Toshiba RAS-M22SKV-E, RAS-M24SKV-E SERVICE MANUAL
SERVICE MANUAL
AIR-CONDITIONER
SPLIT TYPE
Indoor Unit
FILE NO. SVM-10070
<High Wall, Heat Pump Type>
RAS-M22SKV-E
RAS-M24SKV-E
R410A
PRINTED IN JAPAN
CONTENTS
1. SAFETY PRECAUTIONS .......................................................................... 3
2. SPECIFICATIONS...................................................................................... 5
3. REFRIGERANT R410A ............................................................................. 6
4. CONSTRUCTION VIEWS ........................................................................ 14
5. WIRING DIAGRAM .................................................................................. 15
6. SPECIFICATIONS OF ELECTRICAL PARTS ........................................ 16
7. REFRIGERANT CYCLE DIAGRAM ........................................................ 17
8. CONTROL BLOCK DIAGRAM ................................................................ 18
9. OPERATION DESCRIPTION ................................................................... 19
10. INSTALLATION PROCEDURE ................................................................ 40
11. HOW TO DIAGNOSE THE TROUBLE ...................................................... 50
12. HOW TO REPLACE THE MAIN PARTS ................................................... 67
13. EXPLODED VIEWS AND PARTS LIST ................................................... 74
– 2 –
1. SAFETY PRECAUTIONS
For general public use
Power supply cord of outdoor unit shall be more than 1.5 mm ² (H07RN-F or 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
This appliance must be connected to the main power supply by a circuit breaker or a switch with a contact
separation of at least 3 mm.
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
REGISTERS, 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 WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM.
IF THE REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS
MAY RESULT.
WARNING
• Never modify this unit by removing any of the safety guards or bypass any of the safety interlock
switches.
• Do not install in a place which cannot bear the weight of the unit. Personal injury and property
damage can result if the unit falls.
• After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas
may generate.
• The electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive circuit.
An insufficient circuit capacity or inappropriate installation may cause fire.
• When wiring, use the specified cables and connect the terminals securely to prevent external
forces applied to the cable from affecting the terminals.
• Be sure to provide grounding.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.
• Conform to the regulations of the local electric company when wiring the power supply.
Inappropriate grounding may cause electric shock.
CAUTION
• Exposure of unit to water or other moisture 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 performed 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
3
3
∅
∅
(
(
∅
∅
RAS-M22SKV-E, RAS-M24SKV-E
Unit model RAS-M22SKV-E RAS-M24SKV-E
Cooling capacity (kW)
Cooling capacity range (kW)
Heating capacity (kW)
Heating capacity range (kW)
Power supply 1Ph/50Hz/220-240V 1Ph/50Hz/220-240V
Electric Indoor Operation mode Cooling Heating Cooling Heating
characteristic Running current (A) 0.38-0.35 0.38-0.35 0.38-0.35 0.38-0.35
Power consumption (W) 50 50 50 50
Power factor (%) 60 60 60 60
Outdoor Operation mode Cooling Heating Cooling Heating
Running current (A)
Power consumption (W)
Power factor (%)
Starting current (A) * *
COP (Cooling/Heating) * *
Operating Indoor High (Cooling/Heating) (dB-A) 47/47 49/49
noise Medium (Cooling/Heating) (dB-A) 41/41 43/43
Low (Cooling/Heating) (dB-A) 35/35 37/37
Outdoor (Cooling/Heating) (dB-A) * *
Indoor unit Dimension High (mm) 320 320
Medium (mm) 1050 1050
Depth (mm) 228 228
Net weight (kg) 13 13
Fan motor output 30 30
(m
Air flow rate (Cooling/Heating)
Outdoor unit Unit model
Dimension High (mm)
Medium (mm)
Depth (mm)
Net weight (kg)
Compressor Motor output (W)
Type
/min)
**
1Ph/60Hz/220V 1Ph/60Hz/220V
**
18.0/18.3 18.9/19.2
**
Model
Fan motor output (W)
/min)
Air flow rate (Cooling/Heating)
Piping Type Flare connection Flare connection
connection Indoor unit Liquid side (mm)
Gas side (mm)
Outdoor unit Liquid side (mm)
Gas side (mm)
Maximum length (m)
Maximum chargeless length (m)
Maximum height difference (m)
Refrigerant Name of refrigerant R410A R410A
Weight (kg) * *
Wiring Power supply (Outdoor) 3Wires:includes earth 3Wires:includes earth
connection Interconnection 4Wires:includes earth 4Wires:includes earth
Usable temperature range Indoor unit (Cooling/Heating)
Outdoor unit (Cooling/Heating)
Accessory Indoor unit Installation plate 1 1
Wireless remote control 1 1
Batteries 2 2
Remote control holder 1 1
TOSHIBA IAQ Filter 4 4
Mounting screw (
Pan head wood screw
for Remoto control holder (
Installation manual 1 1
Owner's manual 1 1
4x25L) 6 6
(m
6.35 ∅ 6.35
12.7 ∅ 12.7
**
°C) 21-32 / 0-28 21-32 / 0-28
°C) * *
3.1x16L)
22
Outdoor unit -
-
* Refer to SERVICE MANUAL of connected outdoor unit.
