Toshiba RAS-09LAV-UL, RAS-09LKV-UL, RAS-12LAV-UL, RAS-12LKV-UL User Manual
SERVICE MANUAL
Indoor Unit Outdoor Unit
<High Wall, Heat Pump Type> <Heat Pump Type>
FILE NO. SVM-10019
SPLIT TYPE
RAS-09LKV-UL RAS-09LAV-UL
RAS-12LKV-UL RAS-12LAV-UL
R410A
Feburary, 2010
FILE NO. SVM-10019
CONTENTS
1. SAFETY PRECAUTIONS .......................................................................... 3
2. SPECIFICATIONS ..................................................................................... 6
3. REFRIGERANT R410A ............................................................................. 8
4. CONSTRUCTION VIEWS ........................................................................ 16
5. WIRING DIAGRAM .................................................................................. 18
6. SPECIFICATIONS OF ELECTRICAL PARTS ......................................... 20
7. REFRIGERANT CYCLE DIAGRAM ........................................................ 21
8. CONTROL BLOCK DIAGRAM ................................................................ 24
9. OPERATION DESCRIPTION................................................................... 26
10. INSTALLATION PROCEDURE ................................................................ 51
11. HOW TO DIAGNOSE THE TROUBLE...................................................... 66
12. HOW TO REPLACE THE MAIN PARTS................................................... 93
13. EXPLODED VIEWS AND PARTS LIST ................................................. 109
– 2 –
FILE NO. SVM-10019
1. SAFETY PRECAUTIONS
Installing, staring up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical
components, and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should install, start-up, and service this equipment.
Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should be
performed by trained service personnel.
When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes, Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher near by
when brazing. Use care in handling, rigging, and setting bulky equipment.
Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit.
Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety information.
This is the safety-alert symbol
potential for personal injury. Understand these signal words : DANGER, WARNING, and CAUTION. These words are
used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in severs personal injury or death. WARNING signifies
hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result
in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in
enhanced installation, reliability, or operation.
! . When you see this symbol on
the unit and in instructions or manuals, be alert to the
• Before installation, please read these precautions for safety carefully.
• Be sure to follow the precautions provided here to avoid safety risks. The symbols and their meanings are shown below.
WARNING : It indicates that incorrect use of this unit may cause severe injury or death.
CAUTION : FAILURE TO FOLLOW THIS CAUTION may result in equipment damage or improper operation and
personal injury.
CAUTION
New refrigerant air conditioner installation
• THIS AIR CONDITIONER USES THE NEW HFC REFRIGERANT (R410A), WHICH DOES NOT DESTROY THE
OZONE LAYER.
R410A refrigerant is affected by inpurities such as water and oils because the pressure of R410A refrigerant is approx.
1.6 times of refrigerant R22.
ALSO NEW OILS ARE USED WITH R410A, THUS ALWAYS USE NEW REFRIGERANT PIPING AND DO NOT
ALLOW MOISTURE OR DUST TO ENTER THE SYSTEM.
To avoid mixing refrigerant and refrigerant machine oil, the sizes of charging port on the main unit is different than
those used on R22 machines and different tools will be required.
• EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must
be a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length
is buried, refrigerant may migrate to the cooter buried section during extended periods of system shutdown. This
causes refrigerant slugging and could possibly damage the compressor at start-up.
− 3 −
FILE NO. SVM-10019
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 WRONGLY,
ELECTRIC PARTS MAY BE DAMAGED.
• CHECK THE EARTH WIRE THAT IT 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 OVERHEATION THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY
(MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEATERS, FURNACE, STOVES, ETC.
• WHEN MOVING THE AIR CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT
TO GET THE SPECIFIED REFRIGERANT (R410A) 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 LEAK, DURING INSTALLATION WORK, IMMEDIATELY ALLOW FRESH AIR
INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSE GENERATION
OF POISONOUS GAS.
WARNING
• ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may
be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label.
• Never modify this unit by removing any of the safety guards or bypassing any of the safety interlock switches.
• Installation work must be purformed by qualified personnel only.
• Specified tools and pipe parts for model R410A are required, and installation work must be done in accordance with the
manual. HFC type refrigerant R410A has 1.6 times more pressure than that of conventional refrigerant (R22). Use the
specified pipe parts, and ensure correct installation, otherwise damage and/or injury may be caused. At the same time,
water leakage, electrical shock, and fire may occur.
• Be sure to install the unit in a place which can sufficiently bear its weight. If the load bearing of the unit is not enough, or
installation of the unit is improper, the unit may fall and result in injury.
• Electrical work must be performed by trained, qualified installers and service mechanics in accordance with the code governing
such installation work, internal wiring regulations, and the manual. A dedicated circuit and the rated voltage must be used.
Insufficient power supply or improper installation may cause electrical shock or fire.
• Use a cabtyre cable to connect wires in the indoor/outdoor units. Midway connection is not allowed. Improper connection or
fixing may cause a fire.
• Wiring between the indoor unit and outdoor units must be well shaped so that the cover can be firmly placed. Improper
cover installation may cause increased heat, fire, or electrical shock at the terminal area.
• Be sure to use only approved accessories or the specified parts. Failure to do so may cause the unit to fall, water leakage,
fire or electrical shock.
• After the installation work. ensure that there is no leakage of refrigerant gas. If the refrigerant gas leaks out of the pipe into
the room and is heated by fire or something else from a fanheater, stove or gas range, it causes generation of poisonous gas.
• Make sure the equipment is properly grounded. Do not connect the ground wire to a gas pipe, water pipe, lightning
conductor, or telephone earth wire. Improper earth work may be the cause of electrical shock.
• Do not install the unit where flammable gas may leak. If there is any gas leakage or accumulation around the unit, it can
cause a fire.
• Do not select a location for installation where there may be excessive water or humidity, such as a bathroom. Deterioration
of insulation nay cause electrical shock or fire.
• Installation work must be performed following the instructions in this installation manual. Improper installation may cause
water leakage, electrical shock or fire. Check the following items before operating the unit.
- Be sure that the pipe connection is well placed and there are no leaks.
- Check that the service valve is open. If the service valve is closed, it may cause overpressure and result in compressor
damage. At the same time, if there is a leak in the connection part, it may cause air suction and overpressure, resulting
in damage to the unit or injury.
• In a pump-down operation, be sure to stop the compressor unit before removing the refrigerant pipe. If removing the
refrigerant pipe while the compressor is operating with the service valve opened, it may cause air suction and overpressure,
resulting in damage to the unit or injury.
• Do not modity the power cable, connect the cable midway, or use a multiple outlet extension cable. Doing so may cause
contact failure, insulation failure, or excess current, resulting in fire or electrical shock.
• If you detect any damage, do not install the unit. Contact your dealer immediately.
