Toshiba RAS-13SAVR-E2, Service Manual

Page 1: ...R410A SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit High Wall Heat PumpType Heat PumpType RAS 13SKVR E2 RAS 13SAVR E2 March 2009 FILE NO SVM 09041 ...

Page 2: ...4 5 WIRING DIAGRAM 16 6 SPECIFICATIONS OF ELECTRICAL PARTS 17 7 REFRIGERANT CYCLE DIAGRAM 18 8 CONTROL BLOCK DIAGRAM 20 9 OPERATION DESCRIPTION 22 10 INSTALLATION PROCEDURE 48 11 HOW TO DIAGNOSE THE TROUBLE 62 12 HOW TO REPLACE THE MAIN PARTS 84 13 EXPLODED VIEWS AND PARTS LIST 102 FILE NO SVM 09041 ...

Page 3: ...nd 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 fit...

Page 4: ...ed 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...

Page 5: ...C 23FZ2 Fan motor output W 43 Air flow rate Cooling Heating m3 min 37 5 37 5 Piping connection Type Flare connection Indoor unit Liquid side mm 6 35 Gas side mm 9 52 Outdoor unit Liquid side mm 6 35 Gas side mm 9 52 Maximum length m 20 Maximun charge less length m 15 Maximum height difference m 10 Refrigerat Name of refrigerat R410A Weight kg 0 80 Wiring Power supply 3 Wires Includes earth Outdoor...

Page 6: ...0 o C Outdoor DB 7o C WB 6 o C Air Flow High Pip Length 5m Voltage 230V 2 3 Capacity Variation Ratio According to Temperature Cooling 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Outdoor temp Capacity ratio Conditions Indoor DB27 WB19 Indoor air flow High Pipe length 5m Heating 0 20 40 60 80 100 120 15 10 5 0 5 10 Outdoor temp Heating Capacity ratio Condition ...

Page 7: ... in the refrig eration 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 l...

Page 8: ...et 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...

Page 9: ... to 0 5 0 to 0 5 0 to 0 5 0 to 0 5 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 Table 3 2 4 Dimensions related to flare processing for R22 Nominal diameter 1 4 3 8 1 2 5 8 Outer diameter mm 6 35 9 52 12 70 15 88 Thickness mm 0 8 0 8 0 8 1 0 A mm Flare tool for R22 clutch type 0 to 0 5 0 to 0 5 0 to 0 5 0 t...

Page 10: ...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 tighten ing 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 manufac...

Page 11: ...ant 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 R410A air water heat pump installation Existence of new equipment for R410A Yes Yes Yes Yes Yes Yes Yes Yes Note 2 W...

Page 12: ...d the connecting port of the electronic balance and charge liquid refrigerant Indoor unit Outdoor unit Opened Opened Refrigerant cylinder with siphon Check valve Open close valve for charging Electronic balance for refrigerant charging Opened Closed Service port 3 4 Recharging of Refrigerant When it is necessary to recharge refrigerant charge the specified amount of new refrigerant according to th...

Page 13: ... of silver and copper It is used to join iron copper or copper alloy and is relatively expensive though it excels in solderability 2 Phosphor bronze brazing filler Phosphor bronze brazing filler is generally used to join copper or copper alloy 3 Low temperature brazing filler Low temperature brazing filler is generally called solder and is an alloy of tin and lead Since it is weak in adhesive stre...

Page 14: ... flux which does not contain chlorine 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 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 pip...

Page 15: ... 0 40m Connecting pipe 0 35m Installation plate hanger Flare 6 35mm Flare 9 52mm 116 Air ionizer 62 69 49 205 63 7 48 Front panel Knock out system Knock out system 48 7 63 Installation plate outline Center line Hanger Hanger Hanger 621 170 or more 170 or more 65 or more Minimum distance to wall Minimum distance to wall Minimum distance to ceiling 14 26 Remote controller holder 63 125 Wireless remo...

Page 16: ...r Liquid side Flare 6 35 Ø Gas side Service port 2 11 x 14 Long holes For 8 10 anchor bolt Installation dimension Air outlel 100 or more 100 or more 600 or more 600 or more Air intlel Ø Ø Ø Ø6 hole 86 Ø6 hole Ø11x14 hole R15 28 A 320 R5 5 36 108 125 50 137 92 5 4 600 320 90 600 90 275 290 550 Ø 436 Z R15 50 36 2 320 342 69 2 R5 5 x 17L Ushape For 8 10 anchor bolt FILE NO SVM 09041 Flare 9 52 Ø ...

Page 17: ... 16 5 WIRING DIAGRAM FILE NO SVM 09041 ...

