Toshiba R410A User Manual

FILE NO. A03-006

SERVICE MANUAL

<OWNERS MANUAL/INSTALLATION MANUAL>

SPLIT TYPE

RAV-SM561BT-E/RAV-SM560AT-E

RAV-SM801BT-E/RAV-SM800AT-E RAV-SM1101BT-E/RAV-SM1100AT-E RAV-SM1401BT-E/RAV-SM1400AT-E

R410A

PRINTED IN JAPAN, Feb., 2004 ToMo

ADOPTION OF NEW REFRIGERANT

This Air Conditioner is a new type which adopts a new refrigerant HFC (R410A) instead of the conventional refrigerant R22 in order to prevent destruction of the ozone layer.

RAV-SM560AT-E

RAV-SM800AT-E

WARNING

Cleaning of the air filter and other parts of the air filter involves dangerous work in high places, so be sure to have a service person do it. Do not attempt it yourself . The cleaning diagram for the air filter is there for the service person, and not for the customer.

RAV-SM1100AT-E

RAV-SM1400AT-E

RAV-SM561BT-E/RAV-SM801BT-E

RAV-SM1101BT-E/RAV-SM1401BT-E

ACCESSORIES

Outdoor Unit ––––––––––––––––––––––––––––––––––––––––––––––––––––––––

INSTALLATION MANU AL RAV-SM560AT-E/RA V-SM800AT-E

PRECAUTIONS FOR SAFETY.................................... 4

ACCESSORY AND REFRIGERANT ........................... 6

SELECTION OF INSTALLATION ................................ 6

REFRIGERANT PIPING ............................................ 11

EVACUATING............................................................. 13

ELECTRICAL WORK................................................. 15

FINAL INSTALLATION CHECKS.............................. 16

Outdoor Unit ––––––––––––––––––––––––––––––––––––––––––––––––––––––––

INSTALLATION MANU AL RAV-SM1100AT-E/RAV-SM1400AT-E

PRECAUTIONS FOR SAFETY.................................. 18

ACCESSORY AND REFRIGERANT ......................... 20

SELECTION OF INSTALLATION .............................. 20

REFRIGERANT PIPING ............................................ 24

EVACUATING............................................................. 26

ELECTRICAL WORK................................................. 28

FINAL INSTALLATION CHECKS.............................. 29

Indoor Unit –––––––––––––––––––––––––––––––––––––––––––––––––––––

RAV-SM561BT-E/RAV-SM801BT-E/RAV-SM1101BT-E/RAV-SM1401BT-E Concealed Duct Type OWNER’S NANUAL

ACCESSORIES (SOLD SEPARATELY) ........................................ 31

PRECAUTIONS FOR SAFETY......................................................31

PARTS NAME ................................................................................33

PARTS NAME OF REMOTE CONTROLLER................................34

CORRECT USAGE ........................................................................37

AUTOMATIC OPERATION (Auto Changeover) ...........................37

TIMER OPERATION ......................................................................38

MAINTENANCE .............................................................................40

AIR CONDITIONER OPERATIONS AND PERFORMANCE ........41

RE-INSTALLATION........................................................................42

TROUBLES AND CAUSES ...........................................................42

TROUBLES AND CAUSES (Concerning Remote Controller)...44

RAV-SM560AT-E

RAV-SM800AT-E

RAV-SM1100AT-E

RAV-SM1400AT-E

Concealed Duct Type INSTALLATION MANUAL

Accessory parts and Parts to be procured locally ...... 45

PRECAUTIONS FOR SAFETY.................................. 46

SELECTION OF INSTALLATION PLACE ................. 48

INSTALLATION OF INDOOR UNIT........................... 49

AIR DUCTING WORK ................................................ 53

DRAIN PIPING WORK ............................................... 58

REFRIGERANT PIPING ............................................ 60

EVACUATING............................................................. 61

ELECTRICAL WORK................................................. 63

TEST RUN ................................................................. 65

TROUBLESHOOTING........................................... 66

Applicable Controls ............................................. 67

INST ALLATION/SER VICING TOOLS.................... 70

MAINTENANCE .................................................... 70

Accessories ––––––––––––––––––––––––––––––––––––––––––––––––––––

O WNER’S MANUAL

WEEKLY TIMER FOR AIR CONDITIONER (SPLIT TYPE)

<Program Weekly Timer T ype> RBC-EXW21E .......................................................................................................... 72

REMOTE CONTROLLER FOR AIR CONDITIONER

<Simple Operation Type> RBC-AS21E ............................................................................................................. 78

INSTALLATION MANU AL

Standard Remote Controller RBC-AMT21E........................................................................................................... 81

Simple Remote Controller RBC-AS21E ............................................................................................................. 82

