Toshiba RAV-SM801AT-E, RAV-SM1101AT-E, RAV-SM561AT-E, RAV-SM1401AT-E User Manual

0 (0)

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

 

INSTALLATION MANUAL

 

RAV-SM561AT-E, RAV-SM801AT-E ....................................................................

4

RAV-SM1101AT-E, RAV-SM1401AT-E ..............................................................

16

INDOOR

 

OWNER’S MANUAL

 

4-Way Air Discharge Cassette Type

 

RAV-SP1100UT-E,

 

RAV-SM560UT-E, RAV-SM800UT-E,

 

RAV-SM1100UT-E, RAV-SM1400UT-E .............................................................

31

Concealed Duct Type

 

RAV-SM561BT-E, RAV-SM801BT-E,

 

RAV-SM1101BT-E, RAV-SM1401BT-E .............................................................

45

Under Ceiling Type

 

RAV-SM561CT-E, RAV-SM801CT-E,

 

RAV-SM1101CT-E, RAV-SM1401CT-E .............................................................

59

INSTALLATION MANUAL

 

4-Way Air Discharge Cassette Type

 

RAV-SP1100UT-E,

 

RAV-SM560UT-E, RAV-SM800UT-E,

 

RAV-SM1100UT-E, RAV-SM1400UT-E .............................................................

74

Concealed Duct Type

 

RAV-SM561BT-E, RAV-SM801BT-E,

 

RAV-SM1101BT-E, RAV-SM1401BT-E .............................................................

92

Under Ceiling Type

 

RAV-SM561CT-E, RAV-SM801CT-E,

 

RAV-SM1101CT-E, RAV-SM1401CT-E ...........................................................

117

– 2 –

 

OUTDOOR

 

 

INSTALLATION MANUAL

 

 

CONTENTS

 

RAV-SM561AT-E, RAV-SM801AT-E

 

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

 

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

 

Fin

 

Fin

Suction

Suction

Before installation

Be careful to the following items before installation.

Length of refrigerant pipe

<SM56>

Length of refrigerant

 

pipe connected to

Item

indoor/outdoor unit

 

 

 

20 m or shorter

Addition of refrigerant is

unnecessary at the local site.

 

 

 

21 m to 30 m

<Addition of refrigerant>

Add 20 g of refrigerant for every

 

1 m of pipe which exceeds 20 m.

 

 

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

 

pipe connected to

Item

indoor/outdoor unit

 

 

 

20 m or shorter

Addition of refrigerant is

unnecessary at the local site.

 

 

 

21 m to 30 m

<Addition of refrigerant>

Add 40 g of refrigerant for every

 

1 m of pipe which exceeds 20 m.

 

 

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

 

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 unit installation

 

500 moreor

 

 

 

 

 

 

 

2.

Serial installation of two or more units

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1000 or more

– 7 –

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>

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1000

300

 

 

1500

 

2000

 

200

 

or more

or more

 

or more

 

 

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)

 

90

600

90

 

 

108

 

330

306

60

 

 

 

Ø28 Drain hole

 

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)

 

Parts name

Q’ty

 

 

 

A

Refrigerant piping

Each one

Liquid side : Ø6.4 mm or Ø9.5 mm

 

Gas side : Ø12.7 mm or Ø15.9 mm

 

 

 

 

B

Pipe insulating material (polyethylene

1

foam, 6 mm thick)

 

 

 

 

 

 

C

Putty, PVC tapes

Each one

 

 

 

Refrigerant Piping Connection

<Piping connection>

Capacity

Liquid side

Gas side

rank

 

 

 

 

Outer

Thickness

Outer

Thickness

 

RAV-

diameter

diameter

 

 

 

 

 

SM56

Ø6.4

0.8

Ø12.7

0.8

 

 

 

 

 

SM80

Ø9.5

0.8

Ø15.9

1.0

 

 

 

 

 

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)

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

+0

Outer diam. of copper pipe

- 0.4

 

 

 

R410A

 

R22

 

 

 

 

 

 

6.4

9.1

 

9.0

 

 

 

 

9.5

13.2

 

13.0

 

 

 

 

12.7

16.6

 

16.2

 

 

 

 

15.9

19.7

 

19.4

 

 

 

 

*In case of flaring for R410A with the conventional flare tool, pull it out approx. 0.5 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

of copper

 

 

 

 

 

 

R410A

R22

R410A

R22

pipe

 

 

 

 

 

 

6.4

 

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

 

9.5

 

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

 

12.7

 

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

 

15.9

 

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

 

Imperial (Wing nut type)

Outer diam. of copper pipe

R410A

R22

 

 

 

6.4

1.5 to 2.0

1.0 to 1.5

 

 

 

9.5

1.5 to 2.0

1.0 to 1.5

 

 

 

12.7

2.0 to 2.5

1.5 to 2.0

 

 

 

15.9

2.0 to 2.5

1.5 to 2.0

 

 

 

– 9 –

RAV-SM561AT-E, RAV-SM801AT-E

4 REFRIGERANT PIPING

Tightening of Connecting Part

 

(Unit: N•m)

 

 

Outer diam. of copper pipe

Tightening torque

 

 

6.4 mm (diam.)

14 to 18 (1.4 to 1.8 kgf•m)

 

 

9.5 mm (diam.)

33 to 42 (3.3 to 4.2 kgf•m)

 

 

12.7 mm (diam.)

50 to 62 (5.0 to 6.2 kgf•m)

 

 

15.9 mm (diam.)

68 to 82 (6.8 to 8.2 kgf•m)

 

 

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

Externally

 

Internally

threaded side

 

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 –

Toshiba RAV-SM801AT-E, RAV-SM1101AT-E, RAV-SM561AT-E, RAV-SM1401AT-E User Manual

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

 

 

pipe length (m)

Outdoor unit at upper side

Outdoor unit at lower side

wrench size

 

 

 

 

 

 

 

 

 

SM56 type

30

30

30

4 mm

 

 

SM80 type

6 mm

 

 

 

 

 

 

 

 

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

–101kPa

 

(–76cmHg)

Manifold valve

 

Handle Lo

Handle Hi

 

(Keep fully closed)

Charge hose

Charge hose

(For R410A only)

(For R410A only)

 

 

Vacuum pump adapter

 

for counter-flow prevention

 

(For R410A only)

 

Vacuum

 

pump

Packed valve (Gas side)

Service port (Valve core (Setting pin))

Valve unit

 

 

 

Flare nut

 

 

 

 

 

 

 

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)

 

 

 

Valve size

Ø9.5

33 to 42 N•m (3.3 to 4.2 kgf•m)

 

 

Ø12.7

33 to 42 N•m (3.3 to 4.2 kgf•m)

 

 

 

 

 

Ø15.9

33 to 42 N•m (3.3 to 4.2 kgf•m)

 

 

 

Charge port

14 to 18 N•m (1.4 to 1.8 kgf•m)

 

 

 

– 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

 

 

 

Power supply

220 – 240 V

 

Single phase 50 Hz

 

 

 

 

 

 

Maximum running current

15 A

 

 

 

 

Installation fuse rating

25 A (D type

)

 

 

Power cable

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-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).

 

 

 

When purchasing a charge hose, be sure to check the port size.

 

 

 

 

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.

 

 

 

 

 

 

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.

 

 

 

 

Flare tool

¡

 

By increasing the clamp bar’s receiving hole, strength of spring in the tool

(clutch type)

 

has been improved.

 

 

 

 

 

 

Gauge for projection adjustment

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.

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

 

 

 

 

 

 

vacuum pump oil (mineral) mixes with R410A, sludge may occur and

 

 

 

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

 

 

 

 

 

 

 

2.

Serial installation of two or more units

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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>

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1000

300

 

 

1500

 

2000

 

200

 

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

 

 

 

 

 

430

 

 

 

Drain hole

40

 

 

 

 

 

400

365

Knockout hole

Drain nipple mounting hole

 

 

 

 

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

 

 

 

 

B

Pipe insulating material

1

(polyethylene foam, 6 mm thick)

 

 

 

 

 

C

Putty, PVC tapes

Each one

 

 

 

 

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

 

 

 

 

Ø 9.5

0.8

Ø15.9

1.0

 

 

 

 

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

 

 

 

 

6.4

9.1

9.0

 

 

 

9.5

13.2

13.0

 

 

 

12.7

16.6

16.2

 

 

 

15.9

19.7

19.4

 

 

 

• Projection margin in flaring :

 

 

 

 

 

B

B (Unit : mm)

 

 

 

 

 

 

 

 

 

 

 

Rigid (Clutch type)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Outer dia.

R410A tool used

Conventional tool used

of copper

 

 

 

 

 

 

 

 

 

 

 

 

R410A

R22

 

R410A

 

 

R22

pipe

 

 

 

 

 

 

 

 

6.4

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

9.5

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

12.7

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

15.9

0 to 0.5

(Same as left)

1.0 to 1.5

0.5 to 1.0

 

 

 

 

 

 

 

 

 

 

 

 

 

Imperial (Wing nut type)

Outer dia. of copper pipe

R410A

R22

 

 

 

6.4

1.5 to 2.0

1.0 to 1.5

 

 

 

9.5

1.5 to 2.0

1.0 to 1.5

 

 

 

12.7

2.0 to 2.5

1.5 to 2.0

 

 

 

15.9

2.0 to 2.5

1.5 to 2.0

 

 

 

*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

 

 

(Unit: N•m)

 

 

 

Outer dia. of copper pipe

 

Tightening torque

 

 

 

6.4 mm (diam.)

