Toshiba RAS-07SKSX-1, RAS-09SKSX-1, RAS-07S2AX-1, RAS-09SASX-1 Service Manual

SERVICE MANUAL

AIR CONDITIONER

RAS-07SKSX-1 / RAS-07S2AX-1

FILE NO. SVM-08028

SPLIT WALL TYPE

RAS-09SKSX-1 / RAS-09SASX-1

April, 2008

CONTENTS

1. SPECIFICATIONS

2. CONSTRUCTION VIEWS

2-1 Indoor Unit
2-2 Outdoor Unit (RAS-07S2AX-1)
2-3 Outdoor Unit (RAS-09SASX-1)

3. WIRING DIAGRAM

4. SPECIFICATION OF ELECTRICAL PARTS

4-1 Indoor Unit
4-2 Outdoor Unit (RAS-07S2AX-1)
4-3 Outdoor Unit (RAS-09SASX-1)

5. REFRIGERATION CYCLE DIAGRAM

5-1 RAS-07SKSX-1 / RAS-07S2AX-1
5-2 RAS-09SKSX-1 / RAS-09SASX-1

6. CONTROL BLOCK DIAGRAM

FILE NO. SVM-08028

7. OPERATION DESCRIPTION

7-1 Outline of Air Conditioner Control
7-2 Description of Operation Circuit

Low-Temperature Limit Control

7-3
7-4 Auto Restart Function

8. INSTALLATION PROCEDURE

8-1 Safety Cautions
8-2 Installation Diagram of Indoor and Outdoor Units
8-3 Installation
8-4 Indoor Unit
8-5 Outdoor Unit
8-6 How to Set Remote Control Selector Switch
8-7 Others

9. TROUBLESHOOTING CHART

9-1 Troubleshooting Procedure
9-2 Basic Check Items
9-3 Primary Judgement
9-4 Self-Diagnosis by Remote Control (Check Code)
9-5 Troubleshooting Flowcharts
9-6 Troubleshooting for Remote Control (Including The Indoor P.C. Board)

− 1 −

10. PARTS REPLACEMENT

10-1 Indoor Unit
10-2 Outdoor Unit (RAS-07S2SX-1)

10-3 Outdoor Unit (RAS-09SASX-1)

11. EXPLODED VIEWS AND PARTS LIST

11-1

Indoor Unit (E-Parts Assy)

11-2 Indoor Unit

11-3 Outdoor Unit (RAS-07S2SX-1)
11-4 Outdoor Unit (RAS-09SASX-1)

FILE NO. SVM-08028

− 2 −

1. SPECIFICATIONS

FILE NO. SVM-08028

MO DE L

RAS-07SKSX-1 / RAS-07S2AX-1

IT E M Cooling

Capacity

Power source V 220 - 240

Power consumption kW 0.62 0.66 0.84 0.88

Power factor % 98 96 98 98

Running Indoor A 0.15

current Outdoor A 2.72 2.72 3.75 3.60
Starting current A 13 15
Moisture removal lit/h 0.5 1.2

Noise

Refrigerant

Refrigerant control Capillary tube

Interconnection

pipe

Indoor (H/M/L) dB 40/35/30 43/38/33
Outdoor dB 46 47 46 47

Name of refrigerant R22
Rated amount kg 0.58

Gas side size mm  

Connection type Flare connection

Liquid side size mm 6.35

Connection type Flare connection

Maximum length
(One way)

Maximum height
difference

kW 2.00 2.00 2.50 2.50

Phase 1

Hz 50

m

m

220V 240V 220V 240V

10

RAS-09SKSX-1 / RAS-09SASX-1

9.52

*1

5

INDOOR UNIT RAS-07SKSX-1 RAS-09SKSX-1

Height mm 250

Dimensions Width mm 740

Depth mm 185

Net weight kg

Evaporator type Finned tube

Indoor fan type Cross flow fan

High fan m3/h

Air volume

Fan motor output W 20

Air filter Honeycomb woven filter with PP frame

OUTDOOR UNIT RAS-07S2AX-1 RAS-09SASX-1

Dimensions Width mm 660

Net weight kg 25

Condenser type Finned tube

Outdoor fan type Propeller fan

Airflow volume m3/h

Fan motor output W 20 20

Compressor

Safety device

Louver type Automatic louver

Usable outdoor temperature range

Medium fan

Low fan

Height mm 530

Depth mm 240

Model PH108X1C-4DZDN2
Output W 605 780

m3/h

m3/h

1580

°C

510

430

350

1620 1720

Fuse, Overload relay

8

540

470

390

26

1640

QK164PBA

21 ~ 43

– 3 –

Note : 1

• Capacity is based on the following temperature conditions.