The specification is different to each ooutdoor unit.
• The specfications may be subject to change without notice for purpose of improvement.
**
– 5 –
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 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 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.
– 6 –
Table 3-2-1 Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter
1/4
3/8
1/2
5/8
Outer diameter (mm)
6.35
9.52
12.70
15.88
R410A R22
0.80 0.80
0.80 0.80
0.80 0.80
1.00 1.00
2. Joints
For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.
a) Flare Joints
Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds
20 mm. In such a case, socket joints can be used.
Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-2-6 below.
b) Socket Joints
Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose
diameter is larger than 20 mm.
Thicknesses of 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
– 7–
A
ØD
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
Fig. 3-2-1 Flare processing dimensions
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
Table 3-2-4 Dimensions related to flare processing for R22
Nominal
diameter
Outer
diameter
(mm)
1/4 6.35 0.8
3/8 9.52 0.8
Thickness
(mm)
Thickness
(mm)
Flare tool for R410A
clutch type
0 to 0.5
0 to 0.5
0 to 0.5
0 to 0.5
Flare tool for R22
clutch type
0 to 0.5
0 to 0.5
A (mm)
Conventional flare tool
Clutch type Wing nut type
1.0 to 1.5 1.5 to 2.0
1.0 to 1.5 1.5 to 2.0
1.0 to 1.5 2.0 to 2.5
1.0 to 1.5 2.0 to 2.5
A (mm)
Conventional flare tool
Clutch type Wing nut type
0.5 to 1.0 1.0 to 1.5
0.5 to 1.0 1.0 to 1.5
1/2 12.70 0.8
5/8 15.88 1.0
Table 3-2-5 Flare and flare nut dimensions for R410A
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
– 8 –
0 to 0.5
0 to 0.5
0.5 to 1.0 1.5 to 2.0
0.5 to 1.0 1.5 to 2.0
Dimension (mm)
ABCD
9.1 9.2 6.5 13
13.2 13.5 9.7 20
16.0 16.6 12.9 23
19.0 19.7 16.0 25
Flare nut width
(mm)
17
22
26
29
Table 3-2-6 Flare and flare nut dimensions for 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
45˚ to 46˚
B A
Dimension (mm)
ABCD
9.0 9.2 6.5 13
13.0 13.5 9.7 20
16.0 16.2 12.9 20
19.0 19.7 16.0 23
23.3 24.0 19.2 34
D
C
43˚ to 45˚
Flare nut width
(mm)
17
22
24
27
36
Fig. 3-2-2 Relations between flare nut and flare seal surface
2. Flare Connecting Procedures and Precautions
a) Make sure that the flare and union portions do not have any scar or dust, etc.
b) Correctly align the processed flare surface with the union axis.
c) Tighten the flare with designated torque by means of a torque wrench.
The tightening torque for R410A is the same as that for conventional R22.
Incidentally, when the torque is weak, the gas leakage may occur.
When it is strong, the flare nut may crack and may be made non-removable.
When choosing the tightening torque, comply with values designated by manufacturers.
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)
1/4 6.35 14 to 18 (140 to 180)
torque wrenches available on the market
Tightening torque of
N•m (kgf•cm)
16 (160), 18 (180)
3/8 9.52 33 to 42 (330 to 420)
1/2 12.70 50 to 62 (500 to 620)
5/8 15.88 63 to 77 (630 to 770)
– 9 –
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 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
No.
