Toshiba RAS-16SAVP-E, Service Manual

Page 1: ...utdoor Unit High Wall Heat Pump Type Heat Pump Type Standard Type RAS B10SKVP E RAS 10SAVP E RAS B13SKVP E RAS 13SAVP E RAS B16SKVP E RAS 16SAVP E North Europe Type RAS 10SKVP ND RAS 10SAVP ND RAS 13SKVP ND RAS 13SAVP ND RAS 16SKVP ND RAS 16SAVP ND PRINTED IN JAPAN Fub 2007 ToMo ...

Page 2: ...G DIAGRAM 20 6 SPECIFICATIONS OF ELECTRICAL PARTS 22 7 REFRIGERANT CYCLE DIAGRAM 23 8 CONTROL BLOCK DIAGRAM 25 9 OPERATION DESCRIPTION 27 10 INSTALLATION PROCEDURE 55 11 HOW TO DIAGNOSE THE TROUBLE 68 12 HOW TO REPLACE THE MAIN PARTS 89 13 EXPLODED VIEWS AND PARTS LIST 108 14 SET UP OF SERVICE P C BOARD 118 ...

Page 3: ...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 fittin...

Page 4: ...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...

Page 5: ...ler holder Mounting screw Accessory unit Remote controller holder mounting screw Plasma pure filter Installation manual Owner s manual Outdoor Drain nipple unit Water proof rubber cap RAS B10SKVP E RAS B13SKVP E RAS B16SKVP E RAS 10SAVP E RAS 13SAVP E RAS 16SAVP E 2 5 3 5 4 5 0 5 3 5 0 6 4 5 0 8 5 0 3 2 4 2 5 5 0 6 6 1 0 6 6 9 0 8 8 0 1 Ph 50Hz 220 240 V 1 Ph 60Hz 220 V Cooling Heating Cooling Hea...

Page 6: ...ounting screw Accessory unit Remote controller holder mounting screw Plasma pure filter Installation manual Owner s manual Outdoor Drain nipple unit Water proof rubber cap RAS 10SKVP ND RAS 13SKVP ND RAS 16SKVP ND RAS 10SAVP ND RAS 13SAVP ND RAS 16SAVP ND 2 5 3 5 4 5 0 5 3 5 0 6 4 5 0 8 5 0 3 2 4 2 5 5 0 6 6 1 0 6 6 9 0 8 8 0 1 Ph 50Hz 220 240 V Cooling Heating Cooling Heating Cooling Heating 0 15...

Page 7: ...ipe length 5m Voltage 230V 7 8 6 5 4 3 2 1 0 Current A Compressor speed rps 0 20 40 60 80 120 100 Conditions Indoor DB 27 C WB 19 C Outdoor DB 35 C Air flow High Pipe length 5m Voltage 230V Current A 7 8 9 9 10 10 6 5 4 3 2 1 0 Compressor speed rps 0 20 40 60 80 120 140 140 100 Conditions Indoor DB 20 C Outdoor DB 7 C WB 6 C Air flow High Pipe length 5m Voltage 230V 2 2 Operation Characteristic Cu...

Page 8: ...gh Pipe length 5m 100 110 90 80 70 60 50 32 34 36 38 40 42 33 35 37 39 41 43 44 45 46 Outdoor temp C Capacity ratio 120 100 80 60 40 20 0 15 10 5 0 5 7 10 Capacity ratio Outdoor temp C Conditions Indoor DB 20 C Indoor air flow High Pipe length 5m Conditions Indoor DB27 C WB19 C Indoor air flow High Pipe length 5m 2 3 Capacity Variation Ratio According to Temperature RAS B10SKVP E RAS B13SKVP E RAS...

Page 9: ...e 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...

Page 10: ...ure 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 pr...

Page 11: ...o 2 5 Table 3 2 4 Dimensions related to flare processing for R22 Table 3 2 5 Flare and flare nut dimensions for R410A 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 R410A clutch type 0 to 0 5 0 to 0 5 0 to 0 5 0 to 0 5 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...

Page 12: ... 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 1 4 3 8 1 2 5 8 3 4 Outer diameter mm 6 35 9 52 12 70 15 88 ...

Page 13: ... 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 R410A air water heat pump installation Existence of new equipment for R410A Yes Yes Yes Yes Yes Yes Yes Yes...

Page 14: ...and the connecting port of the electronic balance and charge liquid refrigerant Water heat exchanger 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...

Page 15: ... 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 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 adhe...

Page 16: ...fore use a flux which does not contain chlorine 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 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 ...

Page 17: ... Plasma pure filter Air filter Front panel Knockout system Knockout system 55 65 208 790 60 7 250 7 51 5 Indoor heat exchanger 54 5 60 60 54 5 53 53 Installation plate hanging section 290 Installation plate hanging section Drain hose Outside length 0 54m Connecting pipe Outside length 0 4m Flare Ø9 52 B16SKVP E Ø12 7 Connecting pipe Outside length 0 45m Flare Ø6 35 47 or more 74 or more 140 or mor...

Page 18: ... Air filter Front panel Knockout system Knockout system 55 65 208 790 60 7 250 7 51 5 Indoor heat exchanger 54 5 60 60 54 5 53 53 Installation plate hanging section 290 Installation plate hanging section Drain hose Outside length 0 54m Connecting pipe Outside length 0 4m Flare Ø9 52 16SKVP ND Ø12 7 Connecting pipe Outside length 0 45m Flare Ø6 35 47 or more 74 or more 140 or more Minimum distance ...

Page 19: ... two of directions A B C and D shown in the figure below 50 or more Outside line of product 100 or more 200 or more 250 or more 600 320 Intake Intake Outlet Charging port 4 dia 4 5 embossment Drain long hole Drain hole 320 Anchor bolt long hole pitch 290 306 Dia 7 hole pitch 600 69 5 147 483 dia 436 108 780 32 500 20 28 88 dia 25 108 125 22 25 71 257 145 157 31 143 5 4 5 4 342 79 20 21 21 8 550 48...

Page 20: ...rge pipe Temp Sensor TD 3 2 1 3 2 1 Condenser pipe Temp Sensor TE 2 1 2 1 Thermo Sensor TA 1 2 1 2 CN62 BLU BLK BLK Heat Exchanger Sensor TC 1 2 1 2 CN63 YEL CN42 WHI CN01 CN02 CN51 BLK BLK Heat Exchanger Sensor TCJ 1 2 1 2 Outdoor Temp Sensor TO 2 1 2 1 R321 R320 R319 P19 P18 Reactor Reactor Coil for 4 way Valve Power Supply 220 240V 50Hz 220 220V 60Hz Indoor Terminal Block Wireless Unit Assembly...

Page 21: ...mp Sensor TD 3 2 1 3 2 1 Condenser pipe Temp Sensor TE 2 1 2 1 Thermo Sensor TA 1 2 1 2 CN62 BLU BLK BLK Heat Exchanger Sensor TC 1 2 1 2 CN63 YEL CN42 WHI CN01 CN02 CN51 BLK BLK Heat Exchanger Sensor TCJ 1 2 1 2 Outdoor Temp Sensor TO 2 1 2 1 R321 R320 R319 P19 P18 Reactor Reactor Coil for 4 way Valve Heater for Anti Freeze Power Supply 220 240V 50Hz Indoor Terminal Block Wireless Unit Assembly M...

Page 22: ...0kΩ at 25 C 10kΩ at 25 C Output Rated 1W 16 poles DC12V No 1 2 3 4 5 6 7 8 9 10 11 12 Parts name Reactor Outside fan motor Suction temp sensor TS sensor Discharge temp sensor TD sensor Outside air temp sensor TO sensor Heat exchanger temp sensor TE sensor Terminal block 6P Compressor Coil for P M V Coil for 4 way valve Cord heater assembly ND model only Heater fuse assembly ND model only Model nam...

