Page 2 - CONTENTS
– 2 – CONTENTS Precaution for Safety ............................................................................................................ 6New Refrigerant (R410A) .................................................................................................... 11 1. SPECIFICATIONS ..........
Page 3 - Original instruction; Generic Denomination: Air Conditioner; described in the table below.; Agent
– 3 – Original instruction Please read carefully through these instructions that contain important information which complies with the “Machinery” Directive (Directive 2006/42/EC), and ensure that you understand them. Generic Denomination: Air Conditioner Definition of Qualified Installer or Qualifi...
Page 4 - Definition of Protective Gear; electric shocks and other injuries.; Indication; DANGER; Explanation; when an incorrect work has been executed.; Mark
– 4 – Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’ work clothing.In addition to such normal protective gear, wear the protective gear described below when undertaking the special work deta...
Page 5 - Warning Indications on the Air Conditioner Unit; Warning indication; ELECTRICAL SHOCK HAZARD; Disconnect all remote electric; WARNING; BURST HAZARD; Open the service valves before the; Description; Open the service valves before the operation,
– 5 – Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positionsIf removing the label during parts replace, stick it as the original. Warning indication WARNING ELECTRICAL SHOCK HAZARD Disconnect all r...
Page 6 - Precaution for Safety
– 6 – Precaution for Safety The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position. Otherwise, elec...
Page 10 - Declaration of Conformity; DI series
– 10 – Explanations given to user • If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person to have the repairs done.Do not set the circuit breaker to the ON position until the rep...
Page 11 - Safety Caution Concerned to New Refrigerant; ) Do not mix the other refrigerant or refrigerating oil.
– 11 – New Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer. 1. Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the former refrigerant (R22).Accompanied with change of refrigerant,...
Page 12 - Required Tools for R410A; Used tool; attaching vacuum pump adapter.
– 12 – 4. Tools 1. Required Tools for R410A Mixing of different types 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 conv...
Page 14 - • Capacity variation ratio according to temperature
– 14 – 20 18 16 14 12 10 0 20 40 60 Compressor speed (rps) 80 100 120 8 6 4 2 0 Current (A) 20 22 22 18 16 14 12 10 0 20 40 60 Compressor speed (rps) 80 100 120 8 6 4 2 0 Current (A) • ConditionsIndoor : DB27˚C/WB19˚COutdoor : DB35˚CAir flow : HighPipe length : 7.5m230V • ConditionsIndoor : DB20˚COu...
Page 17 - . REFRIGERATING CYCLE DIAGRAM; Indoor unit; Height diff
– 17 – 3 . REFRIGERATING CYCLE DIAGRAM RAV-SM1103AT-E1, RAV-SM1403AT-E1 Indoor unit Outdoor unit Distributor(Strainer incorporated) TCJ sensor Air heat exchanger Strainer Strainer TC sensor Strainer Ball valve Outer dia. ØA Packed valve Outer dia. ØB Max.50m Min.5m TS sensor Pressure switch P TD sen...
Page 20 - SPECIFICATIONS OF ELECTRIC PARTS
– 20 – 5. SPECIFICATIONS OF ELECTRIC PARTS Compressor Outdoor fan motor Reactor 4-way valve coil High-pressure SW PMV coil P.C. board Fuse Fuse Fuse Surge absorber Rectifier Electrolytic condenser Power relay Relay Switching transformer Fuse DA422A3F-12M WDF-340-A100-1 CH62-2Z-T STF-H01AJ1949A1 ACB-...
Page 21 - NOTE
– 21 – 6. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer.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 ...
Page 22 - Flare Processing Procedures and Precautions; b) Removing Burrs and Chips
– 22 – Table 6-2-1 Thicknesses of annealed copper pipes 1. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In...
Page 23 - to secure “dimension A” by using a gauge for; Table 6-2-3 Dimensions related to flare processing for R410A / R22
– 23 – c) Insertion of Flare Nutd) 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 conventional flare tool.Flare processing dimensions differ according to the type ...