 

14 to 18 (1.4 to 1.8 kgf•m)

 

 

 

9.5 mm (diam.)

 

33 to 42 (3.3 to 4.2 kgf•m)

 

 

 

12.7 mm (diam.)

 

50 to 62 (5.0 to 6.2 kgf•m)

 

 

 

15.9 mm (diam.)

 

68 to 82 (6.8 to 8.2 kgf•m)

 

 

 

 

Flare at

 

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

Externally

 

Internally

threaded side

 

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

 

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

 

 

 

pipe length (m)

Outdoor unit at upper side

Outdoor unit at lower side

wrench size

 

 

 

 

 

 

 

 

SM110, SM140 type

50

30

30

4 mm

 

 

 

 

 

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

 

(–76cmHg)

Manifold valve

 

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

 

SM140

 

 

 

Power supply

220 – 240 V

Single phase 50 Hz

 

 

 

 

Maximum running current

22.0 A

 

22.8 A

 

 

 

 

Installation fuse rating

25 A (D type

)

 

 

Power cable

H07 RN-F or 245 IEC 66

(2.5 mm2 or more)

 

 

 

 

CAUTION

Stripping length power cord and connecting cable

L N

10

10

1 2 3

10

 

 

10

50

40

40

30

Earth line

Earth line

(mm)

 

 

Power cable

Connecting

 

 

cable

 

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

 

 

 

 

Earth screw

 

 

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

 

Cycle control P.C. board

 

 

 

 

 

LED indication

 

LED indication

Cause

 

 

 

 

 

 

 

D800

D801

D802

D803

 

 

 

 

 

 

 

 

 

¡

 

l

l

l

Heat exchanger sensor (TE) error

 

 

 

 

 

 

 

 

l

 

l

¡

l

Suction sensor (TS) error

 

 

 

 

 

 

 

 

¡

 

¡

l

l

Discharge sensor (TD) error

 

 

 

 

 

 

 

D800 ¡ : Red

l

 

¡

l

¡

Thermostat for compressor activated.

 

 

 

 

 

 

D801 ¡ : Yellow

l

 

¡

l

l

Outdoor temperature sensor (TO) error

D802 ¡ : Yellow

 

 

 

 

 

 

¡

 

¡

¡

l

DC outside fan error

D803 ¡ : Yellow

 

 

 

 

 

 

 

¡

 

l

l

¡

Communication error between IPDU (Abnormal stop)

 

 

 

 

 

 

 

 

 

¥ : Rapid flash

l

 

¡

l

¡

High-pressure release operation

l : Go off

 

 

 

 

 

 

l

 

¡

¡

l

Discharge temp. error

¡ : Go on

 

 

 

 

 

 

 

¡

 

¡

l

¡

EEPROM error

 

 

 

 

 

 

 

 

 

 

l

 

l

¡

¡

Communication error between IPDU (No abnormal stop)

 

 

 

 

 

 

 

 

¥

 

l

l

l

G-Tr short-circuit protection

 

 

 

 

 

 

 

 

l

 

¥

l

l

Detect circuit error

 

 

 

 

 

 

 

 

¥

 

¥

l

l

Current sensor error

 

 

 

 

 

 

 

 

l

 

l

¥

l

Comp. lock error

 

 

 

 

 

 

 

 

¥

 

l

¥

l

Comp. break down

 

 

 

 

 

 

 

– 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

 

 

 

 

 

×

 

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).

 

 

 

When purchasing a charge hose, be sure to check the port size.

 

 

 

 

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.

 

 

 

 

 

 

Torque wrench

×

 

The size of opposite sides of flare nuts have been increased. Incidentally,

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

 

a common wrench is used for nominal diameters 1/4 and 3/8.

 

 

 

 

Flare tool

¡

 

By increasing the clamp bar’s receiving hole, strength of spring in the tool

(clutch type)

 

has been improved.

 

 

 

 

 

 

Gauge for projection adjustment

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.

Vacuum pump adapter

¡

 

The charge hose connecting part has two ports-one for conventional

 

refrigerant (7/16 UNF 20 threads per inch) and one for R410A.

 

 

 

 

 

 

If the vacuum pump oil (mineral) mixes with R410A a sludge may occur

 

 

 

and damage the equipment.

 

 

 

 

Gas leakage detector

×

 

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.

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 –

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