Page 23: ... TCJ Indoor heat exchanger Cross flow fan 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 motor valve at liquid side CAM B22YGTF 3 Ø1 2 x 80 Ø1 2 x 80 TD 4 way valve STF 0108Z Compressor DA111A1F 24F TS Outdoor heat e...

Page 24: ...to 1 1 0 8 to 1 0 Heat exchanger pipe temp T1 C T2 C 13 to 15 36 to 39 10 to 13 37 to 39 8 to 11 37 to 40 Indoor fan mode High High High Outdoor fan mode High High High Compressor revolution rps 35 56 82 Temperature condition C Indoor Outdoor 20 7 6 Model name RAS B10SKVP E 10SKVP ND B13SKVP E 13SKVP ND B16SKVP E 16SKVP ND Standard pressure P MPa 2 1 to 2 3 2 4 to 2 6 2 8 to 3 0 Heat exchanger pip...

Page 25: ... Clock Frequency Oscillator Circuit Power Supply Circuit Infrared Rays 36 7kHz Remote Controller 8 C ND model only Operation Mode Selection AUTO COOL DRY HEAT REMOTE CONTROLLER OFF 1 3 5 9H OFF timer Air Purifier Hi POWER SLEEP MODE Louver Direction Setting Louver AUTO Swing OFF TIMER Setting ON TIMER Setting Fan Speed Selection Thermo Setting Operation START STOP Heat Exchanger Sensor Tc Heat Exc...

Page 26: ... current sensor PWM 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 In...

Page 27: ...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 P M V control 4 way valve control Detection of inverter input current and current release op...

Page 28: ...on of abnormality 39 13 Discharge temperature control 40 14 Pulse motor valve P M V control 41 15 Clean operation 42 16 Clean operation release 43 17 Select switch on remote controller 44 18 Set temp correction 45 19 Outdoor Quiet control 46 20 8 C HEAT operation ND model only 47 21 Cord heater control ND model only 49 9 3 Auto Restart Function 50 9 3 1 How to Set the Auto Restart Function 50 9 3 ...

Page 29: ...unction Compressor Outdoor fan motor 4 way valve Pulse motor valve P M V Freeze prevention heater ND model only Signal receiving Indoor unit control Operation command Serial signal send receive Selection of operation conditions ON OFF Serial signal send receive Outdoor unit control Inverter Item 1 Basic operation Operation flow and applicable data etc 1 Operation control Receiving the user s opera...

Page 30: ... 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 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 r...

Page 31: ...wing 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 tempera ture room temperature and heat exchanger temperature Fig 1 Fan speed level...

Page 32: ... etc In heating operation Fig 3 Fig 4 Fig 5 Cold draft preventive control Fig 6 Description 1 When setting the fan speed to L L M M or H on the remote controller the operation is per formed with the constant speed shown in Fig 3 and Table 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 5 according to the ...

Page 33: ...stops and an alarm is displayed if the fan is locked 4 According to each operation mode by the conditions of outdoor temperature To and compressor revolution the speed of the outdoor fan shown in the table is selected Outdoor fan speed rpm T ap f 1 f 2 f 3 f 4 f 5 f 6 f 7 f 8 10SAVP E 13SAVP E 16SAVP E 10SAVP ND 13SAVP ND 16SAVP ND 200 200 200 300 300 300 390 390 390 450 450 450 500 500 500 500 50...

Page 34: ...s and room temperature Ta is calculated 2 According to the temperature difference the correction value of Hz signal which determines the compressor speed is set up 3 The rotating position and speed of the motor are detected by the electromotive force occurred on the motor winding with operation of the compressor 4 According to the difference resulted from comparison of the correction value of Hz s...

Page 35: ...condensation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value Description 1 When temperature of the indoor heat exchanger drops below 5 C the compressor speed is re duced P zone 2 When temperature of the indoor heat exchanger rises in the range from 6 C to under 7 C the compressor speed is kept Q zone 3 When temperature of ...

