Toshiba Air Conditioner RAV SP240AT2 UL User Manual

AIR CONDITIONER (SPLIT TYPE)  
Installation manual  
For OUTDOOR USE only  
Outdoor Unit  
Model name:  
RAV-SP240AT2-UL  
Installation manual  
Air conditioner (Split type)  
English  
1
Manuel d'installation  
Climatiseur (Type split)  
Français  
23  
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1 DIMENSION  
0.5"(12)  
Drain hole  
15.0"(380)  
(
1.0"(25) burring hole)  
7.9"(200)  
2.4"(60)  
B legs  
Air inlet  
port  
Mounting bolt hole  
(
0.5"(12)~ 0.7"(17) U-shape hole)  
Air inlet  
port  
Details of B legs  
3.0"(75)  
Air outlet  
port  
Mounting bolt hole  
0.5"(12) ~ 0.7"(17) long hole)  
A legs  
2.8"(70)  
(
15.1"(383)  
1.5"(39)  
3.8"(96)  
Details of A legs  
5.9"(150)  
23.6"(600)  
5-drain hole  
0.8"(20) ~ 3.5"(88)  
burring hole  
35.4"(900)  
21.7"(550)  
12.6"(320)  
Refrigerant pipe  
2.0"(52)  
connecting port  
0.4"(9.5) flare  
at liquid side  
1.2"(30)  
Refrigerant pipe  
connecting port  
0.6"(15.9) flare  
at gas side  
Conduit hole  
0.9"(22) hole)  
(
Refrigerant piping hole  
Refrigerant  
piping hole  
Z
2.4"(60)  
2.7"(68)  
7"(178)  
7"(178)  
7"(178)  
0.7"(18)  
3.9"(99)  
2.3"(58)  
20.4"(518)  
12.9"(327)  
0.5"(12)  
2.5"(64)  
3.3"(83)  
0.3"(7)  
15.7"(400)  
Mounting hole sold separately  
(12 - 0.1"(3) emboss)  
Knockout for downward piping  
Z views  
EN  
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2 ACCESSORY PARTS  
Part name  
Q’ty  
Shape  
Usage  
(Hand this directly to the customer.)  
Installation manual  
1
This manual  
Drain nipple  
1
Waterproof rubber cap  
Edge Guard  
5
1
Protects piping against sharp edges  
NOTE  
Use drain nipple and waterproof rubber cap as necessary.  
3-EN  
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3 SYSTEM REQUIREMENTS  
Refrigerant charge  
Piping (Field supplied)  
• Minimum refrigerant line length between the outdoor  
unit and indoor unit is 16.5” (5 m)  
Length of refrigerant  
pipe connected to  
indoor/outdoor unit  
Additional refrigerant  
• Maximum pipe lengths  
16’5” - 98’5”  
(5 - 30 m)  
None  
Allowable  
pipe length  
(ft (m))  
Height difference  
(Indoor-outdoor H)  
(ft (m))  
Number of  
Add 0.43 oz/ft (40 g/m) of  
refrigerant for piping that exceeds  
98’5” (30 m) up to 164’1” (50 m).  
bent portions  
*98’5” - 164’1”  
(30 - 50 m)  
Totallength  
L
Indoor unit: Outdoor unit:  
Upper  
Lower  
10 or less  
* Caution during addition of refrigerant  
Max. amount of additional refrigerant is 1.8 lbs (800  
g).  
Charge the refrigerant accurately. Overcharging  
may cause serious trouble with the compressor.  
164’1” (50)  
98’5” (30)  
98’5” (30)  
Figure of Single  
Indoor Unit  
* Minimum refrigerant pipe is 16’5”(5 m).  
This may cause a malfunction of the compressor or  
other devices.  
Metering Device is an electronic EXV (PMV) in  
outdoor unit.  
