Toshiba RAV-SM2244AT8Z-E, RAV-SM2804AT8Z-E, RAV-SM2244AT7Z, RAV-SM2244AT7ZG, RAV-SM2244AT7 INSTALLATION MANUAL

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AIR CONDITIONER (SPLIT TYPE)

Installation manual

Outdoor Unit

Model name:

RAV-SM2244AT7 RAV-SM2804AT7 RAV-SM2244AT7Z RAV-SM2804AT7Z RAV-SM2244AT7ZG RAV-SM2804AT7ZG RAV-SM2244AT8-E RAV-SM2804AT8-E RAV-SM2244AT8Z-E RAV-SM2804AT8Z-E RAV-SM2244AT8ZG-E RAV-SM2804AT8ZG-E

English EN

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Please read this Installation Manual carefully before installing the Air Conditioner.

• This Manual describes the installation method of the outdoor unit.

• For installation of the indoor unit, follow the Installation Manual attached to the indoor unit.

ADOPTION OF NEW REFRIGERANT

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

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to Ssc (*1) at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to Ssc (*1).

Ssc (*1)

Model Ssc (MVA)

RAV-SM2244AT8(Z)(ZG)-E 1.41

RAV-SM2804AT8(Z)(ZG)-E 1.72

Contents

1 ACCESSORY PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 INSTALLATION OF NEW REFRIGERANT AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . 4

4 INSTALLATION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 REFRIGERANT PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 ELECTRICAL WORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 EARTHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 FINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

10 TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

11 ANNUAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

12 AIR CONDITIONER OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

13 FUNCTIONS TO BE IMPLEMENTED LOCALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

14 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

15 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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1 ACCESSORY PARTS

 Accessory Parts

Part name Q’ty Shape Usage

Installation manual 1 (Hand this directly to the customer.)

Drain nipple 1

Waterproof rubber cap 1

Protective bush 1 For protecting wires (pipe cover)

Guard material for passage part 1 For protecting passage part (pipe cover)

Clamp filter 1

Ø19.1 mm pipe 1 For the pipe inside the outdoor unit

Joint (Ø19.1 – Ø25.4 mm) 1 For connecting the pipe

Joint (Ø25.4 – Ø28.6 mm) 1 For connecting the pipe

Elbow 1 For connecting the pipe

For conforming to EMC standards (Used for power wire)

INFORMATION

• The main pipe on the gas side of this outdoor unit has a diameter of Ø28.6 mm, but a Ø19.1 mm flare connection is used where the valve is connected. Be sure to use the Ø19.1 mm pipe and joint provided as accessories for the pipe connection.

• Before installing the unit, check that the unit has the correct model name to prevent the wrong unit from being installed in the wrong place.

• Before proceeding to weld the refrigerant pipe, be sure to pass nitrogen through the pipe.

• Before installing the indoor units, read the instructions in the installation manual provided with the indoor units.

• Before installing a branch pipe, read the instructions in the installation manual provided with the branch pipe kit.

• In the case of a simultaneous double twin system, use indoor unit with the same capacity for all four indoor units.

Branch pipe kit Combination indoor unit

RAV-SM2244 RBC-DTWP101E SM56 × 4 units RAV-SM2804 RBC-DTWP101E SM80 × 4 units

• P.C. board settings are required for some of the indoor units if they are to be used in a twin, triple or double twin system. Refer to the instructions in the installation manual of the branch pipe kit, and ensure that the settings are selected correctly.

• Combination with the indoor units Combination with the indoor units is possible only when units with the same type are combined. Combinations of units with different types cannot be used.

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2 SAFETY PRECAUTIONS

• Ensure that all Local, National and International regulations are satisfied.

• Read these “SAFETY PRECAUTIONS” carefully before installation.

• The precautions described below include 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 to the customer how to use and maintain the unit.

• Ask the customer to keep the Installation Manual together with the Owner’s Manual.

WARNING

• Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner. Perform installation work properly according to the Installation Manual.

Inappropriate installation may result in water leakage, electric shock or fire.

• Be sure to connect earth wire (grounding work).

Incomplete grounding cause an electric shock. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone wires.

• Turn off the main power supply switch or breaker before attempting any electrical work and maintenance.

Make sure all power switches are off. Failure to do so may cause electric shock. Use an exclusive power circuit for the air conditioner. Use the rated voltage.

• Connect the connecting wire correctly.

If the connecting wire is incorrect, electric parts may be damaged.

• When moving the air conditioner for installation to another place, be very careful not to allow the specified refrigerant (R410A) to become mixed with any other gaseous body into the refrigeration cycle.

If air or any other gas mixes with the refrigerant, the gas pressure in the refrigeration cycle will become abnormally high and it may result in the pipe bursting or personal injuries.

• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches.

• Do not touch the intake or aluminum fins of the outdoor unit.

Doing so may result in injury.

• Tighten the flare nut with a torque wrench in the specified manner.

Excessive tightening of the flare nut may cause a crack in the flare nut after a long period, which may result in refrigerant leakage.

