FILE NO. A05-002
OWNER’S MANUAL/INSTALLATION MANUAL
SPLIT TYPE
<NEW DIGITAL INVERTER>
OUTDOOR UNIT
RAV-SM561AT-E, RAV-SM801AT-E, RAV-SM1101AT-E, RAV-SM1401AT-E
R410A
PRINTED IN JAPAN, Apr.,2005 ToMo
CONTENTS
OUTDOOR |
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INSTALLATION MANUAL |
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RAV-SM561AT-E, RAV-SM801AT-E .................................................................... |
4 |
RAV-SM1101AT-E, RAV-SM1401AT-E .............................................................. |
16 |
INDOOR |
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OWNER’S MANUAL |
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4-Way Air Discharge Cassette Type |
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RAV-SP1100UT-E, |
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RAV-SM560UT-E, RAV-SM800UT-E, |
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RAV-SM1100UT-E, RAV-SM1400UT-E ............................................................. |
31 |
Concealed Duct Type |
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RAV-SM561BT-E, RAV-SM801BT-E, |
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RAV-SM1101BT-E, RAV-SM1401BT-E ............................................................. |
45 |
Under Ceiling Type |
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RAV-SM561CT-E, RAV-SM801CT-E, |
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RAV-SM1101CT-E, RAV-SM1401CT-E ............................................................. |
59 |
INSTALLATION MANUAL |
|
4-Way Air Discharge Cassette Type |
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RAV-SP1100UT-E, |
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RAV-SM560UT-E, RAV-SM800UT-E, |
|
RAV-SM1100UT-E, RAV-SM1400UT-E ............................................................. |
74 |
Concealed Duct Type |
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RAV-SM561BT-E, RAV-SM801BT-E, |
|
RAV-SM1101BT-E, RAV-SM1401BT-E ............................................................. |
92 |
Under Ceiling Type |
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RAV-SM561CT-E, RAV-SM801CT-E, |
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RAV-SM1101CT-E, RAV-SM1401CT-E ........................................................... |
117 |
– 2 –
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OUTDOOR |
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INSTALLATION MANUAL |
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CONTENTS |
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RAV-SM561AT-E, RAV-SM801AT-E |
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1 |
PRECAUTIONS FOR SAFETY .................................................................. |
4 |
2 |
ACCESSORY AND REFRIGERANT .......................................................... |
5 |
3 |
SELECTION OF INSTALLATION ............................................................... |
6 |
4 |
REFRIGERANT PIPING ............................................................................. |
9 |
5 |
EVACUATING ........................................................................................... |
11 |
6 |
ELECTRICAL WORK ............................................................................... |
13 |
7 |
FINAL INSTALLATION CHECKS ............................................................. |
14 |
8 |
APPLICABLE CONTROL OF OUTDOOR UNIT ...................................... |
15 |
RAV-SM1101AT-E, RAV-SM1401AT-E |
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|
1 |
PRECAUTIONS FOR SAFETY ................................................................ |
16 |
2 |
ACCESSORY AND REFRIGERANT ........................................................ |
18 |
3 |
SELECTION OF INSTALLATION ............................................................. |
18 |
4 |
REFRIGERANT PIPING ........................................................................... |
22 |
5 |
EVACUATING ........................................................................................... |
24 |
6 |
ELECTRICAL WORK ............................................................................... |
26 |
7 |
FINAL INSTALLATION CHECKS ............................................................. |
27 |
8 |
APPLICABLE CONTROL OF OUTDOOR UNIT ...................................... |
29 |
– 3 –
RAV-SM561AT-E, RAV-SM801AT-E
1 PRECAUTIONS FOR SAFETY
•Ensure that all Local, National and International regulations are satisfied.
•Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.
•The precautions described below include the important items regarding safety. Observe them without fail.
•After the installation work, perform a trial operation to check for any problem.
Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.
•Turn off the main power supply switch (or breaker) before the unit maintenance.
•Ask the customer to keep the Installation Manual together with the Owner’s Manual.
CAUTION
New Refrigerant Air Conditioner Installation
•THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.
The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle.
To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging port of the main unit and installation tools are charged from those for the conventional refrigerant. Accordingly the exclusive tools are required for the new refrigerant (R410A).
For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance force and impurity in it.
CAUTION
To Disconnect the Appliance from Main Power Supply
This appliance must be connected to the main power supply by means of a switch with a contact separation of at least 3 mm.
The installation fuse (25A D type ) must be used for the power supply line of this conditioner.
WARNING
•Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner.
Inappropriate installation may result in water leakage, electric shock or fire.
•Turn off the main power supply switch or breaker before attempting any electrical work.
Make sure all power switches are off. Failure to do so may cause electric shock.
•Connect the connecting cable correctly.
If the connecting cable is connected in a wrong way, electric parts may be damaged.
•When moving the air conditioner for the installation into another place, be very careful not to enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.
If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnormally high and it may resultingly causes pipe burst and injuries on persons.
•Do not modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches.
•Exposure of unit to water or other moisture before installation may cause short-circuit of electrical parts.
Do not store it in a wet basement or expose to rain or water.
•After unpacking the unit, examine it carefully if there are possible damage.
•Do not install in a place that might increase the vibration of the unit.
•To avoid personal injury (with sharp edges), be careful when handling parts.
•Perform installation work properly according to the Installation Manual.
Inappropriate installation may result in water leakage, electric shock or fire.
–4 –
RAV-SM561AT-E, RAV-SM801AT-E
•When the air conditioner is installed in a small room, provide appropriate measures to ensure that the concentration of refrigerant leakage occur in the room does not exceed the critical level.
•Install the air conditioner securely in a location where the base can sustain the weight adequately.
•Perform the specified installation work to guard against an earthquake.
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.
•If refrigerant gas has leaked during the installation work, ventilate the room immediately.
If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.
•After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas might generate.
•Electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive power supply.
An insufficient power supply capacity or inappropriate installation may cause fire.
•Use the specified cables for wiring connect the terminals securely fix. To prevent external forces applied to the terminals from affecting the terminals.
•Be sure to provide grounding.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.
•Conform to the regulations of the local electric company when wiring the power supply.
Inappropriate grounding may cause electric shock.
•Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.
If a combustible gas leaks, and stays around the unit, a fire may occur.
Required tools for installation work
1) |
Philips screwdriver |
11) |
Electro circuit tester |
2) |
Hole core drill (65 mm) |
12) |
Hexagonal wrench |
3) |
Spanner |
13) |
Flare tool |
4) |
Pipe cutter |
14) |
Pipe bender |
5) |
Knife |
15) |
Level vial |
6) |
Reamer |
16) |
Metal saw |
7)Gas leak detector
8)Tape measure
9)Thermometer
10)Mega-tester
R410A (Special requirement)
17)Gauge manifold
(Charge hose : R410A special requirement)
18)Vacuum pump
(Charge hose : R410A special requirement)
19)Torque wrench
1/4 (17 mm) 16 N•m (1.6 kgf•m) 3/8 (22 mm) 42 N•m (4.2 kgf•m) 1/2 (26 mm) 55 N•m (5.5 kgf•m)
5/8 (15.9 mm) 120 N•m (12.0 kgf•m)
20)Copper pipe gauge adjusting projection margin
21)Vacuum pump adapter
2 ACCESSORY AND REFRIGERANT
Accessory and Installation Parts
1
Outdoor unit Installation manual × 1
2
Waterproof rubber cap |
Drain nipple |
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.
