FILE NO. A03-013 SERVICE MANUAL SPLIT TYPE RAV-SP1100UT-E RAV-SP560AT-E, RAV-SP800AT-E RAV-SP1100AT-E, RAV-SP1400AT-E R410A The type of all the indoor units described in this Service Manual is a new model, RAV-SP1100UT-E only. For the other indoor units to be combined, refer to the Service Manuals for the following models.
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.
Indoor Unit (4-Way Air Discharge Cassette Type) –––––––––––––––––––––––– RAV-SP1100UT-E ACCESSORIES (SOLD SEPARATELY) ............................... 4 ADJUSTMENT OF WIND DIRECTIONd ............................ 11 PRECAUTIONS FOR SAFETY ............................................ 4 TIMER OPERATION ........................................................... 12 PARTS NAME ....................................................................... 6 MAINTENANCE ..............................................
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.
• When the air conditioner is installed in a small room, provide appropriate measures to ensure that the concentration of refrigerant leakage occur in the room does not exceed the critical level. • Be sure to provide grounding. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables. • Conform to the regulations of the local electric company when wiring the power supply. Inappropriate grounding may cause electric shock.
3 SELECTION OF INSTALLATION CAUTION Length of refrigerant pipe connected to indoor/outdoor unit When using an air conditioner under low outside temperature condition (Outside temp.:–5°C or lower) with COOL mode, prepare a duct or wind shield so that it is not affected by the wind. 20m or shorter *21m to 50m Discharge Fin Discharge guide Fin Suction Addition of refrigerant is unnecessary at the local site.
Installation Place 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 diam. 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 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 diam. 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.) 68 to 82 (6.8 to 8.2kgf•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.
5 EVACUATING How to open the valve Compound pressure gauge Pressure gauge –101kPa (–76cmHg) Valve unit Manifold valve Handle Lo Handle Hi (Keep fully closed) Charge hose (For R410A only) Handle Pull out the handle and using cutting pliers, etc. turn it counterclockwise by 90˚.
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.
Installation/Servicing Tools Changes in the product and components In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged 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.
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.
• When the air conditioner is installed in a small room, provide appropriate measures to ensure that the concentration of refrigerant leakage occur in the room does not exceed the critical level. • Install the air conditioner securely in a location where the base can sustain the weight adequately. • Perform the specified installation work to guard against an earthquake. If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.
3 SELECTION OF INSTALLATION CAUTION When using an air conditioner under low outside temperature condition (Outside temp.:–5°C or lower) with COOL mode, prepare a duct or wind shield so that it is not affected by the wind. upward/downward ( Discharge or leftward is also available.
Installation Place 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 150 600 150 400 365 Drain hole Open the upper side and both right and left sides.
Optional Installation Parts (Local Procure) Knockout of Pipe Cover Parts name Q’ty A Refrigerant piping Liquid side : Ø9.5 mm Gas side : Ø15.9 mm B Pipe insulating material (polyethylene foam, 6 mm thick) C Putty, PVC tapes Each one 1 Rear direction Each one Pipe cover Side direction Front direction Refrigerant Piping Connection Down direction CAUTION TAKE NOTICE THESE IMPORTANT 4 POINTS BELOW FOR PIPING WORK Knockout procedure 1.
3 SELECTION OF INSTALLATION In order to avoid the force applied to on the connecting section, be sure to fix the cables to the cord clamps provided on the pipe valve fixing plate and the electric parts box. How to remove the front panel 1. Remove screws of the front panel. 2. Pull the front panel downward. Front panel Electric parts box Removing the front panel, the electric parts appear at the front side. • The metal pipes are attachable to the piping holes.
4 REFRIGERANT PIPING Tightening of Connecting Part REQUIREMENT (Unit: N•m) Outer dia. of copper pipe Tightening torque 6.4 mm (diam.) 14 to 18 (1.4 to 1.8 kgf•m) 9.5 mm (diam.) 33 to 42 (3.3 to 4.2 kgf•m) 12.7 mm (diam.) 50 to 62 (5.0 to 6.2 kgf•m) 15.9 mm (diam.) 68 to 82 (6.8 to 8.2 kgf•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.
Compound pressure gauge Handle position Pressure gauge –101kPa (–76cmHg) Handle Lo Charge hose (For R410A only) Service port (Valve core (Setting pin)) Manifold valve Handle Hi (Keep fully closed) Charge hose (For R410A only) Vacuum pump adapter for counter-flow prevention (For R410A only) Vacuum pump Handle Closed completely Opened fully *1. Use the vacuum pump, vacuum pump adapters, and gauge manifold referring to the manuals attached to each tool before using them.
6 ELECTRICAL WORK For the air conditioner that has no power cable, connect a power cable as mentioned below. Model Stripping length power cord and connecting cable SM1400AT-E SM1100AT-E SP1100AT-E SP1400AT-E RAV- L N 10 1 2 3 10 220 – 240 V Single phase 50 Hz Power supply Maximum running current 22.0 A Installation fuse rating 25 A (D type 40 22.8 A ) 50 40 Earth line Earth line H07 RN-F or 245 IEC 66 (2.
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.
7 FINAL INSTALLATION CHECKS Installation/Servicing Tools Changes in the product and components In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged 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.