FILE NO. SVM-08028

Temperature

Indoor unit inlet air temperature

Outdoor unit inlet air temperature

Note : 2

*1 No need to charge extra refrigerant.

Condition

(DB) 27°C

(WB)

(DB) 35°C

(WB) 24°C

JIS C9612

Cooling

19°C

− 4 −

2. CONSTRUCTION VIEWS

FILE NO. SVM-08028

2-1. Indoor Unit

– 5 –

135

1654

Wireless remote control

2-2. Outdoor Unit

FILE NO. SVM-08028

C

L

C

L

280

− 6 −

400

3. WIRING DIAGRAM

FILE NO. SVM-08028

SINGLE PHASE

1∅220‑240V

50Hz



BRW
BLU
GRN&YEL

Heatexchanger

Heatexchanger
Sensor(TC)

Thermosensor(TA)

CN25

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

andindicationparts.

Infraredraysreceiver

WP‑017

WHI

BLK

GRN&YEL

CN01

N

1

1

22

CN03

1

1

2

2

CN12

BLU

1

1

BLU

2

2

BLU

3

3

BLU

4

4

BLU

5

5

BLU

6

6

BLU

7

7

WHI

8

8

F01

6.3A

250VAC

R62

CN31

4

C25

RY01

R63

21

3

BLK
P04

3

SG01

DSA

C26

L01

4

DB01

R64

C27

Switchingpowersupply

DC5V

Voltageregulator

12V

3

4

MCU

IC03

WP‑018

1

2

CN04

22

11

PNK

DC12V

C07

PNK

Tempfuse73C

CN07

1
22

3
44
55

CN11

1

2

3

CN10

5

33

1

WHI

1

1

1

YEL

22

YEL

3

3

3

YEL

44

YEL

55

YEL

1

GRY

2

BRW

3

WHI

5

BLK

RED

1

o

1
2
3
4
565

1
2
3
4

6

Louvermotor

ACmotor

Fanmotor

TERMINAL
BLOCK

OUTDOOR
TERMINAL
BLOCK

BLK

BLK

OVERLOAD RELAY

(L)

1

FAN MOTOR

BLK

(N)

2

RED

RED
WHI

COMPRESSOR

INDOOR

TERMINAL

CHASSIS

RED

CAPACITOR

PNK
WHI

BLOCK

1

BLK

INDOOR

OUTDOOR

CAPACITOR

GRN&YEL

2

WHI

FAN MOTOR

Type "A" Type "B"

− 7 −

FILE NO. SVM-08028

4. SPECIFICATION OF ELECTRICAL PARTS

4-1. 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) 10k at 25 C
3 Switching power supply (T01)
4 Microcontroller unit (IC30) TMP87CM40ANG-6P68
5 Heat exchanger sensor

(TC-sensor)
6 Line filter (L01) LC*SS11V-06270 27mH, 600mA
7 Bridge rectifier (DB01) DB105G 1A, 600 V
8 Capacitor (C27) EKMH401VSN470MP20S 47mF, 400 V
9 Fuse (F01) BET6.3A 6.3A, 250VAC

10 Varistor (R62, R63) SR561K14DL 560 V
11 Resistor (R64)
12 Louver motor MP24ZCT 12VDC

ST-001

RF-2TK5R6

W

W

10k at 25 C

W

5.6 , 2 W

°

°

13 Relay (Comp., RY01) G4A-1A-E-CA Rating 20A/AC250 V, 12VDC

4-2. Outdoor Unit (RAS-07S2AX-1)

Specifications

Output (Rated) 605W, 2 poles, 1 phase, 220 - 240V~, 50Hz

PH108X1C-4DZDN2 Compressor1

WLF-240-20A

(Type "A")

Fan motor (for outdoor)2

SKF-240-20B

(Type "B")

Running capacitor

3

(for fan motor)

Running capacitor

4 RS44B256U0213S

(for compressor)

DS451155NPQB

Winding resistance (Ω)
(at 20ºC) 4.84 4.40
Output (Rated) 20 W, 6 poles, 1 phase, 220 - 240 V~, 50Hz
Winding resistance (Ω)
(at 20ºC) 410 435
Output (Rated) 20 W, 6 poles, 1 phase, 220 - 240 V, 50Hz
Winding resistance (Ω)
(at 20ºC) 235.2 260.1

AC 450 V~, 1.5µF

AC 440 V~, 25µF

C-R C-S

Red-Black White-Black

Red-Black White-Black

5 Overload relay U/T : 4

JMRA99208-9102

− 8 −

.2A (80ºC), Open : 135±5ºC, Close : 69±11ºC

4-3. Outdoor Unit (RAS-09SASX-1)

z

FILE NO. SVM-08028

No. Parts name Type

Output (Rated) 780W, 2 poles, 1 phase, 220 - 240 V~, 50H

Compressor1

Fan motor (for outdoor)2

Running capacitor

3

(for fan motor)
Running capacitor

4 RS44B356U0215S

(for compressor)

5 Overload relay U/T : 6.1A (80ºC), Open : 135±5ºC, Close : 75±11ºC

QK164PBA

WLF-240-20A

(Type "A")

SKF-240-20B

(Type "B")

DS451155NPQB

LPAP960B

Winding resistance (Ω)
(at 20ºC) 3.51 3.67
Output (Rated) 20 W, 6 poles, 1 phase, 220 - 240 V~, 50Hz
Winding resistance (Ω)
(at 20ºC) 410 435
Output (Rated) 20 W, 6 poles, 1 phase, 220 - 240 V, 50Hz
Winding resistance (Ω)
(at 20ºC) 235.2 260.1

AC 450 V~, 1.5µF

AC 440 V~, 35µF

Specifications

C-R C-S

Red-Black White-Black

Red-Black White-Black

− 9 −

5. REFRIGERATION CYCLE DIAGRAM

5-1. RAS-07SKSX-1 / RAS-07S2AX-1

FILE NO. SVM-08028

Indoor unit

Cooling

0.39m
(Connecting pipe)
∅9.52

O.D.:9.52mm O.D.:6.35mm

Cooling

Packed valve

Cooling

P

(∅9.52)

Compressor

PH108X1C-4DZD

Heat exchanger

Cross flow fan

N2

T1

0.49m
(Connecting pipe)
∅6.35

Packed valve

(∅6.35)

Capillary tube

∅1.2x500s

xchanger

Heat e

Refrigerant

58 kg.

R22 : 0.

Cooling

Propeller fan
Outdoor unit

Mark ( ) means check points of Gas Leak.

Ambient temp.

50Hz

Standard

pressure

(MPaG)

P

Surface temp. of heat

exchanger interchanging

pipe

T1

(°C)

Fan speed

(indoor)

conditions DB/WB

(°C)

Indoor Outdoor

Standard 0.57 13.0 High 27/19 35/24

Cooling Overload 0.68 17.5 High 32/23 43/26

Low temperature 0.42 4.0 Low 21/15 21/15

Note

• Measure the heat exchanger temperature at the center of U-bend. (By means of TC sensor)

– 10 –

5-2. RAS-09SKSX-1 / RAS-09SASX-1

FILE NO. SVM-08028

Indoor unit

Cooling

0.39m
(Connecting pipe)
∅9.52

O.D.:9.52mm O.D.:6.35mm

Cooling

Packed valve

Cooling

P

(∅9.52)

Compressor

QK164PBA

Heat exchanger

Cross flow fan

T1

Packed valve

(∅6.35)

Capillary tube

700s

∅1.5x

0.49m
(Connecting pipe)
∅6.35

Heat exchanger

Refrigerant

0.58

Cooling

Propeller fan
Outdoor unit

R22 :

Mark ( ) means check points of Gas Leak.

kg.