Outdoor Unit  
Connecting power and control  
cables (Field supplied)  
• The main power is supplied to the outdoor unit. The  
field supplied connecting cables from the outdoor  
unit to the indoor unit consist for 4 wires and provides  
the power for the indoor unit as well as the  
communication signal between the outdoor and  
indoor unit.  
Refrigerant sizes  
Liquid side  
Outer  
Gas side  
Outer  
Thickness  
Thickness  
diameter  
diameter  
• System interconnection wire size must be AWG12.  
• Breaker must have a capacity specified in the  
following table.  
• All wiring must comply with local electric codes and  
NEC (National Electric Code) or CEC (Canadian  
Electric Code).  
0.04”  
(1.0 mm)  
Ø3/8”  
0.03”  
Ø5/8”  
(9.5 mm)  
(0.8 mm)  
(15.9 mm)  
Flare nuts and flaring  
• The flare nuts and flaring are different from those for  
the conventional refrigerant.  
Use the flare nuts supplied with the air conditioner or  
those for R410A.  
Model RAV-  
SP240  
208/230 V, 60 Hz  
24 A  
• Before performing flaring, carefully read  
“REFRIGERANT PIPING”  
Power supply  
MCA  
MOCP (MAX Fuse/CB)  
Breaker  
40 A  
Insulation  
Both lines need to be insulated. Use a minimum 0.4”  
(10 mm) wall thickness.  
25 A  
System interconnection wires  
MCA = Minimum Circuit Amps  
AWG12  
MOCP =Maximum Over Protection Device Amps.  
EN  
– 4 –  
4-EN  
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4 PRECAUTIONS FOR SAFETY  
Installing, starting up, and servicing air--conditioning equipment can be hazardous due to system pressures,  
electrical components, and equipment location (roofs, elevated structures, etc.).  
Only trained, qualified installers and service mechanics should install, start--up, and service this equipment.  
Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should  
be performed by trained service personnel.  
When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached  
to the equipment.  
Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher nearby  
when brazing. Use care in handling, rigging, and setting bulky equipment.  
Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the  
unit. Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety  
information. This is the safety--alert symbol  
. When you see this symbol on the unit and in instructions or  
manuals, be alert to the potential for personal injury.Understand these signal words: DANGER, WARNING, and  
CAUTION. These words are used with the safety--alert symbol.  
DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING  
signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which  
may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which  
will result in enhanced installation, reliability, or operation.  
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 ground the equipment  
Improper grounding may 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.  
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 aluminium 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.  
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 NEC or local code. 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.  
5-EN  
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WARNING  
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.  
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.  
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 over pressurized, 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.  
EQUIPMENT DAMAGE HAZARD  
Failure to follow this caution may result in equipment damage or improper operation.  
Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must be  
a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length is  
buried, refrigerant may migrate to the cooler buried section during extended periods of system shutdown. This causes  
refrigerant slugging and could possibly damage the compressor at start-up.  
EN  
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5 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.  
Required Tools/Equipment and Precautions for Use  
Prepare the tools and equipment listed in the following table before starting the installation work.  
: R410A exclusive  
: Generic  
Tools/equipment  
Manifold gauge*  
Use  
Vacuuming/charging refrigerant  
and operation check  
Charging hose  
Gas leak detector  
Gas leak check  
Vacuum drying  
Vacuum pump with backflow  
prevention function  
Flare tool  
Flare machining of pipes  
Bending pipes  
Usable if dimensions are adjusted.  
Bender  
Refrigerant recovery equipment  
Torque wrench  
Pipe cutter  
Refrigerant recovery  
Tightening flare nuts  
Cutting pipes  
Ø1/2” (12.7 mm) and 5/8” (Ø15.9 mm)  
Brazing torch and nitrogen  
cylinder  
Braze pipes  
Refrigerant charging scales  
4 mm hexagon wrench  
Charging refrigerant  
Opening liquid valve  
7-EN  
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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, one of the following is  
recommended.  
