Toshiba RAS-10SKV-E, RAS-10SAV-E, RAS-10SKV-A, RAS-10SAV-A User Manual

0 (0)

FILE NO. SVM-07008-1

SERVICE MANUAL

AIR CONDITIONER

SPLIT WALL TYPE

RAS-10SKV-E / RAS-10SAV-E

RAS-10SKV-A / RAS-10SAV-A

Revised May, 2007

FILE NO. SVM-07008

CONTENTS

1.

SAFETY PRECAUTIONS ..........................................................................

2

2.

SPECIFICATIONS .....................................................................................

4

3.

REFRIGERANT R410A .............................................................................

6

4.

CONSTRUCTION VIEWS ........................................................................

14

5.

WIRING DIAGRAM ..................................................................................

16

6.

SPECIFICATIONS OF ELECTRICAL PARTS .........................................

18

7.

REFRIGERANT CYCLE DIAGRAM ........................................................

20

8.

CONTROL BLOCK DIAGRAM ................................................................

22

9.

OPERATION DESCRIPTION ...................................................................

24

10.

INSTALLATION PROCEDURE ................................................................

47

11.

HOW TO DIAGNOSE THE TROUBLE ......................................................

59

12.

HOW TO REPLACE THE MAIN PARTS ...................................................

79

13.

EXPLODED VIEWS AND PARTS LIST ...................................................

89

– 1 –

FILE NO. SVM-07008

1. SAFETY PRECAUTIONS

For general public use

Power supply cord of outdoor unit shall be more than 1.5 mm2 (H07RN-F or 60245IEC66) polychloroprene sheathed flexible cord.

Read this “SAFETY PRECAUTIONS” carefully before servicing.

The precautions described below include the important items regarding safety. Observe them without fail.

After the servicing work, perform a trial operation to check for any problem.

Turn off the main power supply switch (or breaker) before the unit maintenance.

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 of refrigerant R22. Accompanied with the adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type refrigerant R410A air conditioner circuit.

To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port on main unit and installation tools are different from those used for 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. Moreover, do not use the existing piping because there are some problems with pressure fittings and possible impurities in existing piping.

CAUTION

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY

This appliance must be connected to the main power supply by a circuit breaker or a switch with a contact separation of at least 3 mm.

DANGER

ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO INSTALL/MAINTAIN THE AIR CONDITIONER.

INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE.

TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

DANGER: HIGH VOLTAGE

The high voltage circuit is incorporated.

Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand.

CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED, ELECTRIC PARTS MAY BE DAMAGED.

CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND INSTALLATION. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

2 –

FILE NO. SVM-07008

DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC.

WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL BECOME ABNORMALLY HIGH AND IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES.

IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE WORK AND THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY RESULT.

WARNING

Never modify this unit by removing any of the safety guards or bypass any of the safety interlock switches.

Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls.

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 generate.

The electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive circuit.

An insufficient circuit capacity or inappropriate installation may cause fire.

When wiring, use the specified cables and connect the terminals securely to prevent external forces applied to the cable from affecting the terminals.

Be sure to provide grounding.

Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.

Conform to the regulations of the local electric company when wiring the power supply.

Inappropriate grounding may cause electric shock.

CAUTION

Exposure of unit to water or other moisture before installation may result in an electrical short. Do not store in a wet basement or expose to rain or water.

Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise level of the unit or where noise or discharged air might disturb neighbors.

To avoid personal injury, be careful when handling parts with sharp edges.

Perform the specified installation work to guard against an earthquake.

If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.

For Reference:

If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.

It is recommended to procure an antifreeze heater locally for a safe installation of the air conditioner.

For details, contact the dealer.

– 3 –

 

 

 

 

2. SPECIFICATIONS

FILE NO. SVM-07008

 

 

 

 

 

 

2-1. Specifications

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit model

Indoor

 

 

 

RAS-10SKV-E, RAS-10SKV-A

 

 

Outdoor

 

 

 

RAS-10SAV-E, RAS-10SAV-A

 

Cooling capacity

 

 

 

(kW)

 

2.5

 

Cooling capacity range

 

 

(kW)

 

1.1 - 3.0

 

Heating capacity

 

 

 

(kW)

 

3.2

 

Heating capacity range

 

 

(kW)

 

0.9 - 4.1

 

Power supply

 

 

 

 

 

1Ph/50Hz/220-240V

 

Electric

Indoor

Operation mode

 

Cooling

 

Heating

 

characteristic

 

Running current

(A)

0.16 - 0.14

 

0.16 - 0.14

 

 

 

Power consumption

(W)

30

 

30

 

 

 

Power factor

 

(%)

87

 

87

 

 

Outdoor

Operation mode

 

Cooling

 

Heating

 

 

 

Running current

(A)

3.44 - 3.16

 

3.96- 3.63

 

 

 

Power consumption

(W)

720

 

830

 

 

 

Power factor

 

(%)

95

 

95

 

 

 

Starting current

(A)

 

4.12 - 3.77

 

COP (Cooling / Heating)

 

 

 

 

3.33/3.72

 

Operating

Indoor

High

(Cooling / Heating)

(dB-A)

 

38/40

 

noise

 

Medium

(Cooling / Heating)

(dB-A)

 

33/35

 

 

 

Low

(Cooling / Heating)

(dB-A)

 

29/30

 

 

Outdoor

 

(Cooling / Heating)

(dB-A)

 

48/50

 

Indoor unit

Unit model

 

 

 

RAS-10SKV-E, RAS-10SKV-A

 

 

Dimension

Height

 

(mm)

 

250

 

 

 

Width

 

(mm)

 

740

 

 

 

Depth

 

(mm)

 

195

 

 

Net weight

 

 

(kg)

 

8

 

 

Fan motor output

 

 

(W)

 

20

 

 

Air flow rate

 

(Cooling / Heating)

(m3 / min)

 

8.7/9.6

 

Outdoor unit

Unit model

 

 

 

RAS-10SAV-E, RAS-10SAV-A

 

 

