TOSHIBA RAV-GV1601ATP-E (01) PDF DOCUMENT

The TOSHIBA RAV-GV1601ATP-E air conditioner adopts the HFC refrigerant (R32), which does not destroy the ozone layer. This outdoor unit is designed exclusively for use with R32 refrigerant and must be used in combination with an R32 refrigerant indoor unit.

Yes, this equipment complies with IEC 61000-3-12, provided that the short-circuit power Ssc is greater than or equal to 1,600 kVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user to ensure, by consulting 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 this value.

The required Ssc (kVA) values are as follows:

To prevent fire hazards from refrigerant leaks, please adhere to the following installation space instructions:

• If the outdoor unit is installed in a small space, a refrigerant leak could lead to an accumulation of highly concentrated refrigerant, creating a fire hazard. Always follow the installation space instructions in the manual and provide open space on at least one of the four sides of the outdoor unit.

• If both the discharge and intake sides face walls, and obstacles are present on the other two sides, you must provide a space wide enough for a person to pass (600 mm or more) on one side. This is to prevent the accumulation of leaked refrigerant.

The TOSHIBA RAV-GV1601ATP-E appliance must be connected to the main power supply by means of a switch that has a contact separation of at least 3 mm.

Additionally, do not wash the air conditioner with pressure washers, as electric leaks may cause electric shocks or fires.

The following accessory parts are supplied with the outdoor unit:

When installing the TOSHIBA RAV-GV1601ATP-E, please observe the following precautions:

• This air conditioner uses HFC refrigerant (R32). During installation, ensure that water, dust, former refrigerant, or refrigerant oil does not enter the R32 refrigerant cycle.

• To prevent mixing of refrigerant or oil, the connecting sections of the charge port on the main unit and installation tools are different from those of conventional refrigerant units.

• Special tools are required for R32 or R410A refrigerant units.

• For connecting pipes, use new and clean piping materials with high-pressure fittings made for R32 or R410A only, to prevent water and/or dust from entering.

• If you are using existing piping, refer to the “Existing piping” section in the appendix.

The following tools and equipment are required for installation. Newly prepared tools must be used exclusively for R32 refrigerant.

For refrigerant piping, please adhere to the following requirements:

Material: Use seamless phosphorous deoxidized copper pipe.

Wall Thickness:

• Ø6.35, Ø9.52, Ø12.7: Wall thickness 0.8 mm or more

• Ø15.88: Wall thickness 1.0 mm or more

Flaring:

• Incomplete flaring can cause refrigerant gas leakage.

• Do not re-use flares. Use new flares to prevent refrigerant gas leakage.

• Use flare nuts that are included with the unit. Using different flare nuts may cause refrigerant gas leakage.

Support: If the refrigerant pipe is long, provide support brackets at intervals of 2.5 to 3 m to clamp the refrigerant pipe to prevent abnormal sounds.

Pipe Length:

• The length of the refrigerant pipe connected to the indoor/outdoor unit should be between 5 to 30 m.

• Do not connect a refrigerant pipe that is shorter than 5 m, as this may cause a malfunction of the compressor or other devices.

Airtight test:

1. Before starting, 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 of 4.15 MPa to conduct the test.

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

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:

• Fix the power wires and system interconnection wires with clamps to prevent them from contacting the cabinet, etc.

Earthing (Grounding):

• WARNING: Make sure that proper earthing is provided. Improper earthing may cause an electric shock. Contact the dealer or a professional installation company for details on how to check earthing.

• Proper earthing prevents charging of electricity on the outdoor unit surface and prevents electric shock. If the outdoor unit is not properly earthed, you may be exposed to an electric shock.

• WARNING: Be sure to connect the earth wire. 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.

Install the outdoor unit in a location that meets the following conditions, after obtaining the customer’s consent:

• A well-ventilated location free from obstacles near the air intakes and air discharge.

• 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.

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

• A location in which drain water poses no problems.

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.

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), as special maintenance is required.

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

• A location in which organic solvent is used.

• Places where iron or other metal dust is present. If metal dust collects on the interior of the air conditioner, it may spontaneously combust and start a fire.

• A location where high-frequency equipment (e.g., inverter equipment, private power generator, medical equipment) is used, as it may cause malfunction or problems due to noise.

• 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.

The following are the necessary space requirements (in mm) for installation:

Obstacle at rear side only (Upper side is free):

• At least 150 mm from the rear side.

Obstacles on both right and left sides:

• At least 150 mm from the rear side.

• At least 300 mm from the side with the service connections.

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

Serial installation of two or more units (side-by-side):

• At least 150 mm from the rear side.

