TOSHIBA RAV-GV561ATP-E (01) PDF DOCUMENT

Please read the 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.

This 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. Be sure to use in combination with a R32 refrigerant indoor unit.

If the outdoor unit is installed in a small space and refrigerant leaks, accumulation of highly concentrated refrigerant may cause a fire hazard. Therefore, be sure to follow the installation space instructions in the Installation Manual, and provide open space on at least one of the four outdoor unit sides.

In particular, when both the discharge and intake sides face walls and obstacles are also placed on both sides of the outdoor unit, take steps to provide space wide enough for a person to pass (600 mm or more) on one side to prevent leaked refrigerant from accumulating.

To disconnect the appliance from the main power supply, it must be connected by means of a switch with a contact separation of at least 3 mm.

Do not wash air conditioners with pressure washers, as electric leaks may cause electric shocks or fires.

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

△: Conventional tools (R32 or R410A)

◯: Prepared newly (Use for R32 only)

Use the following item for the refrigerant piping:

Material: Seamless phosphorous deoxidized copper pipe.

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

Ø15.88 Wall thickness 1.0 mm or more

Requirement: When the refrigerant pipe is long, provide support brackets at intervals of 2.5 to 3 m to clamp the refrigerant pipe. Otherwise, abnormal sound may be generated.

CAUTION:

Incomplete flaring may 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.

Length of refrigerant pipe:

For models GV56 and GV80, the pipe length should be between 5 to 30 m. No additional refrigerant is needed for pipe lengths up to 20 m. If the length exceeds 20 m, add refrigerant as specified. Caution: Charge the refrigerant accurately. Overcharging may cause serious trouble with the compressor. Do not connect a pipe shorter than 5 m.

Airtight test:

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

2. Pressurize the pipe with nitrogen gas from the service port to the design pressure (4.15 MPa).

3. Check for gas leaks using a leak tester for HFC refrigerant.

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

Air purge:

Use a vacuum pump to purge air. Do not use the refrigerant charged in the outdoor unit for this purpose.

Electrical wiring:

Fix power and interconnection wires with clamps so they do not contact the cabinet.

Earthing:

Make sure proper earthing is provided to prevent electric shock. 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.

WARNING: Install the outdoor unit properly in a location that is durable enough to support its weight. Insufficient durability may cause the unit to fall, resulting in injury.

CAUTION: Do not install the outdoor unit in a location subject to combustible gas leaks, as this may cause a fire.

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

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

A location not exposed to rain or direct sunlight.

A location that does not increase operating noise or vibration.

A location that does not produce any drainage problems.

Do not install the outdoor unit in the following locations:

A location with a saline atmosphere or full of sulfide gas.

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

A location where organic solvent is used.

Places where iron or other metal dust is present.

A location where high-frequency equipment is used.

A location where discharged air blows against a neighboring window.

A location where operating noise is transmitted.

When installed in an elevated position, be sure to secure its feet.

A location where drain water poses any problems.

All measurements are in mm.

Obstacle at rear side:

1. Single unit installation (Upper side is free): At least 150 mm from the rear.

2. Obstacles on both right and left sides: At least 200 mm above, 150 mm from the rear, and 300 mm from the sides. The height of the obstacle should be lower than the outdoor unit.

3. Serial installation of two or more units: At least 200 mm above, 150 mm from the rear, and 300 mm between units. The height of the obstacle should be lower than the outdoor unit.

Obstacle also above unit:

At least 500 mm above and 150 mm from the rear.

Obstacle in front (Above unit is free):

1. Single unit installation: At least 500 mm in front.

2. Serial installation of two or more units: At least 1,000 mm in front.

Obstacle also at the above unit:

At least 1,000 mm in front.

Obstacles in both front and rear of unit (Open above and to the sides):

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

1. Standard single unit installation: At least 1,000 mm in front and 150 mm in the rear.

2. Standard serial installation: At least 1,000 mm in front, 200 mm from the rear, and 300 mm between units.

Serial installation in front and rear (Open above and to the sides):

At least 1,000 mm front clearance, 200 mm rear clearance, 300 mm between the first two units, 1,500 mm to the next, and 2,000 mm to the one after.

Before installation, check the strength and horizontalness of the base so that abnormal sounds do not emanate.

Fix the base firmly with anchor bolts (M10 x 4 pairs). The anchor bolt should have an out margin of 15 mm or less.

Install the foundation and vibration-proof rubber pads to directly support the bottom surface of the fixing leg that is in contact with and underneath the bottom plate of the outdoor unit. Do not support the outdoor unit only with the fixing leg, as it may deform.

When water is to be drained through the drain hose, attach the drain nipple and waterproof rubber cap, and use a drain hose (Inner dia.: 16 mm). Seal the screws securely with silicone material to prevent water from leaking. When draining water completely, use a drain pan.