– 5 –
RAV-SM561AT-E, RAV-SM801AT-E
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.
<Example>
Suction hood (Side) Discharge hood
Suction hood (Rear side)
Discharge
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Fin |
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Fin |
Suction |
Suction |
Before installation
Be careful to the following items before installation.
Length of refrigerant pipe
<SM56>
Length of refrigerant |
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pipe connected to |
Item |
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indoor/outdoor unit |
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20 m or shorter |
Addition of refrigerant is |
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unnecessary at the local site. |
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21 m to 30 m |
<Addition of refrigerant> |
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Add 20 g of refrigerant for every |
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1 m of pipe which exceeds 20 m. |
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Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds 20 m, add 20 g/m of refrigerant and the maximum total length of pipe is 30 m.
(Max. amount of additional refrigerant is 200 g.)
Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor.
<SM80>
Length of refrigerant |
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pipe connected to |
Item |
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indoor/outdoor unit |
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20 m or shorter |
Addition of refrigerant is |
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unnecessary at the local site. |
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21 m to 30 m |
<Addition of refrigerant> |
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Add 40 g of refrigerant for every |
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1 m of pipe which exceeds 20 m. |
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Air purge
•For air purge, use a vacuum pump.
•Do not use refrigerant charged in the outdoor unit for air purge. (The refrigerant for air purge is not contained in the outdoor unit.)
Electrical cabling
•Be sure to fix the power cables and indoor/outdoor connecting cables with clamps so that they do not contact with the cabinet, etc.
Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds 20 m, add 40 g/m of refrigerant and the maximum total length of pipe is 30 m.
(Max. amount of additional refrigerant is 400 g.)
Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor.
– 6 –
RAV-SM561AT-E, RAV-SM801AT-E
Installation Place
•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.
CAUTION
1.Install the outdoor unit at a place where discharge air is not blocked.
2.When an outdoor unit is installed in a place that is always exposed to a strong wind like a coast or on a high story of a building, secure a normal fan operation by using a duct or a wind shield.
3.When installing the outdoor unit in a place that is constantly exposed to a strong wind such as the upper stairs or rooftop of a building, apply the windproof measures referring to the following examples.
1)Install the unit so that its
discharge port faces to 500 the wall of the building.
Keep a distance 500 mm
or more between the unit
and the wall surface.
2)Supposing the wind direction during the operation season of the air conditioner, install the unit so that the discharge port is set at right angle to the wind direction.
Strong wind
Strong wind
4.Installation in the following places may result in some troubles. Do not install the unit in such places below.
•A place full of machine oil.
•A place full of sulfuric gas.
•A place where high-frequency radio waves are likely to be generated as from audio equipment, welders, and medical equipment.
Necessary Space for Installation
Obstacle at rear side
<Upper side is free>
1. Single unit installation
150 or more
2. Obstacles at both right and left sides.
200 ormore |
obstacle should be |
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The height of the |
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lower than the height |
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of the outdoor unit. |
150 |
300 |
or more |
or more |
3. Serial installation of two or more units
200 or more
150 |
300 |
300 |
300 |
or more |
or more |
or more |
or more |
The height of the obstacle should be lower than the height of the outdoor unit.
<Obstacle also at the upper side>
500 ormore |
150 |
or more |
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Obstacle at front side
<Upper side is free>
1. |
Single unit installation |
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500 moreor |
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2. |
Serial installation of two or more units |
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1000 or more
– 7 –
3 SELECTION OF INSTALLATION
<Obstacle also at the upper side>
1000 |
1000 moreor |
or more |
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Obstacles at both front and rear sides
Open the upper side and both right and left sides. The height of obstacle at both front and rear side, should be lower than the height of the outdoor unit.
<Standard installation>
1. Single unit installation
1000 150 or more or more
2. Serial installation of two or more units
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200 or more |
300 |
300 |
1000 moreor |
or more |
or more |
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Serial installation at front and rear sides
Open the upper side and both right and left sides. The height of obstacle at both front and rear sides should be lower than the height of the outdoor unit.
<Standard installation>
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1000 |
300 |
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1500 |
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2000 |
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200 |
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or more |
or more |
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or more |
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or more |
or more |
RAV-SM561AT-E, RAV-SM801AT-E
Installation of Outdoor Unit
•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)
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90 |
600 |
90 |
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108 |
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330 |
306 |
60 |
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Ø28 Drain hole |
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Set the out margin of the
15 or less
anchor bolt to 15 mm or less.
•In case of draining through the drain hose, attach the following drain nipple and the waterproof rubber cap, and use the drain hose (Inner diam.: 16 mm) sold on the market. And also seal the screws securely with silicone material, etc. so that water does not drop down. Some conditions may cause dewing or dripping of water.
Drain nipple |
Waterproof rubber cap |
Waterproof
rubber cap
Base plate
Drain nipple
For Reference
If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, draining of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.
It is recommended to procure an anti-freeze heater locally for a safety installation of the air conditioner.
For details, contact the dealer.
– 8 –
RAV-SM561AT-E, RAV-SM801AT-E
Optional Installation Parts (Local Procure)
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Parts name |
Q’ty |
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A |
Refrigerant piping |
Each one |
Liquid side : Ø6.4 mm or Ø9.5 mm |
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Gas side : Ø12.7 mm or Ø15.9 mm |
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B |
Pipe insulating material (polyethylene |
1 |
foam, 6 mm thick) |
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C |
Putty, PVC tapes |
Each one |
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Refrigerant Piping Connection
<Piping connection>
Capacity |
Liquid side |
Gas side |
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rank |
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Outer |
Thickness |
Outer |
Thickness |
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RAV- |
diameter |
diameter |
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SM56 |
Ø6.4 |
0.8 |
Ø12.7 |
0.8 |
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SM80 |
Ø9.5 |
0.8 |
Ø15.9 |
1.0 |
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CAUTION
TAKE NOTICE THESE IMPORTANT 4 POINTS BELOW FOR PIPING WORK
1.Keep dust and moisture away from inside the connecting pipes.
2.Tightly connect the connection between pipes and the unit.
3.Evacuate the air in the connecting pipes using VACUUM PUMP.
4.Check gas leak at connected points.
4 REFRIGERANT PIPING
Flaring
1. Cut the pipe with a pipe cutter.
OK |
NO GOOD |
90˚ |
Obliquity Roughness Warp |
2.Insert a flare nut into the pipe, and flare the pipe.
As the flaring sizes of R410A differ from those of refrigerant R22, the flare tools newly manufactured for R410A are recommended.
However, the conventional tools can be used by adjusting projection margin of the copper pipe.
