Toshiba RAS-10N3AV2-A, RAS-10N3KV2-A, RAS-13N3KV2-A, RAS-13N3AV2-A, RAS-16N3KV2-A Service Manual

SERVICE MANUAL

FILE NO. SVM-13001

SPLIT TYPE

SPLIT TYPE

Indoor Unit Outdoor Unit

<High Wall, Heat Pump Type> <Heat Pump Type>

RAS-10N3KV2-A / RAS-10N3AV2-A

RAS-13N3KV2-A / RAS-13N3AV2-A

RAS-16N3KV2-A / RAS-16N3AV2-A

R410A

January, 2013

FILE NO. SVM-13001

CONTENTS

1. SAFETY PRECAUTIONS .......................................................................... 2

2. SPECIFICATIONS ..................................................................................... 5

3. REFRIGERANT R410A ............................................................................. 9

4. CONSTRUCTION VIEWS ........................................................................ 17

5. WIRING DIAGRAM .................................................................................. 19

6. SPECIFICATIONS OF ELECTRICAL PARTS ......................................... 21

7. REFRIGERANT CYCLE DIAGRAM ........................................................ 22

8. CONTROL BLOCK DIAGRAM ................................................................ 26

9. OPERATION DESCRIPTION................................................................... 28

10. INSTALLATION PROCEDURE ................................................................ 53

11. HOW TO DIAGNOSE THE TROUBLE...................................................... 69

12. HOW TO REPLACE THE MAIN PARTS................................................... 94

13. EXPLODED VIEWS AND PARTS LIST ................................................. 111

– 1 –

FILE NO. SVM-13001

1. SAFETY PRECAUTIONS

The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual.
Be sure to read this installation manual carefully before installing.
Recommend to the owner to perform maintenance periodically when using over long periods of time.
Be sure to follow the precautions provided here to avoid safety risks. The symbols and their meanings are shown below.

DANGER : It indicates that incorrect use of this unit can result in a high possibility of severe injury (*1) or death.
WARNING : It indicates that incorrect use of this unit may cause severe injury of death.
CAUTION : It indicates that incorrect use of this unit may cause personal injury (*2) or property damage (*3).

*1 : A severe injury refers to blindness, injury, burns (hot or cold), electrical shock, bone fracture, or
poisoning that leaves aftereffects and requires hospitalization or extended out-patient treatment.
*2 : Personal injury means a slight accident, burn, or electrical shock which does not require admission
or repeated hospital treatment.
*3 : Preperty damage means greater damage which affects assets or resources.

For general public use

Power supply cord of parts of appliance for outdoor use shall be at least polychloroprene sheathed flexible cord
(design H07RN-F) or cord designation 60245 IEC66 (1.5 mm2 or more). (Shall be installed in accordance with national
wiring regulations.)

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 membranes, and oils because the
pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. As well as the adoption of this new refrigerant,
refrigerating machine oil has also been changed. Therefore, during installation work, be sure that water, dust,
former refrigerant, or refrigerating machine oil does not enter the refrigeration cycle of a new-refrigerant air
conditioner. To avoid mixing refrigerant and refrigerating machine oil, the sizes of charging port connecting port
connecting sections on the main unit are different from those for the conventional refrigerant, and different size tools
are also required. For connecting pipes, use new and clean piping materials with highpressure withstand
capabilities, designed for R410A only, and ensure that water or dust does not enter. Moreover, do not use any
existing piping as its pressure withstand may be insufficient and may contain impurities.

DANGER

• FOR USE BY QUALIFIED PERSONS ONLY.

• MEANS FOR DISCONNECTION FROM THE SUPPLY HAVING A CONTACT SEPERATION OF AT LEAST 3 mm

IN ALL POLES MUST BE INCORPORATED IN THE FIXED WIRING.

• TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK, MAKE SURE ALL POWER
SWITCHES ARE OFF FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

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

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

• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS.

FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

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

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

• IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE INSTALLATION WORK,
IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR
SOMETHING ELSE, IT CAUSES GENERATION OF POISONOUS GAS.

• WHEN INSTALLING OR RE-INSTALLING THE AIR CONDITIONER, DO NOT INJECT AIR OR OTHER SUBSTANCES
BESIDES THE DESIGNATED REFRIGERANT "R410A" INTO THE REFRIGERATION CYCLE. IF AIR OR OTHER
SUBSTANCES ARE MIXED, AN ABNORMAL PRESSURE CAN OCCUR IN THE REFRIGERATING CYCLEL, AND
THIS CAN CAUSE AN INJURY DUE TO A PIPE RUPTURE.

–

– 2 –

FILE NO. SVM-13001

WARNING

• Installation work must be requested from the supplying retail dealership or professional vendors. Self-installation may
cause water leakage, electrical shock, or fire as a result of improper installation.

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

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

• Electrical work must be performed by a qualified elecrical engineer in accordance with the code governing such
installation work, inernal wiring regulations, and the manual. A dedicated circuit and the rated voltage must be used.
Insufficient power supply or improper installation may cause electrical shock or fire.

