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

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Page 1

SERVICE MANUAL

AIR-CONDITIONER

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

FILE NO. SVM-04038

SPLIT WALL TYPE

Page 2

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

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Page 3

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 –

Page 4

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.

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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)

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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.

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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

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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

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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 –

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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

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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

Page 12

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 –

Page 13

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 –

Page 14

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

Page 15

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)

Page 16

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 –

Page 17

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 –

Page 18

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 –

Page 19

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 –

Page 20

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 –

Page 21

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 –

Page 22

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 –

Page 23

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 –

Page 24

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 –

Page 25

FILE NO. SVM-04038

8-1-4. Prevent-freezing control

The indoor heat exchanger sensor detects refrigerant vapor temperature in COOL/DRY operation. If the temperature is below the specified value, compressor motor speed is reduced so that operation is performed in temperature below the specified value to preventfreezing of indoor heat exchanger.

8-1-5. Louver control

(1) Vertical air flow louvers

Positions of vertical air flow louvers are automatically controlled according to the operation status (AUTO (A), COOL ( ), DRY (

FAN ONLY (

). Besides, positions of vertical air

), HEAT( ) and

flow louvers can be arbitrarily set by pressing the [FIX] button.

(2) Swing

If the [SWING] button is pressed during running operation, vertical air flow louvers start swinging. When the [FIX] button is pressed, swinging stops.

Table 8-1-2

8-1-6. Indoor fan control (DC fan motor)

(1) The indoor fan is operated by the stepless speed

change DC motor.

(2) For air flow level, speed of the indoor fan motor is

controlled in five steps (LOW, LOW+, MED, MED and HIGH) as described in Table 8-1-2. If AUTO mode is selected, the fan motor speed is automatically controlled by the difference between the preset temperature and the room temperature.

LOW+=

LOW+MED

MED+=

MED+HIGH

Fan mode Motor Air flow Motor Air flow

Remote speed volume speed volume control (rpm) (m3/h) (rpm) (m3/h)

Cooling H HIGH

and M

Fan only MED

M MED

LOW

L LLOW

L– 750 305 810 340

Heating H HIGH

MED

M MED

LOW

LLOW

L– 860 370 880 380 UL 750 305 810 340 SUL 640 240 660 250

DRY L

L 810 340 L– 750 305 UL 720 285 SUL 660 250

Normal Powerful

1,140 535 1,140 535 1,100 510 1,140 535

1,070 495 1,100 510

1,000 510 1,060 490

900 395 960 430 860 370 880 380

810 340 860 370

1,250 600 1,250 600 1,200 600 1,250 600

1,150 540 1,170 555

1,060 490 1,100 510 1,000 455 1,060 490

970 435 1,050 485

880 380 1,000 455

860 370

– 24 –

Page 26

FILE NO. SVM-04038

8-2. Description of Operation Circuit

(1) When turning on the breaker, the operation lamp

blinks. This means that the power is on (or the power supply is cut off.)

(2) When pressing [START/STOP] button on the

remote control, receiving beep sounds from the indoor unit, and the next operation is performed together with opening the vertical air flow louver.

(3) Once the operation mode is set, it is memorized in

the microcomputer so that the previous operation can effected thereafter simply by pressing [START/STOP] button.

8-2-1. Fan only operation ([MODE] button on the remote control is set to the

Fan only (

(1) When [FAN] button is set to AUTO, the indoor fan

motor operates as shown in Fig. 8-2-1. When [FAN] button is set to LOW, LOW+, MED, MED+ or HIGH, the motor operates with a constant air flow.

Preset temp.

NOTE :

*1: The values marked with *1 are calculated and

controlled by the difference in motor speed between M+ and L–.

(2) Hi POWER operation cannot be set.

8-2-2. Cooling operation ([MODE] button on the remote control is set to the

Cool ( ) operation.)

• Once the setting is made, the operation mode is memorized in the microcomputer so that the same operation can be effected thereafter simply by pushing [START/STOP] button.

• A cooling operation signal is transmitted to outdoor unit.

) operation.)

+3 +2.5

(Preset temp.)

–

+1.5 +1 +0.5

(Room temp.)

Fig. 8-2-1 Setting of air flow [FAN:AUTO]

M+

*1 *1 *1 L

• The outdoor unit controls the outdoor fan relay R01, R02 and R03, and the compressor motor speed according to the operation command signal sent from the indoor unit.

• When [FAN] button is set to AUTO, the indoor fan motor operates as shown in Fig. 8-2-2. When [FAN]

button is set to LOW

MED

, HIGH

, LOW

, MED

, the motor oper-

ates with a constant air flow.

(Preset temp.)

–

(Room temp.)

Preset temp.

+3 +2.5 +2 +1.5 +1 +0.5

-0.5

M+

*1 *1 *1

NOTE :

*1: The values marked with *1 are calculated and

controlled by the difference in motor speed between M+ and L–.

Fig. 8-2-2 Setting of air flow [FAN:AUTO]

(1) Cooling capacity control

• The cooling capacity and room temperature are controller by changing the compressor motor speed according to both the difference between the temperature detected by the room temperature sensor and the temperature set by temperature (

temperature.

• When compressor has been activated or reactivated, it operates with Max.33 rps for 2 minutes, with Max.57 rps from 2 minutes to 3 minutes, and with Max.64 rps after 3 minutes passed.

• When room temperature is lower than set temperature, indoor fan motor is operated at fan speed L as shown in Fig. 8-2-1 while the outdoor unit stops.

(2) Prevent-freezing control

If temperature of indoor heat exchanger detected by the indoor heat exchanger sensor is 5°C lower, compressor motor speed is gradually lower to prevent freezing of the indoor heat exchanger. If temperature is 7°C or higher, return the operation to the above item (1).

) button and also any change in room

– 25 –

Page 27

FILE NO. SVM-04038

(3) Current release control

The input current of compressor and outdoor fan motor (Precisely inverter main circuit control section) which occupy most of air conditioner input is detected by the outdoor current sensor, and compressor motor speed is gradually lowered so that current value does not exceed 7.1A if current value exceeds 7.1A. When the current value lowers to 6.6A, return the operation to the above item (1).

Comp. motor

7.1

6.6

Current value (A)

Normal control

speed down

Comp. motor speed keep

Fig. 8-2-3

(4) Outdoor temperature release control

The outdoor temperature release is controlled by changing the current release points 7.1 and 6.6 in the above item according to temperature detected by the outdoor temperature sensor. For example, if the outdoor temperature is 43°C, the value of current release point becomes 5.0A.

(5) Limit for maximum compressor motor speed

by indoor fan speed

When the indoor heat exchanger sensor detected 17°C or lower, the maximum compressor motor speed is limited by the indoor fan speed. For example, the compressor motor speed is limited as described in the table below.

Air flow rate To < 32°C To 32°C

after 1H running

H5454

48 49 MED. 41 44 M, L+, L–, L 35 39 L, L–, UL, SUL 28 28

(6) Louver control

The vertical air flow louvers are automatically set to horizontal or cool memory position. When temperature of indoor heat exchanger becomes 5°C or lower by the prevent-freezing control and the compressor is turned off, the vertical air flow louvers close once and then return to the position of previous time.

(7) ECO operation control

When the ECO button of the remote controller is pushed, quiet and mild operation is performed by restraining air flow and operating motor speed.

1) Indoor air flow is controlled between SUL and L.

2) Setting 32 rps as the maximum operating compressor motor speed, the minimum capacity operation range is widened every 1 hour and 4 hours have passed after ECO operation had started.

Indoor

6.0

5.0

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5 0

(Room temp.) - (Preset temp.)

-0.5

-1.0

-2.0 1H

2H 3H 4H

fan

L-

SUL

Comp.

motor

speed

32rps

*1 *1 *1 *1 *1

22rps

OFF

Fig. 8-2-4

NOTE

*1: The values marked with *1 are calculated and controlled by the difference in motor speed between 32 rps

and 22 rps.

– 26 –

Page 28

FILE NO. SVM-04038

8-2-3. DRY operation ([MODE] button on the remote control is set the

Dry (

) operation.)

• Once the setting is made, the operation mode is memorized in the microcomputer so that the same operation can be effected thereafter simply by pushing [START/STOP] button.

• Dry operation signal is transmitted to outdoor unit.

•

The Cooling operation giving priority to dehumidifying, which restrains the indoor fan speed and compressor motor speed, is performed.

•

The indoor fan motor operates as shown in Fig. 8-2-5. (Fan speed is AUTO only.)

• The outdoor unit controls the outdoor fan relay R01, R02 and R03, and the compressor motor speed according to the operation command signal sent from the indoor unit.

+2.5

+2.0

+1.5

L-

8-2-4. Heat operation ([MODE] button on the remote control is set the

Heat ( ) operation.)

Transferring of heat operation signal from indoor unit to outdoor unit starts. The indoor fan motor operates by the room temperature when selecting “AUTO” of “FAN” as shown in Fig. 8-2-6, and operates with a set air flow when selecting

“LOW

” to “HIGH

”.

However, to prevent cold draft, revolution speed of the fan is restricted by indoor heat exchanger when air flow is AUTO (Fig. 8-2-7) and starting of FAN Manual.

[Basic control]

Set temperature

–

)

(Room temp

-0.5

-1

-1.5

-2

-2.5

)

-5.0

(Set temp

-5.5

[FAN AUTO]

LOW

*1 *2

HIGH

(Room temp.) - (Set temp.)

Set temp.

+1.0

+0.5

-0.5

SUL

NOTE :

*1 : Middle motor speed between L– and SUL SUL : Super ultra Low

Fig. 8-2-5 Setting of air flow

*1,*2, *3 : Approximate revolution speed of M+ and L to linear accordingly to temperature.

Fig. 8-2-6 Setting of air flow

[Cold draft preventing control]

The upper limit of fan revolution speed is shown below.

464534

333221

*2 *2

A+4 A–8

FAN

AUTO

A+4 A–8

Starting

of FAN Manual

HIGH

Approximate revolution speed of HIGH and SUL linear by Tc.

SUL

SUL (NOTE : *1) Stop

Fig. 8-2-7 Cold draft preventing control

NOTES :

*1 : Stops for 2 minutes after thermostat-OFF. *2 : 24°C when the set temperature is 24°C or more

Set temperature when the set temperature is below 24°C

– 27 –

Page 29

[In starting and in stability]

In starting In stability

FAN AUTO

• Until 12 minutes passed after operation start

• When 12 to 25 minutes passed after operation start and room temperature is 3°C or lower than set temperature.

• When 12 to 25 minutes passed after operation start and room temperature is higher than (set temp. –3°C)

• When 25 minutes or more passed after operation start

FAN Manual

• Room temperature < Set temperature –4°C

• Room temperature Set temperature –3.5°C

The outdoor unit controls the outdoor fan based upon the operation signal sent from the indoor unit, and also controls revolution speed of the compressor motor.

The power coupler (IC20) for 4 way valves is turned on, and turned off in defrost operation.

(1) Heating capacity control

Calculate the difference between temperature detected by room temperature sensor every minute and the set temperature set on “Tempera- ture indicator” and variation amount of room temperature. Then, obtain the correction amount of the command signal, and correct the current frequency command signal.

(2) High-temperature release control

If temperature of the indoor heat exchanger detected by the indoor heat exchanger sensor is 55°C or higher, compressor motor speed is gradually lowered to prevent over temperature rising of compressed pressure. If temperature becomes below 48°C, return to above item (1).

(3) Current release control

The input current of compressor and outdoor fan motor (Precisely inverter main circuit control section) which occupies most of air conditioner input is detected by the outdoor current sensor. The compressor motor speed is lowered gradually according to the range of TO (outside air temperature) if the input current exceeds the current value determined in each zone as shown in Fig. 8-2-8 so that the input current does not exceed the set value. In case that the current lowered by approx. 0.5A than each set value, return to above item (1).

16.0

15.5

11.0

10.5

Outside air temp. (°C)

(4) Defrost control

1) Detection of frost In heating operation, time duration while the compressor operates is counted, and defrost operation starts by any condition described below.

a. The counted time is 28 minutes or more, and

status that temperature of the outdoor heat exchanger detected by the outdoor heat exchanger is –20°C or lower continued for 2 minutes or more.

b. The counted time is 28 minutes or more, and

status that temperature of the outdoor heat exchanger detected by the outdoor heat exchanger is –7°C or lower and temperature lowered by 2.5°C than the minimum value of the outdoor heat exchanger during 10 to 15 minutes count time continued for 2 minutes or more.

c. The counted time is 34 minutes or more, and

status that temperature of the outdoor heat exchanger detected by the outdoor heat exchanger is -5°C or lower and temperature lowered by 3.0°C than the minimum value of the outdoor heat exchanger during 10 to 15 minutes count time continued for 2 minutes or more.

d. If the following three conditions are satisfied,

defrost operation (Timer defrost) starts after heating operation for 37 minutes. 1 Setting on remote control, HEAT ( )

(mode), HIGH

(temperature

2 Room temperature is 19°C to 24°C, and

outside air temperature is 5°C or lower.

3 Defrost operation has been already

performed once.

FILE NO. SVM-04038

7.1A

Fig. 8-2-8

(Fan), 30°C

– 28 –

Page 30

FILE NO. SVM-04038

2) Defrost operation Operation of the compressor is stopped once, turn off power coupler for 4 way valves after 10 seconds, and then exchange the 4 way valves. After 20 seconds, restart operation of the compressor. Turn off the outdoor fan just when the compressor stopped. If temperature of the indoor heat exchanger lowered than 38°C, stop the indoor fan.

3) Defrost reset Resetting operation from defrost to heating is performed when anyone of the following conditions is satisfied. a. Temperature of the outdoor heat exchanger

rose to +8°C or higher.

b. A status that temperature of the outdoor heat

exchanger is +5°C or higher continued for 80 seconds.

c. Defrost operation continued for 10 minutes. In resetting defrost operation, the compressor

stops for 50 seconds if defrost has started under condition a. to c. in item1), but the compressor is reset to heating operation keeping operated if defrost has started under condition d. in item 1).

(5) Louver control

When the compressor is turned off by hightemperature release control, the vertical air flow louvers close once and then return to the position of previous time.

8-2-5. Automatic operation

(1)

As shown in Fig. 8-2-9, the operation mode (COOL, DRY, HEAT) is selected according to the Preset temperature and room temperature when the operation has started.

−

If room temperature is higher than 1°C of perset temperature. "Cooling" operation is performed.

−

If room temperture is within 1°C of perset temperature. "Fan only" operation is performed.

(at UL speed).

−

If room temperture is lower than 1°C of perset temperture. "Heating operation is performed.

Cool Operation

Ts+1

Ts Ts-1

Fan Only

Heat Operation

Fig. 8-2-9

Preset temp.

30 +6 29 +5 28 +4 27 +3 26 +2 25 +1 24 0 23 -1 22 -2 21 -3 20 -4 19 -5 18 -6 17 -7

>Ts

– 29 –

Page 31

8-3. T emporary Operation

• Temporary Auto operation, existence of Auto Restart, and Temporary Cooling operation can be set by the TEMPORARY button of the indoor controller.

TEMPORARY button

Table 8-3-1

FILE NO. SVM-04038

TEMPORARY button

OFF → ON

After pushing button

for 3 seconds

After pushing button

for 10 seconds

8-3-1. Temporary auto operation

• When the TEMPORARY button is pushed, the Auto operation with set temperature fixed at 25°C starts. Controlling is same as that of Auto operation by the remote controller.

• When the TEMPORARY button is pushed again, the operation stops.

• During Temporary Auto operation, operation by the remote controller is accepted.

• Using the Auto Restart function, the Temporary Auto operation starts when power failure is reset.

Control

Temporary Auto

operation start

Auto Restart

control select

Temporary Cooling

operation start

8-3-2. Temporary cooling operation

• When the TEMPORARY operation button keeps pushed for 10 seconds, Cooling operation of which compressor motor speed and the indoor fan speed are fixed starts.

Compressor motor speed :

10 : 28 rps

Indoor fan speed : Low

• When the TEMPORARY operation button is pushed again, the operation stops.

• Auto Restart function is unavailable.

– 30 –

Page 32

FILE NO. SVM-04038

8-4. Auto Restart Function

The indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored. This function is not set to work when shipped from the factory. Therefore it is necessary to set it to work.

8-4-1. How to set auto restart function

To set the auto restart function, proceed as follows: The power supply to the unit must be on; the function will not set if the power is off. Push the [TEMPORARY] button located in the center of the front panel continuously for three seconds. The unit receives the signal and beeps three times. The unit then restarts operating automatically in the event of power supply being accidentally shut down.

When the unit is on standby (Not operating)

Operation Motions

Push [TEMPORARY] button for more The unit is on standby. than three seconds.

The unit starts to operate. The green lamp is on.

→ →

After approx. three seconds,

The unit beeps three times The lamp changes from and continues to operate. green to orange.

If the unit is not required to operate at this time, push [TEMPORARY]

TEMPORARY button

button once more or use the remote control to turn it off.

When the unit is in operation

Operation Motions

Push [TEMPORARY] button for more The unit is in operation. The green lamp is on. than three seconds.

The unit stops operating. The green lamp is turned off.

→ →

After approx. three seconds,

The unit beeps three times. If the unit is required to operate at this time, push [TEMPORARY]

TEMPORARY button

button once more or use the remote control to turn it on.

• While this function is being set, if the unit is in operation, the orange lamp is on.

• This function can not be set if the timer operation has been selected.

• When the unit is turned on by this function, the louver will not swing even though it was swinging automatically before shutting down.

• While the filter check lamp is on, the TEMPORARY button has the function of filter reset button.

– 31 –

Page 33

8-4-2. How to cancel auto restart function

To cancel auto restart function, proceed as follows: Repeat the setting procedure: the unit receives the signal and beeps three times. The unit will be required to be turned on with the remote control after the main power supply is turned off.

When the unit is on standby (Not operating)

Operation Motions

Push [TEMPORARY] button for more The unit is on standby. than three seconds.

→

FILE NO. SVM-04038

The unit starts to operate. The orange lamp is on.

→

After approx. three seconds,

The unit beeps three times The lamp changes from and continues to operate. orange to green.

If the unit is not required to operate at this time, push [TEMPORARY]

TEMPORARY button

button once more or use the remote control to turn it off.

When the unit is in operation

Operation Motions

Push [TEMPORARY] button for more The unit is in operation. The orange lamp is on. than three seconds.

The unit stops operating. The orange lamp is turned off.

→ →

After approx. three seconds,

The unit beeps three times. If the unit is required to operate at this time, push [TEMPORARY]

TEMPORARY button

button once more or use the remote control to turn it on.

• While this function is being set, if the unit is in operation, the orange lamp is on.

8-4-3. Power failure during timer operation

When the unit is in Timer operation, if it is turned off because of power failure, the timer operation is cancelled. Therefore, set the timer operation again.

– 32 –

Page 34

8-5. Hi POWER Mode ([Hi POWER] button

on the remote control is pressed.)

When [Hi POWER] button is pressed while the indoor unit is in Auto, Cooling or Heating operation, Hi POWER mark is indicated on the display of the remote control and the unit operates as follows.

(1) Automatic operation

• The indoor unit operates in according to the current operation.

(2) Cooling operation

• The preset temperature drops 1°C. (The value of the preset temperature on the remote control does not change.)

• If the difference between the preset temperature and the room temperature is big, the horizontal louver moves to the Hi POWER position automatically. Then when the difference between them gets smaller, the horizontal louver returns automatically.

(3) Heating operation

• The preset temperature increases 2°C. (The value of the preset temperature on the remote control does not change.)

FILE NO. SVM-04038

(4) The Hi POWER mode can not be set in Dry or Fan

only operation.

8-6. Filter Check Lamp

When the elapsed time reaches 1000 hours, the filter check lamp indicates. After cleaning the filters, turn off the filter check lamp.

8-6-1. How to turn off filter check lamp

(1) Press [FILTER] button on the remote control. (2) Push [TEMPORARY] button on the indoor unit.