Page 18: ...P 20A AC250V 9 COIL FOR P M V DC12V 10 Coil for 4 way valve AC220 240V CAM MD12TCTH 2 STF 01AJ646A1 Compressor 3 phases 4 poles 750W Inverter attached Inverter attached Inverter attached 8 Inverter attached DA89X1C 23FZ2 Parts name Model name Rating CH 69 Z T ICF 140 43 4R No Fan motor for indoor 2 Room temp sensor TA sensor 10kΩ at 25 C 3 Heat exchanger temp sensor TC sensor 10kΩ at 25 C 4 Louver...

Page 19: ...n Deoxidized copper pipe Outer dia 6 35mm Thickness 0 8mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attaching port Vacuum pump connecting port Strainer Pulse Modulating valve at liquid side TD 4 way valve Compressor DA89X1C 23FZ2 TS T2 Outdoor heat exchanger Temp measurement Propeller fan Refrigerant amount 0 80kg OUTDOOR U...

Page 20: ...o 13 46 to 48 High High 75 Heating Tempeature Standard Heat exchanger Indoor Outdoor Compressor condition C pressure pipe temp fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 7 6 2 6 to 2 8 41 to 43 0 to 2 High High 80 NOTES 1 Measure surface temperature of heat exchanger pipe around center of heat exchaner path U bent Thermistor themometer 2 Connecting piping condition 5 m FILE...

Page 21: ...formation Serial Signal Transmitter Receiver Micro Switch Converter D C circuit Noise Filter Indoor Fan Motor Air purifier unit Louver Motor Louver Motor Drive Control Indoor Fan Motor Control Initializing Circuit Clock Frequency Oscillator Circuit Power Supply Circuit Operation START STOP Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Functions Co...

Page 22: ... synthesis function Input current release control IGBT over current detect control Outdoor fan control High power factor correction control Inverter output frequency control A D converter function P M V control Discharge temp control 4 way valve control Signal communication to indoor unit P M V Pulse Motor Valve M C U Micro Control Unit M C U For INDOOR UNIT 4 way valve P M V Inverter DC AC Gate d...

Page 23: ...ion 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 P M V control 4 way valve control Operations followed to judgment of serial signal from indoor side Detection of inverter input current and current release operation ...

Page 24: ...fying control Detection of abnormality 34 12 Discharge temperature control 35 13 Pulse Modulating valve P M V control 36 14 Self Cleaning function 37 15 Selt Cleaning function release 38 16 Remote A or B selection 39 9 3 Auto Restart Function 42 9 3 1 How to Set the Auto Restart Function 42 9 3 2 How to Cancel the Auto Restart Function 43 9 3 3 Power Failure During Timer Operation 43 22 FILTER Ind...

Page 25: ...N 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 ON timer setup OFF timer setup Hi POWER 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 ...

Page 26: ...he operation mode the fan speed is controlled by the previous 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 1 Detects the room temperature Ta whe...

Page 27: ...tant 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 tempera ture room temperature and heat exchanger temperature Fig 1 Fig 2 2 5 Ta C 2 0 1 5 1 0 0 5 Tsc a b c d e M WB 3 4 5 L W6 Air volume AUTO L L M M H W6 L M 2 W9 M H 2 WC Indication Fan speed F...

Page 28: ... c 1 0 d 1 5 e 2 0 f 2 5 g 5 0 5 5 L W9 M WD 1 2 3 H WE H WE Line approximate H and SUL with Tc SUL W2 Stop 46 46 Tc 34 45 45 33 33 33 21 32 32 20 A 4 A 4 A 4 A 4 A 4 A 4 Fan speed MANUAL in starting Fan speed AUTO in stability Fan speed AUTO in starting L L M M H W8 L M 2 WA M H 2 WE Indication Fan speed Fan speed setup HEAT ON AUTO YES NO MANUAL TC 42 C Min air flow rate control Tc 52 51 42 41 L...

Page 29: ...lected 2 Fan speed 400 when the motor stopped Air conditioner ON Remote controller YES YES NO NO Indoor unit controller Fan motor ON 3 Fan lock OFF status of fan motor continues 4 Motor operates as shown in the table below 1 Outdoor unit operation command Outdoor fan control Air conditioner OFF Alarm display Outdoor fan speed rpm Tap f 1 f 2 f 3 f 4 f 5 f 6 f 7 f 8 200 300 370 440 440 500 550 600 ...

Page 30: ...tronic parts of the compressor driving inverter This function also controls drive circuit of the compressor speed so that electric power of the compressor drive circuit does not exceed the specified value 5 Current release control Set temp Ts Room temp Ta Correction of Hz signal Outdoor temp To Setup of current release point Change of compressor speed Remote controller Indoor unit Ts Ta Current de...

Page 31: ...pressor speed is kept Q zone When temperature of the indoor heat exchanger drops in the range from 46 C to under 55 C the compressor speed is kept Q zone 2 When temperature of the indoor heat exchanger rises to 55 C or higher the compressor speed is reduced P zone 3 When temperature of the indoor heat exchanger does not rise to 50 C or when it drops below to 46 C the capacity control operation ret...