1
2
3
4
5
6
7
8
9
10
Used tool
Flare tool
Copper pipe gauge
for adjusting
projection margin
Torque wrench
(For Ø12.7)
Gauge manifold
Charge hose
Vacuum pump
adapter
Electronic balance for
refrigerant charging
Refrigerant cylinder
Leakage detector
Charging cylinder
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
air-water heat pump installation
R410A
Existence of Whether conventional
new equipment equipment can be
for R410A used
Ye s ∗ (Note 1)
Ye s ∗ (Note 1)
Ye s N o
Ye s N o
Ye s N o
Ye s N o
Ye s N o
Ye s N o
∗ (Note 2) No
Conventional air-water
heat pump installation
Whether new equipment
can be used with
conventional refrigerant
Ye s
∗ (Note 1)
No
No
Ye s
Ye s
No
Ye s
No
(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
Use vacuum pump by attaching
vacuum pump adapter.
2. Torque wrench (For Ø6.35, Ø9.52)
3. Pipe cutter
4. Reamer
5. Pipe bender
6. Level vial
7. Screwdriver (+, –)
8. Spanner or Monkey wrench
9. Hole core drill (Ø65)
10. Hexagon wrench
(Opposite side 4mm)
11. Tape measure
12. Metal saw
Also prepare the following equipments for other installation method and run check.
1. Clamp meter
2. Thermometer
3. Insulation resistance tester
4. Electroscope
– 10 –
3-4. Recharging of Refrigerant
When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the
following steps.
Recover the refrigerant, and check no refrigerant
remains in the equipment.
Connect the charge hose to packed valve service
port at the outdoor unit’s gas side.
Connect the charge hose to the vacuum pump
adapter.
Open fully both packed valves at liquid and gas
sides.
When the compound gauge’s pointer has indicated
–0.1 Mpa (–76 cmHg), place the handle Low in the
fully closed position, and turn off the vacuum pump’s
power switch.
Keep the status as it is for 1 to 2 minutes, and ensure
that the compound gauge’s pointer does not return.
Set the refrigerant cylinder to the electronic balance,
connect the connecting hose to the cylinder and the
connecting port of the electronic balance, and charge
liquid refrigerant.
Place the handle of the gauge manifold Low in the
fully opened position, and turn on the vacuum pump’s
power switch. Then, evacuating the refrigerant in the
cycle.
(For refrigerant charging, see the figure below.)
1. Never charge refrigerant exceeding the specified amount.
2. If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.
3. Do not carry out additional charging.
When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the
refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the
specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high
pressure, and may cause a rupture or personal injury.
(Indoor 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
– 11 –
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 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.
Electronic
balance
Siphon
Fig. 3-4-2
1. Phosphor bronze brazing filler tends to react
with sulfur and produce a fragile compound
water solution, which may cause a gas
leakage. Therefore, use any other type of
brazing filler at a hot spring resort, etc., and
coat the surface with a paint.
2. When performing brazing again at time of
servicing, use the same type of brazing filler.
3-5-2. Flux
3. Low temperature brazing filler
Low temperature brazing filler is generally called
solder, and is an alloy of tin and lead.
Since it is weak in adhesive strength, do not use
it for refrigerant pipes.
1. Reason why flux is necessary
• By removing the 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.
– 12 –
Nitrogen gas
cylinder
Pipe
Flow meter
M
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 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
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 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
1) Attach a reducing valve and a flow-meter to
the Nitrogen gas cylinder.
2) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.
3) Apply a seal onto the clearance between the
piping material and inserted copper pipe for
Nitrogen in order to prevent backflow of the
Nitrogen gas.
4) When the Nitrogen gas is flowing, be sure to
keep the piping end open.
5) Adjust the flow rate of Nitrogen gas so that it
is lower than 0.05 m3/Hr or 0.02 MPa
(0.2kgf/cm2) by means of the reducing valve.
6) After performing the steps above, keep the
Nitrogen gas flowing until the pipe cools down
to a certain extent (temperature at which
pipes are touchable with hands).
7) Remove the flux completely after brazing.
