Toshiba RAS-107SKV-E2, RAS-107SAV-E2 SERVICE MANUAL

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SERVICE MANUAL

Indoor Unit Outdoor Unit

FILE NO. SVM-09051

SPLIT TYPE

RAS-107SKV-E2 RAS-107SAV-E2

R410A

March, 2009

FILE NO. SVM-09051

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 ................................................................ 44

11. HOW TO DIAGNOSE THE TROUBLE...................................................... 57

12. HOW TO REPLACE THE MAIN PARTS................................................... 72

13. EXPLODED VIEWS AND PARTS LIST ................................................... 80

– 1 –

FILE NO. SVM-09051

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-09051

• 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 VER Y 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 cab les 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 perf ormed 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 –

FILE NO. SVM-09051

2. SPECIFICATIONS

2-1. Specifications

Unit model Indoor RAS-107SKV-E2

Outdoor RAS-107SAV-E2

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) 3.49 - 3.21 4.03- 3.70 Power consumption (W) 730 840 Power factor (%) 95 96

Starting current (A) 4.15 - 3.80 COP (Cooling / Heating) 3.33 3.72 3.29/3.68 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-107SKV-E2

Dimension Height (mm) 250

Width (mm) 740

Depth (mm) 195

Net weight (kg) 8 Fan motor output (W) 20 Air flow rate (Cooling / Heating)

Outdoor unit Unit model RAS-107SAV-E2

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-23EZ

Fan motor output (W) 20

Air flow rate (Cooling / Heating) Piping Type Flare connection connection Indoor unit Liquid side (mm)

Gas side (mm)

Outdoor unit Liquid side (mm)

Gas side (mm) 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)

Outdoor (Cooling / Heating)

Accessory Indoor unit Installation plate 1

Wireless remote controller 1

batteries 2

Remote controller holder 1

Active Corbon Catechin filter 2

ounting 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 –

/ min)

(

8.7/9.6

27/27

∅6.35 ∅9.52 ∅6.35 ∅9.52

21 - 32/Up to 27

15 - 43/-10 - 24

2-2. Operation Characteristic Curve

FILE NO. SVM-09051

Current (A)

Conditions

Indoor : DB 27 Outdoor : DB 35 Air Flow : High Pip Length : 5m Voltage : 230V

0 102030405060708090100110120

°C/WB 19°C

°C/WB 24°C

Current (A)

0 102030405060708090100110120

Compressor Speed (rp s)

2-3. Capacity Variation Ratio According to Temperature

Conditions Indoor : DB 20 Outdoor : DB 7 Air Flow : High Pip Length : 5m Voltage : 230V

Compressor Speed (rp s)

°C/WB 15°C

°C/WB 6°C

105

100

Cooling Capacity ratio (%)

Capacity ratio 100% is 2.5kw

Conditions Indoor : DB 27 Indoor Air Flow : High Pip Length : 5m Voltage : 230V

°C/WB 19°C

32 33 34 35 36 37 38 39 40 41 42 43

Outside Temperature ( oC)

120

100

Heating Capacity ratio (%)

-10 -5 0 5 10

Capacity ratio 100% is 3.2kw

Conditions Indoor : DB 20 Indoor Air Flow : High Pip Length : 5m Voltage : 230V

°C/WB 15°C

Outside Temperature ( ºC)

– 5 –

3. REFRIGERANT R410A

FILE NO. SVM-09051

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. b y 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 le vel.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal le vel, 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 m ust 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. Ne ver use copper pipes thinner than 0.8 mm even when it is available on the market.

– 6 –

Table 3-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

FILE NO. SVM-09051

Nominal diameter

1/4 3/8 1/2 5/8

Outer diameter (mm)

6.35

9.52

12.70

15.88

R410A R22

0.80 0.80

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 sock et joints are as shown in Table 3-2-2.

Table 3-2-2 Minimum thicknesses of socket joints

Nominal diameter

1/4 3/8 1/2 5/8

Reference outer diameter of

copper pipe jointed (mm)

6.35

9.52

12.70

15.88

Minimum joint thickness

(mm)

0.50

0.60

0.70

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 ma y occur. Carefully remove all burrs and clean the cut surface before installation.

c) Insertion of Flare Nut

– 7 –

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 “dimen- sion A” by using a gauge for size adjustment.

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

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

Fig. 3-2-1 Flare pr ocessing dimensions

Flare tool for R410A

clutch type

FILE NO. SVM-09051

ØD

A (mm)

Conventional flare tool

Clutch type Wing nut type

1/4 3/8 1/2 5/8

Nominal

diameter

1/4 3/8 1/2 5/8

6.35

9.52

12.70

15.88

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

Outer

diameter

(mm)

6.35

9.52

12.70

15.88

0.8

1.0

Thickness

(mm)

0.8

1.0

0 to 0.5 0 to 0.5 0 to 0.5 0 to 0.5

Flare tool for R22

clutch type

0 to 0.5 0 to 0.5 0 to 0.5 0 to 0.5

1.0 to 1.5 1.5 to 2.0

1.0 to 1.5 2.0 to 2.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

0.5 to 1.0 1.0 to 1.5

0.5 to 1.0 1.5 to 2.0

Nominal

diameter

1/4 3/8 1/2 5/8

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

Outer diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

1.0

Dimension (mm)

ABCD

9.1 9.2 6.5 13

13.2 13.5 9.7 20

16.6 16.0 12.9 23

19.7 19.0 16.0 25

– 8 –

Flare nut width

(mm)

17 22 26 29

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

FILE NO. SVM-09051

Nominal

diameter

1/4 3/8 1/2 5/8 3/4

Outer diameter

(mm)

6.35

9.52

12.70

15.88

19.05

45˚ to 46˚

Thickness

(mm)

0.8

1.0

B A

Dimension (mm)

ABCD

9.0 9.2 6.5 13

13.0 13.5 9.7 20

16.2 16.0 12.9 20

19.7 19.0 16.0 23

23.3 24.0 19.2 34

43˚ to 45˚

Flare nut width

(mm)

17 22 24 27 36

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 b y 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 tighten-

ing torque, comply with values designated by man ufacturers. 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

diameter

Outer diameter

(mm)

Tightening torque

N•m (kgf•cm)

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

1/4 3/8 1/2 5/8

6.35

9.52

12.70

15.88

14 to 18 (140 to 180) 33 to 42 (330 to 420) 50 to 62 (500 to 620) 63 to 77 (630 to 770)

– 9 –

16 (160), 18 (180)

42 (420) 55 (550) 65 (650)

FILE NO. SVM-09051

3-3. Tools

3-3-1. Required T ools

The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is changed to prev ent 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 f or 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

air-water heat pump installation

No.

4 5 6

7 8

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection

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

Used tool

Flare tool Copper pipe gauge for

adjusting projection margin

Torque wrench (For Ø12.7)

Gauge manifold Charge hose Vacuum pump adapter

Electronic balance for refrigerant charging

Refrigerant cylinder Leakage detector Charging cylinder

margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

Pipe flaring Flaring by

conventional flare tool

Connection of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating Refrigerant charge Refrigerant charge

Gas leakage check Refrigerant charge

Usage

Existence of new equipment for R410A

Yes

Yes Yes Yes

Yes

(Note 2)

R410A

Whether conventional equipment can be used

*(Note 1)

× ×

× × ×

× ×

Conventional air-water heat pump installation

Whether new equipment can be used with conventional refrigerant

*(Note 1)

× ×

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

5. Pipe bender

6. Level vial

7. Screwdriver (+, –)

8. Spanner or Monkey wrench

9. Hole core drill (Ø65)

10. Hexagon wrench (Opposite side 4mm)

11 . Tape measure

12. Metal saw

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

1. Clamp meter

2. Thermometer

3. Insulation resistance tester

4. Electroscope

– 10 –

FILE NO. SVM-09051

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.

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.

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.

(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)

Opened

(Outdoor unit)

Refrigerant cylinder

(with siphon)

Check valve

Opened Open/close valve for charging

Electronic balance for refrigerant charging

Fig. 3-4-1 Configuration of refrigerant charging

Opened

Closed

Service port

– 11 –

FILE NO. SVM-09051

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

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

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.

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.

Electronic

balance

Siphon

Fig. 3-4-2

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

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. 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 –

FILE NO. SVM-09051

2. Characteristics required for flux

• Activated temperature of flux coincides with the brazing temperature.

• Due to a wide effectiv e temper ature 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 o xide 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

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 prev ent 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.

Piping material

Copper - Copper

Copper - Iron

Iron - Iron

Used brazing filler

Phosphor copper

Silver Silver

Used flux

Do not use

Paste flux 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 w ater which does not contain chlorine (e.g. distilled water or ion-exchange water).

4. Remove the flux after brazing.

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 –

4-1. Indoor Unit

FILE NO. SVM-09051

4. CONSTRUCTION VIEWS

Front panel

Knock out system

250

Air inlet

Air filter

740

Air outlet

6055

Heat exchanger

5560

135500105

Knock out system

195

Hanger

145

290

605

235

215

Hanger

145

Installation plate outline

Center line

Drain hose (0.5m)

Hanger

235

215

250

90 135

– 14 –

Connecting pipe (0.37m) (Flare ∅

Connecting pipe (0.37m)

6.35)

(Flare ∅

For stud bold (

For stud bold (∅

90135

9.52)

∅

45165

10)

∅

Wireless remote control

135

4-2. Outdoor Unit

FILE NO. SVM-09051

280

400

− 15 −

5-1. Indoor Unit

FILE NO. SVM-09051

5. WIRING DIAGRAM

– 16 –

FILE NO. SVM-09051

5-2. Outdoor Unit

– 17 –

FILE NO. SVM-09051

6. SPECIFICATION OF ELECTRICAL PARTS

6-1. Indoor Unit

No. Parts name Type Specifications

1 Fan motor (for indoor) AFN-220-20-4D AC Motor with 145°C thermo fuse 2 Thermo. sensor (TA-sensor) 10 kΩ at 25°C 3 Switching transformer (T01) ST-02 4 Microcontroller unit (IC81) 5 Heat exchanger sensor

(TC-sensor) 6 Line filter (L01) SS11V-R06270 27 m H, AC 0.6A 7 Bridge diode (DB01) DB105G 1A, 600V 8 Capacitor (C27) 9 Fuse (F01) FJL250V3.15A 3.15A, 250 V

10 Regulator IC (IC02) S7805PIC 5VDC, 0.5A

11 Varistor (R01) SR561K14DL 560V 12 Louver motor DC 12V

µPD780076GK-703-9ET-A

10 kΩ at 25°C

EKMH401VSN470MP20S 47µF, 400V

MP24ZCT

– 18 –

FILE NO. SVM-09051

6-2. Outdoor Unit

No. Parts name Model name Rating

1 SC coil L01 GET-04051 0.6mH, 15A

(Noise filter) L03 GET-04052 10A, 2mH

3 Reactor CH-69-Z-T L=19mH, 10A

4 Outside fan motor 5

Fan control relay

Outside air temp.

sensor (TO sensor) Dischenge temp.

sensor (TD sensor)

SWT-72

WLF-240-20A-1

G5NB-1A-CA Coil DC12V Contact AC250V-1.5A

(Inverter attached) 10kΩ (25°C)

(Inverter attached) 62kΩ (20°C)

Primary side DC280V, Secondary2 DC-DC transformer side 7.0 V x 1, 12 V x 1, 17V x 2

20W

Terminal block (5P)

Fuse

Electrolytic capacitor

IGBT

Compressor DA89X1C-23EZ 3-phases 4-poles 750W

Rectifier

14 Running capacitor

(for fan motor)

4-WAY valve coil

STF-01AJ646A1 AC 220-240V

For protection of switching power source 3.15A, AC250V

For protection of inverter input overcurrent 25A, AC250V

JX0-5B

LLQ2G501KHUATF

GT15J321

D15XB60-4001 15A, 600V

DS451155NPQB

20A, AC250V

500µF, DC 400 V x 3 pieces

15A, 600V

AC 450V~, 1.5µF

– 19 –

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

INDOOR UNIT

Indoor heat

exchanger

Temp. measurement

FILE NO. SVM-09051

Pressure measurement Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe Outer dia. : 9.52mm Thickness : 0.8mm

4-way valve (STF-0108Z)

Muffler

Compressor DA89X1C-23EZ

Outdoor heat

exchanger

Cross flow fan

Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm

Sectional shape of heat insulator

Ø1.0 x 600

Allowable height

difference : 10m

Allowable pipe length

Max. : 10m

Min. : 2m Chargeless : 10m

Temp. measurement

Ø1.0 x 600

Propeller fan

OUTDOOR UNIT

NOTE :

Refrigerant amount : 0.63kg

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-09051

7-2. Operation Data

Tempeature Standard Heat exchanger Indoor Outdoor Compressor

condition(°C) pressure pipe temp. fan mode fan mode revolution

Indoor Outdoor P (MPa) T1 (°C) T2 (°C) (rps)

27/19 35/- 0.9 to 1.1 9 to 11 47 to 49 High High 54

Tempeature Standard Heat exchanger Indoor Outdoor Compressor

condition(°C) pressure pipe temp. fan mode fan mode revolution

Indoor Outdoor P (MPa) T1 (°C) T2 (°C) (rps)

20/- 7/6 2.4 to 2.6 43 to 45 0 to 3 High High 68

NOTES :

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

2. Connecting piping condition 5 m

– 21 –

8-1. Indoor Unit

Heat Exchanger Sensor

8. CONTROL BLOCK DIAGRAM

Indoor Unit Control Panel

M.C.U

Functions

• Louver Control

FILE NO. SVM-09051

Operation

Display

Temperature Sensor

Infrared Rays Signal Receiver

Initiallizing Circuit

Infrared

Rays

36.7KHz

Clock Frequency

Oscillator Circuit

Power Supply

Remote

Control

Noise Filter

From Outdoor Unit

Circuit

•

3-minute Delay at Restart for Compressor

•

Motor Revolution Control

•

Processing (Temperature Processing)

•

Timer

•

Serial Signal Communication

Louver ON/OFF Signal

Louver Driver

Serial Signal Transmitter/Receiver

Serial Signal Communication

Timer

Display

Indoor

Fan Motor

Louver Motor

REMOTE CONTROL

Infrared Rays

Remote Control

Operation ( )

Operation Mode Selection AUTO, COOL, DRY, HEAT

Temperature Setting Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECO

– 22 –

8-2. Outdoor Unit (Inverter Assembly)

For INDOOR UNIT

230V 50Hz

signal

Noise

filter

Input

current

sensor

Converter

(AC DC)

P.C.B (MCC 5009)

Over

current

sensor

Gate drive

circuit

Rotor position

detect circuit

Relay

Fan

motor

4way

Valve

Relay

High power factor

correction circuit

1. PWM synthesis function

2. Input current release control

3. IGBT over-current detect control

4. Outdoor fan control

5. High power factor correction control

6.Signal communication to indoor unit M. C. U

M. C. U

Inverter

(DC AC)

Compressor

MICRO-COMPUTER BLOCK DIAGRAM

FILE NO. SVM-09051

– 23 –

Discharge

temp. sensor

Outdoor air

temp. sensor

Heat Exchanger

9. OPERATION DESCRIPTION

FILE NO. SVM-09051

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.

• Compressor operation control

• 4-way valve control

Operations followed to judgment



of serial signal from indoor side.

 

• 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 [Com-

pressor revolution] indoor heat exchanger temperature), the outdoor unit controller monitors the input current to the inverter, and perfor ms 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 transferr ing 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.

– 24 –

FILE NO. SVM-09051

9-2. Operation Description

1. Basic operation ........................................................................................................... 26

1. Operation control ................................................................................................... 26

2. Cooling/Heating operation ..................................................................................... 27

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

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. .................................................................................. 35

Discharge temperature control

11.

Self-Cleaning function ................................................................................................ 36

12.

Selt-Cleaning function release ................................................................................... 37

13.

Remote-A or B selection ............................................................................................ 38

14.

Short Timer ................................................................................................................ 38

9-3. Auto Restart Function ................................................................................................39

9-3-1. How to Set the A uto Restart Function .............................. ........................................ 39

9-3-2. How to Cancel the Au to Restar t Function ................................................................ 40

9-3-3. Power Failure During Timer Operation ................................................................... 40

9-4. Remote Controller and Its Fuctions ..................................................................... 41

9-4-1. Parts Name of Remote Contr oller ............................................................................. 41

9-4-2. Operation of remote control ...................................................................................... 41

9-4-3. Name and Functions of Indications on Remote Contr oller ........................................ 43

– 25 −

FILE NO. SVM-09051

Item

1. Basic operation

Operation flow and applicable data, etc.

1. Operation control

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.

Selection of

operation conditions

ON/OFF

Description

Remote controller

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/MED/HIGH)

• ECO

• ON timer setup

• OFF timer setup

Signal receiving

Indoor unit control

Operation command

Serial signal send/receive

Outdoor unit control

Indoor unit

Indoor unit control

• Command signal generating function of indoor unit operation

• Calculation function (temperature calculation)

• Activation compensation function of indoor fan

• Cold draft preventive function

• Timer function

• Indoor heat exchanger release control

Outdoor unit

Outdoor unit control

• Frequency control of inverter output

• Waveform composite function

• Calculation function

(Temperature calculation)

• AD conversion function

• Quick heating function

• Delay function of compressor reactivation

• Current release function

• GTr over-current preventive function

• Defrost operation function

• Indoor fan motor

• Louver motor

Inverter

• Compressor

• Outdoor fan motor

• 4-way valve

– 26 –

FILE NO. SVM-09051

Item

1. Basic operation

Operation flow and applicable data, etc.

2. Cooling/Heating 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

Indoor unit control

Sending of operation command signal

Outdoor unit control

Setup of remote controller

Indoor fan motor control / Louver control / Operation Hz

Control (Requierment)

Compressor revolution control / Outdoor fan motor control / Operation Hz control (Include limit control)

4-way valve control In cooling operation: In heating operation:

[ ]

Description

OFF

3. AUTO operation

Selection of operation mode As shown in the following figure, the operation starts by selecting automatically the status of room temperature (Ta) when starting AUTO operation.

*1. When reselecting the operation mode, the fan

speed is controlled by the previous operation mode.

Cooling operation

Ts + 1

Monitoring (Fan)

Ts – 1

Heating operation

4. DRY operation

DRY operation is performed according to the difference between room temperature and the setup temperature as shown below.

In DRY operation, fan speed is controlled in order to prevent lower ing of the room temperature and to avoid air flow from blowing directly to persons.

[˚C]

L– (W5)

1) Detects the room temperature (Ta) when the operation started.

2) Selects an operation mode from Ta in the left figure.

3) Fan operation continues until an operation mode is selected.

4) When AUTO operation has started within 2 hours after heating operation stopped and if the room temperature is 20°C or more, the fan operation is performed with ”Super Ultra LOW” mode for 3 minutes. Then, select an operation mode.

5) If the status of compressor-OFF continues for 15 minutes the room temperature after selecting an operation mode (COOL/HEAT), reselect an operation mode.

1) Detects the room temperature (Ta) when the DRY operation started.

2) Starts operation under conditions in the left figure according to the temperature difference between the room temperature and the setup temperature (Tsc). Setup temperature (Tsc) = Set temperature on remote controller (Ts) + (0.0 to 1.0)

3) When the room temperature is lower 1°C or less than the setup temperature, turn off the compressor.

+ +

Tsc

1.0

0.5

(W5+W3) / 2

SUL (W3)

Fan speed

− 27 −

FILE NO. SVM-09051

Item

2. Indoor fan motor control

COOL ON

Fan speed setup

AUTO

[˚C]

+2.5

+2.0

+1.5

+1.0

Operation flow and applicable data, etc.

(This 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 mode, and in 5 stages in AUTO mode, respectively. (Table 1)

MANUAL

(Fig. 1)

Indication

M H

Fan speed

(Fig. 2)

Air volume AUTO

M+(WB)

*3 *4 *5

*3 : Fan speed = (M + –L) x 3/4 + L *4 : Fan speed = (M + –L) x 2/4 + L *5 : Fan speed = (M + –L) x 1/4 + L

Description

* Symbols

UH : Ultra High H : High M+ : Medium+ M : Medium L+ : Low+ L: Low L- : Low– UL : Ultra Low SUL : Super Ultra Low

* The fan speed broadly varies due

to position of the louver, etc. The described value indicates one under condition of inclining downward blowing.

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. 1.

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 Fig. 2 and Table 1 according to the setup temperature, room temperature, and heat exchanger temperature.

+0.5

Tsc

d e

(Table 1) Indoor fan air flow rate

Fan speed

COOL HEAT DRY

level

WF UH WE H WD UH M+ WC H WB M+ WA W9 M L+ W8 L W7 L+ LW6

L W5 L- UL LW4 UL UL W3 SUL SUL W2 SUL W1

L(W6)

H M+ M

L+

(Linear approximation from M+ and L)

Fan speed Air flow rate

(rpm) (m3/h)

1350 607 1300 576 1250 554 1200 522 1120 486 1100

1040 444

960 402

910 376

880 360 830 334 800 318 700 266 650 239 600 213

468

– 28 –

[C]

5.5

)

FILE NO. SVM-09051

Item

2. Indoor fan motor control

HEAT

Fan speed setup

AUTO

TC ≥ 42˚C

Operation flow and applicable data, etc.

MANUAL

Indication

M H

YES

(Fig. 3)

Fan speed

Min air flow rate contro

Limited to Min WD tap

Description

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. 3 and Table 1.

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 Fig. 5 according to the set temperature and room temperature.

3) Min air flow rate is controlled by temperature of the indoor heat exchanger (Tc) as shown in Fig. 4.

4) Cold draft prevention, the fan speed is controlled by temperature of the indoor heat exchanger (Tc) as shown in Fig. 6.

5) In order to prevent Cold draft when compressor step during heating

operation. Then louver will move to upper position and fan speed will reduce or off.

*Fan speed =

(TC - (42 + a)) / 10 x (WD - W8) + W8

a : In up operation 1, in down operation 0

Fan spee

AUT

L+ (W9)

*1 *2

M+ (WD)

H (WE

Basic fan contr

–0.

–1.0

–1.5

–2.0

–2.5 –5.0

(Fig. 4)

*1: Fan speed = (M + -L+) x 1 4 + L+ *2: Fan speed = (M + -L+) x 2 4 + L+ *3: Fan speed = (M + -L+) x 3 4 + L+ (Calculated with linear approximation from M+ and L+)

(Fig. 5)

No limi

W8) + W

Cold draft preventive control

T 46 46 45 45 33

33 33 21 32 32 20

*A+4 *A+4 *A+4

*A-4 *A-4 *A-4

* No limitation while fan speed MANUAL mode is in stabilit * A: When Tsc 24, A is 24, and when Tsc < 24, A is Ts

Tsc: Set valu

Fan speed MAN Fan speed AUTO in stabilit Fan speed AUTO in startin

H (WE

Line-approximate H and S

SUL (W2

AL in startin

L with Tc

Stop

(Fig. 6)

[In starting and in stability]

FAN AUTO

F AN Man ual

In starting

• Until 12 minutes passed after operation start

• When 12 to 25 minutes passed after operation start and room temp. is 3°C or lo w er than set temp.

• Room temp. < Set temp. –4°C

• When 12 to 25 minutes passed after operation start and room temp. is higher than (set temp. –3°C)

• When 25 minutes or more passed after operation start

• Room temp. ≥ Set temp. –3.5°C

In stability

– 29 –

FILE NO. SVM-09051

Item

3. Capacity control

Remote controller Indoor unit

Operation flow and applicable data, etc.

The cooling or heating capacity depending on the load is adjusted.

According to difference between the setup value of temperature and the room temperature, the capacity is adjusted by the compressor revolution.

Set temp. (Ts)

Ts –Ta

Correction of Hz signal

Detection of electromotive force

of compressor motor winding

Detection of motor speed and rotor position

Correction value of Hz signal ≤ Operating Hz

Inverter output change

Commutation timing change

Room temp. (Ta)

Description

1) The difference between set temperature on remote controller (Ts) and room temperature (Ta) is calculated.

2) According to the temperature difference, the correction value of Hz signal which determines the compressor speed is set up.

3) The rotating position and speed of the motor are detected by the electromotive force occurred on the motor winding with operation of the compressor.

4) According to the difference resulted from comparison of the correction value of Hz signal with the present operation Hz, the inverter output and the commutation timing are varied.

5) Change the compressor motor speed by outputting power to the compressor.

* The contents of control

operation are same in cooling operation and heating operation

4. Current release control

Outdoor unit inverter main

circuit control current

Operating current ≤

Setup value

Low

Capacity control continues.

Outdoor temp.

Change of compressor speed

This function prevents troubles on the electronic parts of the compressor driving inverter.

This function also controls drive circuit of the compressor speed so that electric power of the compressor drive circuit does not exceed the specified value.

Outdoor temp. To

Setup of current release point

High

Reduce compressor speed

Current decrease

Cooling current

release value

Heating current

release value

1) The input current of the outdoor unit is detected in the inverter section of the outdoor unit.

2) According to the detected outdoor temperature, the specified value of the current is selected.

3) Whether the current value exceeds the specified value or not is judged.

4) If the current value exceeds the specified value, this function reduces the compressor speed and controls speed up to the closest one commanded from the indoor unit within the range which does not exceed the specified value.

45°C 40°C 44°C 16°C 39°C 11°C 15.5°C

10.5°C

3.60A

5.17A

7.72A

9.26A

10.80A

– 30 –

FILE NO. SVM-09051

Item

5. Release protective control by temperature of indoor heat exchanger

7˚C

6˚C

5˚C

Indoor heat exchanger temperature

Operation flow and applicable data, etc.

(Prevent-freezing control for indoor heat exchanger) In cooling/dry operation, the sensor of indoor heat

exchanger detects evaporation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value.

Usual cooling capacity control

When the value is in Q zone, the

compressor speed is kept.

Reduction of compressor speed

Description

1) When temperature of the indoor heat exchanger drops below 5°C, the compressor speed is reduced. (P zone)

2) When temperature of the indoor heat exchanger rises in the range from 6°C to under 7°C, the compressor speed is kept. (Q zone)

3) When temperature of the indoor heat exchanger rises to 7°C or higher, the capacity control operation returns to the usual control in cooling operation. (R zone)

55˚C

52˚C

48˚C

Indoor heat exchanger temperature

(Prevent-overpressure control for refrigerating cycle) In heating operation, the sensor of indoor heat ex-

changer detects condensation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value.

Reduction of compressor speed

When the value is

in Q zone, the compressor speed is kept.

Usual heating capacity control

1) When temperature of the indoor heat exchanger rises in the range from 50°C to 55°C, the compressor speed is kept. (Q zone)

When temperature of the indoor heat exchanger drops in the range from 46°C to under 55°C, the compressor speed is kept. (Q zone)

2) When temperature of the indoor heat exchanger rises to 55°C or higher, the compressor speed is reduced. (P zone)

3) When temperature of the indoor heat exchanger does not rise to 50°C, or when it drops below to 46°C, the capacity control operation returns to the usual control in heating operation. (R zone)

– 31 –

FILE NO. SVM-09051

Item

6. Defrost control (Only in heating operation)

Start of heating operation

0’ 10’ 15’ 27’40” 34’

–5˚C –7˚C

–20˚C

Outdoor heat exchanger temperature

A zone

B zone

C zone

Operation flow and applicable data, etc.

(This function removes frost adhered to the outdoor heat exchanger.)

The temperature sensor of the outdoor heat exchanger (Te sensor) judges the frosting status of the outdoor heat exchanger and the defrost operation is performed with 4-way valve reverse defrost system.

Operation time (Minute)

C zone

A zone

B zone

* The minimum value of Te sensor 10 to 15 minutes

after start of operation is stored in memory as Te0.

Table 1

When T e0 - TE ≥ 2.5 continued for 2 minutes in A zone, defrost operation starts.

When the operation continued for 2 minutes in B zone, defrost operation starts.

When T e0 - TE ≥ 3 continued for 2 minutes in C zone, defrost operation starts.

Description

The necessity of defrost operation is detected by the outdoor heat exchanger temperature. The conditions to detect the necessity of defrost operation differ in A, B, or C zone each. (Table 1)

• Defrost operation in A to C zones

1) Stop operation of the compressor for 20 seconds.

2) Invert (OFF ) 4- way valve 10 seconds after stop of the compressor.

3) The outdoor fan stops at the same time when the compressor stops.

4) When temperature of the indoor heat exchanger becomes 38°C or lower, stop the indoor fan.

• Returning conditions from defrost

operation to heating operation

1) Temperature of outdoor heat exchanger rises to +8°C or higher.

2) Temperature of outdoor heat exchanger is kept at +5°C or higher for 80 seconds.

3) Defrost operation continues for 15 minutes.

1) Stop operation of the compressor for approx. 50 seconds.

2) Invert (ON) 4-way valve approx. 40 seconds after stop of the compressor.

3) The outdoor fan starts rotating at the same time when the compressor starts.

– 32 –

FILE NO. SVM-09051

Item

7. Louver control

1) Louver position

Operation flow and applicable data, etc.

This function controls the air direction of the indoor unit.

• The position is automatically controlled according to the operation mode (COOL/HEAT).

• The set louver position is stored in memory by the microcomputer, and the louver returns to the stored position when the next operation

is performed. (Cooling/Heating memory position)

The angle of the louver is indicated as the louver closes fully is 0°.

1) Louver position in cooling operation

Cooling operation/

AUTO (COOL)

Initial setting of "Cooling storage position" Louver : Directs downward (48.0°)

2) Louver position in heating operation

Description

2) Air direction adjustment

Horizontal

blowing

3) Swing

• Swing operation is performed in width 35° with the stop position as

the center.

• If the stop position exceeds either upper or lower limit position,

swing operation is performed in width 35° from the limit which the stop position exceeded.

Heating operation/

AUTO (HEAT)

Initial setting of “Heating storage position” Louver : Directs downward (115.7˚)

Air direction

Inclined blowing

Blowing

downward

Inclined blowing

• The louver position can be arbitrarily set up by pressing [FIX] button.

Horizontal

blowing

• Swing When pressing [SWING] button during operation, the louver starts swinging.

– 33 –

FILE NO. SVM-09051

Item

8. ECO operation

+6.5 +6.0

+5.5

+5.0 +4.5 +4.0

+3.5

+3.0

+2.5

+2.0 +1.5 +1.0

+0.5

TSC

-0.5

-1.0

-2.0

Operation flow and applicable data, etc.

When pressing [ECO] button on the remote controller, a Economic operation is performed.

This function operates the air conditioner with the difference between the set and the room temperature as shown in the following figure.

Frequency

Zone

Dry Max

*12 *11

*10

4 3

Min

OFF

1H 2H

Time

Description

1) The control target temperature increase 0.5ºC per hour up to 2ºC starting from the set temperature

when ECONO has been received.

2) The indoor fan speed is controlled between L+ and UL after setting ECO operation.

3) The compressor speed is controlled as shown in the left figure.

–0.5 –1.0 –1.5 –2.0 –2.5 –3.0 –4.0 –5.0 –6.0 –7.0 –8.0

(Room temp. – Set temp.)

–9.0 –10.0 –11.0

* 12 (DRY max - COOL min) /6 x 5 + COOL min * 11 (DRY max - COOL min) /6 x 4 + COOL min * 10 (DRY max - COOL min) /6 x 3 + COOL min

* 9 (DRY max - COOL min) /6 x 2 + COOL min * 8 (DRY max - COOL min) /6 x 1 + COOL min

30 minutes

Cool min

DRY max

→ Time Compressor

speed

0Hz

A zone

aHz

B zone

a to cHz

C zone

cHz

1) Setting the compressor speed to Max. aHz, the temperature zone in which the operation can be

performed with Max. cHz is

gradually widened after 30 minutes passed when starting ECO operation.

2) The indoor fan speed is

controlled within L- as maximum speed after setting ECO operation.

– 34 –

FILE NO. SVM-09051

Item

9. Temporary operation

Operation flow and applicable data, etc.

Pressing [RESET] button starts the temporary operation of [AUTO] operation. When keeping [RESET] button pressed for 10 seconds or more, the temporary [COOL] operation is performed.

1) When pressing [RESET] button, the temporary [AUTO] operation starts.

2) When keeping [RESET] button pressed for 3 seconds or more, Pi, Pi, Pi sound is heard and [AUTO RESTART] control is changed.

Filter lamp ON

Did you press [RESET] button

for 3 seconds or more?

YES

Did you press [RESET] button

for 10 seconds or more?

Switch to [AUTO RESTART] control.

YES

Press RESET button.

Temporary [AUTO] operation

Temporary [COOL] Operation

3) When keeping [RESET] button pressed for 10 seconds or more, “Pi” sound is heard and the temporary [COOL] operation starts.

4) If the filter lamp goes on, press [RESET] button to go off the filter lamp, and then press [RESET] button again.

5) To stop the temporary operation, press the button again.

10. Discharge temperature control 1. Purpose

Td value

117°C 112°C 108°C 105°C

98°C

Control operation

Judges as an error and stops the compressor. Reduce the compressor speed. Reduce slowly compressor speed. Keeps the compressor speed. If the operation is performed with lower speed than one

commanded by the serial signal, speed is slowly raised up to the commanded speed.

Operates with speed commanded by the serial signal.

This function detects error on the refrigerating cycle or error on the compressor, and performs protective control.

2. Operation

• Control of the compressor speed

The speed control is performed as described in the left table based upon the discharge temperature.

Description

– 35 –

FILE NO. SVM-09051

Item

Operation flow and applicable data, etc.

11. Self-Cleaning

function

Unit now performing cooling or dry operation

Press “STOP” button

Only timer indicator lights, and Self Cleaning operation starts

Time set now elapses

Operation stops

Description

1. Purpose

The Self-Cleaning operation is to minimize the growth of mold, bacteria etc. by running the fan and drying so as to keep the inside of the air conditioner clean.

Self-Cleaning operation

When the cooling or dry operation shuts down, the unit automatically starts the Self- Cleaning operation which is then performed for the specified period based on duration of the operation which was performed prior to the shutdown, after which the Self-Cleaning operation stops. (The Self-Cleaning operation is not performed after a heating operation.)

2. Operation

1) When the stop signal from the remote

controller or timer-off function is received, only the timer indicator light.

2) The period of the Self-Cleaning operation

is determined by the duration of the operation performed prior to the reception of the stop code.

3) After the Self-Cleaning operation has

been performed for the specified period, the unit stops operating.

• During Self-Cleaning operations: The louver opens slightly. The indoor fan operates continuously at a speed of 500 rpm.

Self-Cleaning operation times

Self-Cleaning operation time

No Self-Cleaning operation

performed (0 minutes)

30 mins.

Cooling: Auto (cooling) Dry

Heating: Auto (heating) Auto (fan only) Shutdown

Operation time

Up to 10 minutes 10 minutes

or longer

No Self-Cleaning operation performed

• To stop an ongoing Self-Cleaning operation at any time Press the start/stop button on the remote controller twice during the Self-Cleaning operation. (After pressing the button for the first time, press it for the

second time without delay (within 10 minutes).)

– 36 –

FILE NO. SVM-09051

Item Operation flow and applicable data, etc.

Description

• Self-Cleaning diagram

Operation display ON OFF OFF

FCU fan

FCU louver OPEN OPEN (12.7º) CLOSE

Timer display

Compressor

CDU fan ON or OFF

12. Self-Cleaning function release

rpm is depend on presetting. (500RPM)

depend on presetting of timer function. depend on presetting of timer function.

depend on presetting per room temperature.

Cool mode or dry mode

operation more than 10 mins.

How to cencel Self-Cleaning function

To cancel the Self-Cleaning function, proceed as

ON ON

ON or OFF

Turn off by remote controller or

timer-off function.

OFF OFF

Self-Cleaning mode

operate 30 mins.

Automatically turn-off.

follows:

OFF

ON or OFF

Operation time

• Press [RESET] button one time or use remote control to turn on air conditioner. Display will show in green color.

• Hold down the [RESET] button for more than

20 seconds. (The air conditioner will stop suddenly when the [RESET] is pressed but keep holding it

continue. The will beep 3 times in the first

3 seconds but it is not related to Self-Cleaning

function)

• After holding about 20 seconds, the air conditioner

will beep 5 times without any blinking of display.

• The Self-Cleaning Operation had been cancelled.

Remark

Presetting of Self-Cleaning function above, AUTORESTART function had been cancelled. To set

AUTO-RESTART again, please follow item 9-3-1

How to set Self-Cleaning function

To set the Self-Cleaning function, proceed as follows.

• Press [RESET] button one time or use remote control to turn on air conditioner. Display will show

in green color.

• Hold down the [RESET] button for more than 20 seconds. (The air conditioner will stop suddenly

when the [RESET] is pressed but keep holding it continue. Then will beep 3 times is the first 3 seconds but it is not related to Self-Cleaning

function)

• After holding about 20 seconds, the air conditioner will beep 5 times and OPERATION display blinks

5 times.

• The Self-Cleaning function had been set.

Remark

Presetting of Self-Cleaning function above, AUTORESTART function had been cancelled. To set

AUTO-RESTART again, please follow item 9-3-1

RESET button

− 37 −

FILE NO. SVM-09051

Item

13. Remote-A or B selection

Operation flow and applicable data, etc.

Setting the remote controller

To separate using of remote control for each indoor unit in case of 2 air conditioner are installed nearly.

Remote Control B Setup.

1) Press RESET button on the indoor unit to turn the air conditioner ON.

2) Point the remote control at the indoor unit.

3) Push and hold CHK • button on the Remote

Control by the tip of the pencil. "00" will be shown shown on the display.

4) Press CHK • during pushing MODE • . "B" will show on the display and "00" will disappear and

the air conditioner will turn OFF. The Remote

Control B is memorized.

Note : 1. Repeat above step to reset Remote Control

to be A.

2. Remote Control A has not "A" display.

3. Default setting of Remote Control from factory is A.

TOSHIBA

MODE

TEMP.

FAN

AUTO

QUIET

AUTO COOL

DRY HEAT

Description

1. Purpose

This operation is to operate only one indoor unit using one remote controller.

2. Description

When operating one indoor unit in a situation where two indoor units have been installed in the same room or nearby rooms, this operation prevents the remote controller signal from being received simultaneously by both units, thus preventing both units from operating.

3. Operation

The indoor unit on which the remote controller selection has been set to B receives the signal of the remote controller also set to B. (At the factory the remote controller selection is set to A on all the indoor units. There is no A setting display.)

14. Short Timer

START/STOP

SWING

FIX

FAN

MODE

ON OFF SET CLR

[MODE]

button

RST

TIMER

CHK

ECO

[CHECK]

button

In the normal condition, after switching one circuit breaker, 3-minute delay time for compressor and 1 hour for plasma air purifier are set for the maintenance of the unit.

Purpose

To start the unit immediately for the purpose of testing, trial...etc, short timer can be used. maintenance of the unit.

Short Timer Setting

Press [ ] button to turn the unit OFF.

k Set the operation mode or plasma air

purifier on the remote control without

sending the signal to the unit.

l Use the tip of the pencil to push the

[CHK] button and hold, "00" will show

on display, them press [CLR] button to make "00" disappear.

Press [ ] button to turn the unit ON.

n When short timer is activated, all

setting on the remote operates

immediately, besides, all indicatiors on

front panel turns ON continuously for

3 seconds.

− 38 −

FILE NO. SVM-09051

9-3. Auto Restart Function

This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the ev ent of a power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored.

This function is not set to work when shipped from the factory. Therefore it is necessary to set it to work.

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

To set the auto restart function, proceed as follows: The power supply to the unit must be on ; the function will not set if the power is off. Press the [RESET] button located in the center of the front panel continuously f or three seconds. The unit receives the signal and beeps three times. The unit then restarts operating automatically in the event of power supply being accidentally shut down.

• When the unit is standby (Not operating)

Operation

Press [RESET] button for more than three seconds. (Less than 10 seconds)

RESET button

• When the unit is in operation

Operation

Press [RESET] button for more than three seconds. (Less than 10 seconds)

Motions

The unit is on standby.

↓

The unit starts to operate. The green indicator is on.

↓ After approx. three seconds,

The unit beeps three times The green indicator flashes and continues to operate. for 5 seconds.

If the unit is not required to operate at this time, press [RESET] button once more or use the remote controller to turn it off.