• Install the unit so that its discharge faces the wall of  
the structure.  
Installation Location  
WARNING  
Install the outdoor unit in a location that can support  
the weight of the outdoor unit.  
Insufficient durability may cause the outdoor unit to fall,  
which may result in injury.  
Keep a distance 19.7” (500 mm) or more between the  
unit and wall.  
19.7" (500 mm)  
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.  
• A well-ventilated location free from obstacles near the  
air inlets and air outlet  
• Install the unit so that the discharge is at a right angle  
relative to the wind direction.  
• 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  
Strong wind  
Strong wind  
• Location with easy access to power.  
Do not install the outdoor unit in the following  
location.  
• A location with a saline atmosphere (coastal area) or  
one that is full of sulfide gas (hot-spring area) (Special  
maintenance is required.)  
• Use wind baffle. Produce those parts in the field.  
• When outside temperature conditions are 23 °F (-5  
°C) or lower and unit is running in cooling mode.  
<Example>  
Wind baffle  
Wind baffle  
• 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.  
EN  
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Unit : in (mm)  
Outdoor Unit  
Required Clearances  
Barrier at rear side  
Barrier in front  
Upper side is free  
1. Single unit installation  
Above unit is free  
1. Single unit installation  
2. Barrier on right, left and rear.  
2. Multiple units installation  
The height of the  
barrier should be  
lower than the height  
of the outdoor unit.  
5.9” (150)  
or more  
11.8” (300) or more  
3. Multiple units installation  
Barrier also above unit  
39.4” (1000)  
or more  
5.9”  
(150)  
or more  
11.8”  
11.8”  
11.8”  
(300)  
(300)  
(300)  
or more  
or more  
or more  
The height of the obstacle should be lower than the  
height of the outdoor unit.  
Barrier also above unit  
5.9” (150)  
or more  
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Barriers in front and back of unit  
Installation of Outdoor Unit  
• Before installation, check the strength and horizontal  
of the base so that abnormal sounds do not  
emanate.  
• According to the following base diagram, fix the base  
firmly with the anchor bolts.  
(Anchor bolt, nut: 3/8” (M10) x 4 pairs)  
Open above and to the right and left of the unit.  
The height of an barrier 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  
Drain hole  
5.9” (150)  
20.7” (525)  
5.9” (150)  
23.6” (600)  
1.8” (45)  
Drain  
nipple mounting hole  
2. Multiple unit installation  
Drain hole  
a. Intake and supply parallel  
1) Field fabricate a snow or an ice stand for the  
unit using the above dimension.  
2) Place snow or ice stand on a foundation/pad  
and secure it to the foundation/pad and secure  
it to the foundation/pad by anchor bolts.  
NOTE  
11.8” (300)  
or more  
When the outdoor unit is anchored directly on  
the foundation/pad (cooling only protrude a  
minimum of 6” (15 mm)).  
11.8” (300) or more  
b. Intake and supply in line  
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.  
0.6” (15 mm) or less  
Standard installation  
7.9”  
(200)  
or more  
59.1”  
(1500)  
or more  
78.7”  
(2000)  
or more  
39.4”  
(1000)  
or more  
11.8”  
(300) or  
more  
EN  
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3) Place unit on stand. Make sure it is level and  
• When water is to be drained through the drain hose,  
attach the following drain nipple and waterproof  
rubber cap, and use the drain hose (Inner diameter:  
0.6” (16 mm)) sold on the market. Also seal the  
screws securely with silicone material, etc., to  
prevent water from leaking.  
Some conditions may cause condensation or  
dripping of water.  
• When collectively draining discharged water  
completely, use a drain pan.  
fasten securely to the stand.  
As shown in the figure below, install the  
foundation and vibration-proof rubber pads to  
directly support the bottom surface of the fixing  
leg that is in contact with the bottom plate of the  
outdoor unit.  
When installing the foundation for an outdoor  
unit with downward piping, consider the piping  
work.  
