Toshiba RAS-10NAV-E, RAS-10NAV-A, RAS-10NKV-A SERVICE MANUAL

FILE NO. SVM-05026

SERVICE MANUAL

AIR-CONDITIONER

SPLIT WALL TYPE

RAS-10NKV-E / RAS-10NAV-E

RAS-10NKV-A / RAS-10NAV-A

June 2005

FILE NO. SVM-05026

CONTENTS

1.SPECIFICATIONS

1-1. Specifications

1-2. Operation Characteristic Curve

2.REFRIGERANT R-410A

2-1. Safety During Installation/Servicing

2-2. Refrigerant Piping Installation

2-3. Tools

2-4. Recharging of Refrigerant

2-5. Brazing of Pipes

3.CONSTRUCTION VIEWS

3-1. Indoor Unit

3-2. Outdoor Unit

4. WIRING DIAGRAM

4-1. Indoor Unit

4-2. Outdoor Unit

5. SPECIFICATION OF ELECTRICAL PARTS

5-1. Indoor Unit

5-2. Outdoor Unit

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

6-2. Operation Data

7. CONTROL BLOCK DIAGRAM

7-1. Indoor Unit

7-2. Outdoor Unit (Inverter Assembly)

8. OPERATION DESCRIPTION

8-1. Outlined of Air Conditioner Control

8-2. Description of Operation Circuit

8-3. Temporary Operation

8-4. Auto Restart Function

8-5. Filter Check Lamp

8-6. Remote control

9.INSTALLA TION PROCEDURE

9-1. Safety Cautions

9-2. INDOOR UNIT 9.3. OUTDOOR UNIT

−1 −

FILE NO. SVM-05026

10.HOW TO DIAGNOSE THE TROUBLE

10-1. First Confirmation

10-2. Primary Judgement

10-3. Judgement by Flashing LED of Indoor Unit 10-4. Self-Diagnosis by Remote Control (Check Code) 10-5. Judgement of Trouble by Every Symptom

10-6. Check Code 1C (Miswiring in indoor/outdoor units) and 1E 10-7. How to Diagnose Trouble in Outdoor Unit

10-8. How to Check Simply the Main Parts

10-9. How to Simply Judge Whether Outdoor Fan Motor is Good or Bad

11.HOW TO REPLACE THE MAIN PARTS

11-1. Indoor Unit

11-2. Microcomputer

11-3. Outdoor Unit

12.EXPLODED VIEWS AND PARTS LIST

12-1. Indoor Unit (E-Parts Assy)

12-2. Indoor Unit

12-3. Outdoor Unit

12-4. Outdoor Unit (E-Parts Assy)

– 2 –

FILE NO. SVM-05026

1. SPECIFICATIONS

1-1. Specifications

Unit model	Indoor				RAS-10NKV-E (A)
	Outdoor				RAS-10NAV-E (A)
Cooling capacity				(kW)		2.5
Cooling capacity range				(kW)		0.9 − 3.0
Heating capacity				(kW)		3.2
Heating capacity range				(kW)		0.7 − 4.0
Power supply					220− 240V− 1Ph− 50/60Hz
Electric	Indoor	Operation mode			Cooling		Heating
characteristics		Running current		(A)	0.15		0.15
		Power consumption		(W)	30		30
	Outdoor	Power factor		(%)	87		87
		Operation mode			Cooling		Heating
		Running current		(A)	3.33		3.39
		Power consumption		(W)	730		810
		Power factor		(%)	95		95
COP (Cooling / Heating)						3.29/3.81
Operation noise	Indoor	High	(Cooling / Heating)	(dB∙ A)		38/39
		Medium	(Cooling / Heating)	(dB∙ A)		34/35
		Low	(Cooling / Heating)	(dB∙ A)		27/29
	Outdoor (Cooling / Heating)			(dB∙ A)		46/47
Indoor unit	Unit model				RAS-10NKV-E (A)
	Dimension	Height		(mm)		275
		Width		(mm)		790
		Depth		(mm)		218
	Net weight			(kg)		10
	Fan motor output			(W)		20
	Air flow rate	(Cooling / Heating)		(m3/h)		540/610
Outdoor unit	Unit model				RAS-10NAV-E (A)
	Dimension	Height		(mm)		530
		Width		(mm)		660
		Depth		(mm)		240
	Net weight			(kg)		30
	Compressor	Motor output		(W)		750
		Type			Single rotary type with DC-inverter variable speed control
		Model				DA89X1F-23F
	Fan motor output			(W)		20
	Air flow rate	(Cooling / Heating)		(m3/h)		1320/1320
Piping connection	Type				Flare connection
	Indoor unit	Liquid side				6.35
		Gas side				9.52
	Outdoor unit	Liquid side				6.35
		Gas side				9.52
	Maximum length (Per unit)			(m)		10
	Maximum chargeless length			(m)		10
	Maximum height difference			(m)		8
Refrigerant	Name of refrigerant					R410A
	Weight			(kg)		0.64
Wiring connection		Power supply			3 Wires:includes earth (Outdoor)
		Interconnection			4 Wires:includes earth
Usable temperature range		Indoor	(Cooling / Heating)	(°C)	21 − 32 / Up to 27 °C
		Outdoor	(Cooling / Heating)	(°C)	15 − 43 / − 10 − 24

