11.HOW TO DIAGNOSE THE TROUBLE ...................................................... 80
12.HOW TO REPLACE THE MAIN P ARTS................................................. 100
13.EXPLODED VIEWS AND PARTS LIST ................................................. 116
– 2 –
1. SAFETY PRECAUTIONS
For general public use
Power supply cord of outdoor unit shall be more than 1.5 mm² (H07RN-F or 60245IEC66) polychloroprene
sheathed flexible cord.
• Read this “SAFETY PRECAUTIONS” carefully before servicing.
• The precautions described below include the important items regarding safety. Observe them without fail.
• After the servicing work, perform a trial operation to check for any problem.
• Turn off the main power supply switch (or breaker) before the unit maintenance.
CAUTION
New Refrigerant Air Conditioner Installation
• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT
DESTROY OZONE LAYER.
R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because
the working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the
adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during
installation work, be sure that water , dust, former refrigerant, or refrigeration machine oil does not enter into
the new type refrigerant R410A air conditioner circuit.
To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging
port on main unit and installation tools are different from those used for the conventional refrigerant units.
Accordingly, special tools are required for the new refrigerant (R410A) units. For connecting pipes , use new
and clean piping materials with high pressure fittings made for R410A only, so that water and/or dust does
not enter. Moreover, do not use the existing piping because there are some problems with pressure fittings
and possible impurities in existing piping.
CAUTION
TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY
Disconnection from the supply mains:
The means for disconnection must be incorporated in the fixed wiring in accordance with the wiring rules.
DANGER
• ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO INSTALL/
MAINTAIN THE AIR CONDITIONER.
INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE.
• TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE
ALL POWER SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.
DANGER: HIGH VOLTAGE
The high voltage circuit is incorporated.
Be careful to do the check service, as the electric shock may be caused in case of touching parts
on the P.C. board by hand.
• CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED, ELECTRIC PARTS MAY BE DAMAGED.
• CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND
INSTALLATION. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.
– 3 –
• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE
TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.
• TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE
THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT
RESISTORS , FURNACE, STOVES, ETC.
• WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY
OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS
MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL
BECOME ABNORMALLY HIGH AND IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES.
• IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE
WORK AND THE INSTALLATION W ORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE
REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY
RESULT.
WARNING
• Never modify this unit by removing any of the saf ety guards or bypass any of the safety interlock
switches.
• Do not install in a place which cannot bear the weight of the unit. Personal injury and property
damage can result if the unit falls.
• After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source such as a cooking range, noxious gas
may generate.
• The electrical work must be performed by a qualified electrician in accor dance with the Installation
Manual. Make sure the air conditioner uses an exclusive circuit.
An insufficient circuit capacity or inappropriate installation may cause fire.
• When wiring, use the specified cables and connect the terminals securely to prevent external
forces applied to the cable from affecting the terminals.
• Be sure to provide grounding.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.
• Conform to the regulations of the local electric company when wiring the power supply.
Inappropriate grounding may cause electric shock.
CAUTION
• Exposure of unit to water or other moisture before installation may result in an electrical short.
Do not store in a wet basement or expose to rain or water.
• Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify
the noise level of the unit or where noise or discharged air might disturb neighbors.
• To avoid personal injury, be careful when handling parts with sharp edges.
• Perform the specified installation work to guard against an earthquake.
If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.
For Reference:
If a heating operation would be continuously perf ormed for a long time under the condition that the outdoor
temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate,
resulting in a trouble of the cabinet or fan.
It is recommended to procure an antifreeze heater locally for a safe installation of the air conditioner.
For details, contact the dealer.
– 4 –
2. SPECIFICATIONS
The indoor and outdoor units that can be used in combination are shown in the tables below.
Combinations of indoor unit models that can be connected
Refer to page 8 to 13
Refer to page 14 to 16
Indoor unit
NOTES
1-room connection is not an option for the indoor units (you cannot connect only one indoor unit).
Be sure to connect indoor units in two rooms or more.
The contents noted in this service manual limit the indoor units to the RAS-B10SKVP-E, RAS-B13SKVP-E,
RAS-B16SKVP-E, RAS-M10SKCVP-E, RAS-M13SKCVP-E and RAS-M16SKCVP-E.
For other indoor units that can also be used in combination, see the service manual of each indoor unit.
Net weight(kg)
Fan motor output(W)
Air flow rate (Cooling/Heating)(m³/h)
DimensionWidth(mm)
Net weight(kg)
CompressorType
Fan motor output(W)
Air flow rate(m³/h)
Type
Indoor unitLiquid side
Outdoor unit
Maximum length (per unit)(m)
Minimum length (per unit)(m)
Maximum length (total)(m)
Maximum chargeless length(m)
Additional refrigerant
Maximum height difference(m)
Name of refrigerant
Weight(kg)
Indoor unit
Outdoor unit
Running current(A)
Pow er consumption(W)
Power factor(%)
Operation mode
Running current(A)
Power factor(%)
Starting current(A)
Unit model
Heating
Height(mm)
Height(mm)
Depth(mm)
Motor output(W)
Model
Unit model
Gas side
A unit liquid side/Gas side
B unit liquid side/Gas side
C unit liquid side/Gas side
D unit liquid side/Gas side
Power supply
Interconnection
Indoor (Cooling/Heating)(°C)
Outdoor (Cooling/Heating)(°C)
Installation plate
Wireless remote controller
Label
Remote controller holder
Pan head wood screw
Purifying filter
Deodorizing filter
Batteries
Mounting screw
Installation manual
Installation manual
Specifications
Drain nipple
Water-proof rubber cap
Net weight(kg)
Fan motor output(W)
Air flow rate (Cooling/Heating)(m³/h)
DimensionWidth(mm)
Net weight(kg)
CompressorType
Fan motor output(W)
Air flow rate(m³/h)
Typ
Indoor unitLiquid side
Outdoor unit
Maximum length (per unit)(m)
Minimum length (per unit)(m)
Maximum length (total)(m)
Maximum chargeless length(m)
Additional refrigerant
Maximum height difference(m)
Name of refrigerant
Weight(kg)
Indoor unit
Outdoor unit
Running current(A)
Pow er consumption(W)
Power factor(%)
Operation mode
Running current(A)
Power factor(%)
Starting current(A)
Unit model
Heating
Height(mm)
Height(mm)
Depth(mm)
Motor output(W)
Model
Unit model
Gas side
A unit liquid side/Gas side
B unit liquid side/Gas side
C unit liquid side/Gas side
D unit liquid side/Gas side
2-2-2. Capacity Variation Ratio According to Outdoor Temperature
<Cooling><Heating>
RAS-4M23SAV-E, RAS-4M23SACV-ERAS-4M23SAV-E
105
100
95
90
85
80
75
70
65
Capacity ratio (%)
60
55
50
32 33 34 35 36 37 38 3943–15–10–505710
• Conditions
Indoor : DB27˚C/WB19˚C
Indoor air flow: High
Pipe length: 5m × 4
4 units operating
40 41 42
Outdoor temp. (˚C)
110
100
90
80
70
60
Capacity ratio (%)
50
40
• Conditions
Indoor : DB20˚C/WB15˚C
Indoor air flow: High
Pipe length: 5m × 4
4 units operating
220V
230V
240V
Compressor speed (rps)
Outdoor temp. (˚C)
2-2-3. Capacity Variation Ratio According to Pipe Length
<Cooling><Heating>
RAS-4M23SAV-E, RAS-4M23SACV-ERAS-4M23SAV-E
110
105
100
95
90
85
Coolimg capacity ratio (%)
80
• Conditions
Indoor : DB27˚C/WB19˚C
Outdoor: DB35˚C/WB24˚C
Indoor air flow: High
4 units operating
Standard pipe length 20m
Maximum pipe length 60m
Total pipe length (m)
706050403020100
110
105
100
95
90
85
Heating capacity ratio (%)
80
Standard pipe
length 20m
Maximum pipe length 60m
– 17 –
• Conditions
Indoor : DB20˚C/WB15˚C
Outdoor: DB7˚C/WB6˚C
Indoor air flow: High
4 units operating
Total pipe length (m)
706050403020100
3. REFRIGERANT R410A
This air conditioner adopts the new refrigerant HFC
(R410A) which does not damage the ozone layer.
The working pressure of the new refrigerant R410A
is 1.6 times higher than conventional refrigerant
(R22). The refrigerating oil is also changed in
accordance with change of refrigerant, so be careful
that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of
the air conditioner using the new refrigerant during
installation work or servicing time.
The next section describes the precautions for air
conditioner using the new refrigerant. Conforming
to contents of the next section together with the
general cautions included in this manual, perform
the correct and safe work.
3-1. Safety During Installation/Servicing
As R410A’s pressure is about 1.6 times higher than
that of R22, improper installation/servicing may
cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out
installation/servicing safely while taking the following precautions into consideration.
1. Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.
If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc.
by a rupture.
2. Confirm the used refrigerant name, and use
tools and materials exclusive for the refrigerant
R410A.
The refrigerant name R410A is indicated on the
visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent
mischarging, the diameter of the service por t
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 may result in water leakage,
electric shock and fire, etc.
3-2. Refrigerant Piping Installation
3-2-1. Piping Materials and Joints Used
For the refrigerant piping installation, copper pipes
and joints are mainly used. Copper pipes and joints
suitable for the refrigerant 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 3-2-1. Never use copper
pipes thinner than 0.8 mm even when it is
available on the market.
– 18 –
Table 3-2-1 Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter
1/4
3/8
1/2
5/8
Outer diameter (mm)
6.35
9.52
12.70
15.88
R410AR22
0.800.80
0.800.80
0.800.80
1.001.00
2. Joints
For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.
a) Flare Joints
Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds
20 mm. In such a case, socket joints can be used.
Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-2-6 below.
b) Socket Joints
Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose
diameter is larger than 20 mm.
Thicknesses of socket joints are as shown in Table 3-2-2.
Table 3-2-2 Minimum thicknesses of socket joints
Nominal diameter
1/4
3/8
1/2
5/8
Reference outer diameter of
copper pipe jointed (mm)
6.35
9.52
12.70
15.88
Minimum joint thickness
(mm)
0.50
0.60
0.70
0.80
3-2-2. Processing of Piping Materials
When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not
enter the pipe interior, that no other oil than lubricating oils used in the installed air-water heat pump is used,
and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating
oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or
any other cover.
1. Flare processing procedures and precautions
a) Cutting the Pipe
By means of a pipe cutter, slowly cut the pipe so that it is not deformed.
b) Removing Burrs and Chips
If the flared section has chips or burrs, refrigerant leakage may occur.
Carefully remove all burrs and clean the cut surface before installation.
c) Insertion of Flare Nut
– 19 –
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.
Table 3-2-3 Dimensions related to flare processing for R410A
Nominal
diameter
Outer
diameter
(mm)
Thickness
(mm)
Fig. 3-2-1 Flare processing dimensions
Flare tool for R410A
clutch type
ØD
A
A (mm)
Conventional flare tool
Clutch type Wing nut type
1/4
3/8
1/2
5/8
Nominal
diameter
1/4
3/8
1/2
5/8
6.35
9.52
12.70
15.88
0.8
0.8
0.8
1.0
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
Table 3-2-4 Dimensions related to flare processing for R22
Outer
diameter
(mm)
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
Flare tool for R22
clutch type
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
1.0 to 1.51.5 to 2.0
1.0 to 1.51.5 to 2.0
1.0 to 1.52.0 to 2.5
1.0 to 1.52.0 to 2.5
A (mm)
Conventional flare tool
Clutch type Wing nut type
0.5 to 1.01.0 to 1.5
0.5 to 1.01.0 to 1.5
0.5 to 1.01.5 to 2.0
0.5 to 1.01.5 to 2.0
Nominal
diameter
1/4
3/8
1/2
5/8
Table 3-2-5 Flare and flare nut dimensions for R410A
Outer diameter
(mm)
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
Dimension (mm)
ABCD
9.19.26.513
13.213.59.720
16.616.012.923
19.719.016.025
– 20 –
Flare nut width
(mm)
17
22
26
29
Table 3-2-6 Flare and flare nut dimensions for R22
Nominal
diameter
1/4
3/8
1/2
5/8
3/4
Outer diameter
(mm)
6.35
9.52
12.70
15.88
19.05
45˚ to 46˚
Thickness
(mm)
0.8
0.8
0.8
1.0
1.0
BA
Dimension (mm)
ABCD
9.09.26.513
13.013.59.720
16.216.012.920
19.719.016.023
23.324.019.234
D
C
43˚ to 45˚
Flare nut width
(mm)
17
22
24
27
36
Fig. 3-2-2 Relations between flare nut and flare seal surface
2. Flare Connecting Procedures and Precautions
a) Make sure that the flare and union portions do not have any scar or dust, etc.
b) Correctly align the processed flare surface with the union axis.
c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is
the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage ma y occur.
When it is strong, the flare nut may crack and may be made non-removable. When choosing the tighten-
ing torque, comply with values designated by man ufacturers. Table 3-2-7 shows reference values.
NOTE :
When applying oil to the flare surface, be sure to use oil designated by the manufacturer.
If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.
Table 3-2-7 Tightening torque of flare for R410A [Reference values]
Nominal
diameter
Outer diameter
(mm)
Tightening torque
N•m (kgf•cm)
Tightening torque of torque
wrenches available on the market
N•m (kgf•cm)
1/4
3/8
1/2
5/8
6.35
9.52
12.70
15.88
14 to 18 (140 to 180)
33 to 42 (330 to 420)
50 to 62 (500 to 620)
63 to 77 (630 to 770)
– 21 –
16 (160), 18 (180)
42 (420)
55 (550)
65 (650)
3-3. Tools
3-3-1. Required Tools
The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is
changed to prev ent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing
dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are
lengthened.
The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge,
clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.
1. Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))
2. Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)
3. Tools commonly used for R410A and for conventional refrigerant (R22)
The table below shows the tools exclusive for R410A and their interchangeability.
Tools exclusive for R410A (The following tools for R410A are required.)
Tools whose specifications are changed for R410A and their interchangeability
air-water heat pump installation
No.
1
2
3
4
5
6
7
8
9
10
(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection
(Note 2) Charging cylinder for R410A is being currently developed.
Whether new equipment
can be used with
conventional refrigerant
¡
*(Note 1)
×
×
¡
¡
×
¡
×
General tools (Conventional tools can be used.)
In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary
as the general tools.
1. Vacuum pump
Use vacuum pump by attaching
vacuum pump adapter.
2. Torque wrench (For Ø6.35, Ø9.52)
3. Pipe cutter
4. Reamer
5. Pipe bender
6. Lev el vial
7. Screwdriver (+, –)
8. Spanner or Monkey wrench
9. Hole core drill (Ø65)
10. Hexagon wrench
(Opposite side 4mm)
11 . Tape measure
12. Metal saw
Also prepare the following equipments for other installation method and run check.
1. Clamp meter
2. Thermometer
3. Insulation resistance tester
4. Electroscope
– 22 –
3-4. Recharging of Refrigerant
When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the
following steps .
Recover the refrigerant, and check no refrigerant
remains in the equipment.
Connect the charge hose to packed valve service
port at the outdoor unit’s gas side.
Connect the charge hose to the vacuum pump
adapter.
Open fully both packed valves at liquid and gas
sides.
When the compound gauge’s pointer has indicated
–0.1 Mpa (–76 cmHg), place the handle Low in the
fully closed position, and turn off the vacuum pump’s
power switch.
Keep the status as it is for 1 to 2 minutes, and ensure
that the compound gauge’s pointer does not return.
Set the refrigerant cylinder to the electronic balance,
connect the connecting hose to the cylinder and the
connecting port of the electronic balance, and charge
liquid refrigerant.
Place the handle of the gauge manifold Low in the
fully opened position, and turn on the vacuum pump’s
power switch. Then, evacuating the refrigerant in the
cycle.
(For refrigerant charging, see the figure below.)
1. Never charge refrigerant e xceeding the specified amount.
2. If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.
3. Do not carry out additional charging.
When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the
refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the
specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high
pressure, and may cause a rupture or personal injury.
(Water heat
exchanger unit)
Opened
(Outdoor unit)
Refrigerant cylinder
(with siphon)
Check valve
Opened
Open/close
valve for charging
Electronic balance for refrigerant charging
Fig. 3-4-1 Configuration of refrigerant charging
Opened
Closed
Service port
– 23 –
1. Be sure to make setting so that liquid can be charged.
2. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.
It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant.
Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the
cylinder upside down if cylinder is not equipped with siphon.
[ Cylinder with siphon ][ Cylinder without siphon ]
Gauge manifold
OUTDOOR unit
Refrigerant
cylinder
Gauge manifold
OUTDOOR unit
cylinder
Refrigerant
Electronic
balance
R410A refrigerant is HFC mixed refrigerant.
Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the
characteristics of the equipment varies.
3-5. Brazing of Pipes
3-5-1. Materials for Brazing
1. Silver brazing filler
Silver brazing filler is an allo y mainly composed
of silver and copper. It is used to join iron, copper
or copper alloy, and is relatively expensive though
it excels in solderability.
2. Phosphor bronze brazing filler
Phosphor bronze brazing filler is generally used
to join copper or copper alloy.
Electronic
balance
Siphon
Fig. 3-4-2
1. Phosphor bronze brazing filler tends to react
with sulfur and produce a fragile compound
water solution, which may cause a gas
leakage. Therefore , use any other type of
brazing filler at a hot spring resort, etc., and
coat the surface with a paint.
2. When performing brazing again at time of
servicing, use the same type of brazing filler.
3-5-2. Flux
3. Low temperature brazing filler
Low temperature brazing filler is generally called
solder, and is an alloy of tin and lead. Since it is
weak in adhesive strength, do not use it for
refrigerant pipes.
1. Reason why flux is necessar y
• 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.
– 24 –
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 o xide film removing
capability due to the addition of compounds
such as potassium fluoride, potassium chloride
and sodium fluoride to the borax-boric acid
compound.
4. Piping materials for brazing and used
brazing filler/flux
3-5-3. Brazing
As brazing work requires sophisticated techniques,
experiences based upon a theoretical knowledge, it
must be performed by a person qualified.
In order to prev ent the oxide film from occurring in
the pipe interior during brazing, it is effective to
proceed with brazing while letting dry Nitrogen gas
(N2) flow.
Never use gas other than Nitrogen gas.
1. Brazing method to prevent oxidation
1) Attach a reducing valve and a flow-meter to
the Nitrogen gas cylinder.
2) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.
3) Apply a seal onto the clearance betw een the
piping material and inserted copper pipe for
Nitrogen in order to prevent backflow of the
Nitrogen gas.
4) When the Nitrogen gas is flowing, be sure to
keep the piping end open.
5) Adjust the flow rate of Nitrogen gas so that it
is lower than 0.05 m3/Hr or 0.02 MPa
(0.2kgf/cm2) by means of the reducing valve.
6) After performing the steps above, keep the
Nitrogen gas flowing until the pipe cools down
to a certain extent (temperature at which
pipes are touchable with hands).
7) Remo ve the flux completely after brazing.
Piping material
Copper - Copper
Copper - Iron
Iron - Iron
Used brazing filler
Phosphor copper
Silver
Silver
Used flux
Do not use
Paste flux
Vapor flux
1. Do not enter flux into the refrigeration cycle.
2. When chlorine contained in the flux remains
within the pipe, the lubricating oil deteriorates.
Therefore, use a flux which does not contain
chlorine.
3. When adding water to the flux, use water
which does not contain chlorine (e.g. distilled
water or ion-exchange water).
4. Remove the flux after brazing.
M
Flow meter
Stop valve
Nitrogen gas
cylinder
From Nitrogen cylinder
Pipe
Nitrogen
gas
Rubber plug
Fig. 3-5-1 Prevention of oxidation during braz-
– 25 –
4. CONSTRUCTION VIEWS
42
Hanging section
Stud bolt hole for Ø6
Outline of
installation plate
Lower part
hanging section
Center line of installation plateCenter line of main unit
IGBT: Insulated Gate Bipolar Transistor
PMV: Pulse Motor Valve
TD: Discharge T emp . sensor
TGa to TGd : Temp. sensor at A to D unit gas side
TO: Outdoor T emp. sensor
TE: Evaporator T emp . sensor
TS: SuctionTemp. sensor
∗1 Heat Pump model only
∗2 Heat Pump model only : GRY
Cooling only model only : BLU
Thermostat for
compressor
ORN
ORN
4-way valve coil
Fan motor
FM
PMV
D
PMV
C
PMV
B
PMV
A
1
GRY
RED
YEL
BLK
WHI
RED
WHI
GRY
ORN
RED
YEL
BLK
WHI
GRY
ORN
RED
YEL
BLK
WHI
GRY
ORN
RED
YEL
BLK
WHI
GRY
ORN
RED
YEL
BLK
P501
212
1
P500
313
3
CN705
1
5
5
4
4
3
CN301
2
1
1
3
3
2
2
CN300
1
1
6
6
5
5
4
4
CN704
3
3
BLU
2
2
1
1
6
6
5
5
4
4
CN703
3
3
RED
2
2
1
1
6
6
5
5
4
4
CN702
3
3
WHI
2
2
1
1
6
6
5
5
4
4
CN701
3
3
YEL
2
2
1
1
P07 P03P04
WHI
∗1
SUB P.C. Board
ORN
RED
(MCC-818)
Fan
circuit
F300
Fuse, T3.15A
250V
Photo coupler
PNKYEL
Reactor
Color Identification
CN802
CN608
CN607
CN606
CN605
CN604
∗1
CN603
CN602
CN601
CN302
~
CN800
CN303
CN501
F500
Fuse, T6.3A
~
250V
P05P06
Capacitor
BLK : BLACK
WHI : WHITE
BLU : BLUE
BRW : BROWN
RED : RED
ORN : ORANGE
GRY : GRAY
YEL : YELLOW
PNK : PINK
PUR : PURPLE
GRN : GREEN