• Use a cabtyre cable to connect wires in the indoor/outdoor units. Midway connection, stranded wire, and single-wire
connections are not allowed. Improper connection or fixing may cause a fire.

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

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

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

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

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

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

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

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

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

• In pump down operations, ensure to perform the following procedures.

- Do not inject air into the refrigeration cycle.

- Be sure to close both service valves and stop the compressor before removing the refrigerant pipe. It removing
the refrigerant pipe while the compressor is operating with the service valves opened, it may cause to air absorbed
and abnormal high pressure inside the refrigeration cycle and resulting burst or injury.

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

• Do not use any refrigerant different from the one specified for complement or replacement. Otherwise, abnormally
high pressure may be generated in the refrigeration cycle, which may result in a failure or explosion of the product
or an injury to your body.

• Be sure to comply with local regulations/codes when running the wire from the outdoor unit to the indoor unit,
(Size of wire and wiring method etc.).

• Places where iron or other metal dust is present. If iron or other metal dust adheres to or collects on the interior of
the air conditioner, it may spontaneously combust and start a fire.

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

• Never modify this unit by removing any of the safety guards.

• 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.

– 3 –

FILE NO. SVM-13001

CAUTION

• Please read this installation manual carefbefore installing the unit. It contains further important instructions for proper
installation.

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

• After unpacking the unit, examine it carefully for possible damage.

• Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise

level of the unit or where noise and discharged air might disturb neighbors.

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

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

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

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

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

• Do not install the outdoor unit in a place which can be a nest for small animals. Small animals could enter and contact

internal electrical parts, causing a failure or fire.

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

• Make sure to conduct a trial operation after the installation work, and explain how to use and maintain the unit to the

customer in accordance with the manual. Ask the customer to keep the operation manual along with the
installation manual.

– 4 –

/

/

FILE NO. SVM-13001

2. SPECIFICATIONS

Specification

Unit model Indoor RAS-10N3AV2-A

Cooling capacity (kW) 2.5
Cooling capacity range (kW) 1.1-3.1
Heating capacity (kW) 3.2
Heating capacity range (kW) 0.9-4.8
Power supply
Electric Indoor Operation mode Cooling Heating
characteristic Running current (A) 0.21-0.19 0.24-0.22

COP (Cooling / Heating)
Operating Indoor High (Cooling / Heating) (dB-A) 39/39
noise Medium (Cooling / Heating) (dB-A) 33/34

Indoor unit Unit model RAS-10N3KV2-A

Outdoor unit Unit model RAS-10N3AV2-A

Piping Type Flare connection
connection Indoor unit Liquid side (mm)

Refrigerant Name of refrigerant R410A

Wiring Power supply
connection Interconnection
Usable temperature range Indoor (Cooling / Heating)

Accessory Indoor unit Installation plate 1

* The specification may be subject to change without not i ce f or pur pose of i m pr ovement.

Outdoor RAS-10N3AV2-A

1Ph/50Hz/220-240V

Power consumption (W) 35 40

Outdoor Operation mode Cooling Heating

Outdoor (Cooling / Heating) (dB-A)

Dimension Height (mm) 275

Net weight (kg) 10
Fan motor output (W) 20
Air flow rate (Cooling / Heating)

Dimension Height (mm) 550

Net weicht (kg) 33
Compressor Motor output (W) 750

Fan motor output (W)
Air flow rate (Cooling / Heating)

Outdoor unit Liquid side (mm)

Maximum length (m) 20
Maximum charge-less length (m) 15
Maximum height difference (m) 10

Weight (kg) 0.80

Outdoor unit Drain nipple 1

Power factor (%) 76 76

Running current (A) 2.81-2.58 3.43-3.14
Power consumption (W) 563 710
Power factor (%) 91 94
Starting current (A) 3.67

Low (Cooling / Heating) (dB-A) 26/28

Width (mm) 790
Depth (mm) 225

3

min)

(m

Width (mm) 780
Depth (mm) 290

Type Single rotary type with DC-inverter variable speed conrol
Model DA89X1C-23FZ2

(m3 min)

Gas side (mm)

Gas side (mm)

o

C)

Outdoor (Cooling / Heating)

Wireless remote controller 1
batteries 2
Remote controller holder 1
TOSHIBA IAQ Filter (long type) 1
Mounting screw
Pan head wood screw
Plasma air purifier ­Installation manual 1
Owner's manual 1

Water proof rubber cap 2

(
(oC)

∅6.35
∅9.52
∅6.35
∅9.52

3 Wires: Includes earth (Outdoor )

21-32/0-28

-10-46/-15-24

6 (∅ 4 x 25L)

2 (∅ 3.1 x 16L)

4.18/4.27

46/47

8.6/9.5

43

30/30

4 Wires: Includes earth

– 5 –

FILE NO. SVM-13001

Unit model Indoor RAS-13N3KV2-A RAS-16N3KV2-A

Outdoor RAS-13N3AV2-A RAS-16N3AV2-A
Cooling capacity (kW)
Cooling capacity range (kW
Heating capacity (kW)
Heating capacity range (kW)
Power supply 1Ph, 50Hz/220-240V
Electric Indoor Operation mode Cooling Heating Cooling Heating
characteristic Running current (A) 0.21-0.19 0.24-0.22 0.21-0.19 0.24-0.22

Power consumption (W) 35 40 30 35
Power factor (%)76766565

Outdoor Operation mode Cooling Heating Cooling Heating

Running current (A) 4.19-3.83 5.00-4.59 6.13-5.62 6.50-5.96
Power consumption (W) 885 1080 1310 1405
Power factor %)

Starting current (A)
COP (Cooling / Heating) 3.70/3.75 3.28/3.53
Operating Indoor High (Cooling / Heating) (dB-A) 45/45 47/48
noise Medium (Cooling / Heating) (dB-A) 40/40 42/43

Low (Cooling / Heating) (dB-A) 30/31 32/33

Outdoor (Cooling / Heating) (dB-A) 49/50 51/52

Indoor unit Unit model RAS-13N3KV2-A RAS-16N3KV2-A

Dimention Height (mm) 275 275

Width (mm) 790 790

Depth (mm) 225 225

Net weight (kg) 10 10
Fan motor output (W) 20 30
Air flow rate (Cooling / Heating)

Outdoor unit Unit model RAS-13N3AV2-A RAS-16N3AV2-A

Dimention Height (mm) 550 550

Width (mm) 780 780

Depth (mm) 290 290

Net weight (kg) 37 38
Compressor Motor output (W) 750 1100

Type

Model DA108X1C-23FZ DA131S1B-31FZ

Fan motor output (W) 43 43

Air flow rate (Cooling / Heating)
Piping Type Flare conne ction
connection Indoor unit Liquid side (mm) ∅6.35 ∅6.35

Gas side (mm) ∅9.52 ∅12.7

Outdoor unit Liquid side (mm) ∅6.35 ∅6.35

Gas side (mm) ∅9.52 ∅12.7
Maximum length (m) 20 20
Maximun charge-less length (m) 15 15
Maximum height difference (m) 10 10

Refrigerant Name of refrigerant R410A R410A

Weight (kg) 1.05 1.10

Wiring Power supply 3 Wires: Includes earth (Outdoor) 3 Wires: Includes earth (Outdoor)
connection Interconnection 4 Wires: Includes earth 4 Wires: Includes earth
Usable temperature range Indoor (Cooling / Heating)

Outdoor (Cooling / Heating)

Accessory Indoor unit Installation plate 1 1

Wireless remote controller 1 1

batteries 2 2

Remote controller holder 1 1

TOSHIBA IAQ Filter (long type) 1 1

Mounting screw

Pan head wood screw

3

(m

/ min)

Single rotary type with DC-inverter

3

(m

/ min)

o

(

C)

o

(

C)

6 (∅ 4 x 25L)

2 (∅ 3.1 x 16L)
Plasma air purifier ­Installation manual 1
Owner's manual 1

Outdoor unit Drain nipple 1

Water proof rubber cap 2

3.4

2.0-4.1 0.8-5.0

4.2 5.3

1.8-5.6

96 98 97 98

5.24 7.02

10.4/10.4 11.4/12.3

Twin rotary type with DC-inverter

variable speed control

37.5/37.5 34.0/34.0

21-32/0-28 21-32/0-28

-10-46/-15-24 -10-46/-15-24

­ 1
1
1
2

* The specification may be subject to change without not i ce f or pur pose of i m pr ovement.

4.4

0.9-6.3

variable speed control

6 (∅ 4 x 25L)

2 (∅ 3.1 x 16L)

– 6 –

Operation Characteristic Curve (RAS-10N3KV2-A)

<Cooling> <Heating>

FILE NO. SVM-13001

10

9

8

7

6

5

4

Current (A)

3

2

1

RAS-10N3KV2-A

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

o

0

0 10 20 30 40 50 60 70 80 90 100 110 120

Compressor Speed (rps)

C/WB 19oC

o

C

9

8

7

RAS-10N3KV2-A

6

5

4

Current (A)

3

2

1

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

o

C

o

C/WB 6oC

0

0 102030405060708090100110120

Compressor Speed (rps)

Capacity Variation Ratio According to Temperature (RAS-10N3KV2-A)

<Cooling>

105

100

95

90

85

80

75

Capacity ratio (%)

70

65

Capacity ratio:100%=

2.5kW(RAS-10N3KV2-A)

60

55

50

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

Outdoor temp. (℃)

RAS-10N3KV2-A

Conditions
Indoor:DB27℃/WB19℃
Indoor air flow:High
Pipe length:5m

Voltage : 23

0V

<Heating>

120

100

80

60

40

Heating Capacity ratio (%)

20

0

-15 -10 -5 0 5 10

RAS-10N3KV2-A

Condition
Indoor:DB20℃
Indoor air flow:High
Pipe length:5m

Voltage : 230V

Outdoor temp. (℃)

