Toshiba RAS-10SAH-E, Service Manual

Page 1: ...U A L S P L I 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 N o v 1 9 9 6 T o M o F I L E N O A 0 0 9 6 1 9 A I R C O N D I T I O N E R R A S 1 0 S K H E R A S 1 0 S A H E R A S 1 0 S K H X R A S 1 0 S A H X ...

Page 2: ...g 16 7 6 2 Heating 16 7 7 Current Limit Control 16 7 8 High Temperature Limit Control Heating Operation 17 7 9 Low Temperature Limit Control Cooling Operation 17 7 10 Cool Airflow Prevention Control Heating Operation 17 7 11 Defrost Operation 18 7 11 1 Condition to Start the Defrost Operation 18 7 11 2 Defrost Operation Time Control 18 7 11 3 Ending Condition at Defrost Operation 18 7 12 Auto Rest...

Page 3: ...oor Unit Controller 38 9 2 2 Display of Abnormalities and Judgement of the Abnormal Spots 38 9 3 Troubleshooting Flowcharts 42 9 3 1 Power can not be Turned on 42 9 3 2 Power can not be Turned on after Replacing Indoor PC Board 43 9 3 3 Outdoor Unit does not Operate 43 9 3 4 Only Compressor does not Operate 44 9 3 5 Only Outdoor Fan does not Operate 45 9 3 6 Only 4 Way Valve does not Operate 46 9 ...

Page 4: ...er consumption Power factor Running current Starting current Moisture removal Noise Refrigerant Refrigerant control Interconnection pipe Condensate drain pipe INDOOR UNIT Dimensions Net weight Evaporator type Indoor fan type Air volume Fan motor output Air filter OUTDOOR UNIT Dimensions Net weight Condenser type Outdoor fan type Airflow volume Fan motor output Compressor Safety device Auto louver ...

Page 5: ...n DB WB DB WB 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: ... 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 Mounting dimensio...

Page 8: ...01 L01 C15 IC04 R109 F01 FUSE T3 15A 250V R21 RY01 RY02 WHI BLK 3 4 3 4 T02 C T RY03 RY04 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 2 VARISTOR 3...

Page 9: ...K 40CMP25U1 LB60012 J MRA99269 9200 Parts name Compressor Fan motor for outdoor Running capacitor for fan motor Running capacitor for compressor Solenoid coil for 4 way valve Overload relay Red Black 4 53 White Black 8 73 White Black 370 Red Black 370 No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Type ICF 35 19 3 or TICF 35 19 3 microprocessor SWT 34 TMP87CK40F DI1U microprocessor RF 103YOR6 RBV 406 CEAU...

Page 10: ...ng 50Hz Standard High temperature 1 Low temperature Standard High temperature Low temperature Ambient temp conditions DB WB C Fan speed indoor High Low High High High Low Fig 5 1 Table 5 1 Indoor 20 27 20 27 19 32 23 21 15 Evaporator Indoor unit Cross flow fan Optional piping kits RB P31BEF1 3m RB P51BEF1 5m RB P71BEF1 7m Cooling Heating 4 way valve Heating Cooling Compressor Accumulator Condenser...

Page 11: ...AUTO COOL DRY HEAT FAN ONLY Operation START STOP Relay Driver Louver Driver Clock Frequency Oscillator Circuit Heat Exchanger Sensor Infrared Rays Initializing Circuit C P U Main Unit Control Panel AC220 230 240V 50Hz Remote Control Operation Display Timer Display ECONO Sign Display PRE DEF Sign Display Indoor Fan Motor Louver ON OFF Signal 4 Way Valve ON OFF Signal Outdoor Fan ON OFF Signal Compr...

Page 12: ...to setting of air volume Table 7 1 1 Manual setting of FAN SPEED Indication of FAN SPEED LOW MED HIGH HIGH Air volume m3 n 400 500 600 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 HIGH MED LOW LOW LOW 28 27 26 25 24 Room temp Set temp Set temp Fig 7 2 1 2 Relays RY01 and...

Page 13: ...ig 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 Room temp Set temp 1 Set tem...

Page 14: ...rol 1 By pushing the SET button of the remote control during the operation the louver can be set to the desired position 2 When the AUTO button is pushed the louver ver tically swings within range of 25deg And the louver position is stored in the microcom puter and at the next operation the louvers will be set to the stored position automatically at the next operation 7 4 2 Cool Airflow Control 1 ...

Page 15: ... 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 5 1 Fig 7 5 1 Cooling mode Cooling mode Fan only mode Heating mode 4 1 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 Only the indo...