• Flaring size : A (Unit : mm) |
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A |
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A |
+0 |
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Outer diam. of copper pipe |
- 0.4 |
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R410A |
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R22 |
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6.4 |
9.1 |
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9.0 |
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9.5 |
13.2 |
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13.0 |
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12.7 |
16.6 |
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16.2 |
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15.9 |
19.7 |
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19.4 |
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*In case of flaring for R410A with the conventional flare tool, pull it out approx. 0.5 mm more than that of R22 to adjust to the specified flare size.
The copper pipe gauge is useful for adjusting projection margin size.
•Projection margin in flaring : B (Unit : mm)
B
Rigid (Clutch type)
Outer diam. |
R410A tool used |
Conventional tool used |
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of copper |
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R410A |
R22 |
R410A |
R22 |
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pipe |
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6.4 |
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0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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9.5 |
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0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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12.7 |
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0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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15.9 |
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0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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Imperial (Wing nut type)
Outer diam. of copper pipe |
R410A |
R22 |
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6.4 |
1.5 to 2.0 |
1.0 to 1.5 |
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9.5 |
1.5 to 2.0 |
1.0 to 1.5 |
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12.7 |
2.0 to 2.5 |
1.5 to 2.0 |
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15.9 |
2.0 to 2.5 |
1.5 to 2.0 |
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– 9 –
RAV-SM561AT-E, RAV-SM801AT-E
4 REFRIGERANT PIPING
Tightening of Connecting Part
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(Unit: N•m) |
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Outer diam. of copper pipe |
Tightening torque |
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6.4 mm (diam.) |
14 to 18 (1.4 to 1.8 kgf•m) |
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9.5 mm (diam.) |
33 to 42 (3.3 to 4.2 kgf•m) |
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12.7 mm (diam.) |
50 to 62 (5.0 to 6.2 kgf•m) |
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15.9 mm (diam.) |
68 to 82 (6.8 to 8.2 kgf•m) |
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Flare at
indoor unit side
REQUIREMENT
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.
•After the installation work, be sure to check gas leak of connecting part of the pipes with nitrogen.
NO GOOD
Flare at
outdoor unit side
•Align the centers of the connecting pipes and tighten the flare nut strong as far as possible with your fingers.
Then fix the nut with a spanner and tighten it with torque wrench as shown in the figure.
Half union or packed valve |
Flare nut |
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Externally |
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Internally |
threaded side |
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threaded side |
Fix with spanner. |
Tighten with torque wrench. |
•As shown in the figure, be sure to use a double spanner to loosen or tighten the flare nut of the valve at gas side. If using a single spanner, the nut cannot be tightened with necessary tightening torque.
On the contrary, use a single spanner to loosen or tighten the flare nut of the valve at liquid side.
Flare nut
Spanner for work
Spanner for fixing
Loosened
Single spanner is prohibited
•Pressure of R410A is higher than that of R22 (Approx. 1.6 times). Therefore, using a torque wrench, tighten the flare pipe connecting sections which connect the indoor/outdoor units at the specified tightening torque. Incomplete connections may cause not only a gas leak, but also a trouble of the refrigeration cycle.
Do not apply refrigerating machine oil to the flared surface.
Cap Tightened
SM80 type valve at gas side
– 10 –
RAV-SM561AT-E, RAV-SM801AT-E
5 EVACUATING
Air Purge
This air conditioner can be installed up to the connecting pipe length and height difference in the following table.
Capacity rank |
Max. connecting |
Height difference (m) |
Hexagonal |
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pipe length (m) |
Outdoor unit at upper side |
Outdoor unit at lower side |
wrench size |
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SM56 type |
30 |
30 |
30 |
4 mm |
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SM80 type |
6 mm |
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With respect to the preservation of terrestrial environment, adopt “Vacuum pump” for air purge (Evacuate air in the connecting pipes) when installing the unit.
•Do not discharge the refrigerant gas to the atmosphere to preserve the terrestrial environment.
•Use a vacuum pump to discharge the air (nitrogen, etc.) remained in the set. If the air remains, the capacity may decrease.
For the vacuum pump, be sure to use one with backflow preventer so that the oil in the pump does not backflow into the pipe of the air conditioner when the pump stops. (If oil in the vacuum pump is put in an air conditioner including R410A, it may cause trouble on the refrigeration cycle.)
Vacuum pump
As shown in the right figure, connect the charge hose after the manifold valve are closed completely.
Attach the connecting port of the charge hose with a projection to push the valve core (setting pin) to the charge port of the set.
Open the handle Low fully.
Turn ON the vacuum pump (*1)
Loosen the flare nut of the packed valve (Gas side) a little to check the air passes through. (*2)
Tighten the flare nut again.
Execute vacuuming until the compound pressure gauge indicates –101kPa (–76cmHg). (*1)
Close handle Low completely.
Turn OFF the vacuum pump.
Leave the vacuum pump as it is for 1 or 2 minutes, and check the indicator of the compound pressure gauge does not return.
Open fully the valve stem or the valve handle. (First, at liquid side, then gas side)
Disconnect the charge hose from the charge port.
Tighten valve and caps of the charge port surely.
– 11 –
RAV-SM561AT-E, RAV-SM801AT-E
5 EVACUATING
Compound pressure gauge |
Pressure gauge |
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–101kPa |
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(–76cmHg) |
Manifold valve |
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Handle Lo |
Handle Hi |
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(Keep fully closed) |
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Charge hose |
Charge hose |
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(For R410A only) |
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(For R410A only) |
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Vacuum pump adapter |
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for counter-flow prevention |
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|
(For R410A only) |
|
|
Vacuum |
|
|
pump |
Packed valve (Gas side)
Service port (Valve core (Setting pin))
Valve unit |
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Flare nut |
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|||
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Stopper
Charge cap
Charge port |
Valve rod |
|
*1. Use the vacuum pump, vacuum pump adapters, and gauge manifold referring to the manuals attached to each tool before using them. For the vacuum pump, check oil is filled up to the specified line of the oil gauge.
*2. While the air is purged, check again that the connecting port of charge hose, which has a projection to push the valve core, is firmly connected to the charge port.
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
|
Ø6.4 |
14 to 18 N•m (1.4 to 1.8 kgf•m) |
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Valve size |
Ø9.5 |
33 to 42 N•m (3.3 to 4.2 kgf•m) |
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||
Ø12.7 |
33 to 42 N•m (3.3 to 4.2 kgf•m) |
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Ø15.9 |
33 to 42 N•m (3.3 to 4.2 kgf•m) |
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Charge port |
14 to 18 N•m (1.4 to 1.8 kgf•m) |
||
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– 12 –
RAV-SM561AT-E, RAV-SM801AT-E
6 ELECTRICAL WORK
For the air conditioner that has no power cable, connect a power cable as mentioned below.
Model |
RAV-SM56, RAV-SM80 |
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Power supply |
220 – 240 V |
|
Single phase 50 Hz |
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Maximum running current |
15 A |
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Installation fuse rating |
25 A (D type |
) |
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Power cable |
H07 RN-F or 245 IEC 66 |
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(2.5 mm2 or more) |
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CAUTION
•Wrong wiring may cause a burnout to some electrical parts.
•Be sure to use the cord clamps attached to the product.
•Do not damage or scratch the conductive core and inner insulator of power and inter-connect- ing cables when peeling them.