− 4 −
FILE NO. SVM-10019
CAUTION
CAUTION
• Exposure of unit to water or other moisture before installation could result in electric shock. Do not store it in a wet
basement or expose to rain or water.
• After unpacking the unit, examine it carefully for possible damage. Report any damages to your distributor.
• 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.
• Please read this installation manual carefully before installing the unit. It contains further important instructions
for proper installation.
• This appliance must be connected to the main power supply by means of a circuit breaker depending on the
place where the unit is installed. Failure to do so may cause electrical shock.
• Follow the instructions in this installation manual to arrange the drain pipe for proper drainage from the unit.
Ensure that drained water is discharged. Improper drainage can result is water leakage, causing water damage
to furniture.
• Tighten the flare nut with a torque wrench using the prescribed method. Do not apply excess torque. Otherwise,
the nut may crack after a long period of usage and it may cause the leakage of refrigerant.
• Wear gloves (heavy gloves such as cotton gloves) for installation work. Failure to do so may cause personal
injury when handling parts with sharp edges.
• Do not touch the air intake section or the aluminum fins of the outdoor unit. It may cause injury.
• Do not install the outdoor unit in a place which can be a nest for small animals. Small animals could enter and
contact internal electrical parts, causing a failure or fire.
• Request the user to keep the place around the unit tidy and clean.
• Make sure to conduct a trial operation after the installation work, and explain how to use and maintain the unit
to the customer in accordance with the manual. Ask the customer to keep the operation manual along with the
installation manual.
− 5 −
2. SPECIFICATIONS
FILE NO. SVM-10019
Unit model Indoor
Outdoor
Cooling capacity (Btu/h) 9000 12000
Cooling capacity range (Btu/h) 3750 -10580 2750 - 13950
Heating capacity (Btu/h) 10800 14200
Heating capacity range (Btu/h) 3070 - 16350 3070 - 19000
Power supply
Electric Indoor Operation mode
characteristic Running current (A) 0.22 0.20 0.25 0.23
Power consumption (W) 35 40 30 35
Power factor (%) 76 76 66 66
Outdoor Operation mode
Running current (A) 3.46 3.13 5.26 4.76
Power consumption (W) 655 760 920 1055
Power factor (%) 91 94 95 95
Starting current (A) 3.68 3.33 4.81/4.35 5.51/4.99
EER (Cooling/Heating) (Btu/W.h) 13.0/13.5 12.6 / 13.0
SEER (Btu/W.h) / HSPF (w/w)
Operating Indoor High (Cooling/Heating) (dB-A) 39/40 45/46
noise Medium (Cooling/Heating) (dB-A) 34/35 40/41
Low (Cooling/Heating) (dB-A) 27/29 30/32
Outdoor (Cooling/Heating) (dB-A) 47/47 50/50
Indoor unit Unit model
Dimension Height in. (mm) 10-25/32 (275) 10-25/32 (275)
Width in. (mm) 31-1/8 (790) 31-1/8 (790)
Depth in. (mm) 8-1/16 (205) 8-1/16 (205)
Net weight lbs (kg) 20 (9) 20 (9)
Fan motor output (W) 20 30
Air flow rate (Cooling/Heating)
Outdoor unit Unit model
Dimension Height in. (mm) 21-11/16 (550) 21-11/16 (550)
Width in. (mm) 30-11/16 (780) 30-11/16 (780)
Depth in. (mm) 11-7/16 (290) 11-7/16 (290)
Net weight lbs (kg) 75 (34) 88 (39)
Compressor Motor output (w) 750 750
Type
Model DA89X1C-23FZ2 DA111A1F-20F1
Fan motor output (W) 43 43
Air flow rate (Cooling/Heating)
Piping Type Flare connection Flare connection
connection Indoor unit Liquid side in. (mm)
Gas side in. (mm)
Outdoor unit Liquid side in. (mm)
Gas side in. (mm)
Maximum length ft. (m)
Maximum chargeless length ft. (m) 50 (15) 50 (15)
Maximum height difference ft. (m) 33 (10) 33 (10)
Refrigerant Name of refrigerant R410A R410A
Weight lbs (kg) 1.77 (0.8) 2.43 (1.10)
Wiring Power supply
connection Interconnection 4Wires:includes earth 4Wires:includes earth
Usable temperature range Indoor (Cooling/Heating) °F (°C) 70-90 / 32-82 (21-32/0-28) 70-90 / 32-82 (21-32/0-28)
Outdoor (Cooling/Heating) °F (°C) 14-115 / 5-75 (-10-46/-15-24) 14-115 / 5-75 (-10-46/-15-24)
cfm (m
cfm (m
3
/min)
3
/min)
RAS-09LKV-UL RAS-12LKV-UL
RAS-09LAV-UL RAS-12LAV-UL
1Ph, 60Hz, 208V/230V 1Ph, 60Hz, 208V/230V
Cooling Heating Cooling Heating
Cooling Heating Cooling Heating
20.0/10.0
RAS-09LKV-UL RAS-12LKV-UL
303/335 (8.6)/(9.5) 406/438 (11.5/12.4)
RAS-09LAV-UL RAS-12LAV-UL
Single rotary type with DC-inverter
variable speed control
1060/1060 (30)/(30) 1395/1236 (39.5/35.0)
∅1/4 (∅6.35) ∅1/4 (∅6.35)
∅3/8 (∅9.92) ∅3/8 (∅9.92)
∅1/4 (∅6.35) ∅1/4 (∅6.35)
∅3/8 (∅9.92) ∅3/8 (∅9.92)
66 (20)
3Wires:includes earth (Outdoor) 3Wires:includes earth (Outdoor)
Twin rotary type with DC-inverter
23.0/9.5
variable speed control
66 (20)
* The specifications may be subject to change without notice for purpose of improvement.
