Toshiba RAS-09LAV-UL, RAS-09LKV-UL, RAS-12LAV-UL, RAS-12LKV-UL User Manual

FILE NO. SVM-10019

SERVICE MANUAL

	SPLIT TYPE
Indoor Unit	Outdoor Unit
<High Wall, Heat Pump Type>	<Heat Pump Type>
RAS-09LKV-UL RAS-09LAV-UL
RAS-12LKV-UL	RAS-12LAV-UL

R410A

Feburary, 2010

		FILE NO. SVM-10019
	CONTENTS
1.	SAFETY PRECAUTIONS ..........................................................................	3
2.	SPECIFICATIONS .....................................................................................	6
3.	REFRIGERANT R410A .............................................................................	8
4.	CONSTRUCTION VIEWS ........................................................................	16
5.	WIRING DIAGRAM ..................................................................................	18
6.	SPECIFICATIONS OF ELECTRICAL PARTS .........................................	20
7.	REFRIGERANT CYCLE DIAGRAM ........................................................	21
8.	CONTROL BLOCK DIAGRAM ................................................................	24
9.	OPERATION DESCRIPTION ...................................................................	26
10.	INSTALLATION PROCEDURE ................................................................	51
11.	HOW TO DIAGNOSE THE TROUBLE ......................................................	66
12.	HOW TO REPLACE THE MAIN PARTS ...................................................	93
13.	EXPLODED VIEWS AND PARTS LIST .................................................	109

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FILE NO. SVM-10019

1. SAFETY PRECAUTIONS

Installing, staring up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service mechanics should install, start-up, and service this equipment.

Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should be performed by trained service personnel.

When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment.

Follow all safety codes, Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher near by when brazing. Use care in handling, rigging, and setting bulky equipment.

Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety information. This is the safety-alert symbol ! . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these signal words : DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in severs personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

∙Before installation, please read these precautions for safety carefully.

∙Be sure to follow the precautions provided here to avoid safety risks. The symbols and their meanings are shown below. WARNING : It indicates that incorrect use of this unit may cause severe injury or death.

CAUTION : FAILURE TO FOLLOW THIS CAUTION may result in equipment damage or improper operation and personal injury.

CAUTION

New refrigerant air conditioner installation

∙THIS AIR CONDITIONER USES THE NEW HFC REFRIGERANT (R410A), WHICH DOES NOT DESTROY THE OZONE LAYER.

R410A refrigerant is affected by inpurities such as water and oils because the pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22.

ALSO NEW OILS ARE USED WITH R410A, THUS ALWAYS USE NEW REFRIGERANT PIPING AND DO NOT ALLOW MOISTURE OR DUST TO ENTER THE SYSTEM.

To avoid mixing refrigerant and refrigerant machine oil, the sizes of charging port on the main unit is different than those used on R22 machines and different tools will be required.

∙EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must be a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length is buried, refrigerant may migrate to the cooter buried section during extended periods of system shutdown. This causes refrigerant slugging and could possibly damage the compressor at start-up.

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FILE NO. SVM-10019

DANGER

∙FOR USE BY QUALIFIED PERSONS ONLY.

∙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.

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

∙CHECK THE EARTH WIRE THAT IT IS NOT BROKEN OR DISCONNECTED BEFORE INSTALLATION.

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

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

∙WHEN MOVING THE AIR CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT TO GET THE SPECIFIED REFRIGERANT (R410A) WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CYCLE. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CYCLE BECOMES ABNORMALLY HIGH AND IT RESULTINGLY CAUSES BURST OF THE PIPE AND INJURIES ON PERSONS.

∙IN THE EVENT THAT THE REFRIGERANT LEAK, DURING INSTALLATION WORK, IMMEDIATELY ALLOW FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSE GENERATION OF POISONOUS GAS.

WARNING

∙ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label.

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

∙Installation work must be purformed by qualified personnel only.

∙Specified tools and pipe parts for model R410A are required, and installation work must be done in accordance with the manual. HFC type refrigerant R410A has 1.6 times more pressure than that of conventional refrigerant (R22). Use the specified pipe parts, and ensure correct installation, otherwise damage and/or injury may be caused. At the same time, water leakage, electrical shock, and fire may occur.

∙Be sure to install the unit in a place which can sufficiently bear its weight. If the load bearing of the unit is not enough, or installation of the unit is improper, the unit may fall and result in injury.

∙Electrical work must be performed by trained, qualified installers and service mechanics in accordance with the code governing such installation work, internal wiring regulations, and the manual. A dedicated circuit and the rated voltage must be used. Insufficient power supply or improper installation may cause electrical shock or fire.

∙Use a cabtyre cable to connect wires in the indoor/outdoor units. Midway connection is not allowed. Improper connection or fixing may cause a fire.

∙Wiring between the indoor unit and outdoor units must be well shaped so that the cover can be firmly placed. Improper cover installation may cause increased heat, fire, or electrical shock at the terminal area.

∙Be sure to use only approved accessories or the specified parts. Failure to do so may cause the unit to fall, water leakage, fire or electrical shock.

∙After the installation work. ensure that there is no leakage of refrigerant gas. If the refrigerant gas leaks out of the pipe into the room and is heated by fire or something else from a fanheater, stove or gas range, it causes generation of poisonous gas.

∙Make sure the equipment is properly grounded. Do not connect the ground wire to a gas pipe, water pipe, lightning conductor, or telephone earth wire. Improper earth work may be the cause of electrical shock.

∙Do not install the unit where flammable gas may leak. If there is any gas leakage or accumulation around the unit, it can cause a fire.

∙Do not select a location for installation where there may be excessive water or humidity, such as a bathroom. Deterioration of insulation nay cause electrical shock or fire.

∙Installation work must be performed following the instructions in this installation manual. Improper installation may cause water leakage, electrical shock or fire. Check the following items before operating the unit.

-Be sure that the pipe connection is well placed and there are no leaks.

-Check that the service valve is open. If the service valve is closed, it may cause overpressure and result in compressor damage. At the same time, if there is a leak in the connection part, it may cause air suction and overpressure, resulting in damage to the unit or injury.

∙In a pump-down operation, be sure to stop the compressor unit before removing the refrigerant pipe. If removing the refrigerant pipe while the compressor is operating with the service valve opened, it may cause air suction and overpressure, resulting in damage to the unit or injury.

∙Do not modity the power cable, connect the cable midway, or use a multiple outlet extension cable. Doing so may cause contact failure, insulation failure, or excess current, resulting in fire or electrical shock.

∙If you detect any damage, do not install the unit. Contact your dealer immediately.

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FILE NO. SVM-10019

CAUTION

∙ Exposure of unit to water or other moisture before installation could result in electric shock. Do not store it in a wet basement or expose to rain or water.

∙After unpacking the unit, examine it carefully for possible damage. Report any damages to your distributor.

∙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 and discharged air might disturb neighbors.

∙Please read this installation manual carefully before installing the unit. It contains further important instructions for proper installation.

∙This appliance must be connected to the main power supply by means of a circuit breaker depending on the place where the unit is installed. Failure to do so may cause electrical shock.

∙Follow the instructions in this installation manual to arrange the drain pipe for proper drainage from the unit. Ensure that drained water is discharged. Improper drainage can result is water leakage, causing water damage to furniture.

∙Tighten the flare nut with a torque wrench using the prescribed method. Do not apply excess torque. Otherwise, the nut may crack after a long period of usage and it may cause the leakage of refrigerant.

∙Wear gloves (heavy gloves such as cotton gloves) for installation work. Failure to do so may cause personal injury when handling parts with sharp edges.

∙Do not touch the air intake section or the aluminum fins of the outdoor unit. It may cause injury.

∙Do not install the outdoor unit in a place which can be a nest for small animals. Small animals could enter and contact internal electrical parts, causing a failure or fire.

∙Request the user to keep the place around the unit tidy and clean.

∙Make sure to conduct a trial operation after the installation work, and explain how to use and maintain the unit to the customer in accordance with the manual. Ask the customer to keep the operation manual along with the installation manual.

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								FILE NO. SVM-10019
			2. SPECIFICATIONS
Unit model	Indoor				RAS-09LKV-UL			RAS-12LKV-UL
	Outdoor				RAS-09LAV-UL			RAS-12LAV-UL
Cooling capacity				(Btu/h)	9000				12000
Cooling capacity range				(Btu/h)	3750 -10580			2750 - 13950
Heating capacity				(Btu/h)	10800				14200
Heating capacity range				(Btu/h)	3070 - 16350			3070 - 19000
Power supply					1Ph, 60Hz, 208V/230V			1Ph, 60Hz, 208V/230V
Electric	Indoor	Operation mode			Cooling		Heating	Cooling		Heating
characteristic		Running current		(A)	0.22		0.20	0.25		0.23
		Power consumption		(W)	35		40	30		35
		Power factor		(%)	76		76	66		66
	Outdoor	Operation mode			Cooling		Heating	Cooling		Heating
		Running current		(A)	3.46		3.13	5.26		4.76
		Power consumption		(W)	655		760	920		1055
		Power factor		(%)	91		94	95		95
		Starting current		(A)	3.68		3.33	4.81/4.35		5.51/4.99
EER (Cooling/Heating)				(Btu/W.h)	13.0/13.5				12.6 / 13.0
SEER (Btu/W.h) / HSPF (w/w)					20.0/10.0				23.0/9.5
Operating	Indoor	High	(Cooling/Heating)	(dB-A)	39/40				45/46
noise		Medium	(Cooling/Heating)	(dB-A)	34/35				40/41
		Low	(Cooling/Heating)	(dB-A)	27/29				30/32
	Outdoor		(Cooling/Heating)	(dB-A)	47/47				50/50
Indoor unit	Unit model				RAS-09LKV-UL			RAS-12LKV-UL
	Dimension	Height		in. (mm)	10-25/32 (275)			10-25/32 (275)
		Width		in. (mm)	31-1/8 (790)			31-1/8 (790)
		Depth		in. (mm)	8-1/16 (205)			8-1/16 (205)
	Net weight			lbs (kg)	20 (9)				20 (9)
	Fan motor output			(W)	20				30
	Air flow rate		(Cooling/Heating)	cfm (m3/min)	303/335 (8.6)/(9.5)			406/438 (11.5/12.4)
Outdoor unit	Unit model				RAS-09LAV-UL			RAS-12LAV-UL
	Dimension	Height		in. (mm)	21-11/16 (550)			21-11/16 (550)
		Width		in. (mm)	30-11/16 (780)			30-11/16 (780)
		Depth		in. (mm)	11-7/16 (290)			11-7/16 (290)
	Net weight			lbs (kg)	75 (34)				88 (39)
	Compressor	Motor output		(w)	750				750
		Type			Single rotary type with DC-inverter			Twin rotary type with DC-inverter
					variable speed control			variable speed control
		Model			DA89X1C-23FZ2			DA111A1F-20F1
	Fan motor output			(W)	43				43
	Air flow rate		(Cooling/Heating)	cfm (m3/min)	1060/1060 (30)/(30)			1395/1236 (39.5/35.0)
Piping	Type				Flare connection			Flare connection
connection	Indoor unit	Liquid side		in. (mm)	1/4 ( 6.35)			1/4 ( 6.35)
		Gas side		in. (mm)	3/8 ( 9.92)			3/8 ( 9.92)
	Outdoor unit	Liquid side		in. (mm)	1/4 ( 6.35)			1/4 ( 6.35)
		Gas side		in. (mm)	3/8 ( 9.92)			3/8 ( 9.92)
	Maximum length			ft. (m)	66 (20)				66 (20)
	Maximum chargeless length			ft. (m)	50 (15)				50 (15)
	Maximum height difference			ft. (m)	33 (10)				33 (10)
Refrigerant	Name of refrigerant				R410A				R410A
	Weight			lbs (kg)	1.77 (0.8)				2.43 (1.10)
Wiring	Power supply				3Wires:includes earth (Outdoor)			3Wires:includes earth (Outdoor)
connection	Interconnection				4Wires:includes earth			4Wires:includes earth
Usable temperature range		Indoor	(Cooling/Heating)	°F (°C)	70-90 / 32-82 (21-32/0-28)			70-90 / 32-82 (21-32/0-28)
		Outdoor	(Cooling/Heating)	°F (°C)	14-115 / 5-75 (-10-46/-15-24)			14-115 / 5-75 (-10-46/-15-24)

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

–− 6 −

Current (A)

2-2. Operation Characteristic Curve																			FILE NO. SVM-10019
<Cooling>													<Heating>
8														8
7														7									RAS-12LKV-UL
																							RAS-09LKV-UL
6														6
								RAS-12LKV-UL
5														5
4													(A)
							RAS-09LKV-UL						Current	4
3														3
2							Conditions							2							Conditions
							Indoor : DB 80oF/WB 67oF
																							o	o
								(DB 26.7oC/WB 19.4oC)													Indoor : DB 70 F/WB 60 F
																							o		o
							Outdoor : DB 98oF/WB 75oF															(DB 21.1 C/WB 15.6 C)
																							o		o
								(DB 35oC/WB 23.9oC)													Outdoor : DB 47 F/WB 43 F
1														1									o		o
							Indoor Air Flow : High															(DB 8.3 C/WB 6.1 C)
																					Indoor 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>

Capacity Ratio (%)

105

100

RAS-09LKV-UL

RAS-12LKV-UL

95

90

85

80

75

70Condition

Indoor: DB80°F/WB67°F

(DB26.7°C/WB19.4°C)

65Indoor Air-Flow Volume: High Pipe Length: 16 ft (5m) Voltage : 230V

	60
		Capacity Ratio: 100% =
	55	9000 Btu/h (RAS-09LKV-UL)
		12000 Btu/h (RAS-12LKV-UL)
	50

90 91 93 95 97 99 100 102 104 106 108 109 111 113 115

(32)(33)(34)(35)(36)(37)(38)(39)(40)(41)(42)(43)(44)(45)(46)

Outdoor Temperature (ºC)

Capacity Ratio (%)

120

100

80

60

40

20

0

5 (-15)

RAS-09LKV-UL

RAS-12LKV-UL

Condition

Indoor: DB70°F/WB60°F (DB21.1°C/WB15.6°C)

Indoor Air-Flow Volume: High Pipe Length: 16 ft (5m) Voltage : 230V

Capacity Ratio: 100% =

9000 Btu/h (RAS-09LKV-UL)

12000 Btu/h (RAS-12LKV-UL)

14	23	32	41	50
(-10)	(-5)	(0)	(5)	(10)

Outdoor Temperature (ºC)

– 7 –

FILE NO. SVM-10019

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 0.0315 in. (0.8 mm) even when it is available on the market.

– 8 –

	Table 3-2-1 Thicknesses of annealed copper pipes				FILE NO. SVM-10019
				Thickness in. (mm)
Nominal diameter (in.)		Outer diameter (mm)	R410A			R22
1/4		6.35	0.0315	(0.80)		0.0315 (0.80)
3/8		9.52	0.0315 (0.80)			0.0315 (0.80)
1/2		12.70	0.0315 (0.80)			0.0315 (0.80)

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 0.7874 in. (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 (in)	Reference outer diameter of	Minimum joint thickness
		copper pipe jointed (mm)	in. (mm)
	1/4	6.35	0.0197 (0.50)
	3/8	9.52	0.0236 (0.60)
	1/2	12.70	0.0276 (0.70)

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

– 9 –

FILE NO. SVM-10019

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 in. (mm)
	Nominal
			Thickness			Conventional flare tool
		diameter			Flare tool for R410A
	diameter		in. (mm)
		(mm)
	in.				clutch type	Clutch type	Wing nut type
	1/4	6.35	0.0315 (0.8)		0 to 0.0197 (0 to 0.5)	0.0394 to 0.0591	0.0591 to 0.0787
						(1.0 to 1.5)	(1.5 to 2.0)
	3/8	9.52	0.0315 (0.8)		0 to 0.0197 (0 to 0.5)	0.0394 to 0.0591	0.0591 to 0.0787
						(1.0 to 1.5)	(1.5 to 2.0)
	1/2	12.70	0.0315 (0.8)		0 to 0.0197 (0 to 0.5)	0.0394 to 0.0591	0.07874 to 0.0984
						(1.0 to 1.5)	(2.0 to 2.5)

Table 3-2-4 Dimensions related to flare processingf or R22

Outer

A in. (mm)

Nominal

Thickness

Conventional flare tool

diameter

Flare tool for R22

diameter

in. (mm)

(mm)

in.

clutch type

Clutch type

Wing nut type

1/4

6.35

0.0315 (0.8)

0 to 0.0197 (0 to 0.5)

0.0197 to 0.0394

0.0394 to 0.0591

(0.5 to 1.0)

(1.0 to 1.5)

3/8

9.52

0.0315 (0.8)

0 to 0.0197 (0 to 0.5)

0.0197 to 0.0394

0.0394 to 0.0591

(0.5 to 1.0)

(1.0 to 1.5)

1/2

12.70

0.0315 (0.8)

0 to 0.0197 (0 to 0.5)

0.0197 to 0.0394

0.0591 to 0.0787

(0.5 to 1.0)

(1.5 to 2.0)

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

Nominal

Outer diameter

Thic kness

Dimension

in. (mm)

Flare nut width

diameter

(mm)

in. (mm)

A

B

C

D

in. (mm)

in.

1/4

6.35

0.0315 (0.8)

0.358 (9.1)

0.362 (9.2)

0.256 (6.5)

0.512 (13)

0.669 (17)

3/8

9.52

0.0315 (0.8)

0.520 (13.2)

0.531 (13.5)

0.382 (9.7)

0.787 (20)

0.866 (22)

1/2

12.70

0.0315 (0.8)

0.630 (16.0)

0.653 (16.6)

0.508 (12.9)

0.906 (23)

1.024 (26)

– 10 –

	Table 3-2-6 Flare and flare nut dimensions for R22					FILE NO. SVM-10019
Nominal	Outer diameter	Thic kness		Dimension	in. (mm)			Flare nut width
diameter	(mm)	in. (mm)						in. (mm)
			A	B	C	D
in.
1/4	6.35	0.0315 (0.8)	0.354 (9.0)	0.362 (9.2)	0.256 (6.5)	0.512	(13)	0.669 (17)
3/8	9.52	0.0315 (0.8)	0.512 (13.0)	0.531 (13.5)	0.382 (9.7)	0.787	(20)	0.866 (22)
1/2	12.70	0.0315 (0.8)	0.630 (16.0)	0.638 (16.2)	0.508 (12.9)	0.787	(20)	0.945 (24)

	46
45	to

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)	lbf.ft (N•m)
				lbf.ft (N•m)
	in.
	1/4	6.35	10 to 13 (14 to 18)	12 (16), 13 (18)
	3/8	9.52	24 to 31 (33 to 42)	31 (42)
	1/2	12.70	37 to 46 (50 to 62)	41 (55)

– 11 –

FILE NO. SVM-10019

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 1/2 in. 12.7mm) 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 Ø1/2 (12.7mm)]
	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 Ø1/4, Ø3/8 in.

( 6.35, 9.52mm)] 3. Pipe cutter

4.	Reamer	9.	Hole core drill [Ø2-9/16 in. (65mm)]
5.	Pipe bender	10.	Hexagon wrench
6.	Level vial			[Opposite side 3/16 in. (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

– 12 –

FILE NO. SVM-10019

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 −14.7 Psi (–0.1 Mpa) or −29.9 inHg (–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.

(Indoor Unit)	(Outdoor 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

– 13 –

FILE NO. SVM-10019

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

cylinder Refrigerant

Electronic

balance

Siphon

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.

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

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

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.

•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.

– 14 –

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 1472°F (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-10019

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 0.03 cfm (0.05 m3/Hr) or 2.9 Psi (0.02 MPa) 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

– 15 –

4. CONSTRUCTION VIEWS

FILE NO. SVM-10019

4-1. Indoor Unit

– 16 –

FILE NO. SVM-10019

4-2. Outdoor Unit

	1 ( 25) Water Drain Outlet				4-1/4 (108)	4-15/16 (125)
1-31/32 (50)	23-5/8 (600)			A
	R19/32
1-27/64 (36)
	(R15)
(320)19/32-12 (306)3/64-12		(320)	3/8-3 (86)			9/16-4(116)
	R7/32	12-19/32
	(R5.5)
(	1/4 Hole
	6) Hole					B
Detail-A (Rear Leg)
	17-5/32 (			436)	WIRE GUARD

	12-19/32 (320) 12-3/64 (306)	Unit : Inch (mm)
	1/4-Hole
	( 6)-Hole	R19/32 (R15)
	1-27/64 (36)
		7/16x9/16 Oval-Hole
	1-31/32 (50)
		( 11x14) Oval Hole
	23-5/8 (600)
	Detail-B (Front Leg)
		COVER
		PACKED VALVE

(550)
21-11/16	(275)
	10-7/8

View Z

11-7/16 (290)

3-17/32 (90)

View Z

3-15/16 Or more

(100 mm or more)

12-19/32 (320)

23-5/8 (600)

3-17/32 (90)

2-23/32 (69)

-9/16 (141)	2-3/32 (53)
5
	(88)
	3-15/32

23-5/8 (600)

Air Inlet 3-15/16 Inch or more (100 mm. or more)

Air Outlet

23-5/8 Inch or more

(600 mm. or more)

13-1/2 (342)

Liquid side

(Flare Nut : 1/4 (6.35))

Gas side

(Model 09,12k Flare Nut :3/8 (9.52))

Service Port

2-R7/32x43/64L (R5.5x17L) U-Shape

(For 5/16~13/32 (8~10) Anchor Bolt)

23-5/8 Or more

(600 mm or more)

2-	7/16x9/16 ( 11x14) Oval-Hole
(For	5/16~ 13/32 ( 8~ 10) Anchor Bolt)

– 17 –

FILE NO. SVM-10019

5. WIRING DIAGRAM

5-1. RAS-09LKV-UL / RAS-09LAV-UL

COMPRESSOR

CN300

CM

1

1

RED

P04

3

3

BLK

FM

2

2

WHI

P05

Q200~205

Q300~305

2

2

WHI

BLK

P06

RED

3

3

IGBT

P.C.BOARD

MOS-FET

1

1

YEL

P25

P24

R221

(MCC-5009)

R321

6

6

FAN MOTOR

P23

R220

R320

5

5

4

4

PMV

YEL

P22

R219

R319

CN700 3

3

P21

2

2

BRW

P20

F03

1

1

PULSE MOTOR VALVE

P35

L03

C13

L01

VARISTOR

YEL

FUSE

3

3

T3.15A

P34

DB01

AC250V

CN603

2

1

1

TS

SURGE

(SUCTION PIPE

C12

C14

ABSORBER

2

2

TEMP. SENSOR)

POWER

VARISTOR

CN602 1

1

RELAY

TO

F01

(OUTDOOR

P19

FUSE

3

3

TEMP. SENSOR)

CT

25A

ORN

DB02

AC250V

P02

CN601

2

P03

P01

1

P18

ORN

BLK

WHI

1

TD

P11

RELAY

1

1

(DISCHARGE PIPE

2

2

TEMP. SENSOR)

REACTOR

2

2

P08

CN600 1

1

Q404

TE

P32

CN701

P07

L1 L2 S L1 L2

2

2

(CONDENSER PIPE

TEMP. SENSOR)

P33

P31

P30

1

3

BLK

CN500 1

1

PUR

1

2

1

3

~

~ ~

PRESSURE SW.

1

2

COLOR IDENTIFICATION

COIL

FOR

POWER

BLK:BLACK

WHI:WHITE

4WAY

BLU:BLUE

BRW:BROWN

SUPPLY

RED:RED

ORN:ORANGE

VALVE

208/230-1-60

GRY:GRAY

YEL:YELLOW

PNK:PINK

PUR:PURPLE

REACTOR

Outdoor Terminal Block L1 L2 S

Indoor Terminal Block L1 L2 S

POWER SUPPLY (From Outdoor Unit) 208/230-1-60

1 1 2 2

Heat Exchanger Sensor CN62(BLU) (TC)

1 1 2 2

Thermo Sensor CN61 (TA) (WHI)

BLK WHI RED				GRN&YEL
				Heat
				Exchanger

3	1
CN01		CN51

T3.15A Fuse F01

Varistor Line

Filter

1	1
2	2	6	6
3	3
4	4	5	5	AC Motor
5	5	4	4
CN31		3	3
		2	2
(WHI)
		1	1
1	1			Fan Motor
2	2
3	3

CN33
(WHI)
1	1	WHI	1	1
2	2	YEL	2	2
3	3	YEL	3	3
4	4	YEL	4	4
5	5	YEL	5	5
CN32				Louver Motor
(WHI)

MCC-5044

Wireless Unit Assembly

1	1	WHI	1
2	2		2
3	3	BLU	3
4	4	BLU	4
5	5	BLU	5
6	6	BLU	6
7	7	BLU	7
8	8	BLU	8
9	9	BLU	9
10 10		BLU	10
11 11			11

CN10 CN21

(WHI) (YEL)

DC5V	Supply Circuit
DC12V
+	Power

Main PC Board

WP-020

CN22

(WHI)

1

2

3

4

Color indication

BRW:BROWN

YEL:YELLOW

BLK:BLACK

RED:RED

BLU:BLUE

WHI:WHITE

GRN & YEL: GREEN & YELLOW

– 18 –

FILE NO. SVM-10019

5-2. RAS-12LKV-UL /RAS-12LAV-UL

COMPRESSOR

CN300

CM

1

1

RED

P04

3

3

BLK

FM

2

2

WHI

P05

Q200~205

Q300~305

2

2

WHI

BLK

P06

RED

3

3

IGBT

P.C.BOARD

MOS-FET

1

1

YEL

P25

P24

R221

(MCC-5009)

R321

6

6

FAN MOTOR

P23

R220

R320

5

5

4

4

PMV

YEL

P22

R219

R319

CN700 3

3

P21

2

2

BRW

P20

F03

1

1

PULSE MOTOR VALVE

P35

L03

C13

L01

VARISTOR

YEL

FUSE

3

3

T3.15A

P34

DB01

AC250V

CN603

2

1

1

TS

SURGE

(SUCTION PIPE

C12

C14

ABSORBER

2

2

TEMP. SENSOR)

POWER

VARISTOR

CN602 1

1

RELAY

TO

F01

(OUTDOOR

P19

FUSE

3

3

TEMP. SENSOR)

CT

25A

ORN

DB02

AC250V

P02

CN601

2

P03

P01

1

P18

ORN

BLK

WHI

1

TD

P11

RELAY

1

1

(DISCHARGE PIPE

2

2

TEMP. SENSOR)

REACTOR

2

2

P08

CN600 1

1

Q404

TE

P32

CN701

P07

L1 L2 S L1 L2

2

2

(CONDENSER PIPE

TEMP. SENSOR)

P33

P31

P30

1

3

BLK

CN500 1

1

PUR

1

2

1

3

~

~ ~

PRESSURE SW.

1

2

COLOR IDENTIFICATION

COIL

FOR

POWER

BLK:BLACK

WHI:WHITE

4WAY

BLU:BLUE

BRW:BROWN

SUPPLY

RED:RED

ORN:ORANGE

VALVE

208/230-1-60

GRY:GRAY

YEL:YELLOW

PNK:PINK

PUR:PURPLE

REACTOR

Outdoor Terminal Block L1		L2	S
Indoor Terminal Block L1		L2	S	Heat
POWER SUPPLY	BLK WHI RED			Exchanger
(From Outdoor Unit)				GRN&YEL
208/230-1-60

SHEET METAL

			BLK
		CN02			3	1
				F01	CN01 CN51
							1	1
			250VAC				3	3
				Fuse
							4	4			DC Motor
			T3.15A				5	5
							6	6
							CN31				Fan Motor
			1	1			(WHI)
									WHI
			2	2			1	1		1	1
Heat Exchanger Sensor CN62							2	2	YEL	2	2
(TC)			(BLU)		Varistor		3	3	YEL	3	3
							4	4	YEL	4	4
			1	1			5	5	YEL	5	5
			2	2			CN32				Louver Motor
Thermo Sensor CN61					Line		(WHI)
	(TA)		(WHI)		Filter					CN22
							DC5V	Power Supply Circuit		(WHI)
										1
							DC12V
		1	1		1	1				2
				BLU
		2	2		2	2				3
Wireless Unit Assembly		3	3	BLU	3	3				4
		4	4	BLU	4	4					Color indication
	MCC-5044	5	5	BLU	5	5
		6	6	BLU	6	6					BRW:BROWN
		7	7	BLU	7	7					YEL:YELLOW
		8	8	BLU	8	8					BLK:BLACK
		9	9	BLU	9	9					RED:RED
		10 10		WHI	10 10						BLU:BLUE
		11 11			11 11						WHI:WHITE
		12 12			12 12						GRN & YEL:
		13 13			13 13						GREEN & YELLOW
		14 14			14 14		Main PC Board
		15 15			15 15
		CN10			CN21		MCC-5045
		(WHI)			(WHI)
					– 19 –

FILE NO. SVM-10019

6. SPECIFICATIONS OF ELECTRICAL PARTS

6-1. Indoor Unit

	No.		Parts name	Type	Specifications
	1	Fan motor	RAS-09LKV-UL	AFS-220-20-4D	AC240V, 20W
		(for indoor)	RAS-12LKV-UL	ICF-340U30-2	AC220V, 20W
	2	Room temp. sensor (TA-sensor)		( − )	10kΩ at 25°C
	3	Heat exchanger temp. sensor (TC-sensor)		( − )	10kΩ at 25°C
	4	Louver motor		MP24Z3T	Output (Rated) 1W, 16 poles, DC12V

6-2. Outdoor Unit

	No.	Parts name		Model name			Rating
	1	Reactor			CH-57		L = 10mH, 16A
	2	Outdoor fan motor		ICF-340UA40-2			DC340V, 40W
	3	Suction temp. sensor (TS sensor)		(Inverter attached)			10kΩ (25°C)
	4	Discharge temp. sensor (TD sensor)		(Inverter attached)			62kΩ (20°C)
	5	Outside air temp. sensor (TO sensor)		(Inverter attached)			10kΩ (25°C)
	6	Heat exchanger temp. sensor (TE sensor)		(Inverter attached)			10kΩ (25°C)
	7	Terminal block (5P)					30A, AC600V
	8	Compressor	RAS-09LAV-UL	DA89X1C-23FZ2			3-phases 4-poles 680W
			RAS-12LAV-UL	DA111A1F-20F2			3-phases 4-poles 750W
	9	COIL FOR P.M.V.		CAM-MD 12TCTH-4			DC12V
	10	Coil for 4-way valve			STF
	11	Pressure SW.		ACB-4UB82W			4.7 MPa

– 20 –

FILE NO. SVM-10019

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

RAS-09LKV-UL / RAS-09LAV-UL

P Pressure measurement

Gauge attaching port Vacuum pump connecting port

Deoxidized copper pipe Outer dia. : 3/8 in (9.52mm) Thickness : 1/32 in (0.8mm)

INDOOR UNIT	T1
Indoor heat
exchanger
	TC
Cross flow fan	TA

Deoxidized copper pipe Outer dia. : 1/4 in (6.35mm) Thickness : 1/32 (0.8mm)

Sectional shape of heat insulator

Temp. measurement

33ft(10mm)	length	Max.	: 66ft (20m)
height		Min.	: 6.6ft (2m)
:	Allowablepipe
Allowable difference		Chargeless : 50ft (15m)
		Charge	: 0.22oz/ft
		(51 to 66ft)
		[20g/m (16 to 20m)]

Muffler

4-way valve

	Muffler
	High Pressure switch
	TD
	Compressor
	DA89X1C-23FZ2
TS		TO
	Fusible plug
	Outdoor heat
	exchanger
Temp. measurement T2		TE
	Propeller fan

OUTDOOR UNIT

NOTE :

Strainer

Pulse Modulating valve at liquid side

Strainer

Refrigerant amount : 1.77lbs (0.80kg)

NOTE : Gas leak check position

Refrigerant flow (Cooling) Refrigerant flow (Heating)

•The maximum pipe length of this air conditioner is 66ft (20 m). When the pipe length exceeds 50ft (15m), the additional charging of refrigerant, 0.22 oz/ft (20g/m) for the part of pipe exceeded 50ft (15m) is required. [(Max. 0.22 lbs (100g)]

–21 –

FILE NO. SVM-10019

RAS-12LKV-UL / RAS-12LAV-UL

P Pressure measurement

Gauge attaching port Vacuum pump connecting port

Deoxidized copper pipe Outer dia. : 3/8 in. (9.52mm) Thickness : 1/32 in. (0.8mm)

INDOOR UNIT	T1	Temp. measurement
Indoor heat
exchanger
	TC	(10m)	length
Cross flow fan	TA	height
		33ft:	Allowablepipe
Deoxidized copper pipe		Allowable difference
Outer dia. : 1/4 in. (6.35mm)
Thickness : 1/32 in. (0.8mm)
Sectional shape
of heat insulator

Max. : 66ft (20m) Min. : 6.6ft (2m) Chargeless : 50 ft (15m)

Charge : 0.22oz/ft (51 to 66 ft)

[20g/m (16 to 20m)]

		Muffler		Strainer
4-way valve
		Muffler		Pulse Modulating
				valve at liquid side
		TD
		Compressor
		DA111A1F-20F1
TS			TO
		Outdoor heat	Split capillary
		exchanger
			Ø1.2 x 80
Temp. measurement	T2		Ø1.2 x 80
			TE
		Propeller fan		Refrigerant amount : 2.43 lbs (1.10kg)
		OUTDOOR UNIT		NOTE :	Gas leak check position
					Refrigerant flow (Cooling)
					Refrigerant flow (Heating)

NOTE :

•The maximum pipe length of this air conditioner is 66ft (15 m). When the pipe length exceeds 50ft (15m), the additional charging of refrigerant, 0.22 oz/ft (20g/m) for the part of pipe exceeded 15m is required. [Max. 0.22 lbs (100g)]

–22 –

FILE NO. SVM-10019

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 Psia (MPa)	T1 °F (°C)	T2 °F (°C)				(rps)
	80/67	98/75	09LKV-UL	137 to 160	54 to 57	99 to 102		High	High	60
	(26.7/19.4)	(35/23.9)		(0.9 to 1.1)	(12 to 14)	(37 to	39)
			12LKV-UL	116 to 145	52 to 55	104 to	107	High	High	77
				(0.8 to 1.0)	(11 to 13)	(42 to	44)
	<Heating>
	Tempeature		Model name	Standard	Heat exchanger			Indoor	Outdoor	Compressor
	condition(°C)		RAS-	pressure	pipe temp.			fan mode	fan mode	revolution
	Indoor	Outdoor		P Psia (MPa)	T1 °F (°C)	T2 °F (°C)				(rps)
	70/60	47/43	09LKV-UL	363 to 392	102 to 105	32 to	37	High	High	62
	(21.1/15.6)	(8.3/6.1)		(2.5 to 2.7)	(39 to 41)	(0 to	3)
			12LKV-UL	377 to 406	106 to 106	32 to	36	High	High	64
				(2.6 to 2.8)	(41 to 43)	(0 to	2)

NOTES :

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

2.Connecting piping condition : 16 ft (5m)

– 23 –

FILE NO. SVM-10019

8. CONTROL BLOCK DIAGRAM

8-1. Indoor Unit

M.C.U.	Indoor Unit Control Unit

Heat Exchanger Sensor (Tc)

Room Temperature Sensor (Ta)

Infrared Rays Signal Receiver

and Indication

Initializing Circuit

Clock Frequency

Oscillator Circuit

Functions

•Cold draft preventing Function

•3-minute Delay at Restart for Compressor

• Fan Motor Starting Control

•Processing

(Temperature Processing)

•Timer

•Serial Signal Communication

• Clean Function

Louver

Motor

Louver Motor

Drive Control

Indoor Fan

Motor Control

Indoor

Fan Motor

Power Supply

Circuit

Converter (D.C circuit)

	Noise Filter		Serial Signal Transmitter/Receiver
From Outdoor Unit
			Serial Signal Communication
208/230-1-60
			(Operation Command and Information)
			Remote Controller	Infrared Rays, 36.7kHz

REMOTE CONTROLLER

Operation (START/STOP)

Operation Mode Selection

AUTO, COOL, DRY, HEAT, FAN

Thermo. Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver AUTO Swing

Louver Direction Setting

ECO

Hi-POWER

COMFORT SLEEP

QUIET

SLEEP (1,3,5,9 OFF TIMER)

– 24 –

For INDOOR UNIT	MICRO-COMPUTER BLOCK DIAGRAM

	208/230-1-60
			MCC5009 (P.C.B)				OUTDOOR UNIT
	Indoor unit		M.C.U			Current
	send/receive
	circuit					detect
		•	PWM synthesis function
		•	Input current release control			Gate drive
	Discharge	•	IGBT over-current detect control
		•	Outdoor fan control			circuit
	temp. sensor
		•	High power factor correction control
	Outdoor air	•	Inverter output frequency control
	temp. sensor	•	A/D converter function			Current
		•	P.M.V. control			detect
–	Suction temp.
		•	Discharge temp. control
25	sensor
		•	4-way valve control
–						Gate drive
	Heat exchanger	•	Signal communication to indoor unit
	temp.sensor					circuit
		High Power		Clock
		factor Correction		frequency
			circuit	4MHz
	Noise	Input current		Converter		Inverter	Outdoor
	Filter		sensor	(AC → DC)		(DC → AC)	Fan motor
			Driver circuit		Relay	Inverter	Compressor
			of P.M.V.		circuit	(DC → AC)

P.M.V. : Pulse Motor Valve

4-way M.C.U. : Micro Control Unit P.M.V. valve

Assembly) (Inverter Unit Outdoor .2-8

10019-SVM .NO FILE

FILE NO. SVM-10019

9. OPERATION DESCRIPTION

9-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses AC or DC motor for the indoor for motor and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 11 to 96 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control fan motor are 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 and the pulse Modulating valve. (P.M.V) 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 inverter 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

•Air purifier operation control

2.Role of outdoor unit controller

Receiving the operation command signal (Serial signal) from the indoor unit controller, the outdoor unit performs its role.

•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

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

•Compressor operation control

•Operation control of outdoor fan motor

•P.M.V. control

•4-way valve control

	Operations followed to judgment
	of serial signal from indoor side.

– 26 –

	FILE NO. SVM-10019
9-2. Operation Description
1.	Basic operation ...........................................................................................................	28
	1. Operation control ...................................................................................................	28
	2. Cooling/Heating operation .....................................................................................	29
	3. AUTO operation .....................................................................................................	29
	4. DRY operation ........................................................................................................	29
2.	Indoor fan motor control .............................................................................................	30
3.	Outdoor fan motor control...........................................................................................	32
4.	Capacity control ..........................................................................................................	33
5.	Current release control ...............................................................................................	33
6.	Release protective control by temperature of indoor heat exchanger........................	34
7.	Defrost control (Only in heating operation) ................................................................	35
8.	Louver control .............................................................................................................	36
	1) Louver position .......................................................................................................	36
	2) Air direction adjustment .........................................................................................	36
	3) Swing .....................................................................................................................	36
9.	ECO operation ............................................................................................................	37
10.	Temporary operation ...................................................................................................	38
11.	Discharge temperature control ...................................................................................	38
12.	Pulse Modulating valve (P.M.V.) control .....................................................................	39
13.	Self-Cleaning function ................................................................................................	40
14.	Remote-A or B selection ............................................................................................	42
15.	QUIET mode .............................................................................................................	43
16.	COMFORT SLEEP mode .........................................................................................	43
17.	One-Touch Comfort ..................................................................................................	43
18.	Hi-POWER Mode ......................................................................................................	44
19.	FILTER Indicator ........................................................................................................	44
9-3. Auto Restart Function..
9-3-1. How to Cancel the Auto Restart Function .................................................................		45
9-3-2. How to set the Auto Restart Function .......................................................................		46
9-3-3. Power Failure During Timer Operation ...................................................................		46
9-4. Remote Controller and Its Fuctions
9-4-1. Parts Name of Remote Controller .............................................................................		47
9-4-2. Operation of remote control ......................................................................................		47
9-4-3. Name and Functions of Indications on Remote Controller .......................................		50

– 27 −

FILE NO. SVM-10019

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, 4-way valve and pulse Modulating valve.

Remote controller

Selection of operation conditions

ON/OFF

Control contents of remote controller

•ON/OFF (Air conditioner/Air purifier)

•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)
				• Activation compensation function of indoor fan		• Louver motor
	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

• Pulse Modulating valve

• Delay function of compressor reactivation

(P.M.V.)

• Current release function

• GTr over-current preventive function

• Defrost operation function

– 28 –

		FILE NO. SVM-10019
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, pulse Modulating valve 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: ON

[

In heating operation: OFF ]

Pulse Modulating valve control

3. AUTO operation

1) Detects the room temperature (Ta) when

Selection of operation mode

the operation started.

As shown in the following figure, the operation starts by

2) Selects an operation mode from Ta in

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

68°F (20°C) or more, the fan operation is

°C

Cooling operation

performed with ”Super Ultra LOW” mode

Ts + 1

for 3 minutes.

Monitoring (Fan)

Then, select an operation mode.

5) In AUTO mode, either cooling or heating

Ts – 1

operation will be selected. When room

Heating operation

temperature reach set temperature

commpressor will stop. In case that the

compressor stops for 15 minutes, the

AUTO mode will reselect cooling or

heating operation.

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-

prevent lowering of the room temperature and to avoid air

ture and the setup temperature (Tsc).

flow from blowing directly to persons.

Setup temperature (Tsc)

°F [ C]

= Set temperature on remote controller

(Ts) + 0~1.0°C (0 to 2°F)

Ta

L– (W5)

3) When the room temperature is lower

2°F (1°C) or less than the setup

+2.0 (1.0)

(W5+W3) / 2

temperature, turn off the compressor.

+1.0 (0.5)

SUL (W3)

Tsc

Fan speed

–− 29 −

FILE NO. SVM-10019

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

(Fig. 1)

* The values of fan speed and air flow

volume indicate on the table are measured

when the louver is inclined downward.

AUTO

Indication

Fan speed

Fan speed and air flow volume broadly

L

W6

vary with position of louver.

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 and room temperature.

°F [°C]

M+(WB)

+4.5 (+2.5)

+3.5 (+2.0)

a

*3

*3 : Fan speed = [(M+) –L] x 3/4 + L

+2.7 (+1.5)

b

*4

*4 : Fan speed = [(M+) –L] x 2/4 + L

+2.0 (+1.0)

c

*5

*5 : Fan speed = [(M+) –L] x 1/4 + L

+1.0 (+0.5)

d

L(W6)

(Linear approximation

Tsc

e

from M+ and L)

(Table 1) Indoor fan air flow rate

Fan speed

RAS-09LKV-UL

RAS-12LKV-UL

COOL

HEAT

DRY

level

Fan speed

Air flow rate

Fan speed

Air flow rate

(rpm)

cfm (m3/h)

(rpm)

cfm (m3/h)

WF

UH

1210

336 (571)

1510

433 (735)

WE

H

1210

336 (571)

1510

433 (735)

WD

UH

M+

UH

1170

321 (546)

1480

422 (717)

WC

H

H

1120

303 (515)

1430

404 (686)

WB

M+

M+

1040

274 (465)

1280

350 (594)

WA

M

1000

248 (421)

1220

328 (557)

W9

M

L+

960

235 (400)

1150

302 (514)

W8

L

870

200 (340)

1000

248 (421)

W7

L+

L-

L+

850

194 (330)

980

241 (409)

W6

L

L

760

159 (270)

920

219 (372)

W5

L-

UL

L-

760

159 (270)

900

212 (360)

W4

UL

UL

700

141 (240)

840

190 (323)

W3

SUL

SUL

650

118 (200)

770

165 (280)

W2

SUL

500

65 (110)

620

110 (187)

W1

500

65 (110)

520

74 (126)

– 30 –