Piping material
Copper - Copper
1. Do not enter flux into the refrigeration cycle.
2. When chlorine contained in the flux remains
3. When adding water to the flux, use water
4. Remove the flux after brazing.
Copper - Iron
Iron - Iron
Used brazing filler
Phosphor copper
Silver
Silver
Used flux
Do not use
Paste flux
Vapor flux
within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not
contain chlorine.
which does not contain chlorine
(e.g. distilled water or ion-exchange water).
Fig. 3-5-1
Prevention of oxidation during brazing
– 13 –
4-1. Indoor Unit
RAS-M22SKV-E, RAS-M24SKV-E
4. CONSTRUCTION VIEWS
1050
Front panel
73.5
7
50
Knock out system Knock out system
Air filter
320
Heat exchanger
Installation plate hanger
132 568 200 150
Air inlet
228
50
50
72 78
56 24
Wireless remote controller
73.5
7
204
Installation plate hanger
Connecting plate (0.39m)
(For 18, 22 series; Flare Ø12.70mm)
132 786
85
320
40
47 215.5 262.5 262.5 153.5 109
Center line Instrallation plate outline
235
215 215
Hanger
Hanger
Drain hose
(0.5mm)
235
Hanger
Connecting pipe (0.49m)
(Flare Ø6.35mm)
132
23
40
125
63
Remote controller holder
26
– 14 –
5. WIRING DIAGRAM
Outdoor terminal block
Indoor terminal block
Power supply
(From Outdoor unit)
1Ø, 220 – 240V
1Ø, 220V ~, 60Hz
Sheet metal
Heat exchanger sensor
(TCJ)
1
2
Heat exchanger sensor
(TC)
121
Thermo sensor
(TA)
BLU
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
MCC-5044
9
9
10
10
11
Wireless unit assembly
11
CN10
(WHI)
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
WHI
1
2
3
4
5
6
7
8
9
10
11
CN21
(WHI)
11
22
1
2
2
1
2
3
4
5
6
7
8
9
10
11
BLK
CN02
Fuse F01
T3.15A
AC250V
CN63
(YEL)
CN62
(BLU)
CN61
(WHI)
1 2 3
1 2 3
BLK
WHI
RED
~
, 50Hz
3
1
CN51
CN01
Varistor
Line filter
–
Main P.C. board
MCC-5045
DC5V
DC12V
~
+
~
Heat exchanger
GRN & YEL
Power supply circuit
1
1
3
3
4 4
5
5
6 6
CN31
(WHI)
1
1
2
2
3
3
4
4
5
5
CN32
(WHI)
CN22
(WHI)
1
2
3
4
WHI
YEL
YEL
YEL
YEL
DC motor
Fan motor
1
1
2
2
3
3
4
4
5
5
Louver motor
Color
Identification
YEL :
BLK : BLACK
WHI : WHITE
RED : RED
BLU : BLUE
GRN & YEL :
GRAY &
YELLOW
YELLOW
– 15 –
6-1. Indoor Unit
6. SPECIFICATIONS OF ELECTRICAL PARTS
No.
1
Fan motor
(for indoor)
2
Room temp. sensor (TA-sensor)
3
Heat exchanger temp. sensor (TC-sensor)
4
Heat exchange temp. sensor (TCJ-sensor)
5 Louver motor 24BYJ48-HT Output (Rated) 1W, 16 poles, DE12V
Parts name
Type
MFF-340-30-2
( — )
( — )
( — )
Specifications
DC340V, 30W
10kΩ at 25°C
10kΩ at 25°C
10kΩ at 25°C
– 16 –
7. REFRIGERANT CYCLE DIAGRAM
7-1. Refrigerant Cycle Diagram
RAS-M22SKV-E
RAS-M24SKV-E
P
Pressure measurement
Gauge attaching port
Vacuum pump connecting port
Deoxidized copper pipe
Outer dia. : 12.7mm
Thickness : 0.8mm
INDOOR UNIT
Indoor heat
exchanger
Cross flow fan
Deoxidized copper pipe
Outer dia. : 6.35mm
Thickness : 0.8mm
Sectional shape
of heat insulator
T1 Temp. measurement
TCJ
TC
TA
difference: * m
Allowable height
Per 1 unit
Max. : * m
Min. : * m
Chargeless : * m
Charge : * m
Total
Max. : * m
Allowable pipe length
OUTDOOR UNIT *
NOTE :
* Refer to SERVICE MANUAL of connected outdoor unit.
The specification is different to each outdoor unit.
NOTE:
Gas leak check position
– 17 –
8. CONTROL BLOCK DIAGRAM
8-1. Indoor Unit
RAS-M22SKV-E, RAS-M24SKV-E
Heat Exchanger Sensor (Tcj)
Heat Exchanger Sensor (Tc)
Room Temperature Sensor (Ta)
Infrared Rays Signal Receiver
and Indication
Initializing Circuit
Clock Frequency
Oscillator Circuit
Power Supply Circuit
Converter (D.C circuit)
Noise Filter
M.C.U.
Functions
• Cold draft preventing Function
• 3-minute Delay at Restart
for Compressor
• Fan Motor Starting Control
• Processing
(Temperature Processing)
• Timer
• Serial Signal Communication
• Clean Function
Serial Signal Transmitter/Receiver
Indoor Unit Control Unit
Louver
Motor
Louver Motor
Drive Control
Indoor Fan
Motor Control
Indoor
Fan Motor
From Outdoor Unit
220-240V ~50Hz
220V ~60Hz
REMOTE CONTROLLER
Serial Signal Communication
(Operation Command and Information)
Remote Controller
Infrared Rays, 36.7kHz
Operation (START/STOP)
Operation Mode Selection
AUTO, COOL, DRY, HEAT
Thermo. Setting
Fan Speed Selection
ON TIMER Setting
OFF TIMER Setting
Louver AUTO Swing
Louver Direction Setting
ECO
Hi-POWER
COMFORT SLEEP
QUIET
QUIET
SLEEP (1, 3, 5, 9 OFF TIMER)
– 18 –
9. OPERATION DESCRIPTION
9-1. Outline of Air Conditioner Control
This air conditioner is a capacity-variable type air
conditioner, which uses DC motor for the indoor fan
motor and the outdoor fan motor. And the capacityproportional control compressor which can change the
motor speed in the range from 11 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 controller,
and transfers the operation command to the outdoor
unit controller.
The outdoor unit controller receives operation command from the indoor unit side, and controls the
outdoor fan and the pulse motor valve. (PMV)
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 controller and assumes
the following functions.
• Judgment of suction air temperature of the indoor
heat exchanger by using the indoor temp. sensor.
(TA sensor)
• Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor)
(Prevent-freezing control, etc.)
• Louver motor control
• Indoor fan motor operation control
• LED (Light Emitting Diode) display control
• Transferring of operation command signal
(Serial signal) to the outdoor unit
• Reception of information of operation status
(Serial signal including outside temp. data) to the
outdoor unit and judgment/display of error
• Air purifier operation control
2. Role of outdoor unit controller
Receiving the operation command signal
(Serial signal) from the indoor unit controller, the
outdoor unit performs its role.
• Compressor operation control
• Operation control of outdoor fan motor
• PMV control
• 4-way valve control
Operations followed to judgment
of serial signal from indoor side.
• Detection of inverter input current and current
release operation
• Over-current detection and prevention operation
to IGBT module (Compressor stop function)
• Compressor and outdoor fan stop function when
serial signal is off (when the serial signal does not
reach the board assembly of outdoor control by
trouble of the signal system)
• Transferring of operation information (Serial
signal) from outdoor unit controller to indoor unit
controller
• Detection of outdoor temperature and operation
revolution control
• Defrost control in heating operation (Temp.
measurement by outdoor heat exchanger and
control for 4-way valve and outdoor fan)
3. Contents of operation command signal
(Serial signal) from indoor unit controller to
outdoor unit controller
The following three types of signals are sent from
the indoor unit controller.
• Operation mode set on the remote controller
• Compressor revolution command signal defined
by indoor temperature and set temperature
(Correction along with variation of room temperature and correction of indoor heat exchanger
temperature are added.)
• Temperature of indoor heat exchanger
• For these signals ([Operation mode] and [Com-
pressor revolution] indoor heat exchanger temperature), the outdoor unit controller monitors the
input current to the inverter, and performs the
followed operation within the range that current
does not exceed the allowable value.
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.
– 19 –
9-2. Operation Description
9-2. 1. Basic operation ........................................................................................................... 21
1. Operation control ................................................................................................... 21
2. Cooling/Heating operation ..................................................................................... 22
3. AUTO operation...................................................................................................... 22
4. DRY operation ........................................................................................................ 22
2. Indoor fan motor control.............................................................................................. 23
3. Capacity control .......................................................................................................... 25
4. Current release control ............................................................................................... 25
5. Release protective control by temperature of indoor heat exchanger ........................ 26
6. Louver control ............................................................................................................. 27
1) Louver position....................................................................................................... 27
2) Air direction adjustment ......................................................................................... 27
3) Swing ..................................................................................................................... 27
7. Defrost control (Only in heating operation)................................................................. 28
8. ECO operation ............................................................................................................ 28
9. Temporary operation................................................................................................... 28
10. Pulse motor valve (PMV) control ................................................................................ 29
11. Self-Cleaning function ................................................................................................ 30
12. Remote Controller-A or B selection ............................................................................ 31
13. QUIET mode ............................................................................................................... 32
14. COMFORT SLEEP ..................................................................................................... 32
15. Short Timer ................................................................................................................. 32
16. One Touch Comfort ..................................................................................................... 33
17. Hi POWER Mode ........................................................................................................ 33
9-3. Auto Restart Function............................................................................................. 34
9-3-1. How to Set the Auto Restart Function .................................................................... 34
9-3-2. How to Cancel the Auto Restart Function.............................................................. 35
9-3-3. Power Failure during Timer Operation.................................................................... 35
9-4. Remote Controller ...................................................................................................36
9-4-1. Remote Controller and Its Functions ..................................................................... 36
9-4-2. Operation of Remote Controller .............................................................................. 36
9-4-3. Names and Functions of Indications on Remote Controller ................................ 39
– 20 –
Item
Operation flow and applicable data, etc.
Description
1. Basic
operation
1. Operation control
Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are
controlled.
1) The operation conditions are selected by the remote controller as shown in the below.
2) A signal is sent by ON button of the remote controller.
3) The signal is received by a sensor of the indoor unit and processed by the indoor controllers as
shown in the below.
4) The indoor controller controls the indoor fan motor and louver motor.
5) The indoor controller sends the operation command to the outdoor controller, and sends/
receives the control status with a serial signal.
6) The outdoor controller controls the operation as shown in the left, and also controls the compressor, outdoor fan motor, 4-way valve and pulse motor valve.
Selection of
operation conditions
ON/OFF
Remote controller
Control contents of remote controller
• ON/OFF (Air conditioner / Air purifier)
• Operation select (COOL /HEAT / AUTO / DRY)
• Temperature setup
• Air direction
• Swing
• Air volume select
(AUTO / LOW / LOW+ / MED / MED+ / HIGH)
• ECO • COMFORT SLEEP
• ON timer setup • QUIET
• OFF timer setup • PRESET
• Hi-POWER • ONE-TOUCH
Signal receiving
Indoor unit control
Operation command
Serial signal send/receive
Serial signal send/receive
Outdoor unit control
Indoor unit
Indoor unit control
• Command signal generating function of
indoor unit operation
• Calculation function (temperature calculation)
• Activation compensation function of indoor fan
• Cold draft preventive function
• Timer function
• Indoor heat exchanger release control
Outdoor unit
Outdoor unit control
• Frequency control of inverter output
• Waveform composite function
• Calculation function
(Temperature calculation)
• AD conversion function
• Quick heating function
• Delay function of compressor reactivation
• Current release function
• GTr over-current preventive function
• Defrost operation function
Inverter
• Indoor fan motor
• Louver motor
~
• Compressor
• Outdoor fan motor
• 4-way valve
• Pulse Motor valve
(PMV)
– 21 –
Item
Operation flow and applicable data, etc.
Description
1. Basic
operation
2. Cooling/Heating operation
The operations are performed in the following parts by controls according to cooling/heating conditions.
1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal
starts being transferred form the indoor controller to the outdoor unit.
2) At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan motor
control” and the louver according to the contents of “8. Louver control”, respectively.
3) The outdoor unit controls the outdoor fan motor, compressor, pulse motor valve and
4-way valve according to the operation signal sent from the indoor unit.
Operation ON
Indoor unit control
Sending of operation command signal
Outdoor unit control
3. AUTO operation
Selection of operation mode
As shown in the following figure, the operation starts by
selecting automatically the status of room temperature
(Ta) when starting AUTO operation.
*1. When reselecting the operation mode, the fan speed
is controlled by the previous operation mode.
Ta
Cooling operation
Ts + 1
Monitoring (Fan)
Ts – 1
Heating operation
Setup of remote controller
Indoor fan motor control / Louver control / Operation Hz
Control (Requierment)
Compressor revolution control / Outdoor fan motor control /
Operation Hz control (Include limit control)
4-way valve control In cooling operation: ON
Pulse Motor valve control
[ ]
In heating operation: OFF
1) Detects the room temperature (Ta) when
the operation started.
2) Selects an operation mode from Ta in
the left figure.
3) Fan operation continues until an
operation mode is selected.
4) When AUTO operation has started
within 2 hours after heating operation
stopped and if the room temperature is
20°C or more, the fan operation is
performed with ”Super Ultra LOW” mode
for 3 minutes.
Then, select an operation mode.
5) If the status of compressor-OFF
continues for 15 minutes the room
temperature after selecting an operation
mode (COOL/HEAT), reselect an
operation mode.
4. DRY operation
DRY operation is performed according to the difference
between room temperature and the setup temperature
as shown below.
In DRY operation, fan speed is controlled in order to
prevent lowering of the room temperature and to avoid
air flow from blowing directly to persons.
[C]
Ta
+
1.0
+
0.5
L (W5)
(W5+W3) / 2
SL (W3)
Tsc
Fan speed
– 22 –
1) Detects the room temperature (Ta) when
the DRY operation started.
2) Starts operation under conditions in the
left figure according to the temperature
difference between the room temperature and the setup temperature (Tsc).
Setup temperature (Tsc)
= Set temperature on remote controller
(Ts) + (0.0 to 1.0)
3) When the room temperature is lower
1°C or less than the setup temperature,
turn off the compressor.
Item
Operation flow and applicable data, etc.
Description
2. Indoor fan
motor control
COOL ON
Fan speed setup
AUTO
Ta
[°C]
+2.5
a
+2.0
b
+1.5
c
+1.0
<In cooling operation>
(This operation controls the fan speed at indoor unit side.)
The indoor fan (cross flow fan) is operated by the phase-
control induction motor. The fan rotates in 5 stages in
MANUAL mode, and in 5 stages in AUTO mode, respectively.
(Table 1)
MANUAL
Indication
L
L+
M
M+
H
(Fig. 1)
Fan speed
W6
(L + M) / 2
W9
(M + H) / 2
WC
(Fig. 2)
Air volume AUTO
M+(WB)
*3
*4
*5
*3 : Fan speed = (M + –L) x 3/4 + L
*4 : Fan speed = (M + –L) x 2/4 + L
*5 : Fan speed = (M + –L) x 1/4 + L
∗∗
∗ Symbols
∗∗
UH: Ultra High
H : High
M+: Medium+
M : Medium
L+ : Low+
L: Low
L- : Low–
UL : Ultra Low
SUL : Super Ultra Low
* The fan speed broadly varies due
to position of the louver, etc.
The described value indicates one
under condition of inclining
downward blowing.
1) When setting the fan speed to L,
L+, M, M+ or H on the remote
controller, the operation is
performed with the constant
speed shown in Fig. 1.
2) When setting the fan speed to
AUTO on the remote controller,
revolution of the fan motor is
controlled to the fan speed level
shown in Fig. 2 and Table 1
according to the setup temperature, room temperature, and heat
exchanger temperature.
+0.5
Ts c
d
L(W6)
e
(Linear approximation
from M+ and L)
(Table 1) Indoor fan air flow rate
Fan
speed
level
WF
WE
WD
WC
WB
WA
W9
W8
W7
W6
W5
W4
W3
W2
W1
COOL HEAT DRY
UH
H
M+
H
M+ M
ML+
L
L+ L– L+
L– UL L–
UL UL
SUL SUL
SUL
RAS-M22SKV-E
Fan speed Air flow rate
(rpm) (m
1200 1101
1200 1101
1200 1101
1180 1079
1080 968
1020 902
980 858
850 713
810 669
800 658
760 614
700 547
650 492
500 325
500 325
3
/h)
RAS-M24SKV-E
Fan speed Air flow rate
(rpm) (m
1250 1156
1250 1156
1250 1156
1230 1134
1130 1034
1070 957
1030 913
900 768
860 669
850 713
810 669
750 603
650 492
500 325
500 325
3
/h)
– 23–
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