Program Weekly Timer RBC-EXW21E .......................................................................................................... 83

Remote sensor TCB-TC21LE............................................................................................................ 84

Zeolite-3G Deodorant Filter TCB-FPC11BE/TCB-FPC21BE/TCB-FPC31BE/TCB-FPC41BE ........................... 85

High-Efficiency Filter .................................................................................................................................. 86

High-Efficiency filter (65%) TCB-UFM11BE/TCB-UFM21BE/TCB-UFM31BE/TCB-UFM41BE High-Efficiency filter (90%) TCB-UFH51BE/TCB-UFH61BE/TCB-UFH71BE/TCB-UFH81BE

Deodorant Filter, Ammonium Filter .................................................................................................................................. 87

Deodorant Filter TCB-DF11BE/TCB-DF21BE/TCB-DF31BE/TCB-DF41BE Ammonium Filter TCB-DF11BE-AM/TCB-DF21BE-AM/TCB-DF31BE-AM/TCB-DF41BE-AM

RAV-SM561BT-E/RAV-SM801BT-E

RAV-SM1101BT-E/RAV-SM1401BT-E

ACCESSORIES

• 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.

RAV-SM560AT-E

RAV-SM800AT-E

• After the installation work, perform a trial operation to check for any prob lem. 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.

PRECAUTIONS FOR SAFETY

CAUTION New Refrigerant Air Conditioner Installation

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DE-

STROY 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.

• 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 Installa-

tion Manual. Make sure the air conditioner uses an exclusive power supply.

An insufficient power supply capacity or inappropriate installation may cause fire.

RAV-SM560AT-E

RAV-SM800AT-E

• 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 g round 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

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

ACCESSORY AND REFRIGERANT

Accessory and Installation Parts Refrigerant Piping

• Piping kit used for the conventional refrigerant cannot be used.

Outdoor unit Installation manual x 1

Drain nipple

Waterproof rubber cap

Protective bush (For SM800AT only)

Guard material for passage part (For SM800AT only)

• 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.

SELECTION OF INSTALLATION

Before installation

Be careful to the following items before installation.

Length of refrigerant pipe

<SM560AT-E>

Length of refrigerant pipe

connected to

indoor/outdoor unit

20m or shorter

21m to 30m

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 20m, add 20g/m of refrigerant and the maximum total length of pipe is 30m. (Max. amount of additional refrigerant is 200g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor .

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 20g of refrigerant for every 1m of pipe which exceeds 20m.

Item

<SM800AT-E>

Length of refrigerant pipe

connected to

indoor/outdoor unit

20m or shorter

21m to 50m

* Caution at addition of refrigerant

When the total length of refrigerant pipe exceeds 20m, add 40g/m of refrigerant and the maximum total length of pipe is 50m. (Max. amount of additional refrigerant is 1200g.)

Charge the refrigerant accurately. Overcharge may cause a serious trouble of compressor .

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 40g of refrigerant for every 1m of pipe which exceeds 20m.

Item

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.

500

or more

150

or more

Installation Place

Necessary Space for Installation

• A place which provides a specified space around the outdoor unit.

• A place where the operation noise and discharged air are not given to your neighbors .

• A place that is not exposed to a strong wind.

• A place that does not block a passage.

• When the outdoor unit is installed in an elev ated

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 an y problem.

CAUTION

1. Install the outdoor unit at a place where dis-

charge 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 b y 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 follo wing examples.

1) Install the unit so that its discharge port faces to the wall of the building. Keep a distance 500 mm or more between the unit and the wall surface .

500

Obstacle at rear side

1. Single unit installation

2. Obstacles at both right and left sides.

200

or more

150

or more

The height of the obstacle should be lower than the height of the outdoor unit.

300

or more

3. Serial installation of two or more units

150

or more

The height of the obstacle should be lower than the height of the outdoor unit.

300

or more

300

or more

150

300

or more

200 or more

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

4. Installation in the following places ma y 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.

Obstacle at front side

1. Single unit installation

2. Serial installation of two or more units

500

1000

or more

15 or less

SELECTION OF INSTALLATION

1000

or more

1000

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.

1. Single unit installation

150

or more

1000

or more

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)

<SM560AT-E>

600

115

Ø28 Drain hole

600150 150

430

Drain hole

310

330

<SM800AT-E>

90 90

2. Serial installation of two or more units

200

or more

300

or more

300

or more

1000

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.

400

365

Knockout hole

Drain nipple mounting hole

Set the out margin of the anchor bolt to 15mm or less.

• In case of draining through the drain hose, attach the following dr ain nipple and the waterproof rubber cap, and use the drain hose (Inner diam.: 16mm) sold on the market. And also seal the screws securely with silicone material, etc. so that w ater does not drop down. Some conditions may cause dewing or dripping of water.

1000

or more

300

or more

1500

or more

2000

or more

200

or more

Drain nipple Waterproof rubber cap

<SM560AT-E>

Refrigerant Piping Connection

CAUTION

Waterproof rubber cap

Base plate

Drain nipple

<SM800AT-E>

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 dr ainage ability increases when a knockout hole on the base plate is opened. (Open the knockout hole to outside using a screwdriver, etc.)

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.

Capacity

rank

RAV-

SM560

SM800

Liquid side

Outer

diameter

Ø6.4 0.8 Ø9.5 0.8

Thickness

Gas side

Outer

diameter

Ø12.7 0.8 Ø15.9 1.0

Thickness

For Reference

Optional Installation Parts (Local Procure)

Parts name

Refrigerant piping

Liquid side : Ø6.35 mm or Ø9.52 mm Gas side : Ø12.7 mm or Ø15.9 mm

Pipe insulating material

(polyethylene foam, 6 mm thick)

Putty, PVC tapes

Q’ty

Each one

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.

SELECTION OF INSTALLATION

Knockout of Pipe Cover

<SM800AT-E>

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 knock out 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 guideline.

• 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.

How to remove the front panel

1. Remove scre ws 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 mak e 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

Front panel

Pipe valve fixing plate

Piping hole

Cord clamp

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.

REFRIGERANT PIPING

Pipe Forming/End Positioning

<SM560AT-E>

• Forming of pipe Form the pipe along with a marked line of the cabinet.

• End positioning of pipe Match the ends of both pipes at a distance of

85 mm apart from the marked line.

85mm

Marked line

Flaring

• Flaring siz e : A (Unit : mm)

Outer diam. of copper pipe

6.35

9.52

12.7

15.9

R410A R22

9.1 9.0

13.2 13.0

16.6 16.2

19.7 19.4

- 0.4

* 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)

Rigid (Clutch type)

1. Cut the pipe with a pipe cutter.

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.

Outer diam.

of copper

pipe

6.35

9.52

12.7

15.9

R410A tool used

R410A R22

0 to 0.5 0 to 0.5 0 to 0.5 0 to 0.5

(Same as left) (Same as left) (Same as left) (Same as left)

Imperial (Wing nut type)

Outer diam. of copper pipe

6.35

9.52

12.7

15.9

Conventional tool used

R410A R22

1.0 to 1.5 0.5 to 1.0

R410A R22

1.5 to 2.0 1.0 to 1.5

2.0 to 2.5 1.5 to 2.0

REFRIGERANT PIPING

Tightening of Connecting Part

(Unit: N•m)

Outer diam. of copper pipe

6.35mm (diam.)

9.52mm (diam.)

12.7mm (diam.)

15.9mm (diam.)

Flare at indoor unit side

• Align the centers of the connecting pipes and tighten the flare nut strong as far as possib le with your fingers.

Then fix the nut with a spanner and tighten it with torque wrench as shown in the figure.

Tightening torque

14 to 18 (1.4 to 1.8kgf•m) 33 to 42 (3.3 to 4.2kgf•m) 50 to 62 (5.0 to 6.2kgf•m) 68 to 82 (6.8 to 8.2kgf•m)

Flare at outdoor 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.

Cover

Half union or packed valve Flare nut

Externally threaded side

Fix with spanner.

Tighten with torque wrench.

Internally threaded side

• 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

• 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.

Flare nut

SM800 type valve at gas side

EVACUATING

Air Purge

This air conditioner can be installed up to the connecting pipe length and height difference in the following table.

Capacity rank

SM560 type SM800 type

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 .)

Max. connecting

pipe length (m)

30 50

Outdoor unit at upper side Outdoor unit at lower side

Height difference (m)

30 15 30 15

Hexagonal

wrench size

4mm

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.

EVACUATING

<SM560AT-E>

Compound pressure gauge

–101kPa

(–76cmHg)

Handle Lo

Charge hose (For R410A only)

Packed valve (Gas side)

Service port (Valve core (Setting pin))

Valve unit

Charge port

Pressure gauge

Valve rod

Manifold valve

Handle Hi (Keep fully closed)

Charge hose (For R410A only)

Vacuum pump adapter for counter-flow prevention (For R410A only)

Vacuum

pump

Flare nut

Stopper

Charge cap

How to open the valve

Charge port

Handle position

Valve unit

Handle Pull out the handle and using cutting pliers, etc. turn it counterclockwise by 90˚. (Open fully)

Flare nut

Valve unit

Push in handle.

Flare nut

<SM800AT-E>

Compound pressure gauge

–101kPa

(–76cmHg)

Handle Lo

Charge hose (For R410A only)

Service port (Valve core (Setting pin))

Packed valve at gas side

Pressure gauge

Manifold valve

Handle Hi (Keep fully closed)

Charge hose (For R410A only)

Vacuum pump adapter for counter-flow prevention (For R410A only)

Vacuum

pump

Valve handling precautions

• Open the valve stem or the handle until it strikes the stopper. It is unnecessary to apply further force.

• Securely tighten the cap with a torque wrench.

• Cap tightening torque

Handle

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 size

Charge port

Ø6.4

Ø9.5 Ø12.7 Ø15.9

14 to 18N•m (1.4 to 1.8kgf•m) 33 to 42N•m (3.3 to 4.2kgf•m) 33 to 42N•m (3.3 to 4.2kgf•m) 20 to 25N•m (2.0 to 2.5kgf•m) 14 to 18N•m (1.4 to 1.8kgf•m)

Terminal block

Screw

123LN

Connecting

cable

Power cable

ELECTRICAL WORK

For the air conditioner that has no power cable, connect a power cable as mentioned belo w.

Model RAV-

Power supply

Maximum running current Installation fuse rating

Power cable

SM560AT-E SM800AT-E

220 – 240 V

Single phase 50 Hz

12A 15A

25 A (D type )

H07 RN-F or 245 IEC 66

(2.5 mm2 or more)

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-connecting 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.

Stripping length power cord and connecting cabl e

<SM560AT-E>

How to remove the valve cover

1. Remove screws of the valve cover.

2. Pull the valve cover downward to remove it.

Piping cover

Cord clamp

Indoor/outdoor connecting cables

Power cable

Valve cover

10 10

30 30

10 10

40 40

Earth line Earth line

Power cable

Connecting cable

123

(mm)

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.

FINAL INSTALLATION CHECKS

Check and Test Operation

For R410A, use the leak detector e xclusiv ely 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 appro x. 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.

Piping cover

Check points of outdoor unit

Valve cover

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, b ut is because the setup of the remote controller is being checked. For the second pow er-ON time and after, approx. 1 minute is required to start the operation by the remote controller .

Useful Functions (SM800AT-E only)

In addition to the code checking by remote controller of the indoor unit, troub les of the outdoor unit can be diagnosed by LED indications on the cycle control P.C. board of the outdoor unit. Utilize them for various checks. For the check by remote controller of the indoor unit, refer to the Installation Manual of the indoor unit. Before a check, confirm each bit of the DIP switch is set to OFF position.

Self-Diagnosis by LED Indication

LED indication and code checking

Cycle control P.C. board

LED indication

D800 ¡ : Red

¡ : Yellow

D801

¡ : Yellow

D802

¡ : Yellow

D803

¥ : Rapid flash

l : Go off

¡ : Go on

LED indication

D800 D801 D802 D803

lll

¡¡

l l

¡¡¡

l l

¡¡

¥ l

l ¥ l

¥¥

¥ l ¥

¡¡

l l

Cause

Heat exchanger sensor (TE) error Suction sensor (TS) error Discharge sensor (TD) error High-pressure protection error Outdoor temperature sensor (TO) error DC outside fan error Communication error between IPDU (Abnormal stop) High-pressure release operation Discharge temp. error EEPROM error Communication error between IPDU (No abnormal stop) G-Tr shor t-circuit protection Detect circuit error Current sensor error Comp. lock error Comp. break down

Installation/Servicing T ools

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)

Changes in the product and components

New tools for R410A

Gauge manifold

Charge hose

Electronic balance for refrigerant charging

Torque wrench (nominal diam. 1/2, 5/8)

Flare tool (clutch type)

Gauge for projection adjustment

Vacuum pump adapter

Gas leakage detector

• 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.

Applicable to R22 model

××

×× ××

××

——

××

Changes

As pressure is high, it is impossible to measure by means of conventional 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 size are changed (to 1/2 UNF 20 threads per inch). When purchasing a charge hose, be sure to check the port size.

As pressure is high and gasification speed is fast, it is difficult to read the indicated value by means of charging cylinder, as air bubbles occur.

The sizes of opposite sides of flare nuts have been increased. Incidentally, a common wrench is used for nominal diameters 1/4 and 3/8.

By increasing the clamp bar’s receiving hole, strength of spring in the tool has been improved.

Used when flare is made with using conventional flare tool. Connected to the conventional vacuum pump. It is necessary to use an

adapter to prevent vacuum pump oil from flowing back to the charge hose. 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 vacuum pump oil (mineral) mixes with R410A, sludge may occur and damage the equipment.

Exclusive for HFC refrigerant.

• 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 prob lem. 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.

PRECAUTIONS FOR SAFETY

CAUTION New Refrigerant Air Conditioner Installation

RAV-SM1100AT-E

RAV-SM1400AT-E

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DE-

STROY OZONE LAYER.

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.