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

FILE NO. SVM-04038

SERVICE MANUAL

AIR-CONDITIONER

SPLIT WALL TYPE

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

FILE NO. SVM-004038

CONTENTS

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

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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FILE NO. SVM-04038

10.HOW TO DIAGNOSE THE TROUBLE

10-1. First Confirmation

10-2. Primary Judgement

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

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

10-8. How to Check Simply the Main Parts

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

11.HOW TO REPLACE THE MAIN PARTS

11-1. Indoor Unit

11-2. Microcomputer

11-3. Outdoor Unit

12.EXPLODED VIEWS AND PARTS LIST

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

12-2. Indoor Unit

12-3. Outdoor Unit

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

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								FILE NO. SVM-04038
				1. SPECIFICATIONS
1-1. Specifications
Unit model		Indoor						RAS-10UKV-E3
		Outdoor						RAS-10UAV-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
				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
COP (Cooling / Heating)									3.29
Operation noise		Indoor		High	(Cooling / Heating)	(dB• A)		38/39
				Low	(Cooling / Heating)	(dB• A)		27/29
		Outdoor		(Cooling / Heating)		(dB• A)		46/47
Indoor unit		Unit model						RAS-10UKV-E3
		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
Outdoor unit		Unit model						RAS-10UAV-E3
		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
Piping connection		Type						Flare connection
		Indoor unit		Liquid side					6.35
				Gas side					9.52
		Outdoor unit		Liquid side					6.35
				Gas side					9.52
		Maximum length (Per unit)				(m)			10
		Maximum chargeless length				(m)			10
		Maximum height difference				(m)			8
Refrigerant		Name of refrigerant						R-410A
		Weight				(kg)			0.64
Wiring connection				Power supply			3 Wires: includes earth
				Interconnection			4 Wires: includes earth
Usable temperature range				Indoor	(Cooling / Heating)	(°C)		21 – 32 / 0 – 28
				Outdoor	(Cooling / Heating)	(°C)		10 – 43 / –10 – 24
Accessory		Indoor unit		Installation plate					1
				Wireless remote control					1
				Remote controller holder					1
				Flat head wood screw				2 ( 3.1 x 16L)
				Bioenzyme filter					1
				Zeolite filter					1
				Batteries					2
				Mounting screw				6 (	4 x 25L)
				Installation manual					1
				Owner’s manual					1
		Outdoor unit		Drain nipple					1

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

–3 –

1-2. Operation Characteristic Curve

<Cooling>
	7
	6
	5
(A)	4
Current	3
	2
				a Conditions
				Indoor : DB 27° C/WB 19° C
	1			Outdoor : DB 35° C
				Air flow : High
				Pipe lengthh : 5m
				230V
	0
	0	20	40	60	80	100

Compressor speed (rps)

FILE NO. SVM-04038

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

Compressor speed (rps)

1-3. Capacity Variation Ratio According to Temperature
<Cooling>			<Heating>
	105			120
	100	Current Limited Start		110
	95			100
	90			90
(%)	85		(%)	80
ratio	80		ratio	70
Capacity	75		Capacity	60
	70			50
	65			40
	60	a Conditions		30	a Conditions
		Indoor : DB 27° C/WB 19° C			Indoor : DB 20° C
	55	Indoor air flow : High		20	Indoor air flow : High
		Pipe lengthh 5m			Pipe lengthh : 5m
	50			10
		32 33 34 35 36 37 38 39 40 41 42 43		-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

Outdoor temp. (° C)

Outdoor temp. (° C)

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

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FILE NO. SVM-04038

2. REFRIGERANT R-410A

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

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

Table 2-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter	Outer diameter (mm)	R-410A	R-22
1/4	6.35	0.80	0.80
3/8	9.52	0.80	0.80
1/2	12.70	0.80	0.80
5/8	15.88	1.00	1.00

(2)Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a)Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 2-2-3 to 2-2-6 below.

b)Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm.

Thicknesses of socket joints are as shown in Table 2-2-2.

Table 2-2-2 Minim um thicknesses of soc ket joints

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

2-2-1. Processing of piping materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

(1)Flare Processing Procedures and Precautions

a)Cutting the Pipe

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

b)Removing Burrs and Chips

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

c)Insertion of Flare Nut

d)Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perform the flare processing correctly.

Use either a flare tool for R-410A or conventional flare tool.

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

D

A

Fig. 2-2-1 Flare pr ocessing dimensions

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										FILE NO. SVM-04038
	Table 2-2-3 Dimensions related to flare pr ocessing f or R-410A
	Outer							A (mm)
Nominal		Thickness
	diameter		Flare tool for R-410A						Conventional flare tool
diameter		(mm)
	(mm)
			clutch type					Clutch type				Wing nut type
1/4	6.35	0.8		0 to 0.5					1.0 to 1.5			1.5 to 2.0
3/8	9.52	0.8		0 to 0.5					1.0 to 1.5			1.5 to 2.0
1/2	12.70	0.8		0 to 0.5					1.0 to 1.5			2.0 to 2.5
5/8	15.88	1.0		0 to 0.5					1.0 to 1.5			2.0 to 2.5
	Table 2-2-4 Dimensions related to flare pr ocessing f or R-22
	Outer							A (mm)
Nominal		Thickness
	diameter		Flare tool for R-410A						Conventional flare tool
diameter		(mm)
	(mm)
			clutch type					Clutch type				Wing nut type
1/4	6.35	0.8		0 to 0.5					0.5 to 1.0			1.0 to 1.5
3/8	9.52	0.8		0 to 0.5					0.5 to 1.0			1.0 to 1.5
1/2	12.70	0.8		0 to 0.5					0.5 to 1.0			1.0 to 2.0
5/8	15.88	1.0		0 to 0.5					0.5 to 1.0			1.0 to 2.0
	Table 2-2-5 Flare and flare n ut dimensions for R-410A
Nominal	Outer	Thickness			Dimension (mm)							Flare n ut
	diameter											width
diameter		(mm)	A		B			C		D
	(mm)											(mm)
1/4	6.35	0.8	9.1		9.2		6.5			13	17
3/8	9.52	0.8	13.2		13.5		9.7			20	22
1/2	12.70	0.8	16.6		16.0		12.9			23	26
5/8	15.88	1.0	19.7		19.0		16.0			25	29
	Table 2-2-6 Flare and flare n ut dimensions for R-22
Nominal	Outer	Thickness			Dimension (mm)							Flare n ut
	diameter											width
diameter		(mm)	A		B			C		D
	(mm)											(mm)
1/4	6.35	0.8	9.0		9.2		6.5			13	17
3/8	9.52	0.8	13.0		13.5		9.7			20	22
1/2	12.70	0.8	16.2		16.0		12.9			20	24
5/8	15.88	1.0	19.7		19.0		16.0			23	27
3/4	19.05	1.0	23.3		24.0		19.2			34	36

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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.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 2-2-7 shows reference values.

Note:

When applying oil to the flare surface, be sure to use oil designated by the manufacturer. If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

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

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

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FILE NO. SVM-04038

2-3. Tools

2-3-1. Required tools

The service port diameter of packed valve of the outdoor unit in the air conditioner using R-410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For 12.70 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

(1)Tools exclusive for R-410A (Those which cannot be used for conventional refrigerant (R-22))

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

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

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

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

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

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

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

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

General tools (Conventional tools can be used.)

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

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

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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.

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

Connect the charge hose of the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

When the compound gauge’s pointer has indicated -0.1 Mpa (-76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant.

Place the handle of the gauge manifold Low in	(For refrigerant charging, see the figure below.)
the fully opened position, and turn on the vacuum
pump’s power switch. Then, evacuating the
refrigerant in the cycle.

1 Never charge refrigerant exceeding the specified amount.

2 If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3 Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

(INDOOR unit)

(Liquid side)

(OUTDOOR unit)

Opened

(Gas side)

Refrigerant cylinder (With siphon pipe)

Check valve

Closed

Open/Close valve for charging

Service port

Electronic balance for refrigerant charging

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

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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 without siphon]
Gauge manifold	Gauge manifold
OUTDOOR unit	OUTDOOR unit

Refrigerant Refrigerant cylinder

cylinder

Electronic	Electronic
balance	balance

Siphon

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

Fig. 2-4-2

2-5. Brazing of Pipes

2-5-1. Materials f or brazing

(1)Silver brazing filler

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

(2)Phosphor bronze brazing filler

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

(3)Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes.

1 Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2 When performing brazing again at time of servicing, use the same type of brazing filler.

2-5-2. Flux

(1)Reason why flux is necessar y

•By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

•In the brazing process, it prevents the metal surface from being oxidized.

•By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal.

– 11 –

(2)Characteristics required f or flux

•Activated temperature of flux coincides with the brazing temperature.

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

•It is easy to remove slag after brazing.

•The corrosive action to the treated metal and brazing filler is minimum.

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

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

(3)Types of flux

•Non-corrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 800°C.

•Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

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

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

1Do not enter flux into the refrigeration cycle.

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

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

4Remove the flux after brazing.

FILE NO. SVM-04038

2-5-3. Brazing

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

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

Never use gas other than Nitr ogen gas.

(1)Brazing method to prevent oxidation

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

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

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

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

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

6After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7Remove the flux completely after brazing.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe Nitrogen gas

Rubber plug

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

– 12 –

FILE NO. SVM-04038

3. CONSTR UCTION VIEWS

3-1. Indoor Unit

Front panel	Air inlet	Air filter	Heat exchanger
Back body		790	208

275

6 60

		60
Air outlet	48	6

Knock out system

Knock out system

48

	64	53
120	590	80
	Hanger

Drain hose (0.54m)

Hanger

		45
		Minimum
		distance
	275	to ceiling
		170 or more

90 150

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

Installation plate outline

Center line

– 13 –

FILE NO. SVM-04038

3-2. Outdoor Unit

A Detail Drawing (Back Leg)

660

			50	R 15
	6 Hole		36
	273.5	265		R 5.5

530

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

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

			Liquid side
			(Flare	6.35)
			Gas side
	126	48	(Flare	12.7)
			54
	Z View		Service port
Installation dimension
100 or more	600
	Air inlet 600 or more
325
100 or more	600 or more 4x 11x14 Long holes (for 8- 10 anchor bolt)
Air outlet

– 14 –

FILE NO. SVM-04038

4. WIRING DIAGRAM

4-1. Indoor Unit

or MCC-5014

		Table 4-1-1 Simple Check for Failure Diagnosis
		Check Item	Diagnosis Result
		OPERATION	Check if the OPERATION indicator goes on and off when the
	1		main switch or breaker is turned on.
		INDICATOR
			(Check the primary and secondary voltage of the transformer.)
			Check the power supply voltage between 1 and 2.
		TERMINAL	(Refer to the name plate.)
	2
		BLOCK	(Check the primary and secondary voltage of the transformer.)
			Check the fluctuating voltage between 2 and 3. (15~60VDC)
		FUSE	Check if the fuse blows out.
	3
		3.15A	(Check the R04 of the varistor.)
			Check the voltage at the No. 4 pin on CN13 connector of the
		DC5V	infrared receiver.
	4		(Check the transformer and the power supply circuit of the
			rated voltage.)
	5		Check the voltage at the white lead of the louver motor.
		DC12V	(Check the transformer and the power supply circuit of the
			rated voltage.)
		DC325V	Check the voltage at the No. 1 pin on CN10 connector.
	6		(Check the DB01, R05 and C03.)
		(DC310~340V)

Refer to the service data for the detailed failure diagnosis.

– 15 –

FILE NO. SVM-04038

4-2. Outdoor Unit

TE

TO

COIL FOR

4 WAY VALVE

THERMOSTAT

FOR COMPRESSOR

1 2

1 2

REACTOR

1 2

1

3

1 2

1 2

1 2

1

3

POWER

CN600

CN602

CN08

CN07

CN701

P06

CN500

SUPPLY

CT

REALY

SURGE

220-240V~

50/60Hz

ABSORBER

F01

POWER RELAY

VARISTOR

FUSE

N

P09

15A

CN01

BLK

L

BRW

CN03

ORN

P10

3

TO

2

INDOOR

P11

ELECTRONIC STARTER

CN02

WHI

1

UNIT

PUR

P12

+

C12

C13

F04

RECTIFIER

~

FUSE

~

T3.15A

_

SWITCHING

DB01

TRANSFORMER

P15

YEL

P16

CN300

1 1

RED

+

RELAY

BLK

FM

BU

3 3

C301

EU

5 5

WHI

MODULE

FAN

BV

EV

MOTOR

BW

P.C.BOARD

EW

IGBT

(MCC-866)

BX

BY

BZ

Q200

-

CN17

RED

P14

1

1

CN18

WHI

BLU

2

2

CM

CN19

BLK

3

3

P13

COMPRESSOR

COLOR IDENTIFICATION

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

– 16 –

									FILE NO. SVM-04038
		5. SPECIFICATION OF ELECTRICAL PARTS
	5-1. Indoor Unit
	No.	Parts name			Type			Specifications
	1	Fan motor (for indoor)			ICF-340-30-2		DC 340V, 30W
	2	Thermo. sensor (TA-sensor)			———		10k at 25°C
	3	DC-DC transformer (T01)			SWT-70		DC 390V, Secondary DC 15V, 12V, 7V
	4	Microcomputer			———
	5	Heat exchanger temp.			———		10k at 25°C
		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
	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
	6	Outside air temp.			(Inverter attached)			10k	(25°C)
		sensor (TO sensor)
	7	Heat exchanger temp.			(Inverter attached)			10k	(25°C)
		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
	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 –

FILE NO. SVM-04038

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

T1 Temp. measurement

INDOOR UNIT

P Pressure measurement

Gauge attaching port

Vacuum pump connecting port

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

Indoor heat

exchanger

Cross flow fan

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

Sectional shape of heat insulator

	Allowable height difference : 8m	Allowable pipe length

Max. :10m

4-way valve (VT7101D)

Muffler

TD

Compressor

DA89X1C-23FZ

TS

Outdoor heat

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

Note :

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

– 18 –

FILE NO. SVM-04038

6-2. Operation Data

<Cooling>

	Temperature		Model	Standard	Heat exchanger		Indoor	Outdoor	Compressor
	condition (°C)				pipe temp.
				pressure			fan	fan	revolution
			name
	Indoor	Outdoor		P (MPa)	T1 (°C)	T2 (°C)	mode	mode	(rps)
	27/19	35/–	10UKV-E3	1.1	13.5	49	High	High	54
	<Heating>
	Temperature		Model	Standard	Heat exchanger		Indoor	Outdoor	Compressor
	condition (°C)				pipe temp.
				pressure			fan	fan	revolution
			name
	Indoor	Outdoor		P (MPa)	T1 (°C)	T2 (°C)	mode	mode	(rps)
	20/–	7/6	10UKV-E3	2.4	40	0	High	High	70

Note :

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

(2)Connecting piping condition : 5m

– 19 –

FILE NO. SVM-04038

7. CONTROL BLOCK DIAGRAM

7-1. Indoor Unit

Indoor Unit Control Panel

M.C.U.

Functions

Heat Exchanger Sensor

Operation

•

Louver Control

Display

•

Timer

Temperature Sensor

3-minute Delay at Restart for Compressor

Display

•

Motor Revolution Control

Filter Sign

Infrared Rays Signal Receiver

Display

•

PRE DEF.

Initiallizing Circuit

Processing

Sign Display

Infrared

(Temperature Processing)

Rays

Clock Frequency

•

Timer

Hi Power

Sign Display

36.7KHz

Oscillator Circuit

•

Serial Signal Communication

Indoor Fan

Motor

Power Supply

Louver ON/OFF Signal

Remote

Circuit

Control

Noise Filter

Louver Driver

Louver Motor

Serial Signal Transmitter/Receiver

From Outdoor Unit

Serial Signal Communication

Infrared

Rays

REMOTE CONTROL

Remote Control

Operation (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 –

FILE NO. SVM-04038

7-2. Outdoor Unit (Inverter Assembly)

Compressor

For indoor unit

P.C.B (MCC-866)

Inverter (DC AC)

Gatedrive circuit

Over current sensor

Input Converter current (AC DC) sensor

Highpowerfactor correctioncircuit

Noise

filter

1

230V50Hz

Rotorposition

detectcircuit

Relay

Fan

motor

Relay

4way Valve

M.C.U

1.PWMsynthesisfunction 2.Inputcurrentreleasecontrol 3.IGBTover-currentdetectcontrol 4.Outdoorfancontrol 5.Highpowerfactorcorrectioncontrol 6.SignalcommunicationtoindoorunitM.C.U

signal

Gassidepipe temp.sensor

Outdoorair temp.sensor

– 21 –

FILE NO. SVM-04038

8. OPERATION DESCRIPTION

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	Operations followed
		control
	•		to judgement of serial
		Operation control of
			signal from indoor
		outdoor fan motor
	•		side.
		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).

– 22 –

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

The following three types of signals are sent from the indoor unit controller.

•Operation mode set on the remote control

•Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.)

•For these two types of signals ([Operation mode] and [Compressor revolution]), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value.

•Temperature of indoor heat exchanger by indoor heat exchanger sensor

(Minimum revolution control)

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

The following signals are sent from the outdoor unit controller.

•The current operation mode

•The current compressor revolution

•Outdoor temperature

•Existence of protective circuit operation

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

Contents of 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.

FILE NO. SVM-04038

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 –