Toshiba RAS-22LAV-UL, RAS-17LKV-UL, RAS-15LKV-UL, RAS-17LAV-UL, RAS-15LAV-UL User Manual

SERVICE MANUAL

Indoor Unit Outdoor Unit

<High Wall, Heat Pump Type> <Heat Pump Type>

FILE NO. SVM-10020

SPLIT TYPE

RAS-15LKV-UL RAS-15LAV-UL
RAS-17LKV-UL RAS-17LAV-UL

RAS-22LKV-UL RAS-22LAV-UL

R410A

February, 2010

FILE NO. SVM-10020

CONTENTS

1. SAFETY PRECAUTIONS .......................................................................... 3

2. SPECIFICATIONS ..................................................................................... 6

3. REFRIGERANT R410A ............................................................................. 9

4. CONSTRUCTION VIEWS ........................................................................ 17

5. WIRING DIAGRAM .................................................................................. 19

6. SPECIFICATIONS OF ELECTRICAL PARTS ......................................... 20

7. REFRIGERANT CYCLE DIAGRAM ........................................................ 21

8. CONTROL BLOCK DIAGRAM ................................................................ 24

9. OPERATION DESCRIPTION................................................................... 26

10. INSTALLATION PROCEDURE ................................................................ 50

11. HOW TO DIAGNOSE THE TROUBLE...................................................... 65

12. HOW TO REPLACE THE MAIN PARTS................................................... 89

13. EXPLODED VIEWS AND PARTS LIST ................................................. 105

– 2 –

FILE NO. SVM-10020

1. SAFETY PRECAUTIONS

Installing, staring up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical
components, and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service mechanics should install, start-up, and service this equipment.
Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should be

performed by trained service personnel.

When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the
equipment.

Follow all safety codes, Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher near by
when brazing. Use care in handling, rigging, and setting bulky equipment.

Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit.
Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety information.
This is the safety-alert symbol

potential for personal injury. Understand these signal words : DANGER, WARNING, and CAUTION. These words are
used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in severs personal injury or death. WARNING signifies
hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result
in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in
enhanced installation, reliability, or operation.

! . When you see this symbol on

the unit and in instructions or manuals, be alert to the

• Before installation, please read these precautions for safety carefully.

• Be sure to follow the precautions provided here to avoid safety risks. The symbols and their meanings are shown below.

WARNING : It indicates that incorrect use of this unit may cause severe injury or death.
CAUTION : FAILURE TO FOLLOW THIS CAUTION may result in equipment damage or improper operation and

personal injury.

CAUTION

New refrigerant air conditioner installation

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

OZONE LAYER.
R410A refrigerant is affected by inpurities such as water and oils because the pressure of R410A refrigerant is approx.

1.6 times of refrigerant R22.
ALSO NEW OILS ARE USED WITH R410A, THUS ALWAYS USE NEW REFRIGERANT PIPING AND DO NOT
ALLOW MOISTURE OR DUST TO ENTER THE SYSTEM.
To avoid mixing refrigerant and refrigerant machine oil, the sizes of charging port on the main unit is different than
those used on R22 machines and different tools will be required.

• EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must
be a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length
is buried, refrigerant may migrate to the cooter buried section during extended periods of system shutdown. This
causes refrigerant slugging and could possibly damage the compressor at start-up.

− 3 −

FILE NO. SVM-10020

DANGER

• FOR USE BY QUALIFIED PERSONS ONLY.

• TURN OFF MAIN POWER SUPPLY BEFORE.ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER

SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

• CONNECT THE CONNECTING CABLE CORRECTLY. IF THE CONNECTING CABLE IS CONNECTED WRONGLY,

ELECTRIC PARTS MAY BE DAMAGED.

• CHECK THE EARTH WIRE THAT IT IS NOT BROKEN OR DISCONNECTED BEFORE INSTALLATION.

• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS.

FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

• TO PREVENT OVERHEATION THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY

(MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEATERS, FURNACE, STOVES, ETC.

• WHEN MOVING THE AIR CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT

TO GET THE SPECIFIED REFRIGERANT (R410A) WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION
CYCLE. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION
CYCLE BECOMES ABNORMALLY HIGH AND IT RESULTINGLY CAUSES BURST OF THE PIPE AND INJURIES ON
PERSONS.

• IN THE EVENT THAT THE REFRIGERANT LEAK, DURING INSTALLATION WORK, IMMEDIATELY ALLOW FRESH AIR

INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSE GENERATION
OF POISONOUS GAS.

WARNING

• ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.
Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may
be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label.

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

• Installation work must be purformed by qualified personnel only.

• Specified tools and pipe parts for model R410A are required, and installation work must be done in accordance with the

manual. HFC type refrigerant R410A has 1.6 times more pressure than that of conventional refrigerant (R22). Use the
specified pipe parts, and ensure correct installation, otherwise damage and/or injury may be caused. At the same time,
water leakage, electrical shock, and fire may occur.

• Be sure to install the unit in a place which can sufficiently bear its weight. If the load bearing of the unit is not enough, or

installation of the unit is improper, the unit may fall and result in injury.

• Electrical work must be performed by trained, qualified installers and service mechanics in accordance with the code governing

such installation work, internal wiring regulations, and the manual. A dedicated circuit and the rated voltage must be used.
Insufficient power supply or improper installation may cause electrical shock or fire.

• Use a cabtyre cable to connect wires in the indoor/outdoor units. Midway connection is not allowed. Improper connection or

fixing may cause a fire.

• Wiring between the indoor unit and outdoor units must be well shaped so that the cover can be firmly placed. Improper

cover installation may cause increased heat, fire, or electrical shock at the terminal area.

• Be sure to use only approved accessories or the specified parts. Failure to do so may cause the unit to fall, water leakage,

fire or electrical shock.

• After the installation work. ensure that there is no leakage of refrigerant gas. If the refrigerant gas leaks out of the pipe into

the room and is heated by fire or something else from a fanheater, stove or gas range, it causes generation of poisonous gas.

• Make sure the equipment is properly grounded. Do not connect the ground wire to a gas pipe, water pipe, lightning

conductor, or telephone earth wire. Improper earth work may be the cause of electrical shock.

• Do not install the unit where flammable gas may leak. If there is any gas leakage or accumulation around the unit, it can

cause a fire.

• Do not select a location for installation where there may be excessive water or humidity, such as a bathroom. Deterioration

of insulation nay cause electrical shock or fire.

• Installation work must be performed following the instructions in this installation manual. Improper installation may cause

water leakage, electrical shock or fire. Check the following items before operating the unit.

- Be sure that the pipe connection is well placed and there are no leaks.

- Check that the service valve is open. If the service valve is closed, it may cause overpressure and result in compressor
damage. At the same time, if there is a leak in the connection part, it may cause air suction and overpressure, resulting
in damage to the unit or injury.

• In a pump-down operation, be sure to stop the compressor unit before removing the refrigerant pipe. If removing the

refrigerant pipe while the compressor is operating with the service valve opened, it may cause air suction and overpressure,
resulting in damage to the unit or injury.

• Do not modity the power cable, connect the cable midway, or use a multiple outlet extension cable. Doing so may cause

contact failure, insulation failure, or excess current, resulting in fire or electrical shock.

• If you detect any damage, do not install the unit. Contact your dealer immediately.

− 4 −

FILE NO. SVM-10020

CAUTION

CAUTION

• Exposure of unit to water or other moisture before installation could result in electric shock. Do not store it in a wet

basement or expose to rain or water.

• After unpacking the unit, examine it carefully for possible damage. Report any damages to your distributor.

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

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

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

for proper installation.

• This appliance must be connected to the main power supply by means of a circuit breaker depending on the

place where the unit is installed. Failure to do so may cause electrical shock.

• Follow the instructions in this installation manual to arrange the drain pipe for proper drainage from the unit.

Ensure that drained water is discharged. Improper drainage can result is water leakage, causing water damage
to furniture.

• Tighten the flare nut with a torque wrench using the prescribed method. Do not apply excess torque. Otherwise,

the nut may crack after a long period of usage and it may cause the leakage of refrigerant.

• Wear gloves (heavy gloves such as cotton gloves) for installation work. Failure to do so may cause personal

injury when handling parts with sharp edges.

• Do not touch the air intake section or the aluminum fins of the outdoor unit. It may cause injury.

• Do not install the outdoor unit in a place which can be a nest for small animals. Small animals could enter and

contact internal electrical parts, causing a failure or fire.

• Request the user to keep the place around the unit tidy and clean.

• Make sure to conduct a trial operation after the installation work, and explain how to use and maintain the unit

to the customer in accordance with the manual. Ask the customer to keep the operation manual along with the
installation manual.

− 5 −

FILE NO. SVM-10020

2. SPECIFICATIONS

2-1. Specifications (RAS-15LKV-UL/RAS-15LAV-UL, RAS-17LKV-UL/RAS-17LAV-UL)

Unit model Indoor RAS-15LKV-UL RAS-17LKV-UL

Outdoor RAS-15LAV-UL RAS-17LAV-UL

Cooling capacity (Btu/h) 15000 16200

Cooling capacity range (Btu/h) 2750 - 17050 3750 - 20450

Heating capacity (Btu/h) 18000 20200
Heating capacity range (Btu/h) 2750 - 21500 2750 - 21500

Power supply

Electric Indoor Operation mode Cooling Heating Cooling Heating

characteristic Running current (A) 0.32 - 0.29 0.32 - 0.29 0.32 - 0.29 0.32 - 0.29

Power consumption (W ) 40 40 40 40

Power factor (%) 60 60 60 60

Outdoor Operation mode Cooling Heating Cooling Heating

Running current (A) 5.43 - 4.91 6.65 - 6.01 6.13 - 5.51 7.78 - 7.01

Power consumption (W ) 1110 1360 1245 1590

Power factor (%) 98 98 98 99
Starting current (A) 5.75 - 5.20 6.97 - 6.30 6.45 - 5.80 8.10 - 7.30

EER (Cooling/Heating) (Btu/W.h) 13.00 12.80 12.60 12.40
SEER (Btu/W.h) / HSPF (W/W)

Operating Indoor High (Cooling/Heating) (dB-A) 44/44 47/47

noise Medium (Cooling/Heating) (dB-A) 38/39 41/42

Low (Cooling/Heating) (dB-A) 32/32 35/35

Outdoor (Cooling/Heating) (dB-A) 51/51 52/52

Indoor unit Unit model RAS-15LKV-UL RAS-17LKV-UL

Dimension Height in. (mm) 12-19/32 (320) 12-19/32 (320)

Width in. (mm) 41-5/16 (1050) 41-5/16 (1050)

Depth in. (mm) 8-15/16 (228) 8-15/16 (228)

Net weight lbs (kg) 29 (13) 29 (13)
Fan motor output (W) 30 30

Air flow rate (Cooling/Heating)

Outdoor unit Unit model RAS-15LAV-UL RAS-17LAV-UL

Dimension Height in. (mm) 21-11/16 (550) 21-11/16 (550)

Width in. (mm) 30-11/16 (780) 30-11/16 (780)

Depth in. (mm) 11-7/16 (290) 11-7/16 (290)

Net weight lbs (kg) 91 (41) 91 (41)
Compressor Motor output (W) 1100 1100

Type

Model DA130A1F-27F1 DA130A1F-27F1

Fan motor output (W) 43 43

Air flow rate (Cooling/Heating)

Piping Type Flare connection Flare connection

connection Indoor unit Liquid side in. (mm)

Gas side in. (mm)

Outdoor unit Liquid side in. (mm)

Gas side in. (mm)

Maximum length ft. (m)

Maximum chargeless length ft. (m) 49 (15) 49 (15)

Maximum height difference ft. (m) 33 (10) 33 (10)

Refrigerant Name of refrigerant R410A R410A

Weight lbs (kg) 3.09 (1.40) 3.09 (1.40)

Wiring Power supply

connection Interconnection 4Wires:includes earth 4Wires:includes earth

Usable temperature range Indoor (Cooling/Heating) °F (°C) 70°F-90°F (21°C-32°C)/ 32°F-82°F (0°C-28°C)

Outdoor (Cooling/Heating) °F (°C) 14°F-115°F (-10°C-46°C) / 5°F-75°F (-15°C-24°C)

cfm (m3/min)

cfm (m3/min)

1Ph, 60Hz, 208V/230V 1Ph, 60Hz, 208V/230V

20.0/9.0

562 (15.9)/583 (16.5) 636 (18.0)/646 (18.3)

Twin rotary type with DC-inverter

variable speed control

1282 (36.3)/1127 (31.9) 1636 (38.6)/1127 (31.9)

1/4 ( ∅6.35) ∅1/4 ( ∅6.35)

∅

1/2 ( ∅12.70) ∅1/2 ( ∅12.70)

∅

1/4 ( ∅6.35) ∅1/4 ( ∅6.35)

∅

1/2 ( ∅12.70) ∅1/2 ( ∅12.70)

∅

66 (20)

3Wires:includes earth (Outdoor) 3Wires:includes earth (Outdoor)

Twin rotary type with DC-inverter

19.0/9.0

variable speed control

66 (20)

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

− 6 −

FILE NO. SVM-10020

(RAS-22LKV-UL/RAS-22LAV-UL)

Unit model Indoor RAS-22LKV-UL

Outdoor RAS-22LAV-UL

Cooling capacity (Btu/h) 21400

Cooling capacity range (Btu/h) 4100-22500

Heating capacity (Btu/h) 23200

Heating capacity range (Btu/h) 3450-24350

Power supply

Electric Indoor Operation mode

characteristic Running current (A)

Power consumption (W )

Power factor (%)

Outdoor Operation mode

Running current (A)

Power consumption (W )

Power factor (%)

Starting current (A)

EER (Cooling/Heating) (Btu/W.h)
SEER (Btu/W.h) / HSPF (W/W)

Operating Indoor High (Cooling/Heating) (dB-A) 47/47

noise Medium (Cooling/Heating) (dB-A) 41/42

Low (Cooling/Heating) (dB-A) 35/35

Outdoor (Cooling/Heating) (dB-A) 53/53

Indoor unit Unit model RAS-22LKV-UL

Dimension Height in. (mm) 12-19/32 (320)

Width in. (mm) 41-5/16 (1050)

Depth in. (mm) 8-15/16 (228)

Net weight lbs (kg) 29 (13)
Fan motor output (W) 30

Air flow rate (Cooling/Heating)

Outdoor unit Unit model RAS-22LAV-UL

Dimension Height in. (mm) 21-11/16 (550)

Width in. (mm) 30-11/16 (780)

Depth in. (mm) 11-7/16 (290)

Net weight lbs (kg) 93 (42)
Compressor Motor output (W) 1100

Type

Model DA150A1F-20F1

Fan motor output (W) 43

Air flow rate (Cooling/Heating)

Piping Type Flare connection

connection Indoor unit Liquid side in. (mm)

Gas side in. (mm)

Outdoor unit Liquid side in. (mm)

Gas side in. (mm)

Maximum length ft. (m)

Maximum chargeless length ft. (m) 49 (15)

Maximum height difference ft. (m) 33 (10)

Refrigerant Name of refrigerant R410A

Weight lbs (kg) 3.09 (1.40)

Wiring Power supply

connection Interconnection 4Wires:includes earth

Usable temperature range Indoor (Cooling/Heating) °F (°C) 70°F-90°F (21°C-32°C)/ 32°F-82°F (0°C-28°C)

Outdoor (Cooling/Heating) °F (°C) 14°F-115°F (-10°C-46°C) / 5°F-75°F (-15°C-24°C)

cfm (m3/min)

cfm (m3/min)

Cooling

0.40-0.36

Cooling

12.40-11.14

2520

12.80-11.50

8.30

Twin rotary type with DC-inverter variable speed control

1Ph, 60Hz, 208V/230V

50

60

98

15.5/90

636 (18.0)/646 (18.3)

1636 (38.6)/1314 (37.2)

1/4 ( ∅6.35)

∅

1/2 ( ∅12.70)

∅

1/4 ( ∅6.35)

∅

1/2 ( ∅12.70)

∅

66 (20)

3Wires:includes earth (Outdoor)

Heating

0.40-0.36

Heating

10.50-9.54

2150

10.90-9.90

10.50

50

60

98

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

− 7 −

2-2. Operation Characteristic Curve

<Cooling> <Heating>

FILE NO. SVM-10020

13.00

12.00

11.00

10.00

9.00

8.00

7.00

6.00

Current (A)

5.00

4.00

3.00

2.00

1.00

0.00
0 10 20 30 40 50 60 70 80 90 100 110 120

RAS-22LKV-UL

RAS-17LKV-UL

RAS-15LKV-UL

Compressor Speed (RPS)

13.00

12.00

11.00

10.00

9.00

8.00

7.00

6.00

RAS-22LKV-UL

RAS-15LKV-UL

RAS-17LKV-UL

Current (A)

5.00

4.00

3.00

2.00

1.00

0.00
0 102030405060708090100110120

Compressor Speed (RPS)

2-3. Capacity Variation Ratio According to Temperature

<Cooling> <Heating>

105

100

95

90

85

80

75

70

Capacity Ratio (%)

65

60

55

50

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 –15 –10–50 510

RAS-15LKV-UL
RAS-17LKV-UL
RAS-22LKV-UL

Condition
Indoor: DB80°F/WB67°F

(DB26.7°C/WB19.4°C)

I

ndoor Air-Flow Volume: High

Pipe Length: 25 ft (7.5m)

Capacity Ratio: 100% =
15000 Btu/h (RAS-15LKV-UL)
16200 Btu/h (RAS-17LKV-UL)
21400 Btu/h (RAS-22LKV-UL)

Outdoor Temperature (°C)

120

100

80

60

Capacity Ratio (%)

40

20

0

RAS-15LKV-UL
RAS-17LKV-UL
RAS-22LKV-UL

Condition
Indoor: DB70°F/WB60°F

(DB21.1°C/WB15.6°C)
Indoor Air-Flow Volume: High
Pipe Length: 25 ft (7.5m)

Capacity Ratio: 100% =
18000 Btu/h (RAS-15LKV-UL)

20200 Btu/h (RAS-17LKV-UL)
23200 Btu/h (RAS-22LKV-UL)

Outdoor Temperature (°C)

– 8 –

3. REFRIGERANT R410A

FILE NO. SVM-10020

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

The working pressure of the new refrigerant R410A
is 1.6 times higher than conventional refrigerant
(R22). The refrigerating oil is also changed in
accordance with change of refrigerant, so be careful
that water , dust, and existing refrigerant or refrigerat­ing oil are not entered in the refrigerant cycle of the
air conditioner using the new refrigerant during
installation work or servicing time.

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

3-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may
cause a serious trouble. By using tools and materi­als exclusive for R410A, it is necessary to carry out
installation/servicing safely while taking the following
precautions into consideration.

1. Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.

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

2. Confirm the used refrigerant name, and use tools
and materials exclusive for the refrigerant R410A.

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

3. If a refrigeration gas leakage occurs during
installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire,
a poisonous gas may occur.

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

5. After completion of installation work, check to
make sure that there is no refrigeration gas
leakage.

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

6. When an air conditioning system charged with a
large volume of refrigerant is installed in a small
room, it is necessary to exercise care so that,
even when refrigerant leaks, its concentration
does not exceed the marginal le vel.

If the refrigerant gas leakage occurs and its
concentration exceeds the marginal le vel, an
oxygen starvation accident may result.

7. Be sure to carry out installation or removal
according to the installation manual.

Improper installation may cause refrigeration
trouble, water leakage , electric shock, fire, etc.

8. Unauthorized modifications to the air conditioner
may be dangerous. If a breakdown occurs
please call a qualified air conditioner technician
or electrician.

Improper repair’s may result in water leakage,
electric shock and fire, etc.

3-2. Refrigerant Piping Installation

3-2-1. Piping Materials and Joints Used

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

1. Copper Pipes

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

Otherwise, the expansion valve or capillary tube
may become blocked with contaminants.

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

Thicknesses of copper pipes used with R410A
are as shown in Table 3-2-1. Never use copper
pipes thinner than 0.0315 in. (0.8 mm) even
when it is available on the market.

– 9 –

Table 3-2-1 Thicknesses of annealed copper pipes

Thickness in. (mm)

FILE NO. SVM-10020

Nominal diameter (in.)

1/4
3/8
1/2

Outer diameter (mm)

6.35

9.52

12.70

R410A R22

0.0315 (0.80) 0.0315 (0.80)

0.0315 (0.80)

0.0315 (0.80)

0.0315 (0.80)

0.0315 (0.80)

2. Joints

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

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

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

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose
diameter is larger than 0.7874 in. (20 mm).

Thicknesses of socket joints are as shown in Table 3-2-2.

Table 3-2-2 Minimum thicknesses of socket joints

Nominal diameter (in)

1/4
3/8
1/2

Reference outer diameter of

copper pipe jointed (mm)

6.35

9.52

12.70

Minimum joint thickness

in. (mm)

0.0197 (0.50)

0.0236 (0.60)

0.0276 (0.70)

3-2-2. Processing of Piping Materials

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

1. Flare processing procedures and precautions

a) Cutting the Pipe

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

b) Removing Burrs and Chips

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

c) Insertion of Flare Nut

– 10 –

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 “dimen-
sion A” by using a gauge for size adjustment.

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

Nominal
diameter

in.

Outer

diameter

(mm)

Thickness

in. (mm)

Fig. 3-2-1 Flare pr ocessing dimensions

Flare tool for R410A

clutch type

FILE NO. SVM-10020

ØD

A

A in. (mm)

Conventional flare tool

Clutch type Wing nut type

1/4
3/8
1/2

Nominal

diameter

in.

1/4
3/8
1/2

6.35

9.52

12.70

Table 3-2-4 Dimensions related to flare processingf or R22

Outer

diameter

(mm)

6.35

9.52

12.70

0.0315 (0.8)

0.0315 (0.8)

0.0315 (0.8)

Thickness

in. (mm)

0.0315 (0.8)

0.0315 (0.8)

0.0315 (0.8)

Table 3-2-5 Flare and flare nut dimensions for R410A

0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)

0 to 0.0197 (0 to 0.5)

Flare tool for R22

clutch type

0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)
0 to 0.0197 (0 to 0.5)

0.0394 to 0.0591

0.0394 to 0.0591

0.0394 to 0.0591

0.0197 to 0.0394

0.0197 to 0.0394

0.0197 to 0.0394

0.0591 to 0.0787

(1.0 to 1.5)

(1.0 to 1.5)

(1.0 to 1.5)

A in. (mm)

Conventional flare tool

Clutch type Wing nut type

(0.5 to 1.0)

(0.5 to 1.0)

(0.5 to 1.0)

(1.5 to 2.0)

0.0591 to 0.0787
(1.5 to 2.0)

0.07874 to 0.0984
(2.0 to 2.5)

0.0394 to 0.0591
(1.0 to 1.5)

0.0394 to 0.0591
(1.0 to 1.5)

0.0591 to 0.0787

(1.5 to 2.0)

Nominal

diameter

in.

1/4
3/8
1/2

Outer diameter

(mm)

6.35

9.52

12.70

Thickness

in. (mm)

0.0315 (0.8)

0.0315 (0.8)

0.0315 (0.8)

Dimension in. (mm)

A B C D

0.358 (9.1)

0.520 (13.2) 0.531 (13.5) 0.382 (9.7) 0.787 (20)

0.653 (16.6)

0.362 (9.2) 0.256 (6.5)

0.630 (16.0) 0.508 (12.9)

0.512 (13)

0.906 (23)

– 11 –

Flare nut width

in. (mm)

0.669 (17)

0.866 (22)

1.024 (26)

Table 3-2-6 Flare and flare nut dimensions for R22

FILE NO. SVM-10020

Nominal

diameter

in.

1/4
3/8
1/2

Outer diameter

(mm)

6.35

9.52

12.70

Thickness

in. (mm)

0.0315 (0.8)

0.0315 (0.8)

0.0315 (0.8)

45˚ to 46˚

Dimension in. (mm)

A B C D

0.354 (9.0)

0.362 (9.2) 0.256 (6.5)

0.512 (13)

0.512 (13.0) 0.531 (13.5) 0.382 (9.7) 0.787 (20)

0.638 (16.2)

B A

0.630 (16.0) 0.508 (12.9)

43˚ to 45˚

0.787 (20)

D

C

Flare nut width

in. (mm)

0.669 (17)

0.866 (22)

0.945 (24)

Fig. 3-2-2 Relations between flare nut and flare seal surface

2. Flare Connecting Procedures and Precautions

a) Make sure that the flare and union portions do not hav e any scar or dust, etc.
b) Correctly align the processed flare surface with the union axis.
c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is

the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.
When it is strong, the flare nut may crack and may be made non-removable. When choosing the tighten-

ing torque, comply with values designated by man ufacturers. Table 3-2-7 shows reference values.

NOTE :

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

Table 3-2-7 Tightening torque of flare for R410A [Reference values]

Nominal

diameter

in.

Outer diameter

(mm)

Tightening torque

lbf.ft (N•m)

Tightening torque of torque

wrenches available on the market

lbf.ft (N•m)

1/4
3/8
1/2

6.35

9.52

12.70

10 to 13 (14 to 18)
24 to 31 (33 to 42)

37 to 46 (50 to 62)

– 12 –

12 (16), 13 (18)

31 (42)

41 (55)

FILE NO. SVM-10020

3-3. Tools

3-3-1. Required T ools

The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is
changed to prev ent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing
dimensions and opposite side dimension of flare nut (For ∅1/2 Ø12.7 copper pipe) of the refrigerant piping are
lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as 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 f or R410A and their interchangeability.

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

Tools whose specifications are changed for R410A and their interchangeability

air-water heat pump installation

No.

1

2

3

4
5
6

7
8

9

10

(Note 1) When flaring is carr ied out for R410A using the conventional flare tools, adjustment of projection

(Note 2) Charging cylinder for R410A is being currently developed.

Used tool

Flare tool
Copper pipe gauge for

adjusting projection
margin

Torque wrench

[(For Ø1/2 in. (12.7mm)]

Gauge manifold
Charge hose
Vacuum pump adapter

Electronic balance for
refrigerant charging

Refrigerant cylinder
Leakage detector
Charging cylinder

margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

Pipe flaring
Flaring by

conventional flare tool

Connection of flare nut

Evacuating, refrigerant
charge, run check, etc.

Vacuum evacuating
Refrigerant charge
Refrigerant charge

Gas leakage check
Refrigerant charge

Usage

Existence of
new equipment
for R410A

Yes

Yes

Yes

Yes

Yes
Yes
Yes

Yes

(Note 2)

R410A

Whether conven­tional equipment
can be used

*(Note 1)

*(Note 1)

×
×

×
×
×

×
×

Conventional air-water
heat pump installation

Whether new equipment
can be used with
conventional refrigerant

¡

*(Note 1)

×
×

¡

¡

×

¡

×

General tools (Conventional tools can be used.)

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

1. Vacuum pump
Use vacuum pump by attaching
vacuum pump adapter.

2. Torque wrench [For Ø1/4, Ø3/8 in.

(∅ 6.35, ∅ 9.52mm)]

3. Pipe cutter

4. Reamer

5. Pipe bender

9. Hole core drill [Ø2-9/16 in. (65mm)]

10. Hexagon wrench

6. Level vial

7. Screwdriver (+, –)

11. Tape measure

8. Spanner or Monkey wrench

[Opposite side 3/16 in. (4mm)]

12. Metal saw

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

1. Clamp meter

2. Thermometer

3. Insulation resistance tester

4. Electroscope

– 13 –

FILE NO. SVM-10020

3-4. Recharging of Refrigerant

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

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

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

Connect the charge hose to the vacuum pump
adapter.

Open fully both packed valves at liquid and gas
sides.

When the compound gauge’s pointer has indicated

−

147 Psi (–0.1 Mpa) or − 29.9 inHg (–76 cmHg),
place the handle Low in the fully closed position, and
turn off the vacuum pump's power switch.

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

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

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

(For refrigerant charging, see the figure below.)

1. Never charge refrigerant exceeding the specified amount.

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

3. Do not carry out additional charging.
When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the

refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the
specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high
pressure, and may cause a rupture or personal injury.

(Indoor Unit)

Opened

(Outdoor unit)

Refrigerant cylinder

(with siphon)

Check valve

Opened
Open/close
valve for charging

Electronic balance for refrigerant charging

Fig. 3-4-1 Configuration of refrigerant charging

Opened

Closed

Service port

– 14 –

FILE NO. SVM-10020

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

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

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

[ Cylinder with siphon ] [ Cylinder without siphon ]

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Electronic

balance

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

3-5. Brazing of Pipes

3-5-1. Materials for Brazing

1. Silver brazing filler

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

2. Phosphor bronze brazing filler

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

Electronic

balance

Siphon

Fig. 3-4-2

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

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

3-5-2. Flux

3. Low temperature brazing filler

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

1. Reason why flux is necessary

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

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

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

– 15 –

2. Characteristics required for flux

• Activated temperature of flux coincides with the
brazing temperature.

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

• It is easy to remove slag after brazing.

• The corrosive action to the treated metal and

brazing filler is minimum.

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

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

3. Types of flux

• Noncorrosive flux

Generally, it is a compound of borax and boric
acid.
It is effective in case where the brazing tem­perature is higher than 1472°F (800°C).

• Activated flux

Most of fluxes generally used for silver brazing
are this type.
It features an increased o xide film removing
capability due to the addition of compounds
such as potassium fluoride, potassium chloride
and sodium fluoride to the borax-boric acid
compound.

4. Piping materials for brazing and used
brazing filler/flux

FILE NO. SVM-10020

3-5-3. Brazing

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

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

Never use gas other than Nitrogen gas.

1. Brazing method to prevent oxidation

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

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

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

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

5) Adjust the flow rate of Nitrogen gas so that it
is lower than 0.03 cfm (0.05 m
MPa) (0.2kgf/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.

3

/Hr) or 2.9 psi (0.02

Piping material

Copper - Copper

Copper - Iron

Iron - Iron

Used brazing filler

Phosphor copper

Silver
Silver

Used flux

Do not use

Paste flux
Vapor flux

1. Do not enter flux into the refrigeration cycle.

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

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

4. Remove the flux after brazing.

M

Flow meter

Stop valve

Nitrogen gas

cylinder

From Nitrogen cylinder

Pipe

Nitrogen
gas

Rubber plug

Fig. 3-5-1 Prevention of oxidation during brazing

– 16 –

4-1. Indoor Unit

4. CONSTRUCTION VIEWS

41-5/16(1050)

FILE NO. SVM-10020

Unit : Inch (mm)

Grille Inlet

Front panel

Knockout for leftward
piping

2-7/8(73.5)

9/32(7)

Knockout for bottom leftward piping

Conduit hole
(Ø7/8(22) hole)

Heat exchanger
Air inlet

12-19/32(320)

Air outlet

1-15/16(50)

2-13/16(72)3-1/16(78)

Knockout for bottom rightward piping

Installation plate hanger

10.9"(278) 7.9"(200) 8.7"(222) 7.9"(200) 5.9"(150)

5.2"(132)

2-13/16(72)

Air Þ lter

1-15/16(50)1-15/16(50)

2"(50)

3-1/16(78)

8-15/16(228)

Knockout for rightward
piping

2-7/8(73.5)

9/32(7)

2-3/16(56)

Wireless remote controller

6-3/4(157)

3/4(19)

4-29/32(125)

Drain hose (19-11/16(0.5m))

Connecting pipe (15-5/16(0.39m))
Flare Ø1/2(12.70)

6-11/16(170)or more

12-19/32(320)

1-9/16(40)

1-9/16(47) 6-1/32(154) 4-9/32(109)

Hanger

Minimum

distance

to wall

8-15/32(215.5)

Hanger

2-9/16(65)

20.7"(525)

30-15/16(786)

9-1/4(235)

8-7/16(215)

Hanger

10-5/16(262.5) 10-5/16(262.5)

9-1/4(235)

8-7/16(215)

Minimum
distance

to wall

Center line

2-9/16(65)or more

Installation plate outline

Hanger

2-15/32(63)

Connecting pipe (19-9/32(0.49m))
(Flare Ø1/4(6.35))

1(23)3-11/32(85)

For stud bold (Ø2-1/4(6))

For stud bold (Ø5/16(8)~Ø13/32(10))

Hanger

Minimum

distance

to wall

6-11/16(170)or more

2-9/

16(

65)

Outline of indoor unit

1-9/16(40)

31/32(26)

Remote controller holder

–

17

–

4-2. Outdoor Unit

1 (25) Water Drain Outlet

1-31/32 (50)
1-27/64 (36)

12-3/64 (306)

12-19/32 (320)

Detail-A (Rear Leg)

23-5/8 (600)

R19/32

(R15)

R7/32

(R

5.5

)

1/4 Hole

(

6

) Hole

A

)
86

12-19/32 (320)

3-3/8 (

4-1/4 (

108

FILE NO. SVM-10020

Unit : Inch (mm)

)

4-15/16 (

125

)

12-3/64 (306)

12-19/32 (320)

1/4-Hole

(

6

)-Hole

)

1-27/64 (36)

116

1-31/32 (50)

4-9/16 (

23-5/8 (600)

B

Detail-B (Front Leg)

R19/32 (R15)

7/16x9/16 Oval-Hole

(

11x14) Oval Hole

11-7/16 (

290

17-5/32 (

)
550

436

)

WIRE GUARD

COVER
PACKED VALVE

View Z

21-11/16 (

10-7/8 (275)

)

3-17/32 (90)

23-5/8 (

600

)

3-17/32 (90)

2-23/32 (69)

)

)

53

141

2-3/32 (

5-9/16 (

13-1/2 (342)

Liquid side
(Flare Nut :

Gas side
(Model 15,17,22k Flare Nut :

1/4 (

6.35))
1/2 (

12.7))

3-15/16 Or more

(100 mm or more)

12-19/32 (320)

View Z

23-5/8 (

Air Inlet

Air Outlet

600

)

3-15/16 Inch or more
(100 mm. or more)

23-5/8 Inch or more
(600 mm. or more)

– 18 –

)
88

Service Port

3-15/32 (

2-R7/32x43/64L (R5.5x17L) U-Shape
(For

5/16~

23-5/8 Or more

(600 mm or more)

7/16x9/16 (

2­ (For

5/16~

13/32 (8~10) Anchor Bolt)

13/32 (8~10) Anchor Bolt)

11x14) Oval-Hole

5. WIRING DIAGRAM

FILE NO. SVM-10020

COMPRESSOR

1 1
2 2

CM

3 3

YEL

YEL

BRW

YEL

ORN

1 2 1

REACTOR

2

RED
WHI
BLK

P25

P23

P21

P35

P34

P19

P18
P11

P08

P04
P05
P06

P24

P22

P20

DB01

Q404

Q200~205
IGBT

R221

R220

R219

L03

P.C.BOARD
(MCC-5009)

C13

C12 C14

POWER
RELAY

CT

DB02

RELAY

P33 P31 P30

PUR

REACTOR

1 2
1 2

F03

FUSE

T3.15A

AC250V

CN701 P32

1 3
1

3

R321

R320

R319

COIL
FOR
4WAY
VALVE

Q300~305
MOS-FET

L01

SURGE

ABSORBER

L1

P07
BLK

VARISTOR

VARISTOR

F01
FUSE
25A
AC250V

P03

ORN

L2 S

P01
BLK

L1L2

~ ~

POWER
SUPPLY
208/230-1-60

CN300

CN700

P02
WHI

BLK

3 3

WHI

2 2
1 1

RED

FM

FAN MOTOR

6 6
5 5
4 4

PMV

3 3
2 2
1 1

PULSE MOTOR VALVE

3 3
2

CN603

1 1

(SUCTION PIPE

TEMP. SENSOR)

2 2

CN602

1 1

TEMP. SENSOR)

3 3
2

CN601

1 1

(DISCHARGE PIPE

TEMP. SENSOR)

2 2

CN600

1

1

(CONDENSER PIPE

TEMP. SENSOR)

2

2

CN500

1

1

PRESSURE SW.

COLOR IDENTIFICATION

BLK:BLACK
BLU:BLUE
RED:RED
GRY:GRAY
PNK:PINK

TS

TO

(OUTDOOR

TD

TE

WHI:WHITE
BRW:BROWN
ORN:ORANGE
YEL:YELLOW
PUR:PURPLE

Outdoor Terminal Block

Indoor Terminal Block

POWER SUPPLY
(From Outdoor Unit)
208/230-1-60

SHEET METAL

BLK

CN02

Fuse F01

T3.15A 250VAC

1 1
2 2

(TC)

(TA)

MCC-5044

Wireless Unit Assembly

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8

9 9
1010
1111

CN10

(WHI)

CN62

(BLU)

1 1
2 2

CN61

(WHI)

BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
WHI

Varistor

Heat Exchanger Sensor

Thermo Sensor

3 1

CN01

Line
Filter

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
1010

1111

CN21

(WHI)

L1 L2 S

L1L2 S

BLK

WHI

RED

CN51

Main PC Board

Heat
Exchanger

GRN&YEL

DC5V
DC12V

MCC-5045

1 1
3 3

4 4
5 5
6 6

CN31

(WHI)

1 1
2 2
3 3
4 4
5 5

CN32

(WHI)

WHI
YEL
YEL
YEL
YEL

1 1
2 2
3 3
4

4

5 5

CN22

(WHI)

1
2
3
4

DC Motor

Fan Motor

Louver Motor

Power Supply Circuit

– 19 –

6-1. Indoor Unit

FILE NO. SVM-10020

6. SPECIFICATIONS OF ELECTRICAL PARTS

No.

Fan motor

1

(for indoor)

2 Room temp. sensor (TA-sensor)
3 Heat exchanger temp. sensor (TC-sensor)
4 Louver motor Output (Rated) 1W, 16 poles, DC12V

Parts name

15LKV-UL, 17LKV-UL
22LKV-UL

ICF-340U30-2 DC340V, 30W

( − )
( − )

10kΩ at 25°C
10kΩ at 25°C

MP24Z3T

SpecificationsType

6-2. Outdoor Unit

No.

1

Reactor

2

Outdoor fan motor

3

Suction temp. sensor (TS sensor)

Parts name

(Inverter attached)

Model name

CH-57

ICF-340UA40-2

L = 10mH, 16A

DC340V, 40W

10kΩ (25°C)

Rating

4

Discharge temp. sensor (TD sensor)

5

Outside air temp. sensor (TO sensor)

6

Heat exchanger temp. sensor (TE sensor)

7

Terminal block (5P)

8

Compressor

9

Coil for PMV

10

Coil for 4-way valve

15LAV-UL, 17LAV-UL

22LAV-UL

11 Pressure SW.

(Inverter attached)

(Inverter attached)

(Inverter attached)

——

DA130A1F-27F1

DA150A1F-20F1

CAM-MD12TCTH-4

STF

62kΩ (20°C)

10kΩ (25°C)

10kΩ (25°C)

20A, AC250V

3-phases 4-poles 1100W

DC12V

ACB-4UB82W 4.7 MPa

– 20 –

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

RAS-15LKV-UL / RAS-15LAV-UL, RAS-17LKV-UL / RAS-17LAV-UL

FILE NO. SVM-10020

P

Pressure measurement
Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe

Outer dia.

Thickness

Accumulater tank

: 1/2 in. (12.7mm)

1/32 in (0.8mm)

:

4-way valve

Muffler

INDOOR UNIT

Cross flow fan

Deoxidized copper pipe
Outer dia.

Thickness

Sectional shape
of heat insulator

Muffler

Muffler

High pressure SW

TD

Compressor
DA130A1F-27F1

Indoor heat

exchanger

: 1/4 in. (6.35mm)

1/32 in (0.8mm)

:

T1 Temp. measurement

TC

TA

difference: 33ft (10m)

Allowable height

Strainer

Pulse Modulating valve
at liquid side

Max. : 66ft (20m)

Min. : 6.6ft (2m)
Chargeless : 50ft (15m)

Charge : 0.22oz/ft (20g/m)

(51 to 66ft)

Allowable pipe length

TS

Fusible Plug

Outdoor heat
exchanger

Propeller fan

TO

Split capillary
2-dia. 1.2 × 80

TE

Refrigerant amount: 3.09 lbs (1.40kg)

OUTDOOR UNIT

Distributor

NOTE:

Refrigerant flow (Cooling)
Refrigerant flow (Heating)

Gas leak check position

NOTE :

• The maximum pipe length of this air conditioner is 66 ft (20m). When the pipe length exceeds 50 ft (15m), the
additional charging of refrigerant, 0.22 oz/ft (20g per 1m) for the part of pipe exceeded 50 ft (15m) is required.

[Max. 0.22 lbs (100g)].

– 21 –

RAS-22LKV-UL / RAS-22LAV-UL

FILE NO. SVM-10020

P

Pressure measurement
Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe

Outer dia.

Thickness

Accumulater tank

: 1/2 in. (12.7mm)

1/32 in (0.8mm)

:

4-way valve

Muffler

INDOOR UNIT

Cross flow fan

Deoxidized copper pipe
Outer dia.

Thickness

Sectional shape
of heat insulator

Muffler

Muffler

High pressure SW

TD

Compressor

DA150A1F-20F1

Indoor heat

exchanger

: 1/4 in. (6.35mm)

1/32 in (0.8mm)

:

T1 Temp. measurement

TC

TA

difference: 33ft (10m)

Allowable height

Strainer

Pulse Modulating valve
at liquid side

Max. : 66ft (20m)

Min. : 6.6ft (2m)
Chargeless : 50ft (15m)
Charge : 0.22oz/ft (20g/m)

(51 to 66ft)

Allowable pipe length

TS

Fusible Plug

Outdoor heat
exchanger

Propeller fan

TO

Split capillary
2-dia. 1.2 × 80

TE

Refrigerant amount: 3.09 lbs (1.40kg)

OUTDOOR UNIT

Distributor

NOTE:

Refrigerant flow (Cooling)
Refrigerant flow (Heating)

Gas leak check position

NOTE :

• The maximum pipe length of this air conditioner is 66 ft (20m). When the pipe length exceeds 50 ft (15m), the
additional charging of refrigerant, 0.22 oz/ft (20g per 1m) for the part of pipe exceeded 50 ft (15m) is required.

[Max. 0.22 lbs (100g)].

– 22 –

p

FILE NO. SVM-10020

7-2. O

<Cooling>

condition [°F (°C)]
Indoor Outdoor P [psi (MPa)] T1 [°F (°C)] T2 [°F (°C)] (rps)

80/67 98/75 131 to 160 52 to 55 40 to 42

(26.7/19.4) (35/23.9) (0.9 to 1.1) (11 to 13) (37 to 39)

<Heating>

condition [°F (°C)]
Indoor Outdoor (rps)

70/60 47/43 363 to 392 102 to 105 32 to 37

(21.1/15.6) (8.3/6.1) (2.5 to 2.7) (39 to 41) (0 to 3)

eration Data

Tempeature Model name Standard Heat exchanger Indoor Outdoor Compressor

RAS- pressure pipe temp. fan mode fan mode revolution

High High 5715LKV-UL

17LKV-UL High High 62

22LKV-UL High High 88

Tempeature Model name Standard Heat exchanger Indoor Outdoor Compressor

RAS- pressure pipe temp. fan mode fan mode revolution

15LKV-UL

17LKV-UL

22LKV-UL High High 84

131 to 160 52 to 55 40 to 42
(0.9 to 1.1) (11 to 13) (42 to 44)
131 to 160 52 to 55 41 to 43

(0.9 to 1.1) (11 to 13) (42 to 44)

P [psi (MPa)]

377 to 406 106 to 106 32 to 36
(2.6 to 2.8) (41 to 43) (0 to 2)
116 to 145 52 to 55 104 to 107
(0.8 to 1.0) (11 to 13) (42 to 44)

T1 [°F (°C)] T2 [°F (°C)]

High High

High High 82

74

NOTES :

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

2. Connecting piping condition : 25 ft (7.5m)

– 23 –

8-1. Indoor Unit

FILE NO. SVM-10020

8. CONTROL BLOCK DIAGRAM

Heat Exchanger Sensor (Tc)

Room Temperature Sensor (Ta)

Infrared Rays Signal Receiver

and Indication

Initializing Circuit

Clock Frequency

Oscillator Circuit

Power Supply

Circuit

Converter

(D.C circuit)

Noise Filter

M.C.U.

Functions

• Cold draft preventing Function

• 3-minute Delay at Restart for Compressor

• Fan Motor Starting Control

• Processing

(Temperature Processing)

• Timer

• Serial Signal Communication

• Clean Function

Serial Signal Transmitter/Receiver

Indoor Unit Control Unit

Louver

Motor

Louver Motor
Drive Control

Indoor Fan

Motor Control

Indoor

Fan Motor

From Outdoor Unit

208/230-1-60

REMOTE CONTROLLER

Serial Signal Communication

(Operation Command and Information)

Remote Controller

Operation (START/STOP)

Operation Mode Selection

AUTO, COOL, DRY, HEAT, FAN

Thermo. Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver AUTO Swing

Louver Direction Setting

ECO

Hi-POWER

Infrared Rays, 36.7kHz

COMFORT SLEEP

QUIET

SLEEP (1,3,5,9 OFF TIMER)

– 24 –

8-2. Outdoor Unit (Inverter Assembly)

detect

Current

circuit

Gate drive

detect

Current

FILE NO. SVM-10020

Compressor

Outdoor

Fan motor

Inverter

(DC → AC)

P.M.V. : Pulse Motor Valve

M.C.U. : Micro Control Unit

MICRO-COMPUTER BLOCK DIAGRAM

M.C.U

MCC5009 (P.C.B) OUTDOOR UNIT

• PWM synthesis function

• Input current release control

circuit

Indoor unit

send/receive

circuit

Gate drive

• IGBT over-current detect control

• Outdoor fan control

• High power factor correction control

• Inverter output frequency control

• A/D converter function

• P.M.V. control

• Discharge temp. control

• 4-way valve control

• Signal communication to indoor unit

4MHz

Clock

frequency

circuit

High Power

factor Correction

Converter

(AC → DC)

sensor

Input current

Filter

Noise

Inverter

(DC → AC)

Relay

circuit

of P.M.V.

Driver circuit

valve

4-way

P.M.V.

208/230-1-60

For INDOOR UNIT

Discharge

temp. sensor

Outdoor air

temp. sensor

Suction temp.

– 25 –

sensor

temp.sensor

Heat exchanger

9. OPERATION DESCRIPTION

FILE NO. SVM-10020

9-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air
conditioner, which uses DC motor for the indoor fan
motor and the outdoor fan motor. And the capacity­proportional control compressor which can change the
motor speed in the range from 11 to 120 rps is
mounted. The DC motor drive circuit is mounted to the
indoor unit. The compressor and the inverter to control
fan motor are mounted to the outdoor unit.

The entire air conditioner is mainly controlled by the
indoor unit controller.

The indoor unit controller drives the indoor fan motor
based upon command sent from the remote controller,
and transfers the operation command to the outdoor
unit controller.
The outdoor unit controller receives operation com­mand from the indoor unit side, and controls the
outdoor fan and the pulse motor valve. (PMV)
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)

• Judgment of the indoor heat exchanger tempera­ture by using heat exchanger sensor (TC sensor)
(Prevent-freezing control, etc.)

• Louver motor control

• Indoor fan motor operation control

• LED (Light Emitting Diode) display control

• Transferring of operation command signal
(Serial signal) to the outdoor unit

• Reception of information of operation status
(Serial signal including outside temp. data) to the
outdoor unit and judgment/display of error

• Air purifier operation control

2. Role of outdoor unit controller

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

• Compressor operation control

• Operation control of outdoor fan motor

• PMV control

• 4-way valve control



Operations followed to judgment



of serial signal from indoor side.



• Detection of inverter input current and current
release operation

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

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

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

• Detection of outdoor temperature and operation
revolution control

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

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

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

• Operation mode set on the remote controller

• Compressor revolution command signal defined

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

• Temperature of indoor heat exchanger

• For these signals ([Operation mode] and [Com-

pressor revolution] indoor heat exchanger tem­perature), the outdoor unit controller monitors the
input current to the inverter, and performs the
followed operation within the range that current
does not exceed the allowable value.

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

The following signals are sent from the outdoor unit
controller.

• The current operation mode

• The current compressor revolution

• Outdoor temperature

• Existence of protective circuit operation

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

Contents of judgment are described below.

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

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

unit controller, it is assumed as a trouble.

– 26 –

9-2. Operation Description

FILE NO. SVM-10020

1. Basic operation

1. Operation control ................................................................................................... 28

2. Cooling/Heating operation ..................................................................................... 29

3. AUTO operation .....................................................................................................

4. DRY operation........................................................................................................ 29

2. Indoor fan motor control ............................................................................................. 30

3. Outdoor fan motor control........................................................................................... 32

4. Capacity control .......................................................................................................... 33

5. Current release control ............................................................................................... 33

6. Release protective control by temperature of indoor heat exchanger........................ 34

7. Defrost control (Only in heating operation) ................................................................ 35

8. Louver control ............................................................................................................. 36

1) Louver position....................................................................................................... 36

2) Air direction adjustment ......................................................................................... 36

3) Swing ..................................................................................................................... 36

9. ECO operation ............................................................................................................ 37

10. Temporary operation................................................................................................... 38

11. Discharge temperature control ................................................................................... 38

........................................................................................................... 28

29

12. Pulse Modulating valve (P.M.V.) control ..................................................................... 39

13. Self-Cleaning function ................................................................................................ 40

14. Remote-A or B selection ............................................................................................ 41

15. QUIET mode ............................................................................................................. 42

16. COMFORT SLEEP mode ......................................................................................... 42

17. One-Touch Comfort .................................................................................................. 42

18. Hi-POWER Mode ...................................................................................................... 43

19.

FILTER Indicator ........................................................................................................ 43

9-3. Auto Restart Function ..

9-3-1. How to Cancel the A uto Restart Function ........................ ........................................ 44

9-3-2. How to set the Au to Restar t Function ...................................................................... 45

9-3-3. Power Failure During Timer Operation ................................................................... 45

9-4. Remote Controller and Its Fuctions

9-4-1. Parts Name of Remote Contr oller ............................................................................. 46

9-4-2. Operation of remote control ...................................................................................... 46

9-4-3. Name and Functions of Indications on Remote Contr oller ....................................... 49

– 27 −

FILE NO. SVM-10020

Item

1. Basic
operation

Operation flow and applicable data, etc.

1. Operation control

Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are
controlled.

1) The operation conditions are selected by the remote controller as shown in the below.

2) A signal is sent by ON button of the remote controller.

3) The signal is received by a sensor of the indoor unit and processed by the indoor controllers as
shown in the below.

4) The indoor controller controls the indoor fan motor and louver motor.

5) The indoor controller sends the operation command to the outdoor controller, and sends/receives
the control status with a serial signal.

6) The outdoor controller controls the operation as shown in the left, and also controls the compres­sor, outdoor fan motor, 4-way valve and pulse Modulating valve.

Selection of

operation conditions

ON/OFF

Remote controller

Control contents of remote controller

• ON/OFF (Air conditioner/Air purifier)

• Operation select (COOL/HEAT/AUTO/DRY)

• Temperature setup

• Air direction

• Swing

• Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH)

• ECO

• ON timer setup

• OFF timer setup

• Hi-POWER

• COMFORT SLEEP

• QUIET

• PRESET

• ONE-TOUCH

Description

Signal receiving

Indoor unit control

Operation command

Serial signal send/receive

Serial signal send/receive

Outdoor unit control

Indoor unit

Indoor unit control

• Command signal generating function of
indoor unit operation

• Calculation function (temperature calculation)

• Activation compensation function of indoor fan

• Cold draft preventive function

• Timer function

• Indoor heat exchanger release control

Outdoor unit

Outdoor unit control

• Frequency control of inverter output

• Waveform composite function

• Calculation function

(Temperature calculation)

• AD conversion function

• Quick heating function

• Delay function of compressor reactivation

• Current release function

• GTr over-current preventive function

• Defrost operation function

• Indoor fan motor

• Louver motor

~

Inverter

• Compressor

• Outdoor fan motor

• 4-way valve

• Pulse Modulating valve

(P.M.V.)

– 28 –

FILE NO. SVM-10020

Item

1. Basic
operation

Operation flow and applicable data, etc.

2. Cooling/Heating operation

The operations are performed in the following parts by controls according to cooling/heating conditions.

1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal
starts being transferred form the indoor controller to the outdoor unit.

2) At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan
motor control” and the louver according to the contents of “9. Louver control”, respectively.

3) The outdoor unit controls the outdoor fan motor, compressor, pulse Modulating valve and
4-way valve according to the operation signal sent from the indoor unit.

Operation ON

Indoor unit control

Sending of operation command signal

Outdoor unit control

Setup of remote controller

Indoor fan motor control / Louver control / Operation Hz
Control (Requierment)

Compressor revolution control / Outdoor fan motor control /
Operation Hz control (Include limit control)
4-way valve control In cooling operation: ON

In heating operation: OFF
Pulse Modulating valve control

[ ]

Description

3. AUTO operation

Selection of operation mode
As shown in the following figure, the operation starts by
selecting automatically the status of room temperature
(Ta) when starting AUTO operation.

*1. When reselecting the operation mode, the fan

speed is controlled by the previous operation mode.

Ta

°C

Cooling operation

Ts + 1

Monitoring (Fan)

Ts – 1

Heating operation

4. DRY operation

DRY operation is performed according to the difference
between room temperature and the setup temperature as
shown below.

In DRY operation, fan speed is controlled in order to
prevent lowering of the room temperature and to avoid air
flow from blowing directly to persons.

°F [˚C]

Ta

+2.0 (1.0)

L– (W5)

(W5+W3) / 2

1) Detects the room temperature (Ta) when
the operation started.

2) Selects an operation mode from Ta in
the left figure.

3) Fan operation continues until an
operation mode is selected.

4) When AUTO operation has started
within 2 hours after heating operation
stopped and if the room temperature is
68°F (20°C)
performed with ”Super Ultra LOW” mode
for 3 minutes.
Then, select an operation mode.

5) In AUTO mode, either cooling or heating

operation will be selected. When room
temperature reach set temperature
commpressor will stop. In case that the
compressor stops for 15 minutes, the

AUTO mode will reselect cooling or
heating operation.

1) Detects the room temperature (Ta) when
the DRY operation started.

2) Star ts operation under conditions in the
left figure according to the temperature
difference between the room tempera­ture and the setup temperature (Tsc).
Setup temperature (Tsc)
= Set temperature on remote controller
(Ts) + 0~1.0°C (0 to 2°F)

3) When the room temperature is lower

2°F (1°C) or less than the setup
temperature, turn off the compressor.

or more, the fan operation is

+1.0 (0.5)

Tsc

SUL (W3)

Fan speed

− 29 −

FILE NO. SVM-10020

Item

2. Indoor fan
motor control

COOL ON

Fan speed setup

AUTO

Ta

°F [°C]

+4.5 (+2.5)

+3.5 (+2.0)

+2.7 (+1.5)

+2.0(+1.0)

a
b
c

Operation flow and applicable data, etc.

<In cooling operation>

(This operation controls the fan speed at indoor unit side.)
The indoor fan (cross flow fan) is operated by the phase-

control induction motor. The fan rotates in 5 stages in
MANUAL mode, and in 5 stages in AUTO mode, respec­tively. (Table 1)

MANUAL

(Fig. 1)

Indication

L
L+
M
M+
H

Fan speed

W6

(L + M) / 2

W9

(M + H) / 2

WC

(Fig. 2)

Air volume AUTO

M+(WB)

*3
*4
*5

*3 : Fan speed = [(M+) –L] x 3/4 + L
*4 : Fan speed = [(M+) –L] x 2/4 + L
*5 : Fan speed = [(M+) –L] x 1/4 + L

Description

* Symbols

UH : Ultra High
H : High
M+ : Medium+
M : Medium
L+ : Low+
L: Low
L- : Low–
UL : Ultra Low
SUL : Super Ultra Low

* The values of fan speed and air flow

volume indicate on the table are measured

when the louver is inclined downward.
Fan speed and air flow volume broadly
vary with position of louver.

1) When setting the fan speed to L,
L+, M, M+ or H on the remote
controller, the operation is
performed with the constant
speed shown in Fig. 1.

2) When setting the fan speed to
AUTO on the remote controller,
revolution of the fan motor is
controlled to the fan speed level
shown in Fig. 2 and Table 1
according to the setup temperature
and room temperature.

Tsc

d
e

L(W6)

(Linear approximation
from M+ and L)

+1.0 (+0.5)

(Table 1) Indoor fan air flow rate

Fan speed

level

WF UH 1100 583 (991) 1200 648 (1101)

WE H 1100 583 (991) 1200 648 (1101)

WD UH M+ UH 1090 577 (980) 1200 648 (1101)

WC H H 1070 563 (957) 1180 635 (1079)

WB M+ M+ 980 505 (858) 1080 570 (968)

WA M 940 479 (813) 1020 531 (902)

W9 M L+ 890 446 (758) 980 505 (858)

W8 L 780 374 (636) 850 420 (713)

W7 L+ L- L+ 750 355 (603) 810 394 (669)

W6 L L 740 348 (591) 800 387 (658)

W5 L- UL L- 700 322 (547) 760 361 (614)

W4 UL UL 700 322 (547) 700 322 (547)

W3 SUL SUL 650 290 (492) 650 290 (492)

W2 SUL 500 191 (325) 500 191 (325)

W1 500 191 (325) 500 191 (325)

DRYHEATCOOL

RAS-15LKV-UL

Fan speed Air flow rate Fan speed Air flow rate

(rpm) cfm (m3/h) (rpm) cfm (m3/h)

RAS-17LKV-UL, RAS-22LKV-UL

– 30 –