Motions

The unit is in operation. The green indicator is on.

↓

The unit stops operating. The green indicator is turned off.

↓ After approx. three seconds,

The unit beeps three times. The green indicator flashes

for 5 seconds.

If the unit is required to operate at this time, press [RESET] button once more or use the remote controller to turn it on.

RESET button

• While the filter check indicator is on, the RESET button has the function of filter reset betton.

– 39 –

FILE NO. SVM-09051

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

To cancel auto restart function, proceed as follows : Repeat the setting procedure : the unit receives the signal and beeps three times. The unit will be required to be turned on with the remote controller after the main power supply is turned off.

• When the system is on stand-by (not operating)

Operation

Press [RESET] button for more than three seconds. (Less than 10 seconds)

RESET button

• When the system is operating

Operation

Press [RESET] button for more than three seconds. (Less than 10 seconds)

Motions

The unit is on standby.

↓

The unit starts to operate. The green indicator is on.

↓ After approx. three seconds, The unit beeps three times and continues to operate. If the unit is not required to operate at this time, press [RESET]

button once more or use the remote controller to turn it off.

Motions

The unit is in operation. The green indicator is on.

↓

The unit stops operating. The green indicator is turned off.

↓ After approx. three seconds, The unit beeps three times. If the unit is required to operate at this time, press [RESET] button

once more or use the remote controller to turn it on.

RESET button

9-3-3. Power Failure During Timer Operation

When the unit is turned off because of power failure during timer operation, the timer operation is cancelled. In that case, set the timer operation again.

NOTE :

The Everyday Timer is reset while a command signal can be received from the remote controller even if it stopped due to a power failure .

– 40 –

9-4. Remote control

9-4-1. Remote control and its functions

FILE NO. SVM-09051

1 Infrared signal emitter 2 Set louver button (FIX)

3 Auto louver button (SWING) 4 Mode select button (MODE) 5

Reset button (RST)

6 On timer button (ON) 7

Off timer button (OFF)

Reserve button (SET)

Cancel button (CLR)

Check button (CHK)

ECO button (ECO)

Fan speed button (FAN)

Start/Stop button (START/STOP)

Temperature button ( )

TOSHIBA

MODE

2 3 4

AUT O COOL

DR Y

HEAT

MODE

TEMP .

Hr.ON OFF

TEMP .

ST AR T/ST OP

SWING

RST

ON OFF SET CLR

FIX

CHK

TIMER

ECO

FA N

AUT O QUIET

FA N

11 10

9 8

9-4-2. Operation of remote control

1. AUTOMATIC OPERATION

To automatically select cooling, heating, or fan only operation.

1. Press MODE : Select AUTO.

2. COOLING / HEATING OPERATION

1. Press MODE : Select Cool or Heat.

2. Press TEMP : Set the desired temperature. Cooling: Min. 17°C, Heating : Max, 30°C

3. Press FAN : Select AUTO, QUIET, LOW , MED or HIGH .

− 41 −

3. DRY OPERATION (COOLING ONLY)

For dehumidification, a moderate cooling performance is controlled automatically.

FILE NO. SVM-09051

1. Press

MODE : Select DRY.

2. Press TEMP : Set the desired temperature.

4. ECO OPERATION

To automatically control room to save energy (except in DRY mode)

Press ECO : Start and stop the operation.

Note: Cooling operation; the set temperature will increase automatically 1 degree/

hour for 2 hours (maximum 2 degrees increase). For heating operation the set temperature will decrease.

5. TEMPORARY OPERATION

In case of the misplaced or discharged remote control

• Pressing the RESET button, the unit can start or stop

without using the remote control.

• Operation mode is set on AUTOMATIC

operation, preset temperature is 24°C and fan operation is automatic speed.

6. TIMER OPERATION

Setting the ON Timer Setting the OFF Timer

RESET button

Press TIMER ON : Set the desired ON timer.

Press TIMER SET : Set the timer.

Press TIMER CLR : Cancel the timer.

Press TIMER OFF : Set the desired ON timer.

Press TIMER SET : Set the timer.

Press TIMER CLR : Cancel the timer.

Note:

· Keep the remote control in accessible transmission to the indoor unit; otherwise, the time lag of up to 15 minutes will occur.

7. AUTO RESTART OPERATION

To automatically restart the conditioner after the power failure (Power of the unit must be on.)

Setting

1. Press and hold the RESET button on the indoor unit for 3 seconds to set the operation. (3 beep sound and OPERATION lamp blink 5 time/sec for 5 secpmds)

• Do not operate ON timer and OFF timer.

2. Press and hold the RESET button on the indoor unit for 3 seconds to cancel the operation. (3 beep sound but OPERATION lamp does not blink)

– 42 –

FILE NO. SVM-09051

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

[Display]

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 HEAT)

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.)

6. Operation

Indicate when press the operation ON/OFF button.

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

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

HEAT

•

Hr.ON OFF

•

– 43 –

10. INSTALLATION PROCEDURE

10-1. Installation Diagram of Indoor and Outdoor Units

FILE NO. SVM-09051

120 mm or more

(Attach to the front panel)

…

Active carbon catechin

†

Active carbon

catechin

Pan head wood screw

‚ Wireless remote control

65 mm or more

Remote control holder

„

Vinyl tape Apply after carrying out a drainage test.

Hook

Installation

•

plate

120 mm or more

Shield pipe

For the rear left and left piping

Wall

Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better operation.

Do not allow the drain hose to get slack.

Cut the piping hole sloped slightly.

Make sure to run the drain hose sloped downward.

The auxiliary piping can be connected to the left, rear left,

rear right, right,bottom right or bottom left.

100 mm or more

400 mm o

Before installing the

wireless remote control

With the remote control cover open, load the batteries supplied correctly, observing their polarity.

Wireless remote control

‚

Batteries

r more

or more

45 mm

600 mm or more

Saddle

Extension drain hose (Not available, provided by installer)

600 mm or more

Right

Rear right

Bottom right

Rear left

Bottom left

Insulate the refrigerant pipes separately with insulation, not together.

6 mm thick heat resisting polyethylene foam

Left

– 44 –

10-1-2. Optional installation parts

FILE NO. SVM-09051

Part

Code

Parts name

Refrigerant piping Liquid side : ∅6.35 mm

Gas side : 9.52 mm

Pipe insulating material

(polyethylene foam, 6 mm thick)

Putty, PVC tapes

∅

500 mm

Air inlet

97 mm

53 mm

280 mm

Air outlet

Drain outlet

Q'ty

One

each

One

each

Fig. 9-1-2

•

 Secure the outdoor unit with the fixing bolts and nuts if the unit is likely to be exposed to a strong wind.

•

 Use 8 mm or 10 mm anchor bolts and nuts.

 If it is necessary to drain the defrost water, attach drain nipple r to the bottom plate of the outdoor

∅

•

∅

outdoor unit before installing it.

– 45 −

10-1-3. Accessory and installation parts

Part

No.

Part name (Q’ty)

Part

No.

Part name (Q’ty)

Part

No.

FILE NO. SVM-09051

Part name (Q’ty)

Installation plate x 1

Wireless remote control x 1

Battery x 2

Others

Name

Owner’s manual

Installation manual

Remote control holder x 1

Super Oxi Deo filter x 1

Super Sterilizer filter x 1

Mounting screw ∅4 x 25 s x 6

Flat head wood screw ∅3.1 x 16 s x 2

Drain nipple* x 1

The part marked with asterisk (*) is packaged with the outdoor unit.

– 46 –

FILE NO. SVM-09051

10-2-3. Installation/Servicing T ools

Changes in the product and components

In the case of an air conditioner using R410A, in order to prev ent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valve (3 way v alve) has been changed. (1/2 UNF 20 threads per inch)

• In order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)

New tools for R410A

Gauge manifold

Charge hose

Electronic balance for refrigerant charging

Torque wrench (nominal diam. 1/2, 5/8)

Flare tool (clutch type)

Gauge for projection adjustment

Vacuum pump adapter

Applicable to R22 model

× ×

——

Changes

As pressure is high, it is impossible to measure by means of conventional gauge. In order to prevent any other refrigerant from being charged, each port diameter has been changed.

In order to increase pressure resisting strength, hose materials and port size have been changed (to 1/2 UNF 20 threads per inch). When purchasing a charge hose, be sure to confirm the port size.

As pressure is high and gasification speed is fast, it is difficult to read the indicated value by means of charging cylinder, as air bubbles occur.

The size of opposite sides of flare nuts have been increased. Incidentally, a common wrench is used for nominal diameters 1/4 and 3/8.

By increasing the clamp bar’s receiving hole, strength of spring in the tool has been improved.

Used when flare is made by using conventional flare tool.

Connected to conventional vacuum pump. It is necessary to use an adapter to prevent vacuum pump oil from flowing back to the charge hose. The charge hose connecting part has two por ts-one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R410A a sludge may occur and damage the equipment.

Gas leakage detector

• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the U. S’s ARI specified rose color (ARI color code: PMS 507).

• Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to the charge hose’s port size.

Exclusive for HFC refrigerant.

– 47 –

FILE NO. SVM-09051

10-3. Indoor Unit

10-3-1. Installation Place

• A place which provides enough spaces around the indoor unit as shown in the diagram.

• A place where there are no obstacle near the air inlet and outlet.

• A place which allows easy installation of the piping to the outdoor unit.

• A place which allows the front panel to be opened.

• The indoor unit shall be installed so that the top of

the indoor unit is positioned at least 2m in height.

• Also, a void putting anything on the top of the indoor unit.

CAUTION

• Direct sunlight on the indoor unit wireless

receiver should be avoided.

• The microprocessor in the indoor unit should

not be too close to r-f sources. (For details, see the owner's manual.)

Remote controller

• Should be placed where there are no obstacles, such as curtains, that may block the signal.

• Do not install the remote controller in a place

exposed to direct sunlight or close to a heating source, such as a stove.

• Keep the remote controller at least 1 m away from

the nearest TV set or stereo equipment. (This is necessary to prevent image disturbances or noise interference.)

• The location of the remote controller should be

determined as shown below.

10-3-2. Drilling a Hole and Mounting Instal-

lation Plate

Drilling a hole

When install the refrigerant pipes from the rear.

90 mm

66 mm

65 mm

Pipe hole

42 mm

Fig. 10-3-2

1. After determining the pipe hole position on the installation plate ( ð ) drill the pipe hole (Ø65 mm) at a slight downward slant to the outdoor side.

NOTE :

• When drilling into a wall that contains a metal lath,

wire lath or metal plate, be sure to use a pipe hole brim ring sold separately.

Mounting the installation plate

Anchor bolt holes

Hook

(Side view)

Indoor unit

Reception range

(Top view)

Indoor unit

Remote controller

Fig. 10-3-1

Reception range

Remote controller

170

Pipe hole

Indoor unit

Hook

Thread

Weight

Fig. 10-3-3

Hook

Pipe hole

Mounting screw

82.5

Installation plate

2 m or more from floor

– 48 –

FILE NO. SVM-09051

When the installation plate is directly mounted on the wall

1. Securely fit the installation plate onto the wall by screws with the upper and lower catches, that hold the indoor unit, facing out.

2. To mount the installation plate on a concrete wall use anchor bolts. Drill the anchor bolt holes as illustrated in the above figure.

3. Install the installation plate horizontally and le vel.

CAUTION

When installing the installation plate with mounting screw, do not use the anchor bolt hole. Otherwise the unit may fall down and result in personal injury and property damage.

Anchor bolt

Projection 15mm or less

10-3-3. Electrical Work

1. The supply voltage must be the same as the rated voltage of the air conditioner.

2. Prepare a po wer source for the exclusive use of the air conditioner.

NOTE :

• Wire type :

More than

1.5 mm

H07RN-F or 60245IEC66.

CAUTION

• This appliance can be connected to a main circuit breaker in either of the fo llowing two ways.

1. Connection to fixed wiring:

A switch or circuit breaker which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring. An approved circuit breaker or switch must be used.

2. Connection with power supply plug:

Attach power supply plug with power cord and plug it into wall outlet. An approved power supply cord and plug must be used.

Fig. 10-3-4

5 mm dia. hole

7 Mounting screw Ø4 × 25L

Clip anchor (local parts)

Fig. 10-3-5

CAUTION

Failure to securely install the unit may result in personal injury and/or property damage if the unit falls.

• In case of block, brick, concrete or similar type walls, drill 5 mm dia. holes in the wall.

• Insert clip anchors for the  mounting screws.

NOTE :

• Install the installation plate using mounting screws between 4 to 6, being sure to secure all four corners.

NOTE :

• Perform wiring work being sure the wire length is long enough.

10-3-4. Wiring Connection

How to connect the connecting cable

Wiring the connecting cable can be carried out without removing the front panel.

1. Remove the air inlet grille. Open the air inlet grille

upward and pull it toward y ou.

2. Remo ve the terminal cover and cord clamp.

3. Insert the connecting cable (or as according to

local regulations/codes) into the pipe hole on the wall.

4. Pull the connecting cable through the cable slot

on the rear panel so that it protrudes about 15 cm out of the front.

5. Insert the connecting cable fully into the terminal

block and secure it tightly with scre ws.

6. Tightening torque: 1.2 N•m (0.12 kgf•m)

7. Secure the connecting cable with the cord clamp.

8. Attach the terminal cover, rear plate bushing and

air inlet grille on the indoor unit.

– 49 –

CAUTION

• Be sure to refer to the wiring system diagram labeled inside the front panel.

• Check local electrical regulations for any specific wiring instructions or limitations.

FILE NO. SVM-09051

1. Die-cutting front panel slit

Cut out the slit on the left or right side of the front panel for the left or right connection and the slit on the bottom left or side of thefront panel for the bottom left or right connection with a pair of nippers.

Terminal cover

Screw

Connecting cable

out

Cord clamp

Screw

Stripping length of the connecting cable

Terminal block

Earth line

Connecting cable

10 mm

Fig. 10-3-6

NOTE :

• Use stranded wire only.

• Wire type : H07 RN-F or more

110 mm

10 mm

50 mm

2. Changing drain hose

For left connection, left-bottom connection and rear-left connection’s piping, it is necessary to relocate the drain hose and drain cap.

How to remove the drain cap

Clip drain cap with needle-nose pliers, and pull out.

Earth line

Fig. 10-3-8

How to remove the drain hose

The drain hose is secured in place by a screw. Remove the screw securing the drain hose, then pull

out the drain hose.

10-3-5. Piping and Drain Hose Installation

Piping and drain hose forming

• Since condensation results in machine trouble, make sure to insulate both the connecting pipes separately. (Use polyethylene foam as insulating material.)

Rear right Rear left Bottom left

Changing

Left Bottom right Right

Die-cutting

Front panel slit

Fig. 10-3-7

drain hose

Piping preparation

Screw

Drain hose

Fig. 10-3-9

– 50 –

FILE NO. SVM-09051

How to attach the drain cap

1. Insert hexagonal wrench (4 mm).

4 mm

Fig. 10-3-10

2. Firmly insert drain cap.

No gap

Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. If applied, deterioration and

Insert a hexagon wrench (Ø4mm)

drain leakage of the drain plug may occur.

In case of bottom right or bottom left piping

• After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool.

Slit

Fig. 10-3-13

Left-hand connection with piping

Bend the connecting pipes so that they are positioned within 43 mm above the wall surface.

If the connecting pipes are positioned more than 43 mm above the wall surface, the indoor unit may be unstable.

When bending the connecting pipe, make sure to use a spring bender to avoid crushing the pipe.

Refer to the table below for the bending radius of each connection pipe.

Fig. 10-3-11

How to attach the drain hose

Always use the original scre w that secured the drain hose to the unit. If using a different screw may cause water to leak.

Insert the drain hose firmly until the connector contacts with the insulation, then secure it in place using the original screw .

CAUTION

Securely insert the drain hose and drain cap; otherwise, water may leak.

In case of right or left piping

• After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool.

Outer diameter

6.35 mm

9.52 mm

12.7 mm

Bending radius

30 mm 40 mm 50 mm

To connect the pipe after installation of the unit (figure)

(To the front flare)

270 mm 230 mm

Liquid side

R30 or less (Ø6.35), R40 or less (Ø9. 52), R50 or less (Ø12. 7) Use polishing (polyethylene core or the like for bending pipe).

43 mm

Gas side

Outward form of indoor unit

Use a screwdriver handle, etc.

Slit

Fig. 10-3-12

Fig. 10-3-14

NOTE :

If the pipe is incorrectly bent, the indoor unit may be unstable on the wall.

After passing the connecting pipe through the pipe hole, connect the connecting pipe to the auxiliary pipes and wrap the facing tape around them.

– 51 –

50 mm or more

Do not rise the drain hose.

Do not form the drain hose into the waved shape.

Do not put the drain hose end into water.

Do not put the drain hose end in the drainage ditch.

FILE NO. SVM-09051

CAUTION

• Bind the auxiliary pipes (two) and connecting

cable with facing tape tightly. In case of leftward piping and rear-leftward

piping, bind the auxiliary pipes (two) only with facing tape.

Indoor unit

Auxiliary pipes

Installation plate

Fig. 10-3-18

• Carefully arrange the pipes so that none of the

pipes stick out of the rear plate of the indoor unit.

• Carefully connect the auxiliary pipes and

connecting pipes to each other and cut off the insulating tape wound on the connecting pipe to avoid doub le-taping at the joint, moreo ver, seal the joint with the vinyl tape, etc.

• Since condensation can result in machine

performance trouble, be sure to insulate both connecting pipes. (Use polyethylene foam as insulating material.)

• When bending a pipe, be careful not to crush it.

Connecting cable

10-3-7. Drainage

1. Run the drain hose at a downward sloped angle.

NOTE :

• Hole should be made at a slight downward slant on the outdoor side.

Fig. 10-3-17

2. Put water in the drain pan and make sure that the

water is being drained outside.

3. When connecting extension drain hose, insulate

the connection part of extension drain hose with shield pipe.

Shield pipe

10-3-6. Indoor Unit Installation

1. Pass the pipe through the hole in the wall, and hook the indoor unit on the installation plate at the upper hooks.

2. Swing the indoor unit to right and left to confirm that it is firmly hooked on the installation plate.

3. While pressing the indoor unit onto the wall, hook it at the lower part on the installation plate. Pull the indoor unit toward you to confirm that it is firmly hooked on the installation plate.

Hook

• For detaching the indoor unit from the installation

plate pull the indoor unit toward you while pushing the bottom up at the specified places.

Hook here 1

Installation plate

Fig. 10-3-15

Push (unhook)

Drain hose

Inside the room

Extension drain hose

Fig. 10-3-18

CAUTION

Install the drain pipe for proper drainage . Improper drainage can result in water dripping

inside the room.

This air conditioner has been designed to drain water collected from condensation which forms on the back of the indoor unit, to the drain pan.

Therefore, do not locate the po wer cord and other parts at a high place than the drain guide.

Wall

Drain guide

PushPush

Fig. 10-3-16

– 52 –

Space for pipes

Fig. 10-3-19

FILE NO. SVM-09051

10-4. Outdoor Unit

10-4-1. Installation place

• A place which provides the spaces around the outdoor unit as shown in the left diagram.

• A place which can bear the weight of the outdoor unit and does not allow an increase in noise level and vibration.

• A place where the operation noise and discharged air do not disturb users neighbors.

• A place which is not exposed to a strong wind.

• A place free of a leakage of combustible gases.

• A place which does not block a passage.

• When the outdoor unit is to be installed in an

elevated position, be sure to secure its feet.

• An allowable length of the connecting pipe is up 15 m.

• An allowable height level is up to 10 m.

• A place where the drain water does not raise any

problem.

CAUTION

1. Install the outdoor unit without anything blocking the air discharging.

2. When the outdoor unit is installed in a place exposed always exposed to strong wind like a coast or on a high storey of a building, secure the normal fan operation using a duct or a wind shield.

3. In particularly windy areas, install the unit such as to avoid admission of wind.

4. Installation in the following places may result in trouble. Do not install the unit in such places.

• A place full of machine oil.

• A saline-place such as the coast.

• A place full of sulfide gas.

• A place where high-frequency waves are likely

to be generated as from audio equipment, welders, and medical equipment.

10-4-2. Refrigerant piping connection

1. Cut the pipe with a pipe cutter.

90°

Obliquity

Roughness

Warp

Fig. 10-4-2

2. Insert a flare nut into the pipe, and flare the pipe.

 Projection margin in flaring : A (Unit : mm)

Die

Pipe

Fig. 10-4-3

Rigid (Clutch type)

Outer dia. R410A Conventional

of copper pipe tool used tool used

6.35 0 to 0.5 1.0 to 1.5

9.52 0 to 0.5 1.0 to 1.5

ial (wing nut type)

Imper

Outer dia.

of copper pipe

R410A

6.35 1.5 to 2.0

9.52 1.5 to 2.0

Align the centers of the connecting pipes and tighten the flare nut as far as possible with your fingers. Then tighten the nut with a spanner and torque wrench as shown in the figure.

Strong

wind

Fig. 10-4-1

– 53 –

Flare nutHalf union

Externally threaded side

Use a wrench to secure.

Use a torque wrench to tighten.

Internally threaded side

Fig. 10-4-4

CAUTION

•

Do not apply excess torque.

•

Otherwise, the nut may crack depending on the conditions.

(Unit : Nám)

FILE NO. SVM-09051

Outer dia.

of copper pipe

Tightening torque

∅6.35 mm 16 to 18 (1.6 to 1.8 kgf·m)

∅

9.52 mm 30 to 42 (3.0 to 4.2 kgf·m)

 Tightening torque of flare pipe connections

The operating pressure of R410A is higher than that of R22. (Approx. 1.6 times). It is therefore necessary to firmly tighten the flare pipe connecting sections (which connect the indoor and outdoor units) up to the specified tightening torque. Incorrect connections may cause not only a gas leakage, but also damage to the refrigerant cycle.

Flare at indoor unit side

Flare at outdoor unit side

Fig. 10-4-5

1. How to shape the pipes Shape the pipes along the incused line on the outdoor unit.

2. How to fit position of the pipes Put the edges of the pipes to the place with a distance of 85 mm from the incused line.

Be sure to use a vacuum pump with counter-flow prevention function so that inside oil of the pump does not flow backward into pipes of the air conditioner when the pump stops. (If oil inside of the vacuum pump enters into the air conditioner, which use R410A, refrigeration cycle trouble may result.)

1. Connect the charge hose from the manifold valve to the service port of the gas side packed valve.

2. Connect the charge hose to the port of the vacuum pump.

3. Open fully the low pressure side handle of the gauge manifold valve.

4. Operate the vacuum pump to start evacuating. Perform e piping length is 20 meters

vacuating f

or about 15 minutes if the

. (15 minutes for 20 meters) (assuming a pump capacity of 27 liters per minute. Then confirm that the compound pressure gauge reading is − 101 kPa (76 cmHg).

5. Close the low pressure side valve handle of gauge manifold.

6. Open fully the valve stem of the packed valves (both side of Gas and Liquid).

7. Remove the charging hose from the service port.

8. Securely tighten the caps on the packed valves.

Compound pressure gauge

–101 kPa (76 cmHg)

Handle Lo

Charge hose (For R410A only)

Connecting pipe

Pressure gauge

Manifold valve

Handle Hi (Keep full closed)

Charge hose (For R410A only)

Vacuum pump adapter for counter-flow prevention (For R410A only)

Vacuum

pump

Incused line

Fig. 10-4-6

10-3-3. Evacuating

After the piping has been connected to the indoor unit, you can perform the air purge together at once

AIR PURGE

Evacuate the air in the connecting pipes and in the indoor unit using a vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the manual of the vacuum pump.

– 54 –

Packed valve at gas side

Service port (Valve core (Setting pin))

Packed valve at liquid side

Fig.10-4-7

CAUTION

•

KEEP IMPORTANT 5 POINTS FOR PIPING WORK

(1) Take away dust and moisture (Inside of the

connecting pipes.)

(2) Tight connection (between pipes and unit) (3) Evacuate the air in the connecting pipes using

VACUUM PUMP.

(4) Check gas leak (connected points)

(5) Be save to fully open the packed valves

before operation.

FILE NO. SVM-09051

 Open the valve stem all the way out; but do not try

to open it beyond the stopper.

 Securely tighten the valve stem cap with torque in

the following table:

Gas side 30 to 42 N·m (∅9.52 mm) (3.0 to 4.2 kgf·m)

Liquid side 16 to 18 N·m (∅6.35 mm) (1.6 to 1.8 kgf·m)

Service port

9 to 10 N·m (0.9 to 1.0 kgf·m)

Hexagonal wrench is required.

4 mm

Fig. 10-4-8

10-4-4. Wiring connection

1. Remove the valve cover from the outdoor unit.

2. Connect the connecting cable to the terminal as identified with their respective matched numbers on the terminal block of indoor and outdoor unit.

3. When connecting the connecting cable to the outdoor unit terminal, make a loop as shown in the installation diagram of indoor and outdoor unit, to prevent water coming in the outdoor unit.

4. Insulate the unused cords (conductors) from any water coming in the outdoor unit. Proceed them so that they do not touch any electrical or metal parts.

Terminal block

Connecting cable

1 2 3 L N

Earth line

Power cord

60 50

Power cord

Earth line

Fig. 10-4-8

Power source 50 Hz, 220 - 240 V Single phase

Maximum running current

Installation fuse rating

Power cord

H07RN-F or 245 IEC66 (1.5 mm or more)

25A

CAUTION

• Wrong wiring connection may cause some electrical parts burn out.

• Be sure to comply with local codes on running the wire from indoor unit to outdoor unit (size of wire and wiring method etc).

• Every wire must be connected firmly.

• This installation fuse (25A

be used for the power supply line of this air conditioner.

 If incorrect or incomplete wiring is carried out, it

will cause an ignition or smoke.

 Prepare the power supply for exclusive use with

the air conditioner.

 This product can be connected to the mains.

Connection to fixed wiring: A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring.

) must

NOTE: Connecting cable

• Wire type: More than H07RN-F or 245 IEC66 (1.0 mm2 or more)

– 55 –

FILE NO. SVM-09051

10-4-5. Gas leak test

Check places for indoor unit (Flare nut connection)

Valve cover

Electric parts cover

Check places for outdoor unit

Fig. 10-4-10

• Check the flare nut connections for the gas leak with a gas leak detector or soap water.

-4-8. Auto restart setting

This product is designed so that, after a power failure, it can restart automatically in the same operating mode as before the power failure.

Information

The product was shipped with Auto Restart function in the off position. Turn it on as required.

• Press and hold the RESET button for about

3 seconds. After 3 seconds, the electronic beeper makes three short beeps to tell you the Auto Restart has been selected.

• To cancel the Auto Restart, follow the steps

described in the section Auto Restart Function of the Owner’s Manual.

10-4-7. Test operation

To switch the TEST RUN (COOL) mode, press

RESET button for 10 sec. (The beeper will make a short beep.)

RESET button

Fig. 10-4-13

– 56 –

11. HOW TO DIAGNOSE THE TROUBLE

FILE NO. SVM-09051

The pulse modulating circuits are mounted to both indoor and outdoor units. Therefore, diagnose troubles according to the diagnosis procedure as described below. (Refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.)

Table 11-1

No. Troubleshooting Procedure

1 First Confirmation 2 Primary Judgement 3 Judgement by Flashing LED

of Indoor Unit 4 Self-Diagnosis by Remote Controller 5 Judgement of Trouble by

Every Symptom 6 Check Code 1C (Miswiring in indoor/

outdoor units) and 1E

7 How to Diagnose Trouble in

Outdoor Unit

8 How to Check Simply the Main Parts 9 How to Simply Judge Whether outdoor

Fan Motor is Good or Bad

Discharging position (Discharging period 10 seconds or more)

NOTE:

A large-capacity electrolytic capacitor is used in the outdoor unit controller (inverter). Therefore, if the power supply is turned off, charge (charging voltage DC280V) remains and discharging takes a lot of time. After turning off the power source, if touching the charging section before discharging, an electrical shock may be caused. Discharge the electrolytic capacitor completely by using soldering iron, etc.

(1) Remove the inverter cover (plating) by opening

four mounting claws.

(2) As shown below, connect the discharge resistance

(approx. 100Ω40W) or plug of the soldering iron to voltage between + – terminals of the C12 (“CAUTION HIGH VOLTAGE” is indicated.) electrolytic capacitor (500µF/400V) on P.C. board, and then perform discharging.

Inverter cover

Plug of soldering iron

PC board (Soldered surface)

Fig. 11-1

– 57 –

FILE NO. SVM-09051

11-1-1. Operation which is not a trouble (Program operation)

For controlling the air conditioner, the program operations are built in the microcomputer as described in the following table. If a claim is made for running operation, check whether or not it meets to the contents in the following table. When it does, we inform you that it is not trouble of equipment, but it is indispensable for controlling and maintaining of air conditioner.

Table 11-1-1

No. Operation of air conditioner Description

1 When power breaker is turned “ON”,

the operation lamp (Green) of the indoor unit flashes.

The OPERATION lamp of the indoor unit flashes when power source is turned on. If [START/STOP] button is operated once, flashing stops. (Flashes also in power failure)

2 Compressor may not operate even if

the room temperature is within range of compressor-ON.

3 In Dry and ECO. mode, FAN (air flow)

display does not change even though FAN (air flow select) button is operated.

4 Increasing of compressor motor speed

stops approx. 30 seconds after operation started, and then compressor motor speed increases again approx. 30 seconds after.

5 The set value of the remote control

should be below the room temperature.

6 In AUTO mode, the operation mode is

changed.

7 In HEAT mode, the compressor motor

speed does not increase up to the maximum speed or decreases before the temperature arrives at the set temperature.

11-2. Primary Judgment

The compressor does not operate while compressor restart delay timer (3-minutes timer) operates. The same phenomenon is found after power source has been turned on because 3-minutes timer operates.

The air flow indication is fixed to [AUTO].

For smooth operation of the compressor, the compressor motor speed is restricted to Max. 41 rps for 2 minutes, and Max.91 rps for 2 minutes to 3 minutes, respectively after the operation has started.

If the set value is above the room temperature, Cooling operation is not performed. And check whether battery of the remote control is consumed or not.

After selecting Cool or Heat mode, select an operation mode again if the compressor keeps stop status for 15 minutes.

The compressor motor speed may decrease by high-temp. release control (Release protective operation by temp.-up of the indoor heat exchanger) or current release control.

To diagnose the troubles, use the following methods. (1) Judgment by flashing LED of indoor unit (2) Self-diagnosis by service check remote control (3) Judgment of trouble by every symptom

Firstly, use the method (1) for diagnosis. Then, use the method (2) and (3) to diagnose the details of troubles.

– 58 –

FILE NO. SVM-09051

11-3. Judgment by Flashing LED of Indoor Unit

While the indoor unit monitors the operation status of the air conditioner, if the protective circuit operates, the contents of self-diagnosis are displayed with block on the indoor unit indication section.

Table 11-3-1

Indoor indication

lamp flashes.

Which lamp

does flash?

Item

Check

code

Block display Description for self-diagnosis

OPERATION (Green) Flashing display (1 Hz)

OPERATION (Green) Flashing display (5 Hz)

OPERATION (Green) TIMER (Yellow) Flashing display (5 Hz)

OPERATION (Green)

Flashing display (5 Hz)

OPERATION (Green) TIMER (Yellow)

Flashing display (5 Hz)

Power failure (when power is ON)

Protective circuit operation for indoor P.C. board

Protective circuit operation for connecting cable and serial signal system

Protective circuit operation for outdoor P.C. board

Protective circuit operation for others (including compressor)

NOTES :

1. The contents of items B and C and a part of item E are displayed when air conditioner operates.

2. When item B and C, and item B and a part of item E occur concurrently, priority is given to the block of item B.

3. The check codes can be confirmed on the remote controller for servicing.

– 59 –

FILE NO. SVM-09051

11-4. Self-Diagnosis by Remote Controller (Chec k Code)

1. If the lamps are indicated as shown B to E in Table 11-3-1, execute the self-diagnosis b y the remote controller.

2. When the remote controller is set to the service mode, the indoor controller diagnoses the operation condition and indicates the information of the self-diagnosis on the display of the remote controller with the check codes. If a fault is detected, all lamps on the indoor unit will flash at 5Hz and it will beep for 10 seconds (Beep, Beep, Beep ... ). The timer lamp usually flashes (5Hz) during self-diagnosis.

11-4-1. How to Use Remote Controller in Service Mode

(1) Press [CHK] button with a tip of pencil to set the

remote control to the service mode.

• “00” is indicated on the display of the remote control.

• The timer lamp on the indoor unit blinks continuously. (5 times per 1 sec.)

(2) Press [8TEMP.] button.

If there is no fault with a code, the indoor unit will

MODE

AUTO COOL

DRY

HEAT

TEMP.

Hr.ON OFF

TEMP.

FAN

AUTO

QUIET

beep once (Pi) and the display of the remote control will change as follows:

00 01 1d 1E02 22

•

Check the unit with all 35 check codes (00 to 22).

START/STOP

SWING

FIX

FAN

MODE

ON OFF SET CLR

•

Alphanumeric characters are used for the check code.

RST

TIMER

CHK

ECO

is 5. is 6. is A. is B. is C. is D.

• Press [9TEMP.] button to change the check code backwards.

If there is a fault, the indoor unit will beep for 10 seconds (Pi, Pi, Pi...). Note the check code on the display of the remote control.

• 2-digits alphanumeric will be indicated on the display.

• All lamps on the indoor unit will blink. (5 times per 1 sec.)

(3) Press [START/STOP] button to release the service

mode.

• The display of the remote control returns to as it was before service mode was engaged.

Fig. 11-4-1

– 60 –

FILE NO. SVM-09051

11-4-2. Caution at servicing

(1) After servicing, push the [START/STOP] button to return to the normal mode. (2) After servicing by the check code, turn off breaker of the power supply, and turn on breaker of the power

supply again so that memory in the microcomputer returns the initial status. However, the check codes are not deleted even if the power supply is turned off because they are stored in the fixed memory.

Table 11-4-1

Block distinction Operation of diagnosis function

Check

code code status

Block

Indoor P.C . board etc.

Not displayed

Check

Cause of operation

Short-circuit or disconnection of the room temperature sensor (TA sensor).

Being out of place, disconnection, short-circuit, or migration of heat exchanger sensor (TC sensor)

Lock of indoor fan or trouble on the indoor fan circuit

Trouble on other indoor P.C. boards

Air conditioner

Operation continues.

All off

Operation continues.

Remarks

Displayed when error is detected.

Judgment and action

1. Check the room temp. sensor.

2. When the room temp. sensor is normal, check P.C. board.

1. Check heat exchanger sensor.

2. When heat exchanger sensor is normal, check P.C. board.

1. Check P.C. board.

2. When P.C. board is normal, check the motor.

Replace P.C. board.

Connecting cable and serial signal

Return serial signal is not sent to indoor side from operation started. (1) Defective wiring of

connecting cable

(2) Operation of

compressor thermo. Gas shortage Gas leak

Operation command signal is not sent to outdoor side.

Operation continues.

Flashes when trouble is detected on return serial signal, and normal status when signal is reset.

Flashes when trouble is detected on operation command signal, and normal status when signal is reset.

1. When the outdoor unit never operate: (1) Check connecting cable, and

correct if defective wiring.

(2) Check 25A fuse of inverter

P.C. board

(3) Check 3.15A of inverter

P.C. board.

2. To display [Other] block during operation, check compressor thermo. operation and supply gas (check gas leak also).

3. Unit operates normally during check. If Return serial signal does not stop between 2 and 3 of the indoor terminal block, replace inverter P.C. board. If signal stops between indoor terminal block 2 and 3, replace indoor P.C. board.

If return serial signal does not stop between indoor terminal block 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal block 2 and 3, replace indoor P.C. board.

– 61 –

Block distinction Operation of diagnosis function

Check

code code status

Block

Ondoor P.C. board

Not displayed

Ondoor P.C. board

Others (including compressor)

Check

Cause of operation

Inverter over-current protective circuit operates. (Short time)

Position-detect circuit error or short-circuit between windings of compressor

Current-detect circuit error

Being out of place, disconnection or shortcircuit of outdoor temp. sensor

Disconnection or shortcircuit of discharge temp. sensor

Outdoor fan drive system error

Outdoor heat exchanger temp. sensor error

Compressor drive output error, Compressor error (lock, missing, etc.), Break down

Return serial signal has been sent when operation started, but it is not sent from halfway. (1) Compressor thermo.

operation Gas shortage Gas leak

(2) Instantaneous power

failure

Compressor does not rotate. (Current protective circuit does not operate when a specified time passed after compressor had been activated.)

Discharge temp. exceeded 117°C

Break down of compressor

Four-way valve inverse error (TC sensor value lowered during heating operation.)

Air conditioner

All off

Operation continues.

All off

Operation continues.

All off

Operation continues.

Remarks

Displayed when error is detected.

–––

Displayed when error is detected.

Flashes when trouble is detected on return serial signal, and normal status when signal is reset.

Displayed when error is detected.

–––

FILE NO. SVM-09051

Judgment and action

Even if trying operation again, all operations stop immediately. : Replace P.C. board.

1. Even if connecting lead wire of compressor is removed, positiondetect circuit error occurred. : Replace P.C. board.

2. Measure resistance between wires of compressor, and perform short circuit. : Replace compressor.

Even if trying operation again, all operations stop immediately. : Replace P.C. board.

1. Check outdoor temp. sensors (TE).

2. Check P.C. board.

1. Check discharge temp . sensor (TD).

2. Check P.C. board.

Position-detect error, over-current protective operation of outdoor fan drive system, fan lock, etc. : Replace P.C. board or fan motor.

1. Check outdoor heat exchanger temp. sensor (TE).

2. Check P.C. board.

When 20 seconds passed after startup, position-detect circuit error occurred. : Replace compressor.

1. Repeat Start and Stop with interval of approx. 10 to 40 minutes. (Code is not displayed during operation.) Supply gas. (Check also gas leak.)

2. Unit operates normally during check. If return serial signal does not stop between indoor terminal block, 2 and 3 replace inverter P.C. board. If signal stops between indoor terminal block, 2 and 3 replace indoor P.C. board.

1. Trouble on compressor

2. Trouble on wiring of compressor (Missed phase)

1. Check discharge temp . sensor (TD).

2. Degassing

3. Trouble on P.M.V.

1. Check power voltage. (220-240 V +10%)

2. Overload operation of refrigeration cycle Check installation condition (Short-circuit of outdoor diffuser.)

1. Check 4-way valve operation.

– 62 –

11-5. Judgement of Trouble by Every Symptom

11-5-1. Indoor unit (Including remote controller)

(1) Power is not turned on (Does not operate entirely)

FILE NO. SVM-09051

supply once, and 5 second later, turn it

Is fuse (F01)

of indoor control

board blown?

Turn off power

on again.

Is OPERATION

lamp blinking?

YES

Is it possible to

turn on power

supply by pressing

[START/STOP]

button

on remote

control?

YES

(DB01,C27,T01

and IC02)

are defective.

Parts

Does

transmission

mark on remote control flash normally,

and is its signal

transmitted

properly?

YES

Does

fan motor

connector

between 1

and

short-circuit?

Remote control is

defective.

Refer to (4)

"Troubleshooting for

Remote Control.

YES

Operation

Check item

Conceivable principle

cause

Measure

Item by symptoms

Unit operates

normally.

Is voltage

(DC 12V or 5V)

indicated on rear of indoor control board

normal?

Is the

voltage

across C27

mesured

DC 310V~340V?

YES

Are DC 5V,

DC 12V

supplied

to main

P.C. board?

YES YES

Refer to

or this problem

is one step short

of power P.C.

board block.

Turn off breaker once and turn it

on again after

removing motor.

YES

Are DC 5V,

or DC 12V

supplied

to main

P.C. board?

Microcomputer

is defective.

Regulator IC

(IC02) or T01

are defective

Replace main

P.C. board.

Replace motor

• Be sure to disconnect the motor connector CN31 after shut off the power supply, or it will be a cause of damage of the motor.

– 63 –

(2) Power is not turned on though Indoor P.C. board is replaced <Confirmation procedure>

Turn on power supply.

FILE NO. SVM-09051

Does operation lamp flash?

YES YES

NO NO

Is wired correctly to white and black

lead wires of terminal board?

Correct wiring.

To item of

“Power is not turned on”.

– 64 –

(3) Only the indoor fan does not operate.

Shut off the

power supply once.

Turn the power supply.

FILE NO. SVM-09051

Does the fan stop in

no operating status?

YES

Start the operation

with low fan setting

in cool operation.

Does the fan rotate?

YES

Change the setting of

cooling to high fan.

Does the fan speed

become higher?

Control P.C. board is defective.

Does AC 120 V

or higher voltage apply

to between red and black

lead of fan motor?

YES

Shut off the power supply.

Does the cross flow fan rotate normally?

YES

Turn on the power supply.

Operation

stops

Replace the P.C. board.

Does connecting

terminal, connecting

NO NO

cable or power supply

cord completely?

Does not found the short

wire about connecting

cable and power cord?

YES

Repair the

bearing of

the fan.

Motor control circuit failure

(IC31, Q301) or 12 V

Switching power supply failure.

YES

Normal

−

Is the rotation signal (DC+5 V

output between 2 (gray lead wire)

and 3 (brown lead wire) of the motor

connector (CN33) when rotating the

cross flow fan by hand in no operating

status? (1 pulse/one turn)

YES

Replace the control

P.C. board.

0 V)

– 65 –

Replace the P.C. board.

Replace the fan motor.

Replace connecting the

cable (or power cord),

thermal fuse and

terminal block.

(4) Troubleshooting for remote control

FILE NO. SVM-09051

Is receiver on

indoor unit exposed

to direct sunlight?

YES

Is there any

thyristor fluorescent

light nearby?

YES

NO NO

Press [START/STOP]

button.

Is transmission

mark indicated?

Does indoor unit

operate when

moving remote control

near receiver or

indoor unit?

YES

Batteries are

exhausted.

The unit does not beep at all. OPERATION lamp on indoor unit is not indicated.

Press [START/STOP]

button.

Avoid direct

sunlight.

Keep indoor unit

away from

thyristor

fluorescent light.

Does indoor unit

start to operate by

automatic restart

function?

YES

Does radio sound

is affected by

remote control when

a signal is transmitted

at distance of 5 cm

from radio?

P.C. board is

defective.

Replace

P.C. board.

YES

Replace

batteries.

Is transmission mark

Does indoor unit

beep and operate?

indicated?

YES

Normal

operation

Remote control

is defective.

Replace

remote control.

– 66 –

FILE NO. SVM-09051

11-5-2. Wiring Failure (Interconnecting and serial signal wire) (1) Outdoor unit does not operate.

1) Is the voltage between indoor terminal block 2 and 3 varied? Confirm that transmission from indoor to outdoor is correctly performed based on the following diagram.

NOTE:

• Measurement should be performed 2 minutes and 30 seconds after starting of the operation.

• Be sure to prepare a diode for judgment.

Terminal block on indoor side

Red

White

Normal time : Voltage swings between DC15 V and 60 V. Abnormal time : Voltage does not vary.

(2) Outdoor unit stops in a little while after operation started. <Check procedure> Select phenomena described below.

Terminal block

S5277G

S5277G or equivalent (G or J type) (Diode with rated voltage of 400 V or more is acceptable.)

Tester

1) The outdoor unit stops 10 to 20 minutes after operation started, and 10 minutes or more are required to restart the unit.

Gas circulation amount is down.

Measure gas pressure.

Thermo operation of compressor

Gas shortage Gas leak Pipe clogging

2) If the unit stops once, it dose not operate until the power will be turned on again.

To item of compressor does not operate.

3) The outdoor unit stops 10 minutes to 1 hour after operation started, and an alarm is displayed. (Discharge temp. error check code 03, 1E Sensor temp. error check code 02, 1C)

Gas leak

Miswiring of connecting wires of indoor/outdoor units

Clogging of pipe and coming-off TC sensor

– 67 –

Refer to the chart in 10-6.

FILE NO. SVM-09051

11-6. How to Check Simply the Main Parts

11-6-1. How to check the P.C. board (Indoor unit) (1) Operating precautions

1) When removing the front panel or the P.C. board, be sure to shut off the power supply breaker.

2) When removing the P.C. board, hold the edge of the P.C. board and do not apply force to the parts.

3) When connecting or disconnecting the connectors on the P.C. board, hold the whole housing. Do not pull at the lead wire.

(3) Checking procedure.

Table 11-6-1

No.

Turn off the power supply breaker and remove the P. C. board assembly from electronic parts base. Remove the connecting cables from the terminal block.

Procedure

Check points

Check whether or not the fuse (F01) is blown.

(2) Inspection procedures

1) When a P.C. board is judged to be defective, check for disconnection, burning, or discoloration of the copper foil pattern or this P.C. board.

2) The P.C. board consists of the following 2 parts

a. Main P.C. board part:

DC power supply circuit (5 V, 12 V, 15 V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer, and Driving circuit of louver.

b. Indication unit of infrared ray receiving

Infrared ray receiving circuit, LED:

To check defect of the P.C. board, follow the procedure described below.

Causes

Impulse voltage was applied or the indoor fan motor short-circuited.

Remove the connector of the motor and turn on the power supply breaker. If OPERATION indicator flashes (once per second), it is not necessary to check steps (1 to 3) in the right next column.

Push [START/STOP] button once

to start the unit. (Do not set the mode to On-Timer operation.)

Shorten the restart delay timer and start unit.

Push [START/STOP] button once to start the unit,

• Shorten the restart delay timer.

• Set the operation mode to

COOL.

• Set the fan speed level to AUTO.

• Set the preset temperature much lower than the room temperature. (The unit (compressor) operates continuously in the above condition.)

Check power supply voltage :

1. Between No. 1 and No. 3 of CN01 (AC 220–240V)

2. Between and of C27 (DC 310–340V)

3. Between 12V and GND

4. Between 5V and GND

Check power supply voltage :

1. Between CN51 and No. 1 of CN01 (DC 15–60V)

Check whether or not all indicators (OPERATION and TIMER) are lit for 3 seconds and they return to normal 3 seconds later.

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION indicator flashes.

1. The terminal block or the crossover cable is connected wrongly.

2. The capacitor (C01,C02 or C27),

line filter (L01), resistor (R64), or the diode (DB01) is defective.

3. T01 and IC01 are defective.

4. T01 and IC02 are defective.

IC51 and IC52 are defective.

The indicators are defective or the housing assembly (CN20) is defective.

1. The temperature of the indoor heat exchanger is extremely low.

2. The connection of the heat exchanger sensor is loose. (The connector is disconnected.) (CN62)

3. The heat exchanger sensor and the P.C. board are defective. (Refer to Table 11-4-1.)

4. The main P.C. board is defective.

– 68 –

FILE NO. SVM-09051

No.

If the above condition (No. 5) still continues, start the unit in the following condition.

• Set the operation mode to HEAT.

• Set the preset temperature much higher than room temperature.

Connect the motor connector to the motor and turn on the power supply. Start the unit the following condition.

• Set the fan speed level to HIGH. (The unit (compressor) operates continuously in the above condition in No. 5.)

Procedure

Check points

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION indicator flashes.

1. Check it is impossible to detect the voltage (DC 15V) between 3 and 4 of the motor terminals.

2. The motor does not operate or the fan motor does not rotate with high speed. (But it is possible to receive the signal from the remote controller.)

3. The motor rotates but vibrates strongly.

Causes

1. The temperature of the indoor heat exchanger is extremely high.

2. The connection of the heat exchanger sensor short-circuited. (CN62)

3. The heat exchanger sensor and the P.C. board are defective. (Refer to Table 11-4-1.)

4. The main P.C. board is defective

1. The indoor fan motor is defective. (Protected operation of P.C. board.)

2. The P.C. board is defective.

3. The connection of the motor connector is loose.

100

90 80

70 60 50 40 30

Resistance value (k )

20 10

0102030 4050

Temperature (˚C)

TA, TC, TO, TE

TD : Discharge temp. sensor TA : Room temp. sensor TC : Heat exchanger temp. sensor TO : Outdoor temp. sensor

TE : Outdoor heat exchanger temp.

sensor.

– 69 –

11-6-2. Indoor unit (Other parts)

No. Part name Checking procedure

1 Room temp. (TA) sensor

Heat exchanger (TC) sensor

Disconnect the connector and measure the resistance value with tester. (Normal temp.)

FILE NO. SVM-09051

Temperature

Sensor

10°C 20°C 25°C 30°C 40°C

T A, TC (kΩ) 20.7 12.6 10.0 7.9 4.5

2 Remote control

To item of How to judge whether remote control is good or bad of the Judgment of trouble by symptom.

3 Louver motor

MP24ZCT

Measure the resistance value of each winding coil by using the tester. (Under normal temp. 25°C)

White Yellow Yellow Yellow Yellow

Position Resistance value

1 to 2 1 to 3 1 to 4 1 to 5

4 Indoor fan motor

Refer to 10-5-1

11-6-3. Outdoor unit

No. Part name Checking procedure

1 Compressor

(Model : DA89X1C-23EZ)

Measure the resistance value of each winding by using the tester.

380±40Ω

Outdoor fan motor

(Model : WLF-240-20A-1)

Red

Position Resistance value

Red - White

White - Black 1.1Ω

White Black

Black - Red

Measure the resistance value of winding by using the tester.

Black

Red

C1.5 mF 450V

White

Position Resistance value

White - Black

Black - Red

For details, refer to Section 10-9.

Under 20°C

260.1

235.2

– 70 –

FILE NO. SVM-09051

Mark

3 Outdoor temperature sensor

(TO), discharge temperature

Disconnect the connector, and measure resistance value with the tester. (Normal temperature)

sensor (TD), suction temperature exchanger temperature sensor (TE)

Sensor

Temperature

10°C 20°C 30°C 40°C 50°C

TA, TC (k ) 105 64 41 27 18

TGa : Heat pump model only. TO, TE : Refer to the TA, TC characteristic table in Indoor

(Refer to Table 10-8-3, No.1).

11-6-4. Checking Method for Each Part

No. Part name Checking procedure

1 Electrolytic capacitor 1. Turn OFF the power supply breaker.

(For raising pressure, smoothing) 2. Discharge all three capacitors completely.

3. Check that safety valve at the bottom of capacitor is not broken.

4. Check that vessel is not swollen or exploded.

5. Check that electrolytic liquid does not blow off.

6. Check that the normal charging characteristics are show in continuity test by the tester.

C13

C14

Heat sink IGBT side

C12

MCC-5009

Soldered surface

Case that product is good

Pointer swings once, and returns slowly. When performing test once again under another polarity, the pointer should return.

C12, C13, C14 → 500µF/400V

2 Converter module 1. Turn OFF the power supply breaker.

2. Discharge all three capacitors completely.

3 Check that the normal rectification characteristics are shown in continuity

test by the tester.

Diode check

Tester rod

Resistance value in good product

50kΩ or more

(0Ω in trouble)

– 71 –

FILE NO. SVM-09051

12. PART REPLACEMENT

12-1. Indoor Unit

No. Part name Procedures Remarks

1 Front panel

2 Electrical part

How to remove the front panel

1) Stop the operation of the air conditioner and turn off its main power supply.

2) Pull the air inlet grille toward you to open it and remove the air inlet grille. Then remove the 2 screws fixing the front panel.

3) First open the horizontal louver, and then remove the front panel from the back body by pulling it toward you.

How to mount the front panel

Push the front panel back in and make sure all hooks are locked.

How to remove the electrical part.

1) Remove the front panel with procedure 1 .

2) Remove the screw holding the electrical part cover.

3) Disconnect the 3 connectors 2-(3P) for the fan motor and the connector (5P) for the louver motor from the P.C. board assembly.

4) Pull out the TC sensor from the sensor holder.

5) Remove the screw for the ground connection, remove the screw for the electrical part box.

Then remove the LED and the electrical part

box from the main unit.

2 2-Screws

2 Screws

Sensor

3 Horizontal

louver

How to mount the electrical part.

1) To put back the electrical part box, lock it to the upper hook of the back body.

Tighten the screws on the electrical part box.

3) Connect the 3 connectors and arrange the wiring same as original condition and then tighten the screw from the LED unit to the back body.

4) Attach the TC sensor to the holder.

5) Tighten the screw for the ground connection.

6) Tighten the screw on the electrical part cover.

1) Remove the front panel and the electrical part following procedure 2.

2) Remove the center shaft of the horizontal louver from the back body.

3) Remove the left shaft from the back body.

4) Remove the horizontal louver from the back body.

3 Left shaft

3-Connectors

2 Center shaft

Screws

− 72 −

FILE NO. SVM-09051

No. Part name Procedures Remarks

4 Heat exchanger

5 Cross flow fan

1) Remove the front panel, electrical part and the horizontal louver following procedure 3.

2) Remove the pipe holder at the rear side of main unit.

3) Remove the 2 screws on the heat exchanger at the base bearing.

4) Remove the screw on the heat exchanger at the fixed plate from the back body and then pull out the right hand side until the socket of heat exchanger released from the hook of the

band motor (L), and then pull out the upper side of heat exchanger slowly.

1) Remove the front panel, electrical part, horizontal louver and the heat exchanger following procedure 4.

2) Remove the 2 screws on the band motor (L) and remove the 2 screws on the band motor (R) and then remove the cross flow fan.

3) Loosen the set screw of the cross flow fan then separate the fan and the fan motor.

Notice To assemble cross flow fan and fan motor to the unit, please turn the fan motor unit the center of its terminal meets the top position of band motor (R). Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is

4.7 mm.

2 Pipe holder

2-Screws

2-Screws (R) 2

2-Screws (L)

4.7 mm

6 Set screw

Middle of the fan motor terminal

4 Screws

6 Base bearing

1) Remove the front panel, electrical part, horizontal louver, heat exchanger and the cross flow fan following procedure 5.

2) Remove the 2 screws fixing the base bearing.

3) Remove the bearing from the base bearing. If the housing protrudes from the base bearing, put the housing in position and attach the bearing to the base bearing.

− 73 −

2-Screws

FILE NO. SVM-09051

12-3-1. Outdoor Unit

No. Part name Procedures Remarks

1 Common

procedure

1. Detachment

1) Stop operation of the air conditioner, and turn off the main switch and breaker of the air conditioner.

2) Remove the valve cover. (ST1T∅4 x 10s 1 pc)

• After removing screw, remove the valve

cover pulling it downward.

3) Remove the wiring cover (ST1T∅4 x 10s 2 pcs.), and then remove the power cord, connecting cable, and cord clamp (ST2T∅4 x 16s 3 pcs.).

4) Remove the upper cabinet. (ST1T∅4 x 10s 5 pcs.)

• After removing screws, remove the

upper cabinet pulling it upward.

2. Attachment

1) Attach the upper cabinet. (ST1T∅4 x 10s 5 pcs.)

• Hook the rear side of the upper cabinet

to the claw of the rear cabinet, and then place it on the front cabinet.

2) After connecting the power cord and connecting cable, attach the cord clamp and wiring cover.

• Insert the upper part into the upper

cabinet, and insert the claw which has been hooked to the lower part into the square hole, and then fix it with screw. (ST1T∅4 x 10s 1 pc.)

Attach the valve cover. (ST1T∅4 x 10s 1 pc.)

• Insert the upper part to the upper

cabinet, set the hook claw of the valve cover to square holes (at three positions) of the main unit, and attach it pushing upward.

Upper cabinet

Wiring cover

Valve cover

Upper cabinet

2 Front cabinet

1. Detachment

1) Perform work of item 1 of 1.

2) Remove upper screw (ST1T∅4 x 10s 4 pcs.) of the front cabinet, and lower screws (ST1T∅4 x 10s 8 pcs.) of the front cabinet.

• Both side of front cabinet envelop the

unit, so remove it by pulling sideward.

2. Attachment

1) Assemble front cabinet to the unit.

2) Attach the removed screws to the original positions.

– 74 –

FILE NO. SVM-09051

No. Part name Procedures Remarks

3 Inverter

assembly

1) Perform work of item 1 of 1.

2) Remove screw (ST1T∅4 x 10s 1 pc.) of the upper part of the front cabinet.

• If removing the inverter cover in this

condition, the P.C. board can be checked.

• If there is no space in the upper part of

the upper cabinet, perform work of 2.

Be careful when checking the inverter because high-voltage circuit is incorporated in it.

3) Perform discharging by connecting the e,d polarities by discharging resistance (approx. 100Ω40W) or plug of soldering iron to e,d terminals of the C13 (printed “CAUTION HIGH VOLTAGE” is attached.) electrolytic capacitor (760 µF/400 WV) on the P.C. board.

Be careful to discharge the capacitor because the electrolytic capacitor cannot naturally discharge and voltage remains depending on the malfunction state in some cases.

Discharging time (Discharging period 10 seconds or more)

Inverter cover

PC board (Soldered surface)

Plug of soldering iron

NOTE : This capacitor has mass capacity. Therefore, it is dangerous that a large spark generates if shortcircuiting between the e,d polarities with screwdriver, etc. for discharging.

4) Perform the work of 2.

5) Remove the screw (ST1T∅4 x 10s 1 pc.) fixing the main body and the inverter box.

6) Remove the lead wire from the holder on the terminal block.

7) Disconnect the connectors of various lead wires.

Requirement : As each connector has a lock mechanism, avoid removing the connector by holding the lead wire, but by holding the connector.

Terminal

Partition

block

The connector is one with lock, so remove it while pushing the part indicated by an arrow.

– 75 –

Be sure to remove the connector by holding the connector, not by pulling the lead wire.

FILE NO. SVM-09051

No. Part name Procedures Remarks

Fan motor

„

1) Perform work of item 1 of 1 and 1 of 2.

2) Remove the flange nut fixing the fan motor and the propeller fan.

• Flange nut is loosened by turning

clockwise. (To tighten the flange nut, turn counterclockwise.)

3) Remove the propeller fan.

4) Disconnect the connector for the fan motor from the inverter .

5) Remove the fixing screws (4 pcs.) holding the fan motor by hand so that it does not fall.

6) Cut the motor lead at the point which is 100 mm apart from the connector toward the fan.

7) Use the connector used for the inverter, and pinch the lead wires using the closed end splice.

Propeller fan

Fan motor

100

Flange nut

Closed end splice

…

†

Compressor

Reactor

Perform work of item 1 of 1

and

, 1 of

2) Extract refrigerant gas.

3) Remove the partition board. (ST1T∅4 x 10s 3 pcs.)

4) Remove the sound-insulation material.

5) Remove the terminal cover of the compressor, and disconnect the lead wire of the compressor thermo and the compressor from the terminal.

6) Remove the pipe connected to the compressor with a burner.

• Make sure the flame does not touch the

4 way valve.

7) Remove the fixing screw of the base plate and heat exchanger. (ST1T∅4 x 10s 2 pcs.)

8) Pull upward the refrigeration cycle.

9) Remove the nut fixing the compressor to the base plate.

1) Perform work of item 1 of 1, 1 of 2, and 3.

2) Remove the screw fixing the reactor. (ST1T∅ 4 x 10 2 PCS.)

Compressor

Reactor

– 76 –

FILE NO. SVM-09051

No. Part name Procedures Remarks

Fan guard

1. Detachment

1) Perform work of item 1 of 1 and 1 of 2.

Requirement: Perform the work on a corrugated cardboard, cloth, etc. to prevent scratches to the product.

2) Remove the front cabinet, and place it down so that the fan guard side faces downwards.

3) Remove the hooking claws by pushing a minus screwdriver according to the arrow mark in the right figure, and remove the fan guard.

2. Attachment

1) Insert the claws of the fan guard in the hole of the front cabinet. Push the hooking claws (8 positions) by your hand and fix the claws.

Minus screwdriver

Hooking claw

Requirement: This completes all the attaching work. Check that all the hooking claws are fixed to the specified positions.

– 77 –

FILE NO. SVM-09043

No. Part name Procedures Remarks

4 Control board

assembly

1) Disconnect lead wires and connectors connected from the control board assembly to other parts.

1. Lead wires

• Connection with terminal block : 3 wires (Black, White, Orange)

• Connection with compressor : remove the connector (3P)

• Connection with reactor : remove the connector (2P)

2. Connectors (6 positions) CN300, CN703 : Outdoor fan (3P: white)*

(See Note 1) CN701 : 4 way valve (3P: Yellow)* CN601 : TD sensor (2P: White) CN602 : TO sensor (2P: White) CN500 : Case thermo (2P: White) ∗ Note 1) As the connector has a

stopper, release the housing lock when removing.

∗∗Note 2) Hold the housing (resin part)

with stopper and pull out to remove.

2) Remove the control board assembly from

the inver ter box.

Note 2) Remove the claw of the

board support fixed to the

inverter board, and remove upwards holding the heat sink.

3) Remove the three screws fixing the heat sink and control board assemble.

4) Attach the new contro board assembly.

Note 4) When attaching the new

control board assembly.

insert the P.C. board into the guide rail groove correctly.

CN602

CN601

CN300 CN701

CN500

As CN300 and CN701 are connectors with lock, remove while pushing the part indicated by an arrow

– 78 –

FILE NO. SVM-09051

No. Part name Procedures Remarks

Replacement of

temperature sensor for servicing only

Common service parts of sensor TO, TD

1) Cut the sensor 100 mm longer than old one.

2) Cut the protective tube after pulling out it (200 mm).

3) Move the protective tube toward the thermal sensor side and tear the tip of lead wire in two, then strip the covering part.

4) Pass the stripped part through the thermal constringent tube.

5) Cut the old sensor 100 mm length on the connector side, and recycle that connector.

6) Tear the lead wire in two on the connector side and strip and covering part.

7) Twist the leads on the connector and sensor sides, and solder them.

8) Move the thermal constringent tubes toward the soldered parts and heat them with the dryer and constring them.

9) Wind the attached color tape round the both terminals of the protective tube when colored protective tube is used.

10) Fix the sensor again.

NOTES:

1) Store the joint part of the sensor and the connector in the electric parts box.

2) Never joint them near the thermal sensor part. Otherwise, it would cause insulation inferiority because of dew drops.

3) When replacing the sensor using the colored protective tube, wind the color tape matching the color of that tube.

Thermal sensor part

200

Winding the color tape

Cutting here

Connector

Thermal constringent tube

Cutting here

100

Soldered part

Dryer

100

Cutting here

These are parts for servicing sensors.

Please check that the accessories shown in the right table are packed.

Part name Q’ty Remarks

1 Sensor 1 Length: 3 m 2 Sensor Spring (A) 1 For spare 3 Sensor Spring (B) 1 For spare 4 Thermal constringent tube 3 Including one spare 5 Color tape 1 9 colors 6 Terminal 3

– 79 –

13. EXPLODED VIEWS AND PARTS LIST

13-1. Indoor Unit (E-Parts Assy)

FILE NO. SVM-09051

Location Part Location Part

No. No. No. No.

401 43T60365 TERMINAL BLOCK; 3P 405 43T69612 DISPLAY UNIT 403 43T69319 TEMPERATURE SENSOR 410 43T62003 CORD CLAMP 404 43T69320 TEMPERATURE SENSOR 411 43T69824 PC BOARD

Description Description

– 80 –

13-2. Indoor Unit

FILE NO. SVM-09051

Location Part Location Part

Description Description

No. No. No. No.

201 43T00478 FRONT PANEL ASSY 217 43T22312 BEARING ASSY, MOLD 202 43T09433 GRILLE OF AIR INLET 218 43T39323 BEARING BASE 203 43T03357 BACK BODY ASSY 219 43T20323 ASSY CROSS FLOW FAN 204 43T80317 AIR-FILTER 220 43T39324 MOTOR BAND (LEFT) 205 43T09392 HORIZONTAL LOUVER 221 43T39321 MOTOR BAND(RIGHT) 206 43T70313 HOSE, DRAIN 222 43T21409 FAN MOTOR 207 43T79301 CAP-DRAIN 224 43T82309 INSTALLATION PLATE 208 43T21402 MOTOR; STEPPING 225 43T69426 WIRELESS-REMOCO 209 43T44387 REFRIGERATION CYCLE ASSY 226 43T63002 REMOTE CONTROL HOLDER 210 43T47353 PIPE; SUCTION 227 43T62326 TERMINAL COVER 211 43T47355 PIPE; SUCTION 228 43T60317 CORD MOTOR LOUVER 212 43T11319 PIPE SHIELD 229 43T07311 PIPE HOLDER 213 43T19333 HOLDER, SENSOR

– 81 –

13-3. Outdoor Unit

FILE NO. SVM-09051

Location Part Location Part

No. No. No. No.

1 43T19335 FAN GUARD 15 43T49327 CUSHION,RUBBER 2 43T20324 PROPELLER FAN 18 43T41423 COMPRESSOR(Made in China) 3 43T00482 FRONT CABINET 19 43T19337 PACKED VALVE COVER 4 43T43403 CONDENSOR ASSEMBLY 20 43T00481 UPPER CABINET 5 43T62323 TERMINAL COVER 21 43T00448 FIXING PLATE VALVE 6 43T19336 FIN GUARD 22 43T42331 BASE PLATE ASSEMBLY 7 43T47308 CAPILLARY TUBE; 1.0 DIA 23 43T79305 DRAIN NIPPLE 8 43T46331 VALVE;PACKED 9.52 DIA 24 43T46351 REACTOR

9 43T47332 BONNET, 9.52 DIA 25 43T46343 4 WAY VALVE 10 43T46332 VALVE;PACKED 6.35 DIA 26 43T63320 4 WAY VALVE COIL ASSEMBLY 11 43T47331 BONNET, 6.35 DIA 27 43T04305 PARTITION 12 43T21400 FAN-MOTOR 28 43T39325 MOTOR BASE 13 43T47001 NUT FLANGE 29 43T39334 MOTOR BASE CONNECTION PLATE

Description Description

– 82 –

13-4. P.C. Board Layout

FILE NO. SVM-09051

Location Part Location Part

No. No. No. No.

701 43T62320 HEATSINK 705 43T60377 TEMPERATURE SENSOR 702 43T69819 PC BOARD 706 43T50304 SENSOR;HEAT EXCHANGER 703 43T60391 TERMINAL BLOCK; 5P 707 43T62313 BASE-PLATE-PC 704 43T60326 FUSE 708 43T55325 CAPACITOR; PLASTIC-FILM

Description Description

– 83 –

FILE NO. SVM-03005

TOSHIBA CARRIER (THAILAND) CO.,LTD.

144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI,

AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

– 56 –

Toshiba RAS-107SKV-E2, RAS-107SAV-E2 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

2. SPECIFICATIONS

4. CONSTRUCTION VIEWS

5. WIRING DIAGRAM

6. SPECIFICATION OF ELECTRICAL PARTS

7. REFRIGERANT CYCLE DIAGRAM

8. CONTROL BLOCK DIAGRAM

11. HOW TO DIAGNOSE THE TROUBLE

13. EXPLODED VIEWS AND PARTS LIST