Toshiba RAS-13UKV-E3, RAS-16UAV-E, RAS-13UAV-E3, RAS-16UKV-E SERVICE MANUAL

SERVICE MANUAL

AIR CONDITIONER

SPLIT WALL TYPE

RAS-13UKV-E3 / RAS-13UAV-E3

RAS-16UKV-E / RAS-16UAV-E

FILE NO. SVM-04013

CONTENTS

1. SPECIFICATIONS

1-1 Specifications 1-2 Operation Characteristic Curve 1-3 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 (RAS-13UAV-E3)

4-3 Outdoor Unit (RAS-16UAV-E)

FILE NO. SVM-04013

5. SPECIFICATION OF ELECTRICAL PARTS

5-1 Indoor Unit

5-2 Outdoor Unit (RAS-13UAV-E3)

Outdoor Unit (RAS-16UAV-E)

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 TO 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 (RAS-13UAV-E3) 12-4 Outdoor Unit (RAS-16UAV-E) 12-5 Outdoor Unit (E-Parts Assy)

FILE NO. SVM-04013

− 2 −

1-1. Specifications

FILE NO. SVM-04013

1. SPECIFICATIONS

Unit model Indoor RAS-13UKV-E3

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) 3.27/3.72 Operation noise Indoor High (Cooling / Heating) (dB•A) 39/39

Indoor unit Unit model RAS-13UKV-E3

Outdoor unit Unit model RAS-13UAV-E3

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-E3

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

Outdoor Operation mode Cooling Heating

Running current (A) 4.84 5.16 Power consumption (W) 1040 1100 Power factor (%) 93 94 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) 270 Net weight (kg) 37 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) 0.8

Interconnection 4 Wires: includes earth

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

Wireless remote control 1

Remote controller holder 1

Flat head wood screw 2 (∅3.1 x 16L)

Bioenzyme filter 1

Zeolite filter 1

Batteries 2

Mounting screw 6 (∅4 x 25L)

Installation manual 1

Owner’s manual 1 Outdoor unit Drain nipple 1

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

FILE NO. SVM-04013

Unit model Indoor RAS-16UKV-E

COP (Cooling / Heating) 2.85/3.41 Operation noise Indoor High (Cooling / Heating) (dB•A) 45/44

Indoor unit Unit model RAS-16UKV-E

Outdoor unit Unit model RAS-16UAV-E

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-16UAV-E

Power consumption (W) 30

Outdoor Operation mode

Outdoor (Cooling / Heating) (dB•A) 51/53

Dimension Height (mm) 275

Net weight (kg) 10 Fan motor output (W) 30 Air flow rate (Cooling / Heating) (m3/h) 760/780

Dimension Height (mm) 550

Net weight (kg) 39 Compressor Motor output (W) 750

Fan motor output (W) 43 Air flow rate (Cooling / Heating) (m3/h) 2410/2410

Indoor unit Liquid side ∅6.35

Outdoor unit Liquid side ∅6.35

Maximum length (Per unit) (m) 15 Maximum chargeless length (m) 15 Maximum height difference (m) 10

Weight (kg) 0.95

Outdoor unit Drain nipple 1

Power factor (%) 65

Cooling

Running current (A) 7.20 8.32 Power consumption (W) 1590 1620 Power factor (%) 96 85 Starting current (A) 8.05

Medium (Cooling / Heating) (dB•A) 40/40 Low (Cooling / Heating) (dB•A) 34/34

Width (mm) 790 Depth (mm) 208

Width (mm) 780 Depth (mm) 720

Type Twin rotary type with DC-inverter variable speed control Model DA130A1F-24F

Gas side ∅12.7

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

0.2 30 65

Heating

• The specification may be subject to change without notice for purpose of improvement. – 4 –

1-2.Operation Characteristic Curve

FILE NO. SVM-04013

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% = Nominal Capacity

– 5 –

2. REFRIGERANT R410A

FILE NO. SVM-04013

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.

– 6 –

FILE NO. SVM-04013

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

– 7 –

d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool. Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

∅D

Fig. 2-2-1 Flare processing dimensions

FILE NO. SVM-04013

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

– 8 –

FILE NO. SVM-04013

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·m)

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

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)

– 9 –

FILE NO. SVM-04013

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

– 10 –

FILE NO. SVM-04013

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)

– 11 –

(OUTDOOR unit)

Opened

Closed

Service port

FILE NO. SVM-04013

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.

– 12 –

FILE NO. SVM-04013

(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

– 13 –

3-1. Indoor Unit

FILE NO. SVM-04013

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

– 14 –

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-04013

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

– 15 –

4-1.Indoor Unit

FILE NO. SVM-04013

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

– 16 –

4-2.Outdoor Unit (RAS-13UAV-E3)

FILE NO. SVM-04013

PULSE

MODULATING

VALVE

121

REACTOR

ORN

CONVERTER

MODULE

DB01

BRW

IGBT MODULE

Q200

BLU P18

P10

BU EU BV EV BW EW BX BY BZ

E A

112

CN600

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

– 17 –

4-3.Outdoor Unit (RAS-16UAV-E)

FILE NO. SVM-04013

PULSE

MODULATING

VALVE

THERMOSTAT FOR COMPRESSOR

121

REACTOR

ORN

P10

E A

CONVERTER

MODULE

DB01

BRW

BU EU BV EV BW EW BX

IGBT MODULE

BY BZ

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

– 18 –

FILE NO. SVM-04013

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 (RAS-13UAV-E3)

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-78 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)

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

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)

JXO-6B

30A, 600 VAC

Convertor module

MP 7003

– 19 –

Diode: 25A, 600 V,

IG BT: 40 A, 600V

FILE NO. SVM-04013

5-3. Outdoor Unit (RAS-16UAV-E)

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-78 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)

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 DA130A1F-24F 3-phases 4-poles 1100 W

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)

JXO-6B

30A, 600 VAC

Convertor module

MP 7003

Diode: 25A, 600 V,

IG BT: 40 A, 600V

– 20 –

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

RAS-13UKV-E3 / RAS-13UAV-E3

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-04013

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

NOTE :

Strainer

Pulse modulating valve at liquid side (SEV16RC3)

Refrigerant amount : 0.8 kg

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.

– 21 –

RAS-16UKV-E / RAS-16UAV-E

Pressure measurement Gauge attaching port

Vacuum pump connecting port Deoxidized copper pipe

Outer dia. : 12.7 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-04013

Max. : 15 m

Allowable height

difference : 10m

Allowable pipe length

4-way valve (CHV-0213)

Temp. measurement

Muffler

Compressor DA130A1F-24F

Outdoor heat

exchanger

Propeller fan

OUTDOOR UNIT

Split capillary

∅1.5 x 200 ∅1.5 x 200

NOTE :

Strainer

Pulse modulating valve at liquid side (SEV16RC3)

Refrigerant amount : 0.95 kg

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.

– 22 –

6-2. Operation Data

RAS-13UKV-E3 / RAS-13UAV-E3

FILE NO. SVM-04013

Temperature

condition ( °C)

Indoor Outdoor

27/19 35/− 13UKV-E3 0.8 to 1.0 9 to 11 49 to 45 High High 77

Temperature

condition ( °C)

Indoor Outdoor

20/− 7/6 13UKV-E3 2.5 to 2.7 42 to 44 0 to 3 High High 80

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

RAS-16UKV-E / RAS-16UAV-E

Temperature

condition (° C)

Indoor Outdoor

27/19 35/− 0.9 to 1.2 7 to 10 50 to 45 High High 77

Model

name

16UKV-E

Standard

pressure

P (MPa)

Heat exchanger

pipe temp.

T1 (°C) T2 ( °C)

Indoor

fan

mode

Outdoor

fan

mode

Compressor

revolution

(rps)

Compressor

revolution

(rps)

Compressor

revolution

(rps)

Temperature

condition ( °C)

Indoor Outdoor

20/− 7/6 2.7 to 2.9 42 to 46 0 to 3 High High 82

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

16UKV-E

Standard

pressure

P (MPa)

Heat exchanger

pipe temp.

T1 (°C) T2 (

°C)

Indoor

fan

mode

Outdoor

fan

mode

Compressor

revolution

(rps)

− 23 −

7-1.Indoor Unit

Heat Exchanger Sensor

7. CONTROL BLOCK DIAGRAM

Indoor Unit Control Panel

M.C.U

Functions

• Louver Control

FILE NO. SVM-04013

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

– 24 –

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-04013

– 25 –

8. OPERATION DESCRIPTION

FILE NO. SVM-04013

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.

– 26 –

FILE NO. SVM-04013

(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

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-E3

16UKV-E

Compressor

revolution (rps)

13 to 88

16 to 110

13 to 91

13 to 106

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.

– 27 −

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