Page 36: ...he room temperature is 20 C or lower The indoor temperature sensor detects the room temperature If the detected room temperature is 20 C or lower the outdoor heat exchanger temperature sensor detects the outdoor heat exchanger temperature As shown in the left figure winding of the compressor is heated for each division of the tempera ture for each outdoor temperature and the heat is stored The nec...

Page 37: ...3 Louver Directs downward 8 Louver angle Horizontal 0 Horizontal blowing Inclined blowing Blowing downward Air direction Inclined blowing Horizontal blowing Item 9 Louver control 1 Louver position 2 Air direction adjustment 3 Swing Operation flow and applicable data etc This function controls the air direction of the indoor unit The position is automatically controlled according to the operation m...

Page 38: ...itioner with the difference between the set and the room temperature as shown in the following figure The time correction is performed for 8 minutes each Heating operation Description Heating operation 1 The indoor fan speed is con trolled within W7 as maximum value 2 Setting the compressor speed to Max 52 rps the temperature zone in which the operation can be performed with Max 16 rps is graduall...

Page 39: ... while the air conditioner operates the air conditioner and the air purifier start operation The air ion generator operates linked with the air purifying operation Description 1 When pushing RESET button the temporary AUTO operation starts 2 When keeping RESET button pushed for 3 seconds or more Pi Pi Pi sound is heard and AUTO RESTART control is changed 3 When keeping RESET button pushed for 10 s...

Page 40: ...nction is to alert the user to trouble in the ionizing or air purifying operation 2 Description Trouble is determined to have occurred indicated by the FILTER indicator in the following four cases 1 When a count of 1000H has been reached on the timer 2 When the panel switch has been set to OFF by the opening of the air inlet grile etc 3 When an abnormal discharge caused by a symptom such as the bu...

Page 41: ... the compressor Tc or Te Heat exchanger temperature at evaporation side PMV Pulse Motor Valve Description 1 When starting the operation move the valve until it fits to the stopper Initialize In this time Click sound may be heard 2 Adjust the open degree of valve by super heat amount SH control 3 If the discharge temperature was exces sively up adjust the open degree of valve so that it is in the r...

Page 42: ...ling or dry operation shuts down the unit automatically starts the clean operation which is then performed for the specified period based on duration of the operation which was performed prior to the shutdown after which the clean operation stops The clean operation is not performed after a heating operation 2 Operation 1 When the stop signal from the remote controller is received the S CLEAN indi...

Page 43: ...RATION indicator flashes at 5 Hz intervals This completes the clean operation setting J201 C24 Item 16 Clean operation cancel Operation flow and applicable data etc Setting the clean operation cancel Setting the clean operation Indoor P C board Description NOTE Once J201 is added the RESET button on the unit is designated for CLEAN OPERATION Set Cancel therefore the RESET button can not be used fo...

Page 44: ... controller selection has been set to B receives the signal of the remote control ler also set to B At the factory the remote controller selection is set to A on all the indoor units There is no A setting display 1 Setting the remote controller Q Slide and open the remote controller cover and remove the batteries R Cut the jumper wire inside the battery compartment using nippers The jumper wire sh...

Page 45: ... Description 1 Purpose When the difference between the set temp of the remote controller and the room temp is wide due to the installation condition etc the set temp is corrected HEAT operation only 2 Description The set temp received from the remote controller is corrected The correct value from 2 C to 4 C is changed by the jumper wire on P C board of the indoor microcomputer Jumper wire setup J8...

Page 46: ...r the indoor fan motor and the setup temp value are kept as they are 3 Operation As shown in the table the maximum revolution number of indoor unit compressor can be reduced As the maximum number of revolution of the compressor is restricted the rise up performance at the start time is weakened Maximum number of revolution of compressor at normal time and Quiet control time Outside temp TO COOL 5 ...

Page 47: ...sition S FAN fan speed T PURE pure operation Description Start During stop of air conditioner Pushing 8 C button turns on the Operation lamp Green of the main unit is turned on and the HEAT operation of set temp 8 C starts During operation of air conditioner Pushing 8 C button shifts the operation to HEAT operation with set temp 8 C In case of COOL including automatic cooling or DRY operation 8 C ...