Page 24 - Flare Connecting Procedures and Precautions
– 24 – 43˚to 45˚ 45˚to 46˚ A B C D Fig. 6-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions 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.c) Tight...
Page 25 - Refer to the “; Connect the charge hose of the vacuum pump adapter.; bit by bit; rupture or personal injury.
– 25 – 6-3. Tools 6-3-1. Required Tools Refer to the “ 4. Tools ” 6-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. (INDOOR unit) (Liquid side) Refrigerant cylinder (With siphon pipe) Check va...
Page 26 - liquid; Silver brazing filler
– 26 – Gauge manifold [ Cylinder with siphon ] [ Cylinder without siphon ] OUTDOOR unit Gauge manifold OUTDOOR unit Refrigerant cylinder Electronic balance Refriger ant cylinder Electronic balance Siphon 1) Be sure to make setting so that liquid can be charged. 2) When using a cylinder equipped with...
Page 27 - Characteristics required for flux; • Noncorrosive flux; Piping materials for brazing and used; Prevention of oxidation during brazing; Piping material
– 27 – Nitrogen gas cylinder Pipe Flow meter M Stop valve From Nitrogen cylinder Nitrogen gas Rubber plug 2. Characteristics required for flux • Activated temperature of flux coincides with the brazing temperature. • Due to a wide effective temperature range, flux is hard to carbonize. • It is easy ...
Page 28 - Existing Pipe; Pipe outer diameter; Operation System; Place position
– 28 – 6-6. Instructions for Re-use Piping of R22 or R407C Instruction of Works: The existing R22 and R407C piping can be reused for our digital inverter R410A products installations.NOTE) Confirmation of existence of scratch or dent of the former pipes to be applied and also confirmation of reliabi...
Page 29 - Nitrogen gas pressure 0.5 Mpa; Piping necessary to change the flare nut/
– 29 – 6-6-5. Final Installation Checks Do not apply the refrigerator oil to the flare surface. Existing pipe: NO * Use a new pipes. Clean the pipes or use the new pipes. ∗ In case that a gas pipe Ø19 mm or bigger is used for the outdoor unit of SM80 (3 HP) : (Our R410A model 3 to 6 HPgas pipe size ...
Page 30 - Cautions for using existing pipe; • Do not reuse the flare to prevent gas leak.
– 30 – Reference outside diameter (mm) Ø9.5 Ø15.9 Ø19.1 Wall thickness (mm) 0.8 1.0 1.0 6-6-6. Handling of Existing Pipe When using the existing pipe, carefully check it for the following:• Wall thickness (within the specified range)• Scratches and dents• Water, oil, dirt, or dust in the pipe• Flare...
Page 31 - CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS
– 31 – 7.CIRCUIT CONFIGURATION AND CONTROL SPECIFICATIONS 7-1. Outdoor unit control 7-1-1. Prim circuit board (MCC-1630) Compressor output lead P03, P04, P05 P o w er supply circuit protection fuse F03 (250V , 3.15A, Plastic case) High-pressure SW connector CN501 (Green) J u mper wire J800 to J804, ...
Page 32 - REQUIREMENT; Discharge temperature release control; ) For displayed contents of error, confirm on the check code list.
– 32 – 7-1-2. Outline of Main Controls 1. Pulse Modulating Valve (PMV) control 1) For PMV with 50 to 500 pulses during operation, respectively.2) In cooling operation, PMV is controlled with the temperature difference between TS sensor and TC sensor. 3) In heating operation, PMV is controlled with t...
Page 33 - Current release control; Frequency down; Outdoor fan control; trolled at 1-tap interval of DC fan control.
– 33 – Objective model I 1 value [A] SM110 SM140 COOL HEAT COOL HEAT 20.4 21.2 21.2 21.2 3. Current release control The output frequency and the output voltage are controlled by AC current value detected by T20 on the outdoor P.C. board so that input current of the inverter does not exceed the speci...