Dimension

Height

 

(mm)

 

530

 

 

 

Width

 

(mm)

 

660

 

 

 

Depth

 

(mm)

 

240

 

 

Net weight

 

 

(kg)

 

29

 

 

Compressor

Motor output

 

(W)

 

750

 

 

 

Type

 

 

Single rotary type with DC-inverter variable speed control

 

 

 

Model

 

 

 

DA89X1C-23FZ

 

 

Fan motor output

 

 

(W)

 

20

 

 

Air flow rate

 

(Cooling / Heating)

(m3 / min)

 

27/27

 

Piping

Type

 

 

 

 

Flare connection

 

connection

Indoor unit

Liquid side

 

(mm)

 

6.35

 

 

 

Gas side

 

(mm)

 

9.52

 

 

Outdoor unit

Liquid side

 

(mm)

 

6.35

 

 

 

Gas side

 

(mm)

 

9.52

 

 

Maximum length

 

 

(m)

 

10

 

 

Maximun charge-less length

 

(m)

 

10

 

 

Maximum height difference

 

(m)

 

8

 

Refrigerant

Name of refrigerant

 

 

 

 

R410A

 

 

Weight

 

 

(kg)

 

0.63

 

Wiring

 

Power supply

 

 

3 Wires: Includes earth (Outdoor)

 

connection

 

Interconnection

 

 

4 Wires: Includes earth

 

Usable temperature range

Indoor

(Cooling / Heating)

(oC)

 

21 - 32/Up to 27

 

 

 

Outdoor

(Cooling / Heating)

(oC)

 

15 - 43/-10 - 24

 

Accessory

Indoor unit

Installation plate

 

 

1

 

 

 

Wireless remote controller

 

 

1

 

 

 

batteries

 

 

 

2

 

 

 

Remote controller holder

 

 

1

 

 

 

Super Oxi Deo filter

 

 

1

 

 

 

Super Sterilizer filter

 

 

1

 

 

 

Mounting screw

 

 

6 ( 4 x 25L)

 

 

 

Pan head wood screw

 

 

2 ( 3.1 x 16L)

 

 

 

 

 

 

 

 

 

 

Plasma air purifier

 

 

-

 

 

 

Installation manual

 

 

1

 

 

 

Owner's manual

 

 

1

 

 

Outdoor unit

Drain nipple

 

 

 

1

 

 

 

Water proof rubber cap

 

 

-

* The specification may be subject to change without notice for purpose of improvement.

– 4 –

FILE NO. SVM-07008

2-2. Operation Characteristic Curve

<Cooling>

 

 

 

 

 

 

 

 

 

 

 

 

<Heating>

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

(A)

 

 

 

 

 

 

 

 

 

 

 

 

 

(A)

 

 

 

 

 

 

 

 

 

 

 

 

 

Current

3

 

 

 

 

 

 

 

 

 

 

 

 

Current

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Conditions

 

 

 

 

 

 

 

 

 

 

 

Conditions

 

 

 

 

 

1

 

 

 

 

 

 

 

Indoor : DB 27oC/WB 19oC

 

 

1

 

 

 

 

 

 

Indoor : DB 20oC

 

 

 

 

 

 

 

 

 

 

 

Outdoor : DB 35oC

 

 

 

 

 

 

 

 

 

Outdoor : DB 7oC/WB 6oC

 

 

 

 

 

 

 

 

 

 

Air Flow : High

 

 

 

 

 

 

 

 

 

 

 

Air Flow : High

 

 

 

 

 

 

 

 

 

 

 

 

Pip Length : 5m

 

 

 

 

 

 

 

 

 

 

Pip Length : 5m

 

 

 

 

 

 

 

 

 

 

 

 

Voltage : 230V

 

 

 

 

 

 

 

 

 

 

 

Voltage : 230V

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

0

10

20

30

40

50

60

70

80

90

100

110

120

 

0

10

20

30

40

50

60

70

80

90

100

110

120

Compressor Speed (rps)

Compressor Speed (rps)

2-3. Capacity Variation Ratio According to Temperature

 

 

 

 

<Cooling>

 

 

 

 

 

 

 

 

 

 

 

<Heating>

 

 

 

 

 

105

 

 

 

 

 

 

 

 

 

 

 

 

120

 

 

 

 

 

100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

95

 

 

 

 

 

 

 

 

 

 

 

 

100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

90

 

 

 

 

 

 

 

 

 

 

 

(%)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(%)

85

 

 

 

 

 

 

 

 

 

 

 

ratio

80

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CapacityCoolingratio

80

 

 

 

 

 

 

 

 

 

 

 

CapacityHeating

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

60

 

 

 

 

 

75

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

70

 

 

 

 

 

 

 

 

 

 

 

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

65

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

60

 

 

Capacity ratio: 100%

Conditions

 

 

 

 

20

 

Conditions

 

 

 

 

 

 

2.5kW (RAS-10SKV-E)

Indoor : DB 27oC/WB 19oC

 

 

 

Indoor : DB 20oC

 

 

 

55

 

 

2.5kW (RAS-10SKV-A)

Indoor Air Flow : High

 

 

 

 

 

Indoor Air Flow : High

 

 

 

 

 

 

 

 

 

Pip Length : 5m

 

 

 

 

 

Pip Length : 5m

 

 

 

 

 

 

 

 

 

 

Voltage : 230V

 

 

 

 

 

Voltage : 230V

 

 

 

50

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

32

33

34

35

36

37

38

39

40

41

42

43

 

-10

-5

0

5

10

 

 

 

 

Outside Temperature ( oC)

 

 

 

 

 

 

Outside Temperature ( ºC)

 

 

– 5 –

FILE NO. SVM-07008

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 refrigerating 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 materials 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 conditioner 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 refrigeration cycle. Otherwise, pressure in the refrigeration 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 pressure 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.