− 6 −
2-2. Operation Characteristic Curve
<Cooling> <Heating>
FILE NO. SVM-10019
8
7
6
RAS-12LKV-UL
5
4
RAS-09LKV-UL
Current (A)
3
2
1
Conditions
Indoor : DB 80oF/WB 67oF
(DB 26.7oC/WB 19.4oC)
Outdoor : DB 98oF/WB 75oF
(DB 35oC/WB 23.9oC)
Indoor Air Flow : High
Pip Length : 5m
Voltage : 230V
0
0 102030405060708090100110120
Compressor Speed (rps)
8
RAS-12LKV-UL
7
RAS-09LKV-UL
6
5
4
Current (A)
3
2
1
Conditions
Indoor : DB 70oF/WB 60oF
(DB 21.1oC/WB 15.6oC)
Outdoor : DB 47
(DB 8.3oC/WB 6.1oC)
Indoor Air Flow : High
Pip Length : 5m
Voltage : 230V
o
F/WB 43oF
0
0 102030405060708090100110120
Compressor Speed (rps)
2-3. Capacity Variation Ratio According to Temperature
<Cooling> <Heating>
105
100
95
90
85
80
75
70
Capacity Ratio (%)
65
60
55
RAS-09LKV-UL
RAS-12LKV-UL
Condition
Indoor: DB80°F/WB67°F
(DB26.7°C/WB19.4°C)
Indoor Air-Flow Volume: High
Pipe Length: 16 ft (5m)
Voltage : 230V
Capacity Ratio: 100% =
9000 Btu/h (RAS-09LKV-UL)
12000 Btu/h (RAS-12LKV-UL)
120
100
80
60
Capacity Ratio (%)
40
20
RAS-09LKV-UL
RAS-12LKV-UL
Condition
Indoor: DB70°F/WB60°F
(DB21.1°C/WB15.6°C)
Indoor Air-Flow Volume: High
Pipe Length: 16 ft (5m)
Voltage : 230V
Capacity Ratio: 100% =
9000 Btu/h (RAS-09LKV-UL)
12000 Btu/h (RAS-12LKV-UL)
50
90 91 93 95 97 99 100 102 104 106 108 109 111 113 115
(32)(33)(34)(35)(36)(37)(38)(39)(40)(41)(42)(43)(44)(45)(46)
0
5 14 23 32 41 50
(-15) (-10) (-5) (0) (5) (10)
Outdoor Temperature (ºC)
– 7 –
Outdoor Temperature (ºC)
3. REFRIGERANT R410A
FILE NO. SVM-10019
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.
3-1. Safety During Installation/Servicing
As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may
cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out
installation/servicing safely while taking the following
precautions into consideration.
1. Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.
If other refrigerant than R410A is mixed, pressure
in the refrigeration cycle becomes abnormally
high, and it may cause personal injury, etc. by a
rupture.
2. Confirm the used refrigerant name, and use tools
and materials exclusive for the refrigerant R410A.
The refrigerant name R410A is indicated on the
visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent
mischarging, the diameter of the service port
differs from that of R22.
3. If a refrigeration gas leakage occurs during
installation/servicing, be sure to ventilate fully.
If the refrigerant gas comes into contact with fire,
a poisonous gas may occur.
4. When installing or removing an air conditioner, do
not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so
that a rupture 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 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.
3-2. Refrigerant Piping Installation
3-2-1. Piping Materials and Joints Used
For the refrigerant piping installation, copper pipes
and joints are mainly used. Copper pipes and joints
suitable for the refrigerant must be chosen and
installed. Furthermore, it is necessary to use clean
copper pipes and joints whose interior surfaces are
less affected by contaminants.
1. Copper Pipes
It is necessary to use seamless copper pipes
which are made of either copper or copper alloy
and it is desirable that the amount of residual oil
is less than 40 mg/10 m. Do not use copper
pipes having a collapsed, deformed or discolored
portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube
may become blocked with contaminants.
As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary
to choose adequate materials.
Thicknesses of copper pipes used with R410A
are as shown in Table 3-2-1. Never use copper
pipes thinner than 0.0315 in. (0.8 mm) even when
it is available on the market.
– 8 –
Table 3-2-1 Thicknesses of annealed copper pipes
Thickness in. (mm)
FILE NO. SVM-10019
Nominal diameter (in.)
1/4
3/8
1/2
Outer diameter (mm)
6.35
9.52
12.70
R410A R22
0.0315 (0.80) 0.0315 (0.80)
0.0315 (0.80)
0.0315 (0.80)
0.0315 (0.80)
0.0315 (0.80)
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 3-2-3 to 3-2-6 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 0.7874 in. (20 mm).
Thicknesses of socket joints are as shown in Table 3-2-2.
Table 3-2-2 Minimum thicknesses of socket joints
Nominal diameter (in)
1/4
3/8
1/2
Reference outer diameter of
copper pipe jointed (mm)
6.35
9.52
12.70
Minimum joint thickness
in. (mm)
0.0197 (0.50)
0.0236 (0.60)
0.0276 (0.70)
3-2-2. 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 than lubricating oils used in the installed air-water heat pump 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, slo wly 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
– 9 –
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.
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.
Table 3-2-3 Dimensions related to flare processing for R410A
Nominal
diameter
in.
Outer
diameter
(mm)
Thickness
in. (mm)
Fig. 3-2-1 Flare pr ocessing dimensions
Flare tool for R410A
clutch type
FILE NO. SVM-10019
ØD
A
A in. (mm)
Conventional flare tool
Clutch type Wing nut type
1/4
3/8
1/2
Nominal
diameter
in.
1/4
3/8
1/2
6.35
9.52
12.70
Table 3-2-4 Dimensions related to flare processingf or R22
Outer
diameter
(mm)
6.35
9.52
12.70
0.0315 (0.8)
0.0315 (0.8)
0.0315 (0.8)
Thickness
in. (mm)
0.0315 (0.8)
0.0315 (0.8)
0.0315 (0.8)
Table 3-2-5 Flare and flare nut dimensions for R410A
0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)
Flare tool for R22
clutch type
0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)
0.0394 to 0.0591
0.0394 to 0.0591
0.0394 to 0.0591
0.0197 to 0.0394
0.0197 to 0.0394
0.0197 to 0.0394
0.0591 to 0.0787
(1.0 to 1.5)
(1.0 to 1.5)
(1.0 to 1.5)
A in. (mm)
Conventional flare tool
Clutch type Wing nut type
(0.5 to 1.0)
(0.5 to 1.0)
(0.5 to 1.0)
(1.5 to 2.0)
0.0591 to 0.0787
(1.5 to 2.0)
0.07874 to 0.0984
(2
.0 to 2.5)
0.0394 to 0.0591
(1.0 to 1.5)
0.0394 to 0.0591
(1.0 to 1.5)
0.0591 to 0.0787
(1.5 to 2.0)
Nominal
diameter
in.
1/4
3/8
1/2
Outer diameter
(mm)
6.35
9.52
12.70
Thickness
in. (mm)
0.0315 (0.8)
0.0315 (0.8)
0.0315 (0.8)
Dimension in. (mm)
A B C D
0.358 (9.1)
0.520 (13.2) 0.531 (13.5) 0.382 (9.7) 0.787 (20)
0.630 (16.0)
0.362 (9.2) 0.256 (6.5)
0.653 (16.6)
0.508 (12.9)
0.512 (13)
0.906 (23)
– 10 –
Flare nut width
in. (mm)
0.669 (17)
0.866 (22)
1.024 (26)
Table 3-2-6 Flare and flare nut dimensions for R22
FILE NO. SVM-10019
Nominal
diameter
in.
1/4
3/8
1/2
Outer diameter
(mm)
6.35
9.52
12.70
Thickness
in. (mm)
0.0315 (0.8)
0.0315 (0.8)
0.0315 (0.8)
45 to 46
Dimension in. (mm)
A B C D
0.354 (9.0)
0.362 (9.2) 0.256 (6.5)
0.512 (13)
0.512 (13.0) 0.531 (13.5) 0.382 (9.7) 0.787 (20)
0.630 (16.0)
B A
0.638 (16.2)
43 to 45
0.508 (12.9)
0.787 (20)
D
C
Flare nut width
in. (mm)
0.669 (17)
0.866 (22)
0.945 (24)
Fig. 3-2-2 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.
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 3-2-7 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 3-2-7 Tightening torque of flare for R410A [Reference values]
Nominal
diameter
in.
Outer diameter
(mm)
Tightening torque
lbf.ft (N•m)
Tightening torque of torque
wrenches available on the market
lbf.ft (N•m)
1/4
3/8
1/2
6.35
9.52
12.70
10 to 13 (14 to 18)
24 to 31 (33 to 42)
37 to 46 (50 to 62)
– 11 –
12 (16), 13 (18)
31 (42)
41 (55)
FILE NO. SVM-10019
3-3. Tools
3-3-1. Required T ools
The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A 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 ∅ 1/2 in. 12.7mm) 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 R410A (Those which cannot be used for conventional refrigerant (R22))
2. Tools exclusive for R410A, but can be also used for 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
air-water heat pump installation
No.
1
2
3
4
5
6
7
8
9
10
(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection
(Note 2) Charging cylinder for R410A is being currently developed.
Used tool
Flare tool
Copper pipe gauge for
adjusting projection
margin
Torque wrench
[(For Ø1/2 (12.7mm)]
Gauge manifold
Charge hose
Vacuum pump adapter
Electronic balance for
refrigerant charging
Refrigerant cylinder
Leakage detector
Charging cylinder
margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.
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
Usage
Existence of
new equipment
for R410A
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
(Note 2)
R410A
Whether conventional equipment
can be used
*(Note 1)
*(Note 1)
×
×
×
×
×
×
×
Conventional air-water
heat pump installation
Whether new equipment
can be used with
conventional refrigerant
¡
*(Note 1)
×
×
¡
¡
×
¡
×
General tools (Conventional tools can be used.)
In addition to the above exclusive tools, the following 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 Ø1/4, Ø3/8 in.
(∅ 6.35, ∅ 9.52mm)]
3. Pipe cutter
4. Reamer
5. Pipe bender
9. Hole core drill [Ø2-9/16 in. (65mm)]
10. Hexagon wrench
6. Level vial
7. Screwdriver (+, –)
11. Tape measure
8. Spanner or Monkey wrench
[Opposite side 3/16 in. (4mm)]
12. Metal saw
Also prepare the following equipments for other installation method and run check.
1. Clamp meter
2. Thermometer
3. Insulation resistance tester
4. Electroscope
– 12 –
FILE NO. SVM-10019
3-4. 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 to the vacuum pump
adapter.
Open fully both packed valves at liquid and gas
sides.
When the compound gauge’s pointer has indicated
−
14.7 Psi (–0.1 Mpa) or − 29.9 inHg (–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 the
fully opened position, and turn on the vacuum pump’s
power switch. Then, evacuating the refrigerant in the
cycle.
(For refrigerant charging, see the figure below.)
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)
Opened
(Outdoor unit)
Refrigerant cylinder
(with siphon)
Check valve
Opened
Open/close
valve for charging
Electronic balance for refrigerant charging
Fig. 3-4-1 Configuration of refrigerant charging
Opened
Closed
Service port
– 13 –
FILE NO. SVM-10019
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 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.
3-5. Brazing of Pipes
3-5-1. 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.
Electronic
balance
Siphon
Fig. 3-4-2
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.
3-5-2. Flux
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. Reason why flux is necessary
• 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.
– 14 –
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 1472°F (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
brazing filler/flux
FILE NO. SVM-10019
3-5-3. 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
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 onto 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 0.03 cfm (0.05 m
(0.02 MPa) 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.
3
/Hr) or 2.9 Psi
Piping material
Copper - Copper
Copper - Iron
Iron - Iron
Used brazing filler
Phosphor copper
Silver
Silver
Used flux
Do not use
Paste flux
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
chlorine.
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.
M
Flow meter
Stop valve
Nitrogen gas
cylinder
From Nitrogen cylinder
Pipe
Nitrogen
gas
Rubber plug
Fig. 3-5-1 Prevention of oxidation during brazing
– 15 –
4-1. Indoor Unit
4. CONSTRUCTION VIEWS
FILE NO. SVM-10019
– 16 –
4-2. Outdoor Unit
1 (25) Water Drain Outlet
1-31/32 (50)
1-27/64 (36)
12-3/64 (306)
12-19/32 (320)
Detail-A (Rear Leg)
23-5/8 (600)
R19/32
(R15)
R7/32
(R
5.5
1/4 Hole
(
6
) Hole
)
A
)
86
12-19/32 (320)
3-3/8 (
4-1/4 (
108
FILE NO. SVM-10019
Unit : Inch (mm)
)
4-15/16 (
125
)
12-3/64 (306)
12-19/32 (320)
1/4-Hole
(
6
)-Hole
)
1-27/64 (36)
116
1-31/32 (50)
4-9/16 (
23-5/8 (600)
B
Detail-B (Front Leg)
R19/32 (R15)
7/16x9/16 Oval-Hole
(
11x14) Oval Hole
11-7/16 (
290
17-5/32 (
)
550
436
)
WIRE GUARD
COVER
PACKED VALVE
View Z
21-11/16 (
10-7/8 (275)
)
3-17/32 (90)
23-5/8 (
600
)
3-17/32 (90)
2-23/32 (69)
)
)
53
141
2-3/32 (
5-9/16 (
13-1/2 (342)
Liquid side
(Flare Nut :
Gas side
(Model 09,12k Flare Nut :
1/4 (
6.35))
3/8 (
9.52))
3-15/16 Or more
(100 mm or more)
12-19/32 (320)
View Z
23-5/8 (
Air Inlet
Air Outlet
600
)
3-15/16 Inch or more
(100 mm. or more)
23-5/8 Inch or more
(600 mm. or more)
– 17 –
)
88
Service Port
3-15/32 (
2-R7/32x43/64L (R5.5x17L) U-Shape
(For
5/16~
23-5/8 Or more
(600 mm or more)
7/16x9/16 (
2 (For
5/16~
13/32 (8~10) Anchor Bolt)
13/32 (
8~
11x14) Oval-Hole
10) Anchor Bolt)
5. WIRING DIAGRAM
AC Motor
5-1. RAS-09LKV-UL / RAS-09LAV-UL
FILE NO. SVM-10019
COMPRESSOR
1 1
2 2
CM
3 3
YEL
YEL
BRW
YEL
ORN
1 2 1
2
REACTOR
RED
WHI
BLK
P25
P23
P21
P35
P34
P19
P18
P11
P08
P04
P05
P06
P24
P22
P20
DB01
Q404
Q200~205
IGBT
POWER
RELAY
DB02
P33 P31 P30
R221
R220
R219
CT
RELAY
PUR
L03
C13
C12 C14
P.C.BOARD
(MCC-5009)
REACTOR
Outdoor Terminal Block
1 2
1 2
F03
FUSE
T3.15A
AC250V
CN701 P32
1 3
1
R321
R320
R319
3
COIL
FOR
4WAY
VALVE
L1 L2 S
Q300~305
MOS-FET
L01
SURGE
ABSORBER
L1
P07
BLK
~
VARISTOR
VARISTOR
F01
FUSE
25A
AC250V
P03
ORN
L2 S
P01
BLK
L1 L2
~ ~
POWER
SUPPLY
208/230-1-60
CN300
CN700
P02
WHI
BLK
3 3
WHI
2 2
FM
RED
1 1
FAN MOTOR
6 6
5 5
4 4
PMV
3 3
2 2
1 1
PULSE MOTOR VALVE
3 3
2
CN603
1 1
TEMP. SENSOR)
2 2
CN602
1 1
TEMP. SENSOR)
3 3
2
CN601
1 1
(DISCHARGE PIPE
TEMP. SENSOR)
2 2
CN600
1
1
(CONDENSER PIPE
TEMP. SENSOR)
2
2
CN500
1
1
PRESSURE SW.
COLOR IDENTIFICATION
BLK:BLACK
BLU:BLUE
RED:RED
GRY:GRAY
PNK:PINK
TS
(SUCTION PIPE
TO
(OUTDOOR
TD
TE
WHI:WHITE
BRW:BROWN
ORN:ORANGE
YEL:YELLOW
PUR:PURPLE
Indoor Terminal Block
POWER SUPPLY
(From Outdoor Unit)
208/230-1-60
1 1
2 2
(TC)
(TA)
CN62
(BLU)
1 1
2 2
CN61
(WHI)
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
MCC-5044
1010
11 11
CN10
Wireless Unit Assembly
(WHI)
Heat Exchanger Sensor
Thermo Sensor
L1 L2 S
BLK
WHI
3 1
CN01
T3.15A Fuse F01
Varistor
1
WHI
2
BLU
3
BLU
4
BLU
5
BLU
6
BLU
7
BLU
8
BLU
9
BLU
10
11
CN21
(YEL)
RED
GRN&YEL
Heat
Exchanger
CN51
Line
Filter
DC5V
DC12V
+
Main PC Board
WP-020
1 1
2 2
3 3
4 4
5 5
CN31
(WHI)
1 1
2 2
3 3
CN33
(WHI)
1 1
2 2
3 3
4 4
5 5
CN32
(WHI)
WHI
YEL
YEL
YEL
YEL
1 1
2 2
3 3
4 4
5 5
CN22
(WHI)
1
2
3
4
6 6
5 5
4 4
3 3
2 2
1 1
Color indication
BRW:BROWN
YEL:YELLOW
BLK:BLACK
Power Supply Circuit
RED:RED
BLU:BLUE
WHI:WHITE
GRN & YEL:
GREEN & YELLOW
Fan Motor
Louver Motor
– 18 –
5-2. RAS-12LKV-UL /RAS-12LAV-UL
FILE NO. SVM-10019
COMPRESSOR
1 1
2 2
CM
3 3
YEL
YEL
BRW
YEL
ORN
1 2 1
2
REACTOR
RED
WHI
BLK
P25
P23
P21
P35
P34
P19
P18
P11
P08
P04
P05
P06
P24
P22
P20
DB01
Q404
Q200~205
IGBT
POWER
RELAY
DB02
P33 P31 P30
PUR
R221
R220
R219
L03
CT
RELAY
P.C.BOARD
(MCC-5009)
C13
C12 C14
1 2
1 2
REACTOR
Outdoor Terminal Block
F03
FUSE
T3.15A
AC250V
CN701 P32
1 3
1
L1 L2 S
3
R321
R320
R319
COIL
FOR
4WAY
VALVE
Q300~305
MOS-FET
L01
SURGE
ABSORBER
L1
P07
BLK
~
VARISTOR
VARISTOR
F01
FUSE
25A
AC250V
P03
ORN
L2 S
P01
BLK
L1 L2
~ ~
POWER
SUPPLY
208/230-1-60
CN300
CN700
P02
WHI
BLK
3 3
WHI
2 2
1 1
6 6
5 5
4 4
3 3
2 2
1 1
CN603
CN602
CN601
CN600
CN500
FM
RED
FAN MOTOR
PMV
PULSE MOTOR VALVE
3 3
2
1 1
(SUCTION PIPE
TEMP. SENSOR)
2 2
1 1
TEMP. SENSOR)
3 3
2
1 1
(DISCHARGE PIPE
TEMP. SENSOR)
2 2
1
1
(CONDENSER PIPE
TEMP. SENSOR)
2
2
1
1
PRESSURE SW.
COLOR IDENTIFICATION
BLK:BLACK
BLU:BLUE
RED:RED
GRY:GRAY
PNK:PINK
TS
TO
(OUTDOOR
TD
TE
WHI:WHITE
BRW:BROWN
ORN:ORANGE
YEL:YELLOW
PUR:PURPLE
Indoor Terminal Block
POWER SUPPLY
(From Outdoor Unit)
208/230-1-60
SHEET METAL
BLK
CN02
Fuse F01
T3.15A 250VAC
1 1
2 2
(TA)
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
MCC-5044
1010
11 11
1212
Wireless Unit Assembly
1313
1414
1515
CN10
(WHI)
CN62
(BLU)
1 1
2 2
CN61
(WHI)
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
WHI
Varistor
Heat Exchanger Sensor
(TC)
Thermo Sensor
L1 L2 S
3 1
CN01
Line
Filter
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
1010
11 11
1212
1313
1414
1515
CN21
(WHI)
BLK
WHI
RED
CN51
Main PC Board
MCC-5045
Heat
Exchanger
GRN&YEL
DC5V
DC12V
1 1
3 3
4 4
5 5
6 6
CN31
(WHI)
1 1
2 2
3 3
4 4
5 5
CN32
(WHI)
WHI
YEL
YEL
YEL
YEL
1 1
2 2
3 3
4
4
5 5
CN22
(WHI)
1
2
3
4
DC Motor
Fan Motor
Louver Motor
Color indication
BRW:BROWN
YEL:YELLOW
BLK:BLACK
RED:RED
BLU:BLUE
WHI:WHITE
Power Supply Circuit
GRN & YEL:
GREEN & YELLOW
– 19 –
6-1. Indoor Unit
FILE NO. SVM-10019
6. SPECIFICATIONS OF ELECTRICAL PARTS
No.
Fan motor
1
(for indoor)
2 Room temp. sensor (TA-sensor)
3 Heat exchanger temp. sensor (TC-sensor)
4 Louver motor Output (Rated) 1W, 16 poles, DC12V
Parts name
RAS-09LKV-UL
RAS-12LKV-UL
AFS-220-20-4D AC240V, 20W
ICF-340U30-2 AC220V, 20W
( − )
( − )
MP24Z3T
10kΩ at 25°C
10kΩ at 25°C
SpecificationsType
6-2. Outdoor Unit
No.
1
Reactor
2 Outdoor fan motor
3 Suction temp. sensor (TS sensor)
Parts name
Model name
CH-57
ICF-340UA40-2 DC340V, 40W
(Inverter attached)
L = 10mH, 16A
10kΩ (25°C)
Rating
4 Discharge temp. sensor (TD sensor)
5 Outside air temp. sensor (TO sensor)
6 Heat exchanger temp. sensor (TE sensor)
7 Terminal block (5P) 30A, AC600V
8
Compressor
9 COIL FOR P.M.V.
10 Coil for 4-way valve
11 Pressure SW.
RAS-09LAV-U
RAS-12LAV-UL
L
(Inverter attached)
(Inverter attached)
(Inverter attached)
DA89X1C-23FZ2
DA111A1F-20F2
CAM-MD 12TCTH-4
STF
ACB-4UB82W 4.7 MPa
62kΩ (20°C)
10kΩ (25°C)
10kΩ (25°C)
3-phases 4-poles 680W
3-phases 4-poles 750W
DC12V
– 20 –
7. REFRIGERANT CYCLE DIAGRAM
7-1. Refrigerant Cycle Diagram
RAS-09LKV-UL / RAS-09LAV-UL
INDOOR UNIT
Indoor heat
exchanger
T1
Temp. measurement
TC
FILE NO. SVM-10019
P
Pressure measurement
Gauge attaching port
Vacuum pump connecting port
Deoxidized copper pipe
Outer dia. : 3/8 in (9.52mm)
Thickness : 1/32 in (0.8mm)
4-way valve
TS
Cross flow fan
Deoxidized copper pipe
Outer dia. : 1/4 in (6.35mm)
Thickness : 1/32 (0.8mm)
Sectional shape
of heat insulator
Muffler
Muffler
High Pressure switch
TD
Compressor
DA89X1C-23FZ2
Fusible plug
Outdoor heat
exchanger
TO
TA
Allowable height
difference : 33ft (10mm)
Strainer
Pulse Modulating
valve at liquid side
Strainer
Max. : 66ft (20m)
Min. : 6.6ft (2m)
Chargeless : 50ft (15m)
Charge : 0.22oz/ft
(51 to 66ft)
[20g/m (16 to 20m)]
Allowable pipe length
Temp. measurement
T2
Propeller fan
Refrigerant amount : 1.77lbs (0.80kg)
OUTDOOR UNIT
TE
NOTE :
Gas leak check position
Refrigerant flow (Cooling)
Refrigerant flow (Heating)
NOTE :
• The maximum pipe length of this air conditioner is 66ft (20 m). When the pipe length exceeds 50ft (15m), the additional
charging of refrigerant, 0.22 oz/ft (20g/m) for the part of pipe exceeded 50ft (15m) is required. [(Max. 0.22 lbs (100g)]
– 21 –
RAS-12LKV-UL / RAS-12LAV-UL
INDOOR UNIT
Indoor heat
exchanger
T1
Temp. measurement
TC
FILE NO. SVM-10019
P
Pressure measurement
Gauge attaching port
Vacuum pump connecting port
Deoxidized copper pipe
Outer dia. : 3/8 in. (9.52mm)
Thickness : 1/32 in. (0.8mm)
4-way valve
TS
Cross flow fan
Outer dia. : 1/4 in. (6.35mm)
Thickness : 1/32 in. (0.8mm)
Muffler
Outdoor heat
exchanger
Deoxidized copper pipe
Sectional shape
of heat insulator
Muffler
TD
Compressor
DA111A1F-20F1
TO
Split capillary
Ø1.2 x 80
TA
Allowable height
difference : 33ft (10m)
Allowable pipe length
Strainer
Pulse Modulating
valve at liquid side
Max. : 66ft (20m)
Min. : 6.6ft (2m)
Chargeless : 50 ft (15m)
Charge : 0.22oz/ft
(51 to 66 ft)
[20g/m (16 to 20m)]
Temp. measurement
T2
Propeller fan
Refrigerant amount : 2.43 lbs (1.10kg)
OUTDOOR UNIT
Ø1.2 x 80
TE
NOTE :
Gas leak check position
Refrigerant flow (Cooling)
Refrigerant flow (Heating)
NOTE :
• The maximum pipe length of this air conditioner is 66ft (15 m). When the pipe length exceeds 50ft (15m), the additional
charging of refrigerant, 0.22 oz/ft (20g/m) for the part of pipe exceeded 15m is required. [Max. 0.22 lbs (100g)]
– 22 –
FILE NO. SVM-10019
7-2. Operation Data
<Cooling>
Tempeature Model name Standard Heat exchanger Indoor Outdoor Compressor
condition(°C) RAS- pressure pipe temp. fan mode fan mode revolution
Indoor Outdoor P Psia (MPa) T1 °F (°C) T2 °F (°C) (rps)
80/67 98/75 137 to 160 54 to 57 99 to 102
(26.7/19.4) (35/23.9) (0.9 to 1.1) (12 to 14) (37 to 39)
12LKV-UL High High 77
<Heating>
Tempeature Model name Standard Heat exchanger Indoor Outdoor Compressor
condition(°C) RAS- pressure pipe temp. fan mode fan mode revolution
Indoor Outdoor P Psia (MPa) T1 °F (°C) T2 °F (°C) (rps)
70/60 47/43 363 to 392 102 to 105 32 to 37
(21.1/15.6) (8.3/6.1) (2.5 to 2.7) (39 to 41) (0 to 3)
09LKV-UL
12LKV-UL
116 to 145 52 to 55 104 to 107
(0.8 to 1.0) (11 to 13) (42 to 44)
377 to 406 106 to 106 32 to 36
(2.6 to 2.8) (41 to 43) (0 to 2)
High High 6009LKV-UL
High High
High High 64
62
NOTES :
1. Measure surface temperature of heat exchanger pipe around center of heat exchaner path U bent.
(Thermistor themometer)
2. Connecting piping condition : 16 ft (5m)
– 23 –
8-1. Indoor Unit
FILE NO. SVM-10019
8. CONTROL BLOCK DIAGRAM
Heat Exchanger Sensor (Tc)
Room Temperature Sensor (Ta)
Infrared Rays Signal Receiver
and Indication
Initializing Circuit
Clock Frequency
Oscillator Circuit
Power Supply
Circuit
Converter
(D.C circuit)
Noise Filter
M.C.U.
Functions
• Cold draft preventing Function
• 3-minute Delay at Restart for Compressor
• Fan Motor Starting Control
• Processing
(Temperature Processing)
• Timer
• Serial Signal Communication
• Clean Function
Serial Signal Transmitter/Receiver
Indoor Unit Control Unit
Louver
Motor
Louver Motor
Drive Control
Indoor Fan
Motor Control
Indoor
Fan Motor
From Outdoor Unit
208/230-1-60
REMOTE CONTROLLER
Serial Signal Communication
(Operation Command and Information)
Remote Controller
Operation (START/STOP)
Operation Mode Selection
AUTO, COOL, DRY, HEAT, FAN
Thermo. Setting
Fan Speed Selection
ON TIMER Setting
OFF TIMER Setting
Louver AUTO Swing
Louver Direction Setting
ECO
Hi-POWER
Infrared Rays, 36.7kHz
COMFORT SLEEP
QUIET
SLEEP (1,3,5,9 OFF TIMER)
– 24 –
8-2. Outdoor Unit (Inverter Assembly)
detect
Current
circuit
Gate drive
detect
Current
FILE NO. SVM-10019
Compressor
Outdoor
Fan motor
Inverter
(DC → AC)
P.M.V. : Pulse Motor Valve
M.C.U. : Micro Control Unit
MICRO-COMPUTER BLOCK DIAGRAM
M.C.U
MCC5009 (P.C.B) OUTDOOR UNIT
• PWM synthesis function
• Input current release control
circuit
Indoor unit
send/receive
circuit
Gate drive
• 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
4MHz
Clock
frequency
circuit
High Power
factor Correction
Converter
(AC → DC)
sensor
Input current
Filter
Noise
Inverter
(DC → AC)
Relay
circuit
of P.M.V.
Driver circuit
valve
4-way
P.M.V.
208/230-1-60
For INDOOR UNIT
Discharge
temp. sensor
Outdoor air
temp. sensor
Suction temp.
– 25 –
sensor
temp.sensor
Heat exchanger
9. OPERATION DESCRIPTION
FILE NO. SVM-10019
9-1. Outline of Air Conditioner Control
This air conditioner is a capacity-variable type air
conditioner, which uses AC or DC motor for the indoor
for motor and the outdoor fan motor. And the capacityproportional control compressor which can change the
motor speed in the range from 11 to 96 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. (P.M.V)
Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of
the compressor motor by controlling output voltage of
the inverter and switching timing of the supply power
(current transfer timing) so that motors drive according
to the operation command.
And then, the outdoor unit controller transfers reversely
the operating status information of the outdoor unit to
control the indoor unit controller.
As the compressor adopts four-pole brushless
DC motor, the frequency of the suppl y power
from inverter to compressor is two-times cycles
of the actual number of revolution.
1. Role of indoor unit controller
The indoor unit controller judges the operation
commands from the remote controller and assumes
the following functions.
• Judgment of suction air temperature of the indoor
heat exchanger by using the indoor temp. sensor.
(TA sensor)
• Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor)
(Prevent-freezing control, etc.)
• Louver motor control
• Indoor fan motor operation control
• LED (Light Emitting Diode) display control
• Transferring of operation command signal (Serial
signal) to the outdoor unit
• Reception of information of operation status
(Serial signal including outside temp. data) to the
outdoor unit and judgment/display of error
• Air purifier operation control
2. Role of outdoor unit controller
Receiving the operation command signal (Serial
signal) from the indoor unit controller, the outdoor
unit performs its role.
• Compressor operation control
• Operation control of outdoor fan motor
• P.M.V. control
• 4-way valve control
Operations followed to judgment
of serial signal from indoor side.
• 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 controller to indoor unit
controller
• Detection of outdoor temperature and operation
revolution control
• Defrost control in heating operation (Temp.
measurement by outdoor heat exchanger and
control for 4-way valve and outdoor fan)
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 controller
• 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.)
• Temperature of indoor heat exchanger
• For these signals ([Operation mode] and [Com-
pressor revolution] indoor heat exchanger temperature), 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.
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.
– 26 –
FILE NO. SVM-10019
9-2. Operation Description
1. Basic operation ........................................................................................................... 28
1. Operation control ................................................................................................... 28
2. Cooling/Heating operation ..................................................................................... 29
3. AUTO operation .....................................................................................................
4. DRY operation........................................................................................................ 29
2. Indoor fan motor control ............................................................................................. 30
3. Outdoor fan motor control........................................................................................... 32
4. Capacity control .......................................................................................................... 33
5. Current release control ............................................................................................... 33
6. Release protective control by temperature of indoor heat exchanger........................ 34
7. Defrost control (Only in heating operation) ................................................................ 35
8. Louver control ............................................................................................................. 36
1) Louver position....................................................................................................... 36
2) Air direction adjustment ......................................................................................... 36
3) Swing ..................................................................................................................... 36
9. ECO operation ............................................................................................................ 37
10. Temporary operation................................................................................................... 38
11. Discharge temperature control ................................................................................... 38
12. Pulse Modulating valve (P.M.V.) control ..................................................................... 39
13. Self-Cleaning function ................................................................................................ 40
14. Remote-A or B selection ............................................................................................ 42
15. QUIET mode ............................................................................................................. 43
16. COMFORT SLEEP mode ......................................................................................... 43
17. One-Touch Comfort .................................................................................................. 43
29
18. Hi-POWER Mode ...................................................................................................... 44
19. FILTER Indicator ........................................................................................................ 44
9-3. Auto Restart Function ..
9-3-1. How to Cancel the A uto Restart Function ................................................................. 45
9-3-2. How to set the Au to Restar t Function ....................................................................... 46
9-3-3. Power Failure During Timer Operation ................................................................... 46
9-4. Remote Controller and Its Fuctions
9-4-1. Parts Name of Remote Contr oller ............................................................................. 47
9-4-2. Operation of remote control ...................................................................................... 47
9-4-3. Name and Functions of Indications on Remote Contr oller ....................................... 50
– 27 −
FILE NO. SVM-10019
Item
1. Basic
operation
Operation flow and applicable data, etc.
1. Operation control
Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are
controlled.
1) The operation conditions are selected by the remote controller as shown in the below.
2) A signal is sent by ON button of the remote controller.
3) The signal is received by a sensor of the indoor unit and processed by the indoor controllers as
shown in the below.
4) The indoor controller controls the indoor fan motor and louver motor.
5) The indoor controller sends the operation command to the outdoor controller, and sends/receives
the control status with a serial signal.
6) The outdoor controller controls the operation as shown in the left, and also controls the compressor, outdoor fan motor, 4-way valve and pulse Modulating valve.
Selection of
operation conditions
ON/OFF
Remote controller
Control contents of remote controller
• ON/OFF (Air conditioner/Air purifier)
• Operation select (COOL/HEAT/AUTO/DRY)
• Temperature setup
• Air direction
• Swing
• Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH)
• ECO
• ON timer setup
• OFF timer setup
• Hi-POWER
• COMFORT SLEEP
• QUIET
• PRESET
• ONE-TOUCH
Description
Signal receiving
Indoor unit control
Operation command
Serial signal send/receive
Serial signal send/receive
Outdoor unit control
Indoor unit
Indoor unit control
• Command signal generating function of
indoor unit operation
• Calculation function (temperature calculation)
• Activation compensation function of indoor fan
• Cold draft preventive function
• Timer function
• Indoor heat exchanger release control
Outdoor unit
Outdoor unit control
• Frequency control of inverter output
• Waveform composite function
• Calculation function
(Temperature calculation)
• AD conversion function
• Quick heating function
• Delay function of compressor reactivation
• Current release function
• GTr over-current preventive function
• Defrost operation function
• Indoor fan motor
• Louver motor
~
Inverter
• Compressor
• Outdoor fan motor
• 4-way valve
• Pulse Modulating valve
(P.M.V.)
– 28 –
FILE NO. SVM-10019
Item
1. Basic
operation
Operation flow and applicable data, etc.
2. Cooling/Heating operation
The operations are performed in the following parts by controls according to cooling/heating conditions.
1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal
starts being transferred form the indoor controller to the outdoor unit.
2) At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan
motor control” and the louver according to the contents of “9. Louver control”, respectively.
3) The outdoor unit controls the outdoor fan motor, compressor, pulse Modulating valve and
4-way valve according to the operation signal sent from the indoor unit.
Operation ON
Indoor unit control
Sending of operation command signal
Outdoor unit control
Setup of remote controller
Indoor fan motor control / Louver control / Operation Hz
Control (Requierment)
Compressor revolution control / Outdoor fan motor control /
Operation Hz control (Include limit control)
4-way valve control In cooling operation: ON
In heating operation: OFF
Pulse Modulating valve control
[ ]
Description
3. AUTO operation
Selection of operation mode
As shown in the following figure, the operation starts by
selecting automatically the status of room temperature
(Ta) when starting AUTO operation.
*1. When reselecting the operation mode, the fan
speed is controlled by the previous operation mode.
Ta
°C
Cooling operation
Ts + 1
Monitoring (Fan)
Ts – 1
Heating operation
4. DRY operation
DRY operation is performed according to the difference
between room temperature and the setup temperature as
shown below.
In DRY operation, fan speed is controlled in order to
prevent lowering of the room temperature and to avoid air
flow from blowing directly to persons.
°F [ C]
Ta
+2.0 (1.0)
L– (W5)
(W5+W3) / 2
1) Detects the room temperature (Ta) when
the operation started.
2) Selects an operation mode from Ta in
the left figure.
3) Fan operation continues until an
operation mode is selected.
4) When AUTO operation has started
within 2 hours after heating operation
stopped and if the room temperature is
68°F (20°C)
performed with ”Super Ultra LOW” mode
for 3 minutes.
Then, select an operation mode.
5) In AUTO mode, either cooling or heating
operation will be selected. When room
temperature reach set temperature
commpressor will stop. In case that the
compressor stops for 15 minutes, the
AUTO mode will reselect cooling or
heating operation.
1) Detects the room temperature (Ta) when
the DRY operation started.
2) Starts operation under conditions in the
left figure according to the temperature
difference between the room temperature and the setup temperature (Tsc).
Setup temperature (Tsc)
= Set temperature on remote controller
(Ts) + 0~1.0°C (0 to 2°F)
3) When the room temperature is lower
2°F (1°C) or less than the setup
temperature, turn off the compressor.
or more, the fan operation is
+1.0 (0.5)
Tsc
SUL (W3)
Fan speed
− 29 −
FILE NO. SVM-10019
Item
2. Indoor fan
motor control
COOL ON
Fan speed setup
AUTO
Ta
°F [°C]
+4.5 (+2.5)
+3.5 (+2.0)
+2.7 (+1.5)
+2.0 (+1.0)
a
b
c
Operation flow and applicable data, etc.
<In cooling operation>
(This operation controls the fan speed at indoor unit side.)
The indoor fan (cross flow fan) is operated by the phase-
control induction motor. The fan rotates in 5 stages in
MANUAL mode, and in 5 stages in AUTO mode, respectively. (Table 1)
MANUAL
(Fig. 1)
Indication
L
L+
M
M+
H
Fan speed
W6
(L + M) / 2
W9
(M + H) / 2
WC
(Fig. 2)
Air volume AUTO
M+(WB)
*3
*4
*5
*3 : Fan speed = [(M+) –L] x 3/4 + L
*4 : Fan speed = [(M+) –L] x 2/4 + L
*5 : Fan speed = [(M+) –L] x 1/4 + L
Description
* Symbols
UH : Ultra High
H : High
M+ : Medium+
M : Medium
L+ : Low+
L: Low
L- : Low–
UL : Ultra Low
SUL : Super Ultra Low
* The values of fan speed and air flow
volume indicate on the table are measured
when the louver is inclined downward.
Fan speed and air flow volume broadly
vary with position of louver.
1) When setting the fan speed to L,
L+, M, M+ or H on the remote
controller, the operation is
performed with the constant
speed shown in Fig. 1.
2) When setting the fan speed to
AUTO on the remote controller,
revolution of the fan motor is
controlled to the fan speed level
shown in Fig. 2 and Table 1
according to the setup temperature and room temperature.
Tsc
d
e
L(W6)
(Linear approximation
from M+ and L)
+1.0 (+0.5)
(Table 1) Indoor fan air flow rate
Fan speed
level
WF UH 1210 336 (571) 1510 433 (735)
WE H 1210 336 (571) 1510 433 (735)
WD UH M+ UH 1170 321 (546) 1480 422 (717)
WC H H 1120 303 (515) 1430 404 (686)
WB M+ M+ 1040 274 (465) 1280 350 (594)
WA M 1000 248 (421) 1220 328 (557)
W9 M L+ 960 235 (400) 1150 302 (514)
W8 L 870 200 (340) 1000 248 (421)
W7 L+ L- L+ 850 194 (330) 980 241 (409)
W6 L L 760 159 (270) 920 219 (372)
W5 L- UL L- 760 159 (270) 900 212 (360)
W4 UL UL 700 141 (240) 840 190 (323)
W3 SUL SUL 650 118 (200) 770 165 (280)
W2 SUL 500 65 (110) 620 110 (187)
W1 500 65 (110) 520 74 (126)
DRYHEATCOOL
RAS-09LKV-UL
Fan speed Air flow rate Fan speed Air flow rate
(rpm) cfm (m3/h) (rpm) cfm (m3/h)
RAS-12LKV-UL
– 30 –
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