
PRESET
• Press [TIMER 9] button to change the check
code backwards.
START/STOP
AUTO
FAN
SWING
FIX
MODE
If there is a fault, the indoor unit will beep for 10
seconds (Pi, Pi, Pi...).
ECO
Hi-POWER
TIMER
Note the check code on the display of the remote
control.
MEMO
ON
OFF
SET
CLR
• 2-digits alphanumeric will be indicated on the
display.
FILTER
RESET CLOCK CHECK
• All lamps on the indoor unit will blink. (5 times
per 1 sec.)
(3) Press [CLR] button. After service finish for clear
service code in memory.
• “7F” is indicated on the display of the remote
control.
• Alphanumeric characters are used for the check code.
(4) Press [START/STOP] button to release the service
mode.
is 5.
is A.
is C.
is 6.
is B.
is D.
• The display of the remote control returns to as it
was before service mode was engaged.
– 22 –
FILE NO. SVM-06012
Table 9-2-1
Operation of diagnostic function
Judgement and action
Check
code
Check
code
Unit
status
Block
Symptom
Condition
Indoor
P.C. board
The indoor thermo sensor (TA) is
defective.
Disconnection or short-circuit
Operation
continues.
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the indoor thermo sensor (TA).
2. Check the indoor P.C. board.
The indoor heat exchanger
sensor (TC) is defective.
Disconnection or short-circuit
Operation
continues.
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the indoor heat exchanger
sensor (TC).
2. Check the indoor P.C. board.
The indoor fan motor or its circuit
is defective.
All off
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the connector circuit of the
indoor fan motor (CN10).
2. Check the indoor fan motor.
3. Check the indoor P.C. board.
The part other than the above
parts on the indoor P.C. board is
defective.
Operation
continues.
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the indoor P.C. board.
(EEPROM and peripheral circuits)
EEPROM access error
IOL operation
All off
The lamp on the
indoor unit blinks
when error is
defected.
Overload operation of refrigerating cycle
The block is
unidentifi-
able
The variation of TC, 5 minutes
after starting the compressor,
is 2K or less.
Operation
continues.
The lamp on the
indoor unit blinks
when error is
defected.
1. Check whether or not the TC sensor
comes off.
2. Check whether or not it is possible to
operate the compressor and the
outdoor fan motor.
3. Check gas leak.
The serial signals can not be
Operation
The lamp on the
indoor unit blinks
when error is
defected.
1. In the case of the outdoor unit not
operating at all;
• Check the crossover cable and
connect it properly.
• Check the outdoor P.C. board.
2. In the case of the outdoor unit operating
normally;
• Check whether or not both of serial
LED (Green) and serial LED (Orange)
is blinking.
Cable
connection
transmitted and received between continues.
indoor and outdoor units.
• The crossover wire is
connected wrongly.
• The serial signal transmitting
circuit on the outdoor P.C. board
is defective.
• The serial signal receiving
circuit on the indoor P.C. board
is defective.
If the serial LED (Green) is not
blinking, check the outdoor P.C. board.
If the serial LED (Orange) is not
blinking, check the indoor P.C. board.
The operation command signals
are not transmitted from the
indoor unit to the outdoor unit.
Operation
continues.
The lamp on the
indoor unit blinks
when error is
If the operation command signals continue
to be transmitted between 2 and 3 of the
indoor terminal block, replace the outdoor
P.C. board.
defected. And it
returns to the
normal condition
when recovering
from errors.
Outdoor
P.C. board
The outdoor thermo sensor (TE)
is defective.
Disconnection or short-circuit
All off
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the outdoor thermo sensor (TE).
2. Check the outdoor P.C. board.
The outdoor heat exchanger (TD) All off
sensor is defective.
Disconnection or short-circuit
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the outdoor heat exchanger
sensor (TD).
2. Check the outdoor P.C. board.
The reply serial signal has been
transmitted when starting the
unit, but stops being transmitted
shortly after.
Operation
continues.
The lamp on the
indoor unit blinks
when error is
defected. And it
returns to the
1. Repeatedly turn the indoor unit on and
off with the interval of approx. 10 to 40
minutes. (The check code is not
indicated during operation.) And supply
gas. (Check gas leak.)