– 6 –

FILE NO. SVM-07008

Table 3-2-1 Thicknesses of annealed copper pipes

 

 

 

Thickness (mm)

 

 

 

 

Nominal diameter

Outer diameter (mm)

R410A

R22

 

 

 

 

1/4

6.35

0.80

0.80

 

 

 

 

3/8

9.52

0.80

0.80

 

 

 

 

1/2

12.70

0.80

0.80

 

 

 

 

5/8

15.88

1.00

1.00

 

 

 

 

2.Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a)Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-2-6 below.

b)Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm.

Thicknesses of socket joints are as shown in Table 3-2-2.

Table 3-2-2 Minimum thicknesses of socket joints

Nominal diameter

Reference outer diameter of

Minimum joint thickness

copper pipe jointed (mm)

(mm)

 

 

 

 

1/4

6.35

0.50

 

 

 

3/8

9.52

0.60

 

 

 

1/2

12.70

0.70

 

 

 

5/8

15.88

0.80

 

 

 

3-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil than lubricating oils used in the installed air-water heat pump is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

1.Flare processing procedures and precautions

a)Cutting the Pipe

By means of a pipe cutter, slowly cut the pipe so that it is not deformed.

b)Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation.

c)Insertion of Flare Nut

– 7 –

FILE NO. SVM-07008

d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perform the flare processing correctly.

Use either a flare tool for R410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

ØD

A

Fig. 3-2-1 Flare processing dimensions

Table 3-2-3 Dimensions related to flare processing for R410A

 

Outer

 

 

 

A (mm)

 

 

 

 

 

 

 

Nominal

Thickness

 

 

 

diameter

Flare tool for R410A

Conventional flare tool

diameter

(mm)

(mm)

 

 

 

 

 

clutch type

Clutch type

Wing nut type

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4

6.35

0.8

 

0 to 0.5

1.0 to 1.5

1.5 to 2.0

 

 

 

 

 

 

 

3/8

9.52

0.8

 

0 to 0.5

1.0 to 1.5

1.5 to 2.0

 

 

 

 

 

 

 

1/2

12.70

0.8

 

0 to 0.5

1.0 to 1.5

2.0 to 2.5

 

 

 

 

 

 

 

5/8

15.88

1.0

 

0 to 0.5

1.0 to 1.5

2.0 to 2.5

 

 

 

 

 

 

 

 

Table 3-2-4 Dimensions related to flare processing for R22

 

 

 

 

 

 

 

 

 

Outer

 

 

 

A (mm)

 

 

 

 

 

 

 

Nominal

Thickness

 

 

 

diameter

Flare tool for R22

Conventional flare tool

diameter

(mm)

(mm)

 

 

 

 

 

clutch type

Clutch type

Wing nut type

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4

6.35

0.8

 

0 to 0.5

0.5 to 1.0

1.0 to 1.5

 

 

 

 

 

 

 

3/8

9.52

0.8

 

0 to 0.5

0.5 to 1.0

1.0 to 1.5

 

 

 

 

 

 

 

1/2

12.70

0.8

 

0 to 0.5

0.5 to 1.0

1.5 to 2.0

 

 

 

 

 

 

 

5/8

15.88

1.0

 

0 to 0.5

0.5 to 1.0

1.5 to 2.0

 

 

 

 

 

 

 

Table 3-2-5 Flare and flare nut dimensions for R410A

Nominal

Outer diameter

Thickness

 

Dimension (mm)

 

Flare nut width

 

 

 

 

 

 

diameter

(mm)

(mm)

A

 

B

C

 

D

(mm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4

6.35

0.8

9.1

 

9.2

6.5

 

13

17

 

 

 

 

 

 

 

 

 

 

3/8

9.52

0.8

13.2

 

13.5

9.7

 

20

22

 

 

 

 

 

 

 

 

 

 

1/2

12.70

0.8

16.6

 

16.0

12.9

 

23

26

 

 

 

 

 

 

 

 

 

 

5/8

15.88

1.0

19.7

 

19.0

16.0

 

25

29

 

 

 

 

 

 

 

 

 

 

– 8 –

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FILE NO. SVM-07008

 

 

Table 3-2-6 Flare and flare nut dimensions for R22

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Nominal

Outer diameter

 

 

 

Thickness

 

 

Dimension (mm)

 

 

 

 

 

Flare nut width

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

diameter

 

(mm)

 

 

 

 

 

 

 

 

(mm)

 

A

 

B

 

C

 

D

(mm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/4

6.35

 

 

 

 

 

 

0.8

 

9.0

 

9.2

6.5

 

 

13

17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/8

9.52

 

 

 

 

 

 

0.8

 

13.0

 

13.5

9.7

 

 

20

22

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/2

12.70

 

 

 

 

 

 

0.8

 

16.2

 

16.0

12.9

 

 

20

24

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/8

15.88

 

 

 

 

 

 

1.0

 

19.7

 

19.0

16.0

 

 

23

27

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3/4

19.05

 

 

 

 

 

 

1.0

 

23.3

 

24.0

19.2

 

 

34

36

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to

46˚

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

45˚

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

A

 

 

 

 

 

 

 

 

 

 

 

C

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

43˚

to

 

 

 

 

 

 

 

45˚

Fig. 3-2-2 Relations between flare nut and flare seal surface

2.Flare Connecting Procedures and Precautions

a)Make sure that the flare and union portions do not have any scar or dust, etc.

b)Correctly align the processed flare surface with the union axis.

c)Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 3-2-7 shows reference values.

NOTE :

When applying oil to the flare surface, be sure to use oil designated by the manufacturer.

If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

Table 3-2-7 Tightening torque of flare for R410A [Reference values]

Nominal

Outer diameter

Tightening torque

Tightening torque of torque

wrenches available on the market

diameter

(mm)

N•m (kgf•cm)

N•m (kgf•cm)

 

 

 

 

 

 

 

1/4

6.35

14 to 18 (140 to 180)

16 (160), 18 (180)

 

 

 

 

3/8

9.52

33 to 42 (330 to 420)

42 (420)

 

 

 

 

1/2

12.70

50 to 62 (500 to 620)

55 (550)

 

 

 

 

5/8

15.88

63 to 77 (630 to 770)

65 (650)

 

 

 

 

– 9 –

FILE NO. SVM-07008

3-3. Tools

3-3-1. Required Tools

The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

1.Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))

2.Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)

3.Tools commonly used for R410A and for conventional refrigerant (R22)

The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

 

 

 

R410A

Conventional air-water

 

 

 

air-water heat pump installation

heat pump installation

No.