GOOD  
Mounting leg  
Waterproof rubber cap  
(5pcs.)  
Drain nipple  
Foundation  
GOOD  
Bottom plate  
of outdoor unit  
Drain nipple  
Waterproof rubber cap  
Foundation  
Support the bottom surface of the  
mounting leg that is in contact with  
and underneath the bottom plate of  
the outdoor unit.  
For Reference  
Do not support  
NO GOOD  
the outdoor unit  
only with the  
If only the end of the  
mounting leg is  
supported, it may  
deform.  
If a heating operation is to be continuously performed  
for a long time under the condition that the outdoor  
temperature is 32 °F (0 °C) or lower, draining defrosted  
water may be difficult due to the bottom plate freezing,  
resulting in trouble with the cabinet or fan.  
mounting leg.  
Foundation  
11-EN  
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6 REFRIGERANT PIPING  
Piping connections are inside the front panel of the unit  
and the front panel and pipe cover needs to be  
removed before piping and wiring connections are  
made.  
Flaring  
1. Cut the pipe with a pipe cutter.  
Be sure to remove burrs that may cause a gas  
leak.  
2. Insert the supplied flare nut into the pipe, and then  
flare the pipe.  
Piping can enter the outdoor unit from the back, from  
the side or from the bottom as shown  
As the flaring sizes of R410A differ from those of  
refrigerant R22, the flare tools newly manufactured  
for R410A are recommended.  
Front panel  
Pipe cover  
However, the conventional tools  
B
can be used by adjusting the  
projection margin of the copper  
pipe.  
Rear  
Rearward  
Pipe cover  
Projection margin in flaring : B (Unit : in (mm))  
Rigid (Clutch type)  
Side  
Sideward  
R410A tool  
used  
Conventional  
tool used  
Downward  
Bottom  
Outer diameter of  
copper pipe  
1. Remove the front panel of the unit.  
2. Remove the pipe cover.  
R410A  
0.04” - 0.06”  
(1.0 - 1.5)  
3/8” (9.5)  
0 - 0.02” (0 - 0.5)  
3. Remove the appropriate knockout depending  
on the orientation of the piping.  
5/8” (15.9)  
Flaring diameter size : A (Unit : in (mm))  
The pipe cover is easily mounted by cutting off  
the slit at the lower part of the pipe cover.  
+0  
Outer diameter of copper pipe  
3/8” (9.5)  
A
-0.02" (–0.4)  
0.52” (13.2)  
0.78” (19.7)  
5/8” (15.9)  
* In case of flaring for R410A with the  
conventional flare tool, pull the tool out  
approx. 0.02” (0.5 mm) more than that for  
R22 to adjust it to the specified flare size.  
The copper pipe gauge is useful for  
adjusting the projection margin size.  
A
* Be sure to wear heavy work gloves while working.  
4. Remove the burrs from the knockout opening  
and use the factory supplied protective edge  
guard material around the opening to protect the  
piping and the wiring.  
5. Remove the flare nut from the service valve on  
outdoor unit. Insert the flare nut into the field  
piping, and flare the pipe.  
Bend the pipe approx. 90 degree with a pipe  
bender for side and rear piping.  
6. When the piping connections are complete re-  
install the pipe cover.  
EN  
– 12 –  
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• After the installation work, be sure to check for gas  
leaks of the pipe connections with nitrogen.  
Tightening of Flare  
Connections  
NO GOOD  
1. Align the centers of the flare connections and fully  
tighten the flare nuts with your fingers.  
Cover  
Valve at liquid side  
Cap  
Charge orifice  
Piping valve  
Tightened  
Loosened  
Flare nut  
CAUTION  
2. Use two wrenches to loosen or tighten the flare nut  
on the gas service valve as shown in the figure.  
Use only one wrench to loosen or tighten the flare  
not on the liquid service valve.  