Other parts
(including
compressor)
1. Compressor thermo operation
• Gas shortage
normal condition
when recovering
from errors.
2. The indoor unit operates normally
during the check.
If the reply serial signal continues to be
transmitted between 2 and 3 of the
indoor terminal block, replace the
outdoor P.C. board.
• Gas leak
2. Instantaneous power failure
If the signal stops between them,
replace the indoor P.C. board.
The discharge temperature is
over 120°C.
All off
All off
The lamp on the
indoor unit blinks
when error is
defected.
1. Check the heat exchanger sensor (TD).
2. Gas purging
The IOL operation is defective.
The lamp on the
indoor unit blinks
when error is
detected.
When turning on the unit, the normal
phase (RST) is detected but T-R waveform
has not been detected for 120 seconds or
more.
– 23 –
FILE NO. SVM-06012
Table 9-2-2
Operation of diagnostic function
Judgement and action
Check
code
Unit
status
Block
Symptom
Condition
[MODE]
[TIMER] lamp
5Hz flash
The serial signal is not output
from outdoor unit to indoor unit.
• Miscabling of inter-unit cables
• Defective serial sending circuit
on outdoor P.C. board
• Defective serial receiving circuit
on outdoor P.C. board
• Compressor case thermo
operation
Operation
continues.
Displayed when
error is detected
1. Outdoor unit does not completely
operate.
• Inter-unit cable check, correction of
miscabling
• Outdoor P.C. board check, P.C. board
cables check
• Compressor case thermo check
2. In normal operation
When outdoor sending serial LED
(Green) flashes, the receiving serial
LED (Orange) also flashes. : Indoor
P.C. board (Main P.C. board) check
When the receiving serial LED (Orange)
does not flash: Outdoor P.C. board
check
BUS communication circuit error
* BUS communication was
interrupted over the specified
time.
Operation
continues
(According
to remote
control of
indoor
Displayed when
error is detected
1. Communication line check, miscabling
check
Power supply check for central control
(Central control remote control, etc.)
and indoor unit
2. Communication check (XY terminal)
3. Indoor P.C. board check
4. Central control check
unit)
(Communication P.C. board)
Error in 4-way valve system
• Indoor heat exchanger
temperature rise after start of
cooling operation.
• Indoor heat exchanger
temperature fall after start of
heating operation.
Operation
continues.
Displayed when
error is detected
1. Check 4-way valve.
2. Check 2-way valve and non-return
valve.
3. Check indoor heat exchanger sensor
(TC).
4. Check indoor P.C. board
(Main P.C. board).
Error in other cycles
Operation
continues.
Displayed when
error is detected
1. Compressor case thermo operation.
2. Coming-off of detection part of indoor
heat exchanger sensor.
• Indoor heat exchanger temp
(TC) does not vary after start of
cooling/ heating operation.
3. Check indoor heat exchanger sensor
(TC).
*
4. Check indoor P.C. board
(Main P.C. board).
[MODE] lamp
5Hz flash
Coming-off, disconnection or
short of indoor temp sensor (TA)
Operation
continues.
Displayed when
error is detected
1. Check indoor temp sensor (TA).
2. Check indoor P.C. board
(Main P.C. board).
Coming-off, disconnection or
short of indoor temp sensor (TC)
Operation
continues.
Displayed when
error is detected
1. Check indoor temp sensor (TC).
2. Check indoor P.C. board
(Main P.C. board).
Coming-off, disconnection or
short of indoor temp sensor
(TCJ)
Operation
continues.
Displayed when
error is detected
1. Check indoor temp sensor (TCJ).
2. Check indoor P.C. board (Main P.C.
board).
[MODE] lamp
5Hz flash
Error in indoor fan system
Revolutions frequency error of fan
All stop
Displayed when
error is detected
1. Check indoor fan motor connector
circuit (CN210).
2. Check indoor fan.
3. Check indoor P.C. board
(Main P.C. board).
Error in indoor unit or other
positions
1. EEPROM access error
Operation
continues.
Displayed when
error is detected
1. Check indoor P.C. board
(EEPROM and peripheral circuits)
(Main P.C. board).
Outside error input
Detected by input voltage level
from outside devices
Operation
continues.
Displayed when
error is detected
1. Check outside devices.
2. Check indoor P.C. board
(Main P.C. board).
Outside interlock input
Detected by input voltage level
from outside devices
All stop
Displayed when
error is detected
*: No display in the setting at shipment
– 24 –
FILE NO. SVM-06012
Table 9-2-3
Operation of diagnostic function
Judgement and action
Check code
Symptom
Unit status
Condition
Inverter over-current protective circuit
operates.
(For a short time)
All stop
Displayed when
error is detected
1. Inverter immediately stops even if restarted.
• Compressor rare short
2. Check IPDU.
• Cabling error
Error on current detection circuit
• Current value is high at AC side even
while compressor stops.
All stop
Displayed when
error is detected
1. Compressor immediately stops even if restarted.
: Check IPDU.
2. Phase-missing operation of power supply
• Phase of power supply is missed.
• Check power voltage of R, S, T.
Coming-off, disconnection or short of
outdoor temp sensor
All stop
All stop
All stop
Displayed when
error is detected
1. Check outdoor temp sensor (TE, TS).
2. Check CDB.
Coming-off, disconnection or short of
outdoor temp sensor
Displayed when
error is detected
1. Check outdoor temp sensor (TD).
2. Check CDB.
Compressor drive output error
• Tin thermistor temp, Tin error
(IPDU heat sink temp. is high.)
Communication error between IPDU
• Connector coming-off between CDB and
IPDU
Displayed when
error is detected
1. Abnormal overload operation of refrigerating
cycle
2. Loosening of screws and contact error of IPDU
and heat sink
3. Cooling error of heat sink
4. Check cabling of CDB and IPDU.
Compressor does not rotate. (Over-current All stop
protective circuit works when constant time
passed after activation of compressor.)
Displayed when
error is detected
1. Compressor error (Compressor lock, etc.)
: Replace compressor.
2. Cabling trouble of compressor (Phase missing)
Discharge temp error
• Discharge temp over specified value was
detected.
All stop
Displayed when
error is detected
1. Check refrigerating cycle. (Gas leak)
2. Error of electron control valve
3. Check pipe sensor (TD).
Compressor breakdown
• Operation frequency lowered and stops
though operation had started.
All stop
Displayed when
error is detected
1. Check power voltage. (AC200V±20V)
2. Overload operation of refrigerating cycle
3. Check current detection circuit at AC side.
High-voltage protection error by TE sensor All stop
• TE temp over specified value was
detected.
Displayed when
error is detected
1. Overload operation of refrigerating cycle
2. Check outdoor temp sensor (TE).
DC outdoor fan motor error
• IDC operation or lock was detected by
DC outdoor fan driving.
All stop
Displayed when
error is detected
1. Position detection error
2. Over-current protection circuit operation of
outdoor fan drive unit
• Check CDB.
• Refer to Judgment of outdoor fan.
Error on IPDU position detection circuit
All stop
Displayed when
error is detected
1. Position detection circuit operates even if driving
by removing 3P connector of compressor.
• Replace IPDU.
Coming-off, disconnection or short of
outdoor temp sensor
Operation
continues.
Displayed when
error is detected
1. Check outdoor temp sensor (TO).
2. Check P.C. board.
– 25 –
FILE NO. SVM-06012
Relational graph of temperature sensor resistance value and temperature
20
10
0
40
30
TA sensor
TC, TCJ sensor
Caracteristics-2
Caracteristics-1
Resistance
(k
Resistance
(k
Ω
)
Ω
)
20
10
0
10 20 30
40 50
10
0
10 20
30 40 50 60 70
Temperature [°C]
Temperature [°C]
TE, TO, TS sensor
20
200
Caracteristics-3
Resistance
(k
(10°C or lower)
100
Resistance
(k
Ω
)
Ω)
(10°C or higher)
10
0
0
10
0
10 20 30
40 50 60 70
Temperature [°C]
TD sensor
20
200
Caracteristics-4
Resistance
(k
(50°C or lower)
100
Resistance
(k
(50°C or higher)
10
Ω
)
Ω)
0
0
50
100
Temperature [°C]
– 26 –
FILE NO. SVM-06012
10. DETACHMENTS
10-1. Indoor Unit
No.