Page 32: ...lower stop the indoor fan Finish of defrost operation Returning conditions from defrost operation to heating operation 1 Temperature of outdoor heat exchanger rises to 8 C or higher 2 Temperature of outdoor heat exchanger is kept at 5 C or higher for 80 seconds 3 Defrost operation continues for 15 minutes Returning from defrost operation 1 Stop operation of the compressor for approx 50 seconds 2 I...

Page 33: ...either upper or lower limit position swing operation is performed in width 35 from the limit which the stop position exceeded 3 Swing 2 Louver position in heating operation 2 Air direction adjustment The position is automatically controlled according to the operation The set louver position is stored in memory by the microcomputer The angle of the louver is indicated as the louver closes fully is ...

Page 34: ...x COOL min 6 x 1 COOL min 30 minutes A B C A B C Time Compressor speed 0Hz A zone aHz B zone a to cHz C zone cHz 0 0 5 1 0 1 5 2 0 2 5 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 Room temp Set temp 3 5 3 0 2 5 1 5 1 0 TSC 1 0 2 0 5 5 1H 2H 11 10 7 6 5 4 3 2 1 OFF Dry Max 12 11 9 8 10 TA 6 0 6 5 3H 4H 5 0 4 5 4 0 2 0 0 5 0 5 12 9 8 Time Zone Frequency FAN Min Hz Fan speed depend on presetting and can cha...

Page 35: ...ration of air conditioner air purifier an operation of air conditioner air purifier starts by pushing AC button on the remote controller Operation of air conditioner air purifier is stored in memory 1 Swing is available 2 Fan speed is Fan Auto mode varies in order M 1 L L SL Filter lamp ON Press RESET button Did you press RESET button for 3 seconds or more Did you press RESET button for 10 seconds...

Page 36: ... an error is judged again 12 Discharge temperature control Reset by RESET button Reset by RESET button or by the stop direction from the remote controller When the breaker is turned ON In restart time after power failure or RESET button is pressed while the FILTER indicator is turned on the air purifier is not turned on until the integrated operation time of the indoor fan exceeds 1 hour after ope...

Page 37: ... in the range of set tempera ture Discharge temp control 4 When defrost operation is performed the open degree of valve is adjusted accord ing to each setup conditions during preparation for defrost and during defrost operation 4 way valve is inversed 5 To turn off the compressor while the air conditioner stops by control of the thermostat or by remote controller adjust the open degree of valve to...

Page 38: ... operation performed prior to the reception of the stop code 3 After the Self Cleaning operation has been performed for the specified period the unit stops operating Unit now performing cooling or dry operation Press STOP button Only timer indicator lights and Self Cleaning operation starts Time set now elapses Operation stops function During Self Cleaning operations The louver opens slightly The ...

Page 39: ...d but keep holding it continue The will beep 3 times in the first 3 seconds but it is not related to Self Cleaning function After holding about 20 seconds the air conditioner will beep 5 times without any blinking of display The Self Cleaning Operation had been cancelled Remark Presetting of Self Cleaning function above AUTO How to set Self Cleaning function To set the Self Cleaning function proce...

Page 40: ...ry the remote controller selection is set to A on all the indoor units There is no A setting display Setting the remote controller To separate using of remote control for each indoor unit in case of 2 air conditioner are installed nearly Remote Control B Setup 1 Press RESET button on the indoor unit to turn 2 Point the remote control at the indoor unit 3 Push and hold CHK button on the Remote Cont...

Page 41: ...ton to choose the operating hours Repeat pressing to select the hours If the COMFORT SLEEP button is pressed again means cancel comfort sleep mode Heating mode The preset temperature will drop down as show on ECO operation Item No 9 choose the operating hours Repeat Press the COMFORT SLEEP button to pressing to setect thehours If the COMFORT SLEEP button is pressed again means cancel comfort sleep...

Page 42: ...arget temperature is 24ºC 4 Louver position is set as stored position of the operating mode 5 Fan is controlled as followings Mode POWER mark is indicated on the display of the remote controller and the unit operates as follows 1 Automatic operation The indoor unit operates in according to the current operation 2 Cooling operation remote controller does not change The indoor unit s fan speed level...

Page 43: ... equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidentally shut down The operation will resume without warning three minutes after power is restored This function is not set to work when shipped from the factory Therefore it is necessary to set it to work 9 3 1 How to Set the Auto Re...

Page 44: ...ress RESET button once more or use the remote controller to turn it on 9 3 2 How to Cancel the Auto Restart Function To cancel auto restart function proceed as follows Repeat the setting procedure the unit receives the signal and beeps three times The unit will be required to be turned on with the remote controller after the main power supply is turned off When the system is on stand by not operat...