Page 16: ...own below by detect ing the compressor operation current with a cur rent sensor C T Fig 7 6 2 2 1 Set temp 1H 2H TIME 0H C ECONO button is pushed Set temp is changed Set temp is changed Fig 7 6 1 7 6 2 Heating 1 In the ECONO mode the set temp by the remote control is changed automatically as shown in Fig 7 6 2 2 Fan speed LOW 1 2 Set temp 1H 2H TIME 0H C ECONO button is pushed Set temp is changed ...

Page 17: ...g 7 10 1 Fig 7 8 1 7 9 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 9 1 Fig 7 10 1 2 As soon as the defrost operation starts the indoor fan stops Compressor Less than 5 C continues for 5 minutes OFF ON Outdoor fan 7 Heat exchanger tempera...

Page 18: ...e is 10 minutes When the outdoor temperature is very low however the defrost operation time is 10 minutes minutes 40 minutes 40 minutes 40 minutes 40 Max 6 minutes 10 minutes 1 cycle Heating Heating Heating Heating Defrost Defrost Defrost Defrost Fig 7 11 2 In case of C 1 The heating operation is performed for at least 90 minutes 2 The defrost operation time is 10 minutes 7 11 3 Ending Condition a...

Page 19: ...tings 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 20: ...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 12 3 In Case of Power Failure during the Timer Ope...

Page 21: ...INSTRUCTION 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 C...

Page 22: ...ty 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 approved 13 Amp plug top as outlined in the Regulations Electrical work must be carried by suitably qualified persons and in accordance with all relevant safety standards and ...

Page 23: ...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 24: ...defrost water from the outdoor unit attach 12 drain nipple to the bottom plate of the outdoor unit before installing it The drain nipple is located as shown above Fig 8 3 2 Install the provided drain nipple in the hole of the bottom plate of the outdoor unit See the above figure Perform proper drainage processing using a drain hose sold separately or one on the market Inner diameter 16 mm Do not u...

Page 25: ...ield pipe x 1 Pan head wood screw ø3 1 x 16l x 2 Batteries x 2 Mounting screw ø4 x 25l x 6 Part No Name of parts Q ty Deodorizing filter x 1 Purifying filter x 1 Filter frame x 2 Drain nipple x 1 Name Installation manual Owner s manual Others This model is not equipped with an extension drain hose Option For the extension drain hose use an optionally available RB 821SW or commercially available on...

Page 26: ...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 Top view Indoor unit 5 m 5m 45 45 Remote control Reception range Axial distance Remote control Reception range 7m Side vie...

Page 27: ...ng 15 A Wiring 1mm2 or more Fig 8 4 4 CAUTION Failure to firmly install the unit may result in personal injury and property damage if the unit falls In case of block brick concrete or similar type walls make 5 mm dia holes in the wall Insert 3 clip anchors for appropriate 8 mounting screws NOTE Install the installation plate using 4 to 6 pieces of mounting screw securing four corners with screws I...

Page 28: ...Cut the rear panel following 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 flex...

Page 29: ...local electrical codes and also any specific wiring instructions or limitation Stripping length of connecting cable For a five 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 30: ...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 connecting pipe to avoid double ...

Page 31: ...ing 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 32: ... 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 do...

Page 33: ...ach 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 dependin...

Page 34: ...n the terminal block 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 ...

Page 35: ...s the electronic beeper makes 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 User s Manual Flare nut connections indoor unit Electric parts cover Flare nut connections Outdoor unit A B C D Valve stem cap connection Service cap connection Valve stem cap connection TEMPORARY Fig 8 6 1 ...

Page 36: ... 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 5 cables Make certain that the indoor and outdoor units have been connected properly with terminals assigned the same numbers wired to each other If the c...

Page 37: ...ent of the thermo control The PRE DEF lamp comes on during defrost operation and when the indoor heat exchanger temperature is low when the heating operation is started At this time the indoor fan is stopped to prevent cold air from drifting into the room When the indoor heat exchanger temperature is high the outdoor fan may be stopped by the high temperature limit control operation When the compr...

Page 38: ...s ON Thermo sensor TA short break Heat exchanger sensor TC short break Indoor fan lock abnormality of indoor fan Indoor PC board failure Wrong wiring of connecting cable Thermal fuse is blown Gas shortage other refrigerant cycle trouble Heat exchanger sensor open break short Overload relay trouble Compressor trouble A B C D E F G H 9 2 Primary Judgement of Trouble Sources 9 2 1 Role of Indoor Unit...