1. Do not put the crescent wrench on the charge  
orifice or cover.  
The valve may be broken.  
2. If applying excessive torque, the nut may break  
according to some installation conditions.  
The final tightening with a torque wrench should be  
to the specifications shown in table below.  
Unit : ft•lbs (N•m)  
• Pressure of R410A is higher than that of R22  
(Approx. 1.6 times).  
Outer diameter of copper pipe  
3/8” (9.5 mm)  
Tightening torque  
24 - 31 (33 - 42)  
50 - 60 (68 - 82)  
Therefore, using a torque wrench, tighten the flare  
pipe connecting sections that connect the indoor/  
outdoor units at the specified tightening torque.  
Incomplete connections may cause not only a gas  
leak, but also trouble with the refrigeration cycle.  
5/8” (15.9 mm)  
Valve at gas side  
Cover  
Do not apply refrigerant oil to the flared  
surface.  
Piping valve  
Cap  
Charge orifice  
Flare nut  
Tightened  
Loosened  
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7 ELECTRICAL CONNECTIONS  
Field wiring  
WARNING  
The dashed lines show field wiring.  
ELECTRICAL SHOCK HAZARD  
(Field power  
supply)  
(System  
interconnection wires)  
Failure to follow this warning could result in  
personal injury or death.  
L
1
2
L
1
2
L
L
1
2
Input  
power  
• The unit cabinet must have an uninterrupted or  
unbroken ground to minimize personal injury if an  
electrical fault should occur. The ground may consist  
of electrical wire or metal conduit when installed in  
accordance with existing electrical codes.  
• Before performing service or maintenance, be sure  
main power switch is turned OFF.  
L
L
208/230 V~,  
60 Hz  
Remote  
controller  
S
S
circuit breaker  
Outdoor unit  
Indoor unit  
ground  
• System interconnection wire size must be AWG12.  
• Breaker must have a capacity specified in the  
following table.  
CAUTION  
• All wiring must comply with local electric codes and  
NEC (National Electric Code) or CEC (Canadian  
Electric Code).  
All wiring and connections must comply with NEC, CEC,  
local codes.  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in damage  
or improper operation.  
• Unit failure as a result of operation on improper line  
voltage or excessive phase imbalance constitutes  
abuse and may cause damage to electrical  
components.  
• Wrong wiring may cause a burn-out of some electrical  
parts.  
• Do not damage or scratch the conductive core or inner  
insulator of the power and inter-connecting wires  
when peeling them.  
Model RAV-  
SP240  
208/230 V, 60 Hz  
24 A  
Power supply  
MCA  
MOCP (MAX Fuse/CB)  
Breaker  
40 A  
25 A  
System interconnection wires  
MCA = Minimum Circuit Amps  
AWG12  
MOCP =Maximum Over Protection Device Amps.  
• Connect the system interconnection wires (indoor to  
outdoor) to the identical terminal numbers on the  
terminal block of each unit.  
Electric parts box  
Electric control box  
Incorrect connection may cause a failure.  
Front panel  
Front pane  
1. With the front panel removed the electrical control  
box is exposed at the top right corner of the unit.  
2. Terminate the field wiring conduit (if used) at the  
conduit connection holes provided.  
Field wiring  
terminal  
blocks  
3. Route the field power wires and the system  
interconnection wires as shown on the following  
pages. Terminate the wires at field wiring terminal  
blocks located immediately below the electrical  
control box.  
Valve mounting  
bracket  
Conduit connection  
Conduit connection  
holes  
holes  
Pipe cover  
Front Pipe cover  
Piping knockout  
Piping knockout  
EN  
– 14 –  
14-EN  
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Outdoor Unit  
2. Remove the wire cover from back of the front pipe  
cover.  
Field power supply  
terminal block  
System  
interconncection  
terminal block  
Wire cover  
Cable cover  
L1  
L2  
S
L
1
L2  
Ground screw  
Ground screw  
System  
interconnection  
wires  
Field power  
supply wires  
Banding band  
3. Pass the wires through the conduit connection holes  
and attach the conduit connecters.  
Wiring  
1. Remove the front panel and remove the front pipe  
cover.  
Remove the 4  
screws.  
Conduit connector  
4. Connect the wires to the terminal blocks and fix the  
wires to the wiring guide with the 2 included banding  
band.  
Front pipe cover  
Terminal block  
Do not make the  
wires slack in this  
section.  
Wire guide  
Fix with the 2  
banding band.  
15-EN  
– 15 –  
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5. Pass the wires through the wiring guide of the front  
pipe cover and adjust the wire lengths.  
8. Connect 2 conduits.  
Wiring guide  
conduit  
6. Attach the wire cover and hold the wires with the  
wiring guide hooks.  
Do not clip or damage the wires with the cover.  
Fix with a screw.  
Hook  
Wire cover  
7. Attach the front pipe cover with 4 screws.  
Fix with 4  
screws  
EN  
– 16 –  
16-EN  
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8 EVACUATE AND DEHYDRATE THE  
SYSTEM  
6. After evacuation is complete, fully close the low side  
of manifold gage and stop operation of vacuum  
pump.  
CAUTION  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in equipment  
damage or improper operation.  
Never use the system compressor as a vacuum pump.  
Deep Vacuum Method  
The deep vacuum method requires a vacuum pump  
capable of pulling a vacuum of 500 microns and a  
vacuum gage capable of accurately measuring this  
vacuum depth. The deep vacuum method is the most  
positive way of assuring a system is free of air and  
liquid water.  
Refrigerant tubes and indoor heat exchanger should  
be evacuated using the recommended deep vacuum  
method of 500 microns. The alternate triple evacuation  
method may be used if the procedure outlined below is  
followed. Always break a vacuum with dry nitrogen.  
Deep Vacuum Graph  
5000  
4500  
4000  
SYSTEM VACUUM AND  
CHARGE  
LEAK IN  
3500  
SYSTEM  
3000  
2500  
2000  
Using Vacuum Pump  
1. Completely tighten flare nuts A, B, C, D, connect  
manifold gage charge hose to a charge port of the  
low side service valve.  
VACUUM TIGHT  
1500  
TOO WET  
1000  
TIGHT DRY  
500  
SYSTEM  
Service Valve  
Refrigerant  
Low Side  
Indoor Unit  
0
1
2
3
4
5
6
7
Outdoor Unit  
C
D
A
B
MINUTES  
High Side  
Triple Evacuation Method  
Service Valve  
The triple evacuation method should only be used  
when vacuum pump is only capable of pumping down  
to 28 in. of mercury vacuum and system does not  
contain any liquid water.  
Refer to “Triple Evacuation Method chart” and proceed  
as follows:  
2. Connect charge hose to vacuum pump.  
3. Fully open the low side of manifold gage.  
Manifold  
Manifold Gage  
500 microns  
1. Pump system down to 28 in. of mercury and allow  
pump to continue operating for an additional 15  
minutes.  
Low side valve  
High side valve  
Charge hose  
2. Close service valves and shut off vacuum pump.  
3. Connect a nitrogen cylinder and regulator to system  
and open until system pressure is 2 psig.  
4. Close service valve and allow system to stand for 1  
hr. During this time, dry nitrogen will be able to  
diffuse throughout the system absorbing moisture.  
5. Repeat this procedure as indicated in the chart.  
System will then be free of any cotaminants and  
water vapor.  
Charge hose  
Vacuum pump  
Low side valve  
4. Start vacuum pump.  
5. Evacuate using either deep vacuum or triple  
evacuation method.  
17-EN  
– 17 –  
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Triple Evacuation Method chart  
Open service valves  
EVACUATE  
Open or close the valve.  
Liquid side  
BREAK VACUUM WITH DRY NITROGEN  
Open the valve with a 4 mm hexagon wrench.  
WAIT  
Gas side  
Valve unit  
EVACUATE  
BREAK VACUUM WITH DRY NITROGEN  
WAIT  
Using a straight blade  
EVACUATE  
screwdriver, turn it 90°  
counter clockwise until  
the valve is fully open  
(against the stop).  
Charge orifice  
CHECK FOR TIGHT, DRY SYSTEM  
(IF IT HOLDS DEEP VACCUM)  
Flare nut  
RELEASE CHARGE INTO SYSTEM  
Final Tubing Check  
Handle position  
Fully closed  
Fully opened  
IMPORTANT:  
Check to be certain factory tubing on both indoor and  
outdoor unit has not shifted during shipment. Ensure  
tubes are not rubbing against each other or any sheet  
metal. Pay close attention to feeder rubes, making sure  
wire ties on feeder tubes are secure and tight.  
Stop pin  
Main stopper  
• While the valve is fully opened, after the screwdriver  
has reached the stopper, do not apply torque  
exceeding 4 ft•lbs (5 N•m). Applying excessive  
torque may damage the valve.  
Valve handling precautions  
• Open the valve stem until it reaches the stop.  
It is unnecessary to apply further force.  
• Securely tighten the cap with a torque wrench.  
• Cap tightening torque  
Ø3/8” (9.5 mm)  
24 - 31 ft•lbs (33 - 42 N•m)  
Valve size  
Ø5/8” (15.9 mm) 15 - 18 ft•lbs (20 - 25 N•m)  
10 - 13 ft•lbs (14 - 18 N•m)  
Charge port  
EN  
– 18 –  
18-EN  
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9 FINISHING  
After the refrigerant pipe, inter-unit wires, and drain pipe have been connected, make sure they are supported and  
fixed in place for the entire length.  
Keep the power wires and system interconnection wires away from all factory wiring and piping.  
10TEST RUN  
Turn on the circuit breaker at least 12 hours before starting the system to preheat the compressor and  
prevent damage.  
To protect the compressor, power is supplied from the 208/230 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 over pressurized, which may  
damage the compressor or other components.  
If there is a leak at a connection, air can be sucked in and the internal pressure further increases, which may  
cause a burst or injury.  
• Operate the air conditioner using the correct procedure as specified in the Owner’s Manual.  
11PERIODIC MAINTENANCE  
• 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.  
19-EN  
– 19 –  
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Outdoor Unit  
12TROUBLESHOOTING  
You can perform fault diagnosis of the outdoor unit with the LEDs on the P.C. board of the outdoor unit in addition  
to using the check codes displayed on the wired remote controller of the indoor unit.  
Use the LEDs and check codes for various checks. Details of the check codes displayed on the wired remote  
controller of the indoor unit are described in the Installation Manual of the indoor unit.  
Verifying Fault code status (Outdoor control  
board)  
Verifying Fault code status stored in  
memory (Outdoor control board)  
1. Check that DIP switch SW803 is set to off.  
2. Record the states (on or off) of LED 800 to LED 804  
(Display mode 1).  
1. Check that DIP switch SW803 is set to on.  
2. Record the states (on or off) of LED 800 to LED 804  
(Display mode 1).  
3. Press SW800 for at least 1 second. The LED status  
changes to display mode 2.  
3. Press SW800 for at least 1 second. The LED status  
changes to display mode 2.  
4. Since display mode 1 covers multiple faults with the  
same code display, mode 2 must also be used to  
determine the final fault. Use the status recorded for  
LED 800 to LED 804 in display mode 1 (Item 2  
above) and combine it with the status for the same  
LED’s in display mode 2 (Item 3 above) to determine  
the complete fault code using the chart below.  
4. Since display mode 1 covers multiple faults with the  
same code display, mode 2 must also be used to  
determine the final fault. Use the status recorded for  
LED 800 to LED 804 in display mode 1 (Item 2  
above) and combine it with the status for the same  
LED’s in display mode 2 (Item 3 above) to determine  
the complete fault code using the chart below.  
NOTE  
An outside air temperature (TO) sensor error can be  
checked only when an error occurs.  
Display mode 1  
Display mode 2  
No.  
Cause  
D800 D801 D802 D803 D804 D800 D801 D802 D803 D804  
1
2
3
4
5
6
7
Normal  
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
Discharge (TD) sensor error  
Heat exchanger (TE) sensor error  
Heat exchanger (TL) sensor error  
Outside air temperature (TO) sensor error  
Suction (TS) sensor error  
Heat sink (TH) sensor error  
Outdoor temperature sensor (TE/TS) connection  
error  
8
9
{
{
{
Outdoor EEPROM error  
{
{
{
{
{
{
{
{
{
{
{
10 Compressor lock  
11 Compressor lock  
12 Current detection circuit error  
13 Thermostat for compressor activated  
Model data not set  
14  
{
{
{
(on the service P.C. board)  
15 MCU-MCU communication error  
16 Discharge temperature error  
{
{
{
{
{
{
{
Abnormal power  
(open phase detected or abnormal voltage)  
17  
{
{
{
{
EN  
18 Heat sink overheat  
19 Gas leak detected  
{
{
{
{
{
{
{
{
{
{
{
{
20 4-way valve reverse error  
(:OFF {:ON :Flashing)  
– 20 –  
20-EN  
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Outdoor Unit  
Display mode 1  
Display mode 2  
No.  
Cause  
D800 D801 D802 D803 D804 D800 D801 D802 D803 D804  
21 High pressure release operation  
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
22 Outdoor fan motor error  
23 Compressor driver short-circuit protection  
24 Position detection circuit error in one-line display  
(:OFF {:ON :Flashing)  
* The LEDs and DIP switches are located on the lower left of the P.C. board of the outdoor unit.  
SW801  
SW800  
Enlargedview  
of LEDs  
D800  
LED  
D800  
D801  
D802  
D803  
D804  
D805  
SW804  
D801  
D802  
D803  
D804  
D805  
SW803  
SW802  
21-EN  
– 21 –  
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Outdoor Unit  
13UNIT PUMP DOWN  
• Use the pump down switch SW801 on the P.C. board of the outdoor unit to pump down the unit.  
Procedure  
1. Turn on the power of the air conditioner.  
2. Select the FAN mode for indoor unit operation with the remote controller.  
3. Set SW804 on the P.C. board of the outdoor unit to all OFF, and then press SW801 for 1 second or more. The  
air conditioner enters the forced cooling mode for up to 10 minutes.  
Pump down the unit during this 10 minutes.  
4. Upon completion of pump down the unit, close the valve and press SW801 for at least 1 second to stop  
operation.  
5. Turn off the power.  
Refrigerant  
Pump down  
recovery switch  
SW801  
SW801  
P.C. board  
P.C. board  
switch  
Optional  
Optional connector  
connector CN610  
CN610  
Special operation  
Special operation  
select switch  
select switch  
SW804  
SW804  
Existing pipe  
Power save switch  
s
S
w
W
it SW802  
8
c
0
h
2
DANGER  
Be careful of electric shock because the P.C. board has an electrical current running through it.  
14POWER SAVE  
• Power save can be set by setting SW802 dip switch.  
Procedure  
1. Turn on the SW802 dip switch 2 to activate Power save.  
Power save controls reducing compressor periodicity (by approx. 10%) depending on the indoor unit heat  
exchanger temperature in heating operation  
SW802  
... Power save setting  
* All switches are OFF as factory default.  
CAUTION  
EN  
Do not touch SW802 dip switch 1, 3 and 4.  
If any changes are made, the unit may not work properly.  
22-EN  
– 22 –  
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EH99865401  
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