Toshiba RAS-B13GKVP-E Refrigerant R410A, Safety During Installation/Servicing, Copper Pipes

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3. REFRIGERANT R410A

This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerat- ing oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

3-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materi- als exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

1.Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A.

If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.

2.Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R410A.

The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air condi- tioner using R410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R22.

3.If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire, a poisonous gas may occur.

4.When installing or removing an air conditioner, do not allow air or moisture to remain in the refrig- eration cycle. Otherwise, pressure in the refrig- eration cycle may become abnormally high so that a rupture or personal injury may be caused.

5.After completion of installation work, check to make sure that there is no refrigeration gas leakage.

If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

6.When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

7.Be sure to carry out installation or removal according to the installation manual.

Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc.

8.Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair’s may result in water leakage, electric shock and fire, etc.

3-2. Refrigerant Piping Installation

3-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

1.Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pres- sure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table 3-2-1. Never use copper pipes thinner than 0.8 mm even when it is available on the market.

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Contents Split Type Contents New Refrigerant Air Conditioner Installation Safety PrecautionsFor general public use For Reference Specifications SpecificationsCooling Operation Characteristic CurveCapacity Variation Ratio According to Temperature Cooling HeatingPiping Materials and Joints Used Safety During Installation/ServicingRefrigerant Piping Installation Refrigerant R410A1 Thicknesses of annealed copper pipes Thickness mm Flare processing procedures and precautionsProcessing of Piping Materials Joints13.2 13.5 12.70 16.6 16.0 12.9 15.88 19.7 19.0 Flare tool for R410A Conventional flare toolClutch type Wing nut type Flare tool for R22 Conventional flare toolWrenches available on the market Flare Connecting Procedures and Precautions43˚ Nm kgfcmRequired Tools ToolsGeneral tools Conventional tools can be used Recharging of Refrigerant 1 Configuration of refrigerant chargingMaterials for Brazing Brazing of PipesFlux Never use gas other than Nitrogen gas BrazingIndoor Unit Construction ViewsDetailed a leg part Outdoor UnitDetailed B leg part Color Wiring DiagramIdentification Parts name Type Specifications Specifications of Electrical PartsParts name Model name Rating Refrigerant Cycle Diagram Refrigerant Cycle DiagramRAS-B13GKVP-E/RAS-13GAVP-E, RAS-B16GKVP-E/RAS-16GAVP-E Outdoor MPa T1 C T2 C Rps Temperature Standard Heat exchanger Compressor Condition COperation Data Cooling OutdoorHi-POWER Air Purifier Control Block DiagramRemote Controller Operation START/STOP Operation Mode SelectionMCC5009 P.C.B AssemblyOutdoor Unit Inverter For Indoor UnitRole of outdoor unit controller Operation DescriptionOutline of Air Conditioner Control Role of indoor unit controllerAuto Restart Function Filter IndicatorRemote Controller and Its Fuctions Operation DescriptionIndoor unit Remote controllerOutdoor unit +0.5 Cooling operationTs + +1.0+ H SymbolsIndication Fan speed + MCold draft preventive control Operation flow and applicable data, etc DescriptionHeating operation Indication Fan speedOFF status Operation command Outdoor fan controlAir conditioner Alarm Outdoor unitOutdoor temp Cooling current Heating current Release value Remote controller Indoor unitWhen temperature of the indoor Defrost operation Operation flow and applicable data, etcCase of operation stop ConditionAir direction PowerfulThis function controls the air direction of the indoor unit Louver position in cooling operationFan Cooling operationPresent status Pure button Air conditioner Operation buttonLouver*1 Fan speed *2 Operation PurposeTd value Control operation Ta sensor control Move toSH control PMV open degree control Stop by Room temp. sensorOperation mode Operation time Clean operation time Clean operationIndoor P.C. board Setting the clean operationSetting the selector switch on the main unit Setting the remote controllerWhen the unit is standby Not operating How to Set the Auto Restart FunctionWhen the unit is in operation When the system is operating Power Failure During Timer OperationHow to Turn Off Filter Indicator When the system is on stand-by not operatingParts Name of Remote Controller Display Heating operation Hi-POWER mode can not be set