Toshiba RAS-10YKV-E, RAS-13YKV-E, RAS-10YAV-E, RAS-13YAV-E SERVICE MANUAL

SERVICE MANUAL

AIR-CONDITIONER

FILE NO. A00-T004

SUPPLEMENT

SPLIT TYPE

RAS-10YKV-E RA-88YKV-E

RAS-13YAV-E

RAS-10YAV-E

R410A

PRINTED IN JAPAN, Aug.,2000 ToMo

CONTENTS

1. SPECIFICATIONS ...........................................................3

2. REFRIGERANT R410A...................................................6

3 . CONSTRUCTION VIEWS..............................................14

4. WIRING DIAGRAM........................................................16

5. SPECIFICATIONS OF ELECTRICAL PARTS...............18

6. REFRIGERANT CYCLE DIAGRAM..............................19

7. CONTROL BLOCK DIAGRAM .....................................21

8. OPERATION DESCRIPTION ........................................23

9. INSTALLATION PROCEDURE .....................................36

10. HOW TO DIAGNOSE THE TROUBLE ...........................40

11. HOW TO REPLACE THE MAIN P ARTS ........................59

12. EXPLODED VIEWS AND PARTS LIST.........................69

– 2 –

1. SPECIFICATIONS

1-1. Specifications

RAS-10YKV-E/RAS-10YAV-E

Unit model Current limited —

Cooling capacity (kW) 2,7 Cooling capacity range (kW) 0,8 – 3,4 Heating capacity (kW) 3,6 Heating capacity range (kW) 0,8 – 6,2 Power supply 220 – 230 –240V – 1Ph – 50/60Hz Electric

characteristics

COP (Cooling/Heating) 3,86 / 4,00 Operating noise

Indoor unit

Outdoor unit

Piping connection

Accessory

Indoor Outdoor

Indoor

Outdoor

Indoor

Outdoor (Cooling / Heating) (dB•A) 45 / 46 Unit model Dimension

Net weight (kg) 8 Fan motor output (W) 19 Air flow rate (Cooling / Heating) (m³/h) 480 / 520 Unit model Dimension

Net weight (kg) 38 Compressor

Fan motor output (W) 40 Air flow rate (Cooling / Heating) (m³/h) 2120 / 2120 Type Flare connection

Maximum length (Per unit) (m) 15 Maximum chargeless length (m) 15 Maximum height difference (m) 10 Name of refrigerant R410ARefrigerant Weight (kg) 0,8

Indoor unit

Outdoor unit Drain nipple 1

Operation mode Running current (A) 0,15 0,15 Power consumpti on (W) 30 30 Power factor (%) 87 87 Operation mode Running current (A) 3,39 / 3,23 / 3,09 4,40 / 4,20 / 4,02 Power consumption (W) 670 870 Power factor (%) 90 90 Starting current (A) 4,55 / 4,35 / 4,17

High (Cooling / Heating) (dB•A) 38 / 39 Medium (Cooling / Heating) (dB•A) 34 / 35 Low (Cooling / Heating) (dB•A) 30 / 30

Height (mm) 265 Width (mm) 790 Depth (mm) 189

Height (mm) 550 Width (mm) 780 Depth (mm) 270

Motor output (W) 750 Type Twin rotary type with DC-inverter variable speed control Model DA91A1F-44F

Liquid side Ø6,35Indoor unit Gas side Ø9,52 Liquid side Ø6,35Outdoor unit Gas side Ø9,52

Power supply 3 Wires : includes earthWiring connection Interconnection 4 Wires : includes earth Indoor (Cooling / Heating) (°C) 21 – 32 / 0 – 28Usable temperature range Outdoor (Cooling / Heating) (°C) 10 – 43 / –10 – 21 Installation plate 1 Wireless remote control 1 Label 2 Remote controller holder 1 Pan head wood screw 2 (Ø3,1 x 16L) Purifying filter 1 Deodorizing filter 1 Batteries 2 Mounting screw 6 (Ø4 x 25L) Installation manual 1 Owner's manual 1

Cooling Heating

• The specifications may be subject to change without notice for purpose of improvement.