Page 39: ...erature 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 dis play clock display and setting temperature dis play are turned on and of the clock display is flashing Cautions when doing serv...

Page 40: ...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 41: ...r sensor 3 If heat exchenger sensor is OK check overload relay and thermostat for compressor 4 If overload relay and themostat for compressor are OK check refrigerant cycle 5 If refrigerant cycle is OK check PC board 1 Check compressor 2 If it is OK check PC board Check code Block Indoor PC board Cable connection Thermal fuse Refrigerant system Symptom Thermo sensor short break Heat exchanger sens...

Page 42: ...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 43: ...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 AC220 230 240V supplied between terminal block 1 2 3 2 1 4 2 1 Only Heating mode Is cable connection between indoor and outdoor units correct Check items as following procedure in 9 3...

Page 44: ...inding 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 indo...

Page 45: ...nding normal 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 Is the voltage across the terminal 2 4 220 230 240 VAC Are all the cords for outdoor fan motor normal Correct the wire or repl...

Page 46: ... units correct Replace the PC board See Power can not be turned on NO NO NO NO YES YES YES YES 4 way valve is defective Cables between indoor and outdoor units are defective Correct cabling between indoor and outdoor units NO NO YES YES Is the wiring of solenoid coil for 4 way valve normal Is the voltage across the terminal 2 3 220 230 240 VAC See Power can not be turned on Solenoid coil is defect...

Page 47: ...ion stops Normal Is the voltage measured DC35V between 1 red lead wire and 2 black lead wire of the motor connector CN10 Shut off the power supply Does the cross 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 ha...

Page 48: ...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 49: ... 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 50: ... 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 a...

Page 51: ... 51 9 4 2 PC Board Layout Bottom View Top View ...

Page 52: ... 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 53: ...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 the...

Page 54: ...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 55: ...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 10SKH E RAS 10SKHX No Remarks Replace the thermal fuse terminal block power cord microcomputer ass y and the power supply PC board ass y Part name Co...

Page 56: ...rd 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 Remove OL holder and pull OL relay up 4 Remove Fustons of leads No Part name Common procedure Capacitor for compressor Capacitor fo...

Page 57: ...03 provided on the PC board as follows ON OFF 1 2 3 4 5 6 1 2 3 4 5 6 OFF ON 2 Check the black lead wire is double wound around the current trans CT T02 RY01 C02 RY02 Brown N L Power terminal block T02 PC board Blue White Black Double winding 1 2 3 4 Indoor terminal block ...

Page 58: ... 10kΩ 25 C 411 43T60004 Fuse Temperature 77 C 414 43T69007 PC Board WRS LED MCC 635 Location Part Description No No 415 43T69008 PC Board A ssy MCC 713 416 43T61001 Base E Parts ABS Black UL94 5V 417 43T62006 Base Shield SGCC Z08 LUB 419 43T60001 Base Terminal 2P AC 300V 20A 420 43T60005 Housing 4P Location Part Description No No 403 407 420 411 415 416 417 403 414 410 419 ...

Page 59: ...50V 405 43T32001 Resistor 5 6Ω 5W 406 43T33001 Capacitor Electrolytic 100MFD 450V AUF Location Part Description No No 408 43T55004 Varistor 560V 409 43T34001 Filter Line 0 6A 412 43T30001 IC Switching MA 2830P FJ 413 43T31001 Diode Rectifier RBV 406 600V 418 43T58001 Transformer Current CT422920S 01 Location Part Description No No ...

Page 60: ...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 Fan Cross Flow 229 43T22002 Bearing 230 43T39003 Base Bearing 231 43T03001 Rear Plate 232 43T07002 Pipe Holder 233 43T82001 Installation Plate 234 43T85001 Owner s Manual 10SKH E 234 43T85003 Owner ...

Page 61: ... 43T46002 Packed Valve 6 35 11 43T47003 Bonnet 6 35 DIA 12 43T46003 4 Way Valve VH7100D 13 43T21001 Fan Motor UE6 21SJ5P 14 43T47001 Flange Nut 15 43046255 Solenoid Coil 16 43T19005 Handle 17 43T49001 Rubber Cushion 18 43T79001 Nipple Drain 19 43T19002 Stopper Guard 20 43T63001 Holder OL Relay 21 43054403 Relay Over Load J MRA 99269 9200 22 43T41400 Compressor PH120T1 4C 23 43055483 MF Capacitor 2...

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