• At least 300 mm between units.

• At least 300 mm on the end units’ outer sides.

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

Obstacle also above unit:

• At least 150 mm from the rear side.

• At least 500 mm from the top.

Obstacle in front (Upper side is free):

• At least 500 mm from the front for a single unit.

• At least 1,000 mm from the front for serial installation.

Obstacles in both front and rear of unit (Standard installation):

• Single unit: At least 150 mm from the rear, 1,000 mm from the front.

• Serial installation: At least 200 mm from the rear, open above and to the sides. For front obstacles, maintain 1,000 mm, 1,500 mm, or 2,000 mm depending on configuration, with 300 mm space between units.

The height of an obstacle in both the front and rear of the unit should be lower than the height of the outdoor unit.

Follow these steps for flaring:

1. Cut the pipe with a pipe cutter. Be sure to remove any burrs, as they may cause a gas leak.

2. Insert a flare nut (supplied with the air conditioner or one for R32/R410A) onto the pipe, and then flare the pipe.

CAUTION:

• Do not scratch the inner surface of the flared part when removing burrs. Scratches can cause refrigerant gas leaks.

• Check that the flared part is not scratched, deformed, stepped, or flattened, and has no chips adhered to it.

• Do not apply refrigerating machine oil to the flare surface.

The tables below show the required projection margin (B) and final flaring diameter (A).

Projection margin in flaring: B (Unit: mm)

Flaring dia. size: A (Unit: mm)

1. Align the centers of the connecting pipes and fully tighten the flare nut with your fingers. Then, fix the nut with a wrench and tighten it with a torque wrench to the specified torque.

2. For the valve on the gas side, you must use two wrenches to loosen or tighten the flare nut. For the liquid side, you can use a single crescent wrench.

CAUTION:

• Do not put the crescent wrench on the valve cap or cover, as the valve may break.

• If you apply excessive torque, the nut may break.

• After installation, check for gas leaks at the pipe connections using nitrogen.

• Do not apply refrigerating machine oil to the flared surface.

Tightening torque (Unit: N•m)

After completing the refrigerant piping work, perform an airtight test by connecting a nitrogen gas cylinder and pressurizing the pipes.

CAUTION: Never use oxygen, flammable gas, or noxious gas for the airtight test.

Gas leak check steps:

• Step 1: Pressurize to 0.5 MPa (5 kg/cm²G) for 5 minutes or longer. Major leaks can be discovered.

• Step 2: Pressurize to 1.5 MPa (15 kg/cm²G) for 5 minutes or longer. Major leaks can be discovered.

• Step 3: Pressurize to 4.15 MPa (42 kg/cm²G) for 24 hours. Micro leaks can be discovered.

Note: If the ambient temperature changes, the pressure will change by approximately 0.01 MPa per 1°C. This should be compensated for. If pressure drops, check connections for leakage with foaming liquid, fix any leaks, and repeat the airtight test.

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

Use a vacuum pump to evacuate air from the connecting pipes. Be sure to use a vacuum pump with a backflow preventer.

1. Connect the charge hose from the manifold valve (closed) to the charge port of the set.

2. Open the Handle Low on the manifold fully.

3. Turn ON the vacuum pump.

4. Loosen the flare nut of the packed valve (Gas side) slightly to check that air passes through.

5. Retighten the flare nut.

6. Continue vacuuming until the compound pressure gauge indicates -101 kPa (-76 cmHg).

7. Close the Handle Low on the manifold completely.

8. Turn OFF the vacuum pump.

9. Leave it for 1-2 minutes and check that the indicator of the compound pressure gauge does not return (rise).

10. Fully open the valve stem or valve handle (first at liquid side, then gas side).

11. Disconnect the charge hose from the charge port.

12. Securely tighten the valve and caps of the charge port.

The pump down process is used to recover refrigerant into the outdoor unit.

1. Turn off the Air Conditioner system.

2. Connect the charge hose from the manifold valve to the service port of the packed valve on the gas side.

3. Turn on the Air Conditioner system in cooling operation for more than 10 minutes.

4. Check that the operating pressure is normal.

5. Release the valve rod cap of both service valves.

6. Use a hexagon wrench to fully close the valve rod of the liquid side.

7. Continue operating the air conditioner until the manifold gauge drops into the range of 0.5 – 0 kgf/cm².

8. Use a hexagon wrench to fully close the valve rod of the gas side and immediately turn off the Air Conditioner system.

9. Remove the gauge manifold from the service port.

10. Securely tighten the valve rod cap to both service valves.

CAUTION: During the pump down process, check the compressor operating condition. If any abnormal sound or vibration occurs, turn off the Air Conditioner immediately.