RAS-10YKV-E

RAS-10YAV-E

RAS-10YKV-E

RAS-10YAV-E

– 3 –

RAS-13YKV-E/RAS-13YAV-E

Unit model

Current limited — Cooling capacity (kW) 3,7 Cooling capacity range (kW) 0,8 – 4,0 Heating capacity (kW) 4,8 Heating capacity range (kW) 0,8 – 6,6 Power supply 220 – 230 –240V – 1Ph – 50/60Hz Electric

characteristics

COP (Cooling/Heating) 3,08 / 3,20 Operating noise

Indoor unit

Outdoor unit

Piping connection

Accessory

Indoor Outdoor

Indoor

Outdoor

Indoor

Outdoor (Cooling / Heating) (dB•A) 48 / 50 Unit model Dimension

Net weight (kg) 8 Fan motor output (W) 19 Air flow rate (Cooling / Heating) (m³/h) 530 / 560 Unit model Dimension

Net weight (kg) 38 Compressor

Fan motor output (W) 40 Air flow rate (Cooling / Heating) (m³/h) 2520 / 2520 Type Flare connection

Maximum length (Per unit) (m) 15 Maximum chargeless length (m) 15 Maximum height difference (m) 10 Name of refrigerant R410ARefrigerant Weight (kg) 0,8

Indoor unit

Outdoor unit Drain nipple 1

Operation mode Running current (A) 0,15 0,15 Power consumption (W) 30 30 Power factor (%) 87 87 Operation mode Running current (A) 5,59 / 5,34 / 5,11 7,03 / 6,71 / 6,43 Power consumption (W) 1170 1470 Power factor (%) 95 95 Starting current (A) 7,18 / 6,86 / 6,58

High (Cooling / Heating) (dB•A) 41 / 41 Medium (Cooling / Heating) (dB•A) 36 / 36 Low (Cooling / Heating) (dB•A) 30 / 30

Height (mm) 265 Width (mm) 790 Depth (mm) 189

Height (mm) 550 Width (mm) 780 Depth (mm) 270

Motor output (W) 750 Type Twin rotary type with DC-inverter variable speed control Model DA91A1F-44F

Liquid side Ø6,35Indoor unit Gas side Ø9,52 Liquid side Ø6,35Outdoor unit Gas side Ø9,52

Cooling Heating

RAS-13YKV-E

RAS-13YAV-E

RAS-13YKV-E

RAS-13YAV-E

• The specifications may be subject to change without notice for purpose of improvement.

– 4 –

1-2. Operation Characteristic Curve

RAS-10YKV-E RAS-13YKV-E

Current (A)

• Conditions

Current (A)

Indoor : DB 27˚C/WB 19˚C Outdoor : DB 35˚C

Air flow : High

Pipe length : 5m 230V

0 20 40 60 80 100

Compressor speed (rps)

1-3. Capacity Variation Ratio According to Temperature

RAS-10YKV-E RAS-13YKV-E

• Conditions Indoor : DB 20˚C Outdoor : DB 7˚C/WB 6˚C Air flow : High Pipe length : 5m 230V

Compressor speed (rps)

105

Current Limited Start

100

95 90 85

RAS-10YKV-E RAS-13YKV-E

80 75 70

Capacity ratio (%)

65 60

• Conditions Indoor : DB27˚C/WB19˚C

55 50

32 34

Indoor air flow : High Pipe length 5m

36 38 40 4233 35 37 39 41 43

Outdoor temp. (˚C)

Capacity ratio : 100% = 2,7 kW (RAS-10YKV-E)

100% = 3,7 kW (RAS-13YKV-E)

120 110 100

90 80 70 60 50

Capacity ratio (%)

40 30 20

RAS-10YKV-E RAS-13YKV-E

• Conditions Indoor : DB 20˚C

–10–9–8–7–6–5–4–3–2–1012345678910

Indoor air flow : High Pipe length : 5m

Outdoor temp. (˚C)

– 5 –

2. REFRIGERANT R410A

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

The working pressure of the new refrigerant R410A is 1,6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

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

2-1. Safety During Installation/Servicing

As R410A’s pressure is about 1,6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusiv e for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

(1) Never use refrigerant other than R410A in an air

conditioner which is designed to operate with R410A.

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

(2) Confirm the used refrigerant name, and use

tools and materials exclusive for the refrigerant R410A.

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

(3) If a refrigeration gas leakage occurs during

installation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire,

a poisonous gas may occur.

(4) When installing or removing an air conditioner,

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

(5) After completion of installation work, check to

make sure that there is no refrigeration gas leakage.

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

(6) When an air conditioning system charged with a

large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks , its concentration does not exceed the marginal 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 remova l

according to the installation manual. Improper installation may cause refrigeration

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

(8) Unauthoriz ed 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 refriger ant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants .

(1) Copper Pipes

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

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

Thicknesses of copper pipes used with R410A are as shown in Table 2-2-1. Never use copper pipes thinner than 0,8 mm even when it is available on the market.

– 6 –

Table 2-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter Outer diameter (mm) R410A R22

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 22-6 below .

Table 2-2-2 Minimum thicknesses of socket joints

Nominal diameter

1/4 6,35 0,50 3/8 9,52 0,60 1/2 12,70 0,70

Reference outer diameter of

copper pipe jointed (mm)

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.

Minimum joint thickness

(mm)

5/8 15,88 0,80

2-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil 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.

– 7 –

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 R410A or conventional flare tool.

Table 2-2-3 Dimensions related to flare processing for R410A

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

ØD

Fig. 2-2-1 Flare processing dimensions

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

Flare tool for R410A

clutch type

Conventional flare tool

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 processing for R22

A (mm)

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

Flare tool for R410A

clutch type

Conventional flare tool

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 nut dimensions for R410A

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

ABCD

Dimension (mm)

Flare nut

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

– 8 –

width

(mm)

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

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

ABCD

Dimension (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

46˚

45˚

B A

43˚

45˚

Flare nut

width

(mm)

Fig. 2-2-2 Relations between flare nut and flare seal surface

(2) Flare Connecting Procedures and Precautions

a) Make sure that the flare and union portions

do not have any scar or dust, etc.

b) Correctly align the processed flare surface

with the union axis.

c) Tighten the flare with designated torque by

means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.

Table 2-2-7 Tightening torque of flare for R410A [Reference values]

Nominal

diameter

Outer diameter

(mm)

Tightening torque

1/4 6,35 14 to 18 (140 to 180) 16 (160), 18 (180)

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.

N•m (kgf•cm)

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

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

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)

– 9 –

2-3. Tools

2-3-1. Required T ools

The service port diameter of pack ed valv e of the outdoor unit in the air conditioner using R410A is changed to pre vent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12,7 copper pipe) of the refrigerant piping are lengthened.

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

(1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) (2) Tools exclusive for R410A, but can be also used f or conventional refrigerant (R22) (3) Tools commonly used for R410A and for conventional refrigerant (R22)

The table below shows the tools exclusive for R410A and their interchangeability.

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

Tools whose specifications are changed for R410A and their interchangeability

R410A air conditioner

installation

No. Used tool

 Flare tool

Copper pipe gauge for

 adjusting projection

margin Torque wrench



(For Ø12,7)

 Gauge manifold  Charge hose

 Vacuum pump adapter

Electronic balance for



refrigerant charging

 Refrigerant cylinder  Leakage detector  Charging cylinder

(Note 1) When flaring is carried out for R410A 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 R410A is being currently developed.

Usage

Pipe flaring Flaring by

conventional flare tool

Connection of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating Refrigerant charge

Refrigerant charge Gas leakage check Refrigerant charge

Existence of Whether new equipment conventional for R410A equipment can

Yes

Yes Yes Yes

Yes

(Note 2)

be used

(Note 1)

X X

X X X

Conventional air

conditioner installation

Whether new equipment can be used with conventional refrigerant

(Note 1)

X X

¡ ¡

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the f o llowing equipments which serve also for R22 are necessary as the general tools.

(1) Vacuum pump

Use vacuum pump by

attaching vacuum pump adapter. (2) Torque wrench (For Ø6,35) (3) Pipe cutter

Also prepare the following equipments for other installation method and run check.

(1) Clamp meter (2) Thermometer

(4) Reamer (5) Pipe bender (6) Level vial (7) Screwdriver (+, –) (8) Spanner or Monkey wrench

(3) Insulation resistance tester (4) Electroscope

(9) Hole core drill (Ø65) (10) Hexagon wrench

(Opposite side 5mm)

(11) Tape measure (12) Metal saw

– 10 –

2-4. Recharging of Refrigerant

When it is necessary to recharge refriger ant, 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.

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.

Connect the charge hose of the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

Nev er charge refrigerant exceeding the specified amount.



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



Do not carry out additional charging.



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.

(For refrigerant charging, see the figure below.)

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)

– 11 –

(OUTDOOR unit)

Opened

Closed

Service port

Be sure to make setting so that liquid can be charged.



When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.



It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ] [ Cylinder without siphon ]

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Electronic

balance

R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas , the composition of the charged refrigerant changes and the characteristics of the equipment varies.

2-5. Brazing of Pipes

2-5-1. Materials for Brazing

(1) Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively 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.

Fig. 2-4-2

Electronic

balance

Siphon

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.

When performing brazing again at time of



servicing, use the same type of brazing filler.

2-5-2. Flux

(1) Reason why flux is necessary

• By removing the oxide film and any foreign matter on the metal surface, it assists the flo w 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.

– 12 –

(2) Characteristics required for flux

• Activated temperature of flux coincides with the brazing temperature.

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

• It is easy to remove slag after brazing.

• The corrosive action to the treated metal and

brazing filler is minimum.

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

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

(3) Types of flux

• Noncorrosive flux

Generally, it is a compound of borax and boric acid. It is effective in case where the brazing temperature is higher than 800°C.

• Activated flux

Most of fluxes generally used for silver brazing are this type. It features an increased 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 for brazing and used braz-

ing 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 Nitrogen gas.

(1) Brazing method to prevent oxidation

Attach a reducing valve and a flow-meter to



the Nitrogen gas cylinder. Use a copper pipe to direct the piping



material, and attach a flow-meter to the cylinder.

Apply a seal onto the clearance between the



piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

When the Nitrogen gas is flowing, be sure to



keep the piping end open. Adjust the flow rate of Nitrogen gas so that it



is lower than 0,05 m3/Hr or 0,02 MPa (0,2kgf/ cm2) by means of the reducing valve.

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).

Remove the flux completely after brazing.



Piping

material

Copper - Copper

Copper - Iron

Iron - Iron

Do not enter flux into the refrigeration cycle.



When chlorine contained in the flux remains



within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine.

When adding water to the flux, use water



which does not contain chlorine (e.g. distilled water or ion-exchange water).

Remove the flux after brazing.



Used brazing Used

filler flux

Phosphor copper Do not use

Silver Paste flux Silver Vapor flux

– 13 –

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

3-1. Indoor Unit

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RAS-10YKV-E, RAS-13YKV-E

3. CONSTRUCTION VIEWS

Air inlet

265

Air outlet

Air filter

790

Heat exchanger

50 94

790

Hanger

232 326 232

Back body

Knock out system

Front panel

189

External length reference

Hanger

265

178,5

3,5

321

Connecting pipe (0,39m)

(Flare ø9,52)

65965,5

Hanger

Drain hose (0,54m)

Connecting pipe (0,49m)

(Flare ø6,35)

65,5 450 344 326

Minimum distance

2,5

to ceiling

66 or more

Minimum distance

17 20

to wall

20 20

120 or more 120 or more

Hanger

60,5

126269319

10,5

Hanger

Installation plate outline

Center line

790

Knock out system

Hanger

For stud bolt (ø8~ø10)

For stud bolt (ø6)

Minimum distance to wall

Wireless remote controller

40,5

136

– 14 –

3-2. Outdoor Unit

RAS-10YAV-E RAS-13YAV-E

310

A leg part

296

270

600

Ø25 drain hole

115

Ø11 x 17U-shape hole (For Ø8-Ø10 anchor bolt)

Hanger

(ø6 hole pitch)

(Anchor bolt long hole pitch)

B leg part

Ø4,5 embossing (Ø4STS used) (For sunshade roof attaching)

14749,5

540

548

Fan guard

115,5

780 61

8-Ø6 hole (For fixing outdoor unit)