Page 34 - Coil heating control; ) A judgment for electricity is performed by TD and TO sensors.
– 34 – 4-2. Heating fan control 1) An outdoor fan is controlled by TE sensor, TO sensor and operation frequency. (It is controlled with W1 for minimum and the maximum is controlled according to the following table.) 2) At the start time, the fan is fixed for 3 minutes only with the maximum fan tap c...
Page 35 - Current release control value (; IIIII; Temperature range; TO; HEAT
– 35 – 6. Short intermittent operation preventive control 1) For 3 to 10 minutes after operation start, in some cases, the compressor does not stop to protect the compressor even if receiving the thermostat-OFF signal from indoor.However it is not abnormal status. (The operation continuance differs ...
Page 36 - Start of heating operation; memory as TEO and the minimum temperature of TO as ToO.; 2 Control of compressor case thermo; displayed on the wired remote controller.
– 36 – Start of heating operation 0 10 15 c b a d [min.] * TE [ ˚ C] – 5 – 10– 13 – 18 A zone B zone C zone D zone A zone B zone C zone D zone * From 10 minutes to 15 minutes after a heating operation started, the minimum value of TE is stored in memory as TEO and the minimum temperature of TO as To...
Page 37 - Before troubleshooting; and; Troubleshooting procedure; Trouble
– 37 – 8. TROUBLESHOOTING 8-1. Summary of Troubleshooting <Wired remote controller type> 1. Before troubleshooting 1) Required tools/instruments • + and – screwdrivers, spanners, radio cutting pliers, nippers, push pins for reset switch • Tester, thermometer, pressure gauge, etc. 2) Confirmati...
Page 41 - Returned to usual display; Calling of sensor temperature display
– 41 – <Operation procedure> 1 2 3 4 Returned to usual display 2 4 1 3 SET TIME TIMER SET TEST FILTER LL RESET TEMP. CL FAN SAVE A A SWING/FIX VENT MODE ON / OFF UNIT LOUVER T 8-2-3. Monitor Function of Remote Controller Switch Calling of sensor temperature display <Contents> E...
Page 44 - Error mode detected by indoor unit
– 44 – Error mode detected by indoor unit Operation of diagnostic function Check code E03 E04 E08 L03 L07 L08 L09 L30 P10 P12 P19 P31 F01 F02 F10 F29 E10 E18 Cause of operation No communication from remotecontroller (including wireless) andcommunication adapter The serial signal is not output fromou...
Page 45 - Error mode detected by outdoor unit; The indoor unit check code has been ramified from
– 45 – Error mode detected by outdoor unit The indoor unit check code has been ramified from 4 series and after. The ramified check code is displayed only when combined with 4 -series indoor unit. (Ex. Combination of RAV-SM140 4 UT-E with RAV-SM140 3 AT-E1) When the indoor unit is 3 series and befor...
Page 48 - Contents Error Display; Electric parts cover
– 48 – Contents Error Display ∗ When fixations of the errors were overlapped, the latest error is displayed. ∗ When D800 to D804 are slowly flashing or D805 is flashing, push and hold SW800 and SW801 simulta- neously for 5 seconds or more. The error display changes to the error which is generated. N...
Page 49 - Operation method of the service SW; Display of the latest error
– 49 – 8-2-5. Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller.2) In some cases, a check code indicates multiple symptoms. In this case, confirm LED display on the outdoor P.C. board t...
Page 61 - Output v; Temperature sensor; Representative value; resistance value cannot be measured.
– 61 – Resistance (k Ω ) (50˚C or lo w er) Resistance (k Ω ) (50˚C or higher) 0 0 50 100 150 200 0 5 10 15 20 10 20 30 40 50 60 70 80 90 100 Temperature (˚C) Resistance (k Ω ) 0 0 10 20 30 40 Output v oltage (V) 10 20 30 40 50 60 70 80 90 100 Temperature (˚C) Temperature sensor Temperature – Resista...