•The specification may be subject to change without nitice for purpose of improvement.

–3 –

1-2. Operation Characteristic Curve

<Cooling>
	6
	5
			10NAV
Current (A)	4
	3
	2
				Conditions
				Indoor :DB 27°C/WB 19°C
	1			Outdoor : DB 35°C
				Air flow : High
				Pipe lenght :	5m
				Voltage : 230V
	0	20	40	60	80	100
	0

Compressor speed (rps)

FILE NO. SVM-05026

<Heating>
	6
	5
			10NAV
Current (A)	4
	3
	2
			Conditions
				Indoor : DB 20°C
	1			Outdoor : DB 7°C/WB 6°C
				Air flow : High
				Pipe lenght	: 5m
				Voltage : 230V
	0	20	40	60	80	100
	0

Compressor speed (rps)

1-3. Capacity Variation Ratio According to Temperature

<Cooling>
	105
	100						Current Limited Start
	95
	90
(%)	85
ratio	80
Capacity	75
	70
	65
	60				a Conditions
					Indoor : DB 27°C/WB 19°C
	55				Indoor air flow : High
					Pipe lengthh 5m
	50
	32	33	34	35	36	37	38	39	40	41	42	43

Outdoor temp. (°C)

<Heating>
	120
	110
	100
	90
(%)	80
ratio	70
Capacity	60
	50
	40
	30	a Conditions
		Indoor : DB 20°C
	20	Indoor air flow : High
		Pipe lengthh : 5m
	10
	-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

Outdoor temp. (°C)

* Capacity ratio : 100% = 2.5 kW (Cooling) : 100% = 3.2 kW (Heating)

– 4 –

FILE NO. SVM-05026

2. REFRIGERANT R410A

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

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

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

2-1. 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 of personal injury may be caused.

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

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

(6)When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

(7)Be sure to carry out installation or removal according to the installation manual. Improper installation may cause refrigeration

trouble, water leakage, electric shock, fire, etc.

(8)Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair’s may result in water leakage, electric shock and fire, etc.

2-2. Refrigerant Piping Installation

2-2-1. Piping materials and joints used

For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

(1)Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface). Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table 2-2-1. Never use copper pipes thinner than 0.8 mm even when it is available on the market.

– 5 –

FILE NO. SVM-05026

Table 2-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter	Outer diameter (mm)	R-410A	R-22
1/4	6.35	0.80	0.80
3/8	9.52	0.80	0.80
1/2	12.70	0.80	0.80
5/8	15.88	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 2-2-3 to 2-2-6 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 socket joints are as shown in Table 2-2-2.

Table 2-2-2 Minimum thicknesses of socket joints

	Nominal diameter	Reference outer diameter of	Minimum joint thickness
		copper pipe jointed (mm)	(mm)
	1/4	6.35	0.50
	3/8	9.52	0.60
	1/2	12.70	0.70
	5/8	15.88	0.80

2-2-1. 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 other than lubricating oils used in the installed air conditioner is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

(1)Flare Processing Procedures and Precautions

a)Cutting the Pipe

By means of a pipe cutter, slowly cut the pipe so that it is not deformed.

b)Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation.

c)Insertion of Flare Nut

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 R-410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

D

A

Fig. 2-2-1 Flare pr ocessing dimensions

– 6 –

										FILE NO. SVM-05026
	Table 2-2-3 Dimensions related to flare pr ocessing f or R-410A
	Outer							A (mm)
Nominal		Thickness
	diameter		Flare tool for R-410A						Conventional flare tool
diameter		(mm)
	(mm)
			clutch type					Clutch type				Wing nut type
1/4	6.35	0.8		0 to 0.5					1.0 to 1.5			1.5 to 2.0
3/8	9.52	0.8		0 to 0.5					1.0 to 1.5			1.5 to 2.0
1/2	12.70	0.8		0 to 0.5					1.0 to 1.5			2.0 to 2.5
5/8	15.88	1.0		0 to 0.5					1.0 to 1.5			2.0 to 2.5
	Table 2-2-4 Dimensions related to flare pr ocessing f or R-22
	Outer							A (mm)
Nominal		Thickness
	diameter		Flare tool for R-410A						Conventional flare tool
diameter		(mm)
	(mm)
			clutch type					Clutch type				Wing nut type
1/4	6.35	0.8		0 to 0.5					0.5 to 1.0			1.0 to 1.5
3/8	9.52	0.8		0 to 0.5					0.5 to 1.0			1.0 to 1.5
1/2	12.70	0.8		0 to 0.5					0.5 to 1.0			1.0 to 2.0
5/8	15.88	1.0		0 to 0.5					0.5 to 1.0			1.0 to 2.0
	Table 2-2-5 Flare and flare n ut dimensions for R-410A
Nominal	Outer	Thickness			Dimension (mm)							Flare n ut
	diameter											width
diameter		(mm)	A		B			C		D
	(mm)											(mm)
1/4	6.35	0.8	9.1		9.2		6.5			13	17
3/8	9.52	0.8	13.2		13.5		9.7			20	22
1/2	12.70	0.8	16.6		16.0		12.9			23	26
5/8	15.88	1.0	19.7		19.0		16.0			25	29
	Table 2-2-6 Flare and flare n ut dimensions for R-22
Nominal	Outer	Thickness			Dimension (mm)							Flare n ut
	diameter											width
diameter		(mm)	A		B			C		D
	(mm)											(mm)
1/4	6.35	0.8	9.0		9.2		6.5			13	17
3/8	9.52	0.8	13.0		13.5		9.7			20	22
1/2	12.70	0.8	16.2		16.0		12.9			20	24
5/8	15.88	1.0	19.7		19.0		16.0			23	27
3/4	19.05	1.0	23.3		24.0		19.2			34	36

– 7 –

FILE NO. SVM-05026

Fig. 2-2-2 Relations between flare n ut 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 R-410A is the same as that for conventional R-22. Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 2-2-7 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 2-2-7 Tightening torque of flare for R-410A [Reference v alues]

	Nominal	Outer diameter	Tightening torque	Tightening torque of torque
				wrenches available on the market
	diameter	(mm)	N·m (kgf·cm)
				N·m (kgf·m)
	1/4	6.35	14 to 18 (140 to 180)	16 (160), 18 (180)
	3/8	9.52	33 to 42 (330 to 420)	42 (420)
	1/2	12.70	50 to 62 (500 to 620)	55 (550)
	5/8	15.88	63 to 77 (630 to 770)	65 (650)

– 8 –

FILE NO. SVM-05026

2-3. Tools

2-3-1. Required tools

The service port diameter of packed valve of the outdoor unit in the air conditioner using R-410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For 12.70 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 R-410A (Those which cannot be used for conventional refrigerant (R-22))

(2)Tools exclusive for R-410A, but can be also used for conventional refrigerant (R-22)

(3)Tools commonly used for R-410A and for conventional refrigerant (R-22)

The table below shows the tools exclusive for R-410A and their interchangeability.

Tools exclusive for R-410A (The following tools for R-410A are required.)

Tools whose specifications are changed for R-410A and their interchangeability

			R-410A air conditioner		Conventional air
			installation		conditioner installation
No.	Used tool	Usage
			Existence of	Whether	Whether new equipment
			new equipment	conventional	can be used with
			for R-410A	equipment can	conventional refrigerant
				be used
1	Flare tool	Pipe flaring	Yes	*(Note 1)
2	Copper pipe gauge	Flaring by
	for adjusting projection	conventional flare	Yes	*(Note 1)	*(Note 1)
	margin	tool
3	Torque wrench	Connection of	Yes
	(For 12.70)	flare nut
4	Gauge manifold	Evacuating,
		refrigerant charge,	Yes
5	Charge hose
		run check, etc.
6	Vacuum pump adapter	Vacuum evacuating	Yes
7	Electronic balance for	Refrigerant charge	Yes
	refrigerant charging
8	Refrigerant cylinder	Refrigerant charge	Yes
9	Leakage detector	Gas leakage check	Yes
!	Charging cylinder	Refrigerant charge	(Note 2)

(Note 1) When flaring is carried out for R-410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

(Note 2) Charging cylinder for R-410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R-22 are necessary as

the general tools.					Hole core drill ( 65)
(1)	Vacuum pump	(4)	Reamer	(9)
	Use vacuum pump by	(5)	Pipe bender	(10)	Hexagon wrench
	attaching vacuum pump adapter.	(6)	Level vial		(Opposite side 5 mm)
(2)	Torque wrench (For 6.35)	(7)	Screwdriver (+, –)	(11)	Tape measure
(3)	Pipe cutter	(8)	Spanner of Monkey wrench	(12)	Metal saw
Also prepare the following equipments for other installation method and run check.
(1)	Clamp meter	(3)	Insulation resistance tester
(2)	Thermometer	(4)	Electroscope

– 9 –

FILE NO. SVM-05026

2-4. 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 of 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	(For refrigerant charging, see the figure below.)
the fully opened position, and turn on the vacuum
pump’s power switch. Then, evacuating the
refrigerant in the cycle.

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)

(Liquid side)

(OUTDOOR unit)

Opened

(Gas side)

Refrigerant cylinder (With siphon pipe)

Check valve

Closed

Open/Close valve for charging

Service port

Electronic balance for refrigerant charging

Fig. 2-4-1 Configuration of refrigerant c harging

– 10 –

FILE NO. SVM-05026

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 R-410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[Cylinder with siphon]	[Cylinder without siphon]
Gauge manifold	Gauge manifold
OUTDOOR unit	OUTDOOR unit

Refrigerant Refrigerant cylinder

cylinder

Electronic	Electronic
balance	balance

Siphon

R-410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

Fig. 2-4-2

2-5. Brazing of Pipes

2-5-1. Materials f or brazing

(1)Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

(2)Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

(3)Low temperature brazing filler

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 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.

2-5-2. Flux

(1)Reason why flux is necessar y

•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.

– 11 –

(2)Characteristics required f or 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 tot he type and shape of treated metal, type of brazing filler and brazing method, etc.

(3)Types of flux

•Non-corrosive 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 oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

(4)Piping materials f or brazing and used brazing filler/flux

Piping	Used brazing	Used
material	filler	flux
Copper - Copper	Phosphor copper	Do not use
Copper - Iron	Silver	Paste flux
Iron - Iron	Silver	Vapor flux

1Do not enter flux into the refrigeration cycle.

2When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chloring.

3When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

4Remove the flux after brazing.

FILE NO. SVM-05026

2-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitr ogen gas.

(1)Brazing method to prevent oxidation

1Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3Apply a seal into the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4When the Nitrogen gas is flowing, be sure to keep the piping end open.

5Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 Mpa (0.2 kgf/ cm2) by means of the reducing valve.

6After 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).

7Remove the flux completely after brazing.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe Nitrogen gas

Rubber plug

Fig. 2-5-1 Pre vention of oxidation during brazing

– 12 –

FILE NO. SVM-05026

3. CONSTRUCTION VIEWS

3-1. Indoor Unit

Front panel

Air inlet

Air filter

Heat exchanger

790

275

60	Air outlet
6

218

60

6

48

Knock out system

120

Drain hose (0.54m)

Hanger

		45
		Minimum
	275	distance
		to ceiling
		170 or more

90 150

Knock out system

48

64 53

590	80
Hanger

			Connecting pipe (0.43m)
	320		(Flare 6.35)
			Connecting pipe (0.33m)
235	620	235		For stud bolt
215		215		( 8~ 10)
Minimum	more	Hanger		For stud bolt ( 6)
distance
	65or			26
to ceiling
					45
				Minimum
				distance	190		160
				to ceiling
				170 or more
				32	40
Hanger			Hanger			57	18
160		160	150	90		Wireless remote control
			Installation plate outline
	– 13 –		Center line

FILE NO. SVM-05026

3-2. Outdoor Unit

A Detail Drawing (Back Leg)

660

			50	R 15
	6 Hole		36
	273.5	265		R 5.5

530

	A
	97
		B Detail Drawing (Front Leg)
273.5	59.5	273.5	265
		6 Hole		36 R 15
	25Drain outlet	11x14 Hole		50
		B		660
		2- 11x14 hole
	Fan guard	(for 8- 10 anchor bolt)
				Cover PV
	420			Z

242	500	97.5	(11)	273.5 (pitch)	(12.5)
	660		56	297

			Liquid side
			(Flare 6.35)
			Gas side
	126	48	(Flare 9.52)
			54
	Z View		Service port
Installation dimension
100 or more	600
	Air inlet 600 or more
325
100 or more	600 or more 4x 11x14 Long holes (for 8- 10 anchor bolt)
Air outlet

– 14 –

FILE NO. SVM-05026

4. WIRING DIAGRAM

4-1. Indoor Unit

	COLOR INDICATION
	BRW : BROWN						TERMINAL		2	1
	RED : RED
	WHI : WHITE						BLOCK
	YEL : YELLOW
	BLU : BLUE
	BLK : BLACK
	GRY : GRAY
	PNK : PINK									BLK	WHI	RED
	ORN : ORANGE
	GRN&YEL : GREEN & YELLOW
	GRN : GREEN
					CN01				CN24		CN23	CN21
				BLK	(BLU)
					1	1
				BLK	2	2
HEAT EXCHANGER
	SENSOR				CN03			FUSE
	(TC)				(WHI)
				BLKBLK					F01		3
					1	1	T3.15A
THERMO SENSOR					2	2		250VAC
		(TA)
		CN25			CN13
		(WHI)		BLUBLU	(WHI)
	RECEIVINGAND INDICATINGPARTS	1	1		1	1
INFRAREDRAYS		2	2	BLU 2		2			WP-004
		10	10	BLU	10	10
		3	3		3	3
		4	4	BLU	4	4
		5	5	BLU	5	5
		6	6	BLU	6	6
		7	7	BLU	7	7
		8	8	BLU	8	8	MAIN P.C. BOARD
		9 9 BLU 9 9
		11 11		WHI 11 11
MCC-861												CN08

INDOOR OUTDOOR UNIT UNIT

LINE
FILTER							5
				Power
						CN07
			supply circuit
						(WHI)
R04
				+12 VDC		1	1
				+5 VDC		2	2
		Fan Motor				3	3
						4	4
		Drive circuit
						5	5
CN11 1	2	3	CN10	5	3	1	6
1	2	3		5	3	1

YEL GRY BRW

WHI

BLK

RED

WHI 1		1
YEL	2	2
YEL	3	3
YEL	4	4
YEL	5	5

LOUVER MOTOR

1 2 3 4 56 1 2 3 4 56

	1	4	1 2 3 4	150°C	AC FAN MOTOR
			HA
			JEM-A

		Table 4-1-1 Simple Check for Failure Diagnosis
		Check Item	Diagnosis Result
		OPERATION	Check if the OPERATION indicator goes on and off when the
	1		main switch or breaker is turned on.
		INDICATOR
			(Check the primary and secondary voltage of the transformer.)
			Check the power supply voltage between 1 and 2.
		TERMINAL	(Refer to the name plate.)
	2
		BLOCK	(Check the primary and secondary voltage of the transformer.)
			Check the fluctuating voltage between 2 and 3. (15~60VDC)
		FUSE	Check if the fuse blows out.
	3
		3.15A	(Check the R04 of the varistor.)
			Check the voltage at the No. 4 pin on CN13 connector of the
		DC5V	infrared receiver.
	4		(Check the transformer and the power supply circuit of the
			rated voltage.)

Check the voltage at the white lead of the louver motor.

5 DC12V (Check the transformer and the power supply circuit of the rated voltage.)

		DC325V	Check the voltage at the No. 1 pin on CN10 connector.
	6		(Check the DB01, R05 and C03.)
		(DC310~340V)

Refer to the service data for the detailed failure diagnosis.

