Toshiba RAS-13UKV-E2, RAS-13UAV-E2 User Manual

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SERVICE MANUAL

AIR CONDITIONER

RAS-13UKV-E2 / RAS-13UAV-E2

FILE NO. SVM-03008

SPLIT WALL TYPE

Jun., 2003

CONTENTS

1. SPECIFICATIONS

1-1 Specifications 1-2 Operation Characteristic Curve 1-2 Capacity Variation Ratio According to Temperature

2. REFRIGERANT R410A

2-1 Safety During Installation/Servicing 2-2 Refrigerant Piping Installation 2-3 Tools 2-4. Recharging of Refrigerant 2-5. Brazing of Pipes

3. CONSTRUCTION VIEWS

3-1 Indoor Unit 3-2 Outdoor Unit

4. WIRING DIAGRAM

4-1 Indoor Unit 4-2 Outdoor Unit

FILE NO. SVM-03008

5. SPECIFICATION OF ELECTRICAL PARTS

5-1 Indoor Unit 5-2 Outdoor Unit

6. REFRIGERANT CYCLE DIAGRAM

6-1 Refrigerant Cycle Diagram 6-2 Operation Data

7. CONTROL BLOCK DIAGRAM

7-1 Indoor Unit 7-2 Outdoor Unit (Inverter Assembly)

8. OPERATION DESCRIPTION

8-1 Outlined of Air Conditioner Control 8-2 Description of Operation Circuit 8-3 Temporary Operation 8-4 Auto Restart Function 8-5 Filter Check Lamp 8-6 Remote Control and its Functions 8-7 Hi POWER Mode ([Hi POWER] button on the remote control is pushed.)

9. INSTALLATION PROCEDURE

9-1 Safety Cautions 9-2 INDOOR UNIT 9-3 OUTDOOR UNIT

– 1 –

10. HOW T O DIAGNOSE THE TROUBLE

10-1 First Confirmation 10-2 Primary Judgment 10-3 Judgment by Flashing LED of Indoor Unit 10-4 Self-Diagnosis by Remote Control (Check Code) 10-5 Judgment of Trouble by Every Symptom 10-6 Check Code 1C (Miswiring in indoor/outdoor units) and 1E 10-7 How to Diagnose Trouble in Outdoor Unit 10-8 How to Check Simply the Main Parts 10-9 How to Simply Judge Whether Outdoor Fan Motor is Good or Bad

11. HOW TO REPLACE THE MAIN PARTS

11-1 Indoor Unit 11-2 Microcomputer 11-3 Outdoor Unit

12. EXPLODED VIEWS AND PARTS LIST

12-1 Indoor Unit (E-Parts Assy) 12-2 Indoor Unit 12-3 Outdoor Unit 12-4 Outdoor Unit (E-Parts Assy)

FILE NO. SVM-03008

– 2 –

1-1. Specifications

FILE NO. SVM-03008

1. SPECIFICATIONS

Unit model Indoor RAS-13UKV-E2

Current limited — Cooling capacity (kW) 3.5 Cooling capacity range (kW) 0.9 – 4.0 Heating capacity (kW) 4.2 Heating capacity range (kW) 0.9 – 6.0 Power supply 220 – 240V –1Ph –50/60Hz Electric Indoor Operation mode Cooling Heating characteristics Running current (A) 0.15 0.15

COP (Cooling / Heating) 3.33/3.72 Operation noise Indoor High (Cooling / Heating) (dB•A) 39/39

Indoor unit Unit model RAS-13UKV-E2

Outdoor unit Unit model RAS-13UAV-E2

Piping connection Type Flare connection

Refrigerant Name of refrigerant R410A

Wiring connection Power supply 3 Wires: includes earth (Outdoor)

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

Accessory Indoor unit Installation plate 1

Outdoor RAS-13UAV-E2

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

Outdoor Operation mode Cooling Heating

Running current (A) 4.65 5.01 Power consumption (W) 1020 1100 Power factor (%) 95 95 Starting current (A) 5.31

Medium (Cooling / Heating) (dB•A) 33/34 Low (Cooling / Heating) (dB•A) 26/28

Outdoor (Cooling / Heating) (dB•A) 48/50

Dimension Height (mm) 275

Width (mm) 790

Depth (mm) 208 Net weight (kg) 10 Fan motor output (W) 30 Air flow rate (Cooling / Heating) (m3/h) 530/620

Dimension Height (mm) 550

Width (mm) 780

Depth (mm) 720 Net weight (kg) 40 Compressor Motor output (W) 750

Type Twin rotary type with DC-inverter variable speed control

Model DA91A1F-45F Fan motor output (W) 43 Air flow rate (Cooling / Heating) (m3/h) 2410/2410

Indoor unit Liquid side ∅6.35

Gas side ∅9.52 Outdoor unit Liquid side ∅6.35

Gas side ∅9.52 Maximum length (Per unit) (m) 15 Maximum chargeless length (m) 15 Maximum height difference (m) 10

Weight (kg) 0.9

Interconnection 4 Wires: includes earth

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

Wireless remote control 1

Remote controller holder 1

Flat head wood screw 2 (∅3.1 x 16L)

Purifying filter 1

Zeolite filter 1

Batteries 2

Mounting screw 6 (∅4 x 25L)

Installation manual 1

Owner’s manual 1 Outdoor unit Drain nipple 1

• The specification may be subject to change without nitice for purpose of improvement. – 3 –

1-2.Operation Characteristic Curve

FILE NO. SVM-03008

Current (A)

• Conditions 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)

Current (A)

• Conditions Indoor : DB 20°C Outdoor : DB 7°C/WB 6°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

105 100

95 90 85 80 75 70

Capacity ratio (%)

65 60 55 50

32 34

Current Limited Start

• Conditions Indoor : DB27°C/WB19°C Indoor air flow : High Pipe length 5m

36 38 40 4233 35 37 39 41 43

Outdoor temp. (°C)

120 110 100

90 80 70 60 50

Capacity ratio (%)

40 30 20 10

−10−9−8−7−6−5−4−3−2−1012345678910

• Conditions

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

Outdoor temp. (°C)

Capacity ratio : 100% = 3.5 kW

– 4 –

2. REFRIGERANT R410A

FILE NO. SVM-03008

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 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 instal-

lation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire, a poisonous gas may occur.

(4) When installing or removing an air conditioner,

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

(5) After completion of installation work, check to

make sure that there is no refrigeration gas leakage. If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

(6) When an air conditioning system charged with a

large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level. If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

(7) Be sure to carry out installation or removal

according to the installation manual. Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc.

(8) Unauthorized modifications to the air conditioner

may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician. Improper repair’s may result in water leakage, electric shock and fire, etc.

2-2.Refrigerant Piping Installation

2-2-1. Piping materials and joints used

For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

(1) Copper Pipes

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

– 5 –

FILE NO. SVM-03008

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 2-2-6 below.

Table 2-2-2 Minimum thicknesses of socket joints

Nominal diameter

Reference outer diameter of Minimum joint thickness

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

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm. Thicknesses of socket joints are as shown in Table 2-2-2.

copper pipe jointed (mm) (mm)

2-2-2. 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.

c) Insertion of Flare Nut

– 6 –

d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for 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” b y using a gauge for size adjustment.

∅D

Fig. 2-2-1 Flare processing dimensions

FILE NO. SVM-03008

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

Nominal

diameter

1/4 6.35 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0 3/8 9.52 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0 1/2 12.70 0.8 0 to 0.5 1.0 to 1.5 2.0 to 2.5 5/8 15.88 1.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5

Nominal

diameter

1/4 6.35 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5 3/8 9.52 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5 1/2 12.70 0.8 0 to 0.5 0.5 to 1.0 1.0 to 2.0

Outer

diameter

(mm)

Table 2-2-4 Dimensions related to flare processing for R22

Outer

diameter

(mm)

Thickness

(mm)

Thickness

(mm)

Flare tool for R410A

clutch type

Flare tool for R410A

clutch type

A (mm)

Conventional flare tool

Clutch type Wing nut type

A (mm)

Conventional flare tool

Clutch type Wing nut type

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

Table 2-2-5 Flare and flare nut dimensions for R410A

Nominal

diameter

1/4 6.35 0.8 9.1 9.2 6.5 13 17 3/8 9.52 0.8 13.2 13.5 9.7 20 22 1/2 12.70 0.8 16.6 16.0 12.9 23 26 5/8 15.88 1.0 19.7 19.0 16.0 25 29

Nominal

diameter

1/4 6.35 0.8 9.0 9.2 6.5 13 17

Outer

diameter

(mm)

Outer

diameter

(mm)

Thickness

(mm)

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

Thickness

(mm)

ABCD

Dimension (mm)

Flare nut

width

(mm)

Flare nut

width

(mm)

3/8 9.52 0.8 13.0 13.5 9.7 20 22 1/2 12.70 0.8 16.2 16.0 12.9 20 24 5/8 15.88 1.0 19.7 19.0 16.0 23 27 3/4 19.05 1.0 23.3 24.0 19.2 34 36

– 7 –

FILE NO. SVM-03008

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 Outer diameter Tightening torque

diameter (mm) N·m (kgf·cm)

1/4 6.35 14 to 18 (140 to 180) 16 (160), 18 (180) 3/8 9.52 33 to 42 (330 to 420) 42 (420) 1/2 12.70 50 to 62 (500 to 620) 55 (550) 5/8 15.88 63 to 77 (630 to 770) 65 (650)

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

Note:

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

Tightening torque of torque

wrenches available on the market

N·m (kgf·m)

– 8 –

FILE NO. SVM-03008

2-3. T ools

2-3-1. Required tools

The service port diameter of packed valve of the outdoor unit in the air conditioner 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 ∅12.70 copper pipe) of the refrigerant piping are lengthened.

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

(1) Tools exclusive for 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

R410A air conditioner Conventional air

installation conditioner installation

No. Used tool Usage Existence of Whether Whether new equipment

new equipment conventional can be used with for R410A equipment can conventional refrigerant

be used

1 Flare tool Pipe flaring Yes *(Note 1) 2 Copper pipe gauge Flaring by

for adjusting projection conventional flare Yes *(Note 1) *(Note 1) margin tool

3 Torque wrench Connection of

(For ∅12.70) flare nut

4 Gauge manifold 5 Charge hose

6 Vacuum pump adapter Vacuum evacuating Yes

Electronic balance for

refrigerant charging

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

Evacuating, refrigerant charge, Yes run check, etc.

Refrigerant charge Yes

Yes

(Note 1) When flaring is carried out for 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.

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 (4) Reamer (9) Hole core drill (∅65)

Use vacuum pump by (5) Pipe bender (10) Hexagon wrench

attaching vacuum pump adapter. (6) Level vial (Opposite side 5 mm) (2) Torque wrench (For ∅6.35) (7) Screwdriver (+, –) (11) Tape measure (3) Pipe cutter (8) Spanner of Monkey wrench (12) Metal saw

Also prepare the following equipments for other installation method and run check. (1) Clamp meter (3) Insulation resistance tester (2) Thermometer (4) Electroscope

– 9 –

FILE NO. SVM-03008

2-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.

Recover the refrigerant, and check no refrigerant remains in the equipment.

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

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

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

Connect the charge hose to the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

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

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

Place the handle of the gauge manifold Low in

(For refrigerant charging, see the figure below.)

the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

1 Never charge refrigerant exceeding the specified amount. 2 If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode. 3 Do not carry out additional charging.

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

(INDOOR unit)

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

Electronic balance for refrigerant charging

Fig. 2-4-1 Configuration of refrigerant charging

(Liquid side)

(Gas side)

– 10 –

(OUTDOOR unit)

Opened

Closed

Service port

FILE NO. SVM-03008

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

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.

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

Siphon

Fig. 2-4-2

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.

1 Phosphor bronze brazing filler tends to react

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

2 When performing brazing again at time of

servicing, use the same type of brazing filler.

2-5-2. Flux (1) Reason why flux is 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.

– 11 –

FILE NO. SVM-03008

(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.

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

1 Attach a reducing valve and a flow-meter to the

Nitrogen gas cylinder.

2 Use a copper pipe to direct the piping material,

and attach a flow-meter to the cylinder.

3 Apply a seal into the clearance between the

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

4 When the Nitrogen gas is flowing, be sure to

keep the piping end open.

5 Adjust the flow rate of Nitrogen gas so that it is

lower than 0.05 m3/Hr or 0.02 Mpa (0.2 kgf/ cm2) by means of the reducing valve.

6 After performing the steps above, keep the

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

7 Remove the flux completely after brazing.

(4) Piping materials for brazing and used brazing

filler/flux

Piping Used brazing Used

material filler flux

Copper - Copper Phosphor copper Do not use

Copper - Iron Silver Paste flux

Iron - Iron Silver Vapor flux

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.