Ambient temp.

50Hz

Standard

pressure

(MPaG)

P

Surface temp. of heat

exchanger interchanging

pipe

T1

(°C)

Fan speed

(indoor)

conditions DB/WB

(°C)

Indoor Outdoor

Standard 0.50 11.0 High 27/19.5 35/24

Cooling Overload 0.60 15.0 High 32/23 43/26

Low temperature 0.40 2.2 Low 21/15 21/15

Note

• Measure the heat exchanger temperature at the center of U-bend. (By means of TC sensor)

– 11 –

Heat Exchange sensor

6. CONTROL BLOCK DIAGRAM

Main Unit Control Panel M.C.U.

Functions

FILE NO. SVM-08028

Operation

Display

Thermo. Sensor

Infrared Rays Signal Reciver

• Louver Control

•3-minutes Delay at Restart

for Compressor

Initiallizing Circuit

Clock Frequency
Oscillator Circuit

Power Supply

Circuit

Noise Filter Relay Driver, Louver Driver

•Motor Revolution Control

•Processing

(Temperature Processing)

•Timer

Compressor

ON/OFF

Signal

Relay

RY01

Timer

Display

Fan Only

Sign Display

Indoor Fan

Motor

Louver

ON/OFF

Signal

Louver

Motor

220-240 V~, 50Hz

REMOTE CONTROL

Compressor, Outdoor Fan Motor

Infrared Rays

Remote Control

Operation (START/STOP)

Operation Mode Selection

AUTO, COOL, DRY, AUTO FAN

Temperature Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECO

− 12 −

7. OPERATION DESCRIPTION

FILE NO. SVM-08028

7-1. Remote control

7-1-1. Function of Push Putton

Infrared signal emitter

1

2

Set louver button (FIX)

Auto Louver button (SWING)

3

Mode select button (MODE)

4

Reset button (RST)

5

On timer button (ON)

6

7

Off timer button (OFF)

Reserve button (SET)

8

Cancel button (CLR)

9

10

Check button (CHK)

11

ECO button (ECO)

12

Fan speed button (FAN)

13

Start/Stop button (START/STOP)

14

Temperature button ( )

1

MODE

AUTO

COOL

AUTO FAN

2

DRY

SWING

TEMP.

Hr.ON OFF

TEMP.

START/STOP

3

MODE

4
5

6

RST

TIMER

ON OFF SET CLR

7

FIX

CHK

FAN

AUTO

B

QUIET

14

13

FAN

12

ECO

11

10

9

8

− 13 −

FILE NO. SVM-08028

7-1-2. Display of Remote Control

All indications, except for the clock time indicator, are displayed by pressing the button.

1. Transmission mark

This transmission mark
remote controller transmits signals to the indoor
unit.

indicates when the

2. Mode indicator

Indicates the current operation mode.
(AUTO, COOL, DRY and AUTO FAN)

3. Temperature indicator

Indicates the temperature setting.
(17°C to 30°C)

4. ECO indicator

Indicates when the ECO is in activated.
Press the ECO button to start and press it again

to stop operate.

5. A, B change indicator remote controller

When the remote controller switching function is
set, "B" appears in the remote controller display

(When the remote controller seting is "A", there is
no indication at this position.)

1

3

2

7

6

6. Swing

Indicate when louver is swing.
Press swing button to start the swing operation

and press it again to stop the swing operation.

7. FAN speed indicator

Indicates the selected fan speed.
AUTO, QUIET or three fan speed levels

( LOW , MED , HIGH can be shown.
Indicate Auto will be appear with Dry operation
only.

8. ON/OFF TIMER indicator

Indicates when the ON/OFF TIMER operation.
(ON TIMER [Hr. ON], OFF TIMER [OFF]).