Page 45: ... control 1 ONE TOUCH Press the ONE TOUCH button for fully automated operation that is customised to the typical consumer preferences in your region of the world The coutomised settings control temperature air flow strength air flow direction and other settings to provide you alternate contact with ONE TOUCH OF THE BUTTON If you prefer other settings you can select from the many other operation fun...

Page 46: ...d FAN ONLY mode Press ECO Start and stop the operation Note Cooling operation the set temperature will increase automatically 1 degree hour for 2 hours maximum 2 degrees increase For heating operation the set temperature will decrease 8 TEMPORARY OPERATION In case of the misplaced or discharged remote control Pressing the RESET button the unit can start or stop without using the remote control Ope...

Page 47: ... for 5 secpmds Do not operate ON timer and OFF timer 2 Press and hold the RESET button on the indoor unit for 3 seconds to cancel the Setting operation 3 beep sound but OPERATION lamp does not blink 12 QUIET OPERATION To operate at super low fan speed for quiet operation except in DRY mode Press QUIET Start and stop the operation Note Under certain conditions QUIET operation may not provide adequa...

Page 48: ...dicates when the Hi POWER operation starts Press the Hi POWER button to start and press it again to stop the operation 8 PRESET indicator Flashes for 3 seconds when the PRESET button is pressed during operation The mark is shown when holding down the button for more than 3 seconds while the mark is flashing Press another button to turn off the mark 9 ECO indicator Indicates when the ECO is in acti...

Page 49: ...in hose sloped downward Do not allow the drain hose to get slack Cut the piping hole sloped slightly The auxiliary piping can be connected to the left rear left rear right right bottom right or bottom left Right Rear right Bottom right Rear left Bottom left Left 6 mm thick heat resisting polyethylene foam 1 Batteries Pan head wood screw Remote control holder Vinyl tape Apply after carrying out a d...

Page 50: ... m Æ If it is necessary to drain the defrost water attach drain nipple 9 and cap water proof 10 to the bottom plate of the outdoor unit before installing it FILE NO SVM 09041 10 2 Installation 10 2 1 Optional installation parts Fixing bolt arrangement of outdoor unit Part Code A B C Q ty One each 1 One each Parts name Refrigerant piping Liquid side 6 35 mm Gas side 9 52 mm Pipe insulating material...

Page 51: ...xi Deo filter x 1 Super Sterilizer filter x 1 Part No 4 5 6 Part No 7 8 9 Others Name Owner s manual Installation manual Part name Q ty Mounting screw 4 x 25 s x 6 Flat head wood screw 3 1 x 16 s x 2 Drain nipple x 1 10 2 2 Accessory and installation parts The part marked with asterisk is packaged with the outdoor unit Cap water proof x 2 For 09k model only 10 ...

Page 52: ... size have been changed to 1 2 UNF 20 threads per inch When purchasing a charge hose be sure to confirm the port size As pressure is high and gasification speed is fast it is difficult to read the indicated value by means of charging cylinder as air bubbles occur The size of opposite sides of flare nuts have been increased Incidentally a common wrench is used for nominal diameters 1 4 and 3 8 By i...

Page 53: ...ght or close to a heating source such as a stove Keep the remote controller at least 1 m away from the nearest TV set or stereo equipment This is necessary to prevent image disturbances or noise interference The location of the remote controller should be determined as shown below Fig 10 3 1 10 3 2 Drilling a Hole and Mounting Instal lation Plate Drilling a hole When install the refrigerant pipes ...

Page 54: ...e air conditioner NOTE Wire type More than 1 5 mm2 H07RN F or 60245IEC66 CAUTION This appliance can be connected to a main circuit breaker in either of the following two ways 1 Connection to fixed wiring A switch or circuit breaker which discon nects all poles and has a contact separa tion of at least 3 mm must be incorporated in the fixed wiring An approved circuit breaker or switch must be used ...

Page 55: ...ain hose The drain hose is secured in place by a screw Remove the screw securing the drain hose then pull out the drain hose Screw Drain hose Fig 10 3 12 NOTE Use stranded wire only Wire type H07 RN F or more Fig 9 2 7 Stripping length of connecting cable 10 mm 10 mm 50 mm 110 mm Earth line Connecting cable Stripping length of the connecting cable about 15 cm Terminal cover Screw Screw Cord clamp ...

Page 56: ... less Ø6 35 R40 or less Ø9 52 R50 or less Ø12 7 Use polishing polyethylene core or the like for bending pipe Liquid side No gap Insert a hexagon wrench Ø4mm Do not apply lubricating oil refrigerant machine oil when inserting the drain cap If applied deterioration and drain leakage of the drain plug may occur 2 Firmly insert drain cap Fig 10 3 14 How to attach the drain hose Always use the original...

