Toshiba RAS-3M23YACV-E DATA BOOK

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Page 1

FILE NO. SVM-03016

SUPPLEMENT

SERVICE MANUAL

AIR-CONDITIONER

SPLIT TYPE

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E /

RAS-3M23YACV-E

R410A

June, 2003

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CONTENTS

1. SPECIFICATIONS........................................................................................................... 3

2. REFRIGERANT R410A................................................................................................... 7

3. CONSTRUCTION VIEWS.............................................................................................. 15

4. WIRING DIAGRAM ....................................................................................................... 17

5. SPECIFICATIONS OF ELECTRICAL PARTS .............................................................. 19

6. REFRIGERANT CYCLE DIAGRAM.............................................................................. 20

7. CONTROL BLOCK DIAGRAM ..................................................................................... 22

8. OPERATION DESCRIPTION ........................................................................................ 24

9.INSTALLATION PROCEDURE.....................................................................................36

10.HOW TO DIAGNOSE THE TROUBLE...........................................................................50

11.HOW TO REPLACE THE MAIN PARTS........................................................................71

12.EXPLODED VIEWS AND PARTS LIST........................................................................82

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1. SPECIFICATIONS

1-1. Specifications

Unit model Indoor Cooling capacity (kW)

Cooling capacity range (kW) Power supply Electric

characteristics

COP Operating noise Indoor Unit model

Indoor unit Unit model

Outdoor unit Unit model

Piping connection Type

Refrigerant Name of refrigerant Wiring connection Power supply Usable temperature range Indoor (°C) Accessory Indoor unit Installation plate

Outdoor

Indoor Unit model

Running current (A) Power consumption (W) Power factor (%)

Outdoor Unit model

Running current (A) Power consumption (W) Power factor (%)

Starting current (A)

High (dB•A) Medium (dB•A) Low (dB•A)

Outdoor Unit model

10-1 unit operating (dB•A)

3 units operating (dB•A)

Dimension Height (mm)

Width (mm)

Depth (mm) Net weight (kg) Fan motor output (W) Air flow rate (m³/h)

Dimension Height (mm)

Width (mm)

Depth (mm) Net weight (kg) Fan motor output (W) Air flow rate (m³/h)

Indoor unit Unit model

Liquid side

Gas side Outdoor unit Unit model

A unit

B unit

C unit Maximum length (per unit) (m) Maximum length (total) (m) Maximum chargeless length (m) Maximum height difference (m)

Weight (kg)

Interconnection

Outdoor (°C)

Wireless remote control

Label

Remote control holder

Pan head wood screw

Purifying filter

Zeodorizing filter

Batteries

Mounting screw

Installation manual Outdoor unit Installation manual

Owner's manual

• For performance when each indoor unit is combined with other unit, ref er to the separate table .

• The specifications may be subject to change without notice f or purpose of improv ement.

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

RAS-3M23YACV-E

6,7

2,2~7,0

220–240V–1Ph–50Hz

220V 230V 240V

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

0,15

91 87 83

RAS-3M23YACV-E

9,84 9,39 8,98

2060

10,29 9,84 9,43

3,12

RAS-M10UKCV-ERAS-M13UKCV-ERAS-M16UKCV-E

36 39 42 333539

28 28 33

RAS-3M23YACV-E

45 48

RAS-M10UKCV-ERAS-M13UKCV-ERAS-M16UKCV-E

275275275 790790790

208 208 208

10 10 10

191919

470 520 600

RAS-3M23YACV-E

695 780 270

48 40

2100

Flare connection

RAS-M10UKCV-ERAS-M13UKCV-ERAS-M16UKCV-E

Ø6,35 Ø6,35 Ø6,35 Ø9,52 Ø9,52 Ø12,7

RAS-3M23YACV-E

Ø6,35 / Ø12,7 Ø6,35 / Ø9,52 Ø6,35 / Ø9,52

20 40 40 10

R410A

1,5 3 Wires : includes earth 4 Wires : includes earth

21–32 10–43

1 1

2 (Ø3,1 x 16L)

1 1 2

6 (Ø4 x 25L)

1 1 1

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1-2.

Specifications of Performance When Each Indoor Unit is Combined with Other Unit

Operating

status

1 unit 220

2 units 220

3 units 220

Power

supply

(V)

230 240 220 230 240 220 230 240

230 240 220 230 240 220 230 240 220 230 240 220 230 240 220 230 240

230 240 220 230 240 220 230 240 220 230 240

Indoor unit Unit capacity (kW)

ABCABC

10 — — 2,7 — — 10 — — 2,7 — — 10 — — 2,7 — — 13 — — 3,7 — — 13 — — 3,7 — — 13 — — 3,7 — — 16 — — 4,5 — — 16 — — 4,5 — — 16 — — 4,5 — — 10 10 — 2,7 2,7 — 10 10 — 2,7 2,7 — 10 10 — 2,7 2,7 — 10 13 — 2,45 3,35 — 10 13 — 2,45 3,35 — 10 13 — 2,45 3,35 — 10 16 — 2,21 3,69 — 10 16 — 2,21 3,69 — 10 16 — 2,21 3,69 — 13 13 — 2,95 2,95 — 13 13 — 2,95 2,95 — 13 13 — 2,95 2,95 — 13 16 — 2,71 3,29 — 13 16 — 2,71 3,29 — 13 16 — 2,71 3,29 — 16 16 — 3,05 3,05 — 16 16 — 3,05 3,05 — 16 16 — 3,05 3,05 — 10 10 10 2,13 2,13 2,13 10 10 10 2,13 2,13 2,13 10 10 10 2,13 2,13 2,13 10 10 13 1,99 1,99 2,72 10 10 13 1,99 1,99 2,72 10 10 13 1,99 1,99 2,72 10 13 13 1,80 2,45 2,45 10 13 13 1,80 2,45 2,45 10 13 13 1,80 2,45 2,45 10 10 16 1,83 1,83 3,04 10 10 16 1,83 1,83 3,04 10 10 16 1,83 1,83 3,04

Cooling Power Operation Outdoor

capacity consumption current noise

(kW) (W) (A) (dB)

2,7 770 4,12 45

(1,4 to 3,2) (320 to 950) (2,08 to 5,08)

2,7 770 3,94 45

(1,4 to 3,2) (320 to 950) (1,99 to 4,86)

2,7 770 3,77 45

(1,4 to 3,2) (320 to 950) (1,90 to 4,66)

3,7 1200 6,34 48

(1,4 to 4,4) (320 to 1470) (2,08 to 7,51)

3,7 1200 6,07 48

(1,4 to 4,4) (320 to 1470) (1,99 to 7,18)

3,7 1200 5,81 48

(1,4 to 4,4) (320 to 1470) (1,90 to 6,88)

4,5 1600 7,66 48

(1,4 to 4,9) (320 to 1750) (2,08 to 8,37)

4,5 1600 7,32 48

(1,4 to 4,9) (320 to 1750) (1,99 to 8,01)

4,5 1600 7,02 48

(1,4 to 4,9) (320 to 1750) (1,90 to 7,68)

5,4 1500 7,18 48

(1,8 to 6,0) (360 to 1880) (2,34 to 9,00)

5,4 1500 6,86 48

(1,8 to 6,0) (360 to 1880) (2,24 to 8,60)

5,4 1500 6,58 48

(1,8 to 6,0) (360 to 1880) (2,14 to 8,25)

5,8 1800 8,61 48

(1,8 to 6,3) (360 to 1970) (2,34 to 9,43)

5,8 1800 8,24 48

(1,8 to 6,3) (360 to 1970) (2,24 to 9,02)

5,8 1800 7,89 48

(1,8 to 6,3) (360 to 1970) (2,14 to 8,64)

5,9 1830 8,76 48

(1,8 to 6,4) (360 to 2000) (2,34 to 9,57)

5,9 1830 8,38 48

(1,8 to 6,4) (360 to 2000) (2,24 to 9,15)

5,9 1830 8,03 48

(1,8 to 6,4) (360 to 2000) (2,14 to 8,77)

5,9 1830 8,76 48

(1,8 to 6,4) (360 to 2000) (2,34 to 9,57)

5,9 1830 8,38 48

(1,8 to 6,4) (360 to 2000) (2,24 to 9,15)

5,9 1830 8,03 48

(1,8 to 6,4) (360 to 2000) (2,14 to 8,77)

6,0 1850 8,85 48

(1,8 to 6,4) (360 to 2000) (2,34 to 9,57)

6,0 1850 8,50 48

(1,8 to 6,4) (360 to 2000) (2,24 to 9,15)

6,0 1850 8,11 48

(1,8 to 6,4) (360 to 2000) (2,14 to 8,77)

6,1 1870 8,95 48

(1,8 to 6,5) (360 to 2050) (2,34 to 9,81)

6,1 1870 8,56 48

(1,8 to 6,5) (360 to 2050) (2,24 to 9,38)

6,1 1870 8,20 48

(1,8 to 6,5) (360 to 2050) (2,14 to 8,99)

6,4 1880 9,00 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)

6,4 1880 8,60 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)

6,4 1880 8,25 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)

6,7 2150 10,29 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)

6,7 2150 9,84 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)

6,7 2150 9,43 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)

6,7 2150 10,29 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)

6,7 2150 9,84 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)

6,7 2150 9,43 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)

6,7 2150 10,29 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)

6,7 2150 9,84 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)

6,7 2150 9,43 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)

• The above specification values are those under the conditions that the indoor DB/WB=27/19°C and the outdoor DB=35°C.

•Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E

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1-2-1. Operation Characteristic Curve

• Conditions

Indoor : DB27˚C/WB19˚C Outdoor : DB35˚C

Air flow : High Pipe length 5m × 3

3 units operating

8 7 6 5

Current (A)

4 3 2 1 0

100 2030405060708090100

Inverter output frequency (rps)

220V

240V

230V

1-2-2. Capacity Variation Ratio According to Temperature

105115

• Conditions

110

105

100

Capacity ratio (%)

Indoor : DB27˚C Outdoor : DB35˚C Indoor air flow: High Pipe length 5m × 3 3 units operating

Indoor air wet bulb temp. (˚C)

100

95 90 85 80 75 70

Capacity ratio (%)

65 60 55 50

32 34 36 38 40 42 44 4614 16

Current Limited Start

• Conditions Indoor : DB27˚C/WB19˚C Indoor air flow: High Pipe length 5m × 3 3 units operating

Outdoor temp. (˚C)

* Capacity ratio : 100% = 6,7 kW

4318 20 22 24

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1-3. Electrical Data

Combination of

indoor unit operation

1 unit 10 — —

13 — — 16 — —

2 units 10 10 —

13 10 — 16 10 — 13 13 — 16 13 — 16 16 —

3 units 10 10 10

13 10 10 13 13 10 16 10 10

1 unit 10 — —

13 — — 16 — —

2 units 10 10 —

13 10 — 16 10 — 13 13 — 16 13 — 16 16 —

3 units 10 10 10

13 10 10 13 13 10 16 10 10

1 unit 10 — —

13 — — 16 — —

2 units 10 10 —

13 10 — 16 10 — 13 13 — 16 13 — 16 16 —

3 units 10 10 10

13 10 10 13 13 10 16 10 10

System

Volts-

50 220-1 198 264

50 230-1 198 264

50 240-1 198 264

Voltage range Power supply

Ph.

Min. Max. MCA ICF

MOCP

(Amps)

4,99 4,99 8,46 7,76 7,76 13,45 9,41 9,41 16,42

8,78 8,78 15,16 10,56 10,56 18,37 10,75 10,75 18,71 10,75 10,75 18,71 10,86 10,86 18,91 10,99 10,99 19,14 11,01 11,01 19,06 12,63 12,63 21,97 12,63 12,63 21,97 12,63 12,63 21,97

4,76 4,76 8,05

7,43 7,43 12,85

8,99 8,99 15,66

8,38 8,38 14,44 10,10 10,10 17,54 10,28 10,28 17,86 10,28 10,28 17,86 10,43 10,43 18,13 10,50 10,50 18,26 10,51 10,51 18,16 12,06 12,06 20,95 12,06 12,06 20,95 12,06 12,06 20,95

4,55 4,55 7,67

7,10 7,10 12,26

8,61 8,61 14,98

8,03 8,03 13,81

9,66 9,66 16,75

9,84 9,84 17,07

9,94 9,94 17,25 10,05 10,05 17,45 10,08 10,08 17,38 11,55 11,55 20,03 11,55 11,55 20,03 11,55 11,55 20,03

Compressor Fan motor FLA

MSC RLA Indoor Outdoor

3,47 3,47 0,15 x 1 = 0,15 0,5 5,69 5,69 0,15 x 1 = 0,15 0,5 7,01 7,01 0,15 x 1 = 0,15 0,5 6,38 6,38 0,15 x 2 = 0,30 0,5 7,81 7,81 0,15 x 2 = 0,30 0,5 7,96 7,96 0,15 x 2 = 0,30 0,5 7,96 7,96 0,15 x 2 = 0,30 0,5 8,05 8,05 0,15 x 2 = 0,30 0,5 8,15 8,15 0,15 x 2 = 0,30 0,5 8,05 8,05 0,15 x 3 = 0,45 0,5 9,34 9,34 0,15 x 3 = 0,45 0,5 9,34 9,34 0,15 x 3 = 0,45 0,5 9,34 9,34 0,15 x 3 = 0,45 0,5 3,29 3,29 0,15 x 1 = 0,15 0,5 5,42 5,42 0,15 x 1 = 0,15 0,5 6,67 6,67 0,15 x 1 = 0,15 0,5 6,06 6,06 0,15 x 2 = 0,30 0,5 7,44 7,44 0,15 x 2 = 0,30 0,5 7,58 7,58 0,15 x 2 = 0,30 0,5 7,58 7,58 0,15 x 2 = 0,30 0,5 7,70 7,70 0,15 x 2 = 0,30 0,5 7,76 7,76 0,15 x 2 = 0,30 0,5 7,65 7,65 0,15 x 3 = 0,45 0,5 8,89 8,89 0,15 x 3 = 0,45 0,5 8,89 8,89 0,15 x 3 = 0,45 0,5 8,89 8,89 0,15 x 3 = 0,45 0,5 3,12 3,12 0,15 x 1 = 0,15 0,5 5,16 5,16 0,15 x 1 = 0,15 0,5 6,37 6,37 0,15 x 1 = 0,15 0,5 5,78 5,78 0,15 x 2 = 0,30 0,5 7,09 7,09 0,15 x 2 = 0,30 0,5 7,23 7,23 0,15 x 2 = 0,30 0,5 7,23 7,23 0,15 x 2 = 0,30 0,5 7,31 7,31 0,15 x 2 = 0,30 0,5 7,40 7,40 0,15 x 2 = 0,30 0,5 7,30 7,30 0,15 x 3 = 0,45 0,5 8,48 8,48 0,15 x 3 = 0,45 0,5 8,48 8,48 0,15 x 3 = 0,45 0,5 8,48 8,48 0,15 x 3 = 0,45 0,5

NOTE :

Model of Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E MCA : Minimum Circuit Amps. ICF : Maximum Instantaneous Current Flow

(Equivalent to MCA in case of inv erter air conditioner) MOCP : Maximum Overcurrent Protection (Fuse only) MSC : Maximum Starting Current

Indoor temp. °C 27 19

FLA : Full Load Amps. RLA : Rated Load Amps. RLA under conditions on the right.