– 7 –

Operation Characteristic Curve (RAS-13,16N3KV2-A)

g

<Cooling> <Heating>

FILE NO. SVM-13001

9

8

7

RAS-16N3KV2-A

6

5

4

Current (A)

3

2

1

0

0 102030405060708090100110120

Compressor Speed (rps)

Conditions
Indoor : DB 27oC/WB 19oC
Outdoor : DB 35
Air Flow : High
Pipe Length : 5m
Voltage : 230V

RAS-13N3KV2-A

o

C

9

8

7

6

5

4

Current (A)

3

2

1

0

0 102030405060708090100110120

RAS-16N3KV2-A

Compressor Speed (rps)

RAS-13N3KV2-A

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

o

C/WB 6oC

Capacity Variation Ratio According to Temperature (RAS-13,16N3KV2-A)

<Cooling><

105

100

RAS-13N3KV2-A

95

90

85

80

75

Capacity ratio (%)

70

65

Capacity ratio :100%

60

3.4kW (RAS-13N3KV2-A)

4.4kW (RAS-16N3KV2-A)

55

50

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

Outdoor temp. (oC)

RAS-16N3KV2-A

Conditions
Indoor : DB 27oC/WB 19oC
Outdoor : DB 35
Air Flow : High
Pipe Length : 5m
Voltage : 230V

o

C

Heatin

– 7 –

>

120

100

RAS-13N3KV2-A

80

60

Capacity ratio (%)

40

Conditions
Indoor : DB 20oC

20

Outdoor : DB 7
Air Flow : High
Pipe Length : 5m
Voltage : 230V

0

-15 -10 -5 0 5 10

o

C/WB 6oC

Outdoor temp. (oC)

RAS-16N3KV2-A

Capacity ratio :100%

4.2kW (RAS-13N3KV2-A)

5.3kW (RAS-16N3KV2-A)

– 8 –

3. REFRIGERANT R410A

FILE NO. SVM-13001

This air conditioner adopts the new refrigerant HFC
(R410A) which does not damage the ozone layer .

The working pressure of the new refrigerant R410A
is 1.6 times higher than conventional refrigerant
(R22). The refrigerating oil is also changed in
accordance with change of refrigerant, so be careful
that water , dust, and existing refrigerant or refrigerat­ing oil are not entered in the refrigerant cycle of the
air conditioner using the new refrigerant during
installation work or servicing time.

The next section describes the precautions for air
conditioner using the new refrigerant. Conforming to
contents of the next section together with the
general cautions included in this manual, perform
the correct and safe work.

3-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may
cause a serious trouble. By using tools and materi­als exclusive for R410A, it is necessary to carry out
installation/servicing safely while taking the following
precautions into consideration.

1. Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.

If other refrigerant than R410A is mixed, pressure
in the refrigeration cycle becomes abnormally
high, and it may cause personal injury, etc. by a
rupture.

2. Confirm the used refrigerant name, and use tools
and materials exclusive for the refrigerant R410A.

The refrigerant name R410A is indicated on the
visible place of the outdoor unit of the air condi­tioner using R410A as refrigerant. To prevent
mischarging, the diameter of the service port
differs from that of R22.

3. If a refrigeration gas leakage occurs during
installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire,
a poisonous gas may occur.

4. When installing or removing an air conditioner, do
not allow air or moisture to remain in the refrig­eration cycle. Otherwise, pressure in the refrig­eration cycle may become abnormally high so
that a rupture or personal injury may be caused.

5. After completion of installation work, check to
make sure that there is no refrigeration gas
leakage.

If the refrigerant gas leaks into the room, coming
into contact with fire in the fan-driven heater,
space heater, etc., a poisonous gas may occur.

6. When an air conditioning system charged with a
large volume of refrigerant is installed in a small
room, it is necessary to exercise care so that,
even when refrigerant leaks, its concentration
does not exceed the marginal 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. Never use copper
pipes thinner than 0.8 mm even when it is
available on the market.

– 9 –

Table 3-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

FILE NO. SVM-13001

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

– 10 –

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-13001

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

– 11 –

Flare nut width

(mm)

17
22
26
29

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

FILE NO. SVM-13001

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 by means of a torque wrench. The tightening torque for R410A is

the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.
When it is strong, the flare nut may crack and may be made non-removable. When choosing the tighten-

ing torque, comply with values designated by man ufacturers. Table 3-2-7 shows reference v alues.

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)

– 12 –

16 (160), 18 (180)

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

FILE NO. SVM-13001

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 for conventional refrigerant (R22)

3. Tools commonly used for R410A and for conventional refrigerant (R22)
The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

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. Le vel vial

7. Screwdriver (+, –)

8. Spanner or Monkey wrench

9. Hole core drill (Ø65)

10. He xagon 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

– 13 –

FILE NO. SVM-13001

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

– 14 –

FILE NO. SVM-13001

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 ]

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

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 e xpensive 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.

– 15 –

2. Characteristics required for flux

• Activated temperature of flux coincides with the
brazing temperature.

• Due to a wide effective temperature range, flux
is hard to carbonize.

• It is easy to remove slag after brazing.

• The corrosive action to the treated metal and

brazing filler is minimum.

• It excels in coating performance and is harm­less to the human body.

As the flux works in a complicated manner as
described above, it is necessary to select an
adequate type of flux according to the type and
shape of treated metal, type of brazing filler and
brazing method, etc.

3. Types of flux

• Noncorrosive flux

Generally, it is a compound of borax and boric
acid.
It is effective in case where the brazing tem­perature is higher than 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

FILE NO. SVM-13001

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, k eep 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 water
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

– 16 –

4. CONSTRUCTION VIEWS

FILE NO. SVM-13001

4-1. Indoor Unit

Front panel

63

48

7

Air filter

Heat exchanger

790

Air filter

225

48

63

7

116

Installation plate hanger

Connecting pipe (0.35m)

(For 10,13k series : Flare

(For 16k series : Flare

84.5

Minimum

distance

to wall

275

170 or more

Installation plate hanger

9.52mm)

12.70mm)
235

215

Hanger

480

621

Drain hose (0.50m)

Connecting pipe (0.40m)

235

215

Minimum

distance

to ceiling

65 or more

172

58

19

Wireless remote controller

6.35mm)(Flare

149

84.5

63

17.5

Remote controller holder

45

Minimum

distance

to wall

170 or more

190

40

Hanger

84.5 150 84.5

160.5 160.5 150

Center line

Hanger

Installation plate outline

– 17 –

40

4-2. Outdoor Unit

28

FILE NO. SVM-13001

A

108 125

600

320

50

36

306

R5.5

R

Ø

15

6 hole

A detail Drawing (Back leg)

290

86

320

FAN-GUARD

436

Ø

550

275

Ø

25 Drain outlet

2

-

Ø

11 x 14

(For 8 -

Ø

Hole

10 anchor bolt)

Ø

80

306

320

Ø

6 hole

11x14 hole

Ø

36
50

R

15

B Detail Drawing (Front leg)

COVER-PV

Z

9060090

69

320
342

100 or more

320

100 or more

Air outlel

Z View

600

Air intlel

600 or more

5

92

4

Service port

137

2 - R5-5 x 17L Ushape

(For ∅ 8 - ∅10 anchor bolt)

600 or more

2 - ∅11 x 14 Long holes (For ∅8- ∅10 anchor bolt)

Electrical part cover

Liquid side
(Flare 6.35)

Ø

Gas side
(10,13

: Flare ∅ 9.52)

(16

: Flare ∅12..7)

Installation dimension

– 18 –

WHI

RED

5-1. For 10,13k

5. WIRING DIAGRAM

FILE NO. SVM-13001

COMPRESSOR

1 1

CM

REACTOR

2 2
3 3

YEL

YEL

BRW

YEL

ORN

2

121

RED
WHI
BLK

P25

P23

P21

P35

P34

P19

P18
P11

P08

P04
P05
P06

P24

P22

P20

DB01

Q404

Q200~205
IGBT

R221

R220

R219

POWER
RELAY

DB02

P33 P31 P30

PUR

L03

C12 C14

CT

RELAY

P.C.BOARD

(MCC-5009)

C13

YEL

F03

FUSE

T3.15A

AC250V

CN701P32

1 3
1

3

Q300~305
MOS-FET

R321

R320

R319

ABSORBER

P07
BLK

COIL
FOR
4WAY
VALVE

L01

SURGE

VARISTOR

VARISTOR

F01
FUSE

2

25A
AC250V

P03

ORN

2 3

CN300

CN700

P02

P01

WHI

BLK

L N

~ ~ ~

POWER
SUPPLY

(From Main Line)

BLK

3 3

WHI

2 2
1 1

RED

FM

FAN MOTOR

6 6
5 5
4 4
3 3
2 2
1 1

CN603

CN602

CN601

CN600

PMV

PULSE MOTOR VALVE

3 3
2
1 1

(SUCTION PIPE

TEMP. SENSOR)

2 2
1 1

TEMP. SENSOR)

3 3
2
1 1

(DISCHARGE PIPE

TEMP. SENSOR)

2 2
111

(CONDENSER PIPE

TEMP. SENSOR)

COLOR IDENTIFICATION

BLK:BLACK
BLU:BLUE
RED:RED
GRY:GRAY
PNK:PINK

TS

TO

(OUTDOOR

TD

TE

WHI:WHITE
BRW:BROWN
ORN:ORANGE
YEL:YELLOW
PUR:PURPLE

Indoor terminal block

POWER SUPPLY

(From outdoor Unit)

Heat Exchanger Sensor

(TC)

Thermo Sensor

(TA)

and indication parts

Infrared rays receiver

21
CN11
(BLK)

CN01

11
22

CN62

(BLU)

11
22

CN61
(WHI)

1

2

2

3

3

4

4

5

5

6

6

WP-027

7

7

8

8

9

9

10

10
11
CN10

(WHI)

1 2 3

BLK

3 1

T3.15A Fuse F01

Varistor

WHI

2

BLU

3

BLU

4

BLU

5

BLU

6

BLU

7

BLU

8

BLU

9

BLU

10

CN21

GRN&YEL

GRN&YEL

Heat exchanger

CN51

Line
Filter

DC 5V
DC 12V

Main PC Board

WP-020

RED

1

1

BLK

3

3

WHI

5

5
CN31

(WHI)
1

2
3

CN33

(WHI)
1

2
3
4

5
CN32
(WHI)

1
2

3

1
2
3
4
5

YEL
GRY

BRW

WHI
YEL
YEL
YEL
YEL

1
2
3
4
5

CN22

(WHI)

1

2
3
4

AC Motor

FAN motor

1
2
3
4
5

Louver Motor

Color indication

BRW:BROWN
YEL:YELLOW
BLK:BLACK

Power Supply Circuit

RED:RED
BLU:BLUE
WHI:WHITE
GRN & YEL:
GREEN & YELLOW

– 19 –

5-2. For 16k

FILE NO. SVM-13001

COMPRESSOR

1 1
2 2

CM

3 3

YEL

YEL

BR W

YEL

ORN

2

REACT OR

RED

P04
P05

WHI
BLK

P06

P25

P24

P23

P22

P21

P20

P35

P34

P19

P18
P11

121

P08

DB01

Q200~205
IGBT

POWER
RELA Y

DB02

Q404

P33 P31 P30

PUR

R221

R220

R219

L03

CT

RELA Y

P.C.BOARD

(MCC-5009)

C13

C12 C14

1 2
1 2

REACT OR

F03

FUSE

T3.15A

AC250V

Q300~305
MOS-FET

R321

R320

R319

L01

VARIST OR

SURGE

ABSORBER

VARIST OR

F01
FUSE
25A
AC250V

P03

WHI

BLK

CN701P32

1 3
1

3

P07
BLK

COIL
FOR
4WAY
VALVE

2 3

CN300

CN700

P02

P01

ORN BLK WHI

L N

~ ~ ~

POWER
SUPPL Y

(From main line)

BLK

3 3

WHI

2 2
1 1

RED

FM

FAN MOT OR

6 6
5 5
4 4

PMV

3 3
2 2
1 1

PULSE MOT OR V AL VE

3 3
2

CN603

1 1

2 2

CN602

1 1

3 3
2

CN601

1 1

(DISCHARGE PIPE

2 2

CN600

111

(CONDEN SER PIPE

COLOR IDENTIFICA TION

BLK:BLACK
BLU:BLUE
RED:RED
GR Y:GRAY
PNK:PINK

TS

(SUCTION PIPE

TEMP . SENSOR)

TO

(OUTDOOR

TEMP . SENSOR)

TD

TEMP . SENSOR)

TE

TEMP . SENSOR)

WHI:WHITE
BR W:BROWN
ORN:ORANGE
YEL:YELLOW
PUR:PURPLE

Indoor terminal block

POWER SUPPLY

(From outdoor Unit)

SHEET MET AL

BLK

CN02

T3.15A 250VAC

Heat Exchanger Sensor

(TCJ)

Heat Exchanger Sensor

(TC)

Thermo Sensor

(TA)

CN11

(BLK)

Wireless Unit Assembly

21

1 1
2

2

3 3

44
5665

7 7
8 8
9 9

WP-027

10 10

1111

CN10

(WHI)

CN63
(YEL)

CN62

(BLU)

CN61
(WHI)

BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
WHI

1

Fuse F01

2112

2112

Varistor

11
22

10

11

CN21

(WHI)

2

BLK

3 1

Line
Filter

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

11

WHI

3

RED

CN51CN01

GRN&YEL

Heat exchanger

6 6

CN31

(WHI)

4 4

CN32

(WHI)

DC 5V

DC 12V

Main P.C Board

MCC-5045

11

33
44
55

WHI

121

YEL

2

YEL

33

YEL
YEL

55

Power Supply Circuit

DC Motor

Fan Motor

1 1

22

3 3

44

5 5

Louver Motor

CN22

(WHI)

1
2
3
4

Color indication

BR W:BROWN
YEL:YELLOW
BLK:BLACK
RED:RED
BLU:BLUE
WHI:WHITE
GRN & YEL:
GREEN & YELLOW

– 20 –

FILE NO. SVM-13001

6. SPECIFICATIONS OF ELECTRICAL PARTS

6-1. Indoor Unit

No. Parts name Type Specifications

Fan motor

1

(for indoor)

2 Room temp. sensor (TA-sensor) ( - ) 10kW at 25°C
3 Heat exchanger temp. sensor (TC-sensor) ( - ) 10kW at 25°C
4 Louver motor 24BYJ48-HT Output (Rated) 1W, 16 poles, DC12V

10,13k AFN-220-20-4D AC 240V, 20W
16k ICF-340-30-2B DC 340V, 30W

6-2. Outdoor Unit

No. Parts name Type Specifications

Reactor

1

2 Outdoor fan motor ICF-140-43-4R DC140V, 43W
3 Suction temp. sensor (TS sensor) (Inverter attached) 10kW (25°C)
4 Discharge temp. sensor (TD sensor) (Inverter attached) 62kW (20°C)
5 Outside air temp. sensor (TO sensor) (Inverter attached) 10kW (25°C)
6 Heat exchanger temp. sensor (TE sensor) (Inverter attached) 10kW (25°C)

Terminal block7

Compressor8

COIL FOR P.M.V.

9

Coil for 4-way valve

10

16k
10,13k CH-69 (1 Pc) L = 19mH, 10A

10k

13k

16k

CH-57 (2 Pcs)

JX0-5B

DA89X1C-23FZ2
DA108X1C-23FZ

DA131S1B-31FZ

CAM-MD12TCTH-5

STF

L = 10mH, 16A

20A, AC250V

3-phases 4-poles 750W

3-phases 4-poles 750W

3-phases 4-poles 1100W

DC12V
AC220-240V

– 21 –

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

RAS-10N3KV2-A / RAS-10N3AV2-A

INDOOR UNIT

Indoor heat

exchanger

T1

Temp. measurement

TC

FILE NO. SVM-13001

P

Pressure measurement
Gauge attaching port

Vacuum pump connecting port

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

4-way valve

TS

Sectional shape
of heat insulator

Muffler

Muffler

Compressor
DA89X1C-23FZ2

Outdoor heat

exchanger

Cross flow fan

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

TD

TO

TA

Allowable height

difference : 10m

Strainer

Pulse Modulating
valve at liquid side

Strainer

Max. : 20m

Min. : 2m
Chargeless : 15m

Charge : 20g/m
(16 to 20m)

Allowable pipe length

Temp. measurement

T2

TE

Propeller fan

OUTDOOR UNIT

NOTE :

Refrigerant amount : 0.80kg

Gas leak check position
Refrigerant flow (Cooling)
Refrigerant flow (Heating)

NOTE :

• The maximum pipe length of this air conditioner is 20 m. When the pipe length exceeds 15m, the additional

charging of refrigerant, 20g per 1m for the part of pipe exceeded 15m is required. (Max. 100g)

– 22 –

RAS-13N3KV2-A / RAS-13N3AV2-A

INDOOR UNIT

Indoor heat

exchanger

T1

Temp. measurement

TC

FILE NO. SVM-13001

P

Pressure measurement
Gauge attaching port

Vacuum pump connecting port

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

4-way valve

TS

Sectional shape
of heat insulator

Muffler

Muffler

Compressor
DA108X1C-23FZ

Outdoor heat

exchanger

Cross flow fan

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

TD

TO

TA

Allowable height

difference : 10m

Strainer

Pulse Modulating
valve at liquid side

Max. : 20m

Min. : 2m
Chargeless : 15m

Charge : 20g/m
(16 to 20m)

Allowable pipe length

Temp. measurement

T2

TE

Propeller fan

OUTDOOR UNIT

NOTE :

Refrigerant amount : 1.05kg

Gas leak check position
Refrigerant flow (Cooling)
Refrigerant flow (Heating)

NOTE :

• The maximum pipe length of this air conditioner is 20 m. When the pipe length exceeds 15m, the additional

charging of refrigerant, 20g per 1m for the part of pipe exceeded 15m is required. (Max. 100g)

– 23 –

RAS-16N3KV2-A / RAS-16N3AV2-A

INDOOR UNIT

Indoor heat

exchanger

T1

Temp. measurement

TC

FILE NO. SVM-13001

P

Pressure measurement
Gauge attaching port

Vacuum pump connecting port
Deoxidized copper pipe

Outer dia. : 12.7mm(16)

Thickness : 0.8mm

4-way valve

TS

Muffler

Muffler

Compressor
DA131S1B-31FZ

Outdoor heat

exchanger

Cross flow fan

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

Sectional shape
of heat insulator

TD

TO

Split capillary

Ø1.2 x 80

TA

Allowable height

difference : 10m

Strainer

Pulse Modulating
valve at liquid side

Max. : 20m

Min. : 2m
Chargeless : 15m

Charge : 20g/m
(16 to 20m)

Allowable pipe length

Temp. measurement

T2

Propeller fan

OUTDOOR UNIT

Ø1.2 x 80

TE

NOTE :

Refrigerant amount : 1.10kg

Gas leak check position
Refrigerant flow (Cooling)
Refrigerant flow (Heating)

NOTE :

• The maximum pipe length of this air conditioner is 15 m. When the pipe length exceeds 15m, the additional

charging of refrigerant, 20g per 1m for the part of pipe exceeded 15m is required. (Max. 100g)

– 24 –

7-2. Operation Data

<Cooling>

FILE NO. SVM-13001

Tempeature Heat exchanger

condition(°C)

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

27/19 35/-

Model name Standard Indoor Outdoor Compressor

RAS- pressure fan mode fan mode revolution

10N3KV2-A
13N3KV2-A
16N3KV2-A

0.9 to 1.1 12 to 14 37 to 39 High High 49

0.8 to 1.0 11 to 13 46 to 48 High High 59

0.8 to 1.0 11 to 13 40 to 42 High High 67

pipe temp.

<Heating>

Tempeature Heat exchanger

condition(°C)

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

20/- 7/6 10N3KV2-A 2.5 to 2.7 39 to 41 0 to 3 High High 60

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

13N3KV2-A 2.6 to 2.8 41 to 43 0 to 2 High High 66
16N3KV2-A 2.7 to 2.9 43 to 45 0 to 2 High High 67

pipe temp.

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

– 25 –

8-1. Indoor Unit

FILE NO. SVM-13001

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

Power Supply

(From Outdoor Unit)

REMOTE CONTROLLER

Serial Signal Communication

(Operation Command and Information)

Remote Controller

Operation [ ]

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

Hi-POWER

Infrared Rays, 36.7kHz

COMFORT SLEEP

QUIET

– 26 –

8-2. Outdoor Unit (Inverter Assembly)

detect

Current

circuit

Gate drive

detect

Current

FILE NO. SVM-13001

Compressor

Outdoor

Fan motor

Inverter

(DC → AC)

P.M.V. : Pulse Motor Valve

M.C.U. : Micro Control Unit

MICRO-COMPUTER BLOCK DIAGRAM

M.C.U

MCC5009 (P.C.B) OUTDOOR UNIT

• PWM synthesis function

• Input current release control

circuit

Indoor unit

send/receive

circuit

Gate drive

• IGBT over-current detect control

• Outdoor fan control

• High power factor correction control

• Inverter output frequency control

• A/D converter function

• P.M.V. control

• Discharge temp. control

• 4-way valve control

• Signal communication to indoor unit

4MHz

Clock

frequency

circuit

High Power

factor Correction

Converter

(AC → DC)

sensor

Input current

Filter

Noise

Inverter

(DC → AC)

Relay

circuit

of P.M.V.

Driver circuit

valve

4-way

P.M.V.

Power Supply

(From Outdoor Unit)

For INDOOR UNIT

Discharge

temp. sensor

Outdoor air

temp. sensor

Suction temp.

– 27–

sensor

Heat exchanger

temp.sensor

9. OPERATION DESCRIPTION

FILE NO. SVM-13001

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 performs the
followed operation within the range that current
does not exceed the allowable value.

4. Contents of operation command signal
(Serial signal) from outdoor unit controller
to indoor unit controller

The following signals are sent from the outdoor unit
controller.

• The current operation mode

• The current compressor revolution

• Outdoor temperature

• Existence of protective circuit operation

For transferring of these signals, the indoor unit
controller monitors the contents of signals, and
judges existence of trouble occurrence.

Contents of judgment are described below.

• Whether distinction of the current operation
status meets to the operation command signal

• Whether protective circuit operates
When no signal is received from the outdoor

unit controller, it is assumed as a trouble.

– 28 –

FILE NO. SVM-13001

9-2. Operation Description

1. Basic operation ........................................................................................................... 30

1. Operation control ................................................................................................... 30

2. Cooling/Heating operation ..................................................................................... 31

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

4. DRY operation........................................................................................................ 31

2. Indoor fan motor control ............................................................................................. 32

3. Outdoor fan motor control........................................................................................... 34

4. Capacity control .......................................................................................................... 35

5. Current release control ............................................................................................... 35

6. Release protective control by temperature of indoor heat exchanger........................ 36

7. Defrost control (Only in heating operation) ................................................................ 37

8. Louver control ............................................................................................................. 38

1) Louver position....................................................................................................... 38

2) Air direction adjustment ......................................................................................... 38

3) Swing ..................................................................................................................... 38

9. ECO operation ............................................................................................................ 39

10. Temporary operation................................................................................................... 40

11.

Discharge temperature control ................................................................................... 40

12.

Pulse Modulating valve (P.M.V.) control ..................................................................... 41

13.

Self-Cleaning function ................................................................................................ 42

14.

Remote-A or B selection ............................................................................................ 44

15.

QUIET mode ............................................................................................................. 45

COMFORT SLEEP mode ......................................................................................... 45

16.

17.

Short Timer ................................................................................................................ 45

31

18.

One-Touch Comfort .................................................................................................. 46

19.

Hi-POWER Mode ...................................................................................................... 46

20. FIL

TER Indicator ...............................................................................................46

9-3. Auto Restart Function ..

9-3-1. How to Set the A uto Restart Function .............................. ........................................ 47

9-3-2. How to Cancel the Au to Restar t Function ................................................................. 48

9-3-3. Power Failure During Timer Operation .................................................................... 49

9-4. Remote Controller and Its Fuctions

9-4-1. Parts Name of Remote Contr oller ............................................................................... 50

9-4-2. Operation of remote control ....................................................................................... 50

9-4-3. Name and Functions of Indications on Remote Contr oller ......................................... 53

– 29 −