Toshiba RAS-107SKV-E2, RAS-107SAV-E2 SERVICE MANUAL
SERVICE MANUAL
Indoor Unit Outdoor Unit
FILE NO. SVM-09051
SPLIT TYPE
<High Wall, Heat Pump Type> <Heat Pump 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
M
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 –
3
/ min)
(m
3
/ min)
(m
o
C)
(
o
C)
(
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
<Cooling> <Heating>
FILE NO. SVM-09051
6
5
4
3
Current (A)
2
Conditions
1
Indoor : DB 27
Outdoor : DB 35
Air Flow : High
Pip Length : 5m
Voltage : 230V
0
0 102030405060708090100110120
°C/WB 19°C
°C/WB 24°C
6
5
4
3
Current (A)
2
1
0
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
<Cooling> <Heating>
105
100
95
90
85
80
75
70
Cooling Capacity ratio (%)
65
Capacity ratio 100% is 2.5kw
60
55
Conditions
Indoor : DB 27
Indoor Air Flow : High
Pip Length : 5m
Voltage : 230V
°C/WB 19°C
50
32 33 34 35 36 37 38 39 40 41 42 43
Outside Temperature ( oC)
120
100
80
60
Heating Capacity ratio (%)
40
20
0
-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
0.80 0.80
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
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
0.8
0.8
1.0
Thickness
(mm)
0.8
0.8
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 1.5 to 2.0
1.0 to 1.5 2.0 to 2.5
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 1.0 to 1.5
0.5 to 1.0 1.5 to 2.0
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
0.8
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
0.8
0.8
1.0
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
D
C
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.
1
2
3
4
5
6
7
8
9
10
(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
Yes
Yes
Yes
(Note 2)
R410A
Whether conventional equipment
can be used
*(Note 1)
*(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.
M
Flow meter
Stop valve
Nitrogen gas
cylinder
From Nitrogen cylinder
Pipe
Nitrogen
gas
Rubber plug
Fig. 3-5-1 Prevention of oxidation during brazing
– 13 –
4-1. Indoor Unit
FILE NO. SVM-09051
4. CONSTRUCTION VIEWS
Front panel
60
8
Knock out system
250
50
Air inlet
Air filter
740
Air outlet
6055
Heat exchanger
5560
135500105
Knock out system
50
195
58
52
8
Hanger
145
290
605
235
215
Hanger
Hanger
145
Installation plate outline
Center line
Drain hose (0.5m)
Hanger
235
215
45
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
38
∅
45165
40
8~
10)
∅
6)
54
Wireless remote control
135
16
4-2. Outdoor Unit
FILE NO. SVM-09051
C
L
C
L
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.
6
sensor (TO sensor)
Dischenge temp.
7
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)
8
9
Fuse
10
Electrolytic capacitor
11
IGBT
12
Compressor DA89X1C-23EZ 3-phases 4-poles 750W
13
Rectifier
14 Running capacitor
(for fan motor)
15
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
T1
Temp. measurement
TC
FILE NO. SVM-09051
P
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
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
TD
TO
Ø1.0 x 600
TA
Allowable height
difference : 10m
Allowable pipe length
Max. : 10m
Min. : 2m
Chargeless : 10m
Temp. measurement
T2
Ø1.0 x 600
TE
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
<Cooling>
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
<Heating>
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
1
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
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
27
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 −
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