Flow meter

Stop valve

Nitrogen gas

cylinder

From Nitrogen cylinder

Pipe

Rubber plug

Nitrogen gas

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

– 12 –

3-1. Indoor Unit

FILE NO. SVM-03008

3. CONSTRUCTION VIEWS

Front panel

Back body

660

Knock out system

Air inlet

Air filter

790

Heat exchanger

275

Air outlet

120 80

590

Hanger

208

Knock out system

660

Drain hose (0.54m)

Hanger

Minimum distance to ceiling

275

r m

320

620

235 235

215 215

Minimum distance to ceiling

o r m

Hanger

– 13 –

Connecting pipe (0.43m)

(Flare ∅6.35) Connecting pipe (0.33m) Flare ∅9.52

Hanger

150150 160160

Installation plate outline

Center line

For stud bolt (∅8~∅10)

For stud bolt (∅6)

4519040

Minimum distance to ceiling

r m

9090

160

57 18

Wireless remote control

3-2.Outdoor Unit

FILE NO. SVM-03008

A Detail drawing (Back Leg)

∅6 Hole

310

600 52 36

302

270

R15

R5.5

32.5

310

302

∅30 Drain outlet

∅436

530

265

FAN GUARD

115 125

2-∅11 x 14 Hole (For ∅8-∅10 anchor bolt)

600 780

102

∅6 Hole

∅11 x 14 Hole

B Detail drawing (Front Leg)

310

302

36 52

R15

310 330

COVER PV

Electrical part cover

600 or more

320

100 or more

Z View

Installation dimension

600

Air inlet

Air outlet

600 or more

4 x ∅11 x 14 Long holes (For ∅8 − ∅10 anchorbolt)

600 or more

120

Liquid side (Flare ∅6.35) Gas side (Flare ∅9.52)

Service port

– 14 –

4-1.Indoor Unit

FILE NO. SVM-03008

4. WIRING DIAGRAM

Table 4-1-1 Simple Check for Failure Diagnosis

Check Item

OPERATION

INDICATOR

TERMINAL BLOCK

FUSE 3.15A

DC5V

4 5

DC12V DC325V

(DC310 to 340V)

Refer to the service data for the detailed failure diagnosis.

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

Check the power supply v oltage between 1 and 2. (Refer to the name plate.) (Check the primary and secondary voltage of the transformer.) Check the fluctuating voltage between 2 and 3. (DC15 to 60 V)

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

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

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

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

Diagnosis Result

– 15 –

4-2.Outdoor Unit

FILE NO. SVM-03008

PULSE

MODULATING

VALVE

THERMOSTAT FOR COMPRESSOR

121

REACTOR

ORN

P10

G E A

CONVERTER

MODULE

DB01

BRW

BU EU BV EV BW EW BX

IGBT MODULE

Q200

BLU P18

112

CN600 CN500

P07 P08

P09

P19 P20

P17

11223

POEWR RELAY

ELECTRONIC STAR TER

P.C. BOARD

(MCC-813)

P21 P22 P23

RED

WHI BLK

112

C12 C13 C14

COMPRESSOR

11223311223

CN701

RELAY

COIL for 4-WAY VALVE

BLK P06 CN703CN603CN602CN601

VARIST OR

Q300

WHI

112

SURGE ABSORBER

F04 FUSE T3.15A

PMV

YEL

ORN

BLU

RED

GRY

44556

F01

FUSE

T25A

P01

BLK ORN

P03

WHI

P02

P11 P12

P13

P14

CN300

CN301

IGBT : Insulated Gate Bipolar Transistor

121

L 3 2 1

REACTOR

PUR

FAN MOTER

RED WHI BLK

YEL

PNK GRY

POWER SUPPLY 220-240V~ 50/60Hz

TO INDOOR UNIT

– 16 –

FILE NO. SVM-03008

5. SPECIFICATION OF ELECTRICAL PARTS

5-1. Indoor Unit

No. Parts name Type Specifications

1 Fan motor (for indoor) ICF-340-30-2 DC 340 V, 30 W 2 Thermo. sensor (TA-sensor) ——— 10 kΩ at 25°C 3 DC-DC transformer (T01) SWT-70 DC 390 V, Secondary DC 15 V, 12 V, 7 V 4 Microcomputer µPD780024AGK 5 Heat exchanger sensor

(TC-sensor) 6 Line filter (L01 SS11V-06270 27mH, AC 0.6A 7 Diode (DB01) D3SBA60 4A, 600 V 8 Capacitor (C03) KMH450VNSN120M25C 120µF, 450 V 9 Fuse (F01) FCU250V, 3.15A T3.15A, 250 V

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

13 Louver motor MP24GA

——— 10 kΩ at 25°C

Output (Rated) 1 W,16 poles, 1 phase, DC 12 V

5-2.Outdoor Unit

No. Parts name Model name Rating

1 SC coil L01 ADR2516-0R6TB 20A, 150µH

(Noise filter) L03 ADR2520-R15TB 15A, 0.6mH

Primary side DC280V, Secondary

2 DC-DC transformer SWT-43 side 7.5 V x 1, 13 V x 1, 26.5V x 3,

16 V x 1, 15 V x 1 3 Reactor CH-57-Z-T L=10mH, 16A x 2 4 Outside fan motor ICF-140-43-1 DC140 V, 43 W 5 Suction temp. sensor

(TS sensor) Discharge temp. sensor

(TD sensor) Outside air temp. sensor

(TO sensor) Heat exchanger temp.

sensor (TE sensor)

9 Terminal block (6P) ——— 20A, AC 250 V

10 Fuse

11 Electrolytic capacitor LLQ2G501KHUATF, 400LISN500K35F 500µF, DC 400 V x 3 pieces 12 Transistor module 6MBI25GS-060-01 or 6MBI25GS-060-01A 25A, 600 V 13 Compressor DA91A1F-45F 3-phases 4-poles 750 W 14 Compressor thermo. PW-2AL OFF: 125 ± 4°C, ON: 90 ± 5°C

15 Converter module MP7003

For protection of switching power source 3.15A, AC 250 V

For protection of inverter input overcurrent 25A, AC 250 V

(Inverter attached) 10 kΩ (25°C)

(Inverter attached) 62 kΩ (20°C)

(Inverter attached) 10 kΩ (25°C)

Diode: 25A, 600 V,

IGBT: 40 A, 600V

– 17 –

6. REFRIGERANT CYCLE DIAGRAM

6-1.Refrigerant Cycle Diagram

Pressure measurement Gauge attaching port

Vacuum pump connecting port Deoxidized copper pipe

Outer dia. : 9.52 mm Thickness : 0.8 mm

INDOOR UNIT

Indoor heat

exchanger

Cross flow fan

Deoxidized copper pipe Outer dia. : 6.35 mm Thickness : 0.8 mm

Sectional shape of heat insulator

Temp. measurement

FILE NO. SVM-03008

Max. : 15 m

Allowable height

difference : 10m

Allowable pipe length

4-way valve (CHV-0213)

Temp. measurement

Muffler

Compressor DA91A1F-45F

Outdoor heat

exchanger

Propeller fan

OUTDOOR UNIT

Split capillary

∅1.5 x 200 ∅1.5 x 200

Strainer

Pulse modulating valve at liquid side (SEV16RC3)

Refrigerant amount : 0.9 kg

NOTE :

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

Note :

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

– 18 –

6-2.Operation Data

FILE NO. SVM-03008

Temperature

condition (°C)

Indoor Outdoor

27/19 35/– 13UKV-E2 0.8 to 1.0 9 to 11 49 to 45 High High 77

Temperature

condition (°C)

Indoor Outdoor

20/– 7/6 13UKV-E2 2.5 to 2.7 42 to 44 0 to 3 High High 83

Note :

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

(Thermistor themometer)

(2) Connecting piping condition : 5m

Model

name

Model

name

Standard pressure

P (MPa)

Standard pressure

P (MPa)

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

Indoor

fan

mode

Indoor

fan

mode

Outdoor

fan

mode

Outdoor

fan

mode

Compressor

revolution

Compressor

revolution

(rps)

– 19 –

7-1.Indoor Unit

Heat Exchanger Sensor

7. CONTROL BLOCK DIAGRAM

Indoor Unit Control Panel

M.C.U

Functions

• Louver Control

FILE NO. SVM-03008

Operation

Display

Temperature Sensor

Infrared Rays Signal Receiver

Initiallizing Circuit

Infrared

Rays

36.7KHz

Clock Frequency

Oscillator Circuit

Power Supply

Remote

Control

Noise Filter

From Outdoor Unit

Circuit

•

3-minute Delay at Restart for Compressor

•

Motor Revolution Control

•

Processing (Temperature Processing)

•

Timer

•

Serial Signal Communication

Louver ON/OFF Signal

Louver Driver

Serial Signal Transmitter/Receiver

Serial Signal Communication

Timer

Display

Filter

Sign Display

PRE DEF.

Sign Display

Indoor

Fan Motor

Louver

Motor

Louver Motor

REMOTE CONTROL

Infrared Rays

Remote Control

Operation (START/STOP) Operation Mode Selection

AUTO, COOL, DRY, HEAT, FAN ONLY

Temperature Setting Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECO

Hi power

Filter Reset

– 20 –

7-2.Outdoor Unit (Inverter Assembly)

220 − 240 V

50/60 Hz

MICRO-COMPUTER BLOCK DIAGRAM

Over current

sensor

Driver circuit

of P.M.V.

Over current

sensor

Heat exchanger

temp.sensor

Suction temp.

sensor

Outdoor air

temp. sensor

Discharge

temp. sensor

Inddor unit

send/receive

circuit

Relay

circuit

Noise

Filter

Converter

(AC → DC)

Clock

frequency

16MHz

High Power

factor Correction

circuit

Input current

sensor

Rotor position

detect circuit

Rotor position

detect circuit

• 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

P.M.V : Pulse Modulating Valve

M.C.U : Micro Control Unit

M.C.U

For INDOOR UNIT

4-way

valve

P.M.V.

Inverter

(DC → AC)

Over current

detect circuit

Gate drive

circuit

Gate drive

circuit

Over current

sensor

Inverter

(DC → AC)

Outdoor

Fan motor

Compressor

MCC813 (P.C.B)

OUTDOOR UNIT

FILE NO. SVM-03008

– 21 –

8. OPERATION DESCRIPTION

FILE NO. SVM-03008

8-1.Outlined of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor fan motor and the outdoor fan motor. And the capacity proportional control compressor which can change the motor speed in the range from 13 to 110 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 control, 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 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 (TA sensor)

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

• 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

(2) Role of outdoor unit controller

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

• Compressor operation control

• Operation control of outdoor fan motor

• P.M.V. control

• Detection of inverter input current and current

release operation

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

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

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

• Detection of outdoor temperature and operation revolution control

• Defrost control in heating operation (Temp. measurement by outdoor heat exchanger and control for 4-way valve and outdoor fan)

Operations followed to judgment of serial signal from indoor side.

– 22 –

FILE NO. SVM-03008

(3) Contents of operation command signal (Serial

signal) from indoor unit controller to outdoor unit controller The following three types of signals are sent from the indoor unit controller.

• Operation mode set on the remote control

• Compressor revolution command signal

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

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

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

(4) Contents of operation command signal (Serial

signal) from outdoor unit controller to indoor unit controller The following signals are sent from the outdoor unit controller.

• The current operation mode

• The current compressor revolution

• Outdoor temperature

• Existence of protective circuit operation

For transferring of these signals, the indoor unit controller monitors the contents of signals, and judges existence of trouble occurrence. Contents of 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 220-240 V power to DC once, and controls capacity by changing supply power status to the compressor with transistor module (includes 6 transistors). The outline of the control is as follows:

The revolution position and revolution speed of the motor are detected by detecting winding electromotive force of the compressor motor under operation, and the revolution speed is changed so that the motor drives based upon revolution speed of the operation command by changing timing (current transfer timing) to exchange inverter output voltage and supply power winding.

Detection of the revolution position for controlling is performed 12 times per 1 revolution of compressor. The range of supply power frequency to the compressor differs according to the operation status (COOL, HEAT, DRY).

Table 8-1-1 Compressor revolution range

Operation Model

mode name

COOL

HEAT

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.

13UKV-E2

Compressor

revolution (rps)

13 to 88

16 to 110

8-1-3. Power factor improvement control

Power factor improvement control is performed mainly aiming to reduce the current on much power consumption of cooling/heating operation. Controlling starts from the time when input power has reached at a certain point. To be concrete, IGBT of the power factor improvement circuit is used, and the power factor is improved by keeping IGBT on for an arbitrary period to widen electro-angle of the input current.

– 23 –

FILE NO. SVM-03008

8-1-4. Prevent-freezing control

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

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

Using P.M.V., refrigerant flow of refrigeration cycle is varied for the optimum 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.

8-1-6. Louver control

(1) Vertical air flow louvers

Positions of vertical air flow louvers are automatically controlled according to the operation status (AUTO (A), COOL ( ), DRY ( ), HEAT( ) and FAN ONLY ( ). Besides, positions of vertical air flow louvers can be arbitrarily set by pushing the [FIX] button.

(2) Swing

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

8-1.7. Indoor fan control (DC fan motor)

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

change DC motor.

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

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

LOW+=

MED+=

LOW+MED

MED+HIGH

Table 8-1-2

Operation

mode

Fan

mode

RAS-13UKV-E2

Motor speed Air flow rate

(rpm) (m3/h)

H 1210 530

COOL M 1010 420

L 810 330

DRY — 780 320

H 1290 620

HEAT M 1110 470

L 930 380

– 24 –

FILE NO. SVM-03008

8-1-8. Outdoor fan control (DC fan motor)

Although the outdoor fan motor drives the outdoor fan by non-step variable system of the revolution speed, the revolution speed is restricted to three steps on the convenience of controlling. If a strong wind is lashing outside of the room, the operation may be continued as the outdoor fan stops in order to protect the outdoor fan motor.

If a fan lock occurred due to entering of foreign matter, the air conditioner stops and an alarm is displayed.

<COOL, DRY>

Table 8-1-3

Model name RAS-13UAV-E2

Compressor revolution (rps) To 13.8 To 34.7 From 35.3

TO ≥ 38°C 390 840 840

Outdoor temp. sensor TO TO < 38°C 390 700 840

TO < 15°C 390 TO ≥ 38°C 390 700 840

ECONO. operation TO < 38°C 390 390 700

TO < 15°C 390

TO is abnormal 700 700 840

<HEAT>

Table 8-1-4

Model name RAS-13UAV-E2

Compressor revolution (rps) To 16.8 To 57.4 From 58.0

Outdoor temp. sensor TO

ECONO. operation

TO is abnormal 390 650 840

TO ≥ 5°C 390 650 840 TO < 5°C 650 650 840 TO ≥ 5°C 390 390 650 TO < 5°C 390 650 650

– 25 –

FILE NO. SVM-03008

8-2. Description of Operation Circuit

• Turning [ON] the breaker flashes the operation lamp. (1Hz) This is the display of power-ON (or notification of power failure).

• When pushing [START/STOP] button of the remote control, receive sound is issued from the main unit, and the next operations are performed together with opening the vertical air flow louvers.

8-2-1. Cooling operation

(The Remote Control MODE Button is Set to the COOL Position)

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

• A cooling operation signal is transmitted to outdoor unit.

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

• When [FAN] button is set to AUTO, the indoor fan motor operates as shown in Fig. 8-2-1. When [FAN] button is set to LOW , LOW MED , MED

, HIGH , the

motor operates with a constant air flow.

°C

+3 +2.5 +2 +1.5 +1

(Room temp.) − (Set temp.)

+0.5

Set temp.

−0.5

NOTE :

*1: Calculated from difference in motor speed of M+

and L, and controlled.

M+ *1 *1 *1

In normal operation

(1) Cooling capacity control

• The cooling capacity and room temperature are controller by changing the compressor motor speed according to both the difference between the temperature detected by the room temperature sensor and the temperature set by TEMP button and also any change in room temperature.

• When compressor has been activated or reactivated, it operates with Max.41 rps for 2 minutes, with Max.91 rps from 2 minutes to 3 minutes, and with Max.88 rps after 3 minutes passed.

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

(2) Prevent-freezing control

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

(3) Current release control

The input current of compressor and outdoor fan motor (Precisely inverter main circuit control section) which occupy most of air conditioner input is detected by the outdoor current sensor, and compressor motor speed is gradually lowered so that current value does not exceed 9.0A if current value exceeds 9.0A. When the current value lowers to 8.5A, return the operation to the above item (1).

Comp. motor

9.0

8.5

Current value (A)

Normal control

speed down

Comp. motor speed keep

Fig. 8-2-2

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

– 26 –

FILE NO. SVM-03008

(4) Limit for maximum compressor motor speed

by indoor fan speed

When outdoor temperature sensor detected 32°C or lower, and indoor heat exchanger sensor detected 17°C or lower, the maximum compressor motor speed is limited by the indoor fan speed. For example, the compressor motor speed is limited as described in the table below.

Table 8-2-1

Air flow rate

RAS-13UKV-E2

(rps)

HIGH 77

M+ 65

MED. 53

L–, L 30

UL, SUL 30

rps : round per second

(5) Louver control

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

(6) Discharge temperature control

(Common control to cooling and heating)

The discharge temperature of refrigerant gas from the compressor is detected by the discharge temperature sensor, and controls operating compressor motor speed.

1) Control 1 (A zone) : Normal operation zone When TD detect value is 98°C or lower, the operation is performed with operating motor speed instructed by the serial signal.

2) Control 2 (B zone) : Slow-up zone of motor speed When TD detect value is 98°C or higher, operating motor speed is slowly up.

3) Control 3 (C zone) : Keep zone When TD detect value is 105°C or higher, operating motor speed is not changed if raising operation speed.

4) Control 4 (D zone) : Slow down zone of motor speed When TD detect value is 108°C or higher, operating motor speed is slowly down.

5) Control 5 (E zone) : Normal down of motor speed When TD detect value is 112°C or higher, operating motor speed is down.

6) Control 6 (F zone) : Operation stop zone If TD detect value exceeds 117°C during operation, stop the operation immediately. Then, restart the operation when TD detect value becomes 105°C or lower.

Zone

(°C) 117

112

108

105

Operation stop zone Normal down zone

of motor speed Slow down of

motor speed

Keep zone : Motor speed is not changed.

Slow-up zone of motor speed

Normal operation zone

Fig. 8-2-3 Compressor motor speed control

(7) ECO operation control

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

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

2) The set temperature increases 0.5°C per 1 hour up to +2°C starting from the set temperature when ECO mode has been received.

TA [°C]

+4.0 +3.5 +3.0 +2.5 +2.0 +1.5 +1.0 +0.5

Tsc

−0.5

−1.0

−2.0

rps FAN

40 35 31 27 22 18 13

OFF

Fig. 8-2-4

Release of motor speed

L−

SUL

– 27 –

FILE NO. SVM-03008

−0.5

−1

−1.5

−2

−5.0

−5.5

(Room temp.) −

(Set temp.)

Set temp.

[FAN AUTO]

LOW

M+

HIGH

8-2-2. DRY operation

(The Remote Control MODE Button is Set to the DRY Position)

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

• Dry operation signal is transmitted to outdoor unit.

• The Cooling operation giving priority to

dehumidifying, which restrains the indoor fan speed and compressor motor speed, is performed.

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

• The outdoor fan motor operates as described in Table 8-1-3, and the compressor motor speed according to the operation command signal sent from the indoor unit.

+2.5

(Room temp.) − (Set temp.)

Set temp.

+2.0

+1.5

+1.0

+0.5

−0.5

L−

SUL

NOTE :

*1 : Middle motor speed between L– and SUL

Fig. 8-2-5 Setting of air flow

8-2-3. Heating operation

Transferring of heat operation signal from indoor unit to outdoor unit starts. The indoor fan motor operates by the room temperature when selecting “AUTO” of “FAN” as shown in Fig. 8-2-6, and operates with a set air flow when selecting “LOW ” to “HIGH ”. However, to prevent cold draft, revolution speed of the fan is restricted by indoor heat exchanger when air flow is AUTO (Fig. 8-2-7) and starting of FAN Manual.

[Basic control]

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

Fig. 8-2-6 Setting of air flow

[Cold draft preventing control]

The upper limit of fan revolution speed is shown below.

44 43

31 30

A + 4 A − 8

FAN

AUTO

33 32

20 19

A − 8

Starting of FAN Manual

HIGH

Approximate revolution speed of HIGH and SUL linear by Tc.

SUL

( NOTE : *1)

SUL

Stop

Fig. 8-2-7 Cold draft preventing control

NOTES :

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

Set temp. when the set temp. is below 24°C

*3 : SUL : Super ultra low

– 28 –

FILE NO. SVM-03008

[In starting and in stability]

FAN AUTO

In starting

• Until 12 minutes passed after operation start

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

In stability

• When 12 to 25 minutes passed after operation start and room temp. is higher than (set temp.

–3°C)

• When 25 minutes

or more passed after operation start

FAN Manual

• Room temp. < Set temp. –4°C

• Room temp. Set temp. –3.5°C

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

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

(1) Heating capacity control

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

(2) High-temp. release control

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

(3) Current release control

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

16.0

15.5

11.0

10.5

Outside air temp. (°C)

(4) Defrost control

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

a. The counted time is 28 minutes or more,

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

b. The counted time is 28 minutes or more,

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

c. The counted time is 34 minutes or more,

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

d. If the following three conditions are satis-

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

(mode), HIGH (Fan), 30°C (temp.).

2 Room temp. is 19°C to 24°C, and

outside air temp. is 5°C or lower.

3 Defrost operation has been already

performed once.

9.8A

10.3A

10.8A

Fig. 8-2-8

– 29 –

FILE NO. SVM-03008

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

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

rose to +8°C or higher.

b. A status that temperature of the outdoor

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

c. Defrost operation continued for 15 minutes.

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

(5) Louver control

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

8-2-4. Automatic operation

(1) As shown in Fig. 8-2-9, the operation mode

(2) After selecting the operation mode (COOL, DRY,

(3) Powerful Cool mode control

TA 28

26 24 23

Ts correction by outside temperature ( To)

(COOL, DRY, HEAT) is selected according to the outside temperature and room temperature when the operation has started. The operation in Fan mode continues until an operation mode is selected. If the room temperature is 20°C or higher when

“AUTO” operation started within 2 hours after “HEAT” operation had stopped, select an operation

mode after Fan operation of ultra low fan. In AUTO operation, the set temperature of each operation can be corrected by the remote controller in the range of 17 to 30°C.

HEAT), select an operation mode again when a status that the compressor was turned off by the room temperature or outside air temperature continues for 15 minutes.

When the outside temperature is above 32°C and indoor temperature is above 28°C, select Cool mode control. In Cool mode, the air flow louver directs downward. When the room temperature gains access to the set temperature, it becomes cool memory position.

Powerful Cooling/Drying with setting on remote controller Ts = 25°C

Cooling/Drying with setting on remote controller Ts = 25°C

Monitoring Heating with setting on remote controller Ts = 25°C

−2 −10+1

15 18 24 32 To

(Follow to the Fan control in

previous mode when being

selected again.)

– 30 –

Fig. 8-2-9

8-3. T emporary Operation

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

TEMPORARY button

Fig. 8-3-1

Table 8-3-1

FILE NO. SVM-03008

TEMPORARY button

OFF → ON

After pushing button

for 3 seconds

After pushing button

for 10 seconds

8-3-1. Temporary auto operation

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

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

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

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

8-3-2. Temporary cooling operation

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

Temporary Auto operation start

Control

Auto Restart

control select

Temporary Cooling

operation start

Compressor motor speed :

13 : 30 rps

Indoor fan speed : Low

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

• Auto Restart function is unavailable.

– 31 –

FILE NO. SVM-03008

8-4. Auto Restart Function

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

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

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

• When the unit is on standby (Not operating)

Operation Motions

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

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

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

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

TEMPORARY button

→ →

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

After approx. three seconds,

• When the unit is in operation

Operation Motions

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

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

→ →

After approx. three seconds,

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

TEMPORARY button

• While this function is being set, if the unit is in

operation, the orange lamp is on.

• This function can not be set if the timer operation

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

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

has been selected.

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

– 32 –

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

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

• When the system is on standby (Not operating)

Operation Motions

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

→

FILE NO. SVM-03008

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

→

After approx. three seconds,

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

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

TEMPORARY button

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

• When the system is operating

Operation Motions

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

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

→ →

After approx. three seconds,

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

TEMPORARY button

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

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

8-4-3. Power failure during timer operation

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

NOTE:

The Every Timer is reset while a command signal can be received from the remote controller even if it stopped due to a power failure.

8-5. Filter Check Lamp

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

8-5-1. How to turn off filter check lamp

Push [FILTER] button on the remote control. Or push [TEMPORARY] b utton on the indoor unit.

Then we have to clarify it.

NOTE :

If [TEMPORARY] button is pushed while the filter check lamp is not indicating, the indoor unit will start the automatic operation.

When you want a temporary operation while the filter lamp lights, put out the lamp once, and then push the TEMPORARY button.

– 33 –

15 12

10 18

8-6.Remote Control and its Functions

8-6-1. Parts name of remote control

1 Infrared signal emitter

Transmits a signal to the indoor unit.

2 START/STOP button

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

3 Mode select button (MODE)

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

: Fan only, and back to A.

(A receiving beep is heard.)

4 Temperature button ( )

,.......The set temperature is increased up to

30°C.

9.......The set temperature is dropped down to

17°C. (A receiving beep is heard.)

5 Fan speed button (FAN)

Push this button to select fan speed. When you select AUTO, the fan speed is automatically adjusted according to the room temperature. You can also manually select the desired fan speed from among five settings. (LOW , LOW HIGH ) (A receiving beep is heard.)

6 Auto louver button (SWING)

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

7 Set louver button (FIX)

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

8 Off timer button (OFF)

Push this button to set the OFF timer.

9 On timer button (ON)

Push this button to set the ON timer.

! Reserve button (SET)

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

" Cancel button (CLR)

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

# High power button (Hi-POWER)

Push this button to start the high power operation.

, MED , MED

FILE NO. SVM-03008

$ Memory button (MEMO)

Keep pushing the MEMO button for 2 seconds from the beginning, or keep pushing the button for 2 seconds after pushing it once for a short time. Then the set data is stored in the memory and is displayed.

% Automatic operation button (AUTO)

Push this button to operate the air conditioner automatically.

& ECO timer button (ECO)

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

((

( FILTER button

((

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

))

) PRESET button

))

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

~ TIMER button

Use this button to change the clock, ON timer, and OFF timer times. To forward the time, push the “TIMER ” button. To set back the time, push the “TIMER ” button.

AUTOA

A B

– 34 –

2 5

5 6

6 7

7 9

9 8

START/STOP

FAN MODE

SWING

FIX

OFF SET CLR

FILTER

ECO

TIMER

PRESET

Hi-POWER

MEMO

CLOCK CHECKRESET

AUTO

14 15

12 13

17 11

10 18

FILE NO. SVM-03008

8-6-2. Names and functions of indications on

remote control

[Display]

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

1 Transmission mark

This transmission mark , indicates when the remote controller transmits signals to the indoor unit.

2 Mode display

Indicates the current operation mode. (AUTO : Automatic control, A : Auto changeover control, : Cool, : Dry, : Heat, : Fan only)

3 Temperature display

Indicates the temperature setting (17 C to 30 C). When you set the operating mode to : Fan only, no temperature setting is indicated.

4 Louver operation display

Indicates the louver positioning and operation. Five selectable positions

,,,,

Automatic

Swing

5 FAN speed display

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

, HIGH ) can

be indicated. Indicates AUTO when the operating mode is either AUTO or : Dry.

6 TIMER and clock time display

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

7 Hi-POWER display

Indicates when the Hi-POWER operation starts. Push the Hi-POWER button to start and push it again to stop the operation.

8 (MEMORY) display

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

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

9 ECO TIMER display

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

13 2 8

AUTOA

A B

9 67 5

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

A B

– 35 –

8-7.Hi POWER Mode ([Hi POWER] button

on the remote control is pushed.)

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

(1) Automatic operation

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

(2) Cooling operation

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

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

(3) Heating operation

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

FILE NO. SVM-03008

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

only operation.

– 36 –

FILE NO. SVM-03008

9. INSTALLATION PROCEDURE

9-1. Safety Cautions

For general public use

Power supply cord of parts of appliance for outdoor use shall be at least polychloroprene sheathed flexible cord (design H07RN-F), or cord designation 245 IEC66. (1.5 mm2 or more)

CA UTION

• THIS AIR CONDITIONER USES THE NEW HFC REFRGERANT (R410A), WHICH DOES NOT

DESTROY THE OZONE LAYER.

R410A refrigerant is apt to be affected by impurity such as water, oxidizing membranes, and oils because the pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. As well as the adoption of this new refrigerant, refrigerating machine oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating machine oil does not enter into the refrigerating cycle of a new-refrigerant air conditioner. To avoid mixing refrigerant and refrigerating machine oil, the sizes of charging port connecting sections on the main unit are different from those for the conventional refrigerant, and different size tools are also required. Accordingly, special tools are required for the new refrigerant (R410A) as shown below. For connecting pipes, use new and clean piping materials with high-pressure withstand capabilities, designed for R410A only, and ensure that water or dust does not enter. Moreover, do not use any existing piping as its pressure withstand may be insufficient, and may contain impurities.

CA UTION

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

The installation fuse (25A D type ) must be used for the power supply line of this air conditioner. (RAS-13UKV-E2 only)

New Refrigerant Air conditioner Installation

To Disconnect the Appliance from the Main Power Supply

– 37 –

FILE NO. SVM-03008

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 T O FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

• TO PREVENT OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, 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 WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CYCLE. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CYCLE BECOMES ABNORMALLY HIGH AND IT RESULTINGLY CAUSES BURST OF THE PIPE AND INJURIES ON PERSONS.

• IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSES GENERATION OF POISONOUS GAS.

WARNING

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

• Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls.

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

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

CA UTION

• 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.

• Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify

the noise level of the unit or where noise and discharged air might disturb neighbors.

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

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

instructions for proper installation.

– 38 –

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

65 mm or more

Hook

1 Installation

plate

FILE NO. SVM-03008

For the rear left and left piping

Wall

(Attach to the front panel)

5 Zeolite filter

Before installing the wireless remote control

• With the remote control cover

open, load the batteries supplied correctly, observing their polarity.

2 Wireless remote control

Cover

3 Batteries

6 Purifying filter

2 Wireless remote control

ilt

8 Flat head wood screw

4 Remote control holder

Vinyl tape Apply after carrying out a drainage test

r m

Shield pipe

the indoor unit and wall, and lift the indoor unit for better operation.

Do not allow the drain hose to get slack.

Insert the cushion between

Cut the piping hole sloped slightly

Make sure to run the drain hose sloped downward.

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

Right

Rear right

Bottom right

Rear left

Left

Bottom left

100 m

or m

from

ore

all

200 mm or more

As show in the figure, hang power cord and connecting cable downward, and take out it along piping connection port.

600 mm or more

50 mm or more

from wall

Fig. 9-1-1

– 39 –

250 m

from

or m

ore

all

Saddle

Extension drain hose (Option: RB–821SW)

Insulate the refrigerant pipes separately with insulation, not together.

6 mm thick heat resisting polyethylene foam

9-1-2. Optional installation parts

FILE NO. SVM-03008

Part

Code

Parts name

Refrigerant piping Liquid side : ∅6.35 mm

Gas side : ∅9.52 mm Pipe insulating material

(polyethylene foam, 6 mm thick) Putty, PVC tapes

600

Suction side

115

310

Diffuser

Drain hole

Fig. 9-1-2

Q’ty

One

each

One

each

• Secure the outdoor unit with the fixing bolts and nuts if the unit is likely to be exposed to a strong wind.

• Use ∅8 mm or ∅10 mm anchor bolts and nuts.

• If it is necessary to drain the defrost water, attach drain nipple to the bottom plate of the outdoor unit

before installing it.

– 40 –

9-1-3. Accessory and installation parts

Part

No.

Part name (Q’ty)

Part

No.

Part name (Q’ty)

Part

No.

FILE NO. SVM-03008

Part name (Q’ty)

Installation plate x 1

Wireless remote control x 1

Battery x 2

Others

Name

Remote control holder x 1

Zeolite filter x 1

Purifying filter x 1

Mounting screw ∅4 x 25 s x 6

Flat head wood screw ∅3.1 x 16 s x 2

Drain nipple* x 1

The part marked with asterisk (*) is packaged with the outdoor unit.

Owner’s manual

Installation manual

This model is not equipped with an extension drain hose.

Option :

For the extension drain hose, use an optionally available RB-821SW or commercially available one.

– 41 –

FILE NO. SVM-03008

9-1-4. Installation/Servicing Tools <Changes in the product and components>

In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valv e (3 way valve) has been changed. (1/2 UNF 20 threads per inch)

• In order to increase the pressure resisting strength of the refrigerant piping, flare processing diameter and size of opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)

New tools for R410A

Gauge manifold

Charge hose

Electronic balance for refrigerant charging

Torque wrench (nominal diam. 1/2, 5/8)

Flare tool (clutch type)

Gauge for projection adjustment

V acuum pump adapter

Applicable to R22 model Changes

As pressure is high, it is impossible to measure by means of conventional gauge. In order to prevent any other refrigerant from being charged, each port diameter has been changed.

In order to increase pressure resisting strength, hose materials and port size have been changed (to 1/2 UNF 20 threads per inch). When purchasing a charge hose, be sure to confirm the port size.

As pressure is hight and gasification speed is fast, it is difficult to read the indicated value by means of charging cylinder, as air bubbles occur.

The size of opposite sides of flare nuts have been increased. Incidentally, a common wrench is used for nominal diameters 1/4 and 3/8.

By increasing the clamp bar’s receiving hole, strength of spring in the tool has been improved.

—

Used when flare is made by using conventional flare tool.

Connected to conventional vacuum pump. It is necessary to use an adapter to prevent vacuum pump oil from flowing back to the charge hose. The charge hose connecting part has two ports-one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R410A a sludge may occur and damage the equipment.

Gas leakage detector

• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the U. S’s ARI specified rose color (ARI color code: PMS 507).

• Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to the charge hose’s port size.

Exclusive for HFC refrigerant.

– 42 –

FILE NO. SVM-03008

82.5

170

9-2.Indoor Unit

9-2-1. Installation place

• A place which provides the spaces around the indoor unit as shown in the above diagram.

• A place where there is no obstacle near the air inlet and outlet.

• A place that allows easy installation of the piping to the outdoor unit.

• A place which allows the front panel to be opened.

• The indoor unit shall be installed as top of the

indoor unit comes to at least 2 m height. Also it must be avoided to put anything on the top of the indoor unit.

CAUTION

• Direct sunlight to the indoor unit’s wireless

receiver should be avoided.

• The microprocessor in the indoor unit should not

be too close to RF noise sources.

(For details, see the owner’s manual.)

• A place where there are no obstacles such as a curtain that may block the signal from the indoor unit.

• Do not install the remote control in a place exposed to direct sunlight or close to a heating source, such as a stove.

• Keep the remote control at least 1 m apart from the nearest TV set or stereo equipment. (This is necessary to prevent image disturbances or noise interference.)

• The location of the remote control should be determined as shown below.

9-2-2. Cutting a hole and mounting installation

plate

When installing the refrigerant pipes from the rear.

Pipe hole

65 mm

The center of the pipe hole is above the arrow.

100 mm

Fig. 9-2-2

1. After determining the pipe hole position on the mounting plate (A), drill the pipe hole (∅65 mm) at a slight downward slant to the outdoor side.

NOTE:

• When drilling a wall that contains a metal lath, wire lath or metal plate, be sure to use a pipe hole brim ring sold separately.

For installation of the indoor unit, use the paper pattern on the back.

Anchor bolt holes

Hook

Remote control

(Top view)

Indoor unit

Reception range

* : Axial distance

5 m

45°

5 m

Remote control

* 7 m

Pipe hole

Indoor unit

Hook

Thread

Fig. 9-2-3

7 Mounting screw

Weight

Hook

Pipe hole

Installation plate

2 m or more from floor

Indoor unit

(Side view)

7 m

Reception range

Fig. 9-2-1

– 43 –

FILE NO. SVM-03008

1. Securely fit the installation plate onto the wall by screwing it in the upper and lower parts to hook up the indoor unit.

2. To mount the installation plate on a concrete wall with anchor bolts, utilize the anchor bolt holes as illustrated in the above figure.

3. Install the installation plate horizontally in the wall.

CAUTION

When installing the installation plate with a mounting screw , do not use the anchor bolt hole. Otherwise the unit may fall down and result in personal injury and property damage.

Installation plate <Keep horizontal direction>

Anchor bolt

Projection 15 mm or less

9-2-3. Electrical work

1. The supply voltage must be the same as the rated voltage of the air conditioner.

2. Prepare the power source for exclusive use with the air conditioner.

NOTE:

• Wire type : More than H07RN-F or 245 IEC66

(1.0 mm2 or more)

CAUTION

• This appliance can be connected to the mains in either of the following two ways. (1) Connection to fixed wiring :

A switch or circuit breake which disconnects all poles and has a contact separation of at least 3 mm must be incorporate in the fixed wiring. An approved circuit breaker or switches must used.

(2) Connection with power supply plug :

Attach power supply plug with power cord and plug it into wall outlet. An approved power supply cord and plug must be used.

Fig. 9-2-4

5 mm dia. hole

7 Mounting

screw

∅4 x 25

Clip anchor (local parts)

Fig. 9-2-5

CAUTION

Failure to firmly install the unit may result in personal injury and property damage if the unit falls.

• In case of block, brick, concrete or similar type walls, make 5 mm dia. holes in the wall.

• Insert clip anchors for appropriate mounting screws

NOTE:

• Secure four corners and lower parts of the installation plate with 4 to 6 mounting screws to install it.

NOTE:

• Perform wiring works so as to allow a generous wiring capacity.

– 44 –

FILE NO. SVM-03008

9-2-4. Wiring connection <How to connect the connecting cable> Wiring of the connecting cable can be carried out

without removing of the front panel.

1. Remove the air inlet grille. Open the air inlet grille upward and pull it toward you.

2. Remove the terminal cover and cord clamp.

3. Insert the connecting cable (according to the local cords) into the pipe hole on the wall.

4. Take out the connecting cable through the cable slot on the rear panel so that it protrudes about 15 cm from the front.

5. Insert the connecting cable fully into the terminal block and secure it tightly with screws.

6. Tightening torque : 1.2 N·m (0.12 kgf·m)

7. Secure the connecting cable with the cord clamp.

8. Fix the terminal cover, rear plate bushing and air inlet grille on the indoor unit.

CAUTION

• Be sure to refer to the wiring system diagram labeled inside the front panel.

• Check local electrical cords and also any specific wiring instructions or limitations.

Terminal block

Connecting cable

Terminal cover

Cord clamp

Screw

9-2-5. Piping and drain hose installation <Piping and Drain Hose Forming>

* Since dewing results in a machine trouble, make

sure to insulate both the connecting pipes. (Use

polyethylene foam as insulating material.) Rear right Rear left

Bottom left Left

Bottom right Right

Die-cutting

Front panel slit

Changing

drain hose

Piping preparation

Fig. 9-2-8

1. Die-cutting Front panel slit

Cut out the slit on the left or right side of the front panel for the left or right connection and the slit on the bottom left or right side of the front panel for the bottom left or right connection with a pair of nippers.

2. Changing drain hose

For left connection, bottom-leftward connection and rear-leftward connection’s piping, it is necessary to change the drain hose and drain cap.

Clip drain cap by needle-nose pliers, and pull out.

About 15 cm

Earth line

Screw

Connecting cable

Fig. 9-2-6

10 mm

80 mm

10 mm

50 mm

Earth line

NOTE:

• Wire type : More than H07RN-F or 245 IEC66 (1.0 mm2 or more)

Fig. 9-2-7 Stripping length of connecting cable

Fig. 9-2-9

Firmly insert drain hose connecting part until hitting on a heat insulator.

Heat insulator

Drain hose

Fig. 9-2-10

– 45 –

FILE NO. SVM-03008

1) Insert hexagonal wrench (∅4 mm) in a center head.

∅4 mm

Fig. 9-2-11

2) Firmly insert drains cap.

No gap

Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. Application causes deterioration and drain

Insert a hexagon wrench (∅4 mm)

leakage of the plug.

Fig. 9-2-12

CAUTION

Firmly insert the drain hose and drain cap; otherwise, water may leak.

• After scribing slits of the front panel with a knife or a

making-off pin, cut them with a pair of nippers or an equivalent tool.

<Left-hand connection with piping>

Bend the connecting pipe so that it is laid within 43 mm above the wall surface. If the connecting pipe is laid exceeding 43 mm above the wall surface, the indoor unit may unstably be set on the wall. When bending the connecting pipe, make sure to use a spring bender so as not to crush the pipe.

Bend the connection pipe within a radius of 30 mm (∅6.35) 40 mm (∅9.52).

To connect the pipe after installation of the unit (figure)

(To the forefront of flare)

270 mm

170 mm

R 30 mm or less (∅6.35) R 40 mm or less (∅9.52) (Use polisin (polyethylene core) or the like for

43 mm

bending pipe.)

Liquid side

Gas side

Outward form of indoor unit

Use the handle of screwdriver, etc.

Fig. 9-2-15

NOTE:

If the pipe is bent incorrectly, the indoor unit may unstably be set on the wall. After passing the connecting pipe through the pipe hole, connect the connecting pipe to the auxiliary pipes and wrap the facing tape around them.

Slit

Fig. 9-2-13

• After scribing slits of the front panel with a knife or a

making-off pin, cut them with a pair of nippers or an equivalent tool.

Slit

Fig. 9-2-14

– 46 –

CAUTION

• Bind the auxiliary pipes (two) and connecting cable with facing tape tightly. In case of leftward piping and rear-leftward piping, bind the auxiliary pipes (two) only with facing tape.

Indoor unit

Auxiliary pipes

Installation plate

Fig. 9-2-16

• Carefully arrange pipes so that any pipe does not stick out of the rear plate of the indoor unit.

• Carefully connect the auxiliary pipes and connecting pipes to each other and cut off the insulating tape wound on the connecting pipe to avoid double-taping at the joint, moreover, seal the joint with the vinyl tape, etc.

• Since dewing results in a machine trouble, make sure to insulate both the connecting pipes. (Use polyethylene foam as insulating material.)

• When bending a pipe, carefully do it not to crush it.

Connecting cable

FILE NO. SVM-03008

9-2-6. Indoor unit fixing

1. Pass the pipe through the hole in the wall, and hook the indoor unit on the installation plate at the upper hooks.

2. Swing the indoor unit to right and left to confirm that it is firmly hooked up on the installation plate.

3. While pressing the indoor unit onto the wall, hook it at the lower part on the installation plate. Pull the indoor unit toward you to confirm that it is firmly hooked up on the installation plate.

Hook

Hook here

1 Installation plate

Push

(unhook)

Fig. 9-2-17

• For detaching the indoor unit from the installation plate pull the indoor unit toward you while pushing its bottom up at the specified parts.

2. Put water in the drain pan and make sure that the water is drained out of doors.

3. When connecting extension drain hose, insulate the connecting part of extension drain hose with shield pipe.

Shield pipe

Drain hose

Inside the room

Extension drain hose

Fig. 9-2-20

CAUTION

Arrange the drain pipe for proper drainage from the unit. Improper drainage can result in dew-dropping.

This air conditioner has the structure designed to drain water collected from dew, which forms on the back of the indoor unit, to the drain pan. Therefore, do not store the power cord and other parts at a height above the drain guide.

PushPush

Fig. 9-2-18

9-2-7. Drainage

1. Run the drain hose sloped downwards.

NOTE:

• Hole should be made at a slight downward slant on the outdoor side.

Do not form the Do not rise the drain hose.

50 mm or more

Do not put the drain hose end into water.

drain hose into

a wavy shape.

Do not put the drain hose end in the drainage ditch.

Wall

Drain guide

Space for pipes

Fig. 9-2-21

Fig. 9-2-19

– 47 –

FILE NO. SVM-03008

9-3.Outdoor Unit

9-3-1. Installation place

• A place which provides the spaces around the outdoor unit as shown in the left diagram.

• A place which can bear the weight of the outdoor unit and does not allow an increase in noise level and vibration.

• A place where the operation noise and discharged air do not disturb users neighbors.

• A place which is not exposed to a strong wind.

• A place free of a leakage of combustible gases.

• A place which does not block a passage.

• When the outdoor unit is to be installed in an

elevated position, be sure to secure its feet.

• An allowable length of the connecting pipe is up 15 m.

• An allowable height level is up to 10 m.

• A place where the drain water does not raise any

problem.

CAUTION

1. Install the outdoor unit without anything blocking the air discharging.

2. When the outdoor unit is installed in a place exposed always exposed to strong wind like a coast or on a high storey of a building, secure the normal fan operation using a duct or a wind shield.

3. In particularly windy areas, install the unit such as to avoid admission of wind.

4. Installation in the following places may result in trouble. Do not install the unit in such places.

• A place full of machine oil.

• A saline-place such as the coast.

• A place full of sulfide gas.

• A place where high-frequency waves are likely

to be generated as from audio equipment, welders, and medical equipment.

9-3-2. Refrigerant piping connection <Flaring>

1. Cut the pipe with a pipe cutter.

90°

Obliquity

Roughness

Warp

Fig. 9-3-2

2. Insert a flare nut into the pipe, and flare the pipe.

• Projection margin in flaring : A (Unit : mm)

Die

Pipe

Fig. 9-3-3

Rigid (Clutch type)

Outer dia. R410A Conventional

of copper pipe tool used tool used

6.35 0 to 0.5 1.0 to 1.5

9.52 0 to 0.5 1.0 to 1.5

Imperial (wing nut type)

Outer dia.

of copper pipe

R410A

6.35 1.5 to 2.0

9.52 1.5 to 2.0

Align the centers of the connecting pipes and tighten the flare nut as far as possible with your fingers. Then tighten the nut with a spanner and torque wrench as shown in the figure.

Strong

wind

Fig. 9-3-1

Flare nutHalf union

Externally threaded side

Use a wrench to secure.

Use a torque wrench to tighten.

Fig. 9-3-4

CAUTION

• Do not apply excess torque.

• Otherwise, the nut may crack depending on the

conditions.

– 48 –

Internally threaded side

FILE NO. SVM-03008

(Unit : N·m)

Outer dia.

of copper pipe

Tightening torque

∅6.35 mm 16 to 18 (1.6 to 1.8 kgf·m) ∅9.52 mm 30 to 42 (3.0 to 4.2 kgf·m)

• Tightening torque of flare pipe connections

The operating pressure of R410A is higher than that of R22. (Approx. 1.6 times). It is therefore necessary to firmly tighten the flare pipe connecting sections (which connect the indoor and outdoor units) up to the specified tightening torque. Incorrect connections may cause not only a gas leakage, but also damage to the refrigerant cycle.

Flare at indoor unit side

Flare at outdoor unit side

Fig. 9-3-5

1. How to shape the pipes Shape the pipes along the incused line on the outdoor unit.

2. How to fit position of the pipes Put the edges of the pipes to the place with a distance of 85 mm from the incused line.

Incused line

9-3-3. Evacuating

After the piping has been connected to the indoor unit, you can perform the air purge together at once.

AIR PURGE

Evacuate the air in the connecting pipes and in the indoor unit using a vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the manual of the vacuum pump.

Be sure to use a vacuum pump with counter-flow prevention function so that inside oil of the pump does not flow backward into pipes of the air conditioner when the pump stops. (If oil inside of the vacuum pump enters into the air conditioner, which use R410A, refrigeration cycle trouble may result.)

1. Connect the charge hose from the manifold valve to the service port of the gas side packed valve.

2. Connect the charge hose to the port of the vacuum pump.

3. Open fully the low pressure side handle of the gauge manifold valve.

4. Operate the vacuum pump to start evacuating. Perform evacuating for about 15 minutes if the piping length is 20 meters. (15 minutes for 20 meters) (assuming a pump capacity of 27 liters per minute. Then confirm that the compound pressure gauge reading is –101 kPa (–76 cmHg).

5. Close the low pressure side valve handle of gauge manifold.

6. Open fully the valve stem of the packed valves (both side of Gas and Liquid).

7. Remove the charging hose from the service port.

8. Securely tighten the caps on the packed valves.

Compound pressure gauge

-101kPa (-76cmHg)

Handle Lo

Charge hose (For R410A only)

Connecting pipe

Pressure gauge

Manifold valve

Handle Hi (Keep full closed)

Charge hose (For R410A only)

Vacuum pump adapter for counter-flow prevention (For R410A only)

Fig. 9-3-6

Vacuum pump

Packed valve at liquid side

Packed valve at gas side

Service port (Valve core (Setting pin))

Fig. 9-3-7

CAUTION

• KEEP IMPORTANT 4 POINTS FOR PIPING

WORK

(1) Take away dust and moisture (Inside of the

connecting pipes.) (2) Tight connection (between pipes and unit) (3) Evacuate the air in the connecting pipes using

VACUUM PUMP. (4) Check gas leak (connected points)

– 49 –

FILE NO. SVM-03008

• Open the valve stem all the way out; but do not try to open it beyond the stopper.

• Securely tighten the valve stem cap with torque in the following table:

Gas side 30 to 42 N·m (∅9.52 mm) (3.0 to 4.2 kgf·m)

Liquid side 16 to 18 N·m (∅6.35 mm) (1.6 to 1.8 kgf·m)

Service port

9 to 10 N·m (0.9 to 1.0 kgf·m)

Hexagonal wrench is required.

4 mm

Fig. 9-3-8

9-3-4. Wiring connection

1. Remove the valve cover from the outdoor unit.

2. Connect the connecting cable to the terminal as identified with their respective matched numbers on the terminal block of indoor and outdoor unit.

3. When connecting the connecting cable to the outdoor unit terminal, make a loop as shown in the installation diagram of indoor and outdoor unit, to prevent water coming in the outdoor unit.

4. Insulate the unused cords (conductors) from any water coming in the outdoor unit. Proceed them so that they do not touch any electrical or metal parts.

Terminal block

Power cord

Connecting cable

30 30

Connecting cable

40 40

Earth line

Power cord

Earth line

Fig. 9-3-9

Model RAS-13UKV-E2

Power source 50/60 Hz, 220 – 240 V Single phase Maximum

running current Installation fuse

rating Power cord

25A (D type

H07RN-F or 245 IEC66 (1.5 mm or more)

11A

)

CAUTION

• Wrong wiring connection may cause some electrical parts burn out.

• Be sure to comply with local codes on running the wire from indoor unit to outdoor unit (size of wire and wiring method etc).

• Every wire must be connected firmly.

• This installation fuse (25A D type ) must

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

• If incorrect or incomplete wiring is carried out, it will cause an ignition or smoke.

• Prepare the power supply for exclusive use with the air conditioner.

• This product can be connected to the mains. Connection to fixed wiring: A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring.

NOTE: Connecting cable

• Wire type: More than H07RN-F or 245 IEC66 (1.0 mm2 or more)

– 50 –

FILE NO. SVM-03008

9-3-5. Gas leak test

Check places for indoor unit (Flare nut connection)

Valve cover

Electric parts cover

Check places for outdoor unit

Fig. 9-3-10

• Check the flare nut connections for the gas leak with a gas leak detector or soap water.

9-3-7. Auto restart setting

This product is designed so that, after a power failure, it can restart automatically in the same operating mode as before the power failure.

Information

The product was shipped with Auto Restart function in the off position. Turn it on as required.

• Press and hold down the TEMPORARY button for about 3 seconds. After 3 seconds, the electronic beeper makes three short beeps to tell you the Auto Restart has been selected.

• To cancel the Auto Restart, follow the steps described in the section Auto Restart Function of the Owner’s Manual.

9-3-6. Test operation

To switch the TEST RUN (COOL) mode, push TEMPORARY button for 10 sec. (The beeper will make a short beep.)

TEMPORARY button

Fig. 9-3-11

– 51 –

10. HOW TO DIAGNOSE THE TROUBLE

FILE NO. SVM-03008

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

Table 10-1

No. Troubleshooting Procedure Page

1 First Confirmation 52 2 Primary Judgment 53 3 Judgment by Flashing LED 54

of Indoor Unit 4 Self-Diagnosis by Remote Control 55 5 Judgment of Trouble by 58

Every Symptom 6 How to Check Simply the Main Parts 66

Discharging position (Discharging period 10 seconds or more)

NOTE:

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

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

mounting claws.

(2) As shown below, connect the discharge resistance

(approx. 100Ω40W) or plug of the soldering iron to voltage between + – terminals of the C14 (“CAUTION HIGH VOLTAGE 380 V” is indicated.) electrolytic capacitor (500µF/400 V) on P.C. board, and then perform discharging.

Plug of soldering iron

Inverter cover

P . C. boar d (Soldered surface)

10-1. First Confirmation

10-1-1. Confirmation of power supply

Confirm that the power breaker operates (ON) normally.

Fig. 10-1

10-1-2. Confirmation of power voltage

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

– 52 –

FILE NO. SVM-03008

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

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

Table 10-1-1

No. Operation of air conditioner Description

1 When power breaker is turned “ON”,

the operation lamp (Green) of the

indoor unit flashes.

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

2 Compressor may not operate even if

the room temperature is within range of

compressor-ON.

3 In Dry and ECO. mode, FAN (air flow)

display does not change even though

FAN (air flow select) button is operated.

4 Increasing of compressor motor speed

stops approx. 30 seconds after

operation started, and then compressor

motor speed increases again approx.

30 seconds after.

5 The set value of the remote control

should be below the room temperature.

6 In AUTO mode, the operation mode is

changed.

7 In HEAT mode, the compressor motor

speed does not increase up to the

maximum speed or decreases before

the temperature arrives at the set

temperature.

10-2. Primary Judgment

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

The air flow indication is fixed to [AUTO].

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

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

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

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

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

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

– 53 –

FILE NO. SVM-03008

10-3. Judgment by Flashing LED of Indoor Unit

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

Table 10-3-1

Indoor indication

lamp flashes.

Which lamp

does flash?

Item

Check

code

Block display Description for self-diagnosis

OPERATION (Green) Flashing display (1 Hz)

OPERATION (Green) Flashing display (5 Hz)

OPERATION (Green) TIMER (Yellow) Flashing display (5 Hz)

OPERATION (Green) PRE DEF. (Orange) Flashing display (5 Hz)

OPERATION (Green) TIMER (Yellow) PRE DEF. (Orange) Flashing display (5 Hz)

Power failure (when power is ON)

Protective circuit operation for indoor P.C. board

Protective circuit operation for connecting cable and serial signal system

Protective circuit operation for outdoor P.C. board

Protective circuit operation for others (including compressor)

NOTES:

(1) The contents of items B and C and a part of item E are displayed when air conditioner operates. (2) When item B and C, and item B and a part of item E occur concurrently, priority is given to the block of item B. (3) The check codes can be confirmed on the remote control for servicing.

– 54 –

10-4. Self-Diagnosis by Remote Control

(Check Code)

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

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

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

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

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

lamp usually flashes (5Hz) during self-diagnosis.

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

SET CLR

CLOCK CHECKRESET

AUTOA

A B

FILE NO. SVM-03008

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

remote control to the service mode.

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

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

START/STOP

FAN MODE

SWING

TIMER

FIX

OFF SET CLR

FILTER

ECO

PRESET

AUTO

Hi-POWER

MEMO

CLOCK CHECKRESET

(2) Push [TIMER 8] button.

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

00 01 1d 1E02 22

• Check the unit with all 35 check codes (00 to 22) as shown in Table 10-4-1.

• Push [TIMER 9] button to change the check code backward.

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

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

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

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

service code in memory.

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

Alphanumeric characters are used for the check code.

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

Fig. 10-4-1

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

mode.

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

– 55 –

FILE NO. SVM-03008

10-4-2. Caution at servicing

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

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

Table 10-4-1

Block distinction Operation of diagnosis function Check

code code status

Block

Indoor P.C. board etc.

Not displayed

Check

Cause of operation

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

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

Lock of indoor fan or trouble on the indoor fan circuit

Trouble on other indoor P.C. boards

Air conditioner

Operation continues.

All off

Operation continues.

Remarks

Displayed when error is detected.

Judgment and action

1. Check the room temp. sensor.

2. When the room temp. sensor is normal, check P.C. board.

1. Check heat exchanger sensor.

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

1. Check P.C. board.

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

Replace P.C. board.

Connecting cable and serial signal

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

connecting cable

(2) Operation of

compressor thermo. Gas shortage Gas leak

Operation command signal is not sent to outdoor side.

Operation continues.

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

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

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

correct if defective wiring.

(2) Check 25A fuse of inverter

P.C. board

(3) Check 3.15A of inverter

P.C. board.

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

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

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

– 56 –

Block distinction Operation of diagnosis function Check

code code status

Block

Ondoor P.C . board

Not displayed

Ondoor P.C . board

Others (including compressor)

Check

Cause of operation

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

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

Current-detect circuit error

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

Disconnection or shortcircuit of discharge temp. sensor

Outdoor fan drive system error

Outdoor heat exchanger temp. sensor error

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

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

operation Gas shortage Gas leak

(2) Instantaneous power

failure

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

Discharge temp. exceeded 117°C

Break down of compressor

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

Air conditioner

All off

Operation continues.

All off

Operation continues.

All off

Operation continues.

Remarks

Displayed when error is detected.

–––

Displayed when error is detected.

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

Displayed when error is detected.

–––

FILE NO. SVM-03008

Judgment and action

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

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

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

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

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

2. Check P.C. board.

1. Check discharge temp . sensor (TD).

2. Check P.C. board.

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

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

2. Check P.C. board.

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

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

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

1. Trouble on compressor

2. Trouble on wiring of compressor (Missed phase)

1. Check discharge temp . sensor (TD).

2. Degassing

3. Trouble on P.M.V.

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

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

1. Check 4-way valve operation.

– 57 –

10-5. Judgment of Trouble by Every Symptom

10-5-1. Indoor unit (Including remote contro) (1) Power is not turned on (Does not operate entirely) <Primary check>

1. Is the supply voltage normal?

2. Is the normal voltage provided to the outdoor unit?

3. Is the crossover cable connected properly?

4. Is the fuse (F01) blown?

FILE NO. SVM-03008

Operation

Check Item

Considerable principle cause

of indoor control

(DC12 V or 5 V)

indicated on rear of

Is DC310-340 V

supplied to

primary side of

transfer switch?

YES

Are DC15 V, 12 V

and 7 V supplied to

secondary side of

transfer switch?

YES

Turn off power supply once, and

5 second later, turn it on again.

Is OPERATION lamp flashing?

YES

Is it possible to turn on

power supply by pushing

[START/STOP] button

on remote control?

YES

Unit operates normally.

Is fuse (F01) board blown?

Is voltage

indoor control

board normal?

NO NO

Turn off breaker once

and turn it on again

after removing motor.

YES

Parts (R01, R04, DB01, C01,

C03, IC01 and T01) are defective.

YES

Refer to <Primary check>

or this problem is one step

short of power P.C. board block.

Are DC15 V, 12 V

and 7 V supplied to

secondary side of

transfeor switch?

Does transmission mark

NO NO

on remote control flash

normally, and is its signal

transmitted properly?

YES

Does fan

motor connector

between 1 and 2

short-circuit?

Microcomputer

is defective.

Transfer swith,

IC (IC01) for

power supply or

fan motor is

defective.

Measures

Item by symptoms

Remote control is defective.

Refer to (5) Troubleshooting

for remote control .

YES

Replace main

P.C. board

Replace motor.

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

– 58 –

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

Turn on power supply.

FILE NO. SVM-03008

Does operation

lamp flash?

YES YES

NO NO

Is wired connectly to white and black

lead wires of terminal block?

Correct wirng.

To item of Power supply

is not turned on .

– 59 –

FILE NO. SVM-03008

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

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

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

Turn off power

supply once, and

turn it on again.

Does fan motor

continue to operate?

Start to operate

indoor unit in cooling

operation at airflow

level LOW .

Does indoor

fan operate?

YES

Change airflow level

to HIGH .

Is it possible to

change airflow level

to HIGH ?

YES

Fan motor

operates normally.

Is it possible to detect

YES

DC 1V or more between

5e and 3d of

motor connector (CN10).

YES

Is it possible to detect

DC 310−340 V between

1e and 3d of motor

connector (CN10).

YES

(Motor connection condition)

Is it possible to detect DC 15 V

between 4e and 3d of

motor connector (CN10).

YES

Start to operate the

indoor unit in except

heating operation.

At this time, is it possible to

detect DC 1V or more between

5e and 3d of motor

connector (CN10)?

YES

Is it possible to

rotate cross-flow fan by

hand properly?

YES

Turn off indoor unit

and rotate cross-flow

fan by hand when the

unit is on standby. At this time, is it possible to detect DC 1V or more

between 5e and 3d

of motor connector

(CN10).

YES

Turn off indoor unit and remove

connector from motor.

Then push START/STOP button

on remote control to stop

flashing lamp on indoor unit.

Is it possible to detect

DC 15 V between

4e and 3d of motor

connector (CN10).

Turn off indoor unit and

remove connector from motor.

Then start to operate indoor

unit with remote control.

Start to operate the

indoor unit in except

heating operation.

At this time, is it possible

to detect DC 1V or more

between 5e and 3d

of motor connector (CN10)?

(Check this condition

within 15 seconds after

starting unit.)

YES

Peplace indoor

fan motor.

Peplace main

P.C. board.

Peplace

bearing.

– 60 –

FILE NO. SVM-03008

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

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

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

NOTE:

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

• Use a thin test rod.

Indoor fan starts rotating when power supply is turned on.

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

Measure voltage between 2 (GND:BLACK) and 3 (V line:YELLOW) of motor connector

(CN10) while indoor fan motor is rotating.

DC 1.0 V or more

P.C. board is defective.

Replace P.C. board.

Under DC 1.0 V

Motor is defective.

Replace motor.

Yellow

Black

P.C. board

CN10

6 (Blue) 5 (Yellow)

4 (White) 3 (Black)

2 — 1 (Red)

– 61 –

(5) Troubleshooting for remote control

FILE NO. SVM-03008

Is receiver on

indoor unit exposed

to direct sunlight?

YES

Is there any

thyristor fluorescent

light nearby?

YES

NO NO

Press START/STOP

button.

Is transmission

mark indicated?

Does indoor unit

operate when

moving remote control

near receiver or

indoor unit?

YES

Batteries are

exhausted.

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

Press RESET button

on remote control

with tip of pencil.

Press START/STOP

button.

Avoid direct

sunlight.

Keep indoor unit

away from

thyristor

fluorescent light.

Does indoor unit

start to operate by

automatic restart

function?

YES

Does radio sound

is affected by

remote control when

a signal is transmitted

at distance of 5 cm

from radio?

P.C. board is

defective.

Replace

P.C. board.

YES

Is transmission mark

indicated?

Does indoor unit

beep and operate?

Replace

batteries.

Note : After replacing batteries,

press the RESET button with a tip of a pencil.

operation

YES

Normal

Remote control

is defective.

Replace

remote control.

– 62 –

FILE NO. SVM-03008

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

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

NOTE:

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

• Be sure to prepare a diode for judgment.

Terminal block on indoor side

Red

White

Normal time : Voltage swings between DC15 V and 60 V. Abnormal time : Voltage does not vary.

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

Terminal block

S5277G

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

Tester

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

required to restart the unit.

Gas circulation amount is down.

Measure gas pressure.

Thermo operation of compressor

Gas shortage Gas leak Pipe clogging

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

To item of compressor does not operate.

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

Gas leak P.M.V. is defective. Miswiring of connecting wires of indoor/outdoor units Clogging of pipe and coming-off TC sensor

– 63 –

Refer to the chart in 10-6.

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

1C 1E

Gas leakage, disconnection of TS/TC sensors (Check code 02, 1C)

Valve drive check

Discharge temp. error, gas leakage (Check code 03, 1E)

FILE NO. SVM-03008

Is coil of the pulse modulation valve

(P.M.V.) correctly set?

YES

Is connector of coil connected to inverter?

YES

Is positioning sound of valve (sound hitting to stopper) heard from valve when the air conditioner starts the operation after turning off power of the air conditioner once?

NOTE :

After all the operations stopped by the remote control, the power keeps being supplied to outdoor unit for approx. 3 minutes. If operating the air conditioner by remote control again just after all the operations stopped by the remote control, positioning of the valve is not performed when outdoor unit is activated because supplying power to the outdoor unit is not interrupted. After positioning of the valve, activate the compressor and the outdoor fan. It takes approx. 7 seconds for positioning of the valve, and sound ticktack (hitting sound to stopper) is heard for approx. 0.5 seconds at least of that period. As the sound is low, check sound by using screwdriver, etc.

YES

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

NOTE :

The temperature sensors which are used to control electronic control valve include indoor heat exchanger sensor (TC), outdoor heat exchanger temp. sensor (TE), and outdoor suction temp. sensor (TS).

YES

Set it correctly.

Replace coil valve.

Set it correctly.

Gas amount check and valve clogging check

Remove TC sensor connector from the P.C. board in indoor unit.(Remove connector from the P.C. board.) Operate the air conditioner in COOL mode by TEMP button ( Pi sound is heard if keeping pushed for 10 seconds.). The operation enters temporary operation mode which fixes opening degree of P.M.V. and No. of revolution of compressor. Check condensation at outlet of P.M.V., and then check operating pressure from the service port.

If there is condensation at outlet (1/4 inch=∅6.35mm valve side),

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

Existence of condensation at outlet of P.M.V.

the valve is clogged.

YES

– 64 –

Replace valve.

Add gas.

FILE NO. SVM-03008

10-7. How to Diagnose Trouble in Outdoor Unit

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

Table 10-7-1

Diagnosis/Process flowchart Item Contents Summary

Remove

connector of

compressor.

Check 15 A fuse

(Part No.F01).

Check

terminal voltage

of electrolytic

capacitor.

Replace fuse.

Check

electrolytic

capacitor,

diode block

(DB01), etc.

Check

electrolytic

capacitor,

diode

(DB01), etc.

Preparation

Check

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

• Check whether 25 A fuse on the control board assembly is blown or not. (F01)

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

• Connect discharge resistance (approx. 100Ω40W) or soldering iron (plug) between +, – terminals of the electrolytic capacitor (500µF) of C14 (with printed CAUTION HIGH VOLTAGE) on P.C. board.

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Does outdoor

fan rotate?

YES

Replace

outdoor

fan motor.

Does LED on control

board flash or go on?

Remove connector

CN300 of outdoor

fan motor, and using

a tester, check

resistance value

between every phase

at motor side

YES

A B C

Operation

Measurement

Check

Stop

Check

Measurement

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

500µF: 400WV x 3

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

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

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

OK if 500µF → DC280 to 380 V

Remove CN300 by pushing the part an arrow because CN01 is a connector with lock.

→ Resistance between

phases should be approx. 55 to 77Ω.

→ Should be 10MΩ or

more.

– 65 –

FILE NO. SVM-03008

Diagnosis/Process flowchart Item Contents Summary

Replace

outdoor

fan

motor.

Check

compressor

winding

resistance.

Replace

control board.

winding of

compressor.

Check

fan motor

position

detect

signal.

Replace control board assembly.

CBA

Check

Replace

pressor.

Replace

compressor.

com-

Check

Operation

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

• Is not grounded.

• Is not short-circuited

between windings.

• Winding is not opened. Remove connector CN300 of

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

While connecting connector 5P (CN301) for position detection, using a tester, measure voltage between 1-5. Between 5-4 : 5 V

→ OK if 10MΩ or more →

OK if 0.51Ω → 0.57Ω

}

(Check by a digital tester.)

a) One or two of three

voltages should be 5 V, and others should be 0V. (When all are 0V or 5 V, it is not accepted.)

b) When rotating the fan

slowly with hands, the voltage between pins should move from 0V to 5 V. (Check it with an analog tester.)

10-8. How to Check Simply the Main Parts

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

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

2) When removing the P.C. board, hold the edge of the P.C. board and do not apply force to the parts.

3) When connecting or disconnecting the connectors on the P.C. board, hold the whole housing. Do not pull at the lead wire.

(2) Inspection procedures

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

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

a. Main P.C. board part:

DC power supply circuit (5 V, 12 V, 15 V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer, and Driving circuit of louver.

b. Indication unit of infrared ray receiving

Infrared ray receiving circuit, LED:

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

– 66 –

FILE NO. SVM-03008

(3) Check procedures

Table 10-8-1

No. Procedure Check points (Symptom) Causes

1 Turn off the power supply and

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

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

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

2 Remove the connector of the motor

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

3 Push [START/STOP] button once to

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

4 Shorten the line of the restart delay

timer and start unit.

5 Push [START/STOP] button once to

start the unit.

• Shorten the time of the restart delay timer.

• Set the operation mode to COOL.

• Set the fan speed level to AUTO.

• Set the preset temperature much

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

Check power supply voltage :

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

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

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

4. Between 12 V and GND

5. Between 5 V and GND

Check power supply voltage :

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

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

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION lamp flashes.

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

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

3. IC01, IC02 and T01 are defective.

4. IC01, IC02 and T01 are defective.

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

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

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

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

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

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

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

6 If the above condition (No. 5) still

continues, start the unit in the following condition.

• Set the operation mode to HEAT.

• Set the preset temperature much

higher than room temperature.

7 Connect the motor connector to the

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

• Set the operation mode to FAN.

• Set the fan speed level to HIGH.

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

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION lamp flashes.

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

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

3. The motor rotates but vibrates strongly.

– 67 –

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

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

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

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

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

2. The connection or the motor connector is loose.

3. The P.C. board is defective.

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

FILE NO. SVM-03008

GND

+12V

+5V

[1] Sensor characteristic table

100

90 80

70 60 50

40 30

Resistance value (kΩ)

20 10

100203040

Bottom View

(For the Top View, refer to page 65.)

TD : Discharge temp. sensor TA : Room temp. sensor TC : Heat exchanger temp. sensor

T A, TC, TO, TE, TS

TO : Outdoor temp. sensor TE : Outdoor heat exchanger temp. sensor TS : Suction temp. sensor

Temperature (°C)

– 68 –

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

No. Part name Checking procedure

1 Room temp. (TA) sensor

Heat exchanger (TC) sensor

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

FILE NO. SVM-03008

Temperature

Sensor

10°C 20°C 25°C 30°C 40°C

T A, TC (kΩ) 20.7 12.6 10.0 7.9 4.5

2 Remote control

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

3 Louver motor

MP24GA

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

White Yellow Yellow Yellow Yellow

Position Resistance value

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

4 Indoor fan motor

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

10-8-4. Outdoor unit

No. Part name Checking procedure

1 Compressor

(Model : DA91A1F-45F)

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

Red

Position Resistance value

Red - White

White - Black 0.51 to 0.57Ω

White Black

Black - Red

380±40Ω

Under 20°C

2 Outdoor fan motor

(Model : ICF-140-43-1)

3 Compressor thermo. Bimetal type

(Model : US-622KXTMQO-SS)

4 Outdoor temperature sensor

(TO), discharge temperature sensor (TD), suction temperature sensor (TS), outdoor heat exchanger temperature sensor (TE)

Measure the resistance value of winding by using the tester.

Red

White Black

1 Yellow 4 Pink

5 Gray

Position Resistance value

Yellow - Pink 5 to 20kΩ

For details, refer to Section 10-9.

Check conduction by using the tester.

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

Temperature

Sensor

10°C 20°C 30°C 40°C 50°C

T A, TC (kΩ) 105 64 41 27 18

TGa : Heat pump model only. TO, TS, TE : Refer to the TA, TC characteristic table in Indoor

(Refer to Table 10-8-3, No.1).

– 69 –

10-8-5. Checking Method for Each Part

No. Part name Checking procedure

1 Electrolytic capacitor 1. Turn OFF the power supply breaker.

(For raising pressure, smoothing) 2. Discharge all three capacitors completely.

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

4. Check that vessel is not swollen or exploded.

5. Check that electrolytic liquid does not blow off.

6. Check that the normal charging characteristics are show in continuity test by the tester.

FILE NO. SVM-03008

C12 C13 C14

MCC-813 Soldered

Heat sink IGBT side

C12, C13, C14 → 500µF/400V

2 Converter module 1. Turn OFF the power supply breaker.

2. Discharge all four capacitors completely.

3 Check that the normal rectification characteristics are shown in continuity

test by the tester.

+ ~

−

E G

surface

Diode check IGBT check

Tester rod

+ ~

Resistance value

in good product

−

(0Ωin trouble)

50kΩor more

~ ~ ~ ~

+ ~

Case that product is good

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

Mark

−

Tester rod

−

Resistance value

in good product

(0Ωin trouble)

E G

50kΩor more

– 70 –

FILE NO. SVM-03008

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

1. Symptom

• Outdoor fan motor does not rotate.

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

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

Remote controller check code “02 : Outdoor block, 1A : Outdoor fan drive system error”

2. Cause

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

1) Mechanical lock of the outdoor fan motor

2) Winding failure of the outdoor fan motor

3) Position-detect circuit failure inside of the outdoor fan motor or

4) Motor drive circuit failure of the outdoor P.C. board

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

Turn OFF the breaker.

Disconnect two connectors (CN300 and CN301)

of the outdoor fan motor from the inverter.

Does the fan rotate without trouble

when rotating it with hands?

YES

If the resistance value between

1 (Red lead) − 2 (White lead) 2 (White lead) − 3 (Black lead) 3 (Black lead) − 1 (Red lead)

of the connector

(CN300 : Motor winding)

is 17 to 25Ω, it is normal.

YES

If the resistance value between

1 (Yellow lead) − 4 (Pink lead)

of the connector

(CN301 : Motor position detection)

is 5k to 20kΩ, it is normal.

YES

Fan motor is normal.

(Outdoor P.C. board error)

CN300

CN301

Fan motor error

NOTE :

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

– 71 –

FILE NO. SVM-03008

2 4-Screws

2 2

6 2-Screws

11. HOW TO REPLACE THE MAIN PARTS

11-1. Indoor Unit

No. Part name Procedures Remarks

1 Front panel

2 Electrical part

How to remove the front panel

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

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

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

How to mount the front panel

Mount the front panel in position and make sure all hooks are locked.

How to remove the electrical part.

1) Remove the front panel with the procedure 1.

2) Remove the screw holding the electrical part cover.

3) Remove the drain guide.

4) Disconnect the connector (6P) for the fan motor and the connector (5P) for the louver motor from the P.C. board assembly.

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

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

2 Screws

3 Drain guide

5 TC Sensor

3 Horizontal louver

How to mount the electrical part.

1) Fix the electrical part box by the upper hook of the back body.

2) Tighten 2 screws on the electrical part box.

3) Connect the 2 connectors and arrange the wiring same as original condition and then tighten the screw to fix the LED unit to the back body.

4) Attach the TC sensor to the holder.

5) Tighten the screw for the ground wire.

6) Mount the drain guide (the TC sensor wire should be covered with the drain guide).

7) Tighten the screw of the electrical part cover.

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

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

3) Remove the left shaft from the back body.

4) Remove the horizontal louver from the back body.

6 Screws

3 Left shaft

2-Connectors

2 Center shaft

– 72 –

FILE NO. SVM-03008

3 2-Screws

No. Part name Procedures Remarks

4 Heat exchanger

5 Fan motor

1) Remove the front panel, electrical part and the

horizontal louver with the procedure 3.

2) Remove the pipe holder on the rear side of the

main unit.

3) Remove 2 screws of the heat exchanger on the

base bearing side.

4) Remove 2 screws of the heat exchanger on the

left side (upper and lower) from the back body, and then pull out the upper side of the heat exchanger slowly.

1) Remove the front panel and the electrical part

with the procedure 2.

2) Loosen the set screw of the cross flow fan.

3) Remove 2 screws fixing the motor band (R).

4) Pull out the fan motor.

2 Pipe holder

4 2-Screws

Mounting the fan motor as shown in figure below.

Connector cover

Reference line

When mouting the fan motor, put the R end of the connector cover this reference line.

Reference line

Pull out the lead wires of the fan motor from this hole.

– 73 –

FILE NO. SVM-03008

No. Part name Procedures Remarks

6 Cross flow fan

7 Base bearing

1) Remove the front panel, electrical part,

horizontal louver and the heat exchanger with the procedure 4.

2) Remove 2 screws of the band motor (L) and

other 2 screws of the band motor (R) and then remove the cross flow fan.

3) Loosen the set screw of the cross flow fan then

disconnect the fan and the fan motor.

Notice

For position of the fan motor connector and drawing out of the lead cables, refer to the procedure 5. Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is 4.5 mm.

1) Remove the front panel, electrical part,

horizontal louver, heat exchanger and the cross flow fan with the procedure 5 and 6 .

2) Remove the 2 screws fixing the base bearing.

3) Remove the bearing from the base bearing.

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

2 2-Screws (R)

2 2-Screws (L)

4.5 mm

3 Set screws

2 2-Screws

– 74 –

FILE NO. SVM-03008

11-2. Microcomputer

No. Part name Procedures Remarks

1 Common

procedure

<P.C. board layout>

RY01

DB01

L01

1) Turn the power supply off to stop the operation

of air conditioner.

2) Remove the front panel.

• Remove the 4 fixing screws.

3) Remove the electrical part base.

Fuse C01

R04

CN10

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

CN13

IC03

IC02

R05

C03

CN04

T op View

T01 IC01 C02 R01

– 75 –

FILE NO. SVM-03008

11-3. Outdoor Unit

No. Part name Procedures Remarks

1 Common

procedure

1. Detachment

1) Stop operation of the air conditioner, and turn off

the main switch of the breaker for the air conditioner.

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

• After removing screw, remove the valve cover pulling it downward.

3) Remove wiring cover (ST1T∅4 x 10s 2 pcs.), and then remove connecting cable.

4) Remove the upper cabinet. (ST1T∅4 x 10s 2 pcs.)

• After removing screws, remove the upper

cabinet pulling it upward.

2. Attachment

1) Attach the upper cabinet. (ST1T∅4 x 10s 2 pcs.)

• Hook the rear side of the upper cabinet to

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

2) Perform cabling of connecting cable, and attach the wiring cover.

• Insert the upper part into the upper cabinet,

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

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

• Insert the upper part to the upper cabinet,

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

Upper cabinet

Wiring cover

Valve cover

2 Front cabinet

1. Detachment

1) Perform work of item 1 of 1.

2) Remove screw (ST1T∅4 x 10s 2 pc.) of the front cabinet and inverter cover and screws (ST1T∅4 x 10s 3 pcs.) of the front cabinet and lower part.

• The left side of the front is made to insert to

the rear cabinet, so remove it pulling upward.

2. Attachment

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

2) Hook the lower part at the right side of the front to concave part of the bottom plate. Insert claw of the rear cabinet into square hole of the front cabinet.

3) Attach the removed screws to the original positions.

Claw

Square hole

Concave section

– 76 –

FILE NO. SVM-03008

No. Part name Procedures Remarks

3 Inverter

assembly

1) Perform work of item 1 of 1.

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

• If removing the inverter cover in this condition,

P.C. board can be checked.

• If there is no space in the upper part of the

upper cabinet, perform work of 2.

Be careful to check the inverter because high-voltage circuit is incorporated in it.

3) Perform discharging by connecting e, d polarity by discharging resistance (approx. 100Ω40W) or plug of soldering iron to e, d terminals of the C14 (printed “CAUTION HIGH VOLTAGE” is attached.) electrolytic capacitor (500 µF) on P.C . board.

Be careful to discharge the capacitor because the electrolytic capacitor cannot naturally discharge and voltage remains according to trouble type in some cases.

NOTE : This capacitor is one with mass capacity. Therefore, it is dangerous that a large spark generates if short-circuiting

between the

d polarity with screw-

driver, etc. for discharging.

Inverter cover

Discharging position (Discharging period 10 seconds or more)

P . C. board (Soldered surface)

Plug of soldering iron

4) Remove screw (ST1T∅4 x 10s 2 pc.) fixing the main body and the inverter box.

5) Remove various lead wires from the holder at upper part of the inverter box and wiring holder at right side of the terminal block.

6) Remove the lead wire from the bundled part at left side of the terminal block.

7) Pull the inverter box upward.

8) Disconnect connectors of various lead wires.

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

Bundled part

Holder

Terminal block

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

– 77 –

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

FILE NO. SVM-03008

CN701

CN500

CN703 CN602 CN301

CN300

CN603

CN601 CN600

Reactor

No. Part name Procedures Remarks

4 Control board

assembly

1) Disconnect lead wires and connectors connected from the control board assembly to other parts.

1. Lead wires

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

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

• Connection with reactor : Remove the relay connectors from P07, 08 (2P, White) and P12, 13 (2P, Yellow).

2. Connectors CN300 : Outdoor fan (3P, White) CN301 : Outdoor fan position detection

(5P, White) CN701 : 4-way valve (3P, Yellow) CN600 : TE sensor (2P, White) CN601 : TD sensor (3P, White) CN603 : TS sensor (3P, White) CN602 : TO sensor (2P, White) CN500 : Case thermo. (2P, White) CN703 : Pulse modulating valve

(6P, White)

2) Remove the control board assembly from P.C. board base.

1. Main control board assembly side

• Remove two claws of P.C. board base, and remove upward the heat sink with hands.

• Remove three screws fixing the heat sink and main control board assembly side, and replace the board with a new one.

CN300, CN301 and CN701, etc. at the control board assembly side are connectors with locks. Therefore, remove the connector while pushing the part indicated by an arrow.

P.C. board base

P.C. board

5 Rear cabinet

When mounting a new board, check that the board is correctly set in the groove of base holder of P.C. board base.

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

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

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

4) Remove fixed screw fixing to the valve mounting plate. (ST1T∅4 x 10s 1 pc.)

– 78 –

FILE NO. SVM-03008

No. Part name Procedures Remarks

6 Fan motor

7 Compressor

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

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

• Flange nut is loosened by turning clockwise.

(To tighten the flange nut, turn counterclockwise.)

3) Remove the propeller fan.

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

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

1) Perform work of item 1 of 1 and 2, 3, 4, 5.

2) Extract refrigerant gas.

3) Remove the partition board.

(ST1T∅4 x 10s 2 pcs.)

4) Remove the sound-insulation material.

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

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

7) Remove the fixing screw of the bottom plate and heat exchanger. (ST1T∅4 x 10s 2 pc.)

8) Remove the fixing screw of the bottom plate and valve clamping plate. (ST1T∅4 x 10s 2 pcs.)

9) Pull upward the refrigeration cycle.

10) Remove the nut fixing the compressor to the

bottom plate.

Fan motor

Propeller fan

Flange nut

Partition board

Valve clamping plate

Compressor thermo.

Compressor

8 Reactor

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

2) Remove lead wires clung in holder on the partition board.

3) Remove the screw fixing the reactor.

(ST1T∅4 x 10s 2 pcs.)

Reactor

– 79 –

FILE NO. SVM-03008

Hooking claw

Minus screwdriver

No. Part name Procedures Remarks

9 Pulse modulating

valve coil

! Fan guard

1. Detachment

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

2) Turn the coil clockwise (counterclockwise) by 90 degrees, and remove coil from the pulse modulating valve.

2. Attachment

1) Set take-out part of the lead wire of coil to the coil inserting position of the pulse modulating valve, and attach the coil.

2) Turn the coil by 90 degrees, set surely the concave part at lower part of the coil to the positioning hole of the pulse modulating valve, and then fix the coil.

The pulse modulating valve has A room side and B room side. After mounting it, check that coil at B room side (Red marking is marked on the pulse modulating valve.) is connected to CN13 of the control board assembly.

1. Detachment

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

2) Remove the front cabinet, and put it down so that fan guard side directs downward.

Take-out part of lead wire

Notch

Coil inserting position

Coil fix position

Positioning hole

Perform work on a corrugated cardboard, cloth, etc. to prevent flaw to the product.

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

2. Attachment

1) Insert claw of the fan guard in the hole of the front cabinet. Push the hooking claws (10 positions) by hands and fix the claws.

All the attaching works have completed. Check that all the hooking claws are fixed to the specified positions.

– 80 –

FILE NO. SVM-03008

No. Part name Procedures Remarks

" Replacement of

temperature sensor for servicing only

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

1) Cut the sensor 100 mm longer than old one.

2) Cut the protective tube after pulling out it

(200 mm).

3) Move the protective tube toward the thermal

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

4) Pass the stripped part through the thermal

constringent tube.

5) Cut the old sensor 100 mm length on the

connector side, and recycle that connector.

6) Tear the lead wire in two on the connector side

and strip and covering part.

7) Twist the leads on the connector and sensor

sides, and solder them.

8) Move the thermal constringent tubes toward

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

9) Wind the attached color tape round the both

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

10) Fix the sensor again.

NOTES:

1) Store the joint part of the sensor and the

connector in the electric parts box.

2) Never joint them near the thermal sensor part.

Otherwise, it would cause insulation inferiority because of dew drops.

3) When replacing the sensor using the colored

protective tube, wind the color tape matching the color of that tube.

Thermal sensor part

200

Winding the color tape

Cutting here

Connector

Thermal constringent tube

Cutting here

100

Soldered part

Dryer

100

Cutting here

These are parts for servicing sensors.

Please check that the accessories shown in the right table are packed.

Part name Q’ty Remarks

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

– 81 –

<P.C. board layout> MCC-813

FILE NO. SVM-03008

– 82 –

12. EXPLODED VIEWS AND PARTS LIST

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

405

403

FILE NO. SVM-03008

406

402

404

401

Location Part

No. No.

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

Description

Location Part

No. No.

404 43T62003 Cord Clamp 405 43169079 P.C. Board ASSY, WRS-LED 406 43T69322 P.C. Board, MCC-867

– 83 –

Description

12-2. Indoor Unit

212

210

201

211

215

205

218

219

217

220

216

217

208

FILE NO. SVM-03008

214

225

203

204

202

234

206

Location Part

No. No.

Description

201 43T00366 Front Panel Assy 202 43T09316 Inlet Grille Assy 203 43T03302 Back Body Assy 204 43T80301 Air Filter 205 43T09309 Horizontal Louver 206 43T08350 LED Panel Assy 207 43T70002 Drain Hose 208 43T79301 Cap Drain 209 43T21321 Motor, Louver, MP24GA, DC 12V 210 43T44320 Refrigeration Cycle Assy 211 43T47006 Pipe, Delivery ∅6.35 212 43T47305 Pipe, Suction ∅8.00 214 43T11301 Pipe Shield 215 43T19302 Holder Sensor 216 43T49302 Plate of EVA Seal 217 43T49006 Holder, Plate EVA Seal

204

228

229

Location Part

207

233

222

223

224

221

226

227

No. No.

Electric Parts

Assembly

209

231

232

Description

218 43T79302 Guide Drain 219 43T22002 Bearing 220 43T39301 Base, Bearing 221 43T20302 Cross Flow Fan 222 43T39302 Band Motor-L 223 43T21327 Motor, Fan, ICF-340-30-2, DC 340V 224 43T39303 Band Motor-R 225 43T82301 Plate, Installation 226 43T69306 Remote Control 227 43T83003 Holder Remote Control 228 43T85325 Owner’s Manual 229 43T62302 Terminal Cover 231 43T60317 Cord Motor Louver 232 43T60316 Cord Motor Fan 233 43T07303 Holder Pipe 234 43T01003 Mark

– 84 –

12-3. Outdoor Unit

FILE NO. SVM-03008

Location Part

No. No.

01 43T00377 Cabinet, Front, Assy 02 43T00381 Cabinet, Back, Assy 03 43T42304 Base, Assy 04 43T00380 Cabinet, Upper, Assy 05 43T09318 Guard, Fan 06 43T52310 Cover, Packed Valve 07 43T62311 Cover, Wiring, Assy 08 43T41336 Compressor 09 43T43330 Condenser, Assy 10 43T46317 Valve, Packed 6.35 Dia. 11 43T46320 Valve, Packed 9.52 Dia. 12 43T47020 Bonnet, 6.35 Dia. 13 43T47021 Bonnet, 9.52 Dia. 14 43T03303 Fixing Plate Valve, Assy 15 43T47008 Tube, Capillary

Description

Location Part

No. No.

16 43T46326 Body-PMV 17 43T63305 Coil-PMV 18 43T58303 Reactor 19 43T54304 Thermostat, Bimetal 20 43T63005 Holder, Thermostat, Bimetal 21 43T20307 Fan, Propeller 22 43T21334 Motor, Fan 23 43T47001 Nut, Flange 24 42T47324 Bolt, Compressor (M6) 25 43T49308 Cushion, Rubber 26 43T46323 Valve, 4-way 27 43T63304 Coil, 4-way, Assy 28 43T63306 Holder, Sensor 29 43T79305 Nipple, Drain

– 85 –

Description

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

FILE NO. SVM-03008

701

702

704

706

707

TE Sensor (∅6) TS Sensor (∅6) TO Sensor (∅6)

TD Sensor (∅4)

705

703

Location Part

No. No.

701 43T62312 Heatsink 702 43T69345 P.C. Board 703 43T60027 Terminal 6P 704 43T60326 Fuse

Description

Location Part

No. No.

705 43T50305 Temperature Sensor 706 43T50304 Temperature Sensor 707 43T62313 Base-Plate-P.C.

– 86 –

Description

FILE NO. SVM-03008

TOSHIBA CARRIER CORPORATION

– 87 –

Toshiba RAS-13UKV-E2, RAS-13UAV-E2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual