FILE NO. A02-013 SERVICE MANUAL SPLIT TYPE RAV-SM560AT-E/RAV-SM800AT-E RAV-SM560UT-E/RAV-SM800UT-E RAV-SM560BT-E/RAV-SM800BT-E RAV-SM560KRT-E/RAV-SM800KRT-E R410A PRINTED IN JAPAN, Apr.
ADOPTION OF NEW REFRIGERANT This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer. WARNING Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have a service person do it. Do not attempt it yourself. The cleaning diagram for the air filter is there for the service person, and not for the customer.
INSTALLATION MANUAL Accessory parts and Parts to be procured locally ............ PRECAUTIONS FOR SAFETY .............................................. SELECTION OF INSTALLATION PLACE .............................. DRAIN PIPING WORK ........................................................... REFRIGERANT PIPING ......................................................... EVACUATING ......................................................................... ELECTRICAL WORK .........................................
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.
RAV-SM800AT-E RAV-SM800AT-E • 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.
ACCESSORY AND REFRIGERANT Accessory and Installation Parts 1 Refrigerant Piping • Piping kit used for the conventional refrigerant cannot be used. • Use copper pipe with 0.8 mm or more thickness for Ø6.4, Ø9.5, Ø12.7. Use copper pipe with 1.0 mm or more thickness for Ø15.9. • 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.
Necessary Space for Installation • 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. • 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. • A place where the drain water does not make any problem.
3 SELECTION OF INSTALLATION • Before installation, check strength and horizontality of the base so that abnormal sound does not generate. • According to the following base diagram, fix the base firmly with the anchor bolts. (Anchor bolt, nut: M10 x 4 pairs) 1000 or more 1000 or more Installation of Outdoor Unit 90 600 90 115 330 310 Open the upper side and both right and left sides.
Refrigerant Piping Connection CAUTION TAKE NOTICE THESE IMPORTANT 4 POINTS BELOW FOR PIPING WORK Waterproof rubber cap 1. Keep dust and moisture away from inside the connecting pipes. 2. Tightly connect the connection between pipes and the unit. 3. Evacuate the air in the connecting pipes using VACUUM PUMP. 4. Check gas leak at connected points.
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. 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.
4 REFRIGERANT PIPING • Flaring size : A (Unit : mm) Pipe Forming/End Positioning A +0 - 0.4 Outer dia. of copper pipe • Forming of pipe Form the pipe along with a marked line of the cabinet. • End positioning of pipe Match the ends of both pipes at at a distance of 85 mm apart from the marked line. R410A R22 6.35 9.1 9.0 9.52 13.2 13.0 12.7 16.6 16.2 15.9 19.7 19.4 * In case of flaring for R410A with the conventional flare tool, pull it out approx. 0.
4 REFRIGERANT PIPING Tightening of Connecting Part REQUIREMENT (Unit: N•m) Outer dia. of copper pipe Tightening torque 6.35mm (diam.) 14 to 18 (1.4 to 1.8kgf•m) 9.52mm (diam.) 33 to 42 (3.3 to 4.2kgf•m) 12.7mm (diam.) 50 to 62 (5.0 to 6.2kgf•m) 15.9mm (diam.) 63 to 77 (6.3 to 7.7kgf•m) 1. Do not put the spanner on the cap. The valve may be broken. 2. If applying excessive torque, the nut may be broken according to some installation conditions.
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) Outdoor unit at upper side Outdoor unit at lower side SM560 type 30 30 15 SM800 type 50 30 15 Capacity rank Hexagonal wrench size 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.
5 EVACUATING Valve unit OPEN Compound pressure gauge Pressure gauge –101kPa (–76cmHg) Manifold valve Handle Lo Handle Pull out the handle and using cutting pliers, etc. turn it counterclockwise by 90˚. (Open fully) Handle Hi (Keep fully closed) Charge hose (For R410A only) Charge hose (For R410A only) Charge port Vacuum pump adapter for counter-flow prevention (For R410A only) Flare nut Valve unit CLOSE Vacuum pump Packed valve (Gas side) Push in handle.
6 ELECTRICAL WORK For the air conditioner that has no power cable, connect a power cable as mentioned below. Model RAV- SM560AT-E 220 – 240 V Single phase 50 Hz Maximum running current 12A Power cable 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.
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.
Changes in the product and components Installation/Servicing Tools In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged accidentally, 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.
ACCESSORIES Screws (two pcs.) Standard 4-way cassette panel optional parts PRECAUTIONS FOR SAFETY WARNING WARNINGS ABOUT INSTALLATION • Make sure to ask the qualified installation professional in electric work to install the air conditioner. If the air conditioner is inappropriate installed by yourself, it may cause water leak, electric shock, fire, and so on. • Ground the air conditioner without fail. Do not connect the ground wire to gas pipe, water pipe, lightning rod or ground wire of telephone.
CAUTION CAUTIONS ABOUT INSTALLATION RAV-SM560UT-E RAV-SM800UT-E • Certainly lay the drain hose for perfect draining. Bad drainage may cause flooding in the house and getting furniture wet. • Make sure to connect the air conditioner to an exclusive AC outlet of the rated voltage, otherwise the unit may break down or cause a fire. • Do not install the unit in a place where inflammable gas may leak. If inflammable gas accumulates around the unit, it may cause a fire.
PARTS NAME Indoor unit Button Earth screw Provided in the electric parts box Discharge flap of discharge port Air filter Removes dust or trash. (Provided on the suction port.) Change the direction of the air to be discharged according to cool/heat mode. Suction air port The air in the room is sucked in from this port.
PARTS NAME OF REMOTE CONTROLLER Display section CODE No. In the display example, all indicators are displayed for the explanation. In reality only, the selected contents are indicated. • When turning on the leak breaker at the first time, [SET DATA] flashes on the display part of the remote controller. While this display is flashing, the model is being automatically confirmed. Accordingly, wait for a while after [SET DATA] display has disappeared, and then use the remote controller. SET DATA UNIT No.
Operation section Push each button to select a desired operation. • The details of the operation needs to be set up once, afterward, the air conditioner can be used by pushing button only. 1 7 8 2 3 9 4 UNIT 5 SET 10 CL 6 1 2 3 4 5 Check button The CHECK button is used for the check operation. During normal operation, do not use this button. 9 Operation select button Selects desired operation mode. 10 Fan button FAN button is used when a fan which is sold on the market or etc. is connected.
CORRECT USAGE When you use the air conditioner for the first time or when you change the SET DATA value, follow the procedure below. From the next time, the operation displayed on the remote controller will start by pushing the button only. Preparation Turn on the main power switch and/or the leakage breaker. • When the power supply is turned on, a partition line is displayed on the display part of the remote controller.
Stop Push button. The operation lamp goes off, and the operation stops. AUTOMATIC OPERATION (Auto Changeover) When you set the air conditioner in mode or switch over from AUTO operation because of some settings change, it will automatically select either cooling, heating, or fan only operation depending on the indoor temperature. Start 1 button Push this button to start the air conditioner. 2 Mode select button (MODE) Select Auto. 3 • • • • • • Temperature button Set the desired temperature.
ADJUSTMENT OF WIND DIRECTIONd • When the air conditioner stops, the flap (adjustment plate of up/down wind direction) directs downward automatically. • When the heating operation is in READY states, the flap (adjustment plate of up/down wind direction) directs is displayed on the remote upward. The swinging starts after HEAT READY status cleared, SWING controller even if the heating operation is in READY status. How to set up the wind direction 1 Push during operation.
TIMER OPERATION A type of timer operation can be selected from the following three types. OFF timer : The operation stops when the time of timer has reached the set time. Repeat OFF timer : Every time, the operation stops after the set time has passed. ON timer : The operation starts when the time of timer has reached the set time. 1 Timer operation UNIT 2 SET CL 34 1 Push TIMER SET button. • The timer display (type) changes for every push of the button. • SET DATA and display flashes.
HINTS FOR ECONOMICAL OPERATION Maintain room temperature at comfortable level Clean air filters The clogged air filter impairs the performance of the air conditioner. Clean them every 2 weeks. Never open doors and windows more often than necessary To keep cool or warm air in the room, never open doors and windows more often than necessary. Window curtains In cooling, close the curtains to avoid direct sunlight. In heating, close the curtains to keep the heat in.
If you do not plan to use the unit for more than 1 month (1) Operate the fan for 3 to 4 hours to dry inside the unit • Operate “FAN ONLY” mode with set temperature 30°C. (2) Stop the air conditioner and turn off the main power switch or the circuit breaker. Checks before operation (1) Check that the air filters are installed. (2) Check that the air outlet or inlet is not blocked. (3) Turn on the main power switch or the circuit breaker for the mains AC outlet to turn on the air conditioner.
Use a vacuum cleaner to remove dust from the filters or wash them with water. • After rinsing the air filters with water, dry them in the shade. • Set the air filter into the air conditioner. Cleaning of discharge flap The discharge flap can be removed to clean. 1. Remove the discharge flap. • Holding the both ends of the discharge flap, remove the flap sagging the center downward. 2. Cleaning with water • If the dirt is terrible, clean the flap by tepid water with neutral detergent or water.
AIR CONDITIONER OPERATIONS AND PERFORMANCE 3 minutes protection function 3-minutes protection function prevents the air conditioner from starting for initial 3 minutes after the main power switch/circuit breaker is turned on for re-starting the air conditioner. Power failure Power failure during operation will stop the unit completely. • To restart the operation, push the START/STOP button on the remote controller. • Lightning or a wireless car telephone operating nearby may cause the unit to malfunction.
RE-INSTALLATION DANGER Ask the dealer or an installation professional to re-install the air conditioner to a new place or move it to another place and to observe the following items. If the air conditioner is inappropriate installed by yourself, it may cause electric shock or fire. Do not install the air conditioner in the following places • Do not install the air conditioner in any place within 1 m from a TV, stereo, or radio set.
Before you ask for servicing or repairs, check the following points. Inoperative • The main power switch is turned off. • The circuit breaker is activated to cut off power supply. • The main power fuse has blown out. Recheck • Stoppage of electric current. Does not cool well or heat well • The air inlet and/or outlet of the outdoor unit is blocked. • Doors or windows are opened. • The fan speed is set to low. • The air conditioner is set in the DRY mode. • The set temperature is too high.
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Accessory parts and Parts to be procured locally H Accessory parts Q’ty Shape Usage 1 This manual (Be sure to hand over to customers) Installation Manual Heat insulating pipe Installation pattern Part name Q’ty Shape Usage Washer 8 For hanging-down unit Hose band 1 For connecting drain pipe Flexible hose 1 For adjusting core-out of drain pipe Heat insulator 1 For sealing of wire connecting port Owner’s Manual 1 (Be sure to hand over to customers) For heat insulation of pipe connec
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.
1 PRECAUTIONS FOR SAFETY • 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.
2 SELECTION OF INSTALLATION PLACE WARNING • Install the air conditioner at enough strong place to withstand the weight of the unit. If the strength is not enough, the unit may fall down resulting in injury. • Install the air conditioner at a height 2.5m or more from the floor. CAUTION • 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.
2 SELECTION OF INSTALLATION PLACE Selection of installation place Discharge direction In case of continued operation of the indoor unit under high-humidity conditions as described below, dew may condense and water may drop. Especially, high-humidity atmosphere (dew point temperature : 23°C or more) may generate dew inside the ceiling. 1. Unit is installed inside the ceiling with slated roof. 2. Unit is installed at a location using inside of the ceiling as fresh air take-in path. 3.
External view REQUIREMENT Strictly comply with the following rules to prevent damage of the indoor units and human injury. • Do not put a heavy article on the indoor unit. (Even units are packaged) • Carry in the indoor unit as it is packaged if possible. If carrying in the indoor unit unpacked by necessity, be sure to use buffering cloth, etc. to not damage the unit. • To move the indoor unit, hold the hooking metals (4 positions) only.
2 SELECTION OF INSTALLATION PLACE Opening a ceiling and installation of hanging bolts The ceiling differs according to structure of building. For details, consult your constructor or interior finish contractor. In the process after the ceiling board has been removed, it is important to reinforce ceiling foundation (frame) and to keep horizontal level of installed ceiling correctly in order to prevent vibration of ceiling board. (1) Cut and remove the ceiling foundation.
REQUIREMENT Installation of ceiling panel (Sold separately) Before installation of the indoor unit, be sure to remove the cushion for transportation between the fan and the bell mouth. Running the unit without removing the cushion may damage the fan motor. Install the ceiling panel according to Installation Manual attached with it after piping/wiring work has completed. Check that installation of indoor unit and ceiling opening part is correct, and then install it.
3 DRAIN PIPING WORK Piping/Heat insulating material CAUTION Require the following materials for piping and heat insulating at site. • Following the Installation Manual, perform the drain piping work so that water is properly drained, and apply a heat insulation so as not to cause a dew. Inappropriate piping work may result in water leakage in the room and wet of furniture. Piping Heat insulator Hard vinyl chloride pipe VP25 (Outer dia.
Connection procedure Check the draining Connect a socket and a hard vinyl chloride pipe. • Using adhesive agent for vinyl chloride pipe, connect the drain pipes certainly so that water does not leak. • It takes approx. 10 hours to dry and harden the adhesive agent. During this period, do not apply force to the connecting part with the drain pipe. In the test run, check that water drain is properly performed and water does not leak from the connecting part of the pipes.
4 REFRIGERANT PIPING • Flaring dia meter size : A (Unit : mm) Refrigerant Piping A 1. If the outdoor units are to be mounted on a wall, make sure that the supporting platform is sufficiently strong. The platform should be designed and manufactured to maintain its strength over a long period of time, and sufficient consideration should be given to ensuring that the outdoor unit will not fall. 2. Use copper pipe with 0.8 mm or more thickness. 3.
5 EVACUATING REQUIREMENT AIR PURGE Evacuate the air in the connecting pipes and in the indoor unit using vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the manual of vacuum pump. • Charging an excessive or too little amount of refrigerant causes a trouble of the compressor. Be sure to charge the refrigerant of specified amount.
5 EVACUATING Packed valve handling precautions Compound pressure gauge Pressure gauge • Open the valve stem all the way out ; do not try to open it beyond the stopper. • Securely tighten the valve stem cap at the torque as follows: –101kPa (–76cmHg) Handle Lo Charge hose Gas side (15.9 mm (diam.)) 63 to 77 N•m (6.3 to 7.7 kgf•m) Gas side (12.7 mm (diam.)) 50 to 62 N•m (5.0 to 6.2 kgf•m) Packed valve at liquid side Gas side (9.52 mm (diam.)) 33 to 42 N•m (3.3 to 4.
6 ELECTRICAL WORK WARNING 1. Using the specified cables, ensure to connect the wires, and fix wires securely so that the external tension to the cables do not affect the connecting part of the terminals. Incomplete connection or fixation may cause a fire, etc. 2. Be sure to connect earth wire. (Grounding work) Do not connect the earth wire to gas pipe, city water pipe, lightning rod, or the earth wire of telephone. Incomplete grounding causes an electric shock. 3.
6 ELECTRICAL WORK Cable connection REQUIREMENT • • • • Be sure to connect the cables matching the terminal numbers. Incorrect connection causes a trouble. Be sure to pass the cables through the bushing of cabling connection port of the indoor unit. Keep a margin (Approx. 100mm) on a cable to hang down the electric parts box at servicing, etc. The low-voltage circuit is provided for the remote controller.
Cabling Cabling diagram 1. Remove a screw and then remove cover of the electric parts box. 2. Strip wire ends (10 mm). 3. Match wire colors with terminal numbers on indoor and outdoor units’ terminal blocks and firmly screw wires to the corresponding terminals. 4. Connect the ground wires to the corresponding terminals. 5. Fix the cable with cord clamp. 6. Fix cover of the parts box and the terminal block surely with the fixing screws. Terminal block for remote controller cabling of indoor unit Approx.
7 TEST RUN Before test run • Before turning on the power supply, carry out the following procedure. 1) Using 500V-megger, check 1MΩ or more exists between the terminal block 1 to 3 and the earth. If 1MΩ or less is detected, do not run the unit. Do not apply to the remote controller circuit. 2) Check the valve of the outdoor unit being opened fully. • To protect the compressor at activation time, leave power-ON for 12 hours or more be for operating.
8 TROUBLESHOOTING Confirmation and check CODE No. When a trouble occurred in the air conditioner, the check code and the indoor unit No. appear on the display part of the remote controller. The check code is only displayed during the operation. If the display disappears, operate the air conditioner according to the following “Confirmation of error history” for confirmation. UNIT No. R.C. Check code No. Indoor unit No.
ACCESSORIES Remote controller Screws (two pcs.) PRECAUTIONS FOR SAFETY WARNING • Make sure to ask the qualified installation professional in electric work to install the air conditioner. If the air conditioner is inappropriate installed by yourself, it may cause water leak, electric shock, fire, and so on. • Ground the air conditioner without fail. Do not connect the ground wire to gas pipe, water pipe, lightning rod or ground wire of telephone.
• Certainly lay the drain hose for perfect draining. Bad drainage may cause flooding in the house and getting furniture wet. • Make sure to connect the air conditioner to an exclusive AC outlet of the rated voltage, otherwise the unit may break down or cause a fire. • Do not install the unit in a place where inflammable gas may leak. If inflammable gas accumulates around the unit, it may cause a fire.
PARTS NAME Indoor unit NOTE : Parts marked with XXX indicate the locally procured parts.
PARTS NAME OF REMOTE CONTROLLER Display section CODE No. All display items are shown in right figure for the explanation. Only selected contents are displayed in actual operation. • When turning on the leakage breaker at the first time, [SET DATA] flashes on the display part of the remote controller. While this display is flashing, the model is being automatically confirmed. Accordingly, wait for a while after [SET DATA] display has disappeared, and then use the remote controller. SET DATA UNIT No.
Operation section Push each button to select a desired operation. • The details of the operation needs to be set up once, the same states are used by pushing button. 1 7 8 2 3 4 9 10 UNIT 5 SET CL 6 1 2 3 4 5 7 button When the button is pushed, operation starts, and it stops by pushing the button again. When the operation stops, the operation lamp and all displays disappear. Timer set button TIMER SET button is used when the timer is set up.
CORRECT USAGE When you use the air conditioner for the first time or when you change SET DATA value, follow the procedure below. From the next time, the operation will start as set state by pushing the button. Preparation Turn on the main power switch and/or the leakage breaker. • When the power supply is turned on, display section is displayed on the remote controller. * After the power supply is turned on, the remote controller does not accept an operation for approx. 1 minute, but it is not a failure.
Stop Push button. The operation lamp goes off, and the operation stops. AUTOMATIC OPERATION (Auto Changeover) When you set the air conditioner in mode or switch over from AUTO operation, it will automatically select either cooling, heating, or fan only operation depending on the indoor room temperature. Start 1 button Push this button to start the air conditioner. 2 Mode select button (MODE) Select Auto. 3 Temperature button Set the desired temperature.
TIMER OPERATION A type of timer operation can be selected from the following three types. OFF timer : The operation stops after the set time has passed. Repeat OFF timer : Every time, the operation stops after the set time has passed. ON timer : The operation starts after the set time has passed. Timer operation 1 UNIT 2 SET CL 34 1 Push TIMER SET button. • The timer display (type) changes every push of the button. • SET TIME and , , , display flashes.
HINTS FOR ECONOMICAL OPERATION Maintain room temperature at comfortable level Clean air filters Airflow and performance are reduced if the air filters become blocked. Clean them every 2 weeks. Do not open doors and windows more often than necessary To keep cool or warm air in the room, do not open doors and windows more often than necessary. Window curtains In cooling, close the curtains to avoid direct sunlight. In heating, close the curtains to keep the heat in.
If you do not plan to use the unit for more than 1 month (1) Operate the fan for 3 to 4 hours to dry inside the unit Operate “FAN ONLY” mode with set temperature 30°C. (2) Stop the air conditioner and turn off the main power switch or the circuit breaker. Checks before operation (1) Check that the air filters are installed. (2) Check that the air outlet or inlet is not blocked. (3) Turn on the main power switch or the circuit breaker for the mains AC outlet to turn on the air conditioner.
AIR CONDITIONER OPERATIONS AND PERFORMANCE 3 minutes protection function 3-minutes protection function prevents the air conditioner from starting for initial 3 minutes after the main power switch/circuit breaker is turned on for re-starting the air conditioner. Power failure Power failure during operation will stop the unit completely. • To restart the operation, push the START/STOP button on the remote controller. • Lightning or a wireless car telephone operating nearby may cause the unit to malfunction.
RE-INSTALLATION DANGER Ask the dealer or an installation professional to re-install the air conditioner to a new place or move it to another place and to observe the following items. If the air conditioner is inappropriate installed by yourself, it may cause electric shock or fire. Do not install the air conditioner in the following places • Do not install the air conditioner in any place within 1 m from a TV, stereo, or radio set.
Before you ask for servicing or repairs, check the following points. Inoperative • The main power switch is turned off. • The circuit breaker is activated to cut off power supply. • The main power fuse has blown out. Recheck • Stoppage of electric current. Does not cool well or heat well • The air inlet and/or outlet of the outdoor unit is blocked. • Doors or windows are opened. • The fan speed is set to low. • The air conditioner is set in the DRY mode. • The set temperature is too high.
TROUBLES AND CAUSES (Concerning Remote Controller) Before you ask for servicing or repairs, check the following points: Setting Change is Impossible Symptoms The fan speed can not be changed. Causes • Check whether the MODE indicated on the display is “AUTO”. Reason and Disposal When the automatic mode is selected, the air conditioner automatically selects the fan speed. AUTO • Check whether the MODE indicated on the display is “DRY”.
Accessory parts and Parts to be procured locally r Accessory parts Part name Q’ty Pipe insulator 2 Drain hose socket for drain pipe connection 1 Shape Part name Q’ty Connecting cable for High static pressure tap 1 Installation Manual 1 Owner’s Manual 1 Shape Standard wired remote controller Q’ty Shape 1 r Parts to be procured locally Connecting pipe (Liquid side) (6.35mm (diam.), Nominal (diam.) 1/4” thick 0.
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.
1 PRECAUTIONS FOR SAFETY • 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.
2 SELECTION OF INSTALLATION PLACE WARNING • Install the air conditioner at enough strong place to withstand the weight of the unit. If the strength is not enough, the unit may fall down resulting in injury. • Install the air conditioner at a height 2.5m or more from the floor. If you insert your hands or others directly into the unit while the air conditioner operates, it is dangerous because you may contact with revolving fan or active electricity.
3 INSTALLATION OF INDOOR UNIT WARNING Install the air conditioner certainly at a place to sufficiently withstand the weight. If the strength is insufficient, the unit may fall down resulting in human injury. Perform a specified installation work to guard against an earthquake. An incomplete installation can cause accidents by the units falling and dropping. Installation procedure 1.
External view REQUIREMENT The hanging bolt pitch on horizontal direction (B) is not halved at center with the ceiling opening size. Therefore, check the relational position in the following figure. 90 120 460~640 Refrigerant pipe connecting port (Gas side ØF) Refrigerant pipe connecting port (Liquid side ØG) Drain pipe connecting port For vinyl chloride pipe (Inner dia. 32, Nominal dia.
3 INSTALLATION OF INDOOR UNIT Supply chamber Concealed duct type Channel Supply grille Supplying 200mm (diam.) round duct Supplying Indoor unit Returning Return air grille NOTE: • Recommended supplying grille size 400 cm² each or more Ledge ceiling concealed duct type Supplying Supply grille Indoor unit Supply chamber Supplying 200mm (diam.
4 AIR DUCTING WORK Static pressure characteristics of each model Fig. 1 RAV-SM560BT-E 70% (570m³/h) 12 Standard air volume : 840m³/h 110% (925m³/h) 11 Extra High tap External static pressure (mmAq) 10 9 8 High tap 7 6 Middle Middoletap tap 5 4 3 Low tap 2 1 0 500 570 600 700 800 Air volume (m³/hr.) 900 925 1000 Fig.
4 AIR DUCTING WORK Installation Reference (exp. for RAV-SM800BT-E model) The air supply ducting work is classified in two ways, one is branched by the round ducts, and the other is branched by the square ducts. (Be sure to divide the air supply duct into three or more branches.) (Reference for square duct) When using the square duct, change the type of the air supply flange from round type to square flange at the local site.
Connecting method of the duct 1. Using 6 screws, mount the flange to the supply air port of the indoor unit. (Fig. 2) 2. Make the square duct according to inner dimension of the flange A x B . Use a glass wool board with inside/outside finishing 25mm-thickness and 24kg/m³-density. 3. Connect the flange and each type of duct. (Fig. 3) 1. Supply air side 1.
4 AIR DUCTING WORK Hanging of indoor unit Nut Lift up the unit with a lifter, etc., and set the hanging metal in the hanging bolt. • Hook nut of the hanging bolt to the groove of the hanging metal on the main unit. • Using the level, etc., install the main unit horizontally. Failure to do this will cause water leakage Washer Hanging bracket Hanging bolt Mounting of filter and canvas for suction port 1. Mount a long-life filter or a high-performance filter according to each Installation Manual. 2.
5 DRAIN PIPING WORK Piping material • For laying pipes underground, use hard vinyl chloride pipe. (Inner diam. 20 or 25mm) Indoor unit Thermal insulator 1.5m to 2m Support bracket 1/100 or more downward slope Arched shape Piping and cautions Trap • Set drain side of pipe at downward slope. (1/100 or more) • Be sure to apply thermal insulation (foaming polyethylene, 10mm-thickness or more) for pipes passing through the room.
6 REFRIGERANT PIPING • Flaring dia meter size : A (Unit : mm) Refrigerant Piping A 1. If the outdoor units are to be mounted on a wall, make sure that the supporting platform is sufficiently strong. The platform should be designed and manufactured to maintain its strength over a long period of time, and sufficient consideration should be given to ensuring that the outdoor unit will not fall. 2. Use copper pipe with 0.8 mm or more thickness. 3.
7 EVACUATING AIR PURGE • 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. Evacuate the air in the connecting pipes and in the indoor unit using vacuum pump. Do not use the refrigerant in the outdoor unit.
8 ELECTRICAL WORK For the air conditioner that has no power cord. Cabling 1. As shown in the figure, remove a screw and then remove cover of the electric part. 2. Strip wire ends (10 mm). 3. Match wire colors with terminal numbers on indoor and outdoor units’ terminal blocks and firmly screw wires to the corresponding terminals. 4. Connect the ground wires to the corresponding terminals. 5. Fix the cable with cord clamp. 6.
Remote Controller Cabling Remote controller cabling • Strip approx. 14mm the cable to be connected. • Non polarity, 2 core cable is used for cabling of the remote controller. • Twist cable of the remote controller to be connected with cable of the remote controller unit (or sensor), and press-fit them with a wire joint. (Wire joints (White: 2 pieces) are included in the attachments to the remote controller (sold separately) or the wireless remote controller kit (sold separately). Approx.
ACCESSORIES Remote controller F A N CHECK COOL DRY H E AT AUTO AUTO F I X CENTRAL FAN SPEED Screws (two pcs.) for Remote controller Installation plate Screws for installation plate Ø4mm x 25mm STANDBY FILTER PRE-HEAT DEFROST LOUVER MANUAL TEMP. LOUVER (sold separately) PRECAUTIONS FOR SAFETY WARNING WARNINGS ABOUT INSTALLATION • Make sure to ask the qualified installation professional in electric work to install the air conditioner.
CAUTION CAUTIONS ABOUT INSTALLATION • Certainly lay the drain hose for perfect draining. Bad drainage may cause flooding in the house and getting furniture wet. • Make sure to connect the air conditioner to an exclusive AC outlet of the rated voltage, otherwise the unit may break down or cause a fire. • Do not install the unit in a place where inflammable gas may leak. If inflammable gas accumulates around the unit, it may cause a fire.
PARTS NAME Outdoor unit 1 2 3 4 Air outlet - blows off hot air during cooling or cool air during heating 2,3 1 Power supply box - contains electrical parts Earth screw - in the electrical parts box 4 Refrigerant line connections Indoor unit 1 Room temperature sensor 2 Front panel 3 Air inlet grille 4 Air filter 5 Air outlet 6 Horizontal air flow louver 7 Vertical air flow louver 8 Display panel 9 Infrared signal receiver 10 Remote controller 10 AN MODE FA 2 4 3 1 TEMP P.
NAME AND OPERATIONS OF INDICATORS AND CONTROLS Display section All display items are shown in the figure below for purpose of explanation. Only selected items are displayed in actual operation. (All indicators are displayed for the explanation.) The displayed contents differ according to shape or type. 1 2 3 4 5 8 6 7 RAV-SM560KRT-E RAV-SM800KRT-E 1 2 3 4 5 7 CHECK Displayed during check mode. Set up temperature display The selected set up temp. is displayed. 8 Unit display Unit No.
Operation section Push each button to select a desired operation. 1 2 3 6 Operation select button Selects desired operation mode. Air volume select button Selects the desired air volume mode Set up temp. button Adjusts the required room temperature. 7 Match to the desired set temperature by pushing . 4 5 Filter reset button Resets (Erases) “FILTER” display. 8 CHECK button When an error/fault occurs on the air conditioner, this button is used to check the check code indicating fault status.
CORRECT USAGE When you use the air conditioner at the first time or when you change the setup value, follow the procedure below. From the next time, the operation displayed on the remote controller will start only by pushing ON / OFF button. Preparation Turn on the power switch. • The operation lamp (Red) flashes. REQUIREMENT • While using the air conditioner, operate it only with ON/OFF button without turning off the power switch.
DRY OPERATION Start 1 2 3 START/STOP button Push this button to start the air conditioner. Mode select button (MODE) Select DRY. AN MODE FA T E M P. F A N CHECK ADDRESS C O O L 12 Temperature button Set the desired temperature. T HEA AT AUU TO FIX • The FAN speed display indicates AUTO • The OPERATION lamp (green) on the switch panel of the remote controller lights, and operation starts after approximately 3 minutes.
ADJUSTING AIR FLOW DIRECTION • Adjust the air flow direction properly. Otherwise, it might cause discomfort and make the room temperature uneven. • Adjust the vertical air flow using the remote controller. • Adjust the horizontal air flow manually. Adjust the vertical air flow The air conditioner automatically adjusts the vertical air flow direction in accordance with the operating conditions. To set the air flow direction by yourself Perform this adjustment when the air conditioner is in operation.
HINTS FOR ECONOMICAL OPERATION 1. Clean air filters Air flow and performance are reduced if the air filters become blocked. Clean them every 2 weeks.. 2. Never open doors and windows more often than necessary To keep cool or warm air in the room, never open doors and windows more often than necessary. 3. Use the timer effectively Set the timer for the desired operating time. 4. Allow uniform circulation of room air Adjust the air flow direction for the even circulation of room air.
Check before operation FAN ONLY Operation CAUTION • Check that the air filters are installed. • Check that the air outlet or inlet of the outdoor unit is not blocked. Cleaning the air filter Air filter Clean the air filters every 2 weeks. If the air filters are covered with dust, the performance of the air conditioner will deteriorate. Clean the air filters as often as possible. 1 2 3 4 5 6 Open the air inlet grille. Lift the air inlet grille up to the horizontal position.
Cleaning the air inlet grille 1. Remove the air inlet grille. Hold the both sides of the air inlet grille and open upward. Move the center arm to the left and remove the grille. 2. Wash it with water using a soft sponge or towel. (Do not use metallic scrubbing brush or other hard brushes.) • Use of such hard objects will cause scratches on the surface of the air inlet grille, and the coating to peel off.
Heating capacity If the outdoor temperature is too low, it is recommended that additional heating appliances be used in conjunction with the air conditioner. Power failure Power failure during operation will stop the unit completely. • The OPERATION lamp (green) on the indoor unit will start flashing when power is restored. • To restart operation, push the START/STOP button on the remote controller.
Accessory parts and Parts to be procured locally H Accessory parts Part name Q’ty Shape Part name Q’ty Installation plate 1 Mounting screw Ø4mm x 25mm 8 Installation Manual 1 Pattern paper 1 Owner’s Manual 1 Service contact address label 1 Shape Part name Wired remote controller Q’ty 1 Shape STANDBY F A N CHECK FILTER COOL PRE-HEAT DRY DEFROST H E AT AUTO LOUVER AUTO F I X CENTRAL MANUAL FAN SPEED TEMP. LOUVER Connecting pipe (Liquid side) (6.35mm (diam.
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.
1 PRECAUTIONS FOR SAFETY • 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.
2 INSTALLATION PROCEDURE Installation Diagram of Indoor Unit 65mm or more For rear left and side pipe exit 170 mm or m ore Wall Insulate the refrigerant pipes separately with insulation, not together. Hook 1 Installation plate Hook Insert the cushion between the indoor unit and wall, and lift indoor unit to make work easier. Min. 6 mm thick heat resisting polyethylene foam 170 mm or m ore The auxiliary piping can be connected the left, rear left, rear, right or bottom.