Page 57: ...hooked on the installation plate Installation plate Indoor unit Connecting cable Auxiliary pipes 10 3 7 Drainage 1 Run the drain hose at a downward sloped angle NOTE Hole should be made at a slight downward slant on the outdoor side Fig 10 3 21 2 Put water in the drain pan and make sure that the water is being drained outside 3 When connecting extension drain hose insulate the connection part of e...

Page 58: ...ain water does not cause any problems Precautions for adding refrigerant Use a scale having a precision with at least 10 g per index line when adding the refrigerant Do not use a bathroom scale or similar instrument Use liquid refrigerant when refilling the refrigerant Since the refrigerant is in liquid form it can fill quickly Therefore perform the filling operation carefully and insert the refri...

Page 59: ...d drain off the water For the position where the drain nipple is installed refer to the installation diagram of the indoor and outdoor units Check that the outdoor unit is horizontal and route the drain hose at a downward sloped angle while ensuring that it is connected tautly Do not use ordinary garden hose but one can flatten and prevent water from draining Fig 10 4 3 Commercially available drai...

Page 60: ... the pump does not flow back into the air conditioner pipes when the pump stops If oil inside the vacuum pump enters into the air conditioner circuit which uses R410A trouble with the refrigeration system may develop 1 Connect the charge hose from the manifold valve to the service port of the gas side packed valve 2 Connect the charge hose to the port of the vacuum pump 3 Open fully the low pressu...

Page 61: ...correct wiring connection may cause electri cal parts to burn out Be sure to comply with local regulations codes when running the wire from outdoor unit to indoor unit Size of wire and wiring method etc Every wire must be securely connected If incorrect or incomplete wiring is carried out fire or smoke may result Prepare the power supply for the exclusive use of the air conditioner This product ca...

Page 62: ...tting and A room B room when connecting the piping and cables Remote Control A B Selection To separate using of remote control for each indoor unit in case of 2 air conditioner are installed nearly the remote control signal simultaneously and operate In this Remote Control B Setup 1 Press RESET button on the indoor unit to turn the air conditioner ON 2 Point the remote control at the indoor unit 3...

Page 63: ...rd by hand The new inverter 3DV inverter will be incorporated starting with this unit 3DV 3 shunt Discrete Vector control K The control circuitry has an uninsulated construction No 1 2 3 4 5 Troubleshooting Procedure First Confirmation Primary Judgment Judgment by Flashing LED of Indoor Unit Self Diagnosis by Remote Controller Judgment of Trouble by Every Symptom Page 62 63 63 64 67 No 6 7 8 9 10 ...

Page 64: ...e components Sensor leads Do NOT lay the circuit board assembly flat K Precautions when inspecting the control section of the outdoor unit NOTE A large capacity electrolytic capacitor is used in the outdoor unit controller inverter Therefore if the power supply is turned off charge charging voltage DC280 to 380V remains and discharging takes a lot of time After turning off the power source if touc...

Page 65: ...easing of compressor motor speed stops approx 30 seconds after operation started and then compressor motor speed increases again approx 30 seconds after In AUTO mode the operation mode is changed In HEAT mode the compressor motor speed does not increase up to the maxi mum speed or decreases before the temperature arrives at the set temperature Description The OPERATION lamp of the indoor unit flas...

Page 66: ...onditioner operates 2 When item B and C and item B and a part of item E occur concurrently priority is given to the block of item B 3 The check codes can be confirmed on the remote controller for servicing OPERATION Green Flashing display 1 Hz OPERATION Green TIMER Yellow FILTER Orange Flashing display 5 Hz OPERATION Green FILTER Orange Flashing display 5 Hz OPERATION Green TIMER Yellow Flashing d...

Page 67: ...eep and the display of the remote controller will change as follows The TIMER indicator of the indoor unit flashes continuously 5 times per 1 sec Check the unit with all 52 check codes to as shown in Table 11 4 1 Press ON or OFF button to change the check code backward If there is a fault the indoor unit will beep for 10 seconds Beep Beep Beep Note the check code on the display of the remote contr...

Page 68: ...r returns the initial status However the check codes are not deleted even if the power supply is turned off because they are stored in the fixed memory 3 After servicing press CLR button under check mode status and then send the check code 7F to the indoor unit The error code stored in memory is cleared Table 11 4 1 Block distinction Operation of diagnosis function Block Indoor P C board etc Not d...

Page 69: ...tion Block Outdoor P C board Not displayed Outdoor P C board Others including compressor Operation of diagnosis function Cause of operation Inverter over current protective circuit operates Short time Position detect circuit error or short circuit between windings of compressor Current detect circuit error Being out of place disconnection or short circuit of the outdoor heat exchanger sensor TE or...

Page 70: ...ower supply by pushing START STOP button on remote controller Is voltage DC12V or 5V indicated on rear of indoor control board normal Does transmission mark on remote controller flash normally and is its signal transmitted properly Item by symptoms Operation Check Item Considerable principle cause Measures Parts R01 C01 C02 R02 C03 D01 D02 D03 D04 Remote controller is defective Refer to 5 Troubles...

Page 71: ...cross flow fan by hand at the operation stop condition is the rotation signal DC 12V 0V detected between 2 Purple lead and 3 Blue lead of the motor connector CN33 1 pulse 1 revolutio Dose AC120V or ligher voltage apply to between red and black lead of the motor Is it possible to change airflow level to HIGH Stop the operation Does fan motor continue to operate Does indoor fan operate Fan motor ope...

Page 72: ...Judgment of Trouble by Every Symptom AFS 220 20 4AR Do not disconnect the connector while the fan motor is rotating For P C board side proceed to the item Only indoor fan does not oper 1 3 5 1 2 3 2 1 3 2 1 3 2 1 3 2 1 3 CN31 CN33 P C board WHI BLK RED BLK RED WHI BLU PUR GRY BLU PUR GRY Resistance value Position P C board Between 3 Black 1 Red Between 3 Black 5 White Between 1 Red 5 White 74 15 Ω...

Page 73: ...s are exhausted Does radio sound is affected by remote controller when a signal is transmitted at distance of 5 cm from radio Is transmission mark indicated P C board is defective Replace P C board Replace batteries Replace remote controller Normal operation Remote controller is defective NO YES NO YES NO YES NO YES NO YES NO YES NO YES Does indoor unit start to operate by automatic restart functi...

Page 74: ...transmission from indoor unit to outdoor unit is correctly performed based upon the follow ing diagram NOTE Measurement should be performed 2 minutes and 30 seconds after starting of the operation Be sure to prepare a diode for judgment Normal time Voltage swings between DC15 and 60V Inverter Assembly check 11 8 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while after ope...

Page 75: ...ressure is low Is connecter of coil connected to inverter Is coil of the pulse motor valve P M V correctly set Existence of condensation at outlet of P M V If there is condensation at outlet 1 4 inch Ø6 35mm valve side the valve is clogged Are temp sensors of indoor outdoor units correctly set to the holder NOTE The temperature sensors which are used to control pulse motor valve include indoor hea...

Page 76: ... C board Micro switch is stuck Micro switch malfunction To item Power supply is not turned on Replace the main P C board Replace micro switch Does the PURE indicator go off within 2 seconds after it was ON and does the FILTER indicator Orange go on Are the electric dust collector and ionizer dried Electrode check Dry the electric dust collector and ionizer Is DC 5V to DC 10V applied between Brown ...

Page 77: ...duction of micro switch connector under OFF status of the micro switch Front panel opened Is there conduction of micro switch connector under ON status of the micro switch Front panel closed Does the indoor fan rotate Does the PURE indicator Blue or the FILTER indicator Orange go on Is DC12V applied between Red DC12V and Brown GND of CN1 of the high voltage generator in the air purifier Micro swit...

Page 78: ...or S Summary If fuse was blown be sure to check the electrolytic capacitor and diode block DB01 Connect discharge resistance approx 100Ω 40W or soldering iron plug between terminals of the electro lytic capacitor 500µF or 760µF of C14 with printed CAUTION HIGH VOLTAGE on P C board OK if 500µF or 760µF DC280 to 380V Remove CN300 while pushing the part indicated by an arrow because CN300 is a connec...

Page 79: ...1 How to Check the P C Board Indoor Unit 1 Operating precautions 1 When removing the front panel or the P C board be sure to shut off the power supply breaker 2 When removing the P C board hold the edge of the P C board and do not apply force to the parts 3 When connecting or disconnecting the connectors on the P C board hold the whole housing Do not pull at the lead wire 2 Inspection procedures 1...

Page 80: ... not all indicators OPERATION TIMER FILTER PURE are lit for 3 seconds and they return to normal 3 seconds later 1 Check whether or not the com pressor operates 2 Check whether or not the OP ERATION indicator flashes 1 Check whether or not the com pressor operates 2 Check whether or not the OP ERATION indicator flashes 1 Check it is impossible to detect the voltage AC120V or higher voltage between ...

Page 81: ...0 40 50 Resistance value k Temperature C TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TE Outdoor heat exchanger temp sensor TS Suction temp sensor TA TC TO TE TS TD 1 Sensor characteristic table 80 FILE NO SVM 09041 ...

Page 82: ... Refer to 11 5 1 5 Measure the resistance value of each winding coil by using the tester Under normal temp 25 C Position 1 to 2 1 to 3 1 to 4 1 to 5 Resistance value 250 20Ω Refer to 11 5 1 3 and 4 Under 20 C Disconnect the connector and measure resistance value with the tester Normal temperature Outdoor temperature sensor TO discharge temperature sensor TD suction temperature sensor TS outdoor he...

Page 83: ...Soldered surface Heat sink IGBT side C12 C13 C14 Case that product is good Pointer swings once and returns slowly When performing test once again under another polarity the pointer should return C12 C13 C14 500µF 400V Resistance value in good product Tester rod 2 3 2 3 4 1 1 2 3 DBO1 4 4 2 3 1 10 to 20 Ω when the multimeter probe is reversed 2 Diode block 1 Turn OFF the power supply breaker 2 Comp...

Page 84: ...of the outdoor fan motor 4 Motor drive circuit failure of the outdoor P C board 3 How to simply judge whether outdoor fan motor is good or bad NOTE However GND circuit error inside of the motor may be accepted in some cases when the above check is performed When the fan motor does not become normal even if P C board is replaced replace the outdoor fan motor If the resistance value between 1 Red le...

Page 85: ...gnite any oil mixed with the refrigerant gas 2 Do not use welding equipment in an airtight room Carbon monoxide poisoning may result if the room is not properly ventilated 3 Do not bring welding equipment near flammable objects Flames from the equipment may cause the flammable objects to catch fire If keeping the power on is absolutely unavoidable while doing a job such as inspecting the cir cuitr...

Page 86: ... positions of the air outlet and then hang the hanging hooks 3 pcs at the top side of the front panel to the rear plate 2 Insert the plasma air purifier Press in the plasma air parifier until the protrusions on both sides are completely inserted into the holders If installation is incomplete the FILTER indicator orange may light 3 Tighten two screws Incomplete hanging or incomplete pressing may ca...

Page 87: ...he high voltage generat 4 Attach the air ionizer to the back body How to assemble the high voltage generator 1 Insert the high voltage generator straight into the evaporator voltage generator from the evaporator Check whether it is completed inserted 3 Disconnect the connectors of the high voltage generator 4 Remove the fixing screws 2 pcs and remove the high voltage generator from the evaporator ...

Page 88: ...x assembly onto the claws on the back body and secure it using the fixing screw Now attach the display unit Connect the connectors for the fan motor and louver motor 2 Secure the grounding wire using the fixing screw Insert the TC sensor into the sensor holder Be absolutely sure to loop the grounding wire and TC sensor leads once at the bottom 5 Disengage the display unit by simply pushing at the ...

Page 89: ...m 2 Remove the pipe holder from the rear side of the main unit 3 Remove two fixing screws at the left side of the end plate of the heat exchanger Remarks 4 Remove one fixing screw on the heat exchage fixing holder to separate the heat exchage from the back body 5 Remove right side of the end plate from two fixing rib while sliding slightly the heat exchanger rightward 2 screws Heat exchanger fixin...

Page 90: ... Remove the two screws used to secure the bearing base 3 Remove the bearing base Caution at assembling If the bearing is out from the housing push it into the specified position and then incorporate it in the main body Remarks Two screws Bearing Bearing base FILE NO SVM 09041 ...

Page 91: ...crew of the cross flow fan 3 Remove two fixing screws of the motor cover and them remove the motor cover 4 Remove two more fixing screws of the motor band and remove the motor band Remarks 5 Pull the fan motor outward Set screw Two screws on motor band Motor cover Two Screws FILE NO SVM 09041 ...

Page 92: ...0 5 mm from wall of rear plate of the main unit Holding the set screw install the cross flow fan so that U groove of the fan motor comes to the mounting hole of the set screw Perform positioning of the fan motor as follows When assembling the fan motor the fan motor must be installed in such a way that the fan motor leads will be taken out is positioned at the bottom front After assembling the two...

Page 93: ...pply off to stop the operation of air conditioner 2 Remove the front panel Remove the 2 fixing screws 3 Remove the electrical part base Remarks Replace terminal block microcomputer ass y and the P C board ass y 12 2 Microcomputer P C board layout FILE NO SVM 09041 ...

Page 94: ...e the indoor unit 2 Attach the upper cabinet ST1TØ4 10L 5 pcs 3 Perform cabling of connecting cable and attach the cord clamp Fix the cord clamp by tightening the screws ST2T 4 x 14L 3 pcs fitting 2 concave parts of the cord clamp to each connecting cables 4 Attach the valve cover ST1T 4 x 10L 2 pcs Insert the upper part into the square hole of the side cabinet set hook claws of the valve cover to...

Page 95: ...t is fitted into the side cabinet left at the front left side so pull up the top of the front cabinet to remove it 2 Attachment 1 Insert the claw on the front left side into the side cabinet left 2 Hook the bottom part of the front right side onto the concave section of the bottom plate Insert the claw of the side cabinet right into the square hole in the front cabinet 3 Return the screws that wer...

Page 96: ... This capacitor is one with mass capacity Therefore it is dangerous that a large spark generates if short circuiting between Requirement As each connector has a lock mecha nism avoid to remove the connector by holding the lead wire but by holding the connector Discharging position Discharging period 10 seconds or more Plug of soldering iron The connector is one with lock so remove it while pushing...

Page 97: ...their housing must be released before they are disconnected 2 Remove the control board assembly from the P C board base Remove the heat sink and control board assembly while keeping them screwed together NOTE Disengage the four claws of the P C board base hold the heat sink and lift to remove it 3 Remove the two fixing screws used to secure the heat sink and control board assembly 4 Mount the new ...

Page 98: ...d heat exchanger Remarks Detail A Detail B Detail C 1 Perform work of item 1 of and 2 Remove the flange nut fixing the fan motor and the propeller Flange nut is loosened by turning clock wise To tighten the flange nut turn counterclockwise 3 Remove the propeller fan 4 Disconnect the connector for fan motor from the inverter 5 Remove the fixing screws 4 pcs holding by hands so that the fan motor do...

Page 99: ... Otherwise it may malfunction 7 Remove the fixing screw of the bottom plate and heat exchanger ST1TØ4 10L 1 pc 8 Remove the fixing screw of the bottom plate and valve fixing plate ST1TØ4 10L 1 pc 9 Pull upward the refrigeration cycle 10 Remove BOLT 3 pcs fixing the compres sor to the bottom plate Precautions when assembling the com pressor Tighten the compressor bolts using a tightening torque of ...

Page 100: ...ng claws by pushing minus screwdriver according to the arrow mark in the right figure and remove the fan guard 2 Attachment 1 Insert claws of the fan guard in the holes of the front cabinet Push the hooking claws 9 positions by hands and fix the claws Check that all the hooking claws are fixed to the specified positions FILE NO SVM 09041 1 Detachment 1 Perform step 1 in all the steps in and 1 in 2...

Page 101: ...structed The product will not be controlled properly and trouble will result if the sensors have not been installed in their proper positions Detail C TS sensor Suction pipe temperature sensor Attachment Install the senser onto the straight pipe part of the suction pipe Be careful for the lead direction of the sensor TD sensor Discharge pipe temperature sensor Attachment With its leads pointed upw...

Page 102: ... them 9 Wind the attached color tape round the both terminals of the protective tube when colored protective tube is used 10 Fix the sensor again Remarks 1 2 3 4 5 6 Parts name Sensor Sensor Spring A Sensor Spring B Thermal constringent tube Color tape Terminal Q ty 1 1 1 3 1 3 Cutting here Cutting here Cutting here Soldered part Dryer Winding the color tape 100 200 Connector Thermal sensor part T...

Page 103: ...REFRIGERANT CYCLE ASSEMBLY 206 43T11301 PIPE SHIELD 221 43T00489 PANEL SERVICE ASSEMBLY 207 43T83003 HOLDER REMOTE CONTROL 222 43T80318 AIR FILTER R 209 43T82310 INSTALLATION PLATE 223 43T80319 AIR FILTER L 210 43T69499 UNIT ELECTRIC PURIFIER 224 43T09411 GRILLE OF AIR INLET ORIGINAL SILVER 211 43T19333 HOLDER SENSOR 225 43T80320 HIGH VOLTAGE POWER 212 43T09408 PIPE HOLDER SUPPLY UNIT ASSEMBLY 213...

Page 104: ... Part No No No No 401 43T69319 TEMPERATURE SENSOR 404 43T62003 CORD CLAMP 402 43T60365 TERMINAL BLOCK 3P 405 43T69650 PC BOARD ASSY WRS LED 403 43T69320 TEMPERATURE SENSOR 406 43T69807 PC BOARD Description Description FILE NO SVM 09041 402 405 406 404 401 403 ...

Page 105: ...35 RUBBER CUSHION 8 43T41420 COMPRESSOR Made in China 26 43T46343 4 WAY VALVE 9 43T43434 CONDENSER ASSEMBLY 27 43T63320 4 WAY VALVE COIL ASSEMBLY 10 43T46332 VALVE PACKED 6 35 DIA 28 43T63319 HOLDER SENSOR 11 43T46331 VALVE PACKED 9 52 DIA 29 43T79305 DRAIN NIPPLE 12 43T47331 BONNET 6 35 DIA 30 43T39333 MOTOR BASE CONNECTION PLATE 13 43T47332 BONNET 9 52 DIA 31 43T63318 HOLDER SENSOR 14 43T00448 F...

Page 106: ... 43T62320 HEATSINK 705 43T60377 TEMPERATURE SENSOR 702 43T69815 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60392 TERMINAL 5P 707 43T62313 BASE PLATE PC 704 43T60326 FUSE Description Description 105 13 4 P C Board Layout FILE NO SVM 09041 ...

Page 107: ... 56 FILE NO SVM 03005 TOSHIBA CARRIER THAILAND CO LTD 144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND ...