Toshiba RAS-3M23GACV-E SERVICE MANUAL
SERVICE MANUAL
<Cooling OnlyType>
Indoor Unit
RAS-M10GKCVP-E
FILE NO. A05-014
SPLIT TYPE
RAS-M13GKCVP-E
RAS-M16GKCVP-E
Outdoor Unit
RAS-3M23GACV-E
R410A
PRINTED IN JAPAN, Jan.,2006 ToMo
CONTENTS
1. SAFETY PRECAUTIONS .......................................................................... 3
2. SPECIFICATIONS ..................................................................................... 5
3. REFRIGERANT R410A ............................................................................. 9
4. CONSTRUCTION VIEWS ........................................................................ 17
5. WIRING DIAGRAM .................................................................................. 19
6. SPECIFICATIONS OF ELECTRICAL PARTS ......................................... 21
7. REFRIGERANT CYCLE DIAGRAM ........................................................ 22
8. CONTROL BLOCK DIAGRAM................................................................ 24
9. OPERATION DESCRIPTION................................................................... 26
10. INSTALLATION PROCEDURE................................................................ 47
11. HO W TO DIAGNOSE THE TROUBLE...................................................... 64
12. HOW TO REPLACE THE MAIN PARTS................................................... 84
13. EXPLODED VIEWS AND PARTS LIST ................................................. 101
– 2 –
1. SAFETY PRECAUTIONS
For general public use
Power supply cord of outdoor unit shall be more than 1.5 mm ² (H07RN-F or 245IEC66) polychloroprene
sheathed flexible cord.
• Read this “SAFETY PRECAUTIONS” carefully before servicing.
• The precautions described below include the important items regarding safety. Observe them without fail.
• After the servicing work, perform a trial operation to check for any problem.
• Turn off the main power supply switch (or breaker) before the unit maintenance.
CAUTION
New Refrigerant Air Conditioner Installation
• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT
DESTROY OZONE LAYER.
R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because
the working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the
adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during
installation work, be sure that water , dust, former refrigerant, or refrigeration machine oil does not enter into
the new type refrigerant R410A air conditioner circuit.
To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging
port on main unit and installation tools are different from those used for the conventional refrigerant units.
Accordingly, special tools are required for the new refrigerant (R410A) units . For connecting pipes, use new
and clean piping materials with high pressure fittings made for R410A only, so that water and/or dust does
not enter. Moreover, do not use the existing piping because there are some problems with pressure fittings
and possible impurities in existing piping.
CAUTION
TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY
This appliance must be connected to the main power supply by a circuit breaker or a switch with a contact
separation of at least 3 mm.
The installation fuse (25A D type ) must be used for the power supply line of this air conditioner.
DANGER
• ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO INSTALL/MAINTAIN THE AIR CONDITIONER.
INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE.
• 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.
DANGER: HIGH VOLTAGE
The high voltage circuit is incorporated.
Be careful to do the check service, as the electric shock may be caused in case of touching parts
on the P.C. board by hand.
• CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED, ELECTRIC PARTS MAY BE DAMAGED.
• CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND
INSTALLATION. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.
– 3 –
• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE
TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.
• TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE
THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT
RESISTORS , FURNACE, STOVES , ETC.
• WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY
OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS
MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL
BECOME ABNORMALLY HIGH AND IT MAY RESUL T IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES.
• IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE
WORK AND THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE
REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY
RESULT.
WARNING
• Never modify this unit by removing any of the safety guards or bypass any of the safety interlock
switches.
• Do not install in a place which cannot bear the weight of the unit. Personal injury and property
damage can result if the unit falls.
• After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source such as a cooking range, noxious gas
may generate.
• The electrical work must be performed by a qualified electrician in accordance with the Installation
Manual. Make sure the air conditioner uses an exclusive circuit.
An insufficient circuit capacity or inappropriate installation may cause fire.
• When wiring, use the specified cables and connect the terminals securely to prevent external
forces applied to the cable from affecting the terminals.
• Be sure to provide grounding.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.
• Conform to the regulations of the local electric company when wiring the power supply.
Inappropriate grounding may cause electric shock.
CAUTION
• Exposure of unit to water or other moisture bef ore installation may result in an electrical short.
Do not store in a wet basement or expose to rain or water.
• 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 or discharged air might disturb neighbors.
• To avoid personal injury, be careful when handling parts with sharp edges.
• Perform the specified installation work to guard against an earthquake.
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.
For Reference:
If a heating operation would be continuously perf ormed for a long time under the condition that the outdoor
temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate,
resulting in a trouble of the cabinet or fan.
It is recommended to procure an antifreeze heater locally for a safe installation of the air conditioner.
For details, contact the dealer.
– 4 –
2. SPECIFICATIONS
The indoor and outdoor units that can be used in combination are shown in the tables below.
Table of models that can be connected
Type
Cooling-only
Outdoor unit
RAS-3M23GACV–E
RAS-M10GKCVP–E RAS-M13GKCVP–E RAS-M16GKCVP–E
RAS-M10GKCV–E RAS-M13GKCV–E RAS-M16GKCV–E
RAS-M10GDCV–E RAS-M13GDCV–E RAS-M16GDCV–E
Indoor unit
Table of models that can be used in combination
Type
Cooling-only
Outdoor unit
RAS-3M23GACV-E
Combinations of indoor unit models that can be connected
10 + 10, 10 + 13, 13 + 13, 16 + 13, 16 + 16
10 + 10 + 10, 10 + 10 + 13, 10 + 13 + 13, 10 + 10 + 16
NOTES
A 1-room connection is not an option for the indoor units (you cannot connect only one indoor unit).
Be sure to connect indoor units in two rooms or more.
The contents noted in this service manual limit the indoor units to the RAS-B10GKVP-E, RAS-B13GKVP-E,
RAS-B16GKVP-E, RAS-M10GKCVP-E, RAS-M13GKCVP-E and RAS-M16GKCVP-E.
For other indoor units that can also be used in combination, see the service manual of each indoor unit.
Indoor unit
RAS-M10GDV-E RAS-M10GDCV-E
RAS-M13GDV-E RAS-M13GDCV-E
RAS-M16GDV-E RAS-M16GDCV-E
RAS-M10GKV-E RAS-M10GKCV-E
RAS-M13GKV-E RAS-M13GKCV-E
RAS-M16GKV-E RAS-M16GKCV-E
File No.
A05-010
TBA
– 5 –
(kW)
(kW)
(A)
(W)
(%)
(A)
(W)
(%)
(A)
(
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(
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(
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g
(
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(mm)
(mm)
(mm)
(kg)
(W)
(
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(mm)
(mm)
(mm)
(kg)
(W)
(W)
(
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(m)
(m)
(m)
(m)
(kg)
(°C)
(°C)
2-1. Specifications
RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E / RAS-3M23GACV-E
Unit model
Cooling capacity
Cooling capacity range
Power supply 220–240 V, 1 Ph, 50Hz / 220 V, 1 Ph, 60Hz
Electric
characteristics
COP 3.12
Operating
noise
Indoor unit
Outdoor unit
Piping
connection
Wiring connection
Usable temperature
range
Accessory
Indoor unit
Outdoor unit
Unit model
Indoor unit
Outdoor unit
Indoor unit
Outdoor unit
Unit model
Dimension
Net weight
Fan motor output
Air flow rate
Unit model
Dimension
Net weight
Fan motor output
Air flow rate
Type Flare connection
Indoor unit
Outdoor unit
Maximum length (per unit)
Maximum length (total)
Maximum chargeless length (total)
Maximum height difference
Name of refrigerant R410A
Weight
Indoor
unit
Outdoor
unit
Running current
Power cons um ption
Power factor
Unit model
Running current
Power cons um ption
Power factor
Starting current
Unit model
High
Medium
Low
Unit model
Full indoor units operatin
Height
Width
Depth
Height
Width
Depth
Motor output
Type Twin rotary type with DC-i nvert er variable speed controlCompressor
Model DA130A1F-25F
Unit model
Liquid side/Gas side Ø6.35 / Ø9.52 Ø6.35 / Ø9.52 Ø6.35 / Ø12.7
Unit model
A unit Liquid side/Gas side Ø6.35/ Ø12.7
B unit Liquid side/Gas side Ø6.35/ Ø9.52
C unit Liquid side/Gas side Ø6.35/ Ø9.52
Power supply 3 Wires : includes earth
Interconnection 4 Wires : includes earth
Indoor
Outdoor
Unit model
Installation plate 1 1 1
Wireless remote controller 1 1 1
Batteries 2 2 2
Remote controller holder 1 1 1
Zeolite-plus filter 1 1 1
Plasma pure filter 1 1 1
Remote controller holder mounting screw 2 (Ø3.1 × 16L) 2 (Ø3.1 × 16L) 2 (Ø3.1 × 16L)
Owner’s manual 1 1 1
Mounting screw 6 (Ø4 × 25L) 6 (Ø4 × 25L) 6 (Ø4 × 25L)
Installation manual 1 1 1
Unit model
Installation manual 1
Specifications 1
dB•A
dB•A
dB•A
dB•A
m³/h
m³/h
RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E
RAS-3M23GACV-E
6.7
2.2 – 7.0
RAS-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-E
0.15 0.15 0.15
30 30 30
91 / 87 / 83 91 / 87 / 83 91 / 87 / 83
RAS-3M23GACV-E
10.29 / 9.84 / 9.43
2150
95
10.29 / 9.84 / 9 .43
RAS-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-E
42 43 45
33 34 36
27 27 29
RAS-3M23GACV-E
48
RAS-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-E
250 250 250
790 790 790
215 215 215
999
30 30 30
550 560 640
RAS-3M23GACV-E
695
780
270
48
1100
43
High: 3000, Medium: 2800
RAS-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-E
RAS-3M23GACV-E
20
40
40
10
1.50
21 – 32
10 – 43
RAS-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-E
RAS-3M23GACV-E
• For performance when each indoor unit is combined with other unit, refer to the separate table.
• The specifications may be subject to change without notice for purpose of improvement.
– 6 –
2-2. Specifications of Performance When Each Indoor Unit is Combined with Other Unit
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Operatin
status
1 unit
2 inits
3 units
Power
su
(V)
220 10 ——2.7 ——
230 10 ——2.7 ——
240 10 ——2.7 ——
220 13 ——3.7 ——
230 13 ——3.7 ——
240 13 ——3.7 ——
220 16 ——4.5 ——
230 16 ——4.5 ——
240 16 ——4.5 ——
220 10 10 — 2.7 2.7 —
230 10 10 — 2.7 2.7 —
240 10 10 — 2.7 2.7 —
220 10 13 — 2.45 3.35 —
230 10 13 — 2.45 3.35 —
240 10 13 — 2.45 3.35 —
220 10 16 — 2.21 3.69 —
230 10 16 — 2.21 3.69 —
240 10 16 — 2.21 3.69 —
220 13 13 — 2.95 2.95 —
230 13 13 — 2.95 2.95 —
240 13 13 — 2.95 2.95 —
220 13 16 — 2.71 3.29 —
230 13 16 — 2.71 3.29 —
240 13 16 — 2.71 3.29 —
220 16 16 — 3.05 3.05 —
230 16 16 — 3.05 3.05 —
240 16 16 — 3.05 3.05 —
220 10 10 10 2.13 2.13 2.13
230 10 10 10 2.13 2.13 2.13
240 10 10 10 2.13 2.13 2.13
220 10 10 13 1.99 1.99 2.72
230 10 10 13 1.99 1.99 2.72
240 10 10 13 1.99 1.99 2.72
220 10 13 13 1.80 2.45 2.45
230 10 13 13 1.80 2.45 2.45
240 10 13 13 1.80 2.45 2.45
220 10 10 16 1.83 1.83 3.04
230 10 10 16 1.83 1.83 3.04
240 10 10 16 1.83 1.83 3.04
Indoor unit Unit capacity (kW
ABCABC
Cooling
capacity
(kW)
2.7
(1.4 to 3.2)
2.7
(1.4 to 3.2)
2.7
(1.4 to 3.2)
3.7
(1.4 to 4.4)
3.7
(1.4 to 4.4)
3.7
(1.4 to 4.4)
4.5
(1.4 to 4.9)
4.5
(1.4 to 4.9)
4.5
(1.4 to 4.9)
5.4
(1.8 to 6.0)
5.4
(1.8 to 6.0)
5.4
(1.8 to 6.0)
5.8
(1.8 to 6.3)
5.8
(1.8 to 6.3)
5.8
(1.8 to 6.3)
5.9
(1.8 to 6.4)
5.9
(1.8 to 6.4)
5.9
(1.8 to 6.4)
5.9
(1.8 to 6.4)
5.9
(1.8 to 6.4)
5.9
(1.8 to 6.4)
6.0
(1.8 to 6.4)
6.0
(1.8 to 6.4)
6.0
(1.8 to 6.4)
6.1
(1.8 to 6.5)
6.1
(1.8 to 6.5)
6.1
(1.8 to 6.5)
6.4
(2.2 to 7.0)
6.4
(2.2 to 7.0)
6.4
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
6.7
(2.2 to 7.0)
Power
consum
(W)
770
(320 to 950)
770
(320 to 950)
770
(320 to 950)
1200
320 to 1470
1200
320 to 1470
1200
320 to 1470
1600
320 to 1750
1600
320 to 1750
1600
320 to 1750
1500
360 to 1880
1500
360 to 1880
1500
360 to 1880
1800
360 to 1970
1800
360 to 1970
1800
360 to 1970
1830
360 to 2000
1830
360 to 2000
1830
360 to 2000
1830
360 to 2000
1830
360 to 2000
1830
360 to 2000
1850
360 to 2000
1850
360 to 2000
1850
360 to 2000
1870
360 to 2050
1870
360 to 2050
1870
360 to 2050
1880
420 to 2300
1880
420 to 2300
1880
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
2150
420 to 2300
tion
Operation
current
(A)
4.12
2.08 to 5.08
3.94
1.99 to 4.86
3.77
1.90 to 4.66
6.34
2.08 to 7.51
6.07
1.99 to 7.18
5.81
1.90 to 6.88
7.66
2.08 to 8.37
7.32
1.99 to 8.01
7.02
1.90 to 7.68
7.18
2.34 to 9.00
6.86
2.24 to 8.60
6.58
2.14 to 8.25
8.61
2.34 to 9.43
8.24
2.24 to 9.02
7.89
2.14 to 8.64
8.76
2.34 to 9.57
8.38
2.24 to 9.15
8.03
2.14 to 8.77
8.76
2.34 to 9.57
8.38
2.24 to 9.15
8.03
2.14 to 8.77
8.85
2.34 to 9.57
8.50
2.24 to 9.15
8.11
2.14 to 8.77
8.95
2.34 to 9.81
8.56
2.24 to 9.38
8.20
2.14 to 8.99
9.00
2.73 to 11.0
8.60
2.61 to 10.53
8.25
2.50 to 10.09
10.29
2.73 to 11.0
9.84
2.61 to 10.53
9.43
2.50 to 10.09
10.29
2.73 to 11.0
9.84
2.61 to 10.53
9.43
2.50 to 10.09
10.29
2.73 to 11.0
9.84
2.61 to 10.53
9.43
2.50 to 10.09
Outdoor
noise
(dB)
45
45
45
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
48
• The above specification values are those under the conditions that the indoor DB/WB = 27/19°C and the outdoor
DB = 35°C.
– 7 –
2-2-1. Operation Characteristic Curve
12
• Conditions
11
Indoor : DB 27˚C/WB 19˚C
Outdoor : DB 35˚C
10
Air flow : High
Pipe length : 5m × 3
9
3 units operating
8
7
6
5
Current (A)
4
3
2
1
0
0 102030405060708090100
220V
240V
Inverter output frequency (rps)
230V
2-2-2. Capacity Variation Ratio According to Temperature
115
• Conditions
Indoor : DB 27˚C
Outdoor : DB 35˚C
110
Indoor air flow : High
Pipe length : 5m × 3
3 units operating
105
100
95
Capacity ratio (%)
90
85
0
14 16 18 20 22 24
Indoor air wet bulb temp. (˚C) Outdoor temp. (˚C)
105
100
95
90
85
80
75
70
Capacity ratio (%)
65
60
55
50
Current Limited Start
• Conditions
Indoor : DB 27˚C/WB 19˚C
Indoor air flow: High
Pipe length : 5m × 3
3 units operating
32 34 36 38 40 42 43 44 46
– 8 –
∗ Capacity ratio : 100% = 6.7 kW
3. REFRIGERANT R410A
This air conditioner adopts the new refrigerant HFC
(R410A) which does not damage the ozone layer.
The working pressure of the new refrigerant R410A
is 1.6 times higher than conventional refrigerant
(R22). The refrigerating oil is also changed in
accordance with change of refrigerant, so be careful
that water , dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the
air conditioner using the new refrigerant during
installation work or servicing time.
The next section describes the precautions for air
conditioner using the new refrigerant. Conforming to
contents of the next section together with the
general cautions included in this manual, perform
the correct and safe work.
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 prev ent
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 concentr ation
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 ma y 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 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 0.8 mm even when it is
available on the market.
– 9 –
Table 3-2-1 Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter
1/4
3/8
1/2
5/8
Outer diameter (mm)
6.35
9.52
12.70
15.88
R410A R22
0.80 0.80
0.80 0.80
0.80 0.80
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 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 20 mm.
Thicknesses of sock et joints are as shown in Table 3-2-2.
Table 3-2-2 Minimum thicknesses of socket joints
Nominal diameter
1/4
3/8
1/2
5/8
Reference outer diameter of
copper pipe jointed (mm)
6.35
9.52
12.70
15.88
Minimum joint thickness
(mm)
0.50
0.60
0.70
0.80
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, 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
– 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
Outer
diameter
(mm)
Thickness
(mm)
Fig. 3-2-1 Flare pr ocessing dimensions
Flare tool for R410A
clutch type
ØD
A
A (mm)
Conventional flare tool
Clutch type Wing nut type
1/4
3/8
1/2
5/8
Nominal
diameter
1/4
3/8
1/2
5/8
6.35
9.52
12.70
15.88
0.8
0.8
0.8
1.0
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
Table 3-2-4 Dimensions related to flare processing for R22
Outer
diameter
(mm)
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
Flare tool for R22
clutch type
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
1.0 to 1.5 1.5 to 2.0
1.0 to 1.5 1.5 to 2.0
1.0 to 1.5 2.0 to 2.5
1.0 to 1.5 2.0 to 2.5
A (mm)
Conventional flare tool
Clutch type Wing nut type
0.5 to 1.0 1.0 to 1.5
0.5 to 1.0 1.0 to 1.5
0.5 to 1.0 1.5 to 2.0
0.5 to 1.0 1.5 to 2.0
Nominal
diameter
1/4
3/8
1/2
5/8
Table 3-2-5 Flare and flare nut dimensions for R410A
Outer diameter
(mm)
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
Dimension (mm)
ABCD
9.1 9.2 6.5 13
13.2 13.5 9.7 20
16.6 16.0 12.9 23
19.7 19.0 16.0 25
– 11 –
Flare nut width
(mm)
17
22
26
29
Table 3-2-6 Flare and flare nut dimensions for R22
Nominal
diameter
1/4
3/8
1/2
5/8
3/4
Outer diameter
(mm)
6.35
9.52
12.70
15.88
19.05
45˚ to 46
˚
B A
Thickness
(mm)
0.8
0.8
0.8
1.0
1.0
Dimension (mm)
ABCD
9.0 9.2 6.5 13
13.0 13.5 9.7 20
16.2 16.0 12.9 20
19.7 19.0 16.0 23
23.3 24.0 19.2 34
D
C
43˚ to 45
˚
Flare nut width
(mm)
17
22
24
27
36
Fig. 3-2-2 Relations between flare nut and flare seal surface
2. Flare Connecting Procedures and Precautions
a) Make sure that the flare and union portions do not have any scar or dust, etc.
b) Correctly align the processed flare surface with the union axis .
c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is
the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.
When it is strong, the flare nut may crack and may be made non-removable. When choosing the 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
Outer diameter
(mm)
Tightening torque
N•m (kgf•cm)
Tightening torque of torque
wrenches available on the market
N•m (kgf•cm)
1/4
3/8
1/2
5/8
6.35
9.52
12.70
15.88
14 to 18 (140 to 180)
33 to 42 (330 to 420)
50 to 62 (500 to 620)
63 to 77 (630 to 770)
– 12 –
16 (160), 18 (180)
42 (420)
55 (550)
65 (650)
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 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 for R410A and their interchangeability.
Tools exclusive for R410A (The following tools for R410A are required.)
Tools whose specifications are changed for R410A and their interchangeability
air-water heat pump installation
No.
1
2
3
4
5
6
7
8
9
10
(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection
(Note 2) Charging cylinder for R410A is being currently developed.
Used tool
Flare tool
Copper pipe gauge for
adjusting projection
margin
Torque wrench
(For Ø12.7)
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 f or R22 are necessary
as the general tools.
1. Vacuum pump
Use vacuum pump by attaching
vacuum pump adapter.
2. Torque wrench (For Ø6.35, Ø9.52)
3. Pipe cutter
4. Reamer
5. Pipe bender
6. Level vial
7. Screwdriver (+, –)
8. Spanner or Monkey wrench
9. Hole core drill (Ø65)
10. Hexagon wrench
(Opposite side 4mm)
11 . Tape measure
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 –
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
–0.1 Mpa (–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.
(Water heat
exchanger 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 –
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 allo y mainly composed
of silver and copper. It is used to join iron, copper
or copper alloy, and is relatively expensive though
it excels in solderability.
2. Phosphor bronze brazing filler
Phosphor bronze brazing filler is generally used
to join copper or copper alloy.
Electronic
balance
Siphon
Fig. 3-4-2
1. Phosphor bronze brazing filler tends to react
with sulfur and produce a fragile compound
water solution, which may cause a gas
leakage. Therefore, use any other type of
brazing filler at a hot spring resort, etc., and
coat the surface with a paint.
2. When performing brazing again at time of
servicing, use the same type of brazing filler.
3-5-2. Flux
3. Low temperature brazing filler
Low temperature brazing filler is generally called
solder, and is an alloy of tin and lead. Since it is
weak in adhesive strength, do not use it for
refrigerant pipes.
1. Reason why flux is necessary
• By removing the o xide 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 eff ective temperature range, flux
is hard to carbonize.
• It is easy to remov e 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 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
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 0.05 m3/Hr or 0.02 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 br azing.
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
RAS-M10GKCVP-E
RAS-M13GKCVP-E
RAS-M16GKCVP-E
4. CONSTRUCTION VIEWS
790
Plasma pure filter
Front panel
Indoor heat exchanger
790
Air filter
215
250
60
7
53
Knockout system Knockout system
Zeolite-plus filter
53
Air ionizer
53
6054.5
60 54.5
53
Installation plate hanging section
Wireless remote controller
60
7
Remote controller holder
64
5
125.5
250
Minimum
distance
to wall
167.5
42
140 or more
3
Installation plate
hanging section
91
Lower part
hanging section
Hanging
section
Center line
of main unit
290
Connecting pipe
(Outside length:0.4m)
Flare Ø9.52
(RAS-M16GKCVP-E : Ø12.7)
674
450
288
47 or more
Minimum
distance
to ceilinfg
1010
1010
Outline of
installation plate
Center line of
installation plate
9130430491
790
Drain hose
(Outside length:0.54m)
Connecting pipe
(Outside length:0.45m)
Flare Ø6.35
25
Stud bolt hole
for Ø6
Stud bolt hole
for Ø8 to Ø10
Minimum
distance
to wall
74 or more
42
58
19
163
Parts name of remote controller :
WH-H03JE
– 17 –
4-2. Outdoor Unit
RAS-3M23GACV-E
310
A leg part
296
270
600
90
Ø11 × 17 U-shape hole
50
(For Ø8 to Ø10 anchor bolt)
Hanger
(ø6 hole pitch)
(Anchor bolt long hole pitch)
B leg part
Fan
guard
687
695
8
18
115.5
780
8-Ø6 hole
(For fixing outdoor unit)
Ø11 × 17 long hole
(For Ø8 to Ø10 anchor bolt)
Charging
port
68.5
123.8
332
Valve
cover
53 53
53 53 53
86.2
Z
Connecting pipe port
(Pipe dia.Ø6.35)
Connecting pipe port
(Pipe dia.Ø9.52)
Connecting pipe port
(Pipe dia.Ø12.7)
4 × Ø11 × 17 U-shape hole
(For Ø8 to Ø10 anchor bolt)
Intake
310
100 or
C
more
For installation of the outdoor unit,
open (60cm or more) two directions at
least of A , B , C , and D directions.
Z
Mounting dimensions of anchor bolt
50 or more
200 or more
B
D
Outlet
600
Intake
Outside line
of product
4 × Ø11 × 17 long hole
(For Ø8 to Ø10 anchor bolt)
view
A
250 or more
(Minimum distance
from wall)
Detailed A leg part
50
36
11
310
296
R5.5
310
296
11
36
50
Detailed B leg part
600
2-Ø6 hole
2-Ø6 hole
600
R15
Outside line
of product
Outside line
of product
R15
R5.5
– 18 –
5-1. Indoor Unit
RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E
Color
Identification
RED
:
RED
WHI
BLK
BLU
BRW
ORN
PUR
YEL
GRY
PNK
GRN&
YEL
WHITE
:
BLACK
:
BLUE
:
BROWN
:
ORANGE
:
PURPUL
:
YELLOW
:
GRAY
:
PINK
:
GREEN&
:
YELLO
W
1 2 3 4
1 2 3 4
RED
BRW
BRW
1 2 3 4
BR
W
BLK
1
2
3
4
5
6
BLK
Power suppl
1
2
3
4
5
y
6
Ion electrode
High-voltage
Air purifier
Electrode
INDOOR
TERMINAL
BLOCK
1 2 3 4
LINE
FIL
CN22
TER
CN01
)
BLK
BLK
BLK
BLK
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
WHI
(BLU)
121
CN03
(WHI
121
CN13
(WHI)
9
8
7
6
5
4
3
2
1
2
2
9
8
7
6
5
4
3
2
1
– 19 –
HEAT EXCHANGER
SENSOR (TC)
THERMO SENSOR
MCC-899
Wireless Unit Assembly
A)
(T
CN100
(WHI
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10 10
CN33
(WHI)
FUSE
F01
AC 250V
)
MAIN P.C. BOARD
T3.15A
TNR
(MCC-5020)
CN08 (WHI)
21 43
To outdoor unit
21
3
BLK
WHI
RED
3 1
CN23
DB01
exchanger
GRN &
CN21
DC5V
DC12V
Heat
CN34
POWER SUPPLY
CIRCUIT
YEL
121
2
(RED)
CN10
(WHI
1
1
3
3
4
4
5
5
66
CN07
(WHI)
1
1
2
2
3
3
4
4
5
5
BRW
Micro SW
BLU
)
FAN MOTOR
RED
BLK
WHI
YEL
BLU
WHI
YEL
YEL
YEL
YEL
DC MOTOR
1
1
2
2
3
3
4
4
5
5
LOUVER MOTOR
5. WIRING DIAGRAM
5-2. Outdoor Unit
RAS-3M23GACV-E
NOTE
IGBT : Insulated Gate Bipolar Transistor
PMV : Pulse Motor Valve
TD : Discharge Temp. sensor
TGa to TGc : Temp. sensor at A to C unit gas side
TO : Outdoor Temp. sensor
Thermostat for
compressor
ORN
ORN
Fan motor
FM
PMV
C
PMV
B
PMV
A
P501
212
1
P500
5
5
4
4
3
3
CN301
2
2
1
1
3
3
2
2
CN300
1
1
6
6
5
5
4
4
CN703
3
3
RED
2
2
1
1
6
6
5
5
4
4
CN702
3
3
WHI
2
2
1
1
6
6
5
5
4
4
CN701
3
3
YEL
2
2
1
1
P07 P03 P04
WHI
SUB P.C. Board
(MCC-818)
Fan
circuit
F300
Fuse
3.15A
~
250V
Photo coupler
RED
Varistor
ORN
absorber
Surge
CN802
CN607
CN606
CN605
CN602
CN601
CN302
CN800
CN303
CN501
F500
Fuse
6.3A
250V
P05
Compressor
RED
WHI
CM
BLK
212
313
313
313
313
212
313
5 5 5 5
4 4 4 4
3 3 3 3
212
212
313
RED
212
1
GRN
1
BRW
1
YEL
1
1
1
BLU
YEL
1
BLK
WHI
BLU
RED
PNK
1
PUR
ORN
1
WHI
RED
1
~
PNK
1
1
2
3
TGc
TGb
TGa
TD
TO
1
2
3
CN09
CN10
CN11
Power supply circuit
(For P.C. Board)
313
CN04
1
CN06
212
1
212
CN05
1
5 5
313
CN13
1
F01
Fuse
25A
250V
CN01 CN02 CN03
BLK WHI
Color Identification
BLK : BLACK WHI : WHITE
BLU : BLUE BRW : BROWN
RED : RED ORN : ORANGE
GRY : GRAY YEL : YELLOW
PNK : PINK PUR : PURPLE
GRN : GREEN
T03 CT
T04 CT
F04
Fuse
3.15A
~
250V
Power relay
RY01
RB04
T02 CT
C13
C12
C11
C10
F02
Fuse
25A
250V
P20
P19
P18
P17
~
P23
P24
P13
P12
P22
P21
P09
P08
+
BU
EU
BV
EV
BW
EW
BX
BY
BZ
–
G
C
E
+
~
~
–
+
~
~
–
212
212
module
Q200
YEL
BLU
IGBT
(PFC)
Q404
Diode
block
(PFC)
DB02
Diode
block
DB01
RED
1
Reactor
BRW
1
Reactor
P.C. Board
(MCC-1438)
Varistor
~
absorber
Reactor
Surge
BLK
IGBT
1 2 3
To
Indoor unit
A
1 2 3
To
Indoor unit
B
Terminal block
– 20 –
L N
Power supply
220–240V
220–220V
~
~
50Hz
60Hz
1 2 3
To
Indoor unit
C
6. SPECIFICATIONS OF ELECTRICAL PARTS
6-1. Indoor Unit
RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E
No.
1
Fan motor (for indoor)
2
Room temp. sensor (TA-sensor)
3
Heat exchanger temp. sensor (TC-sensor)
4
Louver motor
Parts name
6-2. Outdoor Unit
RAS-3M23GACV-E
No.
1
2
3
4
5
Parts name
SC coil (Noise filter) (L01)
SC coil (Noise filter) (L02)
DC-DC transformer
Fan motor (For outdoor)
Relay (Power relay)
Discharge temp. sensor
(TD-sensor)
Type
MF-280-30-5R
( – )
( – )
MP24Z
Model name
ADR25H200RBTB
SC-20-S03J
SWT-75
ICF-140-43-2R
G4A-1A-PE
(Inverter attached)
Specifications
DC280–340V, 30W
10kΩ at 25°C
10kΩ at 25°C
Output (Rated) 1W, 16 poles, DC12V
Rating
AC 250V, 20A, 0.88mH
AC 250V, 20A, 0.3mH
Primary side DC 240 – 280V
Secondary side: 7V × 1, 13V × 1
16V × 3
DC 140V, 43W
Coil: DC 12V,
Contact: 20A, AC250V
64kΩ (20°C)
Outside air temp. sensor
6
(TO-sensor)
Temp. sensor at A room
7
gas side (TGa-sensor)
Temp. sensor at B room
8
gas side (TGb-sensor)
Temp. sensor at C room
9
gas side (TGc-sensor)
Terminal block (6P)
10
Terminal block (2P)
11
Fuse
12
Electrolytic capacitor
13
Transistor module
14
Compressor
15
Compressor thermo.
16
(Inverter attached)
(Inverter attached)
(Inverter attached)
(Inverter attached)
—
—
For protection of switching power source (F04)
For protection of
For protection of inverter input overcurrent
For protection of switching power source (F300)
For protection of power source
power factor converter circuit breakage
LLQ2G761KHUATF
6MBI40SS-060-51A
DA130A1F-25F
US622KXTMQO
10kΩ (25°C)
10kΩ (25°C)
10kΩ (25°C)
10kΩ (25°C)
AC 250V, 20A
AC 250V, 20A
AC 250V, 3.15A
AC 250V, 25A
AC 250V, 25A
AC 250V, 3.15A
AC 250V, 6.3A
DC 400V, 760µF
600V, 40A
3 phases, 4 poles, 1,100W
OFF: 125 ± 4°C, ON: 90 ± 5°C
Diode block (Rectifire)
17
Reactor (Main)
18
Reactor (Sub)
19
D25XB60
CH-47-Z-T
CH-43-Z-T
– 21 –
AC 800V, 30A
L = 8mH, 16A
L = 10mH, 1A
7. REFRIGERANT CYCLE DIAGRAM
7-1. Refrigerant Cycle Diagram
To
C room
To
B room
INDOOR UNIT A
Indoor heat
exchanger
T1
Temp. measurement
To
C room
To
B room
Connecting pipe
Thickness : 0.8 mm
Ø9.52 :
RAS-M10GKCVP-E
RAS-M13GKCVP-E
Ø12.7 :
RAS-M16GKCVP-E
Pressure
P
measurement
Gauge attaching port
Vacuum pump
connecting port
Cross flow fan
Connecting pipe
Thickness : 0.8 mm
Ø6.35
Allowable height
Sectional shape
of heat insulator
(Ø9.52) (Ø9.52) (Ø12.7) (Ø6.35) (Ø6.35) (Ø6.35)
Strainer
TGaTGbTGc
Pulse motor valve
at liquid side
(CAM-B22YGTF)
Per 1 unit
Max. : 20m
Min. : 2m
Total
Max. : 40m
difference : 10m
Allowable pipe length
Accumulating tank
Ø51 x 300
(460cc)
Temp. measurement
Outdoor heat
T
2
OUTDOOR UNIT
TD
Compressor
DA130A1F-25F
exchanger
Propeller fan
Refrigerant amount : 1.5kg (R410A)
NOTE :
Gas leak check position
Refrigerant flow
NOTE :
• The maximum pipe length of this air conditioner is 40 m. The additional chaging of refrigerant is unnecessary
because this air cinditioner is designed with charge-less specification.
– 22 –
7-2. Operation Data
<Cooling> RAS-M14GAV-E, RAS-M14GACV-E
Temperature
condition (°C)
Indoor Outdoor
27 / 19 35 / –
No.of
operating
units
1 unit
2 units
3 units
Combinations
of indoor units
10 ——
13 ——
16 ——
10 10 —
13 10 —
16 10 —
13 13 —
16 13 —
16 16 —
10 10 10
13 10 10
16 10 10
13 13 10
Standard
pressure
P (MPa)
0.92
0.85
0.73
0.96
0.92
0.92
0.92
0.92
0.92
1.04
0.98
0.98
0.98
Surface temp. of
heat exchanger
T1 (°C) T2 (°C)
11 42
0947
8 50
10.5 to 11.5 49
11 to 12 51
11 to 12 51
11 to 12 51
11 to 12 51
11 to 12 51
12.5 to 13.5 51
12 to 13 52
12 to 13 52
12 to 13 52
Fan speed
Indoor Outdoor
High Med.
High High
High High
High High
High High
High High
High High
High High
High High
High High
High High
High High
High High
Compressor
revolution
(rps)
37
57
73
69
78
78
78
78
78
81
89
89
89
NOTES :
1. Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent.
(Thermistor themometer)
2. Connecting piping condition : 5 m × 3 units (5 m / each unit)
– 23 –
8. CONTROL BLOCK DIAGRAM
8-1. Indoor Unit
RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E
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
Air purifier
unit
Micro Switch
From Outdoor Unit
~
~
50Hz
60Hz
220-240V
220V
REMOTE CONTROLLER
Serial Signal Communication
(Operation Command and Information)
Remote Controller
Operation (START/STOP)
Operation Mode Selection
AUTO, COOL, DRY
Thermo. Setting
Fan Speed Selection
ON TIMER Setting
OFF TIMER Setting
Louver AUTO Swing
Louver Direction Setting
ECO
Hi-POWER
Infrared Rays, 36.7kHz
– 24 –
Air Purifier
SLEEP
8-2. Outdoor Unit (Inverter Assembly)
RAS-3M23GACV-E
Discharge temp. SensorGas side pipe temp. SensorOutdoor air temp. Sensor
MCC-818 (SUB-P.C. B)
A unit P.M.V.
B unit P.M.V.
C unit P.M.V.
Outdoor
fan
motor
Inverter
(DC ® AC)
Over current
sensor
Driver
circuit of
P.M.V.
Noise filter
Input current
sensor
Converter
(AC ® DC)
M.C.U
• Inverter outdoor frequency control
• A/D converter function
• P.M.V. control
• Discharge temp. control
• Error display
• Signal communication to MCU
• PWM synthesis function
Current detect
circuit
Gate drive
circuit
Over current
detect circuit
Clock frequency
oscillator circuit
10MHz
High power factor
correction circuit
Clock frequency
oscillator circuit
16MHz
Signal communication
to MCU
MCC-1438 (MAIN-P.C. B)
M.C.U
• PWM synthesis function
• Input current release control
• IGBT over current detect control
• High power factor correction control
• Signal communication to MCU
• Output current release control
• A/D converter function
A unit
send/receive
circuit
B unit
send/receive
circuit
C unit
send/receive
circuit
220–240V ~50Hz
220V
~
60Hz
Compressor
Over current
sensor
Inverter
(DC ® AC)
Output current
sensor
P.M.V : Pulse motor valve
PWM : Pulse width modulation
Over current
detect circuit
Gate drive
circuit
IGBT : Insulated gate bipolar
transistor
– 25 –
9. OPERATION DESCRIPTION
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 13 to 92 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. (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.
• 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
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.
1. Role of indoor unit controller
The indoor unit controller judges the operation
commands from the remote controller and assumes
the following functions.
• Judgment of suction air temperature of the indoor
heat exchanger by using the indoor temp. sensor.
(TA sensor)
• Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor)
(Prevent-freezing control, etc.)
• Louver motor control
• Indoor fan motor operation control
• LED (Light Emitting Diode) display control
• Transferring of operation command signal (Serial
signal) to the outdoor unit
• Reception of information of operation status
(Serial signal including outside temp. data) to the
outdoor unit and judgment/display of error
• Air purifier operation control
2. Role of outdoor unit controller
Receiving the operation command signal (Serial
signal) from the indoor unit controller, the outdoor
unit performs its role.
• Compressor operation control
• Operation control of outdoor fan motor
• P.M.V. control
4. 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.
Operations follow ed to
judgment of serial signal
from indoor side.
– 26 –
9-2. Operation Description
9-2. 1. Basic operation ....................................................................................................................... 28
1. Operation control ............................................................................................................... 28
2. Operating mode selection when performing 2-room operation .......................................... 29
3. Cooling operation ............................................................................................................... 29
4. AUTO oper ation ................................................................................................................. 30
5. DRY operation.................................................................................................................... 30
2. Indoor fan motor control.......................................................................................................... 31
<In cooling operation>............................................................................................................. 31
3. Outdoor fan motor control ....................................................................................................... 32
4. Capacity control ...................................................................................................................... 32
5. Current release control ........................................................................................................... 33
6. Release protective control by temperature of indoor heat exchanger ..................................... 33
7. Louver control ......................................................................................................................... 34
1) Louver position................................................................................................................... 34
2) Air direction adjustment ..................................................................................................... 34
3) Swing ................................................................................................................................. 34
8. ECO operation ........................................................................................................................ 35
9. Temporary operation ............................................................................................................... 35
10. Air purifying control ................................................................................................................. 36
Air purifying control [Detection of abnormality] ....................................................................... 37
11. Discharge temperature control................................................................................................38
12. Pulse motor valv e (P.M.V.) control...........................................................................................38
13. Clean operation....................................................................................................................... 39
14. Clean operation release.......................................................................................................... 40
15. Select switch on remote controller .......................................................................................... 41
9-3. Auto Restart Function.............................................................................................42
9-3-1. How to Set the Auto Restart Function ................................................................................ 42
9-3-2. How to Cancel the Auto Restart Function .......................................................................... 43
9-3-3. Power Failure During Timer Operation ................................................................................ 43
9-4. FILTER Indicator ......................................................................................................43
9-4-1. How to Turn Off FILTER Indicator ........................................................................................ 43
9-5. Remote Controller and Its Fuctions ......................................................................44
9-5-1. Parts Name of Remote Controller........................................................................................ 44
9-5-2. Name and Functions of Indications on Remote Controller............................................... 45
9-6. Hi-PO WER Mode
([Hi-POWER] button on the remote controller is pressed) ..................................46
– 27 –
Item
Operation flow and applicable data, etc.
Description
1. Basic
operation
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 and pulse motor valve.
Selection of
operation conditions
ON/OFF
Remote controller
Control contents of remote controller
• ON/OFF (Air conditioner/Air purifier)
• Operation select (COOL/AUTO/DRY)
• Temperature setup
• Air direction
• Swing
• Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH)
• ECO
• ON timer setup
• OFF timer setup
• High power
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
• Timer function
• Indoor heat exchanger release control
• Clean function
Outdoor unit
Outdoor unit control
• Frequency control of inverter output
• Waveform composite function
• Calculation function
(Temperature calculation)
• AD conversion function
• Delay function of compressor reactivation
• Current release function
• GTr over-current preventive function
Inverter
• Indoor fan motor
• Louver motor
~
• Compressor
• Outdoor fan motor
• Pulse motor valve
(P.M.V.)
– 28 –
Item
Operation flow and applicable data, etc.
Description
1. Basic
operation
2. Operating mode selection when performing 2-roomoperation
1) The outdoor unit operating mode conforms to the instructions of the indoor unit that was pressed first.
2) When combined operation consisting of cooling (dry) and heating, fan (air purification) and
heating, or cleaning operation and heating is performed, operation conforms to the instructions of
the indoor unit that was pressed first as shown in the left table.
3) The indoor fan stops for the indoor unit that was pressed last and which instructions are ignored.
4) When three indoor units are operated concurrently, the pr ior ity is also given to operating mode of
the indoor unit which was pressed first as same as the case when two indoor units are operated
concurrently.
No.
Indoor unit
Pressed first
1
Pressed last
Pressed first
2
Pressed last
Pressed first
3
Pressed last
Pressed first
4
Pressed last
Pressed first
5
Pressed last
Pressed first
6
Pressed last
Pressed first
7
Pressed last
Pressed first
8
Pressed last
Pressed first
9
Pressed last
Set operating mode
Cooling (dry)
Cooling (dry)
Fan (solo air purification)
Fan (solo air purification)
Fan (solo air purification)
Cooling (dry)
Cooling (dry)
Fan (solo air purification)
Cleaning operation
Cleaning operation
Cleaning operation
Cooling (dry)
Cooling (dry)
Cleaning operation
Cleaning operation
Fan (solo air purification)
Fan (solo air purification)
Cleaning operation
Actual indoor unit operation
Cooling (dry)
Cooling (dry)
Fan (solo air purification)
Fan (solo air purification)
Fan (solo air purification)
Cooling (dry)
Cooling (dry)
Fan (solo air purification)
Cleaning operation
Cleaning operation
Cleaning operation
Cooling (dry)
Cooling (dry)
Cleaning operation
Cleaning operation
Fan (solo air purification)
Fan (solo air purification)
Cleaning operation
Actual outdoor unit operation
Cooling
Stopped
Cooling
Cooling
Stopped
Cooling
Cooling
Stopped
Stopped
3. Cooling operation
The operations are performed in the following parts by controls according to cooling conditions.
1) Receiving the operation ON signal of the remote controller, the cooling operation signal star ts
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 and pulse motor valve according to
the operation signal sent from the indoor unit.
Operation ON
Indoor unit control
Setup of remote controller
Indoor fan motor control / Louver control
Sending of operation command signal
Outdoor unit control
Compressor revolution control / Outdoor fan motor control
Pulse motor valve control
– 29 –
Item
Operation flow and applicable data, etc.
Description
1. Basic
operation
4. 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.
Ta
Cooling operation
Ts + 1
Monitoring (Fan)
Ts – 1
Fan only operation
*1.When reselecting the operation mode, the fan speed
is controlled by the previous operation mode.
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) If the status of compressor-OFF
continues for 15 minutes the room
temperature after selecting an operation
mode, reselect an operation mode.
5. 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.
[˚C]
Ta
+
1.0
L– (W5)
(W5+W3) / 2
+
0.5
Tsc
SL (W3)
Fan speed
1) Detects the room temperature (Ta) when
the DRY operation started.
2) Starts operation under conditions in the
left figure according to the temperature
difference between the room temperature and the setup temperature (Tsc).
Setup temperature (Tsc)
= Set temperature on remote controller
(Ts) + (0.0 to 1.0)
3) When the room temperature is lower
1°C or less than the setup temperature,
turn off the compressor.
– 30 –
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