• Install the air conditioner securely in a location where the base can sustain the weight of the unit 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 unit falling.

• 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 be generated.

• 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 may be generated.

• 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 only the specified wiring during the unit installation. Ensure that all terminals are securely fixed, so preventing any external forces having a negative effect on the terminals.

• When the air conditioner cannot cool or heat a room well, contact the dealer from whom you purchased the air conditioner as refrigerant leakage is considered as the cause. In the case of repair that requires refill of refrigerant, ask service personnel about details of the repair.

The refrigerant used in the air conditioner is harmless. Generally, the refrigerant does not leak. However, if the refrigerant leaks in a room and a heater or stove burner in the room catches fire, it may generate toxic gas. When you ask service personnel for repairing refrigerant leakage, confirm that the leakage portion has been completely repaired.

• 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 that may be subjected to a risk of exposure to a combustible gas.

If a combustible gas leaks and becomes concentrated around the unit, a fire may occur.

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• Install the refrigerant pipe securely during the installation work before operating the air conditioner.

If the compressor is operated with the valve open and without the refrigerant pipe, the compressor sucks air and the refrigeration cycle is overpressurized, which may cause a burst or injury.

• When carrying out the pump-down work, shut down the compressor before disconnecting the refrigerant pipe.

Disconnecting the refrigerant pipe with the service valve left open and with the compressor still operating will cause air, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly resulting in rupturing, injury, etc.

CAUTION

• Do not climb onto or place objects on top of the outdoor unit.

You may fall or the objects may fall off of the outdoor unit and result in injury.

• Wear heavy gloves during the installation work to avoid injury.

To Disconnect the Appliance from the 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.

• A 25 A installation fuse (all fuse types can be used) must be used for the power supply line of this conditioner.

3 INSTALLATION OF NEW REFRIGERANT AIR

CONDITIONER

CAUTION

New Refrigerant Air Conditioner Installation

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.

R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working pressure of R410A refrigerant is approx. 1.6 times as that of refrigerant R22. Accompanied with the adoption of the new refrigerant, the refrigerant oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerant oil does not enter the new type refrigerant R410A air conditioner cycle. To prevent mixing of refrigerant or refrigerant oil, the sizes of connecting sections of charging port on main unit and installation tools are different from those of the conventional refrigerant units. Accordingly, special tools are required for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittings made for R410A only, so that water and/or dust does not enter.

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 Required Tools/Equipment and Precautions for Use

Prepare the tools and equipment listed in the following table before starting the installation work. Newly prepared tools and equipment must be used exclusively.

Legend

: Prepared newly (Use for R410A only. Do not use for refrigerant R22 or R407C etc.)

: Conventional tools/equipment are available

Tools/equipment Use How to use tools/equipment

Gauge manifold

Charging hose

Charging cylinder Can not be used

Gas leak detector Gas leak check

Vacuum pump Vacuum drying Unusable

Vacuum pump with backflow prevention function

Flare tool Flare machining of pipes

Bender Bending pipes

Refrigerant recovery equipment Refrigerant recovery

Torque wrench Tightening flare nuts

Pipe cutter Cutting pipes

Welding machine and nitrogen cylinder

Refrigerant charging measure Charging refrigerant

Vacuuming/charging refrigerant and operation check

Vacuum drying

Welding pipes

Prepared newly for R410A only

Unusable (Use the refrigerant charging measure instead.)

Prepared newly

R22 (Conventional tools)

Usable if dimensions are adjusted.

R22 (Conventional tools)

For R410A only

Exclusive for Ø12.7 mm and Ø19.1 mm

R22 (Conventional tools)

 Refrigerant Piping

New refrigerant (R410A)

When using the conventional piping

• When using the conventional piping with no indication of applicable refrigerant types, be sure to use it with a wall thickness of 0.8 mm for Ø6.4 mm, Ø9.5 mm, and Ø12.7 mm, with a wall thickness of 1.0 mm for Ø15.9 mm, with a wall thickness of

1.2 mm for Ø19.1 mm, and with a wall thickness of 1.0 mm for Ø28.6 mm (half hard). Do not use the conventional piping with a wall thickness less than these thicknesses due to insufficient pressure capacity.

When using general copper pipes

• Use general copper pipes with a wall thickness of 0.8 mm for Ø6.4 mm, Ø9.5 mm, and Ø12.7 mm, with a wall thickness of

1.0 mm for Ø15.9 mm, with a wall thickness of 1.2 mm for Ø19.1 mm, and with a wall thickness of 1.0 mm for Ø28.6 mm (half hard). Do not use any copper pipes with a wall thickness less than these thicknesses.

Flare nuts and flare machining

• The flare nuts and flare machining are different from those for the conventional refrigerant. Use the flare nuts supplied with the air conditioner or those for R410A.

• Before performing flare machining, carefully read “REFRIGERANT PIPING”.

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4 INSTALLATION CONDITIONS

 Before installation

Be sure to prepare to the following items before installation.

Length of refrigerant pipe

connected to indoor/

outdoor unit

7.5 to 30 m

*31 to 70 m

* If the total length of the refrigerant pipe exceeds 30 m,

add refrigerant in the amount given in the “Adding additional refrigerant”.

* Do not connect a refrigerant pipe that is shorter than

7.5 m. This may cause a malfunction of the compressor or other devices.

Addition of refrigerant is unnecessary at the local site.

<Addition of refrigerant> Add 40 g of refrigerant for every 1 m of piping that exceeds 30 m.

Airtight test

1. Before starting an airtight test, further tighten the spindle valves on the gas and liquid sides.

2. Pressurize the pipe with nitrogen gas charged from the service port to the design pressure (4.15 MPa) to conduct an airtight test.

3. After the airtight test is completed, evacuate the nitrogen gas.

Item

Earthing

WARNING

Make sure that proper earthing is provided.

Improper earthing may cause an electric shock. For details on how to check earthing, contact the dealer who installed the air conditioner or a professional installation company.

• Proper earthing can prevent charging of electricity on the outdoor unit surface due to the presence of a high frequency in the frequency converter (inverter) of the outdoor unit, as well as prevent electric shock. If the outdoor unit is not properly earthed, you may be exposed to an electric shock.

• Be sure to connect the earth wire (grounding work).

Incomplete grounding can cause an electric shock. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone wires.

Test Run

Turn on the leakage breaker at least 12 hours before starting a test run to protect the compressor during startup.

CAUTION

Incorrect installation work may result in a malfunction or complaints from customers.

Air purge

• To purge air, use a vacuum pump.

• Do not use refrigerant charged in the outdoor unit to purge air. (The air purge refrigerant is not contained in the outdoor unit.)

Electrical wiring

• Be sure to fix the power wires and indoor/outdoor connecting wires with clamps so that they do not come into contact with the cabinet, etc.

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 Installation Location

WARNING

Install the outdoor unit properly in a location that is durable enough to support the weight of the outdoor unit.

Insufficient durability may cause the outdoor unit to fall, which may result in injury. This outdoor unit has a weight of about 135 kg. Pay special attention when installing the unit onto a wall surface.

CAUTION

Do not install the outdoor unit in a location that is subject to combustible gas leaks.

Accumulation of combustible gas around the outdoor unit may cause a fire.

Install the outdoor unit in a location that meets the following conditions after the customer’s consent is obtained.

• A well-ventilated location free from obstacles near the air inlets and air outlet

• A location that is not exposed to rain or direct sunlight

• A location that does not increase the operating noise or vibration of the outdoor unit

• A location that does not produce any drainage problems from discharged water

Do not install the outdoor unit in the following locations.

• A location with a saline atmosphere (coastal area) or one that is full of sulfide gas (hot-spring area) (Special maintenance is required.)

• A location subject to oil, vapor, oily smoke, or corrosive gases

• A location in which organic solvent is used

• A location where high-frequency equipment (including inverter equipment, private power generator, medical equipment, and communication equipment) is used (Installation in such a location may cause malfunction of the air conditioner, abnormal control or problems due to noise from such equipment.)

• A location in which the discharged air of the outdoor unit blows against the window of a neighboring house

• A location where the operating noise of the outdoor unit is transmitted

• When the outdoor unit is installed in an elevated position, be sure to secure its feet.

• A location in which drain water poses any problems.

CAUTION

1. Install the outdoor unit in a location where the discharge air is not blocked.

2. When an outdoor unit is installed in a location that is always exposed to strong winds like a coast or on the high stories of a building, secure normal fan operation by using a duct or wind shield.

3. When installing the outdoor unit in a location that is constantly exposed to strong winds such as on the upper stairs or rooftop of a building, apply the windproofing measures referred to in the following examples.

1) Install the unit so that its discharge port faces the

wall of the building. Keep a distance 500 mm or more between the unit and wall surface.

500 mm

2) Consider the wind direction during the operational

season of the air conditioner, and install the unit so that the discharge port is set at a right angle relative to the wind direction.

Strong wind

• When using an air conditioner under low outside

temperature conditions (Outside temp:-5 °C or lower) in COOL mode, prepare a duct or wind shield so that it is not affected by the wind.

Wind shield

EN 7

Wind shield

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 Necessary Space for Installation

(Unit: mm)

Obstacle at rear side

Upper side is free

1. Single unit installation

150 or

2. Obstacles on both right and left sides

The height of the

200 or

150 or

3. Serial installation of two or more units

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

250 or

Obstacle in front

Above unit is free

1. Single unit installation

500 or

2. Serial installation of two or more units

Obstacle also at the above unit

1,000 or

800 or

1,000 or

150 or

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

250 or

Obstacle also above unit

150 or

500 or

250 or

200 or more

Obstacles in both front and rear of unit

Open above and to the right and left of the unit. The height of an obstacle in both the front and rear of the unit, should be lower than the height of the outdoor unit.

Standard installation

1. Single unit installation

150 or

1,000 or

2. Serial installation of two or more units

200 or

250 or

200 or

1,000 or

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