Part name
Procedures
Remarks
Air Inlet grille
1
<How to remove the Air inlet grille>
1) Stop the operation of the Air conditioner
and turn off its main power supply.
2) Open the Air inlet grille with both hands.
Air inlet grille
3) Unfasten 3 screws (about two to three
rounds) for fixing the Panel arms.
4) Move the Air inlet grille toward.
Panel arm
5) Remove the Grille stopper from the axis of
the Front panel. After that, remove the Air
inlet grille.
Grille stopper
Air inlet grille
Panel arm
6) Remove the Panel arms from the Front panel.
<How to install the Air inlet grille>
1) Insert three Panel arms on the Air inlet
grille and fix each securely by screws.
2) Set the Air inlet grille arm to the axis of the
Front panel.
3) Insert the Grille stopper to the correct
position and fix it securely with screws.
4) Push the Air inlet grille to the correct position.
– 27 –
FILE NO. SVM-06012
No.
Part name
Procedures
Remarks
Front panel
2
<How to remove the Front panel>
1) Remove the Air inlet grille. (1)
2) In case of the Drain hose is installed
through the Front panel.
: Remove the Drain band from the Front
panel.
: Cut away the Opening base for piping
from Front panel and keep parts.
Drain panel
Drain band
Cap screws
3) Open 3 Cap screws and remove the
screws.
Front Panel
4) Remove 5 screws fixing the Front panel.
Screws
5) Remove the hooks of the Panel LED nearly
side from the Drain pan.
(Continue)
– 28 –
FILE NO. SVM-06012
No.
Part name
Procedures
Remarks
Front panel
2
6) Remove both side hooks and remove the
Front panel by turn to air inlet part
direction.
Hook
<How to install the Front panel>
1) In case of the Drain hose installation
through the Front panel, install the opening
base for piping in the Back body by a screw
(M4 x 12). Prepare it by yourself.
2) Fit the Front panel in the Drain pan. Then
fix it in the Drain pan with 2 hooks in the
center of the air outlet.
3) Fix 5 hooks around the Front panel with
conformation the Guide-rib is inserting into
the Back body.
4) Fix 8 screws and close 3 Cap screws.
5) Install the Drain band into the Front panel.
6) Check the gap between the Front panel
and the Back body.
Guide-rib
3
<How to remove the Drain pan>
Drain pan
assembly
1) Remove the Air inlet grille and the Front
panel. (1, 2)
2) Remove the Louver motor from the Drain
pan.
Louver motor
Electrical wire
3) Remove the shaft of Horizontal louver.
4) Remove the LED base and Electrical wire.
LED base
Shaft of Horizontal lover
TA sensor
Drain hose
5) Remove the TA sensor wire.
6) Remove the Drain hose.
(Continue)
– 29 –
FILE NO. SVM-06012
No.
Part name
Drain pan
assembly
Procedures
Remarks
Screw
3
7) Remove 7 screws and remove the Drain
pan assembly.
Drain Pan
Screw
Electrical parts
assembly
4
<How to remove the Electrical parts assembly>
Refrigeration
1) Remove the Air inlet grille, the Front panel
and the Drain pan assembly. (1, 2, 3)
2) Remove the Terminal cover.
TC sensor
assembly
Connecting
cable
Earth wire
Cord clamp
3) Unfasten the screw of Cord clamp and
disconnect the connecting cable.
4) Remove the Connector cover and
disconnect the Fan motor cords.
TCJ
sensor
5) Remove the TC sensor, TCJ sensor and
earth wire from Refrigeration assembly.
6) Remove the Electrical parts assembly.
NOTE : When install the electrical parts
assembly, fix the screw after the Back body
is fixed.
Electrical parts
assembly
Fan motor cords
5
<How to remove the Refrigeration assembly>
Refrigeration
assembly
1) Remove the Air inlet grille, the Front panel
and the Drain pan assembly. (1, 2, 3)
2) Stop the gas at the Outdoor unit.