•

•

Hr.ON OFF

•

4

•

•

•

•

B

•

•

•

•

7

7

8

5

8

− 14 −

7-2. Outline of Air Conditioner Control

FILE NO. SVM-08028

This is a fixed capacity type air conditioner, which uses
a AC motor for an indoor fan. The AC motor drive
circuit is mounted in the indoor unit. And electrical
parts which operate the compressor and the outdoor
fan motor, are mounted in the outdoor unit.
The air conditioner is mainly controlled by the indoor
unit controller. The controller operates the indoor fan
motor based upon commands transmitted by the
remote control and transfers the operation commands
to the outdoor unit controller.
The outdoor unit receives operation commands from
the indoor unit, and operates the outdoor fan motor
and the compressor.

(1) Role of indoor unit controller

The indoor unit controller receives the operation
commands from the remote control and executes
them.

• Temperature measurement at the air inlet of the
indoor heat exchanger by the indoor

temperature sensor

• Temperature measurement of the indoor heat
exchanger by the heat exchanger sensor

• Louver motor control

• Indoor fan motor operation control

• LED display control

• Transferring of operation commands to the

outdoor unit

• Receiving of information of the operation status
and judging of the information or indication of
error

(2) Role of outdoor unit controller

The outdoor unit controller receives the operation
commands from the indoor controller and
executes them.

• Compressor operation
control

• Operation control of

outdoor fan motor

Operations according
to the commands
from the indoor unit

• Turning off the compressor and outdoor fan

when the outdoor unit receives the shutdown
command

7-2-1. Louver control

(1) Vertical air flow louver

Position of veritcal air flow louver is automatically
controlled according to the operation mode.
Besides, position of vertical air flow louver can be
arbitrarily set by pressing [FIX] button.
The louver position which is set by [FIX] button is
stored in the microcomputer, and the louver is
automatically set at the stored position for the next
operation.

(2) Swing

If [SWING] button is pressed when the indoor unit
is in operation, the vertical air flow louver starts
swinging. When [FIX] button is pressed, it stops
swinging.

7-2-2. Indoor Fan Control

The operation controls the fan speed at indoor unit
side. The indoor fan (cross flow fan) is operated by
the phase control induction motor. The fan rotates in 3
stages in MANUAL model, and in 5 stages in AUTO
mode, respectively. (Table 7-2-1)

1) When setting the fan speed to L, M or H on
the remote controller, the operation is performed
with the constant speed shown in Fig. 7-2-1.

Fig (7-2-1)

Indication

L

M

H

Fan speed

Low
Med

High

2) When setting the fan speed to AUTO on the remote
controller, revolution of the fan motor is controlled
to the fan speed level shown in Table 1 according to
the setup temperature, room temperature, and heat
exchanger temperature.

3) When setting the fan speed to QUIET on the remote
controller, revolution of the fan motor is controlled
to the fan speed level is L-.

Table 7-2-1 Indoor fan and air flow rate

OPERATION

MODE

RAS-07SKSX-1

Model

RAS-09SKSX-1

Cool
Dry
fan speed (rpm)
Air flow (m
fan speed (rpm)
Air flow (m3/h)

3

/h)

Fan speed level
UH H M+ M L+ L L- UL SUL
UH H M+ M L+ L L- UL SUL

1300 1300 1300 1300 1250 1150 1100 950 950 900 800 750 700 650 500

540 540 540 540 510 470 440 370

1350 1350 1350 1300 1250 1180 1140 1000 980 980 900 800 750 700 550

560 560 560 540 510 500 460 400

370 350 300 270 250 220 150

390 390 350 300 270 250 180

− 15 −

FILE NO. SVM-08028

7-3. Description of Operation Mode

(1) When turning on the breaker, the operation lamp

blinks. This means that the power is on (or the
power supply is cut off.)

(2) When pressing [ ] button on the

remote control, receiving beep sounds from the
indoor unit, and the next operation is performed
together with opening the vertical air flow louver.

(3) Once the operation mode is set, it is memorized in

the microcomputer so that the previous operation
can be effected thereafter simply by pressing
[ ] button.

7-3-1. Fan only operation

([MODE] button on the remote control is set
to the fan only operation.)