– 15 –

FILE NO. SVM-05026

4-2. Outdoor Unit

– 16 –

FILE NO. SVM-05026

5. SPECIFICATION OF ELECTRICAL PARTS

5-1. Indoor Unit

No.	Parts name	Type	Specifications
1	Fan motor (for indoor)	SKF-220-20-4A-1	AC Motor with 150°C thermo fuse
2	Thermo. sensor (TA-sensor)		10 k Ω at 25°C
3	AC-AC transformer (T01)	TT-10	187 - 276V, 6VA
4	Microcomputer	μPD780024AGK
5	Heat exchanger sensor		10 kΩ at 25°C
	(TC-sensor)
6	Line filter (L01)	SS11V-06270	27 μH, AC 0.64A
7	Diode (DB01)	KBP06M	1.5A, 420V
8	Capacitor (C50)	LXV35VB2200MJ20	2200 μF, 35V
9	Fuse (F01)	BET 3.15A 250VAC	T3.15A, 250 V
10	Regulator IC (IC08)	NJM7812	12VDC, 1.5A max
11	Regulator IC (IC11)	NJM7805	5VDC, 1.5A max
12	Varistor (R21, R109)	15G561K	560 V
13	Louver motor	24BYJ48	DC 12V

5-2.		Outdoor Unit
	No.		Parts name			Model name	Rating
	1		SC coil		L01	ADR2516-0R6TB	0.6mH, 15A
			(Noise filter)		L03	ADR2510-020T4B	10A, 2mH
	2		DC-DC transformer			SWT-72	Primary side DC280V, Secondary
							side 7.0 V x 1, 12 V x 1, 17V x 2
	3		Reactor			CH-51-Z-T	L=19mH, 10A
	4		Outside fan motor			HF-240-20B-2	20W
	5		Fan control relay			G5NB-1A	Coil DC12V Contact AC250V-1.5A
	6		Outside air temp.			(Inverter attached)	10kΩ (25°C)
			sensor (TO sensor)
	7		Heat exchanger temp.			(Inverter attached)	10kΩ (25°C)
			sensor (TE sensor)
	8		Dischenge temp.			(Inverter attached)	62kΩ (20°C)
			sensor (TD sensor)
	9		Terminal block (6P)			JX0-6B	20A, AC250V
	10		Fuse			For protection of switching power source	3.15A, AC250V
						For protection of inverter input overcurrent	25A, AC250V
	11		Electrolytic capacitor			LLQ2G761KHUBTF	760μF, DC 400 V x 3 pieces
	12		IGBT			GT20J321	20A, 600
	13		Compressor			DA89X1F-23F	3-phases 4-poles 750W
	14		Compressor thermo.			PW-2AL	OFF: 125 ± 4°C, ON: 90 ± 5°C
	15		Rectifier			D25XB60-4001	20A, 600V
	16		4-way valve coil			SQ583	AC220-240V

– 17 –

FILE NO. SVM-05026

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

T1 Temp. measurement

INDOOR UNIT

P Pressure measurement

Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe Outer dia. : 9.52mm Thickness : 0.80mm

Indoor heat

exchanger

Cross flow fan

Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.80mm

Sectional shape of heat insulator

	Allowable height difference : 8m	Allowable pipe length

Max. :10m

4-way valve

Muffler

TD

Compressor

DA89X1F-23F

TS

Outdoor heat

exchanger	Split capillary
	1.0x600
Temp. measurement T2	1.0x600
	TE
Propeller fan		Refrigerant amount : 0.64kg
OUTDOOR UNIT	NOTE:	Gas leak check position
		Refrigerant flow (Cooling)
		Refrigerant flow (Heating)

Note :

•The maximum length of the pipe for this air conditioner is 10 m. The additional charging of refrigerant is unnecessary because this air conditioner is designed with charge-less specification.

– 18 –

FILE NO. SVM-05026

6-2. Operation Data

<Cooling>

	Temperature		Standard	Heat exchanger		Indoor	Outdoor	Compressor
	condition (°C)			pipe temp.
			pressure			fan	fan	revolution
	Indoor	Outdoor	P (MPa)	T1 (°C)	T2 (°C)	mode	mode	(rps)
	27/19	35/−	1.1	13.5	49	High	High	54
	<Heating>
	Temperature		Standard	Heat exchanger		Indoor	Outdoor	Compressor
	condition (°C)			pipe temp.
			pressure			fan	fan	revolution
	Indoor	Outdoor	P (MPa)	T1 (°C)	T2 (°C)	mode	mode	(rps)
	20/−	7/6	2.4	40	0	High	High	70

Note :

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

(2)Connecting piping condition : 5m

−19 −

FILE NO. SVM-05026

7. CONTROL BLOCK DIAGRAM

7-1. Indoor Unit

Indoor Unit Control Panel

M.C.U.