Important points for piping work:

1. Reusable mechanical connectors and flared joints are not allowed indoors. When reusing, sealing parts shall be renewed and the flare part shall be refabricated.

2. Ensure tight connection between pipes and the unit.

3. Evacuate the air in connecting pipes using a VACUUM PUMP.

4. Check for gas leakage at connected points.

Flaring Procedure:

1. Cut the pipe with a pipe cutter. Be sure to remove burrs that may cause a gas leak.

2. Insert a flare nut into the pipe, and then flare the pipe. Use the flare nuts supplied with the air conditioner or those for R32/R410A.

Tightening the connecting part:

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.

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

After installation, check for gas leaks of the pipe connections with nitrogen. Do not apply refrigerating machine oil to the flared surface.

Piping Connection Details (Unit: mm):

Tightening Torque (Unit: N·m):

Allowable pipe length and height difference:

Pipe diameter and bent portions:

After completing the refrigerant piping work, perform an airtight test. Connect a nitrogen gas cylinder and pressurize the pipes with nitrogen gas. 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.

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

(Note: when the ambient temperature differs during pressurization and after 24 hours, the pressure will change by approximately 0.01 MPa (0.1 kg/cm²G) per 1°C, so this should be compensated.)

If the pressure drops in steps 1 through 3, check the connections for leakage. Check for leaks with foaming liquid, fix any leaks, and then perform the airtight test again.

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

Use a vacuum pump to purge air. Use one with a backflow preventer to ensure oil from the pump does not backflow into the air conditioner pipes.

Vacuum pump procedure:

1. As shown in the manual’s figure, connect the charge hose after the manifold valve is closed completely.

2. Attach the connecting port of the charge hose with a projection to push the valve core to the charge port of the set.

3. Open Handle Low fully.

4. Turn ON the vacuum pump.

5. Loosen the flare nut of the packed valve (Gas side) a little to check that air passes through.

6. Retighten the flare nut.

7. Execute vacuuming until the compound pressure gauge indicates -101 kPa (-76 cmHg).

8. Close Handle Low completely.

9. Turn OFF the vacuum pump.

10. Leave the vacuum pump as it is for 1 or 2 minutes, and check that the indicator of the compound pressure gauge does not return.

11. Open the valve stem or valve handle fully (First, at liquid side, then gas side).

12. Disconnect the charge hose from the charge port.

13. Tighten the valve and caps of the charge port securely.

1. Turn off the Air Conditioner system.

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

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

4. Check the operating pressure of the system.

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

6. Use the Hexagon wrench to turn the valve rod of the Liquid side fully closed.

7. Continue operating the Air Conditioner system until the gauge of the manifold drops into the range of 0.5 – 0 kgf/cm².

8. Use the Hexagon wrench to turn the valve rod of the Gas side fully closed, and turn off the Air Conditioner system immediately.

9. Remove the gauge manifold from the service port of the packed valve.

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

CAUTION: Check the compressor operating condition while pumping down. 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. Open the valve with a hexagon wrench. Do not open or close valves when the ambient temperature is -20°C or less, as it may damage the valve O-rings.

Valve handling precautions: Open the valve stem until it strikes the stopper. It is unnecessary to apply further force. Securely tighten the cap with a torque wrench.

Hexagonal wrench size:

This model is a 20 m chargeless type. When a refrigerant pipe longer than 20 m is used, add the specified amount of refrigerant. Replenish with liquid refrigerant. When gaseous refrigerant is replenished, the refrigerant composition varies, which disables normal operation.

Refrigerant replenishing procedure:

1. After vacuuming the refrigerant pipe, close the valves and then charge the refrigerant while the air conditioner is not working.

2. If the refrigerant cannot be charged to the specified amount, charge the required amount from the charge port of the valve on the gas side during cooling.

Formula for calculating the amount of additional refrigerant:

Amount of additional refrigerant (g) = α x (l – 20)

Where ‘l’ is the length of the pipe in meters.

Gas Leak Inspection:

Use a leak detector manufactured specially for HFC refrigerant (R32, R410A, R134a, etc.). Leak detectors for conventional HCFC refrigerant (R22, etc.) cannot be used, as the sensitivity drops. R32 has a high working pressure, so failure to perform the installation work properly may result in gas leaks. Be sure to perform leak tests on the piping connections.

Insulating the Pipes:

The temperatures at both the liquid side and gas side will be low during cooling, so to prevent condensation, be sure to insulate the pipes at both of these sides. Insulate the pipes separately for the liquid side and gas side.

Requirement: Be sure to use an insulating material which can withstand temperatures above 120°C for the gas side pipe since this pipe will become very hot during heating operations.