3) Remove 2 pipes from the Refrigeration
assembly.
TCJ sensor
TC sensor
Pipe holder
Earth wire
4) Remove the TC sensor and TCJ sensor
from holder.
5) Remove the pipe holder.
6) Remove the earth wire.
(Continue)
– 30 –
FILE NO. SVM-06012
No.
Part name
Procedures
Remarks
Refrigeration
assembly
5
7) Remove 2 screws and remove the
refrigeration assembly with pushing it to
right hand.
2 Screws
Fan cover
6
<How to remove the Multiblade fan and
Fan motor>
Multiblade fan
and Fan motor
1) Remove the Air inlet grille and the Front
panel. (1, 2)
2) Disconnect 2 connectors.
3) Remove the Fan covers.
4) Remove the Motor band with holding the
Fan motor and then remove the Fan motor
with the Multi-blade fans.
Motor band
Motor
2 Connectors
Multi-blade fan
5) Unfasten the Set-screw and remove the
Multi-blade fans.
– 31 –
FILE NO. SVM-06012
11. EXPLODED VIEWS AND PARTS LIST
11-1. Indoor Unit (E-Parts Assy)
401
402
403
404
405
406
407
408
Location
No.
Part
No.
Location
No.
Part
No.
Description
Description
401
401
402
403
404
405
43T69564 PC BOARD (RAV-SM802XT-E)
43T69565 PC BOARD (RAV-SM562XT-E)
43T50004 SENSOR; HEAT EXCHANGER
43T60002 TERMINAL BLOCK; 3P
43T62003 CORD CLAMP
406
407
407
408
43T50302 TEMPERATURE SENSOR
43T69564 PC BOARD (RAV-SM562XT-E)
43T69565 PC BOARD (RAV-SM802XT-E)
43T08349 SWITCH COVER
43T69315 DISPLAY UNIT
– 32 –
FILE NO. SVM-06012
11-2. Indoor Unit
220
222
217
218
227
224
214
208
207
223
208
212
216
203
235
206
219
204
225
202
221
226
213
211
210
229
209
215
233
228
231
234
235
205
201
230
232
Location
No.
Part
No.
Location
No.
Part
No.
Description
Description
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
43T09379 AIR-GRILLE
219
220
221
222
223
224
225
226
227
228
229
230
231
233
43T03339 BACK BODY ASSY
43T09314 VERTICAL LOUVER
43T49303 PIPE HOLDER
43T00445 PANEL ARM ASSY
43T00446 FRONT PANEL ASSY
43T01306 MARK
43T19324 COVER BODY L
43T19325 COVER BODY R
43T19328 COVER BODY LD
43T19326 BUSH BODY R
43T79312 DRAIN BAND
43T80302 AIR FILTER
43T00433 CAP SCREW C
43T00434 CAP SCREW LR
43T20303 FAN COVER
43T19327 BUSH BODY D
43T82308 PLATE; INSTALLATION
43T60314 TERMINAL COVER
43T62303 CONNECTOR COVER
43T83003 HOLDER; REMOTE CONTROLLER
43T69309 WRIRELESS REMOCON
43T49326 FLEXIBLE PIPE ASSY
(SM562XT-E)
43T20318 MOTOR BAND ASSY
43T20317 FAN ASSY (MULTIBLADE FAN)
43T19309 SCREW SET (D-T)
43T21369 FAN MOTOR
43T72309 DRAIN PAN ASSY
43T79311 GUIDE DRAIN
43T21376 MOTOR; STEPPING
43T09378 HORIZONTAL LOUVER FLOCK
43T44377 REFRIGERATION ASSY
(SM562XT-E)
233
43T49328 FLEXIBLE PIPE ASSY
(SM802XT-E)
234
43T80003 FILTER; FRAME
43T00447 ASM-GRILLE-STOPPER
235
218
43T44378 REFRIGERATION ASSY
(SM802XT-E)
– 33 –
T O S H IB A C A R R IE R ( T H A IL A N D ) C O . , LT D .
1 4 4 / 9 MOO 5 , BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI,
AMPHUR MUANG, PATHUMTHANI 1 2 0 0 0 , THAILAND.
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