(1) When [FAN] button is set to AUTO, the indoor fan

motor operates as shown in Fig. 7-3-1. When
[FAN] button is set to LOW, MED, or HIGH
the motor operates with a constant air flow.

°C

7-3-2. Cooling operation

([MODE] button on the remote control is set
to the cooling operation.)

(1) The compressor, outdoor fan and operation

display lamp are controlled as shown in
Fig. 7-3-2.

°C

ON ON

OFF OFF ON

Compressor

Outdoor fan

-

(Room temp.) (Preset temp.)

Preset
temp.

0.5

0

Fig. 7-3-2

display

OPERATION

+3
+2.5
+2

+1.5
+1
+0.5

(Room temp.) − (Preset temp.)

Preset
temp.

0

(Preset temp.: 24 °C)

NOTE1 : *1 : Fan speed = (M + - L) x 3/4 + L

*2 : Fan speed = (M + - L) x 2/4 + L
*3 : Fan speed = (M + - L) x 1/4 + L

(Linear approximation
from M+ and L)

NOTE2 : ECO operation can not be set.

Fig. 7-3-1 Setting of air flow [FAN:AUTO]

M+

*1
*2
*3

(2) When [FAN] button is set to AUTO, the indoor fan

motor operates as shown in Fig. 7-3-5. When
[FAN] button is set to LOW, MED or HIGH
the motor operates with a constant air flow.

°C

(Room temp.) − (Preset temp.)

Preset
temp.

+3
+2.5
+2
+1.5
+1
+0.5

0

-0.5

M+

*1

*2
*3

NOTE1 : *1 : Fan speed = (M + - L) x 3/4 + L

*2 : Fan speed = (M + - L) x 2/4 + L
*3 : Fan speed = (M + - L) x 1/4 + L

(Linear approximation
from M+ and L)

Fig. 7-3-3 Setting of air flow [FAN:AUTO]

− 16 −

FILE NO. SVM-08028

7-3-3. Dry operation

([MODE] button on the remote control is set
to the dry operation.)

(1) The compressor, outdoor fan and operation

display on the remote control are controlled
as shown in Fig. 7-3-4.

°C

ON:6min.

OFF:4min.

ON:6min.

OFF:4min.

ON:5min.

ON:5min.

OFF:5min.

OFF

OFF

Compressor

ON

OFF:5min.

Outdoor fan

-

(Room temp.) (Preset temp.)

Preset
temp.

+3

+2

+1

0

Fig. 7-3-4

display

OPERATION

(1) One of 2 operations (Cooling or Fan only)

is selected according to difference between the
preset temperature and the room temperature at
which the automatic operation has started, as
shown in Fig. 7-3-6. The Fan only operation
continues until the room temperature reaches a
level at which another mode is selected.

(2) Temporary Auto

When the [RESET] button on the indoor unit
is pushed, the preset temperature is fixed at 24°C
and the indoor unit is controlled as shown in
Fig. 7-3-6.

°C

Cooling operation

0

-

Fan only operation

(2) The microcontroller turns the compressor on and

off at the regular intervals (4 to 6 minutes). While
the compressor is turning off, the indoor fan motor
operates in the SUPER LOW position.
The pattern of operation depending on the relation
between room temperature and preset
temperatures is shown in Fig. 7-3-5.

Room temp.

Preset temp.+1
Preset temp.

Compressor
Outdoor fan

Indoor fan

ON ON ON ON

OFF OFF OFF

L *SL SLLL SL L

*

Super Low

Fig. 7-3-5

(3) [FAN] button on the remote control is set to AUTO

only.

(Room temp.) (Preset temp.)

Fig. 7-3-6

7-4. Low-Temperature Limit Control

The microcontroller detects the indoor heat exchanger
temperature to prevent the indoor heat exchanger from
freezing.
The compressor and outdoor fan motor are controlled
as shown in Fig. 7-4-1

Heat exchanger
temperature

(°C)

5

2

Fig. 7-4-1

Compressor Outdoor fan

ON

Less than 2°C continues

for 5 minutes

OFF

(4) The ECO operation cannot be set.

7-3-4. Automatic operation

([MODE] button on the remote control is set
to the automatic operation.)

− 17 −