•Be sure to comply with local regulations of the cable from outdoor unit to indoor unit.
(wire size and cabling method etc.)
•Use the power and Inter-connecting cables with specified thickness, specified type and protective devices required.
How to remove the valve cover
1.Remove screws of the valve cover.
2.Pull the valve cover downward to remove it.
Valve cover
Piping cover
Indoor/outdoor connecting cables
Power cable
How to wire
1.Connect the connecting cable to the terminal as identified with their respective numbers on the terminal block of indoor and outdoor unit.
H07 RN-F or 245 IEC 66 (1.0 mm2 or more)
2.When connecting the connecting cable to the outdoor unit terminal, prevent water coming in the outdoor unit.
3.Insulate the unsheathed cords (conductors) with electrical insulation tape. Process them so that they do not touch any electrical or metal parts.
4.For inter connecting cable, do not use a wire jointed to another on the way.
Use wires long enough to cover the entire length.
Terminal block
1 2 3 L N
Screw
Connecting Power cable cable
Tripping length power cord and connecting cable
L N |
10 |
10 |
1 2 3 |
10 |
|
|
10 |
40 |
40 |
30 |
30 |
Earth line |
Earth line |
(mm) |
|
|
|
Power cable |
Connecting |
|
|
cable |
|
CAUTION
•The installation fuse (25A D type ) must be used for the power supply line of this air conditioner.
•Incorrect/incomplete wiring might cause an electrical fire or smoke.
•Prepare the exclusive power supply for the air conditioner.
•This product can be connected to the mains. Connection to the fixed wiring :
A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring.
– 13 –
RAV-SM561AT-E, RAV-SM801AT-E
7 FINAL INSTALLATION CHECKS
Check and Test Operation
For R410A, use the leak detector exclusively manufactured for HFC refrigerant (R410A, R134a, etc.).
*The conventional leak detector for HCFC refrigerant (R22, etc.) cannot be used because its sensitivity for HFC refrigerant lowers to approx. 1/40.
•Pressure of R410A is approx. 1.6 times higher than that of R22.
If installation work is incompletely finished, a gas leakage may occur when pressure rises during operation.
Therefore, be sure to test the piping connections for leakage.
•Check gas leakage at the flare nut connections, valve stem cap connections and service port cap fittings with a leak detector or soap water.
Valve cover
Piping cover
Check points of outdoor unit
Flare nut connections (Indoor unit)
CAUTION
When the remote controller is used for the first time, it accepts an operation approx. 5 minutes after the power supply has been turned on.
It is not a trouble, but is because the setup of the remote controller is being checked.
For the second power-ON time and after, approx. 1 minute is required to start the operation by the remote controller.
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. (for copper pipes with nominal dimensions 1/2 and 5/8)
New tools for R410A
New tools for R410A |
Applicable to R22 model |
Changes |
|
× |
As pressure is high, it is impossible to measure by means of conventional |
Gauge manifold |
|
gauge. In order to prevent any other refrigerant from being charged, each |
|
|
port diameter is changed. |
|
× |
|
In order to increase pressure resisting strength, hose materials and port |
Charge hose |
|
|
size are changed (to 1/2 UNF 20 threads per inch). |
|
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When purchasing a charge hose, be sure to check the port size. |
|
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Electronic balance |
¡ |
|
As pressure is high and gasification speed is fast, it is difficult to read the |
for refrigerant charging |
|
indicated value by means of charging cylinder, as air bubbles occur. |
|
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||
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Torque wrench |
× |
|
The sizes of opposite sides of flare nuts have been increased. Inciden- |
(nominal diam. 1/2, 5/8) |
|
tally, a common wrench is used for nominal diameters 1/4 and 3/8. |
|
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Flare tool |
¡ |
|
By increasing the clamp bar’s receiving hole, strength of spring in the tool |
(clutch type) |
|
has been improved. |
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||
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Gauge for projection adjustment |
— |
— |
Used when flare is made with using conventional flare tool. |
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Connected to the conventional vacuum pump. It is necessary to use an |
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|
|
adapter to prevent vacuum pump oil from flowing back to the charge hose. |
Vacuum pump adapter |
¡ |
|
The charge hose connecting part has two ports - one for conventional |
|
refrigerant (7/16 UNF 20 threads per inch) and the other for R410A. If the |
||
|
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vacuum pump oil (mineral) mixes with R410A, sludge may occur and |
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|
damage the equipment. |
Gas leakage detector |
× |
X |
Exclusive for HFC refrigerant. |
|
•Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the U.S.’s ARI specified rose color (ARI color code: PMS 507).
•Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to the charge hose’s port size.
–14 –
RAV-SM561AT-E, RAV-SM801AT-E
Recovery method of refrigerant
•When recovering refrigerant in case of reinstallation of the indoor or outdoor unit, etc., use the refrigerant recovery switch on the terminal block of the outdoor unit.
Work procedure
1.Turn on the power supply.
2.Using the remote controller, set FAN operation to the indoor unit.
3.Pushing the refrigerant recovery switch on the terminal block of the outdoor unit starts the forced cooling operation. (Max. 10 minutes), and then the refrigerant is recovered by operation of the valve.
4.After recovery of the refrigerant, push the refrigerant recovery switch together with closing the valve. The operation stops.
5.Turn off the power supply.
DANGER
Take care for an electric shock because the control P.C. board is electrified.
Refrigerant
recovery switch
ON
1 2 3
1 2 3 |
L N |
WARNING
Never touch these switches because they are those for service check; otherwise the air conditioner may not operate normally.
8 APPLICABLE CONTROL OF OUTDOOR UNIT
You can response to the following items by attaching the parts sold separately “Application control kit” (TCB-PCOS1E).
Demand control
•It saves the capacity of the outdoor unit by outside Demand signal to correspond to the temporary peak cut.
•The capacity saving can be adjusted with three steps, 75%, 50%, and operation stop.
Night operation control (Sound reduction)
Sound is controlled to 45dB or less in inputting a timer point contact.
Compressor operation output
The check of the compressor operation time required of a maintenance etc.
– 15 –
RAV-SM1101AT-E, RAV-SM1401AT-E
1 PRECAUTIONS FOR SAFETY
•Ensure that all Local, National and International regulations are satisfied.
•Read this “PRECAUTIONS FOR SAFETY” carefully before Installation.
•The precautions described below include the important items regarding safety. Observe them without fail.
•After the installation work, perform a trial operation to check for any problem.
Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.
•Turn off the main power supply switch (or breaker) before the unit maintenance.
•Ask the customer to keep the Installation Manual together with the Owner’s Manual.
CAUTION
New Refrigerant Air Conditioner Installation
•THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.
The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle.
To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging port of the main unit and installation tools are charged from those for the conventional refrigerant.
Accordingly the exclusive tools are required for the new refrigerant (R410A).
For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance force and impurity in it.
CAUTION
To Disconnect the Appliance from Main Power Supply
This appliance must be connected to the main power supply by means of a switch with a contact separation of at least 3 mm.
The installation fuse (25A D type ) must be used for the power supply line of this conditioner.
WARNING
•Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner.
Inappropriate installation may result in water leakage, electric shock or fire.
•Turn off the main power supply switch or breaker before attempting any electrical work.
Make sure all power switches are off. Failure to do so may cause electric shock.
•Connect the connecting cable correctly.
If the connecting cable is connected in a wrong way, electric parts may be damaged.
•When moving the air conditioner for the installation into another place, be very careful not to enter any gaseous matter other than the specified refrigerant into the refrigeration cycle.
If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnormally high and it may resultingly causes pipe burst and injuries on persons.
•Do not modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches.
•Exposure of unit to water or other moisture before installation may cause a short-circuit of electrical parts.
Do not store it in a wet basement or expose to rain or water.
–16 –
RAV-SM1101AT-E, RAV-SM1401AT-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.
•When the air conditioner is installed in a small room, provide appropriate measures to ensure that the concentration of refrigerant leakage occur in the room does not exceed the critical level.
•Install the air conditioner securely in a location where the base can sustain the weight adequately.
•Perform the specified installation work to guard against an earthquake.
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.
•If refrigerant gas has leaked during the installation work, ventilate the room immediately.
If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.
•After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas might generate.
•Electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive power supply.
An insufficient power supply capacity or inappropriate installation may cause fire.
•Use the specified cables for wiring connect the terminals securely fix. To prevent external forces applied to the terminals from affecting the terminals.
•Be sure to provide grounding.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.
•Conform to the regulations of the local electric company when wiring the power supply.
Inappropriate grounding may cause electric shock.
•Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.
If a combustible gas leaks, and stays around the unit, a fire may occur.
Required tools for installation work
1)Philips screw driver
2)Hole core drill (65 mm)
3)Spanner
4)Pipe cutter
5)Knife
6)Reamer
7)Gas leak detector
8)Tape measure
9)Thermometer
10)Mega-tester
11)Electro circuit tester
12)Hexagonal wrench
13)Flare tool
14)Pipe bender
15)Level vial
16)Metal saw
R410A (Special requirement)
17)Gauge manifold
(Charge hose : R410A special requirement)
18)Vacuum pump
(Charge hose : R410A special requirement)
19)Torque wrench
1/4 (17 mm) 16 N•m (1.6 kgf•m) 3/8 (22 mm) 42 N•m (4.2 kgf•m) 1/2 (26 mm) 55 N•m (5.5 kgf•m)
5/8 (15.9 mm) 120 N•m (12.0 kgf•m)
20)Copper pipe gauge adjusting projection margin
21)Vacuum pump adapter
– 17 –
RAV-SM1101AT-E, RAV-SM1401AT-E
2 ACCESSORY AND REFRIGERANT
Accessory and Installation Parts
1 |
3 |
Outdoor unit |
|
Installation manual x 1 |
Protective bush |
Drain nipple |
|
2 |
4 |
|
Guard material for |
Waterproof rubber cap |
passage part |
Refrigerant Piping
•Piping kit used for the conventional refrigerant cannot be used.
•Use copper pipe with 0.8 mm or more thickness for Ø9.5.
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.
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.
<Example>
Suction hood (Side) Discharge hood
Suction hood (Rear side)
Discharge
|
Fin |
|
Fin |
Suction |
Suction |
Air purge
•For air purge, use a vacuum pump.
•Do not use refrigerant charged in the outdoor unit for air purge. (The refrigerant for air purge is not contained in the outdoor unit.)
Electrical cabling
•Be sure to fix the power cables and indoor/outdoor connecting cables with clamps so that they do not contact with the cabinet, etc.
Before installation
Be careful to the following items before installation.
Length of refrigerant pipe
Length of refrigerant pipe |
Item |
|
connected to indoor/outdoor unit |
||
|
||
|
|
|
30 m or shorter |
Addition of refrigerant is unnecessary at the local site. |
|
|
|
|
31 m to 50 m |
<Addition of refrigerant> |
|
Add 40 g of refrigerant for every 1m of pipe which exceeds 20 m. |
||
|
||
|
|
Caution at addition of refrigerant
When the total length of refrigerant pipe exceeds 30 m, add 40 g /m of refrigerant and the maximum total length of pipe is 50 m. (Max. amount of additional refrigerant is 800 g.)
Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor.
–18 –
RAV-SM1101AT-E, RAV-SM1401AT-E
Installation Place
•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.
CAUTION
1.Install the outdoor unit at a place where discharge air is not blocked.
2.When an outdoor unit is installed in a place that is always exposed to a strong wind like a coast or on a high storey of a building, secure a normal fan operation by using a duct or a wind shield.
3.When installing the outdoor unit in a place that is constantly exposed to a strong wind such as the upper stairs or rooftop of a building, apply the windproof measures referring to the following examples.
1)Install the unit so that its
discharge port faces to 500 the wall of the building.
Keep a distance 500 mm
or more between the unit
and the wall surface.
2)Supposing the wind direction during the operation season of the air conditioner, install the unit so that the discharge port is set at right angle to the wind direction.
Strong wind
Strong wind
4.Installation in the following places may result in some troubles. Do not install the unit in such places below.
•A place full of machine oil.
•A place full of sulphuric gas.
•A place where high-frequency radio waves are likely to be generated as from audio quipment, welders, and medical equipment.
Necessary Space for Installation
Obstacle at rear side
<Upper side is free>
1. Single unit installation
150 or more
2. Obstacles at both right and left sides.
200 ormore |
obstacle should be |
|
The height of the |
|
lower than the height |
|
of the outdoor unit. |
150 |
300 |
or more |
or more |
3. Serial installation of two or more units
200 or more
150 |
300 |
300 |
300 |
or more |
or more |
or more |
or more |
The height of the obstacle should be lower than the height of the outdoor unit.
<Obstacle also at the upper side>
500 ormore |
150 |
or more |
|
|
Obstacle at front side
<Upper side is free>
1. |
Single unitIn installation |
|
500 moreor |
||||||
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||||||||
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|||||
2. |
Serial installation of two or more units |
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1000 or more
– 19 –
3 SELECTION OF INSTALLATION
<Obstacle also at the upper side>
1000 |
1000 moreor |
or more |
|
Obstacles at both front and rear sides
Open the upper side and both right and left sides. The height of obstacle at both front and rear side, should be lower than the height of the outdoor unit.
<Standard installation>
1. Single unit installation
1000 150 or more or more
2. Serial installation of two or more units
|
|
200 or more |
300 |
300 |
1000 moreor |
or more |
or more |
|
Serial installation at front and rear sides
Open the upper side and both right and left sides. The height of obstacle at both front and rear sides should be lower than the height of the outdoor unit.
<Standard installation>
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1000 |
300 |
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1500 |
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2000 |
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200 |
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||||||||
or more |
or more |
|
or more |
|
|
or more |
or more |
RAV-SM1101AT-E, RAV-SM1401AT-E
Installation of Outdoor Unit
•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)
|
|
150 |
|
600 |
150 |
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430 |
|
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Drain hole |
40 |
|
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400 |
365 |
Knockout hole |
Drain nipple mounting hole |
||
|
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|
Set the out margin of the anchor bolt to 15 mm or less.
15 or less
•In case of drainning through the drain hose, attach the following drain nipple and the waterproof rubber cap, and use the drain hose (Inner diam.: 16 mm) sold on the market. And also seal the screws securely with silicone material, etc. so that water does not drop down. Some conditions may cause dewing or dripping of water.
Drain nipple |
Waterproof rubber cap |
Knockout hole
Open
Waterproof rubber cap
Drain nipple
•When there is a possibility of freezing of drain at the cold district or a snowfall area, be careful for drainage ability of drain. The drainage ability increases when a knockout hole on the base plate is opened. (Open the knockout hole to outside using a screwdriver, etc.)
– 20 –
RAV-SM1101AT-E, RAV-SM1401AT-E
Optional Installation Parts (Local Procure)
|
|
Parts name |
Q’ty |
|
|
|
|
||
A |
Refrigerant piping |
Each one |
||
Liquid side |
: Ø9.5 mm |
|||
|
Gas side |
: Ø15.9 mm |
|
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|
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||
B |
Pipe insulating material |
1 |
||
(polyethylene foam, 6 mm thick) |
||||
|
|
|||
|
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|
||
C |
Putty, PVC tapes |
Each one |
||
|
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|
Refrigerant Piping Connection
CAUTION
TAKE NOTICE THESE IMPORTANT
4 POINTS BELOW FOR PIPING WORK
1.Keep dust and moisture away from inside the connecting pipes.
2.Tightly connect the connection between pipes and the unit.
3.Evacuate the air in the connecting pipes using VACUUM PUMP.
4.Check gas leak at connected points.
<Piping connection>
Liquid side |
Gas side |
||
|
|
|
|
Outer diameter |
Thickness |
Outer diameter |
Thickness |
|
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|
Ø 9.5 |
0.8 |
Ø15.9 |
1.0 |
|
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|
For Reference
If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, draining of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.
It is recommended to procure an anti-freeze heater locally for a safety installation of the air conditioner.
For details, contact the dealer.
Knockout of Pipe Cover
Rear direction
Pipe cover
Side direction
Front direction
Down direction
Knockout procedure
•The indoor/outdoor connecting pipes can be connected to 4 directions.
Take off the knockout part of the pipe cover in which pipes or wires pass through the base plate.
•As shown in the figure, do not remove the pipe cover from the cabinet so that the knockout hole can be easily punched. To knock out, it is easily taken off by hands by punching a position at the lower side of 3 connected parts with screwdriver along the guide line.
•After marking the knockout hole, remove the burr and mount the attached protective bush and guard material for pass-through part in order to protect pipes and wires.
After connecting the pipes, be sure to mount the pipe cover. The pipe cover is easily mounted by cutting off the slit at the lower part of the pipe cover.
– 21 –
RAV-SM1101AT-E, RAV-SM1401AT-E
3 SELECTION OF INSTALLATION
How to remove the front panel
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.
•Be sure to fix the power cable and indoor/outdoor connecting cable with bundling band sold on the market so that they do not make contact with the compressor and discharge pipe.
(Temperature of the compressor and discharge pipe becomes high.)
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.
Electric parts box
Service panel
Pipe valve fixing plate
Wiring
hole
Cord clamp
4 REFRIGERANT PIPING
Pipe Forming/End Positioning
Flaring
1. Cut the pipe with a pipe cutter.
OK |
NO GOOD |
90˚ |
Obliquity Roughness Warp |
2. Insert a flare nut into the pipe, and flare the pipe.
As the flaring sizes of R410A differ from those of refrigerant R22, the flare tools newly manufactured for R410A are recommended.
However, the conventional tools can be used by adjusting
projection margin of the copper A pipe.
• Flaring size : A (Unit : mm)
|
A |
+0 |
|
Outer dia. of copper pipe |
|
- 0.4 |
|
R410A |
R22 |
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6.4 |
9.1 |
9.0 |
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9.5 |
13.2 |
13.0 |
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12.7 |
16.6 |
16.2 |
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15.9 |
19.7 |
19.4 |
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• Projection margin in flaring : |
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B |
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B (Unit : mm) |
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Rigid (Clutch type) |
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Outer dia. |
R410A tool used |
Conventional tool used |
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of copper |
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R410A |
R22 |
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R410A |
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R22 |
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pipe |
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6.4 |
0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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9.5 |
0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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12.7 |
0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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15.9 |
0 to 0.5 |
(Same as left) |
1.0 to 1.5 |
0.5 to 1.0 |
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Imperial (Wing nut type)
Outer dia. of copper pipe |
R410A |
R22 |
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6.4 |
1.5 to 2.0 |
1.0 to 1.5 |
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9.5 |
1.5 to 2.0 |
1.0 to 1.5 |
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12.7 |
2.0 to 2.5 |
1.5 to 2.0 |
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15.9 |
2.0 to 2.5 |
1.5 to 2.0 |
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*In case of flaring for R410A with the conventional flare tool, pull it out approx. 0.5 mm more than that of R22 to adjust to the specified flare size. The copper pipe gauge is useful for adjusting projection margin size.
– 22 –
RAV-SM1101AT-E, RAV-SM1401AT-E
Tightening of Connecting Part
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(Unit: N•m) |
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Outer dia. of copper pipe |
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Tightening torque |
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6.4 mm (diam.) |
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14 to 18 (1.4 to 1.8 kgf•m) |
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9.5 mm (diam.) |
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33 to 42 (3.3 to 4.2 kgf•m) |
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12.7 mm (diam.) |
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50 to 62 (5.0 to 6.2 kgf•m) |
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15.9 mm (diam.) |
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68 to 82 (6.8 to 8.2 kgf•m) |
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Flare at |
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indoor unit side |
Flare at
outdoor unit side
•Align the centers of the connecting pipes and tighten the flare nut strong as far as possible with your fingers.
Then fix the nut with a spanner and tighten it with torque wrench as shown in the figure.
Half union or packed valve |
Flare nut |
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Externally |
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Internally |
threaded side |
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threaded side |
Fix with spanner. |
Tighten with torque wrench. |
•As shown in the figure, be sure to use a double spanner to loosen or tighten the flare nut of the valve at gas side. If using a single spanner, the nut cannot be tightened with necessary tightening torque.
On the contrary, use a single spanner to loosen or tighten the flare nut of the valve at liquid side.
Cover
Cap
Piping valve
Loosened |
Tightened |
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Flare nut |
Valve at gas side
REQUIREMENT
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.
•After the installation work, be sure to check gas leak of connecting part of the pipes with nitrogen.
NO GOOD
Cover
•Pressure of R410A is higher than that of R22 (Approx. 1.6 times). Therefore, using a torque wrench, tighten the flare pipe connecting sections which connect the indoor/outdoor units at the specified tightening torque. Incomplete connections may cause not only a gas leak, but also a trouble of the refrigeration cycle.
Do not apply refrigerating machine oil to the flared surface.
– 23 –
RAV-SM1101AT-E, RAV-SM1401AT-E
5 EVACUATING
Air Purge
This air conditioner can be installed up to the connecting pipe length and height difference in the following table.
Capacity rank |
Max. connecting |
Height difference (m) |
Hexagonal |
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pipe length (m) |
Outdoor unit at upper side |
Outdoor unit at lower side |
wrench size |
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SM110, SM140 type |
50 |
30 |
30 |
4 mm |
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With respect to the preservation of terrestrial environment, adopt “Vacuum pump” for air purge (Evacuate air in the connecting pipes) when installing the unit.
•Do not discharge the refrigerant gas to the atmosphere to preserve the terrestrial environment.
•Use a vacuum pump to discharge the air (nitrogen, etc.) remained in the set. If the air remains, the capacity may decrease.
For the vacuum pump, be sure to use one with backflow preventer so that the oil in the pump does not backflow into the pipe of the air conditioner when the pump stops. (If oil in the vacuum pump is put in an air conditioner including R410A, it may cause trouble on the refrigeration cycle.)
Vacuum pump
As shown in the right figure, connect the charge hose after the manifold valve are closed completely.
Attach the connecting port of the charge hose with a projection to push the valve core (setting pin) to the charge port of the set.
Open handle Low fully.
Turn ON the vacuum pump (*1)
Loosen the flare nut of the packed valve (Gas side) a little to check the air passes through. (*2)
Tighten the flare nut again.
Execute vacuuming until the compound pressure gauge indicates –101kPa (–76cmHg). (*1)
Close handle Low completely.
Turn OFF the vacuum pump.
Leave the vacuum pump as it is for 1 or 2 minutes, and check the indicator of the compound pressure gauge does not return.
Open fully the valve stem or the valve handle. (First, at liquid side, then gas side)
Disconnect the charge hose from the charge port.
Tighten valve and caps of the charge port surely.
– 24 –
RAV-SM1101AT-E, RAV-SM1401AT-E
Compound pressure gauge |
Pressure gauge |
–101kPa |
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(–76cmHg) |
Manifold valve |
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Handle Lo
Charge hose (For R410A only)
Service port
(Valve core (Setting pin))
Handle Hi
(Keep fully closed)
Charge hose
(For R410A only)
Vacuum pump adapter
for counter-flow prevention (For R410A only)
Vacuum
pump
Packed valve at gas side
How to open the valve
Valve unit
Handle
Pull out the handle and using cutting pliers, etc. turn it counterclockwise by 90˚. (Open fully)
Charge port
Flare nut
Valve unit
Push in handle.
Charge port
Flare nut
Handle position
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.
For the vacuum pump, check oil is filled up to the specified line of the oil gauge.
*2. While the air is purged, check again that the connecting port of charge hose, which has a projection to push the valve core, is firmly connected to the charge port.
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
Ø9.5 33 to 42 N•m (3.3 to 4.2 kgf•m)
Valve size
Ø15.9 20 to 25 N•m (2.0 to 2.5 kgf•m)
Charge port |
14 to 18 N•m (1.4 to 1.8 kgf•m) |
– 25 –
RAV-SM1101AT-E, RAV-SM1401AT-E
6 ELECTRICAL WORK
For the air conditioner that has no power cable, connect a power cable as mentioned below.
Model RAV- |
SM110 |
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SM140 |
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Power supply |
220 – 240 V |
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Single phase 50 Hz |
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Maximum running current |
22.0 A |
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22.8 A |
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Installation fuse rating |
25 A (D type |
) |
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Power cable |
H07 RN-F or 245 IEC 66 |
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(2.5 mm2 or more) |
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CAUTION
Stripping length power cord and connecting cable
L N |
10 |
10 |
1 2 3 |
10 |
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10 |
50 |
40 |
40 |
30 |
Earth line |
Earth line |
(mm) |
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Power cable |
Connecting |
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cable |
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CAUTION
•Wrong wiring may cause a burn-out to some electrical parts.
•Be sure to use the cord clamps attached to the product.
•Do not damage or scratch the conductive core and inner insulator of power and inter-connect- ing cables when peeling them.
•Be sure to comply with local regulations of the cable from outdoor unit to indoor unit.
(wire size and cabling method etc.)
•Use the power and Inter-connecting cables with specified thickness, specified type and protective devices required.
How to wire
1.Connect the connecting cable to the terminal as identified with their respective numbers on the terminal block of indoor and outdoor unit.
H07 RN-F or 245 IEC 66 (1.0 mm2 or more)
2.When connecting the connecting cable to the outdoor unit terminal, prevent water coming in the outdoor unit.
3.Insulate the unsheathed cords (conductors) with electrical insulation tape. Process them so that they do not touch any electrical or metal parts.
4.For inter connecting cable, do not use a wire jointed to another on the way.
Use wires long enough to cover the entire length.
Power supply |
To Indoor unit |
terminal block |
terminal block |
•The installation fuse (25A D type ) must be used for the power supply line of this air conditioner.
•Incorrect/incomplete wiring might cause an electrical fire or smoke.
•Prepare the exclusive power supply for the air conditioner.
•This product can be connected to the mains. Connection to the fixed wiring :
A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring.
L |
N |
1 |
2 |
3 |
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Earth screw |
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Earth screw |
Power cable |
Connecting cable |
– 26 –
RAV-SM1101AT-E, RAV-SM1401AT-E
7 FINAL INSTALLATION CHECKS
Check and Test Operation
For R410A, use the leak detector exclusively manufactured for HFC refrigerant (R410A, R134a, etc.).
*The conventional leak detector for HCFC refrigerant (R22, etc.) cannot be used because its sensitivity for HFC refrigerant lowers to approx. 1/40.
•Pressure of R410A is approx. 1.6 times higher than that of R22.
If installation work is incompletely finished, a gas leakage may occur when pressure rises during operation. Therefore, be sure to test the piping connections for leakage.
•Check gas leakage at the flare nut connections, valve stem cap connections and service port cap fittings with a leak detector or soap water.
CAUTION
When the remote controller is used for the first time, it accepts an operation approx. 5 minutes after the power supply has been turned on.
It is not a trouble, but is because the setup of the remote controller is being checked.
For the second power-ON time and after, approx. 1 munute is required to start the operation by the remote controller.
Useful Functions |
Self-Diagnosis by LED Indication |
In addition to the code checking by remote controller of the indoor unit, troubles of the outdoor unit can be 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 SW801 is set to OFF position.
LED indication and code checking
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Cycle control P.C. board |
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LED indication |
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LED indication |
Cause |
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D800 |
D801 |
D802 |
D803 |
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¡ |
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l |
l |
l |
Heat exchanger sensor (TE) error |
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l |
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l |
¡ |
l |
Suction sensor (TS) error |
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¡ |
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¡ |
l |
l |
Discharge sensor (TD) error |
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D800 ¡ : Red |
l |
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¡ |
l |
¡ |
Thermostat for compressor activated. |
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D801 ¡ : Yellow |
l |
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¡ |
l |
l |
Outdoor temperature sensor (TO) error |
D802 ¡ : Yellow |
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¡ |
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¡ |
¡ |
l |
DC outside fan error |
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D803 ¡ : Yellow |
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¡ |
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l |
l |
¡ |
Communication error between IPDU (Abnormal stop) |
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¥ : Rapid flash |
l |
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¡ |
l |
¡ |
High-pressure release operation |
l : Go off |
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l |
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¡ |
¡ |
l |
Discharge temp. error |
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¡ : Go on |
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¡ |
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¡ |
l |
¡ |
EEPROM error |
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l |
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l |
¡ |
¡ |
Communication error between IPDU (No abnormal stop) |
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¥ |
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l |
l |
l |
G-Tr short-circuit protection |
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l |
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¥ |
l |
l |
Detect circuit error |
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¥ |
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¥ |
l |
l |
Current sensor error |
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l |
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l |
¥ |
l |
Comp. lock error |
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¥ |
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l |
¥ |
l |
Comp. break down |
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– 27 –
RAV-SM1101AT-E, RAV-SM1401AT-E
7 FINAL INSTALLATION CHECKS
Recovery method of refrigerant
•When recovering refrigerant in case of reinstallation of the indoor or outdoor unit, etc., use the refrigerant recovery switch SW802 on the cycle control P.C. board of the outdoor unit.
Work procedure
1.Turn on the power supply.
2.Using the remote controller, set FAN operation to the indoor unit.
3.Pushing the refrigerant recovery switch SW802 on the cycle control P.C. board of the outdoor unit starts the forced cooling operation. (Max. 10 minutes), and then the refrigerant is recovered by operation of the valve.
4.After recovery of the refrigerant, push the refrigerant recovery switch SW802 together with closing the valve.
The operation stops.
5.Turn off the power supply.
Installation/Servicing Tools
Outdoor unit cycle control
P.C. board
SW802
Refrigerant
recovery
SW
SW801
CN804
Optional connector
DANGER
Take care for an electric shock because the control P.C. board is electrified.
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. (for copper pipes with nominal dimensions 1/2 and 5/8)
New tools for R410A
New tools for R410A |
Applicable to R22 model |
Changes |
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× |
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As pressure is high, it is impossible to measure by means of conventional |
Gauge manifold |
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gauge. In order to prevent any other refrigerant from being charged, each |
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port diameter is changed. |
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× |
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In order to increase pressure resisting strength, hose materials and port |
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Charge hose |
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size are changed (to 1/2 UNF 20 threads per inch). |
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When purchasing a charge hose, be sure to check the port size. |
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Electronic balance |
¡ |
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As pressure is high and gasification speed is fast, it is difficult to read the |
for refrigerant charging |
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indicated value by means of charging cylinder, as air bubbles occur. |
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Torque wrench |
× |
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The size of opposite sides of flare nuts have been increased. Incidentally, |
(nominal diam. 1/2, 5/8) |
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a common wrench is used for nominal diameters 1/4 and 3/8. |
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Flare tool |
¡ |
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By increasing the clamp bar’s receiving hole, strength of spring in the tool |
(clutch type) |
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has been improved. |
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Gauge for projection adjustment |
— |
— |
Used when flare is made with using conventional flare tool. |
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Connected to the conventional vacuum pump. It is necessary to use an |
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adapter to prevent vacuum pump oil from flowing back to the charge hose. |
Vacuum pump adapter |
¡ |
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The charge hose connecting part has two ports-one for conventional |
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refrigerant (7/16 UNF 20 threads per inch) and one for R410A. |
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If the vacuum pump oil (mineral) mixes with R410A a sludge may occur |
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and damage the equipment. |
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Gas leakage detector |
× |
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Exclusive for HFC refrigerant. |
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•Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the U,S.’s ARI specified rose color (ARI color code: PMS 507).
•Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to the charge hose’s port size.
–28 –
RAV-SM1101AT-E, RAV-SM1401AT-E
8 APPLICABLE CONTROL OF OUTDOOR UNIT
You can response to the following items by attaching the parts sold separately “Application control kit” (TCB-PCOS1E).
Demand control
•It saves the capacity of the outdoor unit by outside Demand signal to correspond to the temporary peak cut.
•The capacity saving can be adjusted with three steps, 75%, 50%, and operation stop.
Night operation control (Sound reduction)
Sound is controlled to 45dB or less in inputting a timer point contact.
Compressor operation output
The check of the compressor operation time required of a maintenance etc.
– 29 –
INDOOR
OWNER’S MANUAL
CONTENTS
4-Way Air Discharge Cassette Type
RAV-SP1100UT-E,
RAV-SM560UT-E, RAV-SM800UT-E, RAV-SM1100UT-E, RAV-SM1400UT-E
ACCESSORIES (SOLD SEPARATELY) .......................... |
31 |
PRECAUTIONS FOR SAFETY ....................................... |
31 |
PARTS NAME .................................................................. |
33 |
PARTS NAME OF REMOTE CONTROLLER .................. |
34 |
CORRECT USAGE .......................................................... |
36 |
AUTOMATIC OPERATION (Auto Changeover) ............. |
37 |
ADJUSTMENT OF WIND DIRECTIONd ......................... |
38 |
TIMER OPERATION ........................................................ |
39 |
MAINTENANCE ............................................................... |
41 |
AIR CONDITIONER OPERATIONS AND |
|
PERFORMANCE ............................................................. |
42 |
RE-INSTALLATION ......................................................... |
43 |
TROUBLES AND CAUSES ............................................. |
43 |
Concealed Duct Type
RAV-SM561BT-E, RAV-SM801BT-E, RAV-SM1101BT-E, RAV-SM1401BT-E
ACCESSORIES (SOLD SEPARATELY) .......................... |
45 |
PRECAUTIONS FOR SAFETY ....................................... |
45 |
PARTS NAME .................................................................. |
47 |
PARTS NAME OF REMOTE CONTROLLER .................. |
48 |
CORRECT USAGE .......................................................... |
50 |
AUTOMATIC OPERATION (Auto Changeover) ............. |
51 |
TIMER OPERATION ........................................................ |
52 |
MAINTENANCE ............................................................... |
54 |
AIR CONDITIONER OPERATIONS AND |
|
PERFORMANCE ............................................................. |
55 |
RE-INSTALLATION ......................................................... |
56 |
TROUBLES AND CAUSES ............................................. |
56 |
TROUBLES AND CAUSES |
|
(Concerning Remote Controller) .................................. |
58 |
Under Ceiling Type
RAV-SM561CT-E, RAV-SM801CT-E, RAV-SM1101CT-E, RAV-SM1401CT-E
ACCESSORIES (SOLD SEPARATELY) .......................... |
59 |
PRECAUTIONS FOR SAFETY ....................................... |
59 |
PARTS NAME .................................................................. |
61 |
PARTS NAME OF REMOTE CONTROLLER .................. |
62 |
CORRECT USAGE .......................................................... |
64 |
AUTOMATIC OPERATION (Auto Changeover) ............. |
65 |
ADJUSTMENT OF WIND DIRECTION ........................... |
66 |
TIMER OPERATION ........................................................ |
67 |
MAINTENANCE ............................................................... |
69 |
AIR CONDITIONER OPERATIONS AND |
|
PERFORMANCE ............................................................. |
70 |
RE-INSTALLATION ......................................................... |
71 |
TROUBLES AND CAUSES ............................................. |
71 |
– 30 –