Page 62 - Table Inspection of outdoor unit main parts
– 62 – Red White Black Connector : White Red White Black Table Inspection of outdoor unit main parts No. 1 2 3 Parts name Compressor (Model : DA422A3F-12M) Outdoor fan motor (Model : WDF-340-A100-1) 4-way valve coil (Cooling/heating switching) (Model : STF-H) Checking procedure Measure the resistanc...
Page 63 - SETUP AT LOCAL SITE AND OTHERS
– 63 – 9. SETUP AT LOCAL SITE AND OTHERS 1. Display range on remote controller The setup range (Operation mode/Air volume select/Setup temp) of the indoor unit which was set to the master unit is reflected on the remote controller. 2. Address setup Turn on power of the indoor unit to be controlled i...
Page 64 - Indoor unit power-ON sequence; Power ON
– 64 – Indoor unit power-ON sequence <Cautions at test run> • Power supply/Indoor/Outdoor serial and Gr wiring: OK• Powers of all indoor units are turned on within 3 minutes.• Reception time for remote controller operation (After power supply was turned on) 1) When address is OK : Ap...
Page 65 - LED display; • 4 patterns are provided for LED display.; LED; • In the initial status of LED display, D805 is ON as the right
– 65 – 9-3. Outdoor Unit Various displays and various operations are enabled by push buttons (service) switches and LED on the outdoor control P.C. board. Service switch (SW800, SW801) operations LED display • 4 patterns are provided for LED display. : ON, : OFF, : Rapid flashing (5 times/second), :...
Page 66 - Confirmation method of various settings
– 66 – 9-3-2. Various settings on outdoor unit (Existing piping, power save, cooling-only, etc.) (1) Service switch setting Various settings are available by setting service switches. [Operating method] 1) Check LED display is the initial status. If it is not so, set the initial status.2) Push and h...
Page 67 - In the case to return the setting to one at shipment from factory; be returned in the following procedure.; LED display to return the setting at
– 67 – In the case to return the setting to one at shipment from factory When to return the setting to one at shipment from the factory due to reinstallation and so on, the setting can be returned in the following procedure. 1) Check LED display is the initial status. If it is not the initial status...
Page 69 - A. Error display which occurs at present
– 69 – 1-2. Error display The error which is occurring at present and the latest error (the latest error data including one which is occur- ring now) can be confirmed by lighting LED D800 to D805 on the outdoor control P.C. board. A. Error display which occurs at present : ON, : OFF, : Rapid flashin...
Page 74 - Outdoor; Indoor
– 74 – 10-2. Address Setup & Group Control <Terminology> Indoor unit No. : N - n = Outdoor unit line address N (Max. 30) - Indoor unit address n (Max. 64)Group address : 0 = Single (Not group control) 1 = Master unit in group control 2 = Sub unit in group control Master unit (= 1) : The re...
Page 75 - Only turning on source power supply (Automatic completion); (It is not influenced by the line 2 or 3 address indoor unit.)
– 75 – 1-1 Individual (Master/Sub) 2-1 Sub/Header 1-1 Sub/Header 1-2 Sub/Follower 3-1 Master/Header 3-2 Sub/Follower 3-3 Sub/Follower 10-2-2. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) 1) Single 2) Group operation (Twin, Triple operation) (Multiple out...
Page 76 - Multiple groups operation; Single; Change is necessary
– 76 – 10-2-3. Automatic Address Example from Unset Address (No miswiring) 1. Standard (One outdoor unit) Only turning on source power supply (Automatic completion) 2. Group operation (Multiple outdoor units = Multiple indoor units with serial communication only, without twin) Only turning on source...
Page 77 - Single system; In case that addresses of the indoor units will be
– 77 – AB AB Terminal block for remote controller wiring of indoor unit Terminal block Remote controller unit Remote controller wire (Procured locally) 10-3. Remote Controller Wiring • Strip off approx. 9 mm the wire to be connected.• For single system, use non polarity, 2 core wire is used for wiri...