Functions

Heat Exchanger Sensor

Operation

•

Louver Control

Display

•

Timer

Temperature Sensor

3-minute Delay at Restart for Compressor

Display

•

Motor Revolution Control

Filter Sign

Infrared Rays Signal Receiver

Display

•

PRE DEF.

Initiallizing Circuit

Processing

Sign Display

Infrared

(Temperature Processing)

Rays

Clock Frequency

•

Timer

Hi Power

Sign Display

36.7KHz

Oscillator Circuit

•

Serial Signal Communication

Indoor Fan

Motor

Power Supply

Louver ON/OFF Signal

Remote

Circuit

Control

Noise Filter

Louver Driver

Louver Motor

Serial Signal Transmitter/Receiver

From Outdoor Unit

Serial Signal Communication

Infrared

Rays

REMOTE CONTROL

Remote Control

Operation ()

Operation Mode Selection

AUTO, COOL, DRY, HEAT, FAN ONLY

Temperature Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECO

Hi power

– 20 –

For indoor unit

P.C.B (MCC-5009)

Noise	Input	Converter	Over	Inverter
filter	current	(AC DC)	current	(DC AC)
	sensor		sensor

1 220-240V 50/60Hz

– 21 –

signal

Dischage pipe temp. sensor

Outdoor air temp. sensor

Heat Exchanger temp. sensor

High power factor correction circuit

M. C. U

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

Gate drive circuit

Rotor position detect circuit

Relay Relay

4way	Fan
Valve	motor

2-7 Outdoor .

Compressor Unit(Inverter Assembly)

05026-SVM .NO FILE

Operations followed to judgment of serial signal from indoor side.

FILE NO. SVM-05026

8. OPERATION DESCRIPTION

8-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner. The capacity proportional control compressor which can change the motor speed is mounted. The indoor unit motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control outdoor unit 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 control, 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)

•Temperature setting of the indoor heat exchanger by using heat exchanger sensor (TC sensor) (Prevent-freezing control)

•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

(2)Role of outdoor unit controller

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

• Compressor operation control

• Operation control of outdoor fan motor

•P.M.V. control

•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 to indoor unit

•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)

− 22 −

(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 control

∙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.)

∙For these two types of signals ([Operation mode] and [Compressor revolution]), 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.

∙Temperature of indoor heat exchanger by indoor heat exchanger sensor

(Minimum revolution control)

(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.

FILE NO. SVM-05026

8-1-1. Capacity control

The cooling and heating capacity is varied by changing compressor motor speed. The inverter changes compressor motor speed by changing

AC 220-240 V power to DC once, and controls capacity by changing supply power status to the compressor with transistor module (includes 6 transistors). The outline of the control is as follows:

The revolution position and revolution speed of the motor are detected by detecting winding electromotive force of the compressor motor under operation, and the revolution speed is changed so that the motor drives based upon revolution speed of the operation command by changing timing (current transfer timing) to exchange inverter output voltage and supply power winding.

Detection of the revolution position for controlling is performed 12 times per 1 revolution of compressor. The range of supply power frequency to the compressor differs according to the operation status (COOL, HEAT, DRY).

Table 8-1-1 Compressor revolution range

	Operation	Model	Compressor
	mode	name	revolution (rps)
	COOL	10NKV	21 to 64
	HEAT		21 to 83

8-1-2. Current release control

The outdoor main circuit control section (Inverter assembly) detects the input current to the outdoor unit. If the current value with compressor motor speed instructed from indoor side exceeds the specified value, the outdoor main circuit control section controls compressor motor speed by reducing motor speed so that value becomes closest to the command within the limited value.

8-1-3. Power factor improvement control

Power factor improvement control is performed mainly aiming to reduce the current on much power consumption of cooling/heating operation. Controlling starts from the time when input power has reached at a certain point. To be concrete, IGBT of the power factor improvement circuit is used, and the power factor is improved by keeping IGBT on for an arbitrary period to widen electro-angle of the input current.

– 23 −