Note: if [TEMPORARY] button is pushed while the

filter check lamp is not indicating, the indoor unit will start the Automatic Operation.

– 33 –

Page 35

8-7. Remote control

8-7-1. Remote control and its functions

1 Infrared signal emitter

Transmits a signal to the indoor unit.

2 START/STOP button

Press the button to start operation. (A receiving beep is heard.) Press the button again to stop operation. (A receiving beep is heard.) If no receiving sound is heard from the indoor unit, press the button twice.

3 Mode select button (MODE)

Press this button to select a mode. Each time you press the button, a mode is selected in a sequence that goes from A : Auto changeover control, : Cool,

: Heat,

: Fan only, and back to A.

(A receiving beep is heard.)

4 Temperature button (

,.......

The set temperature is increased up to 30°C.

9.......

The set temperature is dropped down to 17°C. (A receiving beep is heard.)

5 Fan speed button (FAN)

Press this button to select fan speed. When you select AUTO, the fan speed is automatically adjusted according to the room temperature. You can also manually select the desired fan speed from among five settings.

(LOW

MED

, LOW

, HIGH

, MED

(A receiving beep is heard.)

6 Auto louver button (SWING)

Press this button to swing the louver. (A receiving beep is heard.) Press the FIX button to stop the louver swinging. (A receiving beep is heard.)

7 Set louver button (FIX)

Press this button to adjust the air flow direction. (A receiving beep is heard.)

8 Off timer button (OFF)

Press this button to set the OFF timer.

9 On timer button (ON)

Press this button to set the ON timer.

! Reserve button (SET)

Press this button to reserve time settings. (A receiving beep is heard.)

" Cancel button (CLR)

Press this button to cancel ON timer and OFF timer. (A receiving beep is heard.)

# High power button (Hi POWER)

Press this button to start the high power operation.

: Dry,

)

FILE NO. SVM-04038

$ Memory button (MEMO)

Press this button to stand by memorizing the settings. Press the button again for more than 4 seconds to memorize the setting indicated on the remote control and mark is indicated.

% Automatic operation button (AUTO)

Press this button to operate the air conditioner automatically. (A receiving beep is heard.)

& ECO timer button (ECO)

Press this button to start the ECO timer (OFF timer) operation. You can select the OFF timer time from among four settings (1,3,5 or 9 hours).

((

( FILTER button

((

Press this button to turn off the filter cleaning lamp on the indoor unit. Press this button after cleaning the air filter.

))

) PRESET button

))

Press this button to operate the air conditioner according to settings memorized by the MEMO button.

~ TIMER button

Use this button to change the clock, ON timer, and OFF timer times. To forward the time, press the “TIMER

To set back the time, press the “TIMER

AUTOA

A B

START/STOP

FAN MODE

SWING

FIX

OFF SET CLR

FILTER

ECO

TIMER

PRESET

AUTO

Hi-POWER

MEMO

CLOCK CHECKRESET

” button.

– 34 –

Page 36

FILE NO. SVM-04038

8-7-2. Names and functions of indications on remote control Display

All indications, except for clock time indication, are indicated by pressing the START/STOP button.

1 Transmission mark

This transmission mark (,) indicates when the remote control transmits signals to the indoor unit.

2 Mode display

Indicates the current operation mode. (AUTO : Automatic control, A : Auto changeover control, : Cool,

: Dry, : Heat,

3 Temperature display

: Fan only)

Indicates the temperature setting (17°C to 30°C). When you set the operating mode to

: Fan only, no temperature

setting is indicated.

4 Louver operation display

Indicates the louver positioning and operation. Five selectable positions

5 FAN speed display

,,,,

Automatic Swing

Indicates the selected fan speed. AUTO or one of five fan speed levels (LOW

, LOW

, MED

, HIGH

) can be indicated. Indicates AUTO when the operating mode is either AUTO or

6 TIMER and clock time display

: Dry.

The time set for timer operation or clock time is indicated. The present time is always indicated except for TIMER operation.

7 Hi POWER display

Indicates when the Hi POWER operation starts. Press the Hi POWER button to start and press it again to stop the operation.

8 (MEMORY) display

Flashes for 4 seconds when the MEMO button is pressed during operation.

mark is indicated when keeping the button depressed for more than 4 seconds while the mark is flashing. Press another button to turn off the mark.

9 ECO TIMER display

Indicates when the ECO TIMER is in operation. Each time you press the ECO button, the display changes in the sequence of 1,3,5 or 9h.

13 2 8

AUTOA

A B

9 67 5

• In the illustration, all indications are indicated for explanation. During operation, only the relevant indications will be indicated on the remote control.

A B

– 35 –

Page 37

FILE NO. SVM-04038

9. INSTALLATION PROCEDURE

9-1. Safety Cautions

For general public use

Power supply cord of parts of appliance for Outdoor use shall be more than polychloroprene sheathed flexible cord (design H07RN-F), or cord designation 245IEC66. (1.5 mm

or more)

CAUTION

• THIS AIR CONDTIONER ADOPTS THE NEW HFC REFRIGERANT (R-410A) WHICH DOES NOT DESTROY OZONE LAYER.

R-410A refrigerant is apt to be affected by impurity such as water , oxidizing membrane, and oils because pressure of R-410A refrigerant is approx. 1,6 times of refrigerant R-22. Accompanied with adoption of the new refrigerant, refrigerating machine oil has been also changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating machine oil does not enter into the refrigerating cycle or new-refrigerant air coditioner. To prevent mixin of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port of the main unit or installation tools are different from those for the coventional refrigerant. Accordingly, the exclusive tools are required for the new refrigerant (R-410A) as shown below. For conecting pipes, use new and clean piping materials with high pressure-tight force, which were made fro R-410A only, so that water or dust does not enter. Moreover, do not use the existing piping because there are problems about pressure-tight forec and inner impurity in the existing piping.

CAUTION

This appliance must be connected to the main power supply by means of a circuit breaker or a switch with a contact separation of at least 3 mm.

The installation fuse (25A D type

New Refrigerant Air Conditioner Installation

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY.

) must be used for the power supply line of this air conditioner.

DANGER

• FOR USE BY QUALIFIED PERSONS ONLY.

• 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 BY WRONG WAY, ELECTRIC PARTS MAY BE DAMAGED.

• CHECK THE EARTH WIRE 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, HEAT REGISTORS, FURNACE, STOVES, ETC.

• WHEN MOVING THE AIR-CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT TO GET THE SPECIFIED REFRIGERANT 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.

WARNING

• Never modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches.

• Do not install in a place which cannot bear the weight of the unit.

Personal injury and property damage can result if the unit falls.

• Before doing the electrical work, attach an approved plug to the power supply cord. And, make sure the equipment to be earthed.

• Appliance shall be installed in accordance with national wiring regulations. If you detect any damage, do not install the unit. Contact your Toshiba dealer immediately.

CAUTION

• Exposure of unit to water or other moisture before installation will result in an electrical short. Do not store 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.

• To avoid personal injury, be careful when handling parts with sharp edges.

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

– 36 –

Page 38

9-1-1. Installation Diagram of Indoor and Outdoor Units

FILE NO. SVM-04038

Zeolite filter

Before installing the wireless remote control

• With the remote control cover open, load the batteries supplied correctly, observing their polarity.

2 Wireless remote control

Cover

170 mm

or more

Air filter

(Attach to the front panel)

Bioenzyme filter

Wireless remote

control

Hook

Flat head wood screw

Remote control holder

Hook

65 mm or more

Installation

plate

Shield pipe

170 mm

or more

For the rear left and left piping

Wall

Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better operation.

Do not allow the drain hose to get slack.

Cut the piping hole sloped slightly

Make sure to run the drain hose sloped downward.

The auxiliary piping can be connected the left, rear left, rear right, right, bottom right or bottom left.

3 Batteries

100 mm or

10. HOW TO DIAGNOSE THE TROUBLE

FILE NO. SVM-04038

The pulse modulating circuits are mounted to both indoor and outdoor units. Therefore, diagnose troubles according to the diagnosis procedure as described below. (Refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.)

Table 10-1

No. Troubleshooting Procedure Page

1 First Confirmation 44 2 Primary Judgement 45 3 Judgement by Flashing LED 46

of Indoor Unit 4 Self-Diagnosis by Remote Controller 47 5 Judgement of Trouble by 50

Every Symptom 6 How to Check Simply the Main Parts 58

NOTE:

A large-capacity electrolytic capacitor is used in the outdoor unit controller (inverter). Therefore, if the power supply is turned off, charge (charging voltage DC280V) remains and discharging takes a lot of time. After turning off the power source, if touching the charging section before discharging, an electrical shock may be caused. Discharge the electrolytic capacitor completely by using soldering iron, etc.

(1) Remove the inverter cover (plating) by opening

four mounting claws.

(2) As shown below, connect the discharge resistance

(approx. 100Ω40W) or plug of the soldering iron to voltage between + – terminals of the C12 (“CAUTION HIGH VOLTAGE” is indicated.) electrolytic capacitor (500µF/400V) on P.C. board, and then perform discharging.

10-1. First Confirmation

10-1-1. Confirmation of power supply

Confirm that the power breaker operates (ON) normally.

Discharging position (Discharging period 10 seconds or more)

Fig. 10-1

10-1-2. Confirmation of power voltage

Confirm that power voltage is AC 220-240 V ± 10%. If power voltage is not in this range, the unit may not operate normally.

Plug of soldering iron

Inverter cover

PC board (Soldered surface)

– 44 –

Page 46

FILE NO. SVM-04038

10-1-3. Operation which is not a trouble (Program operation)

For controlling the air conditioner, the program operations are built in the microcomputer as described in the following table. If a claim is made for running operation, check whether or not it meets to the contents in the following table. When it does, we inform you that it is not trouble of equipment, but it is indispensable for controlling and maintaining of air conditioner.

Table 10-1-1

No. Operation of air conditioner Descriptions

1 When power breaker is turned “ON”, the

operation lamp (Green) of the indoor unit flashes.

2 Compressor may not operate even if the

room temperature is within range of compressor-ON.

3 In Dry and ECONO. Mode, FAN (air flow)

display does not change even though FAN (air flow select) button is operated.

4 Increasing of compressor motor speed stops

approx. 30 seconds after operation started, and then compressor motor speed increases again approx. 30 seconds after.

5 The set value of the remote controller should

be below the room temperature.

6 In AUTO mode, the operation mode is

changed.

7 In HEAT mode, the compressor motor speed

does not increase up to the maximum speed or decreases before the temperature arrives at the set temperature.

The OEPRATION lamp of the indoor unit flashes when power source is turned on. If [START/STOP] button is operated once, flashing stops. (Flashes also in power failure)

The compressor does not operate while compressor restart delay timer (3-minutes timer) operates. The same phenomenon is found after power source has been turned on because 3-minutes timer operates.

The air flow indication is fixed to [AUTO].

For smooth operation of the compressor, the compressor motor speed is restricted to Max. 41 rps for 2 minutes, and Max.91 rps for 2 minutes to 3 minutes, respectively after the operation has started.

If the set value is above the room temperature, Cooling operation is not performed. And check whether battery of the remote controller is consumed or not.

After selecting Cool or Heat mode, select an operation mode again if the compressor keeps stop status for 15 minutes.

The compressor motor speed may decrease by high-temp. release control (Release protective operation by temp.-up of the indoor heat exchanger) or current release control.

10-2. Primary Judgement

To diagnose the troubles, use the following methods. (1) Judgement by flashing LED of indoor unit (2) Self-diagnosis by service check remote controller (3) Judgement of trouble by every symptom

Firstly, use the method (1) for diagnosis. Then, use the method (2) and (3) to diagnose the details of troubles.

– 45 –

Page 47

FILE NO. SVM-04038

10-3. Judgement by Flashing LED of Indoor Unit

While the indoor unit monitors the operation status of the air conditioner, if the protective circuit operates, the contents of self-diagnosis are displayed with block on the indoor unit indication section.

Table 10-3-1

Lamps Self-diagnosis

A OPERATION lamp is blinking. (1Hz) B OPERATION lamp is blinking. (5Hz) C OPERATION lamp is blinking. (5Hz) D OPERATION lamp is blinking. (5Hz) E OPERATION lamp is blinking. (5Hz)

F OPERATION and TIMER lamps are blinking.

(5Hz)

G OPERATION, TIMER and FAN ONLY lamps

are blinking.

H OPERATION, TIMER and FAN ONLY lamps

are blinking.

Power failure (when the power supply is turning on) Thermo sensor (TA) short or break Heat exchanger sensor (TC) short or break Indoor fan motor lock or failure Indoor P.C. board failure Wrong wiring of connecting cable

• Gas shortage or other refrigerant cycle trouble

• Heat exchanger sensor open, break or short

• Overload relay or thermostat trouble of compressor

Cycle failure

NOTES:

(1) The contents of items B and C and a part of item E are displayed when air conditioner operates. (2)

When item B and C, and item B and a part of item E occur concurrently, priority is given to the block of item B.

(3) The check codes can be confirmed on the remote controller for servicing.

– 46 –

Page 48

10-4. Self-Diagnosis by Remote Control

(Check Code)

(1) If the lamps are indicated as shown B to H in Table

10-3-1, exchanger the self-diagnosis by the remote control.

(2) When the remote control is set to the service

mode, the indoor controller diagnoses the operation condition and indicate the information of the self-diagnosis on the display of the remote control with the check codes. If a fault is detected, all lamps on the indoor unit will blink at 5Hz and it will

beep for 10 seconds (Pi, Pi, Pi....). The timer lamp

usually blinks (5Hz) during the self-diagnosis.

10-4-1. How to use remote control in service mode

SET CLR

CLOCK CHECKRESET

AUTOA

A B

FILE NO. SVM-04038

(1) Press [CHECK] button with a tip of pencil to set

the remote control to the service mode.

• “00” is indicated on the display of the remote control.

• The timer lamp on the indoor unit blinks continuously. (5 times per 1 sec.)

START/STOP

FAN MODE

SWING

TIMER

FIX

OFF SET CLR

FILTER

ECO

PRESET

AUTO

Hi-POWER

MEMO

CLOCK CHECKRESET

(2) Press [TIMER 8] button.

If there is no fault with a code, the indoor unit will beep once (Pi) and the display of the remote control will change as follows:

; 00 ; 01 ; 02 ··· 1d ; 1E ; 22

• Check the unit with all 35 check codes (00 to

22). as shown in Table 10-4-1.

• Press [TIMER 9] button to change the check code backwards.

If there is a fault, the indoor unit will beep for 10 seconds (Pi, Pi, Pi...). Note the check code on the display of the remote control.

• 2-digits alphanumeric will be indicated on the display.

• All lamps on the indoor unit will blink. (5 times per 1 sec.)

(3) Press [CLR] button. After service finish for clear

service code in memory.

• “7F” is indicated on the display of the remote control.

• Alphanumeric characters are used for the check code.

is 5. is 6. is A. is B. is C. is D.

(4) Press [START/STOP] button to release the service

mode.

• The display of the remote control returns to as it was before service mode was engaged.

– 47 –

Page 49

FILE NO. SVM-04038

10-4-2. Caution at servicing

(1) After servicing, push the START/STOP button to return to the normal mode. (2) After servicing by the check code, turn off breaker of the power supply, and turn on breaker of the power

supply again so that memory in the microcomputer returns the initial status. However, the check codes are not deleted even if the power supply is turned off because they are stored in the fixed memory.

Table 10-4-1

Block distinction Operation of diagnosis function Check

code code

Block

Indoor P.C. board

Not displayed

Check

Cause of operation

Short-circuit or disconnection of the room temperature sensor (TA sensor).

Being out of place, disconnection, short-circuit, or migration of heat exchanger sensor (TC sensor)

Lock of indoor fan or trouble on the indoor fan circuit

Trouble on other indoor P.C. boards

Air conditioner

status

Operation continues.

All off

Operation continues.

Remark

Displayed when error is detected.

Judgement and action

1. Check the room temp. sensor. 2 When the room temp. sensor is

normal, check P.C. board.

1. Check heat exchanger sensor.

2. When heat exchanger sensor is normal, check P.C. board.

1. Check P.C. board.

2. When P.C. board is normal, check the motor.

Replace P.C. board.

Connecting cable and serial signal

Return serial signal is not sent to indoor side from operation started. (1)Defective wiring of

connecting cable

(2)Operation of compressor

thermo. Gas shortage Gas leak

Operation command signal is not sent to outdoor side.

Operation continues.

Flashes when trouble is detected on Return serial signal, and normal status when signal is reset.

Flashes when trouble is detected on Operation command signal, and normal status when signal is reset.

1. When the outdoor unit never operate: (1)Check connecting cable, and

correct if defective wiring.

(2)Check 25A fuse of inverter

P.C. board

(3)Check 3.15A of inverter

P.C. board.

2. To display [Other] block during operation, check compressor thermo. operation and supply gas (check gas leak also).

3. Unit operates normally during check. If Return serial signal does not stop between 2 and 3 of the indoor terminal block, replace inverter P.C. board. If signal stops between 2 and 3 of the indoor terminal block, replace indoor P.C. board.

If Return serial signal does not stop between 2 and 3 of the indoor terminal block, replace inverter P.C. board. If signal stops between 2 and 3 of the indoor terminal block, replace indoor P.C. board.

– 48 –

Page 50

Block distinction Operation of diagnosis function Check

code code

Block

Outdoor P.C. board

Not displayed

Outdoor P.C. board

Others (including compressor)

Check

Cause of operation

Inverter over-current protective circuit operates. (Short time)

Position-detect circuit error or short-circuit between windings of compressor

Current-detect circuit error

Being out of place, disconnection or shortcircuit of outdoor temp. sensor

Disconnection or shortcircuit of discharge temp. sensor

Outdoor fan drive system error

Outdoor heat exchanger temp. sensor error

Compressor drive output error, Compressor error (lock, missing, etc.), Break down

Return serial signal has been sent when operation started, but it is not sent from halfway. (1) Compressor thermo.

operation Gas shortage Gas leak

(2) Instantaneous power

failure

Compressor does not rotate. (Current protective circuit does not operate when a specified time passed after compressor had been activated.)

Discharge temp. exceeded 117°C

Break down of compressor

Four-way valve inverse error (TC sensor value lowered during heating operation.)

Air conditioner

status

All off

Operation continues

All off

Operation continues

All off

Operation continues

Remark

Displayed when error is detected.

——

Displayed when error is detected.

Flashes when trouble is detected on Return serial signal, and normal status when signal is reset.

Displayed when error is detected.

——

FILE NO. SVM-04038

Judgement and action

Even if trying operation again, all operations stop immediately. : Replace P.C. board.

1. Even if connecting lead wire of compres sor is removed, positiondetect circuit error occurred. : Replace P.C. board.

2. Measure resistance between wires of compressor, and perform short circuit. : Replace compressor.

Even if trying operation again, all operations stop immediately. : Replace P.C. board.

1. Check outdoor temp. sensors (TE, TS).

2. Check P.C. board.

Check discharge temp. sensor (TD).

2. Check P.C. board.

Position-detect error, over-current protective operation of outdoor fan drive system, fan lock, etc. : Replace P.C. board or fan motor.

1. Check outdoor heat exchanger temp. sensor (TE).

2. Check P.C. board.

When 20 seconds passed after start up, position-detect circuit error occurred. : Replace compressor.

1. Repeat Start and Stop with interval of approx. 10 to 40 minutes. (Code is not displayed during operation.) Supply gas. (Check also gas leak.)

2. Unit operates normally during check. If Return serial signal does not stop between 2 and 3 of the indoor terminal block, replace inverter P.C. board. If signal stops between 2 and 3 of the indoor terminal block, replace indoor P.C. board.

1. Trouble on compressor

2. Trouble on wiring of compressor (Missed phase)

Check discharge temp. sensor (TD).

2. Degassing

3. Trouble on P.M.V.

1. Check power voltage. (220-240 V + 10%)

2. Overload operation of refrigeration cycle Check installation condition (Short-circuit of outdoor diffuser.)

1. Check 4 way valve operation.

– 49 –

Page 51

10-5. Judgement of Trouble by Every Symptom

10-5-1. Indoor unit (Including remote controller) (1) Power is not turned on (Does not operate entirely)

FILE NO. SVM-04038

supply once, and 5 second later, turn it

Is fuse (F01)

of indoor control

board blown?

Turn off power

on again.

Is OPERATION

lamp blinking?

YES

Is it possible to

turn on power

supply by

pressing

[START/STOP]

button on

remote control?

YES

(R04, C01,

DB01, C03, R01

IC01 and T01)

are defective.

Parts

Does

transmission

mark on remote control flash normally,

and is its signal

transmitted

properly?

YES

Does

fan motor

connector

between 1

and 2

short-circuit?

Operation

Check item

Conceivable principle

cause

Measure

Item by symptoms

Remote control is

defective.

Refer to (5)

“Troubleshooting for

Remote Control.”

Unit operates

normally.

YES

Is voltage

(DC 12V or 5V)

Is DC

310 – 340V

suppalied to

primary side of

transfer s witch?

YES

Are DC 15V,

DC 12V and

DC 7V

supplied to

secondary

side of

transfer

switch?

YES YES

NO NO

indicated on rear of indoor control board

normal?

Refer to

or this problem

is one step short

of power P.C.

board block.

Turn off breaker once and turn it

on again after

removing motor.

YES

Are DC 15V,

DC 12V or

DC 7V

supplied to

secondary

side of transfer switch?

Microcomputer

is defective.

Transfer switch,

IC (IC01) for

power supply or

fan motor is

defective.

Replace main

P.C. board.

Replace motor.

• Be sure to disconnect the motor connector CN10 after shut off the power supply, or it will be a cause of damage of the motor.

– 50 –

Page 52

(2) Power is not turned on though Indoor P.C. board is replaced <Confirmation procedure>

Turn on power supply.

FILE NO. SVM-04038

Does operation

lamp flash?

YES

Is wired connectly to white and black

lead wires of terminal block?

YES

Correct wirng.

To item of “Power supply

is not turned on”

– 51 –

Page 53

FILE NO. SVM-04038

(3) Only indoor fan motor does not operate. <Primary check>

(1) Is it possible to detect the power supply voltage (200 – 240V) between 1 and 2 on the terminal block? (2) Does the indoor fan motor operate in cooling operation?

(In heating operation, the indoor fan motor does not operate for approximately 5 minutes after it is turned on, to prevent a cold air from blowing in.)

Turn off power

supply once, and

turn it on again.

Operation

Check item

Conceivable principle

cause

Measure

Item by symptoms

Does

compressor

continue to

operate?

Start to operate

indoor unit in

cooling operation

at airflow

level “LOW”.

Does indoor

fan operate?

YES

Change airflow

level to “High”.

Is it possible to

change airflow

level to “High”?

YES

Is it possible to detect

DC 1V or more between

and 3dof motor

connector (CN10).

Is it possible to detect DC

310 – 340V between

and 3d of motor

connector (CN10).

(Motor connection condition)

Is it possible to detect DC 15V

between 4

motor connector (CN10).

Start to operate the indoor unit. At this time, is it possible to detect DC 1V or

more between 5e and 3d

of motor connector (CN10)?

Is it possible to rotate cross-

flow fan by hand properly?

YES

and 3d of

YES

Turn off indoor unit

and remove connector

from motor. Then press

START/STOP button

on remote control to

stop blinking lamp on

indoor unit.

Is it possible to detect

DC 15V between 4

and 3d of motor

connector (CN10).

Turn off indoor unit

and remove connector

from motor.

Then start to operate

indoor unit with remote control.

Replace indoor

fan motor.

Replace main

P.C. board.

Fan motor

operates normally.

Turn off indoor unit and rotate

cross-flow fan by hand when the

unit is on standby. At this time,

is it possible to detect DC 1V or

more between 5e and 3

of motor connector (CN10).

YES

– 52 –

Start to operate the indoor

unit in except heating

operation. At this time, is it

possible to detect DC 1V

or more between 5e and

3d of motor connector

(CN10)? (Check this

condition within 15 seconds

after starting unit.)

YES

Replace bearing.

Page 54

FILE NO. SVM-04038

(4) Indoor fan motor automatically starts to rotate by turning on power supply. <Cause>

The IC is built in the indoor fan motor. Therefore the P.C. board is also mounted to the inside of the motor. If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turning on power supply.

(1) Remove the front panel. (Remove 4 screws.) (2) Remove the cover of the fan motor lead wires. (3) Check DC voltage with CN10 connector while the fan motor is rotating.

NOTE:

• Do not disconnect the connector while the fan motor is rotating.

• Use a thin test rod.

Indoor fan starts rotating when power supply is turned on.

(Check output DC voltage of fan motor on P.C. board.)

Measure voltage between 2

(GND:BLACK) and 3 (V line:YELLOW)

of motor connector

(CN10) while indoor fan motor is rotating.

DC 1.0V or more Under DC 1.0V

Motor is defective.P.C. board is defective.

Yellow

Black

P.C. board

CN10

6 (Blue) 5 (Yellow)

4 (White) 3 (Black)

2 – 1 (Red)

Replace P.C. board. Replace motor.

– 53 –

Page 55

(5) Troubleshooting for remote control

FILE NO. SVM-04038

Is receiver on

indoor unit exposed

to direct sunlight?

YES

Is there any

thyristor fluorescent

light nearby?

YES

Press START/STOP

button.

Is transmission

mark indicated?

Does indoor unit

operate when

moving remote

control near receiver

or indoor unit?

Batteries are

exhausted.

The unit does not beep at all. OPERATION lamp on indoor unit is not indicated.

Press RESET button

Press START/STOP

YES

on remote control

with tip of pencil.

button.

Avoid direct

sunlight.

Keep indoor

unit away from

thyristor

fluorescent light.

Does indoor unit

start to operate by

automatic restart

function?

YES

Does radio sound

is affected by

remote control when

a signal is transmitted

at distance of 5 cm

from radio?

YES

P.C. board is defective.

Replace P.C. board. Replace batteries. Normal operation Replace remote

Note : After replacing batteries,

press the RESET button with a tip of a pencil.

Is transmission

mark indicated?

Does indoor unit

beep and operate?

YES

Remote control

is defective.

control.

– 54 –

Page 56

FILE NO. SVM-04038

10-5-2. Wiring Failure (Interconnected and serial signal wire) (1) Outdoor unit does not operate.

1) Is the voltage between 2 and 3 of the indoor terminal block varied? Confirm that transmission from indoor to outdoor is correctly performed based on the following diagram.

NOTE:

• Measurement should be performed 2 minutes and 30 seconds after starting operation.

• Be sure to prepare a diode for judgment.

Terminal block on indoor side

Red

S5277G

White

Terminal block

Tester

Normal time : Voltage swings between DC15V and 60V. Abnormal time : Voltage does not vary.

(2) Outdoor unit stops in a little while after operation started. <Check procedure> Select phenomena described below.

S5277G or equivalent (G or J type) (Diode with rated voltage of 400V or more is acceptable.)

1) The outdoor unit stops 10 to 20 minutes after operation started, and 10 minutes or more are required to restart the unit.

Gas circulation amount is down.

Gas shortage Gas leak

Measure gas pressure.

Pipe clogging

Thermo operation of compressor

2) If the unit stops once, it dose not operate until the power is turned on again.

To item of compressor does not operate.

3) The outdoor unit stops 10 minutes to 1 hour after operation started, and an alarm is displayed. (Discharge temp. error check code 03, 1E Sensor temp. error check code 02, 1C)

Gas leak Miswiring of connecting wires of indoor/outdoor units

Refer to the chart in 10-6

Clogging of pipe and coming-off TC sensor

– 55 –

Page 57

10-6. Check Code 1C (Miswiring in indoor/outdoor units) and 1E

1C 1E

Gas leakage, disconnection of

TS/TC sensors (Check code

02, 1C)

Valve drive check

Discharge temp.

error, gas leakage

(Check code 03, 1E)

FILE NO. SVM-04038

Operation

Check item

Conceivable principle

cause

Measure

Item by symptoms

Is connector of coil connected to inverter?

YES

Is positioning sound of valve (sound hitting to stopper)

heard from valve when the air conditioner starts the operation after

turning off power of the air conditioner once?

NOTE:

After all the operations stopped by the remote controller, the power

keeps being supplied to outdoor unit for approx. 3 minutes. If operating

the air conditioner by remote controller again just after all the operations

stopped by the remote controller, positioning of the valve is not

performed when outdoor unit is activated because supplying power to

the outdoor unit is not interrupted. After positioning of the valve, activate

the compressor and the outdoor fan. It takes approx. 7 seconds for

positioning of the valve, and sound ticktack (hitting sound to stopper) is

heard for approx. 0.5 seconds at least of that period. As the sound is

low, check sound by using screwdriver, etc.

YES

Are temp. sensors of indoor/outdoor units correctly set to the holder?

NOTE:

The temperature sensors which are used to control electronic control

valve include indoor heat exchanger sensor (TC),

outdoor heat exchanger temp. sensor (TE).

YES

Set it correctly.

Replace coil valve.

Set it correctly.

Gas amount check and valve clogging check

(Remove connector from the P.C. board.) Operate the air conditioner in COOL mode by TEMP button

(“Pi” sound is heard if keeping pushed for 10 seconds.) The operation enters temporary operation mode

which fixes opening degree of P.M.V. and No. of revolution of compressor. Check condensation at

Existence of condensation at outlet of P.M.V. If there is condensation at

outlet (1/4 inch = ∅6.35 mm valve side), the valve is clogged.

Check the operating pressure from service port, and add gas if pressure is low.

Remove TC sensor connector from the P.C. board in indoor unit.

outlet of P.M.V., and then check operating pressure from the service port.

YES

– 56 –

Replace valve.

Add gas.

Page 58

10-7. How to Diagnose Trouble in Outdoor Unit

10-7-1. Summarized inner diagnosis of inverter assembly

FILE NO. SVM-04038

Diagnosis/Process flowchart Item

Remove connector of compressor.

Check 15A fuse

(Part No.F01).

Check

terminal voltage

of electrolytic

capacitor.

Replace fuse.

Check

electrolytic

capacitor, diode

block (DB01),

etc.

Check

electrolytic

capacitor, diode

(DB01), etc.

Preparation

Check

Contents

Turn “OFF” the power breaker, and remove 3P connector which connects inverter and compressor.

• Check whether 15A fuse on the control board assembly is blown or not. (F01)

Summary

If fuse was blown, be sure to check the electrolytic capacitor and diode block. (DB01)

• Connect discharge resistance (approx. 100Ω40W) or soldering iron (plug) between +, – terminals of the electrolytic capacitor (500µF) of C12 (with printed CAUTION HIGH

VOLT -

AGE) on P.C. board.

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Does outdoor

fan rotate?

YES

Replace

outdoor

fan motor.

Does LED on control

board flash or go on?

Remove connector

CN300 of outdoor fan

motor, and using a

tester, check

resistance value

between every phase

at motor side

YES

A B C

Operation

Measurement

Check

Stop

Check

Measurement

Turn on power breaker, and operate the air conditioner in COOL mode by short-circuit of the timer. Measure terminal voltage of the electrolytic capacity.

500mF: 400WV x 2

After operation, turn off the power breaker after 2 minutes 20 seconds passed, and discharge the electrolytic capacity by soldering iron. Check voltage between motor phases.

• Is not winding between 1-2, 2-3, or 1-3 opened or short-circuited?

• Is not frame grounded with 1, 2 or 3?

If 15A fuse is blown, discharge both edges of the electrolytic capacitor with soldering iron.

OK if 500µF

→

DC280 to 320V Remove CN300 by

pushing the part (an arrow indication) because CN01 is a connector with lock.

→

Resistance between phases should be approx. 55 to 77Ω

→

Should be 10MΩ or more

– 57 –

Page 59

FILE NO. SVM-04038

Diagnosis/Process flowchart Item

Check

compressor

winding

resistance.

B C

Replace control

board assembly.

Check

winding of

compressor.

Replace

com-

pressor.

Operation

Check

Contents

Check winding resistance between phases of compressor, and resistance between outdoor frames by using a tester.

• Is not grounded.

• Is not short-circuited

between windings.

• Winding is not opened. Remove connector

CN300 of the outdoor fan motor turn on the power breaker, and perform the operation. (Stops though activation is prompted.) Check operation within 2 minutes 20 seconds after activation stopped.

Summary

→

OK if 10MΩ or more →

OK if 0.51Ω

0.57Ω (Check by a digital tester.)

→

Replace control

board.

Replace

compressor.

10-8. How to Check Simply the Main Parts

10-8-1. How to check the P.C. board (Indoor unit) (1) Operating precautions

1) When removing the front panel or the P.C. board, be sure to shut off the power supply

breaker.

2) When removing the P.C. board, hold the edge

of the P.C. board and do not apply force to the parts.

3) When connecting or disconnecting the connec-

tors on the P.C. board, hold the whole housing. Do not pull at the lead wire.

(2) Inspection procedures

1) When a P.C. board is judged to be defective, check for disconnection, burning, or discoloration of the copper foil pattern or this P.C. board.

2) The P.C. board consists of the following 2 parts

a. Main P.C. board part:

DC power supply circuit (5V, 12V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer, and Driving circuit of top/ bottom louvers.

b. Indication unit of infrared ray receiving

Infrared ray receiving circuit, LED:

To check defect of the P.C. board, follow the procedure described below.

– 58 –

Page 60

FILE NO. SVM-04038

(3) Check procedures

Table 10-8-1

No. Procedure Check points (Symptom) Causes

1 Turn off the power supply and

remove the P.C. board assembly from electronic parts base. Remove the connecting cables from the terminal block.

2 Remove the connector of the motor

and turn on the power supply. If OPERATION lamp flashes (once per second), it is not necessary to check steps (1 to 3) in the right next column.

3 Push [START/STOP] button once to

start the unit. (Do not set the mode to Fan Only or On-Timer operation.)

4 Shorten the line of the restart delay

timer and start unit.

Check whether or not the fuse (F01) is blown.

Check power supply voltage :

1. Between TP2 and TP3 (AC 220-240V)

2. Between e and d (DC 310-340V)

3. Between d of C10 and output side of IC08 (DC 15V)

4. Between 12V and GND

5. Between 5V and GND

Check power supply voltage :

1. Between CN23 and CN24 (DC 15-60V)

Check whether or not all lamps (OPERATION, TIMER, PRE. DEF, FILTER and Hi POWER) are indicated for 3 seconds and they return to normal 3 seconds later.

Impulse voltage was applied or the indoor fan motor short-circuited.

1. The terminal block or the crossover cable is connected wrongly.

2. The capacitor (C01), line filter (L01), resistor (R01), or the diode (DB01) is defective.

3. IC01, IC02 and T01 are defective.

4. IC01, IC02, IC07 and T01 are defective.

<Heating and cooling model> IC03 and IC04 are defective.

The lamps are defective or the housing assembly (CN13) is defective.

5 Push [START/STOP] button once to

start the unit.

• Shorten the time of the restart delay timer.

• Set the operation mode to COOL.

• Set the fan speed level to AUTO.

• Set the preset temperature much

lower than the room temperature. (The unit (compressor) operates continuously in the above condition.)

6 If the above condition (No. 5) still

continues, start the unit in the following condition.

• Set the operation mode to HEAT.

• Set the preset temperature much

higher than room temperature.

7 Connect the motor connector to the

motor and turn on the power supply. Start the unit the following condition

• Set the operation mode to FAN.

• Set the fan speed lev el to HIGH.

(The unit (compressor) operates continuously in the above condition.)

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION lamp flashes.

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION lamp flashes.

1. Check it is impossible to detect the voltage (DC 15V) between 3 and 4 of the motor terminals.

2. The motor does not operate. (But it is possible to receive the signal from the remote controller.)

3. The motor rotates but vibrates strongly.

1. The temperature of the indoor heat exchanger is extremely low.

2. The connection of the heat exchanger sensor is loose. (The connector is disconnected.) (CN01)

3. The heat exchanger sensor and the P.C. board are defectiv e . (Refer to Table 10-4-1)

4. The main P.C. board is defective.

1. The temperature of the indoor heat exchanger is extremely high.

2. The connection of the heat exchanger sensor short-circuited (CN01)

3. The heat exchanger sensor and the P.C. board are defectiv e . (Refer to Table 10-4-1)

4. The main P.C. board is defective.

1. The indoor fan motor is defective (Protected operation of P.C. board.)

2. The connection or the motor connector is loose.

3. The P.C. board is defective.

– 59 –

Page 61

10-8-2. P.C. board layout MCC-867

FILE NO. SVM-04038

[1] Sensor characteristic table

100

90 80

70 60 50

40 30

Resistance value (kW)

20 10

100203040

Bottom View

(For the Top View, refer to page 66.)

TA, TC, TO , TE, TS

TD : Discharge temp. sensor TA : Room temp. sensor TC : Heat exchanger temp. sensor TO : Outdoor temp. sensor TE : Outdoor heat exchanger temp. sensor TS : Suction temp. sensor

Temperature (°C)

– 60 –

Page 62

10-8-3. Indoor unit (Other parts)

No. Part name Checking procedure

FILE NO. SVM-04038

1 Room temp. (TA) sensor

Heat exchanger (TC) sensor

2 Remote controller

3 Louver motor

MP24GA

4Indoor fan motor

10-8-4. Outdoor unit

Disconnect the connector and measure the resistance value with tester. (Normal temp.)

Temperature

Sensor

TA, TC (kΩ)

10°C 20°C 25°C 30°C 40°C

20.7 12.6 10.0 7.9 4.5

To item of How to judge whether remote controller is good or bad of the Judgement of trouble by symptom.

Measure the resistance value of each winding coil by using the tester. (Under normal temp. 25°C)

Position Resistance value

White

Yellow

Yellow Yellow Yellow

2 3 4 5

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

130±10Ω

Since judgement of DC motor is difficult on the single motor, refer to 10-5-1. (3).

No. Part name Checking procedure

1 Compressor

(Model : DA89X1C-23FZ)

Measure the resistance value of each winding by using the tester.

Red

Position Resistance value

Red - White 1.1Ω

White - Black 1.1Ω

Black - Red 1.1Ω

Position Resistance value

Red - White 720 ~ 920Ω

White - Black 410 ~ 510Ω

2 Outdoor fan motor

(Model : HF-240-20B-1)

White Black

Measure the resistance value of winding by using the tester.

Red

Black

White

1 33 55

Black

White

Black - Red 310 ~ 410Ω

For details, refer to Section 10-9.

3 Compressor thermo. Bimetal

Check conduction by using the tester.

type (Model : PW - 2AL)

4 Outdoor temperature sensor

(TO), outdoor heat exchanger temperature sensor (TE)

Disconnect the connector, and measure resistance value with the tester. (Normal temperature)

TGa : Heat pump model only.

Under 20°C

At 20°C

TO, TE : Refer to the TA, TC characteristic table in Indoor (Refer to Table 10-8-3, No.1).

– 61 –

Page 63

10-8-5. Checking method for each part

Mark

No. Part name Checking procedure

FILE NO. SVM-04038

1 Electrolytic capacitor (For

raising pressure, smoothing)

2 Rectifier

1. Turn OFF the power supply breaker.

2. Discharge all four capacitors completely.

3. Check that safety valve at the bottom of capacitor is not broken.

4. Check that vessel is not swollen or exploded.

5. Check that electrolytic liquid does not blow off.

6. Check that the tester shows the normal charging characteristics in continuity test.

C12

C13

Heat sink IGBT side

MCC-866 Soldered surface

Case that product is good

Pointer swings once, and returns slowly. When performing test once again under another polarity, the pointer should return.

C12, C13 → 500µF/400V

1. Turn OFF the power supply breaker.

2. Discharge all four capacitors completely.

3. Check that the normal rectification characteristics are show in continuity test by the tester.

Diode check

Tester rod

Resistance value

in good product

50kΩ or more

(0Ω in trouble)

– 62 –

Page 64

FILE NO. SVM-04038

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

1. Symptom

• Outdoor fan motor does not rotate.

• Outdoor fan motor stops within several ten seconds though it starts rotating.

• Outdoor fan motor rotates or does not rotate according to the position where the fan stopped., etc.

2. Cause

The following causes are considered when the outdoor fan motor does not normally rotate.

1) Mechanical lock of the outdoor fan motor

2) Winding error of the outdoor fan motor

3) Motor drive circuit error of the outdoor P.C. board

3. How to simply judge whether outdoor fan motor is good or bad

Turn OFF the breaker.

Disconnect two connectors (CN300)

of the outdoor fan motor from the inverter.

Does the fan rotate without trouble

when rotating it with hands?

YES

If the resistance value between the connector

(CN300 : Motor winding) is 70 to 150Ω, it is normal.

YES

Fan motor is normal.

(Outdoor P.C. board error)

CN300

Fan motor error

NOTE :

However, GND circuit error inside of the motor may be accepted in some cases when the above check is performed. When the fan motor does not become normal even if P.C. board is replaced the outdoor fan motor.

– 63 –

Page 65

FILE NO. SVM-04038

6 Screw

2 4-Screws

2 2

11. HOW TO REPLACE THE MAIN PARTS

11-1. Indoor Unit

No. Part name Procedures Remarks

1 Front panel

2 Electrical part

How to remove the front panel

1) Stop operation of the air conditioner and turn off its main power supply.

2) Pull the air inlet grille toward you to open it and remove the air inlet grille. Then remove the 4 screws fixing the front panel.

3) First open the horizontal louver, and then remove the front panel from the back body by pulling it toward you.

How to mount the front panel

Push the front panel back in and make sure all hooks are locked.

How to remove the electrical part.

1) Remove the front panel with procedure 1.

2) Remove the screw holding the electrical part cover.

3) Remove the drain guide.

4) Disconnect the 2 connectors (3P) for the fan motor and the connector (5P) for the louver motor from the P.C. board assembly.

5) Pull out the TC sensor from the sensor holder.

6) Remove the screw for the ground connection, remove the screw for the electrical part box and remove the screw from the LED unit. Then remove the LED unit and the electrical part box from the main unit.

How to mount the electrical part.

1) To put back the electrical part box, lock it to the upper hook of the back body.

2) Tighten the screw on the electrical part box.

3) Connect the 3 connectors and arrange the wiring same as original condition and then tighten the screw from the LED unit to the back body.

4) Attach the TC sensor to the holder.

5) Tighten the screw for the ground connection.

6) Assemble the drain guide (the TC sensor wire should be covered by the drain guide).

Tighten the screw on the electrical part cover.

3 Drain guide

6 Screws

2 Screws

5 TC Sensor

3-Connectors

3 Horizontal

louver

1) Remove the front panel and the electrical part following procedure 2.

2) Remove the center shaft of the horizontal louver from the back body.

3) Remove the left shaft from the back body.

4) Remove the horizontal louver from the back body.

– 64 –

3 Left shaft

2 Center shaft

Page 66

FILE NO. SVM-04038

3 2-Screws

No. Part name Procedures Remarks

4 Heat exchanger

5 Cross flow fan

1) Remove the front panel, electrical part and the horizontal louver following procedure 3.

2) Remove the pipe holder at the rear side of main unit.

3) Remove the 2 screws on the heat exchanger at the base bearing.

4) Remove the 2 screws on the heat exchanger at the 2 fixed plates (upper and lower) from the back body, and then pull out the upper side of the heat exchanger slowly.

1) Remove the front panel, electrical part, horizontal louver and the heat exchanger following procedure 4.

2) Remove the 2 screws on the band motor (L) and remove the 2 screws on the band motor (R) and then remove the cross flow fan.

3) Loosen the set screw of the cross flow fan then separate the fan and the fan motor.

2 Pipe holder

4 2-Screws

2 2-Screws (R)

2 2-Screws (L)

6 mm

6 Base bearing

Notice

To assemble cross flow fan and fan motor to the unit, please turn the fan motor unit the center of its terminal meets the lowest point of band motor (R) (point A). Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is 6 mm.

1) Remove the front panel, electrical part, horizontal louver, heat exchanger and the cross flow fan following procedure 5.

2) Remove the 2 screws fixing the base bearing.

3) Remove the bearing from the base bearing. If the housing protrudes from the base bearing, put the housing in position and attach the bearing to the base bearing.

3 Set screws

Middle of the fan motor terminal

2 2-Screws

– 65 –

Page 67

FILE NO. SVM-04038

11-2. Microcomputer

No. Part name Procedures Remarks

1 Common

procedure

<P.C. board layout> MCC-867

1) Turn the power supply off to stop the operation of air conditioner.

2) Remove the front panel.

• Remove the 4 fixing scre ws.

(∅4 x 14s)

3) Remove the Electric parts cover.

Replace the thermal fuse, terminal block, microcomputer ass’y and the P.C. board ass’y

T op View

– 66 –

Page 68

FILE NO. SVM-04038

11-3. Outdoor Unit

No. Part name Procedures Remarks

1 Common

procedure

1. Detachment

1) Stop operation of the air conditioner, and turn off the main switch and breaker of the air conditioner.

2) Remove the valve cover. (ST1T∅4 x 10s 1 pc.)

• After removing screw, remove the valve

cover pulling it downward.

3) Remove the wiring cover (ST1T∅4 x 10s 1 pc.), and then remove the power cord, connecting cable, and cord clamp (ST1T∅4 x 10s 4 pcs.).

4) Remove the upper cabinet. (ST1T∅4 x 10s 4 pcs.)

• After removing screws, remove the

upper cabinet pulling it upward.

2. Attachment

1) Attach the upper cabinet. (ST1T∅4 x 10s 4 pcs.)

• Hook the rear side of the upper cabinet

to the claw of the rear cabinet, and then place it on the front cabinet.

2) After connecting the power cord and connecting cable, attach the cord clamp and wiring cover.

• Insert the upper part into the upper

cabinet, and insert the claw which has been hooked to the lower part into the square hole, and then fix it with screw. (ST1T∅4 x 10s 1 pc.)

Attach the valve cover. (ST1T∅4 x 10s 1 pc.)

• Insert the upper part to the upper

cabinet, set the hook claw of the valve cover to square holes (at three positions) of the main unit, and attach it pushing upward.

Upper cabinet

Wiring cover

Valve cover

Upper cabinet

2 Front cabinet

1. Detachment

1) Perform work of item 1 of 1.

2) Remove upper screw (ST1T∅4 x 10s 1 pc.) of the front cabinet, and lower screws (ST1T∅4 x 10s 3 pcs.) of the front cabinet.

• The left side of the front is for inserting

to the rear cabinet, so remove it pulling upward.

2. Attachment

1) Insert the claw at the left side of the front into the rear cabinet.

2) Attach the removed screws to the original positions.

– 67 –

Page 69

FILE NO. SVM-04038

No. Part name Procedures Remarks

3 Inverter

assembly

1) Perform work of item 1 of 1.

2) Remove screw (ST1T∅4 x 10s 1 pc.) of the upper part of the front cabinet.

• If removing the inverter cover in this

condition, the P.C. board can be checked.

• If there is no space in the upper part of

the upper cabinet, perform work of 2.

Be careful when checking the inverter because high-voltage circuit is incorporated in it.

3) Perform discharging by connecting the e,d polarities by discharging resistance (approx. 100Ω40W) or plug of soldering iron to e,d terminals of the C13 (printed “CAUTION HIGH VOLTAGE” is attached.) electrolytic capacitor (500 µF/330 WV) on the P.C. board.

Be careful to discharge the capacitor because the electrolytic capacitor cannot naturally discharge and voltage remains depending on the malfunction state in some cases.

Discharging time (Discharging period 10 seconds or more)

Inverter cover

PC board (Soldered surface)

Plug of soldering iron

NOTE : This capacitor has mass capacity. Therefore, it is dangerous that a large spark generates if shortcircuiting between the e,d polarities with screwdriver, etc. for discharging.

4) Perform the work of 2.

5) Remove the screw (ST1T∅4 x 10s 1 pc.) fixing the main body and the inverter box.

6) Remove the lead wire from the holder on the terminal block.

7) Disconnect the connectors of various lead wires.

Requirement : As each connector has a lock mechanism, avoid removing the connector by holding the lead wire, but by holding the connector.

Holder

Terminal

Partition

block

The connector is one with lock, so remove it while pushing the part indicated by an arrow.

– 68 –

Be sure to remove the connector by holding the connector, not by pulling the lead wire.

Page 70

FILE NO. SVM-04038

P.C. board support

P.C. board

Remove

Inverter box

No. Part name Procedures Remarks

4 Control board

assembly

1) Disconnect lead wires and connectors

connected from the control board assembly to other parts.

1. Lead wires

• Connection with terminal block : 3 wires (Black, White, Orange)

• Connection with compressor : remove the connector (3P)

• Connection with reactor : remove the connector (2P)

2. Connectors (6 positions) CN300 : Outdoor fan (3P: white)*

(See Note 1) CN701 : 4 way valve (3P: Yellow)* CN601 : TD sensor (2P: White) CN602 : TO sensor (2P: White) CN500 : Case thermo (2P: White) ∗ Note 1) As the connector has a

stopper, release the housing lock when removing.

∗∗Note 2) Hold the housing (resin part)

with stopper and pull out to remove.

2) Remove the screws fixing the control board assembly and inverter box.

3) Remove the control board assembly from the inverter box.

Note 3) Remove the claw of the

board support fixed to the inverter board, and remove upwards holding the heat sink.

4) Remove the three screws fixing the heat sink and control board assembly.

5) Attach the new control board assembly.

Note 4) When attaching the new

control board assembly, insert the P.C. board into the guide rail groove correctly.

CN602

CN601

CN300 CN701

CN500

As CN300 and CN701 are connectors with lock, remove while pushing the part indicated by an arrow

P.C. board

Guide rail

5 Rear cabinet

1) Perform work of item 1 of 1, 1 of 2 and 5 of 3.

2) Remove the fixed screws fixing to the base plate. (ST1T∅4 x 10s 3 pcs.)

3) Remove the fixed screws fixing the heat exchanger. (ST1T∅4 x 10s 2 pcs.)

4) Remove the upper surface of the motor base and the rear cabinet.

• Insert a minus driver into the tip of the hooking claw of the rear cabinet to remove.

– 69 –

Minus screwdriver

Claw for hooking

Rear cabinet

Motor base

Page 71

FILE NO. SVM-04038

No. Part name Procedures Remarks

6 Fan motor

7 Compressor

1) Perform work of item 1 of 1 and 1 of 2.

2) Remove the flange nut fixing the fan motor and the propeller fan.

• Flange nut is loosened by turning

clockwise. (To tighten the flange nut, turn counterclockwise.)

3) Remove the propeller fan.

4) Disconnect the connector for the fan motor from the inverter .

5) Remove the fixing screws (3 pcs.) holding the fan motor by hand so that it does not fall.

6) Cut the motor lead at the point which is 100 mm apart from the connector toward the fan.

7) Use the connector used for the inverter, and pinch the lead wires using the closed end splice.

Perform work of item 1 of 1 and 5

, 1 of 2,

2) Extract refrigerant gas.

3) Remove the partition board. (ST1T∅4 x 10s 3 pcs.)

4) Remove the sound-insulation material.

5) Remove the terminal cover of the compressor, and disconnect the lead wire of the compressor thermo and the compressor from the terminal.

6) Remove the pipe connected to the compressor with a burner.

• Make sure the flame does not touch the

4 way valve.

7) Remove the fixing screw of the base plate and heat exchanger. (ST1T∅4 x 10s 1 pc.)

8) Pull upward the refrigeration cycle.

9) Remove the nut fixing the compressor to the base plate.

Propeller fan

Flange nut

Fan motor

Compressor

100

Closed end splice

8 Reactor

1) Perform work of item 1 of 1, 1 of 2, and 3.

2) Remove the screw fixing the reactor. (SHOULDER SCREW x 4 pcs.)

– 70 –

Reactor

Page 72

FILE NO. SVM-04038

No. Part name Procedures Remarks

9 Fan guard

1. Detachment

1) Perform work of item 1 of 1 and 1 of 2.

Requirement: Perform the work on a corrugated cardboard, cloth, etc. to prevent scratches to the product.

2) Remove the front cabinet, and place it down so that the fan guard side faces downwards.

3) Remove the hooking claws by pushing a minus screwdriver according to the arrow mark in the right figure, and remove the fan guard.

2. Attachment

1) Insert the claws of the fan guard in the hole of the front cabinet. Push the hooking claws (12 positions) by your hand and fix the claws.

Requirement: This completes all the attaching work. Check that all the hooking claws are fixed to the specified positions.

Minus screwdriver

Hooking claw

– 71 –

Page 73

FILE NO. SVM-04038

No. Part name Procedures Remarks

! Replacement of

temperature sensor for servicing only

Common service parts of sensor TO , TS, TE, TD

Cut the sensor 100 mm longer than old one.

2) Cut the protective tube after pulling out it

(200 mm).

3) Move the protective tube toward the

thermal sensor side and tear the tip of lead wire in two, then strip the covering part.

4) Pass the stripped part through the ther-

mal constringent tube.

5) Cut the old sensor 100 mm length on the

connector side, and recycle that connector.

6) Tear the lead wire in two on the connector

side and strip and covering part.

7) Twist the leads on the connector and

sensor sides, and solder them.

8) Move the thermal constringent tubes

toward the soldered parts and heat them with the dryer and constring them.

9) Wind the attached color tape round the

both terminals of the protective tube when colored protective tube is used.

10) Fix the sensor again.

NOTES:

1) Store the joint part of the sensor and the connector in the electric parts box.

2) Never joint them near the thermal sensor part. Otherwise, it would cause insulation inferiority because of dew drops.

3) When replacing the sensor using the colored protective tube, wind the color tape matching the color of that tube.

Thermal sensor part

200

Winding the color tape

Cutting here

Connector

Thermal constringent tube

Cutting here

100

Soldered part

Dryer

100

Cutting here

These are parts for servicing sensors. Please check that the accessories shown in the right table are packed.

Part name Q’ty Remarks

1 Sensor 1 Length: 3 m 2 Sensor Spring (A) 1 For spare 3 Sensor Spring (B) 1 For spare 4 Thermal constringent tube 3 Including one spare 5 Color tape 1 9 colors 6 Terminal 3

– 72 –

Page 74

<P.C. board layout> MCC-866

FILE NO. SVM-04038

– 73 –

Page 75

12. EXPLODED VIEWS AND PARTS LIST

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

405

403

FILE NO. SVM-04038

406

402

404

Location Part

No. No.

401 43T69319 Temperature Sensor, TC 10kΩ 25°C 402 43T60001 Terminal, 2P AC300V, 20A 403 43T69320 Temperature Sensor, TA 10kΩ 25°C

Description

401

Location Part

No. No.

404 43T62003 Cord Clamp 405 43T69079 P.C. Board ASSY, WRS-LED 406 43T69321 P.C. Board , MCC-867

Description

– 74 –

Page 76

12-2. Indoor Unit

212

210

201

211

215

205

218

219

217

220

216

217

208

FILE NO. SVM-04038

214

225

203

204

202

234

206

Location Part

No. No.

20143T00391

Front Panel Assy

Description

202 43T09335 Inlet Grille Assy

203 43T03302 Back Body Assy

204 43T80301 Air Filter

205 43T09328 Horizontal Louver

206 43T08392 LED Panel Assy

207 43T70002 Drain Hose

208 43T79301 Cap Drain

209 43T21321 Motor, Louver, MP24Z, DC 12V

210 43T44320 Refrigeration Cycle Assy

211 43T47006 Pipe, Delivery ∅6.35

212 43T47305 Pipe, Suction ∅8

214 43T11301 Pipe Shield

215 43T19302 Holder Sensor

216 43T49302 Plate of EVA Seal

217 43T49006 Holder, Plate EVA Seal

218 43T79302 Guide Drain

219 43T22002 Bearing

220 43T39301 Base, Bearing

204

228

229

LocationPart

No. No.

221 43T20302 Cross Flow Fan

222 43T39302 Band Motor-L

223 43T21327 Motor, Fan, ICF-340-30-2, DC 340V

224 43T39303 Band Motor-R

225 43T82301 Plate, Installation

226 43T69309 Remote Controller, Wireless

227 43T83003 Holder Remote Controller

228 43T85410 Owner's Manual 228 43T85411 Owner's Manual

228 43T85412 Owner's Manual 228 43T85413 Owner's Manual 228 43T85414 Owner's Manual

228 43T85424 Owner's Manual 229 43T62302 Terminal Cover

231 43T60317 Cord Motor Louver

232 43T60316 Cord Motor Fan

233 43T07303 Holder Pipe

234 43T01003 Mark

226

227

221

Electric Parts

Assembly

WH-H2UE

207

233

209

231

232

Description

222

223

224

− 75 −

Page 77

12-3. Outdoor Unit

FILE NO. SVM-04038

25,26

10,1 1 08,09

07 : Capillary Tube

Location Part

No. No.

01 43T19313 Guard, Fan 02 43T20306 Fan, Propeller 03 43T00362 Cabinet, Front, Assy 04 43T43323 Condenser, Assy 0543T62309Terminal Cover 06 43T00363 Cabinet, Back, Assy 07 43T47308 Tube, Capillary, I.D. 1.0 08 43T46011 Valve, Packed 9.52 0943T47332 Bonnet, 9.52 DIA 1043T46308 Valve, Packed 6.35 1143T47331 Bonnet, 6.35 DIA 1243T21337 Motor, Fan 1343T47001Nut, Flange

Description

Location Part

No. No.

14 43T19312 Handle 15 43T49001 Cushion, Rubber 1643T63308 Cover, Gasket 17 43T54304 Thermostat, Bimetal, PW2AL 1843T41358 Compressor, DA89X1C-23FZ 19 43T62305 Cover, Packed Valve 20 43T00364 Cabinet, Upper, Assy 21 43T63301 Fixing Plate Valve, Assy 22 43T42302 Base, Assy 23 43T79305 Nipple, Drain 24 43T46313 Reactor 2543T46321 Valve, 4-way 2643T46327 Coil, 4-way, Assy

– 76 –

Description

Page 78

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

FILE NO. SVM-04038

701

707

702

703

704

Sensor (˘6)

706

705

Location Part

No. No.

701 43T62306 Invertor Cover 702 43T62307 Heatsink 70343T69396P.C. Board, MCC-866 704 43T62308 Invertor Box 70543T60352 Terminal Box ; 6P, 30A, 600V

Description

Location Part

No. No.

706 43T60315 Fuse, 15A, 250V 70743T50304Temperature Sensor,

70743T50304Temperature Sensor,

– 77 –

Description

TE, 10KΩ, 25°C

TO , 10KΩ, 25°C

Page 79

FILE NO. SVM-02007

TOSHIBA CARRIER CORPORATION

– 78 –

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

Specifications and Main Features

Frequently Asked Questions

User Manual

1. SPECIFICATIONS

3. CONSTR UCTION VIEWS

4. WIRING DIAGRAM

4-2. Outdoor Unit

5. SPECIFICATION OF ELECTRICAL PARTS

6. REFRIGERANT CYCLE DIAGRAM

7. CONTROL BLOCK DIAGRAM

8. OPERATION DESCRIPTION

8-3. T emporary Operation

8-4. Auto Restart Function

8-7. Remote control

9. INSTALLATION PROCEDURE

10. HOW TO DIAGNOSE THE TROUBLE

10-4-2. Caution at servicing

10-5. Judgement of Trouble by Every Symptom

10-7. How to Diagnose Trouble in Outdoor Unit

10-8-3. Indoor unit (Other parts)

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

11. HOW TO REPLACE THE MAIN PARTS

12. EXPLODED VIEWS AND PARTS LIST