in Dry operationAutomatic operation Cooling operationSafety Cautions Installation ProcedureAttachment bolt arrangement of outdoor unit Optional Parts, Accessories and ToolsOptional Installation Parts Accessory and Installation PartsNew tools for R410A Applicable to R22 model Changes Installation/Servicing ToolsChanges in the product and components New tools for R410AWhen install the refrigerant pipes from the rear Installation PlaceRemote controller Mounting the installation plateWiring Connection How to connect the connecting cable When the installation plate is directly mounted on the wallElectrical Work Changing drain hose How to remove the drain capHow to remove the drain hose Die-cutting front panel slitLeft-hand connection with piping How to attach the drain capHow to attach the drain hose Case of bottom right or bottom left pipingDrainage Indoor Unit InstallationPrecautions for adding refrigerant Flaring size B Unit mm Draining the WaterRefrigerant Piping Connection Flaring Projection margin in flaring a Unit mmUse a vacuum pump Tightening ConnectionHexagonal wrench is required Packed Valve handling precautionsWiring Connection Stripping length of connecting cableGas Leak Test Auto Restart SettingHow to Set the Auto Restart Test OperationJAVP-E series insulated type HOW to Diagnose the TroublePrecautions when handling the new inverter 3DV Inverter Control circuitry has an uninsulated constructionDischarging method Do not lay the circuit board assembly flatOperation Which is not a Trouble Program Operation Confirmation of Power SupplyConfirmation of Power Voltage First ConfirmationCheck Primary JudgmentJudgment by Flashing LED of Indoor Unit Block display Description for self-diagnosis CodePress on or OFF button Self-Diagnosis by Remote Controller Check CodeHow to Use Remote Controller in Service Mode Press START/STOP button to release the service modeStatus Block distinctionAir Judgment and action Block Cause of operation RemarksBlock distinction Operation of diagnosis function Indoor Unit Including Remote Controller Judgment of Trouble by Every SymptomIs the fuse F01 blown? Is it possible to Only the indoor motor fan does not operate Primary checkInspection procedure Troubleshooting for remote controller Primary check Normal time Wiring Failure Interconnecting and Serial Signal WireInverter Assembly check Outdoor unit does not operateCheck procedure Check Code 1C Miswiring in indoor/outdoor units and 1E1C1E Operation check TroubleshootingHow to Check Whether the Air Purifier is Good or Not Conduction check of micro-switchPrimary check How to Check Whether the Minus Ion Generator is Good or NotSummarized Inner Diagnosis of Inverter Assembly How to Diagnose Trouble in Outdoor UnitDiagnosis/Process flowchart Contents Summary Inspection procedures How to Check Simply the Main PartsHow to Check the P.C. Board Indoor Unit Operating precautionsProcedure Check points Causes Check proceduresResistance value k 100 Sensor characteristic table11-9-2. P.C.BoardLayout +12V +5VPart name Part name Checking procedureIndoor Unit Other Parts OutdoorUnitCase that product is good Checking Method for Each PartTester rod Resistance value Good product CN300 SymptomPart name Procedures Remarks HOW to Replace the Main Parts12-1 Indoor Unit How to assemble the front panel How to assemble the high voltage generator Drain pan above the claws and at How to assemble the electric parts boxSecure it Raise the left side of the heat exchanger Remove the two screws used to secure Bearing baseSlightly, and remove the bearing base Secure using the fixing screw Screw Motor band Right Drain pipe Microcomputer Part name Procedure RemarksBoard layout Attachment Wear gloves for this jobOtherwise, you may injure your Hands on the parts, etcProcedure Remarks Front cabinet Detachment Some cases Disengage the four claws of the P.C. board base ProcedureTerminal block Lead connected to compressorSide cabinet left Take care to keep the 4-way valve away With a burnerHandling precaution TS sensor Suction pipe temperature sensor TE sensor outdoor heat exchanging temperature sensorShown in the above figure is Parts name Qty Remarks Part name ProcedureMCC-5009 221 43047671 Pipe, Outlet Exploded Views and Parts List13-1 Indoor Unit Part Description402 407, 408 403 404 406 410401 405 14, 15, 17, 18 104 13-3. P.C. Board Layout Applicable Models RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E Required parts for installation work RecommendationPart name ’ty Specifications/Vendor Remarks Appendix-1Part name Specifications Usage Required tools for installation workAppendix-2 Appendix-3 Cord heater installation wiring diagramPhoto / Explanatory diagram Procedure Cord heater installation work procedureAppendix-4 Used screw Screw type Quantity Appendix-5Appendix-6 Appendix-7 Appendix-8 Photo / Explanatory diagram Procedure AssemblyMaterial SGCC-Z08, Thickness 0.8t Appendix-9 Drawing of thermostat fixing plateØ3.4 burring hole Upward Ø3.4 burring hole Downward Appendix-10 Toshiba Carrier Corporation

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