Toshiba RAS-3M23YACV-E DATA BOOK

FILE NO. SVM-03016

S U P P L E M E N T

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			RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E
	Outdoor						RAS-3M23YACV-E
Cooling capacity			(kW)		6,7
Cooling capacity range			(kW)		2,2~7,0
Power supply						220–240V–1Ph–50Hz
Electric				220V			230V		240V
characteristics	Indoor	Unit model		RAS-M10UKCV-E, RAS-M13UKCV-E,				RAS-M16UKCV-E
		Running current	(A)		0,15
		Power consumption	(W)		30
		Power factor	(%)	91			87		83
	Outdoor	Unit model					RAS-3M23YACV-E
		Running current	(A)	9,84		9,39			8,98
		Power consumption	(W)			2060
		Power factor	(%)		95
	Starting current		(A)	10,29			9,84		9,43
COP							3,12
Operating noise	Indoor	Unit model		RAS-M10UKCV-E			RAS-M13UKCV-E	RAS-M16UKCV-E
		High	(dB•A)	36			39		42
		Medium	(dB•A)	33			35		39
		Low	(dB•A)	28			28		33
	Outdoor	Unit model					RAS-3M23YACV-E
		10-1 unit operating	(dB•A)		45
		3 units operating	(dB•A)		48
Indoor unit	Unit model			RAS-M10UKCV-E			RAS-M13UKCV-E		RAS-M16UKCV-E
	Dimension	Height	(mm)	275			275		275
		Width	(mm)	790			790		790
		Depth	(mm)	208			208		208
	Net weight		(kg)	10			10		10
	Fan motor output		(W)	19			19		19
	Air flow rate		(m³/h)	470			520		600
Outdoor unit	Unit model						RAS-3M23YACV-E
	Dimension	Height	(mm)		695
		Width	(mm)		780
		Depth	(mm)		270
	Net weight		(kg)		48
	Fan motor output		(W)		40
	Air flow rate		(m³/h)		2100
Piping connection	Type						Flare connection
	Indoor unit	Unit model		RAS-M10UKCV-E			RAS-M13UKCV-E	RAS-M16UKCV-E
		Liquid side		Ø6,35			Ø6,35		Ø6,35
		Gas side		Ø9,52			Ø9,52		Ø12,7
	Outdoor unit	Unit model					RAS-3M23YACV-E
		A unit			Ø6,35 / Ø12,7
		B unit			Ø6,35 / Ø9,52
		C unit			Ø6,35 / Ø9,52
	Maximum length (per unit)		(m)		20
	Maximum length (total)		(m)		40
	Maximum chargeless length		(m)		40
	Maximum height difference		(m)		10
Refrigerant	Name of refrigerant						R410A
	Weight		(kg)		1,5
Wiring connection		Power supply			3 Wires : includes earth
		Interconnection			4 Wires : includes earth
Usable temperature range		Indoor	(°C)				21–32
		Outdoor	(°C)				10–43
Accessory	Indoor unit	Installation plate			1
		Wireless remote control			1
		Label			1
		Remote control holder			1
		Pan head wood screw					2 (Ø3,1 x 16L)
		Purifying filter			1
		Zeodorizing filter			1
		Batteries			2
		Mounting screw					6 (Ø4 x 25L)
		Installation manual			1
	Outdoor unit	Installation manual			1
		Owner's manual			1

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

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

–3 –

1-2. Specifications of Performance When Each Indoor Unit is Combined with Other Unit

Operating	Power		Indoor unit				Unit capacity (kW)				Cooling	Power	Operation	Outdoor
	supply										capacity	consumption	current	noise
status	(V)	A		B		C	A	B	C		(kW)	(W)	(A)	(dB)
1 unit	220	10		—		—	2,7	—	—	2,7		770	4,12	45
											(1,4 to 3,2)	(320 to 950)	(2,08 to 5,08)
	230	10		—		—	2,7	—	—	2,7		770	3,94	45
											(1,4 to 3,2)	(320 to 950)	(1,99 to 4,86)
	240	10		—		—	2,7	—	—	2,7		770	3,77	45
											(1,4 to 3,2)	(320 to 950)	(1,90 to 4,66)
	220	13		—		—	3,7	—	—	3,7		1200	6,34	48
											(1,4 to 4,4)	(320 to 1470)	(2,08 to 7,51)
	230	13		—		—	3,7	—	—	3,7		1200	6,07	48
											(1,4 to 4,4)	(320 to 1470)	(1,99 to 7,18)
	240	13		—		—	3,7	—	—	3,7		1200	5,81	48
											(1,4 to 4,4)	(320 to 1470)	(1,90 to 6,88)
	220	16		—		—	4,5	—	—	4,5		1600	7,66	48
											(1,4 to 4,9)	(320 to 1750)	(2,08 to 8,37)
	230	16		—		—	4,5	—	—	4,5		1600	7,32	48
											(1,4 to 4,9)	(320 to 1750)	(1,99 to 8,01)
	240	16		—		—	4,5	—	—	4,5		1600	7,02	48
											(1,4 to 4,9)	(320 to 1750)	(1,90 to 7,68)
2 units	220	10		10		—	2,7	2,7	—	5,4		1500	7,18	48
											(1,8 to 6,0)	(360 to 1880)	(2,34 to 9,00)
	230	10		10		—	2,7	2,7	—	5,4		1500	6,86	48
											(1,8 to 6,0)	(360 to 1880)	(2,24 to 8,60)
	240	10		10		—	2,7	2,7	—	5,4		1500	6,58	48
											(1,8 to 6,0)	(360 to 1880)	(2,14 to 8,25)
	220	10		13		—	2,45	3,35	—	5,8		1800	8,61	48
											(1,8 to 6,3)	(360 to 1970)	(2,34 to 9,43)
	230	10		13		—	2,45	3,35	—	5,8		1800	8,24	48
											(1,8 to 6,3)	(360 to 1970)	(2,24 to 9,02)
	240	10		13		—	2,45	3,35	—	5,8		1800	7,89	48
											(1,8 to 6,3)	(360 to 1970)	(2,14 to 8,64)
	220	10		16		—	2,21	3,69	—	5,9		1830	8,76	48
											(1,8 to 6,4)	(360 to 2000)	(2,34 to 9,57)
	230	10		16		—	2,21	3,69	—	5,9		1830	8,38	48
											(1,8 to 6,4)	(360 to 2000)	(2,24 to 9,15)
	240	10		16		—	2,21	3,69	—	5,9		1830	8,03	48
											(1,8 to 6,4)	(360 to 2000)	(2,14 to 8,77)
	220	13		13		—	2,95	2,95	—	5,9		1830	8,76	48
											(1,8 to 6,4)	(360 to 2000)	(2,34 to 9,57)
	230	13		13		—	2,95	2,95	—	5,9		1830	8,38	48
											(1,8 to 6,4)	(360 to 2000)	(2,24 to 9,15)
	240	13		13		—	2,95	2,95	—	5,9		1830	8,03	48
											(1,8 to 6,4)	(360 to 2000)	(2,14 to 8,77)
	220	13		16		—	2,71	3,29	—	6,0		1850	8,85	48
											(1,8 to 6,4)	(360 to 2000)	(2,34 to 9,57)
	230	13		16		—	2,71	3,29	—	6,0		1850	8,50	48
											(1,8 to 6,4)	(360 to 2000)	(2,24 to 9,15)
	240	13		16		—	2,71	3,29	—	6,0		1850	8,11	48
											(1,8 to 6,4)	(360 to 2000)	(2,14 to 8,77)
	220	16		16		—	3,05	3,05	—	6,1		1870	8,95	48
											(1,8 to 6,5)	(360 to 2050)	(2,34 to 9,81)
	230	16		16		—	3,05	3,05	—	6,1		1870	8,56	48
											(1,8 to 6,5)	(360 to 2050)	(2,24 to 9,38)
	240	16		16		—	3,05	3,05	—	6,1		1870	8,20	48
											(1,8 to 6,5)	(360 to 2050)	(2,14 to 8,99)
3 units	220	10		10		10	2,13	2,13	2,13	6,4		1880	9,00	48
											(2,2 to 7,0)	(420 to 2300)	(2,73 to 11,0)
	230	10		10		10	2,13	2,13	2,13	6,4		1880	8,60	48
											(2,2 to 7,0)	(420 to 2300)	(2,61 to 10,53)
	240	10		10		10	2,13	2,13	2,13	6,4		1880	8,25	48
											(2,2 to 7,0)	(420 to 2300)	(2,50 to 10,09)
	220	10		10		13	1,99	1,99	2,72	6,7		2150	10,29	48
											(2,2 to 7,0)	(420 to 2300)	(2,73 to 11,0)
	230	10		10		13	1,99	1,99	2,72	6,7		2150	9,84	48
											(2,2 to 7,0)	(420 to 2300)	(2,61 to 10,53)
	240	10		10		13	1,99	1,99	2,72	6,7		2150	9,43	48
											(2,2 to 7,0)	(420 to 2300)	(2,50 to 10,09)
	220	10		13		13	1,80	2,45	2,45	6,7		2150	10,29	48
											(2,2 to 7,0)	(420 to 2300)	(2,73 to 11,0)
	230	10		13		13	1,80	2,45	2,45	6,7		2150	9,84	48
											(2,2 to 7,0)	(420 to 2300)	(2,61 to 10,53)
	240	10		13		13	1,80	2,45	2,45	6,7		2150	9,43	48
											(2,2 to 7,0)	(420 to 2300)	(2,50 to 10,09)
	220	10		10		16	1,83	1,83	3,04	6,7		2150	10,29	48
											(2,2 to 7,0)	(420 to 2300)	(2,73 to 11,0)
	230	10		10		16	1,83	1,83	3,04	6,7		2150	9,84	48
											(2,2 to 7,0)	(420 to 2300)	(2,61 to 10,53)
	240	10		10		16	1,83	1,83	3,04	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

Current (A)

12

11

10

9

8

7

6

5

4

3

2

1

0

0

• Conditions				220V
Indoor	: DB27˚C/WB19˚C
Outdoor : DB35˚C
Air flow	: High
Pipe length 5m		× 3
3 units operating

230V

240V

10

20

30

40

50

60

70

80

90

100

Inverter output frequency (rps)

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

	115
	110
(%)	105
ratio	100
Capacity	95
	90
	85
	0
	14

• Conditions

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

3 units operating

Capacity ratio (%)

16

18

20

22

24

105
					Current Limited Start
100
95
90
85
80
75
70
65
			• Conditions
60			Indoor		: DB27˚C/WB19˚C
			Indoor air flow : High
55			Pipe length 5m × 3
			3 units operating
50
		34	36	38	40	42	43		44		46
32

Indoor air wet bulb temp. (˚C)	Outdoor temp. (˚C)
*	Capacity ratio : 100% = 6,7 kW

– 5 –

1-3. Electrical Data

									System					Compressor		Fan motor FLA
Combination of							Volts-	Voltage range			Power supply
indoor unit operation						Hz							MOCP
							Ph.	Min.	Max.		MCA	ICF		MSC	RLA	Indoor	Outdoor
													(Amps)
1 unit		10	—		—						4,99	4,99	8,46	3,47	3,47	0,15 x 1 = 0,15	0,5
		13	—		—						7,76	7,76	13,45	5,69	5,69	0,15 x 1 = 0,15	0,5
		16	—		—						9,41	9,41	16,42	7,01	7,01	0,15 x 1 = 0,15	0,5
2 units		10	10		—						8,78	8,78	15,16	6,38	6,38	0,15 x 2 = 0,30	0,5
		13	10		—						10,56	10,56	18,37	7,81	7,81	0,15 x 2 = 0,30	0,5
		16	10		—	50	220-1	198	264		10,75	10,75	18,71	7,96	7,96	0,15 x 2 = 0,30	0,5
		13	13		—						10,75	10,75	18,71	7,96	7,96	0,15 x 2 = 0,30	0,5
		16	13		—						10,86	10,86	18,91	8,05	8,05	0,15 x 2 = 0,30	0,5
		16	16		—						10,99	10,99	19,14	8,15	8,15	0,15 x 2 = 0,30	0,5
3 units		10	10		10						11,01	11,01	19,06	8,05	8,05	0,15 x 3 = 0,45	0,5
		13	10		10						12,63	12,63	21,97	9,34	9,34	0,15 x 3 = 0,45	0,5
		13	13		10						12,63	12,63	21,97	9,34	9,34	0,15 x 3 = 0,45	0,5
		16	10		10						12,63	12,63	21,97	9,34	9,34	0,15 x 3 = 0,45	0,5
1 unit		10	—		—						4,76	4,76	8,05	3,29	3,29	0,15 x 1 = 0,15	0,5
		13	—		—						7,43	7,43	12,85	5,42	5,42	0,15 x 1 = 0,15	0,5
		16	—		—						8,99	8,99	15,66	6,67	6,67	0,15 x 1 = 0,15	0,5
2 units		10	10		—						8,38	8,38	14,44	6,06	6,06	0,15 x 2 = 0,30	0,5
		13	10		—						10,10	10,10	17,54	7,44	7,44	0,15 x 2 = 0,30	0,5
		16	10		—	50	230-1	198	264		10,28	10,28	17,86	7,58	7,58	0,15 x 2 = 0,30	0,5
		13	13		—						10,28	10,28	17,86	7,58	7,58	0,15 x 2 = 0,30	0,5
		16	13		—						10,43	10,43	18,13	7,70	7,70	0,15 x 2 = 0,30	0,5
		16	16		—						10,50	10,50	18,26	7,76	7,76	0,15 x 2 = 0,30	0,5
3 units		10	10		10						10,51	10,51	18,16	7,65	7,65	0,15 x 3 = 0,45	0,5
		13	10		10						12,06	12,06	20,95	8,89	8,89	0,15 x 3 = 0,45	0,5
		13	13		10						12,06	12,06	20,95	8,89	8,89	0,15 x 3 = 0,45	0,5
		16	10		10						12,06	12,06	20,95	8,89	8,89	0,15 x 3 = 0,45	0,5
1 unit		10	—		—						4,55	4,55	7,67	3,12	3,12	0,15 x 1 = 0,15	0,5
		13	—		—						7,10	7,10	12,26	5,16	5,16	0,15 x 1 = 0,15	0,5
		16	—		—						8,61	8,61	14,98	6,37	6,37	0,15 x 1 = 0,15	0,5
2 units		10	10		—						8,03	8,03	13,81	5,78	5,78	0,15 x 2 = 0,30	0,5
		13	10		—						9,66	9,66	16,75	7,09	7,09	0,15 x 2 = 0,30	0,5
		16	10		—	50	240-1	198	264		9,84	9,84	17,07	7,23	7,23	0,15 x 2 = 0,30	0,5
		13	13		—						9,84	9,84	17,07	7,23	7,23	0,15 x 2 = 0,30	0,5
		16	13		—						9,94	9,94	17,25	7,31	7,31	0,15 x 2 = 0,30	0,5
		16	16		—						10,05	10,05	17,45	7,40	7,40	0,15 x 2 = 0,30	0,5
3 units		10	10		10						10,08	10,08	17,38	7,30	7,30	0,15 x 3 = 0,45	0,5
		13	10		10						11,55	11,55	20,03	8,48	8,48	0,15 x 3 = 0,45	0,5
		13	13		10						11,55	11,55	20,03	8,48	8,48	0,15 x 3 = 0,45	0,5
		16	10		10						11,55	11,55	20,03	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 inverter air conditioner)
MOCP : Maximum Overcurrent Protection (Fuse only)
MSC	: Maximum Starting Current
FLA	: Full Load Amps.
RLA	: Rated Load Amps. RLA under conditions on the right.

		DB	WB
Indoor temp.	°C	27	19
Outdoor temp.	°C	35	—

– 6 –

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 existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

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

2-1. Safety During Installation/Servicing

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

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

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

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

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

(3)If a refrigeration gas leakage occurs during 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 level.

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

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

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

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

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

2-2. Refrigerant Piping Installation

2-2-1. Piping Materials and Joints Used

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

(1)Copper Pipes

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

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

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

– 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 socket joints are used. Prior to use, be sure to remove all contaminants.

a)Flare Joints

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

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

b)Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm. Thicknesses of socket joints are as shown in Table 2-2-2.

Table 2-2-2 Minimum thicknesses of socket joints

	Nominal diameter	Reference outer diameter of	Minimum joint thickness
		copper pipe jointed (mm)	(mm)
	1/4	6,35	0,50
	3/8	9,52	0,60
	1/2	12,70	0,70
	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, perform the flare processing correctly.

Use either a flare tool for R410A or conventional flare tool.

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

ØD

A

Fig. 2-2-1 Flare processing dimensions

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

Outer

A (mm)

Nominal

Thickness

diameter

Flare tool for

Conventional flare tool

diameter

(mm)

(mm)

R410A clutch type

Clutch type

Wing nut type

1/4

6,35

0,8

0 to 0,5

1,0 to 1,5

1,5 to 2,0

3/8

9,52

0,8

0 to 0,5

1,0 to 1,5

1,5 to 2,0

1/2

12,70

0,8

0 to 0,5

1,0 to 1,5

2,0 to 2,5

5/8

15,88

1,0

0 to 0,5

1,0 to 1,5

2,0 to 2,5

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

Outer

A (mm)

Nominal

Thickness

diameter

Flare tool for

Conventional flare tool

diameter

(mm)

(mm)

R22 clutch type

Clutch type

Wing nut type

1/4

6,35

0,8

0 to 0,5

0,5 to 1,0

1,0 to 1,5

3/8

9,52

0,8

0 to 0,5

0,5 to 1,0

1,0 to 1,5

1/2

12,70

0,8

0 to 0,5

0,5 to 1,0

1,5 to 2,0

5/8

15,88

1,0

0 to 0,5

0,5 to 1,0

1,5 to 2,0

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

Nominal

Outer diameter

Thickness

Dimension (mm)

Flare nut

width

diameter

(mm)

(mm)

A

B

C

D

(mm)

1/4

6,35

0,8

9,1

9,2

6,5

13

17

3/8

9,52

0,8

13,2

13,5

9,7

20

22

1/2

12,70

0,8

16,6

16,0

12,9

23

26

5/8

15,88

1,0

19,7

19,0

16,0

25

29

– 9 –

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

Nominal	Outer diameter				Thickness																	Dimension (mm)												Flare nut
																																		width
diameter		(mm)					(mm)												A			B	C										D
																																		(mm)
1/4	6,35				0,8												9,0					9,2	6,5						13					17
3/8	9,52				0,8												13,0					13,5	9,7						20					22
1/2	12,70				0,8												16,2					16,0	12,9						20					24
5/8	15,88				1,0												19,4					19,0	16,0						23					27
3/4	19,05				1,0												23,3					24,0	19,2						34					36
					46˚
				~
				45˚
										B			A													C				D

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.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by 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.

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

	Nominal	Outer diameter	Tightening torque	Tightening torque of torque
				wrenches available on the market
	diameter	(mm)	N•m (kgf•cm)
				N•m (kgf•cm)
	1/4	6,35	14 to 18 (140 to 180)	16 (160), 18 (180)
	3/8	9,52	33 to 42 (330 to 420)	42 (420)
	1/2	12,70	50 to 62 (500 to 620)	55 (550)
	5/8	15,88	63 to 77 (630 to 770)	65 (650)

– 10 –

2-3. Tools

2-3-1. Required Tools

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

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

(1)Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))

(2)Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)

(3)Tools commonly used for R410A and for conventional refrigerant (R22)

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

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

Tools whose specifications are changed for R410A and their interchangeability

				R410A air conditioner		Conventional air
				installation		conditioner installation
	No.	Used tool	Usage	Existence of	Whether	Whether new equip-
				new equipment	conventional	ment can be used with
				for R410A	equipment can	conventional refriger-
					be used	ant
	•	Flare tool	Pipe flaring	Yes	*(Note 1)	¡
	‚	Copper pipe gauge for	Flaring by
		adjusting projection	conventional flare	Yes	(Note 1)	(Note 1)
		margin	tool		*	*
	ƒ	Torque wrench	Connection of flare	Yes	X	X
		(For Ø12,7)	nut
	„	Gauge manifold	Evacuating, refriger-		X	X
			ant charge, run	Yes
	…	Charge hose
			check, etc.
	†	Vacuum pump adapter	Vacuum evacuating	Yes	X	¡
	‡	Electronic balance for	Refrigerant charge	Yes	X	¡
		refrigerant charging
	ˆ	Refrigerant cylinder	Refrigerant charge	Yes	X	X
	‰	Leakage detector	Gas leakage check	Yes	X	¡
	Š	Charging cylinder	Refrigerant charge	(Note 2)	X	X

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

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

General tools (Conventional tools can be used.)

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

(1)	Vacuum pump	(4)	Reamer	(9)	Hole core drill (Ø65)
	Use vacuum pump by	(5)	Pipe bender	(10)	Hexagon wrench
	attaching vacuum pump adapter.	(6)	Level vial		(Opposite side 5mm)
(2)	Torque wrench (For Ø6,35)	(7)	Screwdriver (+, –)	(11)	Tape measure
(3)	Pipe cutter	(8)	Spanner or Monkey wrench	(12)	Metal saw

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

(1)	Clamp meter	(3)	Insulation resistance tester
(2)	Thermometer	(4)	Electroscope

– 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.

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.

When the compound gauge’s pointer has indicated –0,1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

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

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

(For refrigerant charging, see the figure below.)

• Never charge refrigerant exceeding the specified amount.

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

ƒDo not carry out additional charging.

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

(INDOOR unit)

(Liquid side)

(OUTDOOR unit)

Opened

(Gas side)

Refrigerant cylinder (With siphon pipe)

Check valve

Closed

Open/Close valve for charging

Service port

Electronic balance for refrigerant charging

Fig. 2-4-1 Configuration of refrigerant charging

– 12 –

• 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	Gauge manifold
OUTDOOR unit	OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

cylinder Refrigerant

Electronic

balance

Siphon

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.

Fig. 2-4-2

2-5. Brazing of Pipes

2-5-1. Materials for Brazing

(1)Silver brazing filler

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

(2)Phosphor bronze brazing filler

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

(3)Low temperature brazing filler

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

•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 foreign matter on the metal surface, it assists the flow of brazing filler.

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

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

– 13 –

(2)Characteristics required for flux

•Activated temperature of flux coincides with the brazing temperature.

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

•It is easy to remove slag after brazing.

•The corrosive action to the treated metal and brazing filler is minimum.

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

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

(3)Types of flux

•Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 800°C.

•Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

(4)Piping materials for brazing and used brazing filler/flux

Piping	Used brazing	Used
material	filler	flux
Copper - Copper	Phosphor copper	Do not use
Copper - Iron	Silver	Paste flux
Iron - Iron	Silver	Vapor flux

• 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.

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

„ Remove the flux after brazing.

2-5-3. Brazing

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

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

Never use gas other than Nitrogen gas.

(1) Brazing method to prevent oxidation

•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.

ƒApply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow 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.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe Nitrogen gas

Rubber plug

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	Air inlet	Air filter	Heat exchanger
Back body		790	208

275

6 60

		60
Air outlet	48	6

Knock out system

Knock out system

48

	64	53
120	590	80
	Hanger

Drain hose (0.54m)

Hanger

		45
		Minimum
		distance
	275	to ceiling
		170 or more

90 150

	320		Connecting pipe (0.43m)
			(Flare	6.35)
			Connecting pipe (0.33m)
			(For 10,13 series ; Flare 9.52
			For 16 series ; Flare		12.7)
	620			For stud bolt
235		235
215		215		( 8~	10)
	more
Minimum		Hanger		For stud bolt (		6)
distance	65or			26
to ceiling
					45
				Minimum
				distance	190		160
				to ceiling
				170 or more
					40
Hanger			Hanger	32		57	18
160		160	150	90		Wireless remote control

Installation plate outline

Center line

– 15 –

3-2. Outdoor Unit

RAS-3M23YACV-E					A leg part
310		bolt long hole pitch)	296		hole pitch)	270
		(Anchor			(ø6

B leg part

Fan guard

Hanger

687

695

8

600

18

115,5

780

	90	ø11 × 17U-shape hole
50
		(For ø8-ø10 anchor bolt)

8-ø6 hole

(For fixing outdoor unit) ø11 × 17 long hole

(For ø8-ø10 anchor bolt)

Charging port

123,8

68,5

332

Valve cover

86,2 53 53 53 53 53

Z

Connecting pipe port (Pipe dia.ø6,35)

Connecting pipe port (Pipe dia.ø9,52)

Connecting pipe port

(Pipe dia.ø12,7)

Z view

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

Intake

310

C100 or more

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

	moreor	600
		D	Intake
	50		A
			250 or more
			(Minimum distance
	moreor		from wall)
			Outside line
			of product
	200	Outlet	4 × ø11 × 17 long hole
		B	(For ø8-ø10 anchor bolt)

Detailed A leg part
			600
		50
		36	R15
		11
			Outside line
			of product
310	296	R5,5	2-ø6 hole
			2-ø6 hole
310	296	11

Outside line of product

36 R15

50

600

R5,5

Detailed B leg part

– 16 –

4. WIRING DIAGRAM

4-1. Indoor Unit

RAS-M10UKCV-E

RAS-M13UKCV-E

RAS-M16UKCV-E

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

	Check items		Diagnosis result
	1	OPERATION	Check to see if the OPERATION indicator goes on and off when the main switch
		INDICATOR	or breaker is turned on. (Check the primary and secondary voltage of transformer.)
	2	TERMINAL	Check for power supply voltage between • and ‚. (Refer to the name plate.)
			(Check the primary and secondary voltage of transformer.)
		BLOCK
			Check for fluctuate voltage between ‚ – ƒ. (DC 15 ~ 60V)
	3	FUSE	Check to see if the fuse blows out.
		6.3A	(Check the R04 of the varistor.)
	4	DC 5V	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.)
	5	DC 12V	Check for voltage at the while lead of louver motor.
			(Check the transformer and the power supply circuit of the rated voltage.)
	6	DC 35V	Check the voltage at the No.1 pin on CN10 connector.
		(DC310 ~ 340V)	(Check the DB01, R05 and C03.)

Refer to the service data for the detailed failure diagnosis.

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

– 17 –

4-2. Outdoor Unit

RAS-3M23YACV-E

POWER

To

To

To

SUPPLY

INDOOR

INDOOR

INDOOR

220–230–240V~

UNIT

UNIT

UNIT

50Hz

A

B

C

~ ~ ~

~ ~ ~ ~

~ ~ ~ ~

~ ~ ~ ~

L N

1 2 3

1 2 3

1 2 3 4

FAN MOTOR

FM

REACTOR

REACTOR

GRY PNK

YEL

RED WHI BLK

REACTOR

1

2

1

2

5

4

3

2

1

1

2

3

BLK

WHI BLK

THERMOSTAT for COMPRESSOR

5 4 3 2 1

1 2 3

P08

P07

CN301 CN300

P06

SURGE

PNK

ORN

ABSORBER

P03

CN08

1

1

P.C. BOARD

ORN

P04

2

2

F01

RED

TD

P05

MCC-758

FUSE

WHI

1

1

BLK

25A

P06

CN02

CT

BRW

BRW

2

2

P09

VARISTOR

1

1 1

3

3

CN704 32

RED

RED

32 32

CN15

TO

ORN

P10

ORN

ORN

BLK

4

YEL

YEL

4 4

F01

CN03

1

1

POWER RELAY

2

2

C13

C15

FUSE 6,3A

BLK

TGa

1

1

BLK

P02

1

1

G

CN501

CONVERTER MODULE

3

3

CN05 2

2

YEL

–

C12

C14

FUSE

3

3

E

F03

GRY

P01

3

3

A

FUSE

ELECTRONIC

15A

P11

1 1 YEL

BLK

TGb

~

STARTER

1

1

F04

2 2 YEL REACTOR

P12

CN06 2

2

BRW

DB01

~

3,15A

P13

PUR

PHOTO

BLK

TGc

+

P19

P14

COUPLER

1

1

YEL

P20

RELAY

CN07 2

2

GRN

3

3

+

BU

6

6

GRY

EU

5

5

RED

BLU

P.M.V.

CN14

4

4

MODULE

BV

3

3

ORN

A UNIT

EV

2

2

YEL

SUB

WHI

BW

1

1

P.C. BOARD

EW

IGBT

MCC-775

6

6

GRY

BX

5

5

BLU

RED

BY

4

4

P.M.V.

CN13 3

3

ORN

B UNIT

BZ

2

2

YEL

Q200

–

1

1

WHI

6

6

GRY

BLU

P18

P21

RED

5

5

RED

P17

P22

WHI

1 1

CM

CN12

4

4

BLU

P.M.V.

P23

BLK

2 2

3

3

ORN

C UNIT

3 3

2

2

YEL

WHI

COMPRESSOR

1

1

COLOR IDENTIFICATION

BLK : BLACK

BLU : BLUE ORN : ORANGE GRY : GRAY PNK : PINK SKB : SKY-BLUE

WHI : WHITE BRW : BROWN RED : RED YEL : YELLOW PUR : PURPLE GRN : GREEN

P.M.V. : PULSE MODULATING VALVE

– 18 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor Unit

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

	No.	Parts name	Type		Specifications
	1	Fan motor (for indoor)	ICF-340-30-2	DC340V, 30W
	2	Thermo. sensor (TA-sensor)	( – )	10kΩ at 25°C
	3	DC-DC transformer (T01)	SWT-70	DC390V, Secondary DC15V, 12V, 7V
	4	Microcomputer	( – )
	5	Heat exchanger sensor	( – )	10kΩ at 25°C
		(TC-sensor)
	6	Line filter (L01)	SS11V-06270	27mH, AC0,64A
	7	Diode (DB01)	D3SBA60	4A,	600V
	8	Capacitor (C03)	KMH450VNSN120M25C	120μF, 450V
	9	Fuse (F01)	FCU250V3.15A	T3,15A, 250V
	10	Power supply IC (IC01)	STR-L472
	11	Varistor (R21, R109)	15G561K	560V
	12	Resistor (R01)	RF-5TK5R6	4,7Ω, 5W
	13	Louver motor	MP24GA	Output (Rated) 1W, 16poles, 1phase DC12V

5-2. Outdoor Unit

RAS-3M23YACV-E

No.	Parts name	Model name				Rating
1	SC coil (Noise filter)	SC-15-S06J		15A,	0,6mH
		SC-20-01J		20A,	150µH
				Primary side DC280V
2	DC-DC transformer	SWT-43		Secondary side		7,5V x 1,	13V x 1
					26,5V x 3, 16V x 1,		15V 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		Coil	DC12V
				Contact	AC125V, 3A
6	Discharge temp. sensor	(Inverter attached)		62kΩ (20°C)
	(TD sensor)
7	Outside air temp. sensor	(Inverter attached)		10kΩ (25°C)
	(TO sensor)
8	Temp. sensor at A room	(Inverter attached)		10kΩ (25°C)
	gas side (TGa sensor)
9	Temp. sensor at B room	(Inverter attached)		10kΩ (25°C)
	gas side (TGb sensor)
10	Temp. sensor at C room	(Inverter attached)		10kΩ (25°C)
	gas side (TGc sensor)
11	Terminal block (9P)	———	20A, AC250V			(9P x 2)
		For protection of		3,15A,	AC250V
		switching power source
12	Fuse	For protection of transistor		15A,	AC250V
		module breakage
		For protection of		25A,	AC250V
		inverter input overcurrent
13	Electrolytic capacitor	LLQ2G501KHUATF		500µF, DC400V X 4 pieces
		400LISN500K35F
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

– 19 –

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

To	To
C room	B room

Connecting pipe Thickness : 0,8 mm

Ø9,52 : RAS-M10UKCV-E RAS-M13UKCV-E

Ø12,7 : RAS-M16UKCV-E

P Pressuremeasurement

Gauge attaching port Vacuum pump connecting port

INDOOR UNIT A

Indoor heat

exchanger

Cross flow fan

T1 Temp. measurement

To	To
C room	B room

Connecting pipe Thickness : 0,8 mm

Ø6,35

Allowable height difference : 10m

Allowable pipe length

Per 1 unit Max. : 20m Min. : 2m

Total

Max. : 40m

			Sectional shape
			of heat insulator
(Ø9,52)	(Ø9,52)	(Ø12,7)	(Ø6,35)	(Ø6,35)	(Ø6,35)
					Strainer
TGc	TGb	TGa

Pulse modulating valve at liquid side (SEV15RC2)

Accumulating tank

Ø51 x 300 TD (460cc)

Compressor DA130A1F-21F

Outdoor heat exchanger

Temp. measurement T2

Propeller fan

Refrigerant amount : 1,5kg (R410A)

OUTDOOR UNIT

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		No. of				Standard	Surface temp. of			Fan speed		Compressor
	condition (°C)			Combinations				heat exchanger
			operating				pressure						revolution
			units	of indoor units			P (Mpa)						(rps)
	Indoor	Outdoor						T1 (°C)		T2 (°C)	Indoor	Outdoor
				10	—	—	0,92	11		42	High	Med.	37
			1 unit	13	—	—	0,85	9		47	High	High	57
				16	—	—	0,73	8		50	High	High	73
				10	10	—	0,96	10,5 to	11,5	49	High	High	69
				13	10	—	0,92	11 to	12	51	High	High	78
			2 units	16	10	—	0,92	11 to	12	51	High	High	78
	27/19	35/–		13	13	—	0,92	11 to	12	51	High	High	78
				16	13	—	0,92	11 to	12	51	High	High	78
				16	16	—	0,92	11 to	12	51	High	High	78
				10	10	10	1,04	12,5 to	13,5	51	High	High	81
			3 units	13	10	10	0,98	12 to	13	52	High	High	89
				16	10	10	0,98	12 to	13	52	High	High	89
				13	13	10	0,98	12 to	13	52	High	High	89

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
							M.C.U.
						Functions
	Heat Exchanger Sensor								Operation
						•	Louver Control		Display
						•
	Temperature Sensor						3-minute Delay at Restart for Compressor		Timer
						•	Motor Revolution Control		Display
Infrared Rays Signal Receiver
						•	Processing		Filter Sign
									Display
							(Temperature Processing)
	Infrared	Initiallizing Circuit
						•			Fan Only
	Rays						Timer
		Clock Frequency
									Sign Display
		Oscillator Circuit
									Indoor Fan
									Motor

Power Supply

Circuit

Remote

Control

Noise Filter

From Outdoor Unit

REMOTE CONTROL

Outdoor unit				Louver ON/OFF Signal
ON/OFF Signal
				Louver Driver				Louver Motor
Relay Driver
		Relay RY04

Outdoor Unit

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 –

– 23 –

For Indoor unit

220–230–240V ~ 50Hz

MCC-775 (SUB P.C.B)

A unit		B unit		C unit
send/receive		send/receive		send/receive
circuit		circuit		circuit

	Discharge
								M.C.U
	temp. sensor
						•	Inverter output frequency control
						•	A/D converter function
	Gas side
	A, B, C pipe					•	P.M.V. control
	temp. sensor					•	Discharge temp. control
						•	Error display
						•	Signal communication to MCU
	Outdoor air
	temp. sensor
								Driver circuit of P.M.V.

MCC-758 (MAIN P.C.B)

								Rotor position
		M.C.U
								detect circuit
	•	PWM synthesis function
						Rotor position
	•	Input current release control
						detect circuit
	•	IGBT over-current detect control
	•	Outdoor fan control								Gate drive
	•	High power factor correction control								circuit
	•	Signal communication to MCU
						Over current
						detect circuit

	High power factor		Over current		Gate drive
	correction circuit		detect circuit		circuit
Noise	Input current	Converter		Over current		Inverter	Outdoor
filter	Sensor	(AC	DC)		sensor	(DC AC)	fan motor

	A unit	B unit	C unit	Over current	Inverter	Compressor
	P.M.V.	P.M.V.	P.M.V.	sensor	(DC AC)

Assembly) (Inverter Unit Outdoor .2-7

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 for 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 valve. Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors drive according to the operation command. And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller.

As the compressor adopts four-pole brushless DC motor, the frequency of the supply power from inverter to compressor is two-times cycles of the actual number of revolution.

(1)Role of indoor unit controller

The indoor unit controller judges the operation commands from the remote 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	üOperations followed
	control
		to judgment of serial
•	Operation control of	ýsignal from indoor

þside.

•P.M.V. control

•Detection of inverter input current and current release operation

•Over-current detection and prevention operation 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 operation revolution control

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

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

•Operation mode set on the remote control

•Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.)

•For these two types of signals ( [Operation mode] and [Compressor revolution] ), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value.

•Temperature of indoor heat exchanger by indoor

heat exchanger sensor (Minimum revolution control)outdoor fan motor

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

Contents of judgment are described below.

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

•Whether protective circuit operates

When no signal is received from the outdoor unit controller, it is assumed as a trouble.

8-1-1. Capacity Control

The cooling 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 by changing timing (current transfer timing) to exchange inverter output voltage and supply power winding.

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

Table 8-1-1 Compressor revolution range

No. of	Combination of	Compressor
operating unit	indoor units	revolution (rps)
	RAS-M16UKCV-E	16 to 77
1 unit	RAS-M13YKCV-E	16 to 72
	RAS-M10YKCV-E	16 to 45
2 units	¡*	19 to 84
3 units	¡*	23 to 92

* : In case that any multiple indoor units are combined.

8-1-2. Current Release Control

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

8-1-3. Power Factor Improvement Control

Power factor improvement control is performed mainly aiming to reduce the current on much power consumption of cooling operation. Controlling starts from the time when input power has reached at a certain point. To be concrete, IGBT of the power factor improvement circuit is used, and the power factor is improved by keeping IGBT on for an arbitrary period to widen electro-angle of the input current.

8-1-4. Prevent-Freezing Control

The indoor heat exchanger sensor detects refrigerant vapor temperature in COOL/DRY 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 exchanger.

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.

– 25 –

8-1-6. Louver Control

(1)Vertical air flow louvers

Positions of vertical air flow louvers are automatically controlled according to the operation status (COOL, AUTO, DRY, 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 louver is automatically set at the stored position in the next operation.

(2)Swing

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

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 relay, so selecting sound does not generate.

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

								Table 8-1-3
	Operation	Fan					RAS-M10UKCV-E			RAS-M13UKCV-E		RAS-M16UKCV-E
						Remote	Motor speed		Air flow rate	Motor speed	Air flow rate	Motor speed	Air flow rate
	mode	mode				Control	( rpm )		( m3/h )	( rpm )	( m3/h )	( rpm )	( m3 /h )
		H				HIGH	1190		560	1210	590	1350	670
	Cooling	M		+			1080		510	1130	530	1250	610
						MED+	1100		510	1130	530	1250	610
	and Fan	M				MED	1000		460	1050	490	1150	550
						LOW+	960		440	990	460	1070	500
	only	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
	DRY	L					910		400	910	400	980	450
		L		-			850		370	850	370	920	410
		UL					720		300	750	310	920	410
		SUL					660		260	700	280	800	340
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 fan by non-step variable system of the revolution speed, the revolution speed is restricted to three steps on the convenience of controlling.

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

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

Table 8-1-4

	Compressor revolution (rps)		~ 17,4	~ 38,9	39 ~
		TO ³ 38°C	500 (rpm)	800 (rpm)	800 (rpm)
	Outdoor temp. sensor
		38°C > TO ³ 15°C	500 (rpm)	700 (rpm)	800 (rpm)
	TO
		15°C > TO	390 (rpm)	390 (rpm)	390 (rpm)
		TO ³ 38°C	500 (rpm)	700 (rpm)	800 (rpm)
	ECONO. operation	38°C > TO ³ 15°C	500 (rpm)	500 (rpm)	700 (rpm)
		15°C > TO	390 (rpm)	390 (rpm)	390 (rpm)
	TO is abnormal		700 (rpm)	700 (rpm)	800 (rpm)

– 26 –