Page 78 - (Follow to the procedure during operation); is displayed on LCD.
– 78 – 1 Push SET + CL + TEST buttons simultaneously for 4 seconds or more. 2 ( ← ← ← ← ← Line address) Using the temperature setup / buttons, set 12 12 12 12 12 to the CODE No. 3 Using timer time / buttons, set the line address. 4 Push SET button. (OK when display goes on.) 5 ( ← ← ← ← ← Indoor uni...
Page 79 - To know the position of indoor unit body by address
– 79 – 2. To know the position of indoor unit body by address • To confirm the unit No. in the group control (Follow to the procedure during operation) (in this procedure, the indoor units in group control stop.) <Procedure> The indoor unit numbers in the group control are successively display...
Page 80 - Setting the jumper wires
– 80 – Model name J 806 J 800 J 801 J 802 J 803 J 804 Factory setting (default) - - - - - - RAV-SM1103AT-E1 - Cut - - - - RAV-SM1403AT-E1 - - Cut - - - Reuse the sub heat sink.Applying thermal grease to the surfaceand the back of the sub heat sink. Apply thermal grease to the back(heat sink contacti...
Page 81 - HOW TO EXCHANGE COMPRESSOR; For exchange of compressors, refer to (11) Compressor in Section
– 81 – 12. HOW TO EXCHANGE COMPRESSOR 12-1. Exchanging Procedure of Compressor (Outline) 12-2. Exchange of Compressor For exchange of compressors, refer to (11) Compressor in Section 13. Detachments . START Has refrigerant recovery work been done? YES Remove the defective compressor. Mount a service...
Page 82 - CAUTION
– 82 – 13. DETACHMENTS No. c Part name Common procedure Remarks RAV-SM1103AT-E1, RAV-SM1403AT-E1 Procedure CAUTION Never forget to put on the gloves at working time, otherwise an injury will be caused by the parts, etc. 1. Detachment 1) Stop operation of the air conditioner, and also turn off switch...
Page 86 - Using a bundling band on the market, be sure; Remarks; Motor base
– 86 – No. h Part name Fan motor Procedure 1) Perform works of items 1 of c , 1 of d , 2) Remove the flange nut fixing the fan motor and the propeller fan.• Loosen the flange nut by turning clock- wise. (To tighten the flange nut, turn it counterclockwise.) 3) Remove the propeller fan.4) Remove the ...
Page 87 - Pay attention to that flame does not involve 4-; When reconnecting the lead wires to the
– 87 – No. i Part name Compressor Procedure 1) Evacuate refrigerant gas.2) Perform works of items 1 of c , 1 of d , e and f . 3) Remove screws which fixes the piping panel (Front) and the bottom plate.(M4 (Hexagon) x 10, 2 pcs.) 4) Remove screw of the piping panel (Front) and the piping panel (Rear)...
Page 88 - PMV main unit
– 88 – Pulse Modulating Valve (PMV) coil No. Part name Procedure Remarks j k PMV main unit Positioning projection PMV coil Dent part Dent part Dent part 1. Detachment 1) Perform works of items 1 of c and e . 2) Remove the coil from PMV body while pulling it upward. 2. Attachment 1) Match the positio...
Page 90 - EXPLODED VIEWS AND PARTS LIST
Page 92 - SENSOR ASSY; Inverter assembly
– 92 – Location Part No. Description No. 701 43150351 SENSOR, TD 702 43150350 SENSOR ASSY 703 43150353 SENSOR 704 43150352 SENSOR 705 43150355 SENSOR 706 43F63338 HOLDER, ASSY (SENSOR) 707 4316V496 PC BOARD ASSY, MCC-1630 708 43160589 FUSE 709 43F63248 SUPPORTER, ASSY 710 43160567 TERMINAL BLOCK, 3P...
