Toshiba 10SAX-1, Service Manual

Page 1: ...T W A L L T Y P E T O S H I B A P R I N T E D I N J A P A N M a y 1 9 9 7 T o M o F I L E N O A 0 0 9 7 0 8 A I R C O N D I T I O N E R R A S 1 0 S K E R A S 1 0 S A E R A S 1 0 S A E 1 R A S 1 0 S K X R A S 1 0 S A X R A S 1 0 S A X 1 ...

Page 2: ... 7 1 How to Set the Auto Restart 16 7 7 2 How to Cancel the Auto Restart 17 7 7 3 In Case of Power Failure during the Timer Operation 17 8 INSTALLATION PROCEDURE 18 8 1 Safety Cautions 18 8 2 Installation Diagram of Indoor and Outdoor Units 20 8 3 Installation 21 8 3 1 Optional Parts 21 8 3 2 Installation Parts 21 8 4 Indoor Unit 22 8 4 1 Cutting a Hole and Mounting Installation Plate 22 8 4 2 Ele...

Page 3: ... be Turned on after Replacing Indoor PC Board 39 9 3 3 Outdoor Unit does not Operate 39 9 3 4 Only Compressor does not Operate 40 9 3 5 Only Outdoor Fan does not Operate 41 9 3 6 Only the Indoor Fan does not Operate 42 9 4 How to Check the Remote Control Including the Indoor PC Board 43 9 4 1 How to Check the PC Board 44 9 4 2 PC Board Layout 46 9 4 3 How to Reduce the Operation Time of the Anti R...

Page 4: ...s side size Connection type Liquid side size Connection type Maximum length of one way Maximum height difference Indoor unit Outdoor unit Outer diameter Height Width Depth High fan Medium fan Low fan Height Width Depth Model Output Specifications are subject to change without notice RAS 10SK E 10SA E 10SA E 1 RAS 10SKX 10SAX 10SAX 1 COOLING 220V 230V 240V 220V 230V 240V 2 65 2 65 2 70 2 70 2 70 2 ...

Page 5: ... Temperature Indoor unit inlet air temperature Outdoor unit inlet air temperature Notes 2 CHARGELESS No additional refrigerant required This air conditioner accepts a connection piping length of up to 10m and a head of up to 5m There is no need to add the refrigerant as long as the total length of the connection piping is up to 10m ...

Page 6: ...ose 0 54m Connecting pipe 0 39m Flare ø6 35 Flare ø9 52 Hanger 659 65 5 326 450 65 5 For stud bolt ø8 ø10 For stud bolt ø6 Hanger Minimum distance to wall Minimum distance to ceiling 265 Knock out system Front panel Back body 20 20 37 40 5 60 5 790 126 269 319 76 Center line Installation plate outline Hanger Hanger 40 5 3 5 Hanger Minimum distance to wall 17 20 46 120 or more 120 or more 66 or mor...

Page 7: ...A 600 R10 50 36 25 216 230 ø11x14 Hole ø6 Hole Handle 11 525 530 5 268 Fan guard ø420 TOSHIBA 770 59 89 200 11 12 Electric parts cover Z 54 62 Access for charging 250 Z View 600 45 or more Inlet port 600 or more Minimum distance of the wall 4 ø11x14 Long holes For anchor bolt ø8 ø10 200 or more Outlet port Center port 230 100 or more Inlet port Visible outline of the product A Detail Drawing Mount...

Page 8: ...C04 R109 F01 FUSE T3 15A 250V R21 RY01 RY02 WHI BLK 3 4 3 4 POWER TERMINAL BLOCK INDOOR TERMINAL BLOCK INFRARED RAYS RECEIVE AND INDICATION PARTS THERMO SENSOR TA HEAT EXCHANGER SENSOR TC LOUVER MOTOR FAN MOTOR BROWN RED WHITE YELLOW BLUE BLACK GRAY PINK ORANGE GREEN YELLOW BRW RED WHI YEL BLU BLK GRY PNK ORN GRN YEL COLOR IDENTIFICATION THERMAL FUSE 77 C x 2 VARISTOR 3 1 1 2 3 4 6 5 1 2 3 4 5 1 2...

Page 9: ...0CMP25U1 J MRA99285 9201 J MRA99285 9086 Red Black 3 88 White Black 5 06 White Black 370 Red Black 370 C R 3 6 C S 4 87 Parts name Fan motor for indoor Thermo sensor TA sensor DC DC transformer T01 Microcomputer Power relay RY01 Com mon relay RY02 Heat exchanger sensor TC sensor Line filter L01 Diode DB01 Capacitor C02 Fuse F01 Power supply IC IC01 Varistor R21 R109 Resistor R01 Louver motor Speci...

Page 10: ...High temperature Low temperature Ambient temp conditions DB WB C Fan speed indoor High High Low Indoor 27 19 32 23 21 15 Fig 5 1 Table 5 1 Evaporator Indoor unit Cross flow fan Optional piping kits RB P31BFH1 3m RB P51BFH1 5m RB P71BFH1 7m Compressor Accumulator Condenser Propeller fan Outdoor unit Dryer Capillary tube ø1 5x1200 PH102T1 4C 10SA E 10SAX 2PS146D5AB02 10SA E 1 10SAX 1 Mark means chec...

Page 11: ...tor Circuit Heat Exchanger Sensor Infrared Rays Initializing Circuit C P U Main Unit Control Panel AC 220 230 240V 50Hz Remote Control Operation Display Timer Display ECONO Sign Display FAN ONLY Sign Display Indoor Fan Motor Louver ON OFF Signal Compressor Outdoor Fan ON OFF Signal Louver Motor Compressor RY02 RY01 Noise Filter Power Supply Circuit Outdoor Fan Motor Relay Thermo Sensor Louver Cont...

Page 12: ...e START STOP button Fig 7 1 1 Auto setting of air volume Table 7 1 1 Manual setting of FAN SPEED 2 Once the setting is made the operation mode is memorized in the microcomputer so that the same operation can be effected thereafter simply by pushing the START STOP button Fig 7 2 1 2 Relays RY01 and RY02 are turned on to energize the outdoor unit and a cool operation is carried out 1 When the FAN is...

Page 13: ... controlled as shown in Fig 7 3 1 Fig 7 3 2 Fig 7 3 1 The microprocessor turns the compressor on and off at regular intervals 4 to 6 minutes on and or off During the compressor off the indoor fan will operate in the super low position The indoor fan will operate in the AUTO position 2 The pattern of operation depending on the relation between room temperature and set temperature is shown below Roo...

Page 14: ...d 7 4 1 Temporary Auto When the TEMPORARY button is pushed the set temperature is fixed at 24 C and controlled in accor dance with the chart shown in Fig 7 4 1 Fig 7 4 1 Cooling mode Cooling mode Dry mode 4 1 The same cooling mode as the room temperature control is set at set temp 1 C The Louver moved downward The same cooling mode as the room temperature control is set at set temp 1 C The same dr...

Page 15: ...is changed automatically as shown in Fig 7 5 1 2 Fan speed LOW 2 1 Set temp 1H 2H TIME 0H C ECONO button is pushed Set temp is changed Set temp is changed 7 6 Low Temperature Limit Control Cooling Operation The microprocessor detects the indoor heat exchanger temperature so as to prevent freezing up the indoor heat exchanger Control is performed as shown in Fig 7 6 1 Fig 7 5 1 Compressor Less than...

Page 16: ...ings can be carried out During subsequent operation the orange light is lit The Auto Restart function will not accept an instruction if timer operation with the remote control is selected Please refer to the section on setting the timer or setting the louver When the system is stand by not running During louver swing AUTO operation after restart by the Auto Restart function the louver swing stops ...

Page 17: ...inuously more than three seconds MOTION Operating The orange light is lit The system stops to operate The orange light is turned off about three seconds after The unit beeps three times The system stops If the system is not required to stop at this time use the remote control and to restart During subsequent operation the green light is lighting 7 7 3 In Case of Power Failure during the Timer Oper...

Page 18: ...NSTRUCTION CAN RESULT IN FIRE OR EXPLOSION TO PREVENT OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD PLACE THE UNIT WELL AWAY MORE THAN 2M FROM HEAT SOURCES SUCH AS RADIATORS HEAT RESISTORS FURNACE STOVES ETC WHEN MOVING THE AIR CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN BE VERY CAREFUL NOT TO GET THE SPECIFIED REFRIGERANT R 22 WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CY...

Page 19: ...ges Please read the installation manual carefully before installing the unit It contains further important instructions for proper installation UK Plugs and Sockets etc Safety Regulations 1994 SI Number 1768 With regard to Schedule 3 Item 7 of the above UK Regulations this appliance must be permanently connected to the fixed wiring of the main electrical supply by means other than the use of an ap...

Page 20: ...ric parts cover 45 mm or more 600 mm or more 2 Wireless remote control 7 Batteries Cover 6 mm thick heat resisting polyethylene foam Bottom Rear Right Rear left Left Cut the piping hole sloped slightly Wall 120 mm or more For the rear and left piping Insert the remote control holder cushion between the indoor unit and wall and lift indoor unit to make work easier Do not allow the drain hose to get...

Page 21: ...on Parts Part code A B C Q ty Each one 1 Each one Parts name Refrigerant piping Liquid side ø6 35 mm Gas side ø9 52 mm Pipe insulating material polyethylene foam 6 mm thick Putty PVC tapes Anchor bolt arrangement of outdoor unit Part No Name of parts Q ty Installation plate x 1 Wireless remote control x 1 Clip anchor x 6 Remote control holder x 1 Part No Name of parts Q ty Shield pipe x 1 Pan head...

Page 22: ...s is necessary to prevent image disturbances or noise interference The location of the remote control should be determined as shown below 8 4 1 Cutting a Hole and Mounting Installation Plate Cutting a hole When installing the refrigerant pipes from the rear Fig 8 4 1 Fig 8 4 3 Fig 8 4 2 1 After determining the pipe hole position with the mounting plate 80 mm drill the pipe hole ø65 mm at a slight ...

Page 23: ...gle phase 7 5 A 16 A 1mm2 or more No adjustment is necessary CAUTION Use power specified in above table This appliance can be connected to the mains in either of the following two ways 1 Connecting the power cord to the main power supply provided with a circuit breaker or switch with a contact of 3 mm or more In this case an approved circuit breaker or switch must be used 2 Attaching a plug to the...

Page 24: ...ing the cutting mark and put the power supply cord through the notch Be sure to smooth out the notch with a file etc 8 4 3 Wiring Connection WARNING To plug the cable in the plug receptacle take the following precaution THIS APPLIANCE MUST BE EARTHED IMPORTANT THE WIRES IN THIS MAINS LEAD ARE COLORED IN ACCORDANCE WITH THE FOLLOWING CODE Fig 8 4 5 As the colors of the flexible cord of this applian...

Page 25: ...local electrical codes and also any specific wiring instructions or limitation Stripping length of connecting cable For a three conductor cable NOTE Use stranded wire only Wire type More than H05 RN F Fig 8 4 10 How to install the front cabinet on the indoor unit Install the front cabinet through the opposite order of How to remove the front cabinet When the panel is removed and mounted again take...

Page 26: ...ind the auxiliary pipes two and connecting cable with facing tape tightly In case of leftward piping and rear leftward piping bind the auxiliary pipes two only with facing tape Carefully arrange pipes so that any pipe does not stick out of the rear plate of the indoor unit Carefully connect the auxiliary pipes and connecting pipes to each other and cut off the insulating tape wound on the connecti...

Page 27: ...hing its bottom up by the specified parts Space for pipes Wall Drain guide Fig 8 4 18 CAUTION Arrange the drain pipe for proper drainage from the unit Improper drainage can result in damage to property This air conditioner has the structure designed to drain water collected from dew which forms on the back of the indoor unit to the drain pan Therefore do not store the power cord and other parts at...

Page 28: ...and discharged air do not disturb your neighbors A place which is not exposed to a strong wind A place free of a leakage of combustible gases A place which does not block a passage When the outdoor unit is to be installed in an elevated position be sure to secure its feet An allowable length of the connecting pipe is up to 10 m An allowable head level is up to 5 m A place where the drain water doe...

Page 29: ...p to each of the packed valve stems Fig 8 5 5 Die Pipe A Fig 8 5 2 2 Insert a flare nut into the pipe and flare the pipe Fig 8 5 3 Tightening connection Align the centers of the connecting pipes and tighten the flare nut as far as possible with your fingers Then tighten the nut with a spanner and torque wrench as shown in the figure CAUTION Do not apply excess torque Otherwise the nut may crack de...

Page 30: ...lock of indoor and outdoor units Strip the sheath of connecting cable with following stripping length to and insert into the terminal block 3 When connecting the connecting cable to outdoor unit terminal make a loop as shown in the installation diagram of indoor and outdoor unit to prevent water coming in the outdoor unit 4 Insulate the unused cords conductors with water coming in the outdoor unit...

Page 31: ...kes three short beeps to tell you the Auto Restart has been selected To cancel the Auto Restart follow the steps described in the section Auto Restart Function of the Owner s Manual TEMPORARY TEMPORARY button Fig 8 6 1 Check the flare nut connections valve stem cap connections and service cap connections for gas leak with a leak detector or soap water 8 6 2 Test Operation To switch the TEST RUN CO...

Page 32: ...Power Supply Voltage The line voltage must be AC 220 230 240V If the line voltage is not within this range this air conditioner may not work normally 9 1 2 Incorrect Cable Connection between Indoor and Outdoor Units The indoor unit is connected to the outdoor unit with 3 cables Make certain that the indoor and outdoor units have been connected properly with terminals assigned the same numbers wire...

Page 33: ... turned on the operation starts automatically Description The OPERATION lamp flashes indicating that power is turned on If this happens push the START STOP button once to cause the lamp to stop flashing A power outage also causes the lamp to flash Fan speed is automatically controlled in the dry mode The compressor will not stop while the compressor on hold timer 3 minutes timer is actuated In the...

Page 34: ...lay flashing 5 Hz OPERATION display flashing 5 Hz OPERATION display flashing 5 Hz OPERATION display flashing 5 Hz OPERATION TIMER and FAN ONLY display flashing 5 Hz Block display Power failure when power is ON Thermo sensor TA short break Heat exchanger sensor TC short break Indoor fan lock abnormality of indoor fan Indoor PC board failure Gas shortage other refrigerant cycle trouble Heat exchange...

Page 35: ...perature is displayed on the display and other display is turned off 2 Selecting ordinary mode Push the all clear button ACL on the rear bot tom of the wireless remote control with a tip of pencil for more than 3 seconds Make sure the operation mode display wind volume display clock display and setting temperature display are turned on and of the clock display is flashing Cautions when doing servi...

Page 36: ...shing This shows that the protection circuit on the indoor PC board is working d Operate theTEMP key and make sure the remote control display shows and flashing of the operation lamp If the op eration lamp is flashing it shows the pro tection circuits for connecting cable is work ing or thermal fuse is blown e In the same way operate the TEMP key so that the display is increased one by one to cont...

Page 37: ...otor then connect the plug of AC power cord again and turn the power on 2 Check the voltage between pin 1 and 2 of the connector CN10 3 If the output voltage is 35V PC board is OK check motor Replace PC board 1 Check gas quantity check gas leakage 2 If it is OK check heat ex changer sensor 3 If heat exchenger sensor is OK check overload relay and thermostat for compressor 4 If overload relay is OK...

Page 38: ...rong wiring of AC cord or connecting cable is defective Replace the thermal fuse set Check connection Is the indication voltage DC12V or 5V of main PC board correct Is the voltage across C02 measured DC310V 340V Refer to the paragraph Pre check or defective circuit before power PC board block Shut off the power supply once and turn it on again after dis connecting the motor connector CN10 Is the s...

Page 39: ...Is it wired as shown in Figure below YES NO Shut off the power supply from AC outlet once and turn it on after 5 seconds Does the OPERATION lamp flash Does the power turn on by pushing the START STOP button of the remote control Is cable connection between indoor and outdoor units correct Check items as following procedure in 9 3 4 9 3 5 9 3 6 Replace the PC board See Power can not be turned on Re...

Page 40: ...winding normal Check the winding resistor Is the capacitor for compressor normal Is the overload relay normal Does the compressor start Compressor starts but it stops after a while Cables between indoor and outdoor units are defective Re wire or replace the defective cords Compressor is defective Capacitor is defective Overload relay is defective Compressor is defective Correct cabling between ind...

Page 41: ...ormal Check the winding resistance Is the capacitor for compressor normal Outdoor fan motor is defective Cables between indoor and outdoor units are defective Outdoor fan motor is defective Correct cabling between indoor and outdoor units NO NO NO NO YES YES YES YES Are all the cords for outdoor fan motor normal Correct the wire or replace the defective cords Capacitor for outdoor fan motor is def...

Page 42: ...ss flow fan rotate normally Repair the bearing of the drain fan Turn on the power supply Is the rotation signal DC 5V 0V output between 4 blue lead wire and 2 black lead wire of the motor connector CN10 when rotating the cross flow fan by hand in no operating status 2 pulses one turn Replace the control PC board Shut off the power supply and turn it on after disconnecting the motor connector CN10 ...

Page 43: ...luorescent light Is operation possible when the transmitter is moved nearer to the infrared signal receiver of the air conditioner Battery life Can any signal tone be heard in a transistor radio when transmitting within 5cm distance from the radio Does the transmission indicator light Is there any beep and operation Short circuit the metal terminal at the side of the battery compartment all clear ...

Page 44: ... PC board hold the whole housing Do not pull at the lead wire 2 Inspection procedures 1 When a PC board is judged to be defective check for disconnection burning or discolora tion of the copper foil pattern or this PC board 2 The PC board consists of the following 2 parts a Main PC board part Power relay indoor fan motor drive circuit and control circuit C P U and peripheral cir cuits buzzer drive...

Page 45: ...No 1 and 2 of connecting cable terminal block 220 230 240V AC 1 All indicators light for 3 sec 2 Indicators do not indicate normally after approximate 3 sec 1 Compressor does not operate 2 OPERATION lamp flashes 1 Compressor does not operate 2 OPERATION lamp flashes 1 The voltage of DC 35V is not measured between the red and black of the motor terminals 2 Motor does not rotate The key operation is...

Page 46: ... 46 9 4 2 PC Board Layout BottomView Top View ...

Page 47: ... Timer Attach the diode 1S1555 or equivalent to the rivet inside the unit through holes on the rear of the wireless remote control unit Push the START STOP button to start operation with the diode attached Fig 9 4 1 Temperature Sensor Themo Sensor 0 C 35 8 10 C 20 7 20 C 12 6 25 C 10 0 30 C 7 92 Timer short diode Wireless remote control ...

Page 48: ... may be covered with frost and have a waterdrop 1 Perform the process above 2 Remove the screw securing the shield metal plate 3 Remove the electrical part cover by pressing the nail located on upper portion of the electrical part cover 4 Remove the drain guide 5 Remove the screw securing to the end plate of the heat exchanger 6 Remove the connector 5p for the fan motor and the connector 6p for th...

Page 49: ...up the left side of the heat exchanger and pull the shaft bearing base out left downwards When assembling it fix it with the set screw on the position where the gap between the rear plate surface and the left end surface of the cross flow fan is 6 7mm 1 Perform the process above 2 Remove the shaft bearing from the shaft bearing base Caution for assembling If a part of the shaft bearing is protrude...

Page 50: ... the process above 2 Remove terminal cover Up Down 3 Disconnect the terminal blocks connected with the connecting cable and the power cord from base E parts by removing the screws 4 Remove the thermal fuse 77 C from base E parts 10 2 Microcomputer RAS 10SK E RAS 10SKX No Remarks Replace the thermal fuse terminal block power cord microcomputer ass y and the power supply PC board ass y Part name Com...

Page 51: ... Remove the front cabinet 7 ST1T ø4 x 10 with nylon washer Pull the front lower portion toward you and remove it pulling out upward 1 Remove the fixing screw securing the capacitor band 1 ST2T ø4 x 8 2 Remove the cable connected to the terminal 1 Remove the fixing screw 1 ST2T ø4 x 8 2 Remove the cable connected to the terminal 1 Perform the process above 2 Remove terminal cover of compressor 3 Re...

Page 52: ... the switch SW03 provided on the PC board as follows 2 Don t through the black lead wire to the current trans CT T02 ON OFF 1 2 3 4 5 6 1 2 3 4 5 6 ON ON OFF RY01 C02 RY02 Brown N L Power terminal block T02 PC board Blue White Black 1 2 Indoor terminal block ...

Page 53: ...or Heat Exchanger 10kΩ 25 C 403 43T69005 Sensor Thermostat 10kΩ 25 C 404 43T60004 Fuse Temperature 77 C Location Part Description No No 405 43T69007 PC Board WRS LED MCC 635 406 43T69008 PC Board MCC 713 407 43T61001 Base E Parts ABS Black UL94 5V 408 43T62006 Base Shield SGCC Z08 LUB Location Part Description No No ...

Page 54: ...ssembly 216 43T47006 Pipe Delivery 217 43T47005 Pipe Suction 218 43T49007 Pipe Shield 219 43T19003 Holder Sensor 220 43T49003 Spring Location Part Description No No 221 43T49005 Plate of EVA SEAL 222 43T49006 Holder for Plate of EVA SEAL 223 43T49004 Rubber of Sound Insulation 224 43T79002 Drain Guide 225 43T39002 Motor Band Left 226 43T39001 Motor Band Right 227 43T21005 Fan Motor 228 43T20007 Fa...

Page 55: ...dle 17 43T49001 Rubber Cushion 19 43T19002 Stopper Guard 20 43T63001 Holder OL Relay RAS 10SA E RAS 10SAX 21 43054408 Relay Over Load J MRA 99285 9201 RAS 10SA E RAS 10SAX 21 43T54008 Relay Over Load J MRA 99285 9086 RAS 10SA E 1 RAS 10SAX 1 22 43T41402 Compressor PH102T1 4C RAS 10SA E RAS 10SAX 22 43T41402 Compressor 2PS146D5AB02 RAS 10SA E 1 RAS 10SAX 1 23 43055483 Capacitor Plastic Comp 25µF 40...

Page 56: ......