Outdoor temp. °C 35 —

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DB WB

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2. 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 e xisting 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. Conf orming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

2-1. Safety During Installation/Servicing

As R410A’s pressure is about 1,6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

(1) Never use refrigerant other than R410A in an air

conditioner which is designed to operate with R410A.

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

(2) Confirm the used refrigerant name, and use

tools and materials exclusive f or 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 lev el.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal lev el, 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 ma y result in w ater leakage, electric shock and fire, etc.

2-2. Refrigerant Piping Installation

2-2-1. Piping Materials and Joints Used

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

(1) Copper Pipes

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

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

Thicknesses of copper pipes used with R410A are as shown in Table 2-2-1. Never use copper pipes thinner than 0,8 mm even when it is available on the mark et.

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Table 2-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter Outer diameter (mm) R410A R22

1/4 6,35 0,80 0,80 3/8 9,52 0,80 0,80 1/2 12,70 0,80 0,80 5/8 15,88 1,00 1,00

(2) Joints

For copper pipes, flare joints or soc k et joints are used. Prior to use, be sure to remo ve all contaminants.

a) Flare Joints

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

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

T a ble 2-2-2 Minim um thic knesses of socket joints

Nominal diameter

1/4 6,35 0,50 3/8 9,52 0,60 1/2 12,70 0,70

Reference outer diameter of Minimum joint thickness

copper pipe jointed (mm) (mm)

b) Socket Joints

Socket joints are such that they are br azed for connections, and used mainly f or thic k pipings whose diameter is larger than 20 mm. Thicknesses of socket joints are as shown in T ab le 2-2-2.

5/8 15,88 0,80

2-2-2. Processing of Piping Materials

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

(1) Flare Processing Procedures and Precautions

a) Cutting the Pipe

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

b) Removing Burrs and Chips

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

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Page 9

c) Insertion of Flare Nut d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perf orm the flare processing correctly .

Use either a flare tool for R410A or conv entional flare tool.

T a ble 2-2-3 Dimensions related to flare pr ocessing f or R410A

Nominal

diameter

Outer

diameter

(mm)

Thickness

(mm)

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

Fig. 2-2-1 Flare processing dimensions

Flare tool for

R410A clutch type

ØD

A (mm)

Conventional flare tool

Clutch type Wing nut type

1/4 6,35 0,8 3/8 9,52 0,8 1/2 12,70 0,8 5/8 15,88 1,0

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

Nominal

diameter

Outer

diameter

(mm)

1/4 6,35 0,8 3/8 9,52 0,8 1/2 12,70 0,8 5/8 15,88 1,0

T a ble 2-2-5 Flare and flare nut dimensions f or R410A

Thickness

(mm)

0 to 0,5 1,0 to 1,5 1,5 to 2,0 0 to 0,5 1,0 to 1,5 1,5 to 2,0 0 to 0,5 1,0 to 1,5 2,0 to 2,5 0 to 0,5 1,0 to 1,5 2,0 to 2,5

A (mm)

Flare tool for

R22 clutch type

Conventional flare tool

Clutch type Wing nut type

0 to 0,5 0,5 to 1,0 1,0 to 1,5 0 to 0,5 0,5 to 1,0 1,0 to 1,5 0 to 0,5 0,5 to 1,0 1,5 to 2,0 0 to 0,5 0,5 to 1,0 1,5 to 2,0

Nominal Outer diameter Thickness

diameter (mm) (mm)

1/4 6,35 0,8 3/8 9,52 0,8 1/2 12,70 0,8 5/8 15,88 1,0

Dimension (mm)

Flare nut

width

ABCD

(mm)

9,1 9,2 6,5 13 17 13,2 13,5 9,7 20 22 16,6 16,0 12,9 23 26 19,7 19,0 16,0 25 29

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T a ble 2-2-6 Flare and flare nut dimensions f or R22

Nominal Outer diameter Thickness

diameter (mm) (mm)

1/4 6,35 0,8 3/8 9,52 0,8 1/2 12,70 0,8 5/8 15,88 1,0 3/4 19,05 1,0

46˚

45˚

B A

Dimension (mm)

Flare nut

width

ABCD

(mm)

9,0 9,2 6,5 13 17 13,0 13,5 9,7 20 22 16,2 16,0 12,9 20 24 19,4 19,0 16,0 23 27 23,3 24,0 19,2 34 36

43˚

45˚

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

(2) Flare Connecting Procedures and Precautions

a) Make sure that the flare and union portions

do not have any scar or dust, etc.

b) Correctly align the processed flare surface

with the union axis.

c) Tighten the flare with designated torque by

means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur .

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

Nominal Outer diameter Tightening torque

diameter (mm) N•m (kgf•cm)

1/4 6,35 14 to 18 (140 to 180) 16 (160), 18 (180)

When it is strong, the flare nut may cra c k and may be made non-remov abl e. When choosing the tightening torque, comply with values designated by manufacturers. Table 2-2-7 shows reference values.

Note:

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

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

3/8 9,52 33 to 42 (330 to 420) 42 (420) 1/2 12,70 50 to 62 (500 to 620) 55 (550) 5/8 15,88 63 to 77 (630 to 770) 65 (650)

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2-3. Tools

2-3-1. Required T ools

The service port diameter of pac ked valv e of the outdoor unit in the air conditioner 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 f ollowing three types .

(1) T ools e xclusive for R410A (Those which cannot be used for con v entional refrigerant (R22)) (2) T ools e xclusive for R410A, but can be also used for con ventional refrigerant (R22) (3) T ools commonly used f or R410A and f or conventional refrigerant (R22)

The table below shows the tools exclusive for R410A and their interchangeability.

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

Tools whose specifications are changed for R410A and their interchangeability

R410A air conditioner

installation

No. 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

 Refr igerant cylinder  Leakage detector  Charging cylinder

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

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

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

Usage

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

Existence of Whether new equipment conventional for R410A equipment can

Yes

Yes Yes Yes

Yes

(Note 2)

be used

(Note 1)

X X

X X X

Conventional air

conditioner installation

Whether new equipment can be used with conventional refrigerant

(Note 1)

X X

¡ ¡

General tools (Conventional tools can be used.)

In addition to the above e xclusiv e 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 Ø6,35) (3) Pipe cutter

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

(1) Clamp meter (2) Thermometer

(4) Reamer (5) Pipe bender (6) Level vial (7) Screwdriver (+, –) (8) Spanner or Monkey wrench

(3) Insulation resistance tester (4) Electroscope

(9) Hole core drill (Ø65) (10) Hexagon wrench

(Opposite side 5mm)

(11) Tape measure (12) Metal saw

– 11 –

Page 12

2-4. Recharging of Refrigerant

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

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

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

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.

Connect the charge hose of the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

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.

Never charge refrigerant e xceeding the specified amount.



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



Do not carry out additional charging.



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.

(For refrigerant charging, see the figure below.)

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

(INDOOR unit)

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

Electronic balance for refrigerant charging

Fig. 2-4-1 Configuration of refrigerant charging

(Liquid side)

(Gas side)

– 12 –

(OUTDOOR unit)

Opened

Closed

Service port

Page 13

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



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.

2-5. Brazing of Pipes

2-5-1. Materials for Brazing

(1) Silver brazing filler

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

(2) Phosphor bronze brazing filler

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

(3) Low temperature brazing filler

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

Fig. 2-4-2

Electronic

balance

Siphon

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.

When performing brazing again at time of



servicing, use the same type of brazing filler.

2-5-2. Flux

(1) Reason why flux is necessary

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

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

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

– 13 –

Page 14

Nitrogen gas

cylinder

Pipe

Flow meter

Stop valve

From Nitrogen cylinder

Nitrogen gas

Rubber plug

(2) Characteristics required for flux

• Activated temperature of flux coincides with the brazing temperature.

• Due to a wide effective temper ature 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 br azing temperature is higher than 800°C.

• Activated flux

Most of fluxes generally used for silver brazing are this type. It features an increased oxide film remo ving 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 braz-

ing filler/flux

2-5-3. Brazing

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

In order to prev ent the o xide 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

Attach a reducing valve and a flow-meter to



the Nitrogen gas cylinder. Use a copper pipe to direct the piping



material, and attach a flow-meter to the cylinder.

Apply a seal onto the clearance between the



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

When the Nitrogen gas is flowing, be sure to



keep the piping end open. 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 .

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).

Remove the flux completely after brazing.



Copper - Copper

Piping

material

Copper - Iron

Iron - Iron

Do not enter flux into the refrigeration cycle.



When chlorine contained in the flux remains



within the pipe, the lubricating oil deteriorates. Therefore , use a flux which does not contain chlorine.

When adding water to the flux, use water



which does not contain chlorine (e.g. distilled water or ion-exchange w ater).

Remove the flux after brazing.



Used brazing Used

filler flux

Phosphor copper Do not use

Silver Paste flux Silver Vapor flux

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

– 14 –

Page 15

3. CONSTRUCTION VIEWS

3-1. Indoor Unit

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

Front panel

Back body

660

Knock out system

Air inlet

Air filter

790

Heat exchanger

275

Air outlet

120 80

590

Hanger

208

Knock out system

660

Drain hose (0.54m)

Hanger

Minimum distance to ceiling

275

170 or more

320

620

235 235

215 215

Minimum distance to ceiling

65 or more

Hanger

– 15 –

Connecting pipe (0.43m)

(Flare ∅6.35) Connecting pipe (0.33m) (For 10,13 series ; Flare ∅9.52

For 16 series ; Flare ∅12.7)

Hanger

For stud bolt (∅6)

Hanger

150150 160160 Installation plate outline

Center line

For stud bolt (∅8~∅10)

Minimum distance to ceiling

170 or more

9090

4519040

160

57 18

Wireless remote control

Page 16

3-2. Outdoor Unit

RAS-3M23YACV-E

310

A leg part

296

270

600

ø11 × 17U-shape hole

(For ø8-ø10 anchor bolt)

Hanger

(ø6 hole pitch)

(Anchor bolt long hole pitch)

B leg part

Fan guard

687

695

115,5

780

8-ø6 hole (For fixing outdoor unit)

ø11 × 17 long hole

(For ø8-ø10 anchor bolt)

Charging port

68,5

123,8

332

Valve cover

53 53 53 53 53

86,2

Connecting pipe port

(Pipe dia.ø6,35)

Connecting pipe port

(Pipe dia.ø9,52)

Connecting pipe port

(Pipe dia.ø12,7)

4 × ø11 × 17U-shape hole (For ø8-ø10 anchor bolt)

Intake

310

100 or

For installation of the outdoor unit, open (60cm or more) two directions at least of A , B , C , and D directions.

Mounting dimensions of anchor bolt

50 or more

200 or more

Outlet

600

Outside line of product

Intake

4 × ø11 × 17 long hole (For ø8-ø10 anchor bolt)

view

250 or more

(Minimum distance from wall)

Detailed A leg part

50 36

310

296

R5,5

310

296

36 50

Detailed B leg part

600

2-ø6 hole

Outside line of product

600

R15

Outside line of product

R15

R5,5

– 16 –

Page 17

4-1. Indoor Unit

RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E

4. WIRING DIAGRAM

Table 4-1-1 Simple check points for diagnosing faults

Check items

OPERATION

INDICATOR

TERMINAL

BLOCK

FUSE

6.3A

DC 5V

DC 12V

DC 35V

(DC310 ~ 340V)

Refer to the service data for the detailed failure diagnosis.

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

Check for power supply voltage between (Check the primary and secondary voltage of transformer.) Check for fluctuate voltage between

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

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

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

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

Diagnosis result

and



– . (DC 15 ~ 60V)



. (Refer to the name plate.)



– 17 –

Color

Identification

BRW : BROWN

RED : RED

WHI : WHITE YEL : YELLOW BLU : BLUE

BLK : BLACK GRY : GRAY PNK : PINK

ORN : ORANGE

GRN : GREEN &

&YEL YELLOW GRN : GREEN

Page 18

4-2. Outdoor Unit

RAS-3M23YACV-E

ORN P10

E A ~

MODULE

–

CONVERTER

DB01

YEL

+ BU EU BV EV

BW EW

IGBT MODULE

BY BZ

–

Q200

BLU

P.C. BOARD

P09

POWER RELAY

ELECTRONIC

P19 P20

P18 P17

REACTOR

MCC-758

STARTER

POWER SUPPLY

220–230–240V~

50Hz

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

N 1 2 3 1 2 3

FAN MOTOR

PNK

YEL

RED

WHI

GRY

221

P07P08

C14C12

CN301

C15C13

RELAY

1234455 123

CN300

F03 FUSE 15A

F04 FUSE 3,15A

BLK

321 321

P06

SURGE

ABSORBER

VARISTOR

WHI

BLKBLK

F01 FUSE 25A

CN704

CN501

P11

P12 P13

P14

INDOOR

UNIT

BRW

RED

ORN

YEL

313

YEL

11 22

YEL

PUR

REDP21 WHIP22 BLKP23

INDOOR

UNIT

REACTOR

PNK ORN RED

WHI

BRW

RED

ORN

YEL

BLK

GRY

REACTOR

COMPRESSOR

INDOOR

UNIT

~ ~ ~ ~

1 2 3 4

REACTOR

THERMOSTAT for COMPRESSOR

1 2 3 4

P03 P04 P05 P06

CN15

P02 P01

FUSE 6,3A

F01

PHOTO

COUPLER

CN08

CN02

CN03

CN05

CN06

CN07

CN14

SUB

P.C. BOARD

MCC-775

CN13

CN12

1 1 2 2

1 1 2 2 3 3

1 1 2 2

1 1 2 2 3 3

6 6 5 5 4 4 3 3 2 2 1 1

ORN

BLK

GRY RED BLU ORN YEL WHI

YEL

BRW

GRN

TGa

TGb

TGc

P.M.V.

A UNIT

P.M.V.

B UNIT

P.M.V.

C UNIT

– 18 –

COLOR IDENTIFICATION

BLK : BLACK BLU : BLUE

ORN : ORANGE

GRY : GRAY PNK : PINK

SKB : SKY-BLUE

P.M.V. : PULSE MODULATING VALVE

WHI : WHITE

BRW : BROWN

RED : RED

YEL : YELLOW

PUR : PURPLE

GRN : GREEN

Page 19

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor Unit

RAS-M10YKCV-E, RAS-M13YKCV-E, RAS-M16YKCV-E

No. Parts name Type Specifications

1Fan motor (for indoor)ICF-340-30-2 DC340V, 30W 2Thermo. sensor (TA-sensor)( – )10kΩ at 25°C 3DC-DC transformer (T01) SWT-70 DC390V, Secondary DC15V, 12V, 7V

4Microcomputer ( – )

Heat exchanger sensor

(TC-sensor) 6Line filter (L01)SS11V-06270 27mH,AC0,64A 7Diode (DB01) D3SBA60 4A, 600V 8Capacitor (C03)KMH450VNSN120M25C 120µF,450V 9Fuse (F01) FCU250V3.15A T3,15A, 250V

10Power supply IC (IC01) STR-L472 11 Varistor (R21, R109) 15G561K 560V 12Resistor (R01) RF-5TK5R64,7Ω,5W 13Louver motorMP24GA Output (Rated) 1W, 16poles, 1phase DC12V

5-2. Outdoor Unit

RAS-3M23YACV-E

( – ) 10kΩ at 25°C

No. Parts name Model name Rating

1 SC coil (Noise filter)

2 DC-DC transformer SWT-43 Secondary side 7,5V x 1, 13V x 1 3 Reactor CH38Z-K L=10mH, 16A x 2

4 Outside fan motor ICF-140-40-8 DC140V, 40W 5 Fan control relay AJQ1341

Discharge temp. sensor

(TD sensor)

Outside air temp. sensor

(TO sensor)

Temp. sensor at A room

gas side (TGa sensor)

Temp. sensor at B room

gas side (TGb sensor)

Temp. sensor at C room

gas side (TGc sensor)

11 Terminal block (9P) ——— 20A, AC250V (9P x 2)

12 Fuse

13 Electrolytic capacitor 14 Transistor module 6MBI25GS-060-01 25A, 600V

15 Compressor DA130A1F-21F 3-phases 4-poles 1100W 16 Compressor thermo. PW-2AL OFF: 125 ± 4°C, ON: 90 ± 5°C 17 Converter module MP7002 Diode: 25A, 600V, IGBT: 40A, 600V 18 Reactor CH43Z-K L = 10mH, 1A x 2

SC-15-S06J 15A, 0,6mH

SC-20-01J 20A, 150µH

Primary side DC280V

Coil DC12V Contact AC125V, 3A

(Inverter attached) 62kΩ (20°C) (Inverter attached) 10kΩ (25°C) (Inverter attached) 10kΩ (25°C) (Inverter attached) 10kΩ (25°C) (Inverter attached) 10kΩ (25°C)

For protection of

switching power source

For protection of transistor

module breakage

For protection of

inverter input overcurrent

LLQ2G501KHUATF

400LISN500K35F

3,15A, AC250V 15A, AC250V 25A, AC250V 500µF, DC400V X 4 pieces

26,5V x 3, 16V x 1, 15V x 1

– 19 –

Page 20

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

C room

B room

INDOOR UNIT A

Indoor heat

exchanger

Temp. measurement

C room

B room

Connecting pipe Thickness : 0,8 mm

Ø9,52 : RAS-M10UKCV-E RAS-M13UKCV-E

Ø12,7 : RAS-M16UKCV-E

Pressure

measurement Gauge attaching port

Vacuum pump connecting port

Cross flow fan

Connecting pipe Thickness : 0,8 mm

Ø6,35

Sectional shape of heat insulator

(Ø9,52) (Ø9,52) (Ø12,7) (Ø6,35) (Ø6,35) (Ø6,35)

TGc

TGb

TGa

Allowable height

Strainer

Pulse modulating valve at liquid side (SEV15RC2)

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

OUTDOOR UNIT

Compressor DA130A1F-21F

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 charging of refrigerant is unnecessary because this air conditioner is designed with charge-less specification.

– 20 –

Page 21

6-2. Operation Data

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 1 1 42 0,85 9 47 0,73 8 50 0,96 10,5 to 11,5 49 0,92 11 to 12 51 0,92 11 to 12 51 0,92 11 to 12 51 0,92 11 to 12 51 0,92 11 to 12 51 1,04 12,5 to 13,5 51 0,98 12 to 13 52 0,98 12 to 13 52 0,98 12 to 13 52

Surface temp. of

heat exchanger

T1 (°C) T2 (°C)

Fan speed

Indoor Outdoor

High Med. 37 High High 57 High High 73 High High 69 High High 78 High High 78 High High 78 High High 78 High High 78 High High 81 High High 89 High High 89 High High 89

Compressor

revolution

(rps)

NOTE :

Model of Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E

NOTES :

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

(Thermistor themometer)

(2) Connecting piping condition : 5 meters x 3 units (5m / each unit)

– 21 –

Page 22

7. CONTROL BLOCK DIAGRAM

7-1. Indoor Unit

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

Indoor Unit Control Panel

Heat Exchanger Sensor

Functions

• Louver Control

M.C.U.

Operation

Display

Temperature Sensor

Infrared Rays Signal Receiver

Initiallizing Circuit

Infrared

Rays

Remote

Clock Frequency Oscillator Circuit

Power Supply

Circuit

Control

Noise Filter

From Outdoor Unit

• 3-minute Delay at Restart for Compressor

• Motor Revolution Control

• Processing

(Temperature Processing)

• Timer

Outdoor unit

ON/OFF Signal

Relay Driver

Relay RY04

Outdoor Unit

Louver ON/OFF Signal

Louver Driver

Timer

Display

Filter Sign

Display

Fan Only

Sign Display

Indoor Fan

Motor

Louver Motor

REMOTE CONTROL

Infrared

Rays

Remote Control

Operation (START/STOP)

Operation Mode Selection

AUTO, COOL, DRY, FAN ONLY

Temperature Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECONO.

– 22 –

Page 23

For Indoor unit

220–230–240V ~ 50Hz

MCC-775 (SUB P.C.B) MCC-758 (MAIN P.C.B)

7-2. Outdoor Unit (Inverter Assembly)

– 23 –

A unit

send/receive

circuit

Discharge temp. sensor

Gas side A, B, C pipe temp. sensor

Outdoor air temp. sensor

B unit

send/receive

circuit

C unit

send/receive

circuit

M.C.U

• Inverter output frequency control

• A/D converter function

• P.M.V. control

• Discharge temp. control

• Error display

• Signal communication to MCU

Driver circuit of P.M.V.

A unit

P.M.V.

B unit

P.M.V.

C unit

P.M.V.

M.C.U

• PWM synthesis function

• Input current release control

• IGBT over-current detect control

• Outdoor fan control

• High power factor correction control

• Signal communication to MCU

High power factor

correction circuit

Noise

filter

Input current

Sensor

Converter

DC)

(AC

Over current

detect circuit

Rotor position

detect circuit

Over current detect circuit

Gate drive

Over current

sensor

Over current

sensor

circuit

Rotor position

detect circuit

Gate drive

circuit

Inverter

(DC AC)

Inverter

(DC AC)

Outdoor

fan motor

Compressor

P.M.V. : Pulse Modulating Valve PWM : Pulse Width Modulation IGBT : Insulated Gate Bipolar Transistor

Page 24

8. OPERATION DESCRIPTION

8-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses DC motor f or the indoor fan motors and the outdoor fan motor . And the capacityproportional control compressor which can change the motor speed in the range from 13 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 control, and transfers the operation command to the outdoor unit controller.

The outdoor unit controller receives operation command from the indoor unit side, and controls the outdoor fan and the pulse modulating valv e. Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inv erter 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 re v ersely the operating status information of the outdoor unit to control the indoor unit controller.

As the compressor adopts four-pole brushless DC motor, the frequenc y of the supply po wer from inverter to compressor is two-times cycles of the actual number of rev olution.

(1) Role of indoor unit controller

The indoor unit controller judges the operation commands from the remote control and assumes the following functions.

• Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor .

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

• Louver motor control

• Indoor fan motor operation control

• LED display control

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

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

(2) Role of outdoor unit controller

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

• Compressor operation Operations followed

control

• Operation control of

outdoor fan motor

• P.M.V. control

• Detection of inverter input current and current

release operation

• Over-current detection and prev ention opera-

tion to transistor module (Compressor stop function)

• Compressor and outdoor fan stop function

when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system)

• Transferring of operation information (Serial

signal) from outdoor unit to indoor unit

• Detection of outdoor temperature and opera-

tion 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 control

• Compressor revolution command signal defined

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

• For these two types of signals ( [Operation

mode] and [Compressor revolution] ), the outdoor unit controller monitors the input current to the inverter, and perf orms the followed operation within the range that current does not exceed the allowab le value.

• T emper ature of indoor heat exchanger b y indoor

heat exchanger sensor (Minimum rev olution control)



to judgment of serial



signal from indoor side.



– 24 –

Page 25

(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 transf erring of these signals, the indoor

unit controller monitors the contents of signals, and judges existence of trouble occurrence .

Contents of judgment are described below.

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

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

outdoor unit controller, it is assumed as a trouble.

8-1-2. Current Release Control

The outdoor main circuit control section (Inverter assembly) detects the input current to the outdoor unit. If the current v alue with compressor motor speed instructed from indoor side exceeds the specified value, the outdoor main circuit control section controls compressor motor speed by reducing motor speed so that value becomes closest to the command within the limited value.

8-1-3. Power Factor Improvement Control

Po w er f actor impro v ement control is perf ormed mainly aiming to reduce the current on much power consumption of cooling operation. Controlling starts from the time when input power has reached at a certain point. To be concrete, IGBT of the power factor improv ement circuit is used, and the po wer factor is improv ed by keeping IGBT on for an arbitrary period to widen electro-angle of the input current.

8-1-1. Capacity Control

The cooling capacity is varied by changing compressor motor speed. The inverter changes compressor motor speed by changing AC 220–230–240V power to DC once, and controls capacity by changing supply power status to the compressor with transistor module (includes 6 transistors). The outline of the control is as follows: The revolution position and revolution speed of the motor are detected by detecting winding electromotive force of the compressor motor under operation, and the revolution speed is changed so that the motor drives based upon revolution speed of the operation command b y changing timing (current transfer timing) to exchange inverter output voltage and supply power winding.

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

T able 8-1-1 Compressor re volution range

8-1-4. Prevent-Freezing Control

The indoor heat exchanger sensor detects refrigerant vapor temperature in COOL/DR Y operation. If the temperature is below the specified value, compressor motor speed is reduced so that operation is performed in temperature below the specified value to prevent-freezing of indoor heat e xchanger.

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

Using P.M.V., refrigerant flow of refrigeration cycle is varied for the optimum temperature . Controlling each unit separately by three P.M.V. corresponds to difference of pipe length, fan speed, and unit temperature.

If an error occurs on cycle temperature when power source of the air conditioner has been turned on, and if start/stop times of the outdoor unit are 30 times, move the valve once until it hits on the stopper for positioning of the valve. In this case, ticktack sound may be heard.

No. of Combination of Compressor

operating unit indoor units revolution (rps)

RAS-M16UKCV-E16 to 77

1 unitRAS-M13YKCV-E16 to 72

RAS-M10YKCV-E16 to 45 2 units 3 units

: In case that any multiple indoor units are combined.

¡ ¡

* *

19 to 84 23 to 92

– 25 –

Page 26

8-1-6. Louver Control

8-1-7.Indoor Fan Control (DC Fan Motor)

(1) Vertical air flow louvers

Positions of vertical air flow louv ers are automatically controlled according to the operation status (COOL, AUTO, DR Y, FAN ONLY). Besides, positions of vertical air flow louvers can be arbitrarily set by pressing the [SET] button. The louver position which has been set by the [SET] button is stored in microcomputer , and the louv er is automatically set at the stored position in the next operation.

(2) Swing

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

FanOperation

Remote

mode mode Control

Motor speed

( rpm )

H HIGH 1190 560 1210 590 1350 670 M 1080 510 1130 530 1250 610

Cooling

and Fan

only

MED 1100 510 1130 530 1250 610

M MED 1000 460 1050 490 1150 550

LOW 960 440 990 460 1070 500

L 950 430 950 430 1050 490

+ L LOW 910 400 910 400 980 450 L 850 370 850 370 920 410

L 950 430 950 430 1050 490

L 910 400 910 400 980 450

DRY

L 850 370 850 370 920 410

UL 720 300 750 310 920 410

SUL 660 260 700 280 800 340

T able 8-1-3

RAS-M10UKCV-E

ir flow rate Motor speed

( m

/h )

The indoor fan is operated by motor speed non-step variable DC drive system motor. For flow rate, motor speed is controlled manually in three steps (LOW, MED , HIGH), and with the unit of 10 rpm from upper limit to lower limit in AUTO mode as described in Table 8-1-3. It is not selected by rela y, so selecting sound does not generate.

RAS-M13UKCV-E RAS-M16UKCV-E

ir flow rate Motor speed Air flow rate

( rpm )

( m

/h )

( rpm )

( m

/h )

NOTE : UL : Ultra Low, SUL : Super Ultra Low

8-1-8. Outdoor Fan Control (DC Fan Motor)

Although the outdoor fan motor drives the outdoor f an b y non-step v ariab le system of the re v olution speed, the revolution speed is restricted to three steps on the con v enience of controlling.

If a strong wind is lashing outside of the room, the operation may be continued as the outdoor f an stops in order to protect the outdoor fan motor.

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

T able 8-1-4

Compressor revolution (rps)

TO ≥ 38°C 500 (r pm) 800 (rpm) 800 (rpm) Outdoor temp. sensor TO

ECONO. operation 38°C > TO ≥ 15°C 500 (rpm) 500 (rpm) 700 (rpm)

TO is abnormal 700 (rpm) 700 (rpm) 800 (rpm)

38°C > TO ≥ 15°C 500 (rpm) 700 (rpm) 800 (rpm)

15°C > TO 390 (rpm) 390 (rpm) 390 (rpm)

TO ≥ 38°C 500 (r pm) 700 (rpm) 800 (rpm)

15°C > TO 390 (rpm) 390 (rpm) 390 (rpm)

17,4

38,9 39

– 26 –

Page 27

8-2. Description of Operation Circuit

• Turning [ON] the breaker flashes the oper ation lamp.

This is the display of power-ON (or notification of power failure).

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

8-2-1. Fan Only Operation

(The Remote Control MODE Button is Set to the FAN ONLY Operation)

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

• When the FAN button is set to the AUTO position, the indoor fan motor operates as shown in Fig. 82-1. When the F AN SPEED b utton is set to LOW, MED, or HIGH, the motor operates with a constant air flow .

• ECONO. mode cannot be set.

8-2-2. Cooling Operation

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

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

• A cooling operation signal is transmitted to outdoor unit.

• The indoor fan motor operates as shown in Fig.82-2 when F AN button is set to AUT O.

• The motor operates with a constant air flow when the FAN button is set to LOW, MED , or HIGH.

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

˚C

(Room temp.) – (Set temp.)

Set temp.

+3 +2,5 +2 +1,5 +1 +0,5 0

(Set temp.) 25˚C

M+ *1 *1 *1 L–

NOTE :

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

and L–, and controlled.

Fig. 8-2-1 Auto setting of air flow

˚C

M+ *1 *1 *1

L–

In normal operation

Set temp.

+2,5 +2 +1,5 +1

(Room temp.) – (Set temp.)

+0,5 0 –0,5

NOTE :

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

and L–, and controlled.

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

– 27 –

Page 28

(1) Cooling capacity control

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

• When compressor has been activated or reactivated, it operates with Max. 33 rps for 2 minute, with Max. 57 rps from 2 to 4 minutes, with Max. 91 rps from 4 to 7 minutes, and with Max. 92 rps after 7 minutes passed.

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

(2) Prevent-freezing control

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

(3) Current release control

The input current of compressor and outdoor fan motor (Precisely inverter main circuit control section) which occupy most of air conditioner input is detected by the outdoor current sensor , and compressor motor speed is gradually lowered so that current value does not e xceed

I1A if current value exceeds I1A. When the

current value lowers to I2A, return the operation to the above item (1).

Comp. motor

speed down

(4) Outdoor temperature release control

The outdoor temperature release is controlled by changing the current release points I1 and I2 in the above item according to temperature detected by the outdoor temperature sensor .

For e xample, if the outdoor temper ature is ov er 40°C, the value of current release point becomes 7,7A.

(5) Limit for maximum compressor motor speed

by indoor fan speed

When outdoor temperature sensor detected 32°C or lower , and indoor heat exchanger sensor detected 17°C or lower , the maximum compressor motor speed is limited by the indoor fan speed.

For e xample, when 1 unit only oper ates , the compressor motor speed is limited as described in the table below.

T able 8-2-2

Air flowM10UKCV-EM13UKCV-EM16UKCV-E

rate (rps) (rps) (rps)

HIGH 45 72 77

M+ 42 59 66

MED. 34 40 54

L–, L 31 31 43

UL, SUL 31 31 31

(6) Louver control

The vertical air flow louvers are automatically set to horizontal or cool memory position.

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

Comp. motor

Current value (A)

Normal control

speed keep

Fig. 8-2-3

T able 8-2-1

Current value Current limit

I1 9.5 I2 9,0

(7) Discharge temperature control

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

1) Control 1 (A zone) : Normal operation zone When TD detect value is 101°C or lower, the

operation is performed with operating motor speed instructed by the serial signal.

2) Control 2 (B zone) : Slow-up z one of motor speed

When TD detect v alue is 101°C or higher, operating motor speed is slowly up.

– 28 –

Page 29

3) Control 3 (C zone) : Keep zone When TD detect v alue is 108°C or higher,

operating motor speed is not changed if raising operation speed.

4) Control 4 (D zone) : Slo w do wn zone of motor speed

When TD detect v alue is 111°C or higher, operating motor speed is slowly down.

(˚C) 120

115 111

Zone

F E D

Operation stop zone Normal down zone of motor speed

Slow down of motor speed

5) Control 5 (E zone) : Normal down of motor speed

When TD detect v alue is 115°C or higher, operating motor speed is down.

6) Control 6 (F zone) : Oper ation stop zone If TD detect v alue exceeds 120°C during

operation, stop the operation immediately. Then, restart the operation when TD detect

value becomes 108°C or lower.

Release of motor speed

108

101

Fig. 8-2-4 Compressor motor speed contr ol

(8) ECONO. operation control

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

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

Compressor motor speed

3,5 3

Keep zone : Motor speed is not changed.

Slow-up zone of motor speed

Normal operation zone

2)Setting M10UKCV-E at 16 rps, M13UKCV-E at 20 rps and M16UKCV-E at 26 rps as the maximum operating compressor motor speed, the minimum capacity operation range is widened every 1 hour and 2 hours hav e passed after ECONO. operation had started.

3) Maximum operating compressor motor speed lowers up to 37 rps when the ECONO. instruction is sent from even a room.

1 unit

Air volume

M13UKCV-EM16UKCV-EM10UKCV-E

20 rps16 rpsL–

16 to 20 rps

26 rps

16 to 26 rps

2 units 3 units

37 rps

19 to 37 rps

23 to 37 rps16 rps(L– + SUL)/2

37 rps

2,5 2 1,5 1

(Room temp.) – (Set temp.)

0,5

Time2H1H

16 rps 16 rps 19 rps 23 rps16 rpsSUL

Fig. 8-2-5

– 29 –

Page 30

Outdoor temp. (˚C)

Powerful Cool mode

Cool mode

Fan Only mode

8-2-3. DRY Operation

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

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

• Dry operation signal is transmitted to outdoor unit.

• The Cooling operation giving priority to dehumidifying, which restrains the indoor fan speed and compressor motor speed, is performed.

• The indoor fan motor operates as shown in Fig. 8-2-6. (Fan speed is AUTO only.)

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

• When the air conditioner operates in Dry mode, the maximum compressor motor speed is restricted.

M10UKCV-E : Max. 22 rps M13UKCV-E : Max. 28 rps M16UKCV-E : Max. 32 rps

While multiple indoor units operate, compressor motor speed is calculated in the outdoor unit to operate.

• When room temperature is lower than set temperature, indoor fan motor is oper ated at fan speed SUL as shown in Fig. 8-2-6 while the outdoor unit stops.

• ECONO. mode cannot be set.

• Other controls than the above-mentioned controls are common to those of Cooling operation.

8-2-4. Auto Operation

+2,5

(Room temp.) – (Set temp.)

Set temp.

+2,0

+1,5

+1,0

+0,5

–0,5

L–

SUL

NOTE :

*1 : Middle motor speed between L– and SUL

Fig. 8-2-6 Setting of air flow

(1) Dehumidifying-preferential Cooling capacity

control

• The compressor operates with maximum 28 rps for 1 minute when started and restarted.

• The operation mode is selected according to the outdoor temperature when Auto operation has started, as shown in Fig. 8-2-7. The Fan only mode will continue until the operation mode is selected. The air flow display on the remote control becomes AUT O.

Fig. 8-2-7

• If the compressor is turned off by room temperature or outdoor temperature for 15 minutes consecutively after operation mode has been selected, the operation mode is selected again.

• In Powerful Cool mode, the louver directs downward, and air flow increases. When room temperature comes close to the set temperature, the louver returns to Cooling operation position.

• The other controls than the above-mentioned controls follow that of each operation.

– 30 –

Page 31

8-3. Temporary Operation

8-3-1. Temporary Auto Operation

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

TEMPORARY button

Fig. 8-3-1

T able 8-3-1

TEMPORARY button Control

→→

OFF

→ ON Temporary Auto operation start

→→

After pushing button

for 3 seconds

Auto Restart control select

• When the TEMPORARY button is pushed, the Auto operation with set temperature fixed at 24°C starts. Controlling is same as that of Auto operation by the remote control.

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

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

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

8-3-2. Temporary Cooling Operation

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

Compressor motor speed : 28 rps Indoor fan speed : Lo w

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

• Auto Restart function is unavailable.

After pushing button Temporary Cooling

for 10 secondsoperation start

– 31 –

Page 32

8-4. Auto Restart Function

8-4-1. How to Set the Auto Restart

This unit is equipped with an Automatic restarting facility which allows the unit to restart and resume the set operating conditions in the event of a po wer supply shutdown without the use of the hand control.

The operation will resume without warning three minutes after the power is restored.

The Auto Restart function is set not to work on shipment from the factory, and so it is necessary to set it to function as required.

• When the system is stand-by (not operating)

Operation

Push the TEMPORARY button continuously more than three seconds.

Stand-by

↓

The system starts to operate. The green light goes on.

↓ about three seconds after

The unit beeps three times. The orange light goes on.

↓

The system is operating. If the system is not required to run at this time, push the TEMPORARY

TEMPORARY button

button once more or use the remote control and the unit will stop.

To set the Auto Restart function, proceed as follows: Access the TEMPORARY button located in the lower

right hand corner beneath the hinged front panel of the indoor unit (please refer to Fig. 8-3-1). The power supply to the unit must be on - the function will not be set if the power is off.

To enable the Auto Restart function, push the TEMPORARY b utton continuously f or three seconds.

The unit will acknowledge the setting and beep three times. The system will now restart automatically .

The above A uto Restart settings can be carried out:

Motion

• When the system is operating

Operation

Push the TEMPORARY button continuously more than three seconds.

Operating The green light goes on.

↓

The system stops to operate. The green light goes off.

↓ about three seconds after

The unit beeps three times.

The system stops.

↓

If the system is not required to stop at this time, use the remote control

TEMPORARY button

and to restart.

During subsequent operation, the orange light goes on.

• The Auto Restart function will not accept an instruction if timer operation with the remote control is selected.

Motion

• During louver swing (A UTO) operation, after restart by the Auto Restart function the louver swing stops.

– 32 –

Page 33

8-4-2. How to Cancel the Auto Restart

To cancel the Auto Restart function, proceed as follows:

Repeat the setting procedure: the unit will acknowledge the instruction and beep three times.

• When the system is stand-by (not operating)

The system will now be required to manually restart with the remote control after the main supply is turned off.

Cancellation is carried out:

Operation

Push the TEMPORARY button continuously more than three seconds.

TEMPORARY button

• When the system is operating

Operation

Push the TEMPORARY button continuously more than three seconds.

TEMPORARY button

Motion

Stand-by

↓

The system starts to oper ate . The orange light goes on.

↓ about three seconds after

The unit beeps three times. The green light goes on.

↓

The system is operating. If the system is not required to run at this time, push the TEMPORARY

button once more or use the remote control and the unit will stop.

Motion

Operating The orange light goes on.

↓

The system stops to operate. The orange light goes off.

↓ about three seconds after

The unit beeps three times.

↓

The system stops. If the system is not required to stop at this time, use the remote control

and to restart.

During subsequent operation, the green light goes on.

8-4-3. In Case of Power Failure during the

Timer Operation

(1) If ON-TIMER operation is reserved with setting

of Auto Restart operation, it is cancelled with power failure . (The OPERATION lamp on the main unit goes on and off to inform of power failure.) In that case, try to reserve ON-TIMER operation once again.

(2) If OFF-TIMER operation is reserved without

setting of Auto Restart operation, the reservation is cancelled with power failure. (The OPERATION lamp on the main unit goes on and off to inform of power failure .) In that case, try to reserve OFF-TIMER operation. When Auto Restart operation is set, OFF-TIMER reservation is also cancelled with power failure.

– 33 –

Page 34

8-5. Remote control

8-5-1. Remote control and its functions

RAS-M10UKCV, RAS-M13UKCV, RAS-M16UKCV

1 Infrared signal emitter

Transmits a signal to the indoor unit.

2 START/STOP button

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

3 Mode select button (MODE)

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

: Heat,

: Fan only, and back to A.

(A receiving beep is heard.)

4 Temperature button (

The set temperature is increased up to 30°C.

,.......

9.......

The set temperature is dropped down to 17°C. (A receiving beep is heard.)

5 Fan speed button (FAN)

Press this button to select fan speed. When you select AUTO, the fan speed is automatically adjusted according to the room temperature. You can also manually select the desired fan speed from among five settings.

(LOW

MED

, LOW

, HIGH

, MED

(A receiving beep is heard.)

6 Auto louver button (SWING)

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

7 Set louver button (FIX)

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

8 Off timer button (OFF)

Press this button to set the OFF timer.

9 On timer button (ON)

Press this button to set the ON timer.

! Reserve button (SET)

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

" Cancel button (CLR)

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

# High power button (Hi POWER)

Press this button to start the high power operation.

: Dry,

)

$ Memory button (MEMO)

Press this button to stand by memorizing the settings. Press the button again for more than 4 seconds to memorize the setting indicated on the remote control and

% Automatic operation button (AUTO)

mark is indicated.

Press this button to operate the air conditioner automatically. (A receiving beep is heard.)

& ECO timer button (ECO)

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

((

( FILTER button

((

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

))

) PRESET button

))

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

~ TIMER button

Use this button to change the clock, ON timer, and OFF timer times. To forward the time, press the “TIMER

To set back the time, press the “TIMER

AUTOA

A B

START/STOP

FAN MODE

SWING

FIX

OFF SET CLR

FILTER

ECO

TIMER

PRESET

AUTO

Hi-POWER

MEMO

CLOCK CHECKRESET

” button.

– 34 –

Page 35

8-5-2. Names and functions of indications on remote control Display

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

1 Transmission mark

This transmission mark (,) indicates when the remote control transmits signals to the indoor unit.

2 Mode display

Indicates the current operation mode. (AUTO : Automatic control, A : Auto changeover control, : Cool,

: Dry, : Heat,

3 Temperature display

: Fan only)

Indicates the temperature setting (17°C to 30°C). When you set the operating mode to

: Fan only, no temperature

setting is indicated.

4 Louver operation display

AUTOA

A B

Indicates the louver positioning and operation. Five selectable positions

5 FAN speed display

,,,,

Automatic Swing

Indicates the selected fan speed. AUTO or one of five fan speed levels

(LOW

, LOW

, MED

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

6 TIMER and clock time display

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

7 Hi POWER display

, HIGH

: Dry.

)

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

Indicates when the Hi POWER operation starts. Press the Hi POWER button to start and press it again to stop the operation.

(MEMORY) display

A B

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

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

9 ECO TIMER display

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

– 35 –

Page 36

9. INSTALLATION PROCEDURE

9-1. Safety Cautions

For general public use

Power supply cord of parts of appliance for Outdoor use shall be more than polychloroprene sheathed flexible cord (design H07RN-F), or cord designation 245IEC66. (1.5 mm

or more)

CAUTION

• THIS AIR CONDTIONER ADOPTS THE NEW HFC REFRIGERANT (R-410A) WHICH DOES NOT DESTROY OZONE LAYER.

R-410A refrigerant is apt to be affected by impurity such as water , oxidizing membrane, and oils because pressure of R-410A refrigerant is approx. 1,6 times of refrigerant R-22. Accompanied with adoption of the new refrigerant, refrigerating machine oil has been also changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating machine oil does not enter into the refrigerating cycle or new-refrigerant air coditioner. To prevent mixin of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port of the main unit or installation tools are different from those for the coventional refrigerant. Accordingly, the exclusive tools are required for the new refrigerant (R-410A) as shown below. For conecting pipes, use new and clean piping materials with high pressure-tight force, which were made fro R-410A only, so that water or dust does not enter. Moreover, do not use the existing piping because there are problems about pressure-tight forec and inner impurity in the existing piping.

CAUTION

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

The installation fuse (25A D type (RAS-13UKV-E only)

New Refrigerant Air Conditioner Installation

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY.

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

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 BY WRONG WAY, ELECTRIC PARTS MAY BE DAMAGED.

• CHECK THE EARTH WIRE 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 OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC.

• WHEN MOVING THE AIR-CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT TO GET THE SPECIFIED REFRIGERANT WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CYCLE. IF AIR OR ANY O THER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CYCLE BECOMES ABNORMALLY HIGH AND IT RESULTINGLY CAUSES BURST OF THE PIPE AND INJURIES ON PERSONS.

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

WARNING

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

• Do not install in a place which cannot bear the weight of the unit.

Personal injury and property damage can result if the unit falls.

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

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

CAUTION

• Exposure of unit to water or other moisture before installation will result in an electrical short. Do not store in a wet basement or expose to rain or water.

• After unpacking the unit, examine it carefully for possible damage.

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

noise and discharged air might disturb neighbors.

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

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

– 36 –

Page 37

9-1-1. Installation/Servicing Tools

Changes in the product and components

In the case of an air condition using R-410A, in order to prevent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads per inch)

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

New tools for R-410A

New tools for R-410A Applicable to R-22 model Changes

As pressure is high, it is impossible to measure by means of conventional gauge .

Gauge manifold

Charge hose

Electronic balance for refrigerant charging

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

Flare tool (clutch type)

Gauge for projection adjustment

Vacuum pump adapter

Gas leakage detector

In order to prevent any other refrigerant from being charged, each port diameter has been changed.

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

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

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

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

Used when flare is made by using conventional flare tool. Connected to conventional vacuum pump. It is necessary to use an adapter to

prevent vacuum pump oil from flowing back to the charge hose. The charge hose connecting part has two ports-one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R-410A a sludge may occur and damage the equipment.

Exclusive for HFC refrigerant.

• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R-410A) and protector coating in the U.S's ARI specified rose color (ARI color code: PMS 507).

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

– 37 –

Page 38

9-2. Indoor unit

RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16

UKCV-E

Zeolite filter

Before installing the wireless remote control

• With the remote control cover open, load the batteries supplied correctly, observing their polarity.

2 Wireless remote control

Cover

170 mm

or more

Air filter

(Attach to the front panel)

Purifying filter

Wireless remote

control

Hook

Flat head wood screw

Remote control holder

Hook

65 mm or more

Installation

plate

Shield pipe

170 mm

or more

For the rear left and left piping

Wall

Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better operation.

Do not allow the drain hose to get slack.

Cut the piping hole sloped slightly

Make sure to run the drain hose sloped downward.

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

3 Batteries

Insulate the refrigerant pipes separately with insulation, not together.

6 mm thick heat resisting polyethylene foam

9-2-1. Accessory and Installation Parts

Part

No.

Part name (Q'ty)

Installation plate x 1

Wireless remote control x 1

Battery x 2

Others

Name

Owner's manual

Installation manual

This model is not equipped with an extension drain hose.

Option :

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

Part

No.

Part name (Q'ty)

Remote control holder x 1

Zeolite filter x 1

Purifying filter x 1

Right

Part

No.

Rear right

Rear left

Bottom right

Part name (Q'ty)

Mounting screw ∅4 x 25 s x 6

Flat head wood screw ∅3.1 x 16 s x 2

B Label x 1

Left

Bottom left

– 38 –

Page 39

9-2-2. Installation Place

∅65 mm

100 mm

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

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

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

•

A place which allows the front panel to be opened.

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

CAUTION

• Direct sunlight to the indoor unit wireless receiver should be

avoided.

• The microprocessor in the indoor unit should not be too close to

r-f noise sources. (For details, see the owner's manual.)

Remote controller

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

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

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

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

Remote

control

(Top view)

Indoor unit

Reception range

* : Axial distance

Fig. 9-2-1

5 m

45°

5 m

45°

Remote control

* 7 m

(Side view)

7 m

Indoor unit

75°

Reception range

9-2-3. Cutting a Hole and Mounting Installation Plate

Cutting a Hole

When install the refrigerant pipes from the rear.

Mounting the Installation Plate

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

Anchor bolt holes

82.5

Installation plate

170

Pipe hole

Indoor unit

Hook

Thread

Weight

Hook

Mounting screw

Pipe hole

Fig. 9-2-3

When the installation plate is directly mounted on the wall

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

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

3. Install the installation plate horizontally in the wall.

CAUTION

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

Anchor bolt

5 mm dia. hole

Clip anchor (local parts)

7 Mounting

screw ∅4 x 25 s

Fig. 9-2-4

Projection 15 mm or less

2 m or more from floor

Pipe hole

The center of the pipe hole is above the arrow.

Fig. 9-2-2

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

NOTE

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

CAUTION

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

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

• Insert clip anchors for appropriate 7 mounting screws.

NOTE

• Install the installation plate using 4 to 6 pieces of mounting screw securing four corners with screws.

9-2-4. Electrical Work

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

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

NOTE

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

– 39 –

Page 40

CAUTION

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

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

(2) Connection with power supply plug :

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

NOTE

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

9-2-5. Wiring Connection

How to connect the connecting cable

Wiring of the connecting cable can be carried out without removing the front panel.

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

2.Remove the terminal cover and cord clamp.

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

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

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

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

7.Secure the connecting cable with the cord clamp.

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

9-2-6 Piping and Drain Hose Installation

Piping and Drain Hose Forming

* Since dewing results in a machine trouble, make sure to insulate both

the connecting pipes. (Use polyethylene foam as insulating material.)

Rear right

Rear left

Bottom left

Changing

Left

Bottom right

Right

Die-cutting

Front panel slit

drain hose

Piping preparation

1. Die-cutting Front panel slit

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

2. Changing drain hose

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

How to remove the Drain Cap

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

CAUTION

• Be sure to refer to the wiring system diagram labeled inside the

front panel.

• Check local electrical cords and also any specific wiring instruc-

tions or limitations.

Cord clamp Teminal block

Screw

Earth wire

Connecting cable

80 mm

10mm

3 2

10mm

50 mm

Earth line

Terminal cover

Screw

NOTE

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

Connecting cable

about

Fig. 9-2-6

How to install the Drain Hose

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

Heat insulator

Drain hose

Fig. 9-2-7

How to fix the Drains Cap

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

4 mm

Fig. 9-2-8

2)Firmly insert drains cap.

No gap

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

Insert a hexagon wrench (4 mm)

Fig. 9-2-9

Fig. 9-2-5

CAUTION

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

– 40 –

Page 41

In case of right or left piping

• After scribing slits of the front panel with a knife or a making-off pin, cut them with a pair of nippers or an equivalent tool.

Slit

Fig. 9-2-10

In case of bottom right or bottom left piping

• After scribing slits of the front panel with a knife or a making-off pin, cut them with a pair of nippers or an equivalent tool.

Slit

Fig. 9-2-11

Left-hand connection with piping

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

Bend the connection pipe within a radius of 30 mm (Ø6.35) 40 mm (Ø9.52).

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

(To the forefront of flare)

270 mm

170 mm

R30 or less (Ø6.35) R40 or less (Ø9.52) (Use polisin (polyethylene core or the like for bending pipe.)

43 mm

Liquid side

Gas side

Outward form of indoor unit

9-2-6 Indoor Unit Fixing

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

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

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

Hook

Hook here

Installation plate

Press

(unhook)

Fig. 9-2-14

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

Push

Fig. 9-2-15

9-2-7 Drainage

1.Run the drain hose sloped downwards.

NOTE

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

Do not rise the drain hose.

Do not form the drain hose into the waved shape.

Use the handle of screwdriver, etc.

Fig. 9-2-12

NOTE

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

CAUTION

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

Indoor unit

Auxiliary pipes

Installation plate

Fig. 9-2-13

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

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

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

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

Connecting cable

50 mm or more

Do not put the drain hose end into water.

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

Fig. 9-2-16

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

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

Shield pipe

Inside the roomDrain hose

Extension drain hose

Fig. 9-2-17

CAUTION

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

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

Space for pipes

Fig. 9-2-18

Wall

Drain guide

– 41 –

Page 42

9-2-8. Setting of Remote Controller Selector

Switch

When two indoor units are installed in the separated rooms, there is no need to change the select switches.

Remote Controller Selector Switch

• When two indoor units are installed in the same room or adjacent two rooms, if operating a unit, two units may receive the remote controller signal simultaneously and operate. In this case, the operation can be preserved by setting either one indoor unit and remote controller to B setting (Both are set to A setting in factory shipment).

• The remote control signal is not received when the settings of indoor unit and remote controller are different.

• There is no relation between A setting/B setting and A room/B room when connecting the piping and cables.

(1) Stop the operation of the air conditioner and turn

turn off its main power supply.

(2) Pull the air inlet grille toward you to open it and remove the air inlet grille.

(3) First open the horizontal louver and then remove

the front panel from the back body by pulling it toward you.

Position of Remote Control Selector Switch

1. Setting of remote controller switch at the indoor unit side

How to remove the front cabinet

Fig. 9-2-20

How to mount the front panel

Push the front panel back in and make sure all hook are locked.

Adhesion of B label (When setting to [B])

Be sure to affix the B label on the front panel same as the below figure.

Fig. 9-2-19

Fig. 9-2-21

– 42 –

Page 43

2. Setting of remote controller selector at the remote controller side

[B] of the remote controller is displayed with liquid crystal only when it is set to [B].

There is no display of [A].

• Enter the batter.

• Push the [CHK] button by something with thin

edge. ([00] is displayed.)

INFORMATION

• If [MODE] button is pushed while pushing [CHK]

button, the small [B] is displayed at the right of the setting temperature indication section.

To reset [A] setting, push the [MODE] button

again while pusing the [CHK] button.

3. Confirm the indoor unit can operate with the changed setting of the remote controller.

9-2-9. Check and Test Operation

¨ 1. Check the unit is firmly hooked up on the

installation plate.

¨ 2. Check the connecting pipes tightened

securely. Confirm that there is no gas leakage.

¨ 3. Confirm that all connecting cables are

secured and correct.

¨ 4. Check the pipes insulation. ¨ 5. Check the drainage. ¨ 6. Connection of the grounding wire. ¨ 7. To switch the TEST RUN (COOL) mode, turn

the switch on. To switch the TEST RUN (COOL) mode,

press TEMPORARY button for 10 sec. (The beeper will make a short beep.)

MODE button

The above remote controller is one for cooling

only model.

PRESET

START/STOP

AUTO

MODE

FAN

SWING

FIX

ON OFF SET CLR

FILTER

ECO

TIMER

Hi-POWER

MEMO

CLOCK CHECKRESET

Fig. 9-2-22

[CHK] button

TEMPORARY button

Fig. 9-2-23

¨ 8. Operate the unit at cooling operation mode

for fifteen minutes or more . Measure the temperature of the intake and

discharge air. Ensure the difference between the intake temperature and the discharge one is more, than 8°C.

NOTE: Three-minutes protection feature

A protection feature prevents the air conditioner from being activated for about 3 minutes when it is restarted immediately after operation or when the power switch is turned on.

¨ 9. Check the remote controller operation.

When finished the check and test operation, make sure to return to REMOTE CONTROLLER. (Push the temporary switch with once again.)

¨ 10. Explain to the customer on the correct usage

of air conditioner simple layman’s terms.

– 43 –

Page 44

9-3. Outdoor Unit

CAUTION

9-3-1. Accessory and Installation Parts

Owner's manual x 1

Outdoor unit installation manual x 1

TIO

Specifications x 1

9-3-2. Refrigerant Piping

• Piping kit used for the conventional refrigerant

cannot be used.

• Use copper pipe with 0.8 mm or more thick-

ness.

• Flare nut and flare works are also different from

those of the conventional refrigerant. Take out the flare nut attached to the main unit of the air conditioner, and use it.

9-3-3. Installation Place

• A place which provides the spaces around the

outdoor unit.

• A place where the operation noise and discharged

air do not disturb your neighbors.

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

• A place which does not block a passage.

• When the outdoor unit is to be installed in an

elevated position, be sure to secure its feet.

• There must be sufficient spaces for carrying the

unit into and out of the site.

• A place where the drain water does not raise any

problem.

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

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

3. Specially in windy area, install the unit to prevent the admission of wind.

Strong wind

Fig. 9-3-1

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

• A place full of machine oil.

• A place full of sulfide gas.

• A place where high-frequency waves are

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

9-3-4. Optional Installation Parts

(Local Supply)

Parts name

Refrigerant piping

Liquid side : Ø6.35 mm Gas side : Ø9.52 mm or Ø12.7 mm

Pipe insulating material (polyethylene foam, 6 mm thick)

Putty, PVC tapes

Each one

9-3-5. Optional Installation Parts

(Separate Sold)

Parts name

RB-M43RE Reducer (Ø12.7 → Ø9.52) RB-M34EE Expander (Ø9.52 → Ø12.7)

Q’ty

– 44 –

Page 45

9-3-6. Refrigerant Piping Connection

CAUTION

KEEP IMPORTANT 4 POINTS FOR PIPING WORK

1. Take away dust and moisture . (Inside of the connecting pipes)

2. Tight connection (between pipes and unit)

3. Evacuate the air in the connecting pipes using VACUUM PUMP.

4. Check gas leak. (connected points)

Flaring

1. Cut the pipe with a pipe cutter.

• Flaring siz e : A (Unit : mm)

Outer dia. of copper pipe

6.35

9.52

12.7

In the case of flaring for R410A with the conven-

tional flare tool, pull out it approx.

R410A R22

0.5 mm more than that for R22 to

- 0.4

9.1 9.0

13.2 13.0

16.6 16.2

adjust to the specified flare size. The copper pipe gauge is useful for adjusting projection margin size.

Fig. 9-3-4

9-3-7. Installation

NOTE : For installation, at least 3 dimensions should

be kept free from obstacles (walls).

90˚

Obliquity Roughness Warp

Fig. 9-3-2

2. Insert a flare nut into the pipe, and flare the pipe. As the flaring sizes of R410A differ from those of

refrigerant R22, the flare tools newly manufactured for R410A are recommended.

However, the con ventional tools can be used by adjusting projection margin of the copper pipe.

Fig. 9-3-3

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

Rigid (Clutch type)

Outer dia. of

copper pipe

6.35

9.52

12.7

R410A tool used

R410A R22

0 to 0.5 (Same as left) 0 to 0.5 (Same as left) 0 to 0.5 (Same as left)

Conventional tool used

R410A R22

1.0 to 1.5 0.5 to 1.0

100mm or

10. HOW TO DIAGNOSE THE TROUBLE

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

Table 11-1

No.

1 2 3 4 5 6 7 8 9

First Confirmation Primary Judgment Judgment by Flashing LED of Indoor Unit Self-Diagnosis by Remote Controller (Check Code) Judgment of Trouble by Every Symptom Trouble Diagnosis by Outdoor LED How to Diagnose Trouble in Outdoor Unit How to Check Simply the Main Parts How to Simply Judge Whether Outdoor Fan Motor is Good or Bad

Troubleshooting Procedure

NOTE :

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

Page

51 51 52 53 56 62 63 64 70

< Discharging method >

(1) Remove the inverter cover (plating) b y opening

four mounting claws.

(2) As shown below, connect the discharge

resistance (approx. 100Ω/40W) or plug of the soldering iron to voltage between + – terminals of the C13 (“CAUTION HIGH VOLT AGE 320V” is indicated.) electrolytic capacitor (760µF/400V) on P.C. board, and then perform discharging.

Discharging position (Discharging period 10 seconds or more)

Fig. 11-1

Plug of soldering iron

Inverter cover

P. C. board (Soldered surface)

– 50 –

Page 51

10-1. First Confirmation

10-1-1. Confirmation of Power Supply

Confirm that the power breaker operates (ON) normally.

10-1-2. Confirmation of Power Voltage

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

Table 10-1-1

10-1-3. Operation Which is not a Trouble

(Program Operation)

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

No.

Operation of air conditioner

When power breaker is turned “ON”, the operation lamp (Green) of the indoor unit flashes.

Compressor may not operate even if the room temperature is within range of compressor-ON.

In DRY and ECONO. mode, FAN (air flow) display does not change even though FAN (air flow select) button is operated.

Increasing of compressor motor speed stops approx. 30 seconds after operation started, and then compressor motor speed increases again approx. 30 seconds after.

The set value of the remote control should be below the room temperature.

Description

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

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

The air flow indication is fixed to [AUTO].

For smooth operation of the compressor, the compressor motor speed is restricted to Max. 33 rps for 2 minutes and Max. 57 rps for 2 minutes to 4 minutes, respectively after the operation has started.

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

10-2. Primary Judgment

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

Firstly use the method (1) for diagnosis. Then, use the method (2) or (3) to diagnose the details of troubles. For any troub le occurred at the outdoor unit side, detailed diagnosis is possible by 5-serial LED on the inverter

P.C. board.

– 51 –

Page 52

10-3. Judgment by Flashing LED of Indoor Unit

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

Table 10-3-1

Lamps Self-diagnosis

A OPERATION lamp is blinking. (1Hz) B OPERATION lamp is blinking. (5Hz) C OPERATION lamp is blinking. (5Hz) D OPERATION lamp is blinking. (5Hz) E OPERATION lamp is blinking. (5Hz) F OPERATION and TIMER lamps are blinking.

(5Hz)

G OPERATION, TIMER and FAN ONLY lamps

are blinking.

H OPERATION, TIMER and FAN ONLY lamps

are blinking.

Power failure (when the power supply is turning on) Thermo sensor (TA) short or break Heat exchanger sensor (TC) short or break Indoor fan motor lock or failure Indoor P.C. board failure Wrong wiring of connecting cable

• Gas shortage or other refrigerant cycle trouble

• Heat exchanger sensor open, break or short

• Overload relay or thermostat trouble of compressor

Cycle failure

NOTES:

(1) The contents of items B and C and a part of item E are displayed when air conditioner operates. (2)

When item B and C, and item B and a part of item E occur concurrently, priority is given to the block of item B.

(3) The check codes can be confirmed on the remote controller for servicing.

(4) When connecting the changing kit, first-push priority control is executed. The secondary operation lamp

continues flashing. For details, refer to the section 10. Changing Kit.

– 52 –

Page 53

10-4. Self-Diagnosis by Remote Control

(Check Code)

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

11-3-1, exchanger the self-diagnosis by the remote control.

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

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

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

usually blinks (5Hz) during the self-diagnosis.

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

SET CLR

CLOCK CHECKRESET

AUTOA

A B

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

the remote control to the service mode.

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

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

START/STOP

FAN MODE

SWING

ECO

TIMER

FIX

OFF SET CLR

FILTER

PRESET

AUTO

Hi-POWER

MEMO

CLOCK CHECKRESET

(2) Press [TIMER 8] button.

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

; 00 ; 01 ; 02 ··· 1d ; 1E ; 22

• Check the unit with all 35 check codes (00 to

22). as shown in Table 10-4-1.

• Press [TIMER 9] button to change the check code backwards.

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

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

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

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

service code in memory.

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

• Alphanumeric characters are used for the check code.

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

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

mode.

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

– 53 –

Page 54

10-4-2. Operation Control by Rated Frequency in Service Mode

In the service mode, pushing “ON” or “OFF” operates the air conditioner by rated frequency of COOL mode for 30 minutes.

10-4-3. Caution at Servicing

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

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

Table 10-4-1

Block distinction

Check

code

Block

Indoor P.C. board etc.

Not displayed

Connecting cable and serial signal

Check

code

Operation of diagnosis function

Cause of operation

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

Coming-off, disconnection, short-circuit, or migration of heat exchanger sensor (TC sensor)

Lock of indoor fan or trouble on the indoor fan circuit

Trouble on other indoor P.C. boards

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

connecting cable

(2) Operation of

compressor thermo. Gas shortage Gas leak

Air

conditioner

status

Operation continues.

All off

Operation continues.

Condition

Displayed when error is detected.

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

Judgment and action

1. Check the room temp. sensor.

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

1. Check heat exchanger sensor.

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

1. Check P.C. board.

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

Replace P.C. board.

1. When the outdoor unit never operate:

(1) Check connecting cable, and

correct if defective wiring.

(2) Check 25A ( or 30A) fuse (F01)

of outdoor main P.C. board.

(3) Check 3.15A fuse (F04) of

outdoor main P.C. board.

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

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

Operation command signal is not sent to outdoor side.

Operation continues.

– 54 –

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

If Operation command signal does not stop between indoor terminal board 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal board 2 and 3, replace indoor P.C. board.

Page 55

Block distinction

Operation of diagnosis function

Check

code

Block

Outdoor P.C. board

Check

code

Cause of operation

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

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

Current-detect circuit error

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

Disconnection or shortcircuit of discharge temp. sensor

Outdoor fan drive system error

Air

conditioner

status

All off

Remarkes

Displayed when error is detected.

Judgment and action

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

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

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

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

Check 5-serial LED.

1. Check P.C. board.

1. Check discharge temp. sensor (TD).

2. Check P.C. board.

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

Not displayed

Outdoor P.C. board

Others (including compressor)

Outdoor temp. sensor error

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

Error exclusive for multiple type

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

Discharge temp. exceeded 120°C.

Break down of compressor

Operation continues.

All off

——

Displayed when error is detected.

1. Check outdoor temp. sensor (TO).

2. Check P.C. board.

Check 5-serial LED. When 20 seconds passed after start-up, position-detect circuit error occurred. : Replace compressor.

Check 5-serial LED.

1. Miswiring of connecting wire of A/B/ C/D rooms in indoor/outdoor units

2. Check gas leakage.

3. Check disconnection of sensor.

4. Electronic control valve error

1. Trouble on compressor

2. Trouble on wiring of compressor (Missed phase)

1. Check dischage temp. sensor (TD).

2. Degassing

3. Trouble on P.M.V.

1. Check power voltage. (220–240 V ±10%)

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

– 55 –

Page 56

10-5. Judgement of Trouble by Every Symptom

10-5-1. Indoor unit (Including remote controller)

(1) Power is not turned on (Does not operate entirely)

supply once, and 5 second later, turn it

Is fuse (F01)

of indoor control

board blown?

Turn off power

on again.

Is OPERATION

lamp blinking?

YES

Is it possible to

turn on power

supply by

pressing

[START/STOP]

button on

remote control?

YES

(R04, C01,

DB01, C03, R01

IC01 and T01)

are defective.

Parts

Does

transmission

mark on remote control flash normally,

and is its signal

transmitted

properly?

YES

Does

fan motor

connector

between 1

and 2

short-circuit?

Operation

Check item

Conceivable principle

cause

Measure

Item by symptoms

Remote control is

defective.

Refer to (5)

“Troubleshooting for

Remote Control.”

Unit operates

normally.

YES

Is voltage

(DC 12V or 5V)

indicated on

rear of indoor

control board

normal?

Is DC

310 – 340V

suppalied to

primary side of

transfer s witch?

YES

Are DC 15V,

DC 12V and

DC 7V

supplied to

secondary

side of transfer switch?

YES YES

NO NO

Refer to

or this problem

is one step short

of power P.C.

board block.

Turn off breaker once and turn it

on again after

removing motor.

YES

Are DC 15V,

DC 12V or

DC 7V

supplied to

secondary

side of transfer switch?

Microcomputer

is defective.

Transfer switch,

IC (IC01) for

power supply or

fan motor is

defective.

Replace main

P.C. board.

Replace motor.

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

– 56 –

Page 57

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

Turn on power supply.

Does operation lamp flash?

YES YES

NO NO

Is wired correctly to white and black

lead wires of terminal board?

Correct wiring.

To item of

“Power is not turned on”.

– 57 –

Page 58

(3) Only indoor fan motor does not operate.

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

(In heating operation, the indoor fan motor does not operate for

Operation

approximately 5 minutes after it is turned on, to prevent a cold air from blowing in.)

Turn off power

supply once, and

turn it on again.

Check item

Conceivable principle

cause

Measure

Item by symptoms

Does

compressor

continue to

operate?

Start to operate

indoor unit in

cooling operation

at airflow

level “LOW”.

Does indoor

fan operate?

YES

Change airflow

level to “High”.

Is it possible to

change airflow

level to “High”?

YES

Is it possible to detect

DC 1V or more between

and 3dof motor

connector (CN10).

Is it possible to detect DC

310 – 340V between

and 3d of motor

connector (CN10).

(Motor connection condition)

Is it possible to detect DC 15V

between 4

motor connector (CN10).

Start to operate the indoor unit. At this time, is it possible to detect DC 1V or

more between 5e and 3d

of motor connector (CN10)?

Is it possible to rotate cross-

flow fan by hand properly?

YES

and 3d of

YES

Turn off indoor unit

and remove connector

from motor. Then press

START/STOP b utton

on remote control to

stop blinking lamp on

indoor unit.

Is it possible to detect

DC 15V between 4

and 3d of motor

connector (CN10).

Turn off indoor unit

and remove connector

from motor.

Then start to operate

indoor unit with remote control.

Replace indoor

fan motor.

Replace main

P.C. board.

Fan motor

operates normally.

Turn off indoor unit and rotate

cross-flow fan by hand when the

unit is on standby. At this time,

is it possible to detect DC 1V or

more between 5e and 3

of motor connector (CN10).

YES

– 58 –

Start to operate the indoor

unit in except heating

operation. At this time, is it

possible to detect DC 1V

or more between 5e and

3d of motor connector

(CN10)? (Check this

condition within 15 seconds

after starting unit.)

YES

Replace bearing.

Page 59

(4) Indoor fan motor starts rotating by turning on power supply alone

<Cause>

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

on power supply.

(1) Rem

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

NOTE :

• Do not disconnect the connector while the fan rotates.

• Use a thin tester rod.

P.C. board

Indoor fan starts rotating when power supply breaker is turned “ON”.

CN10

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

Measure the voltage of the motor connector

CN10 pin 2 (GND : Black) and pin 3 (V line : Yellow)

under condition that the indoor fan rotates.

Above DC 0.4V

P.C. board is defective.

Below DC 0.4V

Motor is defective.

Yellow

Black

6 (Blue)

5 (Yellow)

4 (Blue) 3 (Yellow)

2 —

1 (Red)

– 59 –

Page 60

(5) How to examine whether remote controller is good or bad

• Does setting (A/B) of the remote controller selection match with that indoor unit?

Operation

Check Items

Considerable main cause

Measures

Item by symptom

Is there direct sunlight on the receptor of the

air conditioner?

YES

fluorescent light

Is there any

thyristor near by?

YES

Press the START/STOP button.

Does the transmission

indicator of remote

controller light?

YES

Is operation

possible when the

transmitter is moved

nearer to the infrared

signal receiver of the

air conditioner?

YES

Battery life

There is no beep from the indoor unit. The operation lamp of the air conditioner main unit does not light.

Short-circuit ACL switch with a coin or others at rear side of remote controller.

Push the START/ STOP button

Avoid direct sunlight.

Keep the air

conditioner away

from thyristor

fluorescent light.

Is Temporary Cool

operation possible when

keeping the temporary

switch of the air conditioner

main unit pushed for 10 seconds or more?

YES

Can any signal tone be heard in a transistor radio when transmitting

within 5cm distance

from the radio?

YES

Replace

P.C. board.

Replace the battery.

indicator light?

receiving sound

and operation?

Normal

Does the

transmission

YES

Is there any

YES

Remote controller

is failure.

– 60 –

Page 61

10-5-2.Wiring Failure (Interconnecting and Serial Signal Wire)

(1) Outdoor unit does not operate

1) Is the voltage between

and  of the indoor terminal block varied?



Confirm that transmission from indoor to outdoor is correctly performed based upon the following diagram.

NOTE:

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

• Be sure to prepare a diode for judgment.

Terminal block at indoor side

Red

White

Terminal block

S5277G

Tester

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

Fig. 11-5-1

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

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

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

restart the unit.

Gas circulation amount is down.

Measure gas pressure.

Thermo. operation of compressor

Gas shortage Gas leak Pipe clogging

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

To item of Compressor does not operate.

(3) The outdoor unit stops 10 minutes to 1 hour after operation started, and an alarm is displa y ed.

(Discharge temp. error check code 03, 1E) Gas leak

P.M.V. is defectiv e. Miswiring of connecting wires of indoor/outdoor units Clogging of pipe and coming-off of TG, TC sensors

– 61 –

Page 62

10-6.Trouble Diagnosis by Outdoor LED

For the outdoor unit, the self-diagnosis is possible by five LEDs (Red).

• LEDs (Red) (D11 to D15) are provided on the sub-control board under surface of the inv erter , and as shown below , the y are chec k ed from the wiring port when removing the wiring cover.

1 . If a trouble occurs, LED (Red) goes on accord-

ing to the trouble as described in the table below.

2 . When two or more troubles occur, LEDs go on

cyclically.

3 . Usually, LEDs (Red) go off.

Wiring port

D11 D12 D13 D14 D15

Fig. 11-6-1

LED (Red)

LED display

D11 D12 D13 D14 D15

lllll

llll

¤¤

ll l

¤¤¤

lll

* * * *

¤¤¤¤

¤¤

¤¤¤l ¤

lll

¤¤

ll ll

lll

¤¤

¤ ¤ ¤

Indoor

check

code

None

07 14

16 17

19 1A 1B 1C

––

: LED ON, l : LED OFF P.M.V. : Pulse modulating valve

Description

During normal operation Compressor thermo. operation, instantaneous power failure,

gas leak IGBT short circuit, compressor motor rear shor t Position-detect circuit error Current-detect circuit error Discharge temp. sensor (TD) error Outdoor fan error Outside temp. sensor (TO) error Compressor system error A room gas side temp. sensor (TGa) error B room gas side temp. sensor (TGb) error C room gas side temp. sensor (TGc) error Gas leakage, P.M.V. sensor error Indoor heat exchanger sensor (TC) disconnection, P.M.V.

sensor error

lll

¤¤

1 Back-up operation is performed without block display of the indoor unit.

2 Operated normally when the air conditioners in other rooms are driven.

l l

¤¤ ¤¤

— 1C

1D 1E

Indoor/outdoor miswiring, gas leakage, TC sensor disconnection, P.M.V. sensor error

Communication error between MCU Compressor lock Discharge temp. error, gas leakage Compressor break down

– 62 –

Page 63

10-7.How to Diagnose Trouble in Outdoor Unit

10-7-1.Summarized Inner Diagnosis of Inverter Assembly

Diagnosis/Process flowchart Item

Preparation

Remove connector of compressor.

Check 25A fuse

(Part No.F01).

Check

15A fuse

(Part No.F03).

Replace fuse.

capacitor, diode

Replace control board assembly.

Check

electrolytic

block, etc.

Check

Contents

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

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

Check whether 15A fuse on the control board assembly is blown or not. (F03)

• 15A fuse (F03) on the control board is provided for power factor improvement control circuit. The operation continues even if fuse is blown.

Summary

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

• Connect discharge resistance (approx. 100Ω40W) or soldering iron (plug) between +, – terminals of the electrolytic capacitor (500µF) of C15 (with printed CAUTION HIGH VOLTAGE) on P.C. board.

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Check

terminal voltage

of electrolytic

capacitor.

Does outdoor

fan rotate?

YES

Does LED on control board flash or go on?

Remove connector

CN300 of outdoor fan

tester, check resistance

value between every

phases at motor side.

Replace outdoor fan motor.

Check

electrolytic

capacitor, diode

block, etc.

motor, and using a

YES

CBA

Operation

Measurement

Check

Stop

Check

Measurement

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

500µF:400WV x 4 After operation, turn off the

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

• Is not winding between

, -

, or - opened



or short-circuited?

• Is not frame grounded with , or ?

, 

If 15A fuse is blown, discharge both edges of the electrolytic capacitor with soldering iron.

OK if 500µF

→→

→ DC280V

→→

Remove CN300 while pushing the part indicated by an arrow.

→→

→ Resistance between

→→

phases should be approx. 55 to 77Ω.

→→

→ Should be 10MΩ or more.

→→

– 63 –

Page 64

Diagnosis/Process flowchart Item

Contents

Summary

fan motor

Replace outdoor fan motor.

Check

compressor

winding

resistance.

Replace

control board.

CBA

Check

winding of

compressor.

Check

position

detect

signal.

Replace control board assembly.

Replace

compressor.

Replace compressor.

Check

Operation

Check

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

• Is not grounded.

• Is not shor t-circuited between windings.

• Winding is not opened.

Remove connector CN300 of the outdoor fan motor, turn on the power breaker, and perform the operation. (Stops though activation is prompted.) Check operation within 2 minutes 20 seconds after activation stopped.

While connecting connector 5P (CN301) for position detection, using a tester, measure voltage between

- . Between  -  : 5V



→→

→ OK if 10MΩ or more

→→



→→

→ OK if 0,51Ω → 0,57Ω

→→



(Check by a digital tester.)



a)One or two of three

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

b)When rotating the fan

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

10-8.How to Check Simply the Main

Parts

10-8-1.How to Check the P.C. Board

(Indoor Unit)

(1) Operating precautions

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

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

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

(2) Inspection procedures

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

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

a. Main P .C. boar d part:

DC power supply circuit (5V, 12V, 35V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer, and Driving circuit of top/bottom louvers

b. Indication unit of infrared ray receiving

Infrared ray receiving circuit, LED:

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

– 64 –

Page 65

(3) Check procedures

Table 10-8-1

No.

Shut off the power supply and remove the P.C. board assembly from the electronic parts base.

Remove the connecting cable from the terminal block.

Remove the connector for the motor, and turn the power on.

If the OPERATION lamp flashes (0,5 sec. :ON, 0,5 sec. :OFF) when the power turning on, the checking points described as 1-5 of right column are not necessary to perform.

Make the operation status by pushing once the START/STOP button, except the status of [FAN ONLY], [ON TIMER].

Procedure

Check point (Symptom)

1.Is the fuse blown?

Voltage check

1.Between TP1 and TP2 (220–230–240V AC)

2.Between TP2 and pin 1 of CN04 (220–230–240V AC)

3.Between TP2 and pin 3 of CN04 (220–230–240V AC)

4.Between + and – of C02 (310 ~ 340V DC)

5.Between 35V and GND

6.Between 12V and GND

7.Between 5 V and GND

Voltage check

1. Voltage of relay coil. (DC 12V) Between pin 10 of IC31 and GND Between pin 11 of IC31 and GND

2. Between No. 1 and 2 of connecting cable terminal block.

(220–230–240V AC)

Causes

1.* Application of shock voltage. * Overload by short-circuit of the

parts.

1.* AC power cord is defective. * Poor contact of the terminal plate. * Miss wiring of the power relay.

2.Fuse is defective.

3.Operation of the thermal fuse.

4.* Capacitor (C01, C15) is defective. * Line filter (L01) is defective. * Resistor (R01) is defective. * Diode (DB01) is defective.

5.IC01, IC02, T01 are defective.

6.IC01, IC02, T01, F03 are defective.

7.IC01, IC02, T01, F02, Q29, IC03 are defective.

1.Breaking wire of the relay coil, defective relay driver. (IC31)

2.Poor contact of relay.

Start the operation with the system which the time of the restart delay timer is shortened.

Make the operation status by pressing once the START/STOP button.

1.The time of the restar t delay timer is shortened.

2.Cool operation

3.Air volume [AUTO]

4. Make the setting temperature lower enough than room temperature.

5.Continuous operation.

Tur n the power on after connecting

the motor connector. Start the operation with the following

condition.

1.Operation [Cooling]

2.Airflow [High fan]

3.Continuous operation

1.All indicators light for 3 sec.

2. Indicators do not indicate normally after approximate 3 sec.

1.Compressor does not operate.

2. OPERATION lamp flashes.

1.The voltage of DC 35V is not measured between the red and black of the motor terminals.

2. Motor does not rotate. (The key operation is accepted.)

3. The motor rotates, but it vibrates too much.



Defective indicator, or poor



housing assembly. (CN13)



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

2.Poor contact of the heat exchanger sensor. (The connector is disconnected.) (CN01)

3.Heat exchanger sensor, main P.C. board are defective.

4.Main P.C. board is defective.

1.Indoor fan motor is defective. (Protecting operation on the P.C. board.)

2. Poor contact of the motor connector.

3.P.C. board is defective.

– 65 –

Page 66

10-8-2. P.C. Board Layout

– 66 –

Page 67

100

90 80 70 60 50 40 30

Resistance value (k )

20 10

0102030 4050

Temperature (˚C)

TA, TC, TO, TGa, TGb, TGc, TGd

TD : Discharge temp. sensor TA : Room temp. sensor TC : Heat exchanger temp. sensor TO : Outdoor temp. sensor TGa : Gas side temp. sensor TGb : Gas side temp. sensor TGc : Gas side temp. sensor TGd : Gas side temp. sensor

– 67 –

Page 68

10-8-3.Indoor Unit (Other Parts)

No. Part name

1 Room temp. (TA) sensor

Heat exchanger (TC) sensor

2 Remote control

3 Louver motor

MP24GA

4 Indoor fan motor

11-8-4. Outdoor Unit

Checking procedure

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

Temperature

Sensor

TA, TC (kΩ) 20,7 12,6 10,0 7,9 4,5

10°C 20°C 25°C 30°C 40°C

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

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

White

Yellow Yellow Yellow Yellow

2 3 4 5

Position Resistance value

1 to 4 1 to 6 2 to 3

130 ± 10 Ω

2 to 5

Since judgment of DC motor is difficult on the single motor, ref er to 115-1. (3).

No. Part name

1 Compressor

(Model : D A130A1F-21F)

2 Outdoor fan motor

(Model : ICF-140-40-8)

3 Compressor thermo.

Bimetal type (Model : PW - 2AL)

4 Outdoor temperature sensor

(TO), pipe temperature sensor (TGa, TGb, TGc), discharge temperature sensor (TD)

Checking procedure

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

Red

White Black

Position Resistance value

Red - White 0,51 to 0,57 Ω

White - Black 0,51 to 0,57 Ω

Black - Red 0,51 to 0,57 Ω

Under 20°C

Measure the resistance value of winding by using the tester.

Red

White Black

1 Yellow 4 Pink

5 Gray

Position Resistance value

Yellow - Pink 5 to 20 k Ω

For details, ref er to Section 11-9.

Check conduction by using the tester.

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

Temperature

Sensor

TD (kΩ) 105 64 41 27 18

TO, TGa, TGb, TGc (kΩ) 20,7 12,6 10,0 7,9 4,5

10°C 20°C 30°C 40°C 50°C

– 68 –

Page 69

10-8-5.Checking Method for Each Part

No. Part name

1 Electrolytic capacitor

(For raising pressure, smoothing)

2 Converter module

Checking procedure

1. Turn OFF the power supply break er.

2. Discharge all four capacitors completely. 3 . Check that safety valv e at the bottom of capacitor is not broken. 4 . Check that vessel is not swollen or exploded. 5 . Check that electrolytic liquid does not blow off.

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

C12 C13

Heat sink IGBT side

C14

C15

MCC-758 Soldered surface

Case that product is good

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

C12, C13, C14, C15 → 500µF/400V 1 . Turn OFF the power supply breaker.

2 . Discharge all four capacitors completely. 3 . Check that the normal rectification characteristics are shown in

continuity test by the tester .

Mark

3 IGBT module

+ ~ – ~

Diode check

Tester rod

–

+ ~

–

E G

Resistance value

in good product

50kW or more

(0 in trouble)

+ ~1– ~

IGBT check

Tester rod

+ – ~

1.Turn OFF the po w er supply switch.

2. Discharge all four electrolytic capacitors completely.

3. Execute continuity test with a tester.

–

BZ BY BX BW

W V U

–

Resistance value

in good product

50kW or more (0

E G

in trouble)

BV BU

Tester rod

Case that product is good

– 69 –

+ –

or more

UVW UVW

WVUWVU

100k to 300k

–

200k to 300k

Page 70

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

1. Symptom

• Outdoor fan motor does not rotate.

• Outdoor fan motor stops within several tens seconds though it started rotating.

• Outdoor fan motor rotates or does not rotate according to the position where the fan stopped., etc. Remote control check code “02 : Outdoor block, 1A : Outdoor fan drive system error”

2. Cause

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

1) Mechanical lock of the outdoor fan motor

2) Winding error of the outdoor fan motor

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

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

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

Turn OFF the breaker.

Disconnect two connectors (CN300 and CN301)

of the outdoor fan motor from the inverter.

Does the fan rotate without trouble

when rotating it with hands?

YES

If the resistance value between 1 (Red lead) – 2 (White lead) 2 (White lead) – 3 (Black lead) 3 (Black lead) – 1 (Red lead)

1 (Yellow lead) – 4 (Pink lead)

(CN301 : Motor position detection)

of the connector (CN300 : Motor winding) is 50 to 80

If the resistance value between

of the connector

is 5k to 20k , it is normal.

Fan motor is normal.

(Outdoor P.C. board error)

, it is normal.

YES

CN300

Fan motor error

NOTE :

Howe ver, GND circuit error inside of the motor may be accepted in some cases when the abo ve check is performed.

When the fan motor does not become normal even if P.C. board is replaced, replace the outdoor fan motor.

– 70 –

Page 71

11. HOW TO REPLACE THE MAIN PARTS

6 2-Screws

2 4-Screws

2 2

11-1. Indoor Unit

No. Part name Procedures Remarks

1 Front panel

2 Electrical part

How to remove the front panel

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

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

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

How to mount the front panel

Push the front panel back in and make sure all hooks are locked.

How to remove the electrical part.

1) Remove the front panel with procedure 1.

2) Remove the screw holding the electrical part cover.

3) Remove the drain guide .

4) Disconnect the 2 connectors (3P) for the fan motor and the connector (5P) for the louver motor from the P.C. board assembly.

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

6) Remove the screw for the ground connection, remove the 2 screws for the electrical part box and remove the screw from the LED unit. Then remove the LED unit and the electrical part box from the main unit.

How to mount the electrical part.

1) To put back the electrical part box, lock it to the upper hook of the back body.

2) Tighten the 2 screws on the electrical part box.

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

4) Attach the TC sensor to the holder.

5) Tighten the screw for the ground connection.

6) Assemble the drain guide (the TC sensor wire should be covered by the drain guide).

Tighten the screw on the electrical part cover.

3 Drain guide

6 Screws

2 Screws

5 TC Sensor

3-Connectors

3 Horizontal

louver

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

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

3) Remove the left shaft from the back body.

4) Remove the horizontal louver from the back body.

– 71 –

3 Left shaft

2 Center shaft

Page 72

No. Part name Procedures Remarks

3 2-Screws

4 Heat exchanger

5 Cross flow fan

1) Remove the front panel, electrical part and the horizontal louver following procedure 3.

2) Remove the pipe holder at the rear side of main unit.

3) Remove the 2 screws on the heat exchanger at the base bearing.

4) Remove the 2 screws on the heat exchanger at the 2 fixed plates (upper and lower) from the back body, and then pull out the upper side of the heat exchanger slowly.

1) Remove the front panel, electrical part, horizontal louver and the heat exchanger following procedure 4.

2) Remove the 2 screws on the band motor (L) and remove the 2 screws on the band motor (R) and then remove the cross flow fan.

3) Loosen the set screw of the cross flow fan then separate the fan and the fan motor.

2 Pipe holder

4 2-Screws

2 2-Screws (R)

2 2-Screws (L)

4 mm

6 Base bearing

Notice

To assemble cross flow fan and fan motor to the unit, please turn the fan motor unit the center of its terminal meets the lowest point of band motor (R) (point A). Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is 4 mm.

1) Remove the front panel, electrical part, horizontal louver, heat exchanger and the cross flow fan following procedure 5.

2) Remove the 2 screws fixing the base bearing.

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

3 Set screws

Middle of the fan motor terminal

2 2-Screws

– 72 –

Page 73

11-2.Microcomputer

No.



Part name

Common procedure

Procedure

1) Turn the power supply off to stop the operation of airconditioner.

2) Remove the front panel.

• Remove the two fixing screws. (φ4 x 14l)

3) Remove the electrical part base.

Remarks

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

– 73 –

Page 74

11-3. Outdoor Unit

No. Part name

Common



procedure

Procedure

1. Detachment

1) Stop operation of the air conditioner, and remov e the power plug of the indoor unit from plug socket.

2) Remove the valve cover. (ST1TØ4 x 10

• After removing screw, remove the valve cover

pulling it downward.

3) Remove wiring cover (ST1TØ4 x 10 and then remove connecting cable .

4) Remove the upper cabinet. (ST1TØ4 x 10

• After removing screws, remove the upper

cabinet pulling it upward.

2. Attachment

1) Attach the upper cabinet. (ST1TØ4 x 10

• Hook the rear side of the upper cabinet to claw

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

2) Perf orm cabling of connecting cable , and attach the wiring cover . (ST1TØ4 x 10

3) Attach the valve cover. (ST1TØ4 x 10

• Insert the upper part to the upper cabinet, set

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

l 2 pcs.)

l 1 pc.)

l 2 pcs.),

l 1 pcs.)

Remarks

Upper cabinet

Wiring cover

Valve cover

Upper cabinet

Front cabinet



1. Detachment

1) Perf orm work of item 1 of .

2) Remove screw (ST1TØ4 x 10 cabinet and inverter cover and screws (ST1TØ4

x 10

l 3 pcs.) of the front cabinet and lower part

of the front cabinet and motor base (ST1TØ4 x

l 2 pcs.).

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

the rear cabinet, so remove it pulling upward.

2. Attachment

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

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

3) Attach the removed screws to the original positions.

l 1 pc.) of the front

Square hole

Concave part

Claw

– 74 –

Page 75

No. Part name

Procedure

Remarks



Inverter assembly

1. Detachment

1) Perf orm work of items 1. of  and .

2) Remove screw (ST1TØ4 x 10

l 1 pc.) of the

upper part of the front cabinet.

• If removing the inverter cover in this condition,

P.C. board can be checked.

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

upper cabinet, perform work of .

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

3) Perf orm discharging by connecting + , – polarity by discharging resistance (approx. 100Ω40W) or plug of soldering iron to + , – terminals of the C15 (printed “CAUTION HIGH VOLTAGE” is attached.) electrolytic capacitor (500µF) on P.C . board.

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

Inverter cover

Discharging position (Discharging period 10 seconds or more)

Adjust length of every lead wires other than complete and case thermo., and bundle them.

P. C. board (Soldered surface)

Plug of soldering iron

NOTE : This capacitor is one with mass capacity . Therefore, it is dangerous that a lar ge spark generates if short-circuiting between + , – polarity with screwdriver, etc. for discharging.

4) Remove screw (ST1TØ4 x 10

l 1 pc.) fixing the

main body and the inverter box.

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

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

7) Pull the inverter box upward.

8) Disconnect connectors of various lead wires.

Holder

TO sensor

P.M.V. coil (A, B, and C rooms)

TGa, TGb, TGc sensor

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

– 75 –

Page 76

No. P art name

,

Procedure

Remarks



Control board assembly

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

1. Lead wires

• Connection with terminal block : 10 wires (Black, Orange, Pink, Red, Two white wires, Four white wires (reactors))

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

• Connection with reactor : Remove the relay connectors from P07, 08 (2P, White) and P11, P12 (2P, Yellow).

2. Connectors

• Main control board assembly side CN300 : Outdoor f an (3P, White) CN301 : Outdoor fan position detection (5P, White)

• Sub-control board assembly side CN02 : TD sensor (3P, White) CN05 : TGa sensor (3P, Yellow) CN06 : TGb sensor (3P, Brown) CN07 : TGc sensor (3P, Green) CN08 : Case thermo. (2P, White) CN12 : C room pulse modulating v alv e (6P, Green) CN13 : B room pulse modulating v alve (6P, Red) CN14 : A room pulse modulating v alv e (6P, Black)

2) Disconnect cable connecting the main control board assembly side and sub-control board assembly.

• Main control board assembly side CN704 : Connecting cab le (4P, White)

• Sub.-control board assembly side CN15 : Connecting cab le (4P, White)

Main board

CN15

CN301

CN300

CN04

CN02 CN

CN14

CN 12

CN08

CN05

06 13

Sub-board

CN06 CN07

CN300 and 301 at the main control board assembly side and CN08 and 15 at the sub- control board assembly side are connectors with locks. Therefore , remove the connector while pushing the part indicated by an arrow.



Rear cabinet

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

1. Main control board assembly side

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

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

2. Sub- control board assembly side

• Remove P.C. board base from the in verter box.

• Remove two claws of P.C. board base, and replace the board with a new one.

3. Be sure to use the radiating sheet between heat sink and IGBT and also screws with tube.

1) Perform work of item 1 of , and  .

2) Remove fixed scre ws fixing to the bottom plate . (ST1TØ4 x 10

l 2 pcs.)

3) Remove fixed scre ws fixing to the heat exchanger. (ST1TØ4 x 10

l 2 pcs.)

4) Remove fixed scre w fixing to the valve mounting plate. (ST1TØ4 x 10

l 1 pc.)

P. C. board base

P. C. board

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

– 76 –

Page 77

No. Part name

,

RemarksProcedure





Fan motor

Compressor

1) Perf orm work of item 1 of  and .

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

• Flange nut is loosened by turning clockwise.

(To tighten the flange nut, turn counterclockwise.)

3) Remove the propeller fan.

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

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

1) Perform work of item 1 of  and , , , .

2) Evacuate refrigerant gas.

3) Remove the partition board. (ST1TØ4 x 10

l 3 pcs.)

4) Remove the sound-insulation material.

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

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

7) Remove the fixing screw of the bottom plate and heat exchanger . (ST1TØ4 x 10

l 1 pc.)

8) Remove the fixing screw of the bottom plate and valve clamping plate. (ST1TØ4 x 10

l 2 pcs.)

9) Pull upward the refrigeration cycle.

10) Remove nut fixing the compressor to the

bottom plate.

Propeller fan

Flange nut

Partition board

Fan motor

Valve clamping plate

Compressor thermo.

Compressor



Reactor

1) Perform work of item 1 of , and .

Reactor

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

3) Remove screws fixing the reactor . (ST1TØ4 x 10

l 2 pcs.)

– 77 –

Page 78

No. Part name

RemarksProcedure



Pulse modulating valve coil

1. Detachment

1) Perform work of item 1 of , and , , .

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

2. Attachment

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

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

The pulse modulating valve has A, B and C room side. After mounting it, check that coil at B room side (Red marking is marked on the pulse modulating valve.) is connected to CN13. Check that coil at C room side (Green marking is marked on the pulse modulating valve.) is connected to CN12 of the control board assembly respectivel y.

Take-out part of lead wire

Notch

Coil inserting position

Coil fix position

Positioning hole



Fan guard

1. Detachment

1) Perf orm work of item 1 of , and .

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

Perform w ork on a corrugated cardboar d, cloth, etc. to prevent flaw to the product.

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

2. Attachment

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

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

Minus screwdriver

Hooking claw

– 78 –

Page 79

No. Part name

RemarksProcedure

11 Replacement

of temperature sensor for servicing only

Common service parts of sensor TO , TGa, TGb, TGc (without TD)

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

2) Cut the protective tube after pulling out it (200 mm).

3) Move the protective tube to w ard the thermal sensor side and tear the tip of lead wire in two then strip the covering part.

4) Pass the stripped part through the thermal constringent tube.

5) Cut the old sensor 100 mm length on the connector side, and recycle that connector.

6) Tear the lead wire in two on the connector side and strip the covering part.

7) Twist the leads on the connector and sensor sides, and solder them.

8) Move the thermal constringent tubes toward the soldered parts and heat them with the dryer and constring them.

9) Wind the attached color tape round the both terminals of the protective tube when colored protective tube is used.

10)Fix the sensor again.

NOTES :

1) Store the joint part of the sensor and the connector in the electric parts box.

2) Never joint them near the thermal sensor part. Otherwise it would cause insulation inferiority because of dew drops.

3) When replacing the sensor using the colored protective tube, wind the color tape matching the color of that tube.

Thermal sensor part

200

Thermal constringent tube

Cutting here

100

Winding the color tape

Connector

Soldered part

Dryer

Cutting here

100

Cutting here

These are parts for servicing sensors.

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

Parts name Q'ty Remarks

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

– 79 –

Page 80

MCC-758

CN600

– 80 –

Page 81

MCC-775

– 81 –

Page 82

12-1. Indoor Unit (1)

403

12. EXPLODED VIEWS AND PARTS LIST

406

405

402

404

Location

No.

401 43T69319 Temperature Sensor

402 43T60002 Terminal Block, 3P,

403 43T69320 Temperature Sensor

404 43T69003 Cord Clamp

Part No. Description

TC, 10kΩ, 25°C

AC 300V, 20A

TC, 10kΩ, 25°C

401

Location

No.

406 43T69333 P.C. Board Ass’y,

406 43T69334 P.C. Board Ass’y,

406 43T69335 P.C. Board Ass’y,

Part No. Description

MCC-867(RAS-M10UKCV-E)

MCC-867(RAS-M13UKCV-E)

MCC-867(RAS-M16UKCV-E)

405 43T69079 P.C. Board Ass’y,

WRS-LED

– 82 –

Page 83

217

216

217

Indoor Unit

202

234

204

206

212

210

201

211

215

205

204

218

219

228

220

229

226

227

214

208

203

221

Electric Parts

Assembly

209

233

225

207

222

223

224

Location

No.

Part No. Description

201 43T00352 Panel Ass’y, Front 202 43T09316 Inlet Grille Assy 203 43T03302 Back body Assy 204 43T80301 Air Filter 205 43T09309 Horizontal Louver 206 43T08350 LED Panel Assy 207 13T70002 Drain Hose

208 43T79301

Cap Drain

209 43T21321 Motor Louver

Refrigeration Cycle Assy

211 43T47006 Pipe Delivery 212 43T47305

Pipe Suction

(RAS-M10UKCV-E,M13UKCV-E)

212 43T47016

Pipe Suction

(RAS-M16UKCV-E)

214 43T11301 Pipe Shield 215 43T19302 Holder Sensor 216 43T49302 Plate of EVA Seal 217 43T49006 Holder Plate EVA Seal 218 43T79302 Guide Drain

219 43T22002

Bearing

220 43T39301 Base Bearing

221 43T20302 Fan Cross Flow

222 43T39302 Band Motor - L 223 43T21327 Motor Fan

224 43T39303 Band Motor -R 225 43T82301 Plate Installation

Location

No.

Part No. Description

226 43T69310 Remote Controller

227 43T83003 Holder Remote Controller

228 43T85362 Owner's Manual

229 43T62302 Terminal Cover

231 43T60317 Cord Motor Louver 232 43T60316 Cord Motor Fan 233 43T07303 Holder Pipe 234 43T01303 Mark

– 89 –

Page 84

12-2. Outdoor Unit

12,15

11,14 13,16

24,

Location Part

No. No.

01 43005452 Cabinet, Back, Assembly 02 43005369 Cabinet, Upper, Assembly 03 43005364 Cabinet, Front, Assembly 04 4301V030 Guard, Fan 05 43042461 Base, Assembly 06 4301V029 Cover, Valve, Packed 07 43062230 Cover, Wiring, Assembly 08 4301V021 Hanger 09 43041771 Compressor, DA130A1F-21F 10 43043650 Condenser, Assembly 11 43046332 Valve, Packed, 6,35 DIA 12 43046349 Valve, Packed, 9,52 DIA 13 43046356 Valve, Packed, 12,7 DIA 14 43147196 Bonnet, 1/4 IN 15 43047401 Bonnet, 3/8 IN 16 43147195 Bonnet, 1/2 IN

No. 18 Coil, P.M.V. : F or standardization of the servicing parts, one type only is provided.

Therefore, color of the connector ma y be diff erent in replacement work.

Description

Location Part

No. No.

17 43046351 Valve, Pulse Modulating

(P.M.V.), SEV15RC2 18 43046347 Coil, P.M.V. 19 43058264 Reactor, CH38Z-K 20 43050298 Thermo. Bimetal, CS-7, 125 21 4302C019 Motor, Fan, DC,

ICF-140-40-4 22 43047549 Nut, Flange 23 43020312 Fan, Propeller 24 43097166 Nut 25 43049643 Cushion, Rubber 26 43063187 Holder, Sensor 27 43049654 Holder, Sensor 28 43063195 Holder, Thermo. Bimetal 29 43019904 Holder, Sensor 30 4308N258 Manual

Description

– 75 –

Page 85

12-3. P.C. Board Layout

706

704

709

708

705

710

702

TO Sensor TGa Sensor

TGb Sensor TGc Sensor

TD Sensor

703

711

707

Location Part

No. No.

Description

702 43050382 Sensor, TC (Ø6) 703 43050334 Sensor, TD (Ø4) 704 43060052 Fuse, 25A, 250V, Lead Type 705 4306A027 Terminal block, 9P 706 43060726 Fuse, 15A, 250V, Lead Type 707 4306A030 Terminal block, 9P

– 76 –

Location Part

No. No.

Description

708 43062231 Base, P.C. Board 709 43063308 Heatsink 710 4306S191 P.C. Board Assemb ly,

MCC-758 711 4306S190 P.C. Board Assemb ly,

MCC-775

Page 86

TOSHIBA CARRIER (THAILAND) CO.,LTD.

144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI,

AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.