Fully open the valves of the outdoor unit. First, fully open the valve on the liquid side, and then fully open the valve on the gas side.

• Do not open or close the valves when the ambient temperature is -20°C or less, as this may damage the valve O-rings and result in refrigerant leakage.

• Liquid side: Open the valve with a 4 mm hexagon wrench.

• Gas side: Open the valve with a 5 mm hexagon wrench.

Valve handling precautions:

• Open the valve stem until it strikes the stopper.

• Securely tighten the cap with a torque wrench.

Cap tightening torque:

The stripping length for the power cord and connecting wires should be 10mm for the conductors, with overall specified lengths as shown in the manual diagrams.

For proper performance, operate the air conditioner under the following temperature conditions. If used outside of these conditions, safety protection may activate.

For an air conditioning system that is operated on a regular basis, cleaning and maintenance of the indoor/outdoor units are strongly recommended.

As a general rule, if an indoor unit is operated for about 8 hours daily, the indoor/outdoor units will need to be cleaned at least once every 3 months. This cleaning and maintenance should be carried out by a qualified service person.

Failure to clean the indoor/outdoor units regularly will result in poor performance, icing, water leaking, and even compressor failure.

DANGER: The P.C. board is a high-voltage area. When operating the service switches with power on, wear electrically insulated gloves. Operate the switches with the electric parts cover in place.

Follow these steps to recover the refrigerant:

1. Operate the indoor unit in fan mode.

2. Check that the LED displays are in their initial status (D805 is ON). If not, hold down SW01 and SW02 simultaneously for at least 5 seconds to return them to the initial status.

3. Hold down SW01 for at least 5 seconds, and check that D804 flashes slowly.

4. Press SW01 once to set the LED displays to the “refrigerant recovery LED display” (D800, D801, D802, D803 are OFF; D804 is slow flashing; D805 is ON).

5. Press SW02 to set D805 to rapid flashing. (Each press switches D805 between rapid flashing and OFF).

6. Hold down SW02 for at least 5 seconds. When D804 flashes slowly and D805 lights up, the forced cooling operation starts (Max. 10 minutes).

7. After operating the system for at least 3 minutes, close the valve on the liquid side.

8. After the refrigerant has been recovered, close the valve on the gas side.

9. Hold down SW01 and SW02 simultaneously for at least 5 seconds. The LED displays will return to the initial status, and the cooling and indoor fan operations will stop.

10. Turn off the power.

If you doubt the success of the recovery, hold down SW01 and SW02 simultaneously for at least 5 seconds to return to the initial status, then repeat the steps.

You can perform fault diagnosis using the LEDs (D800-D805) on the outdoor unit’s P.C. board. The display patterns correspond to specific errors. (● = ON, ○ = OFF, ● = Rapid flashing)

Yes, existing R22 and R410A piping can be reused for the R32 TOSHIBA RAV-GV1601ATP-E, but only if specific conditions are met. You must confirm there are no scratches or dents and verify the pipe strength.

Basic conditions needed to reuse existing pipes:

1. Dry: There is no moisture inside the pipes.

2. Clean: There is no dust inside the pipes.

3. Tight: There are no refrigerant leaks.

Restrictions for use of existing pipes (Do not reuse if any of the following apply):

• Scratches or dents are heavy.

• Pipe thickness is thinner than specified below.

• The outdoor unit was left with pipes disconnected for a long period.

• Refrigerant cannot be recovered using a recovery unit (indicating dirty oil or moisture).

• A commercially available dryer is attached to the pipes.

• Refrigerant oil is discolored (e.g., green copper rust), has a large quantity of residue, or a bad smell.

• The previous air conditioner had a compressor failure and replacement.

• The previous system was used for temporary installations (e.g., leased).

• The refrigerator oil of the existing system is not Suniso, Freol-S, MS, alkyl benzene, ester series, or PVE of ether series.

Pipe diameter and thickness (mm)

1. Stick the enclosed refrigerant label adjacent to the service ports for charging/recovering or next to the existing nameplate.

2. Using indelible ink, clearly write the charged refrigerant quantity on the label in the designated fields:

• **①:** Pre-charged refrigerant at factory [kg] (found on the nameplate).

• **②:** Additional charge on installation site [kg].

• **①+②:** Total refrigerant quantity [kg].

• **③:** Total quantity in tonnes of CO2 equivalent, calculated as (GWP x kg) / 1000. For R32, the GWP is 675.

3. Place the included transparent protective sheet over the label to protect the writing.