3 SELECTION OF INSTALLATION PLACE WARNING • Install the air conditioner where there is sufficient strength to withstand the weight of the unit. If the strength is not sufficient, the unit may fall down resulting in injury. CAUTION Upon approval of the customer, install the air conditioner in a place that satisfies the following conditions. • Place where the unit can be installed horizontally. • Place where a sufficient servicing space can be ensured for safe maintenance and check.
5 DRAIN PIPING WORK Piping and Drain Hose Installation In case of right-side exit • Cut out the knockout portion by the slits with a knife or pair of wire cutters as necessary. Slit (Body right) In case of downward pipe exit • Cut out the knockout portion by the slits with a knife or pair of wire cutters as necessary. Slit (Body right) Piping via left-hand connection Bend the connecting pipe so that it is laid within 43mm above the wall surface.
5 DRAIN PIPING WORK CAUTION • Bind the auxiliary pipes (two) and connecting cable with tape tightly. In case of left-side pipe exit and rear-left exit, bind the auxiliary pipes (two) only with facing tape. Indoor unit Auxiliary pipes Connecting cable Drain hose Installation plate • Carefully arrange pipes so that any pipe does not stick out of the rear plate of the indoor unit.
6 REFRIGERANT PIPING Refrigerant Piping 1. If the outdoor units are to be mounted on a wall, make sure that the platform supporting is sufficiently strong. The platform should be designed and manufactured to maintain its strength over a long period of time, and sufficient consideration should be given to ensuring that the outdoor unit will not fall. 2. Use copper pipe with 0.8 mm or more thickness. 3. Flare nut and flare works are also different from those of the conventional refrigerant.
6 REFRIGERANT PIPING • Tightening torque of flare pipe connections Tightening connection Pressure of R410A becomes higher than that of R22. (Approx. 1.6 times) Therefore, using a torque wrench, tighten firmly the flare pipe connecting sections which connect the indoor and outdoor units up to the specified tightening torque. Incorrect connections may cause not only a gas leakage, but also a trouble of the refrigeration cycle or compressor damage.
Packed valve handling precautions • Open the valve stem all the way out ; do not try to open it beyond the stopper. • Securely tighten the valve stem cap in torque as follows: Gas side (12.7 mm (diam.)) 50 to 62 N•m (5.0 to 6.2 kgf•m) Gas side (9.52 mm (diam.)) 33 to 42 N•m (3.3 to 4.2 kgf•m) Compound pressure gauge –101kPa (–76cmHg) Manifold valve Handle Lo Handle Hi (Keep fully closed) Charge hose (For R410A only) Liquid side (6.35 mm (diam.)) 14 to 18 N•m (1.4 to 1.
7 EVACUATING Valve unit Valve handling precautions • Open the valve stem or the handle until it strikes the stopper. It is unnecessary to apply further force. • Securely tighten the cap with a torque wrench. • Cap tightening torque Handle Pull out the handle and using cutting pliers, etc. turn it counterclockwise by 90˚. (Open fully) Charge port Flare nut Valve size 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) Ø12.7 33 to 42N•m (3.3 to 4.2kgf•m) Ø15.
8 ELECTRICAL WORK For the air conditioner that has no power cord. Wiring between units NOTE: 1. Connect the wires between the units correctly. Errors made in the connections can result in the unit malfunctioning. 2. Connect the control wires between the outdoor unit and indoor unit as shown in the figure below : For selection and connection method of the power supply cords, refer to the details in the Installation Manual of the outdoor unit.
8 ELECTRICAL WORK Installation of Remote Controllers Remote Controller Cabling Precautions Cabling diagram 1. Low-voltage circuit provision is used for remote controller communication, and as such, the remote controller cable is subject to the low-power circuit provision of internal wiring regulations and therefore it cannot be brought into direct contact with a highvoltage AC power line, or housed in the same conduit tube as a power line.
9 IMPROVING SYSTEM EFFICIENCY Air flow direction adjustment 1. To improve the effects of cooling and heating, use the outlet louver appropriately for cooling and heating operations. When in cooling operation the most efficient louver position will be horizontal and when in heating operation the optimum louver position is downwards. Increasing heating effect 1. One method increase the warming effect is to fit an additional means of re-circulating the warmed air from the upper part of the room : 2.
10 FINAL INSTALLATION CHECKS Self-Diagnosis by LED Indication Useful Functions (SM800AT-E only) In addition to the code checking by remote controller of the indoor unit, troubles of the outdoor unit can be diagnosed 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.
11 ENVIRONMENT Environmental Issues Product maintenance 1. To minimize the chances of environmental damage and to ensure the efficient operation of the unit, it is recommended to have the air conditioner periodically checked and serviced by a qualified engineer. Product disposal 1. Please dispose of the air conditioner unit in an environmentally responsible manner. Recycling is the preferred disposal method. 2.