Toshiba RAS-3M23YACV-E DATA BOOK

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

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

– 2 –

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

– 3 –

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

– 4 –

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

– 5 –

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 —

– 6 –

DB WB

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.

– 7 –

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.

– 8 –

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

– 9 –

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)

– 10 –

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 –

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

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 –

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 –

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

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 –

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

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

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 –

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 –

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 –

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 –

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

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 –

(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 –

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 –

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