Ø11 x 17 long hole

(For Ø8-Ø10 anchor bolt)

Valve cover

Charging port

Earth terminal

157

322

Connecting pipe port

(Pipe dia.Ø6,35)

Connecting pipe port

(Pipe dia.Ø9,52)

4 x Ø11 x 17U-shape hole (For Ø8-Ø10 anchor bolt)

Intake

100 or

310

200 or more

Mounting dimensions of anchor bolt

600

50 or

Outlet

Intake

Outside line of product

4 x Ø11 × 17 long hole (For Ø8-Ø10 anchor bolt)

view

250 or more

(Minimum distance from wall)

Detailed A leg part

50 36

310

296

R5,5

310

296

36 50

Detailed B leg part

600

2-Ø6 hole

600

R15

Outside line of product

R15

R5,5

– 15 –

4-1. Indoor Unit

RAS-10YKV-E, RAS-13YKV-E

BLK

P04

SG01 DSA

T6,3A 250V

INDOOR

TERMINAL

BLOCK

BLK

1 2 3

WHI RED

CN30

4. WIRING DIAGRAM

R109

VARISTOR

F01 FUSE

J04

R21

LOUVER

MOTOR

R116

BLU

PNK

YEL

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

CN07

IC04

L01

C15

R01

C01

MAIN P.C. BOARD

(MCC-772)

ORN

RED

BRW

DB01

C02

FAN MOTOR

DC MOTOR

4 3 2

3 211

CN10

TO1

C06

DC35V

DC12V

DC7V

DC0V

IC02

OUTDOOR

UNIT

Check items

OPERATION indicator

Terminal block

Fuse 6,3A

DC 5V

DC 12V

DC 35V

GRN & YEL

INDOOR

UNIT

CN23

CN13

BLU

INFRARED RAYS RECEIVE

AND INDICATION PARTS

BLU

5 5

BLU

6 6

PNK

7 7

BLK

8 8

WHI

9 9

Table 4-1-1 Simple check points for diagnosing faults

Diagnosis result

Check to see if the OPERATION indicator goes on and off when the main switch or breaker is turned on, or the power cord is plugged in the wall outlet. (Check the primar y and secondary voltage of transformer.)

Check for power supply voltage between Q – R. (Refer to the name plate.) (Check the primary and secondary voltage of transformer.) Check for fluctuate voltage between R – S. (DC 15 to 60V)

Check to determine if the fuse is open. (Check Var istor : R109, R21)

Check for voltage at the pink lead of the infrared rays receive parts. (Check the transformer and the rated voltage power supply circuit.)

Check for voltage at the (Check the transformer and the rated voltage power supply circuit.)

Check for voltage at the CN10 connector side point. (Check the transformer and the rated voltage power supply circuit.)

lead of louver motor.

CN25

CN03

21 21

BLK

IC01

THERMO SENSOR

(TA)

CN01

21 21

BLK

HEAT

EXCHANGER

SENSOR

(TC)

COLOR

IDENTIFICATION

BROWNBRW : REDRED : WHITEWHI : YELLOWYEL : BLUEBLU : BLACKBLK : GRAYGRY : PINKPNK : ORANGEORN : GREEN &

GRN

&YEL

YELLOW

For detailed diagnostic procedure, refer to the service data. DSA : Surge Absorber

– 16 –

4-2. Outdoor Unit

RAS-10YAV-E, RAS-13YAV-E

TE TD TO TS

BLK

321

C13

C14C12

ORN P10

E A ~

MODULE

–

CONVERTER

DB01

BLK

21 21

P.C. BOARD

MCC-808

P09

POWER RELAY

ELECTRONIC

YEL

BU EU BV

EV BW EW

IGBT MODULE

Q200

BLU

BLK

CN601 CN602 CN603CN600

STARTER

P19 P20

–

P18 P17

GRN

321 321

P22

221

REACTOR

GRY

F03 FUSE 15A

REDP21 WHI BLKP23

PNK

YEL

1234455 123

CN301

COMPRESSOR

P.M.V. : Pulse Modulating Valve

COIL FOR 4WA Y VAL VE

FAN MOTOR

RED

WHI

BLK

321

CN300 CN701 CN703 CN500

F04

FUSE

3,15A

321

RELAY

321

BLK

321

P06 P01 P02 P03P08 P07

THERMOSTAT FOR COMPRESSOR

P.M.V.

WHI

YEL

ORN

BLU

RED

GRY

221

SURGE

ABSORBER

VARISTOR

COLOR IDENTIFICATION

BLK : BLACK

BLU : BLUE RED : RED GRY : GRAY

PNK : PINK

21 21

POWER SUPPLY

220/240V~

50/60Hz

~ ~ ~

L N

BLK

WHI

F01 FUSE 25A

WHI : WHITE

BRW : BROWN

ORN : ORANGE

YEL : YELLOW

PUR : PURPLE

ORN

P11 P12

P13

P14

INDOOR

UNIT

~ ~ ~~

1 2 3

11 22

REACTOR

PUR

– 17 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor Unit

RAS-10YKV-E, RAS-13YKV-E

No. Parts name Type Specifications

1 Fan motor (for indoor) TICF-35-19-4 DC35V, 19W 2 Thermo. sensor (TA-sensor) ( – ) 10kΩ at 25°C 3 DC-DC transformer (T01) SWT-34 or SWT-46 DC390V, Secondary DC35V, 12V, 7V 4 Microcomputer TMP87PM40AF or TMP87CM40AF

Heat exchanger temp. sensor

(TC-sensor) 6 L ine filter (L01) UF-253Y0R7 25mH, AC0,7A 7 Diode (DB01) RBV-406 or D3SBA60 4A, 600V 8 Capacitor (C02) KMH450VNSN100M25B 100µF, 450V 9 Fuse (F01) TSCR6,3A T6,3A, 250V

10 Power supply IC (IC01) MA2830-FJ 4A, 600V 11 Varistor (R21, R109) 15G561K 560V 12 Resistor (R01) ERF-5TK5R6 5,6Ω, 5W 13 Louver motor MP35EA7 Output (Rated) 2W, 10poles, 1phase DC12V

5-2. Outdoor Unit

RAS-10YAV-E, RAS-13YAV-E

( – ) 10kΩ at 25°C

No. Parts name Model name Rating

SC coil

(Noise filter)

2 DC-DC transformer SWT-43 3 Reactor CH38Z-K L=10mH, 16A x 2

4 Outside fan motor ICF-140-40-7 DC140V, 40W 5 Fan control relay AJQ1341

Suction temp. sensor

(TS sensor)

Dischar

(TD sensor)

Outside air temp. sensor

(TO sensor)

Heat exchanger temp.

sensor (TE sensor)

10 Terminal block (9P) —— 20A, AC250V

12 Electrolytic capacitor LLQ2G501KHUATF, 400LISN500K35F 500µF, DC400V X 3 pieces 13 Transistor module 6MBI25GS-060-01 or 6MBI25GS-060-01A 25A, 600V 14 Compressor DA91A1F-44F 3-phases 4-poles 750W 15 Compressor thermo. US-622KXTMQO-SS OFF: 125 ± 4°C, ON: 90 ± 5° C 16 Converter module MP7003 Diode: 25A, 600V, IGBT: 40A, 600V

L03 SC-15-S06J 15A, 0,6mH L01 SC-20-01J 20A, 150µH

(Inverter attached) 10kΩ (25°C)

e temp. sensor

For protection of switching power source 3,15A, AC250V For protection of transistor module breakage 15A, AC250V11 Fuse For protection of inverter input overcurrent 25A, AC250V

(Inverter attached) 62kΩ (20°C)

(Inverter attached) 10kΩ (25°C)

Primary side DC280V, Secondary side 7,5V x 1, 13V x 1, 26,5V x 3, 16V x 1, 15V x 1

Coil DC12V Contact AC125V, 3A

– 18 –

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

RAS-10YKV-E/RAS-10YAV-E RAS-13YKV-E/RAS-13YAV-E

Pressure measurement Gauge attaching port

Vacuum pump connecting port Deoxidized copper pipe

Outer dia. : 9,52mm Thickness : 0,8mm

INDOOR UNIT

Indoor heat

exchanger

Cross flow fan

Deoxidized copper pipe Outer dia. : 6,35mm Thickness : 0,8mm

Sectional shape of heat insulator

Temp. measurement

Allowable height

difference : 10m

Allowable pipe length

Max. : 15m

4 way valve (CHV-0213)

Temp. measurement

Muffler

Compressor DA91A1F-44F

Outdoor heat

exchanger

Propeller fan

OUTDOOR UNIT

Split capillary

Ø1,5 x 200

Strainer

Pulse modulating valve at liquid side (SEV15RC2)

Refrigerant amount : 0,8kg

NOTE :

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

NOTE :

• The maximum pipe length of this air conditioner is 15 m. The additional charging of refrigerant is unnecessary because this air conditioner is designed with charge-less specification.

– 19 –

6-2. Operation Data

Temperature

condition (°C)

Indoor Outdoor

27/19 35/–

Standard

Model name

10YKV-E 0,8 to 1,0 9 to 11 42 to 44 High High 56

13YKV-E 0,8 to 1,0 8 to 10 46 to 48 High High 85

pressure

P (MPa)

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

Indoor fan

mode

Outdoor fan

mode

Compressor

revolution

Temperature

condition (°C)

Indoor Outdoor

20/– 7/6

Standard

Model name

10YKV-E 3,5 to 3,7 42 to 44 2 to 4 High High 70

13YKV-E 2,5 to 2,7 50 to 52 0 to 3 High High 97

pressure

P (MPa)

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

Indoor fan

mode

Outdoor fan

mode

Compressor

revolution

NOTES :

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

(Thermistor themometer)

(2) Connecting piping condition : 5 m

(rps)

– 20 –

7-1. Indoor Unit

RAS-10YKV-E, RAS-13YKV-E

Heat Exchanger Sensor

Temperature Sensor

Infrared Rays Signal Receiver

7. CONTROL BLOCK DIAGRAM

Indoor Unit Control Panel

M.C.U

Functions

• Louver Control

• 3-minute Delay at Restart for Compressor

Operation

Display

Timer

Display

Infrared

Initializing Circuit

Rays

Clock Frequency

Oscillator Circuit

Power Supply

Remote

Circuit

Controller

Noise Filter

From Outdoor Unit

REMOTE CONTROLLER

• Motor Revolution Control

• Processing (Temperature Processing)

• Timer

• Serial Signal Communication

Louver ON/OFF Signal

Serial Signal Transmitter/Receiver

Serial Signal Communication

Louver Driver

Infrared

Rays

ECONO.

Sign Display

PRE DEF.

Sign Display

Indoor

Fan Motor

Louver

Motor

Remote Controller Operation (START/STOP) Operation Mode Selection

AUTO, COOL, DRY, HEAT

Thermo. Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver AUTO Swing

Louver Direction Setting

ECONO.

– 21 –

RAS-10YAV-E, RAS-13YAV-E

7-2. Outdoor Unit (Inverter Assembly)

– 22 –

For INDOOR UNIT

Discharge

temp. sensor

Outdoor air

temp. sensor

Suction temp.

sensor

Heat exchanger

temp.sensor

220–230–240 V

~ 50/60 Hz

Inddor unit

send/receive

circuit

MICRO-COMPUTER BLOCK DIAGRAM

MCC808 (P.C.B) OUTDOOR UNIT

M.C.U

• PWM synthesis function

• Input current release control

• IGBT over-current detect control

• Outdoor fan control

• High power factor correction control

• Inverter output frequency control

• A/D converter function

• P.M.V. control

• Discharge temp. control

• 4-way valve control

• Signal communication to indoor unit

High Power

factor Correction

circuit

Clock

frequency

16MHz

Rotor position

detect circuit

Rotor position

detect circuit

Over current

detect circuit

Over current

sensor

Gate drive

circuit

Gate drive

circuit

Noise

Filter

Input current

sensor

Driver circuit

of P.M.V.

P.M.V.

Converter

(AC DC)

Relay circuit

4-way

valve

Over current

sensor

Over current

sensor

Inverter

(DC AC)

Inverter

(DC AC)

Outdoor

Fan motor

Compressor

8. OPERATION DESCRIPTION

8-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor fan motor and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 13 to 120 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control fan motor are mounted to the outdoor unit. The entire air conditioner is mainly controlled by the indoor unit controller.

The indoor unit controller drives the indoor fan motor based upon command sent from the remote controller, and transfers the operation command to the outdoor unit controller.

The outdoor unit controller receives operation command from the indoor unit side, and controls the outdoor fan and the pulse modulating valve. Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors drive according to the operation command. And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller.

As the compressor adopts four-pole brushless DC motor, the frequency of the supply power from inverter to compressor is two-times cycles of the actual number of revolution.

(1) Role of indoor unit controller

The indoor unit controller judges the operation commands from the remote controller and assumes the following functions.

• Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor.

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

• 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 judgment/display of error

(2) Role of outdoor unit controller

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

• Compressor operation

Operations follow ed

control

• Operation control of outdoor fan motor

• P.M.V. control

• Detection of inverter input current and current release operation

• Over-current detection and prevention operation to transistor module (Compressor stop function)

• Compressor and outdoor fan stop function when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system)

• Transferring of operation information (Serial signal) from outdoor unit to indoor unit

• Detection of outdoor temperature and operation revolution control

• Defrost control in heating operation (Temp. measurement by outdoor heat exchanger and control for f our-way valve and outdoor fan)



to judgment of serial



signal from indoor side.



– 23 –

(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 oper ation within the r ange that current does not exceed the allowable value.

• Temperature of indoor heat exchanger b y indoor heat exchanger sensor (Minimum revolution control)

(4) Contents of operation command signal (Serial

signal) from outdoor unit controller to indoor unit controller

The following signals are sent from the outdoor unit controller.

• The current operation mode

• The current compressor revolution

• Outdoor temperature

• Existence of protective circuit operation For transferring of these signals, the indoor

unit controller monitors the contents of signals, and judges existence of trouble occurrence .

Contents of judgment are described below .

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

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

outdoor unit controller, it is assumed as a trouble.

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 220–230–240V 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 rev olution 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 e xchange inverter output voltage and supply power winding.

Detection of the revolution position for controlling is performed 12 times per 1 rev olution 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 rev olution range

Operation

mode

COOL

HEAT

Model name

10YKV-E 13 to 74 13YKV-E 13 to 94 10YKV-E 16 to 110 13YKV-E 16 to 114

Compressor

revolution (rps)

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 impro ved by keeping IGBT on for an arbitrary period to widen electro-angle of the input current.

– 24 –

8-1-4. Prevent-Freezing Control

8-1-6. Louver Control

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

8-1-5. P. M. V. (Pulse Modulating Valve)

Using P.M.V., refrigerant flow of refrigeration cycle is varied for the optimum temperature . Controlling each unit separately by two P.M.V. corresponds to difference of pipe length, fan speed, and unit temperature.

After the power has been turned on, when a serial operation signal is received from indoor at the first time, or when PMV alarm is detected and the equipment is reactivated, move the valve once until it hits on the stopper for positioning of the valve. In this case, ticktack sound may be heard.

(1) Vertical air flow louvers

Positions of vertical air flow louvers are automatically controlled according to the operation status (AUTO, COOL, DRY, HEAT). Besides, positions of vertical air flow louvers can be arbitrarily set by pressing the [SET] button. The louver position which has been set by the [SET] button is stored in microcomputer, and the louver is automatically set at the stored position in the next operation.

(2) Swing

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

8-1-7. Indoor Fan Control (DC Fan Motor)

The indoor fan is operated by motor speed non-step variable DC drive system motor. For flow rate, motor speed is controlled manually in three steps (LOW, MED, HIGH), and with the unit of 10 rpm from upper limit to lower limit in AUTO mode as described in Table 8-1-2. It is not selected by relay, so selecting sound does not generate.

Table 8-1-2

Operation

mode

DRY — 820 320 820 320

Fan mode

H 1120 480 1210 530 M 980 400 1020 420COOL

L 850 330 850 330

H 1200 520 1270 560 M 1070 450 1100 470HEAT

L 930 380 930 380

Motor speed

RAS-10YKV-E RAS-13YKV-E

(rpm)

Air flow rate

(m³/h)

Motor speed

(rpm)

Air flow rate

– 25 –

(m³/h)

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