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

SERVICE MANUAL

Indoor Unit Outdoor Unit

FILE NO. SVM-08020

SPLIT TYPE

RAS-107SKV-E RAS-107SAV-E

R410A

March, 2008

FILE NO. SVM-08020

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 ................................................................ 46

11. HOW TO DIAGNOSE THE TROUBLE...................................................... 58

12. HOW TO REPLACE THE MAIN PARTS................................................... 76

13. EXPLODED VIEWS AND PARTS LIST ................................................... 90

– 1 –

FILE NO. SVM-08020

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-08020

• 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-08020

2. SPECIFICATIONS

2-1. Specifications

Unit model Indoor RAS-107SKV-E

Outdoor RAS-107SAV-E

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 3.99- 3.66 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-E

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-E

Dimension Height (mm) 530

Width (mm) 660

Depth (mm) 240

Net weight (kg) 29 Compressor Motor output (W) 750

Type Single rotary type with DC-inverter variable speed control

Model DA89X1C-23FZ

Fan motor output (W) 20

Air flow rate (Cooling / Heating) 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-08020

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%

2.5kW (RAS-107SKV-E)

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

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-08020

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-08020

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-08020

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-08020

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-08020

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-08020

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.

(Water heat exchanger 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-08020

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-08020

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-08020

4. CONSTRUCTION VIEWS

Front panel

Knock out system

252

Air inlet

Air filter

739

Air outlet

6055

Heat exchanger

5560

133.41499104.39

Knock out system

195

Hanger

145

290

606

235

215

Hanger

145

Installation plate outline

Center line

Drain hose (0.5m)

Hanger

235

215

45.9

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)

26.6

∅

45.9164.1

10)

∅

Wireless remote control

135

4-2. Outdoor Unit

FILE NO. SVM-08020

− 15 −

5-1. Indoor Unit

FILE NO. SVM-08020

5. WIRING DIAGRAM

– 16 –

FILE NO. SVM-08020

5-2. Outdoor Unit

– 17 –

FILE NO. SVM-08020

6. SPECIFICATION OF ELECTRICAL PARTS

6-1. Indoor Unit

No. Parts name Type Specifications

1 Fan motor (for indoor) AFS-220-20-4AR AC Motor with 145°C thermo fuse 2 Thermo. sensor (TA-sensor) 10 kΩ at 25°C 3 Micro power module (T101) µRM1260V 4 Microcontroller unit (IC81) 5 Heat exchanger sensor

(TC-sensor) 6 Line filter (L01) SS11V-R06270 27µ H, AC 0.6A 7 Diode (D01,D02,D03 and D04) S5688J 8 Capacitor (C03) 9 Fuse (F01) FJL250V3.15A 3.15A, 250 V

10 Regulator IC (IC12) S7805PIC 5VDC, 0.5A

11 Varistor (R21) TNR10V471K-T8 470V 12 Louver motor MP24ZCT DC 12V

µPD780076GK-703-9ET-A

EKMH401VSN470MP20S

10 kΩ at 25°C

47µ F,400V

– 18 –

FILE NO. SVM-08020

6-2. Outdoor Unit

No. Parts name Model name Rating

1 SC coil L01 GET-0451 0.6mH, 15A

(Noise filter) L03

3 Reactor CH-51-Z-T L=19mH, 10A

4 Outside fan motor

Fan control relay

Outside air temp.

sensor (TO sensor) Heat exchanger temp.

sensor (TE sensor) Dischenge temp.

sensor (TD sensor)

GET-0452

SWT-72

WLF-240-20A-1

G5NB-1A Coil DC12V Contact AC250V-1.5A

(Inverter attached) 10kΩ (25°C)

(Inverter attached) 62kΩ (20°C)

20W

2.0 mH, 10A

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

Terminal block (6P)

Fuse

Electrolytic capacitor LLQ2G501KHUATF 500µF, DC 400 V x 3 pieces

IGBT GT15J321 15A, 600

Compressor DA89X1C-23FZ 3-phases 4-poles 750W Compressor thermo. OFF: 125 ± 4°C, ON: 90 ± 5°C

14 15

Rectifier

16 4-way valve coil − 17 Running capacitor DS451155NPQB

(for fan motor)

For protection of switching power source 3.15A, AC250V

For protection of inverter input overcurrent 25A, AC250V

PW-2AL or CS-12AL

JX0-6B

D15XB60-4001 15A, 600V

AC 450V~, 1.5µF

20A, AC250V

AC220-240V

– 19 –

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

INDOOR UNIT

Indoor heat

exchanger

Temp. measurement

FILE NO. SVM-08020

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-23FZ

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. : 1m Chargeless : 10m

Temp. measurement

Ø1.0 x 600

T E

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 –

7-2. Operation Data

FILE NO. SVM-08020

Tempeature Heat exchanger

condition(°C)

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

27/19

35/24

Model name Standard Indoor Outdoor Compressor RAS- pressure fan mode fan mode revolution

107SKV-E

0.9 to 1.1 9 to 11 47 to 49 High High 54

pipe temp.

Tempeature Heat exchanger

condition(°C) pipe temp.

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

20/15

7/6

Model name Standard Indoor Outdoor Compressor

RAS- pressure fan mode fan mode revolution

107SKV-E

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 exchanger path U bent. (Thermistor themometer)

2. Connecting piping condition : 5 m

– 21 –

8-1. Indoor Unit

FILE NO. SVM-08020

8. CONTROL BLOCK DIAGRAM

Heat Exchanger Sensor (Tc)

Room Temperature Sensor (Ta)

Infrared Rays Signal Receiver

and Indication

Initializing Circuit

Clock Frequency

Oscillator Circuit

Power Supply

Circuit

Converter

(D.C circuit)

Noise Filter

M.C.U.

Functions

• Cold draft preventing Function

• 3-minute Delay at Restart for Compressor

• Fan Motor Starting Control

• Processing

(Temperature Processing)

• Timer

• Serial Signal Communication

• Clean Function

Serial Signal Transmitter/Receiver

Indoor Unit Control Unit

Louver

Motor

Louver Motor Drive Control

Indoor Fan

Motor Control

Indoor

Fan Motor

From Outdoor Unit

220-240V

50Hz

REMOTE CONTROLLER

Serial Signal Communication

(Operation Command and Information)

Remote Controller

Operation (START/STOP)

Operation Mode Selection

AUTO, COOL, DRY, HEAT

Thermo. Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver AUTO Swing

Louver Direction Setting

ECO

QUIET

Infrared Rays, 36.7kHz

– 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-08020

– 23 –

Discharge

temp. sensor

Outdoor air

temp. sensor

Heat Exchanger

9. OPERATION DESCRIPTION

FILE NO. SVM-08020

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

• Operation control of outdoor fan motor

• P.M.V. control

• 4-way valve control



Operations follow ed 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-08020

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. Outdoor fan motor control........................................................................................... 30

4. Capacity control .......................................................................................................... 31

5. Current release control ............................................................................................... 31

6. Release protective control by temperature of indoor heat exchanger........................ 32

7. Defrost control (Only in heating operation) ................................................................ 33

8. Louver control ............................................................................................................. 34

1) Louver position....................................................................................................... 34

2) Air direction adjustment ......................................................................................... 34

3) Swing ..................................................................................................................... 34

9. ECO operation ............................................................................................................ 35

10. Temporary operation................................................................................................... 36

11. .................................................................................. 36

Discharge temperature control

12.

Self-Cleaning function ................................................................................................ 37

13.

Selt-Cleaning function release ................................................................................... 38

14.

Remote-A or B selection ............................................................................................ 39

15.

Short Timer ................................................................................................................ 40

9-3. Auto Restart Function ................................................................................................41

9-3-1. How to Set the A uto Restart Function .............................. ........................................ 41

9-3-2. How to Cancel the Au to Restar t Function ................................................................ 42

9-3-3. Power Failure During Timer Operation ................................................................... 42

9-4. Remote Controller and Its Fuctions ..................................................................... 43

9-4-1. Parts Name of Remote Contr oller ............................................................................. 43

9-4-2. Operation of remote control ...................................................................................... 43

9-4-3. Name and Functions of Indications on Remote Contr oller ........................................ 45

– 25 −

FILE NO. SVM-08020

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, 4-way valve and pulse Modulating 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-08020

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, pulse Modulating valve 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: ON In heating operation: OFF

[ ]

Description

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-08020

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

level COOL HEAT DRY

WF UH

WE H

WD UH M+

WC H

WB M+

W9 M L+

W8 L

W7 L+ L-

W5 L- UL L-

W4 UL UL

W3 SUL SUL

W2 SUL

L(W6)

M+

L+

(Linear approximation from M+ and L)

RAS-107SKV-E

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 –

+ 66 hidden pages