CAUTION:

An installation fuse must be used for the power supply line.

Incorrect/incomplete wiring may lead to an electrical fire or smoke.

Prepare an exclusive power supply.

A switch that disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring.

Use the cord clamps attached to the product.

Use power and system interconnection wires with specified thicknesses and types.

Wire Specifications:

How to wire:

1. Remove the valve cover screw and pull the valve cover downward to remove it.

2. Remove the terminal cover by taking off the mounting screw (1 piece).

3. Connect the power supply wires and system interconnection wires to the terminal block, matching the terminal numbers.

4. Tighten the screws of the terminal block. Do not apply tension to the connecting section.

5. Attach the terminal cover.

Insulate the unsheathed cords (conductors) with electrical insulation tape. Process them so they do not touch any electrical or metal parts.

Finishing:

After the refrigerant pipe, inter-unit wires, and drain pipe have been connected, cover them with finishing tape and clamp them to the wall with off-the-shelf support brackets or their equivalent. Keep the power wires and system interconnection wires off the valve on the gas side or pipes that have no heat insulator.

Earthing:

Be sure to connect the earth wire. Incomplete grounding may cause an electric shock. Connect the earth wire properly following applicable technical standards.

Turn on the leakage breaker at least 12 hours before starting a test run to protect the compressor during startup. To protect the compressor, power is supplied from the 220-240 VAC input to the unit to preheat the compressor.

Check the following before starting a test run:

That all pipes are connected securely without leaks.

That the valve is open. If the compressor is operated with the valve closed, the outdoor unit will become overpressurized, which may damage the compressor or other components.

Operate the air conditioner in the correct procedure as specified in the Owner’s Manual.

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.

For proper performance, operate the air conditioner under the following temperature conditions:

If the air conditioner is used outside of the above conditions, safety protection may work.

When using existing pipe, carefully check for the following:

Wall thickness (within the specified range)

Scratches and dents

Water, oil, dirt, or dust in the pipe

Flare looseness and leakage from welds

Deterioration of copper pipe and heat insulator

Cautions for using existing pipe:

Do not reuse a flare nut to prevent gas leaks. Replace it with the supplied flare nut and then process it to a flare.

Blow nitrogen gas or use an appropriate means to keep the inside of the pipe clean. If discolored oil or much residue is discharged, wash the pipe.

Check welds, if any, on the pipe for gas leaks.

When the pipe corresponds to any of the following, do not use it. Install a new pipe instead:

The pipe has been opened (disconnected from indoor or outdoor unit) for a long period.

The pipe has been connected to an outdoor unit that does not use refrigerant R32, R410A.

The existing pipe must have a wall thickness equal to or larger than the following thicknesses:

Do not use any pipe with a wall thickness less than these thicknesses due to insufficient pressure capacity.

The recovery operation can be performed by operating the SW01 and SW02 switches on the P.C. Board of the outdoor unit. Operate the switches with the electric parts cover in place. DANGER: The entire P.C. Board is a high-voltage area. Wear electrically insulated gloves when operating the service switches with the power on.

Steps to recover refrigerant:

1. Operate the indoor unit in fan mode.

2. Check that the LED displays are in their initial status. 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: OFF, D801: ON, D802: OFF, D803: ON, D804: Slow flash, D805: OFF).

5. Press SW02 to set D805 to rapid flashing. (Each time SW02 is pressed, D805 switches between rapid flashing and OFF).

6. Hold down SW02 for at least 5 seconds, and when D804 flashes slowly and D805 lights, the forced cooling operation is started (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 are returned to the initial status, and the operation stops.

10. Turn off the power.

You can perform fault diagnosis of the outdoor unit with the LEDs on the P.C. Board of the outdoor unit. The LEDs and switches are located at the top right of the P.C. Board. The table below shows the error corresponding to the LED display pattern (◯: ON, ●: OFF, ◎: Rapid flashing).

* Under 70 dBA

This product contains fluorinated greenhouse gases (Chemical Name: R32, GWP: 675). Do not vent gases into the atmosphere.

CAUTION:

1. Stick the enclosed refrigerant label adjacent to the service ports for charging or recovering location.

2. Clearly write the charged refrigerant quantity on the label using indelible ink and place the transparent protective sheet over it.

3. Prevent emission of the gas. Ensure it is never vented during installation, service or disposal. If a leak is detected, it must be stopped and repaired as soon as possible.

4. Only qualified service personnel are allowed to access and service this product.

5. Any handling of the gas shall comply under (EU) Regulation No.517/2014 and any relevant local legislation.

6. Periodical inspections for refrigerant leaks may be required depending on legislation.

7. Contact dealers, installers, etc., for any questions.