Used tool

Usage

 

 

 

Existence of

Whether conven-

Whether new equipment

 

 

 

 

 

 

new equipment

tional equipment

can be used with

 

 

 

for R410A

can be used

conventional refrigerant

 

 

 

 

 

 

1

Flare tool

Pipe flaring

Yes

*(Note 1)

°

 

 

 

 

 

 

 

Copper pipe gauge for

Flaring by

 

*(Note 1)

*(Note 1)

2

adjusting projection

Yes

conventional flare tool

 

margin

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

Torque wrench

Connection of flare nut

Yes

×

×

(For Ø12.7)

 

 

 

 

 

 

4

Gauge manifold

Evacuating, refrigerant

Yes

×

×

 

 

5

Charge hose

charge, run check, etc.

 

 

 

 

 

 

 

 

 

 

6

Vacuum pump adapter

Vacuum evacuating

Yes

×

°

7

Electronic balance for

Refrigerant charge

Yes

×

°

refrigerant charging

 

 

 

 

 

 

8

Refrigerant cylinder

Refrigerant charge

Yes

×

×

9

Leakage detector

Gas leakage check

Yes

×

°

10

Charging cylinder

Refrigerant charge

(Note 2)

×

×

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

1.Vacuum pump

Use vacuum pump by attaching vacuum pump adapter.

2.Torque wrench (For Ø6.35, Ø9.52)

3.Pipe cutter

4.

Reamer

9.

Hole core drill (Ø65)

5.

Pipe bender

10.

Hexagon wrench

6.

Level vial

 

(Opposite side 4mm)

7.

Screwdriver (+, –)

11.

Tape measure

 

 

8.

Spanner or Monkey wrench

12.

Metal saw

Also prepare the following equipments for other installation method and run check.

1.

Clamp meter

3.

Insulation resistance tester

2.

Thermometer

4.

Electroscope

– 10 –

FILE NO. SVM-07008

3-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.

Recover the refrigerant, and check no refrigerant remains in the equipment.

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

Connect the charge hose to the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant.

(For refrigerant charging, see the figure below.)

1.Never charge refrigerant exceeding the specified amount.

2.If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3.Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

(Water heat

(Outdoor unit)

exchanger unit)

 

Opened

Refrigerant cylinder

 

(with siphon)

 

Check valve

Opened

 

Opened

 

Open/close

Closed

valve for charging

 

 

Service port

Electronic balance for refrigerant charging

 

Fig. 3-4-1 Configuration of refrigerant charging

– 11 –

FILE NO. SVM-07008

1.Be sure to make setting so that liquid can be charged.

2.When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ]

[ Cylinder without siphon ]

Gauge manifold

Gauge manifold

OUTDOOR unit

OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

cylinder Refrigerant

Electronic

balance

Siphon

Fig. 3-4-2

3-5. Brazing of Pipes

3-5-1. Materials for Brazing

1.Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

2.Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

3.Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes.

1.Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2.When performing brazing again at time of servicing, use the same type of brazing filler.

3-5-2. Flux

1.Reason why flux is necessary

By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

In the brazing process, it prevents the metal surface from being oxidized.

By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal.

– 12 –

2.Characteristics required for flux

Activated temperature of flux coincides with the brazing temperature.

Due to a wide effective temperature range, flux is hard to carbonize.

It is easy to remove slag after brazing.

The corrosive action to the treated metal and brazing filler is minimum.

It excels in coating performance and is harmless to the human body.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

3.Types of flux

Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 800°C.

Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

4.Piping materials for brazing and used brazing filler/flux

Piping material

Used brazing filler

Used flux

 

 

 

Copper - Copper

Phosphor copper

Do not use

 

 

 

Copper - Iron

Silver

Paste flux

 

 

 

Iron - Iron

Silver

Vapor flux

 

 

 

1.Do not enter flux into the refrigeration cycle.

2.When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine.

3.When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

4.Remove the flux after brazing.

FILE NO. SVM-07008

3-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitrogen gas.

1.Brazing method to prevent oxidation

1)Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2)Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3)Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4)When the Nitrogen gas is flowing, be sure to keep the piping end open.

5)Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 MPa (0.2kgf/cm2) by means of the reducing valve.

6)After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7)Remove the flux completely after brazing.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe Nitrogen gas

Rubber plug

Fig. 3-5-1 Prevention of oxidation during brazing

– 13 –

FILE NO. SVM-07008

4. CONSTRUCTION VIEWS

4-1. Indoor Unit

Front panel

Air inlet

Air filter

Heat exchanger

 

 

740

195

250

52

60

8

Air outlet

Knock out system

50

 

 

 

50

55

60

 

60

55

 

 

 

105

500

135

 

58

8

Knock out system

Drain hose (0.5m)

 

290

 

Hanger

 

 

 

605

 

 

235

 

 

215

45

 

 

250

 

 

 

 

Hanger

90

135

145

Connecting pipe (0.37m)

(Flare 6.35)

Connecting pipe (0.37m) (Flare 9.52)

235

215 Hanger

Hanger 145 135

For stud bold (

8~ 10)

 

For stud bold (

6)

 

26

 

 

45

 

 

165

 

157

40

56

19

38

Wireless remote control

90

Installation plate outline

Center line

– 14 –

Toshiba RAS-10SKV-E, RAS-10SAV-E, RAS-10SKV-A, RAS-10SAV-A User Manual

FILE NO. SVM-07008

4-2. Outdoor Unit

C

L

C

L

15

FILE NO. SVM-07008

5. WIRING DIAGRAM

5-1. Indoor Unit

– 16 –

FILE NO. SVM-07008

5-2. Outdoor Unit

– 17 –

 

 

 

FILE NO. SVM-07008

 

6. SPECIFICATION OF ELECTRICAL PARTS

6-1. Indoor Unit

 

 

 

 

 

 

No.

