Toshiba RAS-10UKV-E3, RAS-10UAV-E3 SERVICE MANUAL

SERVICE MANUAL

AIR-CONDITIONER

RAS-10UKV-E3 / RAS-10UAV-E3

FILE NO. SVM-04038

SPLIT WALL TYPE

1. SPECIFICATIONS

1-1. Specifications

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

FILE NO. SVM-004038

CONTENTS

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. Hi POWER Mode ([Hi POWER] button on the remote control is pressed.) 8-6. Filter Check Lamp 8-7. Remote control

9. INSTALLATION PROCEDURE

9-1. Safety Cautions 9-2. INDOOR UNIT

9.3. OUTDOOR UNIT

– 1 –

10. HO W TO DIA GNOSE 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)

FILE NO. SVM-04038

– 2 –

FILE NO. SVM-04038

1. SPECIFICATIONS

1-1. Specifications

Unit model Indoor RAS-10UKV-E3

Current limited — 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

COP (Cooling / Heating) 3.29 Operation noise Indoor High (Cooling / Heating) (dB•A) 38/39

Indoor unit Unit model RAS-10UKV-E3

Outdoor unit Unit model RAS-10UAV-E3

Piping connection Type Flare connection

Refrigerant Name of refrigerant R-410A

Wiring connection Power supply 3 Wires: includes earth

Usable temperature range Indoor (Cooling / Heating) (°C) 21 – 32 / 0 – 28

Accessory Indoor unit Installation plate 1

Outdoor RAS-10UAV-E3

Power consumption (W) 30 30 Power factor (%) 87 87

Outdoor Operation mode Cooling Heating

Running current (A) 3.42 3.69 Power consumption (W) 730 810 Power factor (%) 92 95 Starting current (A) 3.84

Low (Cooling / Heating) (dB•A) 27/29

Outdoor (Cooling / Heating) (dB•A) 46/47

Dimension Height (mm) 275

Width (mm) 790

Depth (mm) 208 Net weight (kg) 10 Fan motor output (W) 30 Air flow rate (Cooling / Heating) (m3/h) 530/590

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 DA89X1C-23FZ Fan motor output (W) 18 Air flow rate (Cooling / Heating) (m3/h) 530/620

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

Weight (kg) 0.64

Interconnection 4 Wires: includes earth

Outdoor (Cooling / Heating) (°C) 10 – 43 / –10 – 24

Wireless remote control 1

Remote controller holder 1

Flat head wood screw 2 (∅3.1 x 16L)

Bioenzyme filter 1

Zeolite filter 1

Batteries 2

Mounting screw 6 (∅4 x 25L)

Installation manual 1

Owner’s manual 1 Outdoor unit Drain nipple 1

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

– 3 –

1-2. Operation Characteristic Curve

FILE NO. SVM-04038

Current (A)

Conditions

Indoor : DB 27°C/WB 19°C

Outdoor : DB 35°C Air flow : High Pipe lengthh : 5m 230V

020406080100

Compressor speed (rps)

1-3. Capacity Variation Ratio According to Temperature

Current (A)

Conditions

Indoor : DB 20°C

Outdoor : DB 7°C/WB 6°C Air flow : High Pipe lengthh : 5m 230V

020406080100

Compressor speed (rps)

105

100

Capacity ratio (%)

Current Limited Start

Conditions Indoor : DB 27°C/WB 19°C Indoor air flow : High Pipe lengthh 5m

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

Outdoor temp. (°C)

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

: 100% = 3.2 kW (Heating)

120

110

100

Capacity ratio (%)

-10 -9

Conditions Indoor : DB 20°C Indoor air flow : High Pipe lengthh : 5m

-7

-8

-3

-5 -4

-6

-1 0 12345678910

-2

Outdoor temp. (°C)

– 4 –

2. REFRIGERANT R-410A

FILE NO. SVM-04038

This air conditioner adopts the new refrigerant HFC (R-410A) which does not damage the ozone lay er.

The working pressure of the new refrigerant R-410A is

1.6 times higher than conventional refrigerant (R-22). 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 R-410A’s pressure is about 1.6 times higher than that of R-22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R-410A, it is necessary to carry out installation/ servicing safely while taking the following precautions into consideration.

(1) Never use refrigerant other than R-410A in an air

conditioner which is designed to operate with R-410A. If other refrigerant than R-410A 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 R-410A. The refrigerant name R-410A is indicated on the visible place of the outdoor unit of the air conditioner using R-410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R-22

(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 R-410A incurs pressure higher than when using R-22, it is necessary to choose adequate materials. Thicknesses of copper pipes used with R-410A 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-04038

T able 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.

T able 2-2-2 Minim um thicknesses of soc ket joints

Nominal diameter

Reference outer diameter of Minimum joint thickness

1/4 6.35 0.50 3/8 9.52 0.60 1/2 12.70 0.70 5/8 15.88 0.80

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.

copper pipe jointed (mm) (mm)

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

– 6 –

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.

Fig. 2-2-1 Flare pr ocessing dimensions

FILE NO. SVM-04038

T able 2-2-3 Dimensions related to flare pr ocessing for R-410A

Nominal

diameter

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

Nominal

diameter

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

Outer

diameter

(mm)

T able 2-2-4 Dimensions related to flare pr ocessing for R-22

Outer

diameter

(mm)

Thickness

(mm)

Thickness

(mm)

Flare tool for R-410A

clutch type

Flare tool for R-410A

clutch type

A (mm)

Con ventional flare tool

Clutch type Wing nut type

A (mm)

Con ventional flare tool

Clutch type Wing nut type

5/8 15.88 1.0 0 to 0.5 0.5 to 1.0 1.0 to 2.0

T able 2-2-5 Flare and flare n ut dimensions for R-410A

Nominal

diameter

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

Nominal

diameter

1/4 6.35 0.8 9.0 9.2 6.5 13 17

Outer

diameter

(mm)

Outer

diameter

(mm)

Thickness

(mm)

T able 2-2-6 Flare and flare n ut dimensions for R-22

Thickness

(mm)

ABCD

Dimension (mm)

Flare nut

width

(mm)

Flare nut

width

(mm)

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-04038

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.

T able 2-2-7 Tightening torque of flare for R-410A [Reference v alues]

Nominal Outer diameter Tightening torque

diameter (mm) N·m (kgf·cm)

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)

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.

Tightening torque of torque

wrenches available on the market

N·m (kgf·m)

– 8 –

FILE NO. SVM-04038

2-3. T ools

2-3-1. Required tools

The service por t 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

(For ∅12.70) flare nut

4 Gauge manifold 5 Charge hose

6 Vacuum pump adapter Vacuum evacuating Yes

Electronic balance for

refrigerant charging

8 Refrigerant cylinder Refrigerant charge Yes 9 Leakage detector Gas leakage check Yes ! Charging cylinder Refrigerant charge (Note 2)

Evacuating, refrigerant charge, Yes run check, etc.

Refrigerant charge Yes

Yes

(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. (1) Vacuum pump (4) Reamer (9) Hole core drill (∅65)

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-04038

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.

When the compound gauge’s pointer has indicated -0.1 Mpa (-76 cmHg), place the handle Low

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

in the fully closed position, and turn off the vacuum pump’s power switch.

Connect the charge hose of the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

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)

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

Electronic balance for refrigerant charging

Fig. 2-4-1 Configuration of refrigerant charging

(Liquid side)

(Gas side)

– 10 –

(OUTDOOR unit)

Opened

Closed

Service port

FILE NO. SVM-04038

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 with siphon] [Cylinder without siphon]

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

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.

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.

Electronic

balance

Siphon

Fig. 2-4-2

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.

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 –

FILE NO. SVM-04038

(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

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

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 into 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 (0.2 kgf/ cm2) by means of the reducing valve.

6 After performing the steps above, keep the

Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7 Remove the flux completely after brazing.

Flow meter

Piping Used brazing Used

material filler flux

Copper - Copper Phosphor copper Do not use

Copper - Iron Silver Paste flux

Iron - Iron Silver 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 chloring.

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.

Stop valve

Nitrogen gas

cylinder

From Nitrogen cylinder

Pipe

Nitrogen gas

Rubber plug

Fig. 2-5-1 Prevention of oxidation during brazing

– 12 –

3-1. Indoor Unit

FILE NO. SVM-04038

3. CONSTR UCTION VIEWS

Front panel

Back body

660

Knock out system

Air inlet

Air filter

790

Heat exchanger

275

Air outlet

120 80

590

Hanger

208

Knock out system

660

Drain hose (0.54m)

Hanger

Minimum distance to ceiling

275

170 or more

320

620

235 235

215 215

Minimum distance to ceiling

65 or more

Hanger

– 13 –

Connecting pipe (0.43m) (Flare

Connecting pipe (0.33m)

Hanger

150150 160160

Installation plate outline

Center line

∅

6.35)

For stud bolt (

∅ 8~∅

10)

For stud bolt (∅ 6)

Minimum distance to ceiling

170 or more

9090

4519040

57 18

Wireless remote control

160

3-2. Outdoor Unit

A Detail Drawing (Back Leg)

660

265

273.5

∅6 Hole

R 15

R 5.5

59.5

273.5

Fan guard

∅25Drain outlet

2-∅11x14 hole (for ∅8-∅10 anchor bolt)

FILE NO. SVM-04038

B Detail Drawing (Front Leg)

265

273.5

∅6 Hole

∅11x14 Hole

36 50

R 15

660

Cover PV

242

530

∅420

500 97.5

660

Z View

(11)

126

(12.5)273.5 (pitch)

297

Liquid side

(Flare ∅6.35) Gas side (Flare ∅12.7)

Service port

Installation dimension

100 or more

325

100 or more

Air outlet

600

Air inlet

600 or more

– 14 –

600 or more

4x∅11x14 Long holes (for ∅8-∅10 anchor bolt)

4-1. Indoor Unit

FILE NO. SVM-04038

4. WIRING DIAGRAM

Check Item

OPERATION

INDICATOR

TERMINAL

BLOCK

FUSE

3.15A

DC5V

DC12V

DC325V

(DC310~340V)

or MCC-5014

Table 4-1-1 Simple Check for Failure Diagnosis

Diagnosis Result

Check if the OPERATION indicator goes on and off when the main switch or breaker is turned on. (Check the primary and secondary voltage of the transformer.)

Check the power supply v oltage betw een 1 and 2. (Refer to the name plate.) (Check the primary and secondary voltage of the transformer.) Check the fluctuating voltage between 2 and 3. (15~60VDC)

Check if the fuse blows out. (Check the R04 of the varistor.)

Check the voltage at the No. 4 pin on CN13 connector of the infrared receiver. (Check the transformer and the power supply circuit of the rated voltage.)

Check the voltage at the white lead of the louver motor. (Check the transformer and the power supply circuit of the rated voltage.)

Check the voltage at the No. 1 pin on CN10 connector. (Check the DB01, R05 and C03.)

Refer to the service data for the detailed failure diagnosis.

– 15 –

4-2. Outdoor Unit

FILE NO. SVM-04038

TE TO

12 12

CN600 CN602

P09

BRW

P10 P11

PUR

P12

+ ~

RECTIFIER

DB01

P15

YEL

P16

BU EU BV EV BW EW BX

IGBT MODULE

BY BZ

Q200

BLU

P14

P13

REACTOR

POWER RELAY

ELECTRONIC STARTER

12 12

CN08

C12 C13

P.C.BOARD

(MCC-866)

CN17 CN18 CN19

COIL FOR 4 WAY VALVE

1 3 1 3

CN701

CN07 P06

REALY

SWITCHING

TRANSFORMER

RELAY

C301

RED WHI

BLK

COMPRESSOR

SURGE

ABSORBER

F04

FUSE

T3.15A

THERMOSTAT

FOR COMPRESSOR

CN500

VARISTOR

F01

FUSE

15A

CN01

CN03

CN02

CN300

BLK ORN

WHI

1 3 5

POWER SUPPLY

220-240V~

50/60Hz

L 3 2 1

RED

BLK

WHI

FAN

INDOOR

UNIT

MOTOR

COLOR IDENTIFICATION

BLK : BLACK BLU : BLUE RED : RED GRY : GRAY PNK : PINK GRN : GREEN WHI : WHITE BRW : BROWN ORN : ORANGE YEL : YELLOW PUR : PURPLE

– 16 –

FILE NO. SVM-04038

5. SPECIFICATION OF ELECTRICAL PARTS

5-1. Indoor Unit

No. Parts name Type Specifications

1 Fan motor (for indoor) ICF-340-30-2 DC 340V, 30W 2 Thermo. sensor (TA-sensor) ——— 10k at 25°C 3 DC-DC transformer (T01) SWT-70 DC 390V, Secondary DC 15V, 12V, 7V 4 Microcomputer ———

Heat exchanger temp.

sensor(TC-sensor) 6 Line filter (L01) SS11V-06270 27mH, AC 0.64A 7 Diode (DB01) D3SBA60 4A, 600V 8 Capacitor (C03) KMH450VNSN120M25C 120µF, 450V 9 Fuse (F01) FCU250V3.15A T3.15A, 250V

10 Power supply IC (IC01) STR-L472 11 Varistor (R21, R109) 15G561K 560V 12 Resistor (R01) RF-5TK4R7 4.7 , 5W

——— 10k at 25°C

13 Louver motor MP24GA Output (Rated) 1W,16poles, 1phase, DC 12V

5-2. Outdoor Unit

No. Parts name Model name Rating

1 SC coil (Noise filter) L01 ADR2510-020T4B 10A, 2mH

Primary side DC280V, Secondary

2 DC-DC transformer SWT-78 side 7.5V x 1, 13V x 1, 26.5V x 3,

16V x 1, 15V x 1 3 Reactor CH-51-Z-T L=19mH, 10A 4 Outside fan motor HF-240-20B-1 20W 5 Fan control relay AJQ1341 Coil DC12V Contact AC250V-2A

Outside air temp.

sensor (TO sensor) Heat exchanger temp.

sensor (TE sensor)

8 Terminal block (6P) ——— 20A, AC250V

9 Fuse

For protection of switching power source 3.15A, AC250V

For protection of inverter input overcurrent 15A, AC250V

(Inverter attached) 10k (25°C)

10 Electrolytic capacitor LLQ2G501KHUATF, 400LISN500K35F 500µF, DC400V x 2 pieces 11 IGBT module MP6761 15A, 600V 12 Compressor DA89X1C-23FZ 3-phases 4-poles 750W 13 Compressor thermo. PW-2AL OFF: 125 ± 4°C, ON: 90 ± 5°C 14 Rectifier D15XB60 15A, 600V 15 4-way valve coil SQ583 AC220-240V

– 17 –

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

Pressure measurement Gauge attaching port Vacuum pump connecting port

Deoxidized copper pipe

Outer dia. : 9.52mm Thickness : 0.80mm

INDOOR UNIT

Indoor heat

exchanger

Cross flow fan

Deoxidized copper pipe

Outer dia. : 6.35mm Thickness : 0.80mm

Sectional shape of heat insulator

Temp. measurement

FILE NO. SVM-04038

Max. :10m

Allowable height

difference : 8m

Allowable pipe length

4-way valve

(VT7101D)

Muffler

Compressor DA89X1C-23FZ

Outdoor heat

exchanger

Split capillary

1.0x600

Temp. measurement

Propeller fan

OUTDOOR UNIT

1.0x600

Refrigerant amount : 0.64kg

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 –

6-2. Operation Data

FILE NO. SVM-04038

Temperature

condition (°C)

Indoor Outdoor

27/19 35/–

Temperature

condition (°C)

Indoor Outdoor

20/– 7/6

Model

name

10UKV-E3

Model

name

10UKV-E3

Standard pressure

P (MPa)

1.1

Standard pressure

P (MPa)

2.4

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

13.5 49

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

40 0

Indoor

fan

mode

High

Indoor

fan

mode

High

Outdoor

fan

mode

High

Outdoor

fan

mode

High

Compressor

revolution

Compressor

revolution

Note :

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

(Thermistor themometer)

(2) Connecting piping condition : 5m

(rps)

– 19 –

7-1. Indoor Unit

Heat Exchanger Sensor

7. CONTROL BLOCK DIAGRAM

Indoor Unit Control Panel

M.C.U.

Functions

• Louver Control

FILE NO. SVM-04038

Operation

Display

Temperature Sensor

Infrared Rays Signal Receiver

Initiallizing Circuit

Infrared

Rays

36.7KHz

Remote

Control

From Outdoor Unit

Clock Frequency Oscillator Circuit

Power Supply

Circuit

Noise Filter

• 3-minute Delay at Restart for Compressor

• Motor Revolution Control

• Processing

(Temperature Processing)

• Timer

• Serial Signal Communication

Louver ON/OFF Signal

Louver Driver

Serial Signal Transmitter/Receiver

Serial Signal Communication

Timer

Display

Filter Sign

Display

PRE DEF.

Sign Display

Hi Power

Sign Display

Indoor Fan

Motor

Louver Motor

REMOTE CONTROL

Infrared

Rays

Remote Control

Operation (START/STOP)

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

Filter Reset

– 20 –

7-2. Outdoor Unit (Inverter Assembly)

For indoor unit

230V 50Hz

signal

Noise

filter

Gas side pipe

temp. sensor

Outdoor air

temp. sensor

Input

current

sensor

Converter

(AC DC)

P.C.B (MCC-866)

Over

current

sensor

Gate drive

circuit

Rotor position

detect circuit

Relay

Fan

motor

4way

Valve

Relay

High power factor

correction circuit

1. PWM synthesis function

2. Input current release control

3. IGBT over-current detect control

4. Outdoor fan control

5. High power factor correction control

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

M. C. U

Inverter

(DC AC)

Compressor

FILE NO. SVM-04038

– 21 –

8. OPERATION DESCRIPTION

FILE NO. SVM-04038

8-1. Outlined of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor fan motor and AC motor for the outdoor fan motor. And the capacity proportional control compressor which can change the motor speed in the range from 18 to 120 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The inverter to control compressor 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 4 way valves. 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.

• Judgement 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).

• Louver motor control

• Indoor fan motor operation control

• LED 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 judgement/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

• 4 way valves

• 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 (Temperature measurement by outdoor heat exchanger and control for 4 way valves and outdoor fan).

Operations followed to judgement of serial signal from indoor side.

– 22 –

FILE NO. SVM-04038

(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 judgement 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.

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 220-240V 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 mode Compressor revolution (rps)

COOL 21 to 66

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 –

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