Parts name

Type

Specifications

 

 

 

 

1

Fan motor (for indoor)

AFS-220-20-4AR

AC Motor with 145°C thermo fuse

 

 

 

 

2

Thermo. sensor (TA-sensor)

 

10 kΩ at 25°C

 

 

 

 

3

Micro power module (T101)

μRM1260V

 

4

Microcontroller unit (IC81)

μPD780076GK-703-9ET-A

 

5

Heat exchanger sensor

 

10 kΩ at 25°C

 

(TC-sensor)

 

 

 

 

 

 

 

 

6

Line filter (L01)

SS11V-R06270

27 mH, AC 0.6A

 

 

 

 

7

Diode (D01,D02,D03 and D04)

S5688J

 

 

 

 

 

8

Capacitor (C03)

EKMH401VSN470MP20S

47μF, 400V

9

Fuse (F01)

FJL250V3.15A

3.15A, 250 V

 

 

 

 

10

Regulator IC (IC12)

S7805PIC

5VDC, 0.5A

 

 

 

 

11

Varistor (R21)

TNR10V471K-T8

470V

12

Louver motor

24BYJ48

DC 12V

 

 

 

 

– 18 –

 

 

 

 

 

FILE NO. SVM-07008

6-2. Outdoor Unit (RAS-10SAV-E, RAS-10SAV-A)

 

 

 

 

 

 

 

 

No.

Parts name

 

Model name

Rating

 

 

 

 

 

 

 

1

SC coil

 

L01

GET-0451

0.6mH, 15A

 

 

 

 

 

 

 

 

(Noise filter)

 

L03

GET-0452

2.0 mH, 10A

 

 

 

 

 

 

 

2

DC-DC transformer

 

SWT-72

Primary side DC280V, Secondary

 

 

 

 

 

side 7.0 V x 1, 12 V x 1, 17V x 2

3

Reactor

 

CH-51-Z-T

L=19mH, 10A

 

 

 

 

 

4

Outside fan motor

 

SKF-240-20B-1

20W

5

Fan control relay

 

G5NB-1A

Coil DC12V Contact AC250V-1.5A

 

 

 

 

 

 

 

6

Outside air temp.

 

(Inverter attached)

10kΩ (25°C)

 

sensor (TO sensor)

 

 

 

 

7

Heat exchanger temp.

(Inverter attached)

10kΩ (25°C)

 

sensor (TE sensor)

 

 

 

 

8

Dischenge temp.

 

(Inverter attached)

62kΩ (20°C)

 

sensor (TD sensor)

 

 

 

 

 

 

 

 

 

 

9

Terminal block (6P)

 

JX0-6B

20A, AC250V

 

 

 

 

 

 

 

10

Fuse

 

For protection of switching power source

3.15A, AC250V

 

 

 

 

 

For protection of inverter input overcurrent

25A, AC250V

 

 

 

 

 

 

 

 

 

 

11

Electrolytic capacitor

 

LLQ2G501KHUBTF

500μF, DC 400 V x 3 pieces

12

IGBT

 

GT15J321

15A, 600

 

 

 

 

 

 

13

Compressor

 

DA89X1C-23FZ

3-phases 4-poles 750W

14

Compressor thermo.

 

PW-2AL

OFF: 125 ± 4°C, ON: 90 ± 5°C

15

Rectifier

 

D15XB60-4001

15A, 600V

 

 

 

 

 

 

16

4-way valve coil

 

AC220-240V

 

 

 

 

 

 

17

Running capacitor

 

DS451155NPQB

AC 450V~, 1.5μF

 

(for fan motor)

 

 

 

 

 

 

 

 

 

 

 

– 19 –

FILE NO. SVM-07008

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

RAS-10SKV-E / RAS-10SAV-E RAS-10SKV-A / RAS-10SAV-A

P Pressure measurement

Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe

Outer dia. : 9.52mm

Thickness : 0.8mm

INDOOR UNIT

T1

Temp. measurement

 

 

 

 

Indoor heat

 

 

 

exchanger

 

 

 

 

TC

heightAllowable 10m:difference

lengthpipeAllowable

Cross flow fan

TA

 

 

Deoxidized copper pipe

 

 

Outer dia. : 6.35mm

 

 

Thickness : 0.8mm

 

 

 

Sectional shape

 

 

 

of heat insulator

 

 

 

Max. : 10m

Min. : 1m

Chargeless : 10m

Muffler

4-way valve (STF-0108Z)

 

Muffler

 

 

TD

 

 

Compressor

 

 

DA89X1C-23FZ

 

 

TO

 

 

Outdoor heat

 

 

exchanger

Ø1.0 x 600

 

 

Temp. measurement T2

 

Ø1.0 x 600

 

 

 

T E

 

Propeller fan

 

Refrigerant amount : 0.63kg

OUTDOOR UNIT

NOTE :

 

Gas leak check position

 

 

 

Refrigerant flow (Cooling)

 

 

 

 

 

 

Refrigerant flow (Heating)

NOTE :

The maximum pipe length of this air conditioner is 10 m. The addition charging of refrigevant is unnecessary because this air condition is design with charge-less specitication.

20 –

FILE NO. SVM-07008

7-2. Operation Data

<Cooling>

Tempeature

Model name

Standard

Heat exchanger

Indoor

Outdoor

Compressor

condition(°C)

RAS-

pressure

pipe temp.

fan mode

fan mode

revolution

Indoor

Outdoor

 

P (MPa)

T1 (°C)

T2 (°C)

 

 

(rps)

27/19

35/-

10SKV-E

0.9 to 1.1

9 to 11

47 to 49

High

High

54

 

 

10SKV-A

 

 

 

 

 

 

 

 

<Heating>

Tempeature

Model name

Standard

Heat exchanger

Indoor

Outdoor

Compressor

condition(°C)

RAS-

pressure

pipe temp.

fan mode

fan mode

revolution

Indoor

Outdoor

 

P (MPa)

T1 (°C)

T2 (°C)

 

 

(rps)

20/-

7/6

10SKV-E

2.4 to 2.6

43 to 45

0 to 3

High

High

68

 

 

10SKV-A

 

 

 

 

 

 

 

 

NOTES :

1.Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent. (Thermistor themometer)

2.Connecting piping condition : 5 m

– 21 –

FILE NO. SVM-07008

8. CONTROL BLOCK DIAGRAM

8-1. Indoor Unit

Indoor Unit Control Panel

 

 

 

 

 

 

 

 

 

 

 

 

 

M.C.U

 

 

 

 

 

 

 

 

 

 

 

Functions

 

 

 

 

Heat Exchanger Sensor

 

 

 

 

 

 

Operation

 

 

 

 

 

 

 

 

 

 

 

 

Louver Control

 

 

Display

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Timer

 

Temperature Sensor

 

 

 

 

3-minute Delay at Restart for Compressor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Motor Revolution Control

 

 

Display

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Infrared Rays Signal Receiver

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Infrared

 

Initiallizing Circuit

 

 

 

Processing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Temperature Processing)

 

 

 

 

Rays

 

Clock Frequency

 

 

 

 

Timer

 

 

Indoor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fan Motor

 

36.7KHz

 

Oscillator Circuit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Serial Signal Communication

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Power Supply

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remote

Circuit

 

 

 

 

 

 

 

Louver ON/OFF Signal

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Noise Filter

 

 

 

 

 

 

 

Louver Driver

 

 

Louver Motor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Serial Signal Transmitter/Receiver

From Outdoor Unit

Serial Signal Communication

REMOTE CONTROL

Infrared Rays

Remote Control

Operation ()

Operation Mode Selection

AUTO, COOL, DRY, HEAT, FAN ONLY

Temperature Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECO

Hi power

Filter Reset

One Touch

– 22 –

FILE NO. SVM-07008

8-2. Outdoor Unit (Inverter Assembly)

Compressor

MICRO-COMPUTERBLOCKDIAGRAM

P.C.B(MCC5009)

For INDOOR UNIT

Inverter

(DC AC)

Gatedrive circuit

Rotorposition detectcircuit

Over

current

sensor

 

Input Converter

current (AC DC) sensor

Highpowerfactor correctioncircuit

M.C.U

1.PWMsynthesisfunction 2.Inputcurrentreleasecontrol 3.IGBTover-currentdetectcontrol 4.Outdoorfancontrol 5.Highpowerfactorcorrectioncontrol 6.SignalcommunicationtoindoorunitM.C.U

Noise

filter

 

 

 

1

230V50Hz

signal

Discharge temp. sensor

Outdoor air temp. sensor

Relay

Fan motor

Relay

4way Valve

Heat Exchanger temp. sensor

– 23 –

FILE NO. SVM-07008

9. OPERATION DESCRIPTION

9-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses AC motor both the indoor

fan motor and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 22 to 83 rps is mounted. The AC motor drive circuit is mounted to the

indoor unit. The compressor and the inverter is mounted to the outdoor unit.

The entire air conditioner is mainly controlled by the indoor unit controller.

The indoor unit controller drives the indoor fan motor based upon command sent from the remote controller, and transfers the operation command to the outdoor unit controller.

The outdoor unit controller receives operation command from the indoor unit side, and controls the

outdoor fan motor. Besides detecting revolution position

of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling

output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors

drive according to the operation command.

And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller.

As the compressor adopts four -pole brushless DC motor , the frequency of the supply power from in verter to compressor is two-times cycles of the actual number of revolution.

1. Role of indoor unit controller

The indoor unit controller judges the operation commands from the remote controller and assumes the following functions.

Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor. (TA sensor)

Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor) (Prevent-freezing control, etc.)

Louver motor control

Indoor fan motor operation control

LED (Light Emitting Diode) display control

Transferring of operation command signal (Serial signal) to the outdoor unit

Reception of information of operation status (Serial signal including outside temp. data) to the outdoor unit and judgment/display of error

2.Role of outdoor unit controller

Detection of inverter input current and current release operation

Over-current detection and prevention operation to IGBT module (Compressor stop function)

Compressor and outdoor fan stop function when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system)

Transferring of operation information (Serial signal) from outdoor unit controller to indoor unit controller

Detection of outdoor temperature and operation revolution control

Defrost control in heating operation (Temp. measurement by outdoor heat exchanger and control for 4-way valve and outdoor fan)

3.Contents of operation command signal (Serial signal) from indoor unit controller to outdoor unit controller

The following three types of signals are sent from the indoor unit controller.

Operation mode set on the remote controller

Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.)

Temperature of indoor heat exchanger

For these signals ([Operation mode] and [Compressor revolution] indoor heat exchanger temperature), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value.

4.Contents of operation command signal (Serial signal) from outdoor unit controller to indoor unit controller

The following signals are sent from the outdoor unit controller.

The current operation mode

The current compressor revolution

Outdoor temperature

Existence of protective circuit operation

For transferring of these signals, the indoor unit controller monitors the contents of signals, and judges existence of trouble occurrence.

Contents of judgment are described below.

Whether distinction of the current operation status meets to the operation command signal

Whether protective circuit operates

Receiving the operation command signal (Serial signal) from the indoor unit controller, the outdoor

unit performs its role.

 

 

When no signal is received from the outdoor unit controller, it is assumed as a trouble.

Compressor operation control

.

 

Operations followed to judgment

4-way valve control

of serial signal from indoor side

24

 

 

FILE NO. SVM-07008

9-2.

Operation Description

 

 

1.

Basic operation ...........................................................................................................

26

 

 

1. Operation control ...................................................................................................

26

 

 

2. Cooling/Heating operation .....................................................................................

27

 

 

3. AUTO operation .....................................................................................................

27

 

 

4. DRY operation ........................................................................................................

27

 

2.

Indoor fan motor control .............................................................................................

28

 

3.

Capacity control ..........................................................................................................

30

 

4.

Current release control ...............................................................................................

30

 

5.

Release protective control by temperature of indoor heat exchanger........................

31

 

6.

Defrost control (Only in heating operation) ................................................................

32

 

7.

Louver control .............................................................................................................

33

 

 

1) Louver position .......................................................................................................

33

 

 

2) Air direction adjustment .........................................................................................

33

 

 

3) Swing .....................................................................................................................

33

 

8.

ECO operation ............................................................................................................

34

 

9.

Temporary operation ...................................................................................................

35

 

10.

Discharge temperature control ...................................................................................

35

 

11.

Self-Cleaning function ................................................................................................

36

 

12.

Selt-Cleaning function release ...................................................................................

37

 

13.

Remote-A or B selection ............................................................................................

38

 

14.

QUIET mode .............................................................................................................

39

 

15.

COMFORT SLEEP mode .........................................................................................

39

 

16.

One-Touch Comfort ..................................................................................................

39

 

17.

Hi-POWER Mode ......................................................................................................

40

9-3.

Auto Restart Function................................................................................................

41

 

9-3-1. How to Set the Auto Restart Function .............................. ........................................

41

 

9-3-2. How to Cancel the Auto Restart Function ................................................................

42

 

9-3-3. Power Failure During Timer Operation ...................................................................

43

9-4. Remote Controller and Its Fuctions ....................................................................

44

 

9-4-1. Parts Name of Remote Controller .............................................................................

44

 

9-4-2.

Operation of remote control ......................................................................................

44

 

9-4-3. Name and Functions of Indications on Remote Controller .......................................

45

25

FILE NO. SVM-07008

9-2. Operation Description

Item

Operation flow and applicable data, etc.

Description

1. Basic 1. Operation control

operation

Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are controlled.

1)The operation conditions are selected by the remote controller as shown in the below.

2)A signal is sent by ON button of the remote controller.

3)The signal is received by a sensor of the indoor unit and processed by the indoor controllers as shown in the below.

4)The indoor controller controls the indoor fan motor and louver motor.

5)The indoor controller sends the operation command to the outdoor controller, and sends/receives the control status with a serial signal.

6)The outdoor controller controls the operation as shown in the left, and also controls the compressor, outdoor fan motor and 4-way valve.

Remote controller

Selection of operation conditions

ON/OFF

Control contents of remote controller

ON/OFF (Air conditioner)

Operation select (COOL/HEAT/AUTO/DRY)

Temperature setup

Air direction

Swing

Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH)

• ECO

COMFORT SLEEP

• ON timer setup

QUIET

• OFF timer setup

PRESET

• Hi POWER

ONE-TOUCH

Indoor unit

 

 

 

 

 

 

 

 

Signal receiving

 

Indoor unit control

 

 

 

 

 

 

 

 

 

 

 

 

• Command signal generating function of

 

 

 

Indoor unit control

 

indoor unit operation

 

• Indoor fan motor

 

 

• Calculation function (temperature calculation)

 

 

 

 

 

 

 

 

 

 

 

• Louver motor

 

 

 

 

• Activation compensation function of indoor fan

 

 

Operation command

 

 

 

 

 

• Cold draft preventive function

 

 

 

 

 

 

 

 

 

 

 

 

• Timer function

 

 

 

Serial signal send/receive

 

• Indoor heat exchanger release control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Outdoor unit

 

~

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Serial signal send/receive

 

Outdoor unit control

Inverter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Frequency control of inverter output

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Outdoor unit control

 

• Waveform composite function

 

 

 

 

 

 

 

 

 

 

 

 

• Calculation function

 

 

 

• Compressor

 

 

 

 

 

 

 

 

 

 

 

 

 

(Temperature calculation)

 

 

 

• Outdoor fan motor

 

 

 

 

 

 

• AD conversion function

 

 

 

 

 

 

 

 

 

 

 

 

• 4-way valve

 

 

 

 

 

 

• Quick heating function

 

 

 

 

 

 

 

 

 

 

 

 

• Delay function of compressor reactivation

 

 

 

 

 

 

 

 

 

 

 

 

• Current release function

 

 

 

 

 

 

 

 

 

 

 

 

• GTr over-current preventive function

 

 

 

 

 

 

 

 

 

 

 

 

• Defrost operation function

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

26

FILE NO. SVM-07008

Item

Operation flow and applicable data, etc.

Description

1. Basic 2. Cooling/Heating operation

operation

The operations are performed in the following parts by controls according to cooling/heating conditions.

1)Receiving the operation ON signal of the remote controller, the cooling or heating operation signal starts being transferred form the indoor controller to the outdoor unit.

2)At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan motor control” and the louver according to the contents of “9. Louver control”, respectively.

3)The outdoor unit controls the outdoor fan motor, compressor and 4-way valve according to the operation signal sent from the indoor unit.

 

 

 

Operation ON

 

 

Setup of remote controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Indoor fan motor control / Louver control / Operation Hz

 

 

 

Indoor unit control

 

 

 

 

 

 

 

Control (Requierment)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sending of operation command signal

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Compressor revolution control / Outdoor fan motor control /

 

 

 

 

 

 

 

 

 

Operation Hz control (Include limit control)

 

 

 

 

 

 

 

 

 

 

 

 

Outdoor unit control

 

 

4-way valve control

 

In cooling operation: OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[

In heating operation: ON ]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. AUTO operation

 

 

 

 

 

 

 

 

1) Detects the room temperature (Ta) when

 

 

Selection of operation mode

 

 

the operation started.

 

 

 

 

2) Selects an operation mode from Ta in

 

 

As shown in the following figure, the operation starts by

 

 

 

selecting automatically the status of room temperature

 

the left figure.

 

 

(Ta) when starting AUTO operation.

 

 

3) Fan operation continues until an

 

 

*1. When reselecting the operation mode, the fan

 

 

 

 

 

 

operation mode is selected.

 

 

 

speed is controlled by the previous operation mode.

4) When AUTO operation has started

 

 

 

 

 

 

 

 

 

 

 

 

 

 

within 2 hours after heating operation

 

 

Ta

 

 

 

 

 

 

 

 

 

 

stopped and if the room temperature is

 

 

 

 

Cooling operation

 

 

20°C or more, the fan operation is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

performed with ”Super Ultra LOW” mode

 

 

Ts + 1

 

 

 

 

 

 

 

 

 

 

for 3 minutes.

 

 

 

 

Monitoring (Fan)

 

 

Then, select an operation mode.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5) If the status of compressor-OFF

 

 

Ts – 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

continues for 15 minutes the room

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heating operation

 

 

temperature after selecting an operation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

mode (COOL/HEAT), reselect an

 

 

 

 

 

 

 

 

 

 

 

 

 

 

operation mode.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4. DRY operation

 

 

 

 

 

 

 

 

1) Detects the room temperature (Ta) when

 

 

DRY operation is performed according to the difference

 

the DRY operation started.

 

 

 

 

 

 

 

between room temperature and the setup temperature as

2) Starts operation under conditions in the

 

 

shown below.

 

 

 

 

 

 

 

 

left figure according to the temperature

 

 

In DRY operation, fan speed is controlled in order to

 

 

difference between the room tempera-

 

 

 

 

ture and the setup temperature (Tsc).

 

 

prevent lowering of the room temperature and to avoid air

 

 

Setup temperature (Tsc)

 

 

flow from blowing directly to persons.

 

 

 

 

 

 

= Set temperature on remote controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[˚C]

 

 

 

 

 

 

 

 

 

 

 

(Ts) + (0.0 to 1.0)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3) When the room temperature is lower

 

 

Ta

 

 

 

 

 

 

 

L– (W5)

 

 

 

 

 

 

 

 

 

 

 

 

 

1°C or less than the setup temperature,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

turn off the compressor.

 

+1.0

 

 

 

 

 

 

(W5+W3) / 2

 

 

 

 

 

 

+0.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SUL (W3)

 

 

 

 

 

 

 

Tsc

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fan speed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

–− 27

FILE NO. SVM-07008

 

 

Item

 

 

Operation flow and applicable data, etc.

 

 

Description

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Indoor fan

<In cooling operation>

 

 

 

 

 

 

 

 

 

motor control

(This operation controls the fan speed at indoor unit side.)

 

 

* Symbols

 

 

 

 

 

 

 

 

 

 

 

 

The indoor fan (cross flow fan) is operated by the phase-

 

UH

: Ultra High

 

 

 

 

 

control induction motor. The fan rotates in 5 stages in

 

H

: High

 

 

 

 

 

MANUAL mode, and in 5 stages in AUTO mode, respec-

 

M+

: Medium+

 

 

 

 

 

tively. (Table 1)

 

 

 

 

 

M

: Medium

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L+

: Low+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L

: Low

 

 

 

 

COOL ON

 

 

 

 

 

 

 

 

 

 

L-

: Low–

 

 

 

 

 

 

 

 

 

 

 

 

 

 

UL

: Ultra Low

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fan speed setup

 

 

 

 

 

 

 

 

SUL

: Super Ultra Low

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MANUAL

 

 

 

 

* The fan speed broadly varies due

 

 

 

 

 

 

 

 

 

 

 

 

(Fig. 1)

 

 

 

 

 

 

 

 

 

 

 

 

to position of the louver, etc.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The described value indicates one

 

 

 

AUTO

 

 

 

Indication

 

Fan speed

under condition of inclining

 

 

 

 

 

 

 

L

 

 

 

W6

downward blowing.

 

 

 

 

 

 

 

 

 

 

1) When setting the fan speed to L,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L+

 

 

 

(L + M) / 2

 

 

 

 

 

 

 

 

 

 

 

L+, M, M+ or H on the remote

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M

 

 

 

W9

 

controller, the operation is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

performed with the constant

 

 

 

 

 

 

 

M+

 

 

 

(M + H) / 2

 

 

 

 

 

 

 

 

 

 

 

 

speed shown in Fig. 1.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

WC

2) When setting the fan speed to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AUTO on the remote controller,

 

 

 

 

 

 

 

 

 

 

 

 

(Fig. 2)

 

revolution of the fan motor is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

controlled to the fan speed level

 

 

 

 

 

 

 

 

 

 

 

 

 

 

shown in Fig. 2 and Table 1

 

 

Ta

 

 

 

Air volume AUTO

 

 

 

 

 

 

according to the setup tempera-

 

 

 

 

 

 

 

 

 

 

 

 

 

ture, room temperature, and heat

 

[˚C]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

exchanger temperature.

 

 

 

 

 

 

 

M+(WB)

 

 

 

 

 

 

 

+2.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+2.0

a

 

 

*3

 

*3 : Fan speed = (M + –L) x 3/4 + L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+1.5

b

 

 

*4

 

*4 : Fan speed = (M + –L) x 2/4 + L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+1.0

c

 

 

*5

 

*5 : Fan speed = (M + –L) x 1/4 + L

 

 

 

 

 

+0.5

d

 

 

 

L(W6)

 

(Linear approximation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

from M+ and L)

 

 

 

 

 

 

Tsc

e

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Table 1) Indoor fan and air flow rate

Fan speed

 

 

 

RAS-10SKV-E

level

COOL

HEAT

DRY

RAS-10SKV-A

 

 

 

 

Fan speed

Air flow rate

 

 

 

 

(rpm)

(m3/h)

WF

 

UH

 

1350

607

WE

 

H

 

1300

576

WD

UH

M+

UH

1250

554

WC

H

 

H

1200

522

WB

M+

M

M+

1120

486

WA

 

 

M

1100

468

W9

M

L+

 

1040

444

W8

 

L

 

960

402

W7

L+

L-

L+

910

376

W6

L

 

L

880

360

W5

L-

UL

L-

830

334

W4

UL

 

UL

800

318

W3

SUL

 

SUL

700

266

W2

 

SUL

 

650

239

W1

 

 

 

600

213

28

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