Page 48: ... speed AUTO L W8 b c d e f g M WD H WE 1 2 3 5 5 5 0 2 5 2 0 1 5 1 0 0 5 TA C TSC TC 52 51 42 41 YES NO Item 20 8 C HEAT operation ND model only Operation flow and applicable data etc Indoor fan control Compressor speed control Refer to 4 Capacity control Description Indoor fan control When 8 C HEAT operation the indoor fan control rises up automati cally When the indoor fan is operated manually i...

Page 49: ...plate cord heater control When TO sensor is defective turn off normal heater output When COOL thermostat is ON turn off the heater output Description 1 Purpose Base plate freeze prevention of the outdoor unit 2 Operation As shown in the left figure the base plate freeze preventive heater is controlled by temperature of the outside temp sensor TO ...

Page 50: ...ntally shut down When the unit is standby Not operating Operation Push RESET button for more than three seconds Less than 10 seconds Motions The unit is on standby The unit starts to operate The green indicator is on After approx three seconds The unit beeps three times The green indicator flashes and continues to operate for 5 seconds If the unit is not required to operate at this time push RESET...

Page 51: ...is in operation The green indicator is on The unit stops operating The green indicator is turned off After approx three seconds The unit beeps three times If the unit is required to operate at this time push RESET button once more or use the remote controller to turn it on 9 3 3 Power Failure During Timer Operation When the unit is turned off because of power failure during timer operation the tim...

Page 52: ...rd 8 ON timer button ON Use this button to change the clock and ON timer times To move up the time push of the ON ON button To move down the time push of the ON ON button 9 OFF timer button OFF Use this button to change the OFF timer times To move up the time push of the OFF OFF button To move down the time push of the OFF OFF button 10 Reserve button SET Push this button to store the time setting...

Page 53: ...ing for timer operation or the clock time is indicated The current time is always indicated except during TIMER operation 7 Hi POWER indicator Indicates when the Hi POWER operation starts Push the Hi POWER button to start and push it again to stop the operation 8 MEMORY indicator Flashes for 3 seconds when the MEMO button is pushed during operation The mark is shown when holding down the button fo...

Page 54: ...on mode selected In the Cooling operation the preset temperature drops 1 C In the Heating operation the preset temperature increases 2 C 2 Cooling operation Manual The preset temperature drops 1 C The value of the preset temperature on the remote controller does not change 3 Heating operation Manual The preset temperature increases 2 C The value of the preset temperature on the remote controller d...

Page 55: ...stalling the outdoor unit leave open in at least two of directions A B C and D shown in the figure below Ensure sufficient space to allow drainage A B C D Power cord Y Wall Bottom right Rear right Right Left Bottom left Rear left As shown in the figure position power cord and connecting cable downward and lead out along piping connection port Before installing the wireless remote controller With t...

Page 56: ...nits are unavailable RAS B10SKVP E RAS B13SKVP E RAS B16SKVP E When using a multi system outdoor unit refer to the installation manual provided with the model concerned Part Code Y Z Parts name Refrigerant piping Indoor unit name Liquid side Outer diameter Gas side Outer diameter RAS B10SKVP E B13SKVP E 6 35 mm 9 52 mm RAS 10SKVP ND 13SKVP ND RAS B16SKVP E 16SKVP ND 6 35 mm 12 7 mm Shield pipe for...

Page 57: ... pump adapter Gas leakage detector Applicable to R22 model Changes As pressure is high it is impossible to measure by means of conventional gauge In order to prevent any other refrigerant from being charged each port diameter has been changed In order to increase pressure resisting strength hose materials and port size have been changed to 1 2 UNF 20 threads per inch When purchasing a charge hose ...

Page 58: ...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 and Mounting Installation Plate Drilling When install the refrigerant pipes from the rear Fig 10 3 2 1 Decide the ins...

Page 59: ... a power source for the exclusive use of the air conditioner NOTE Wire type More than H07RN F or 60245IEC66 1 0mm CAUTION A switch or circuit breaker that can disconnect all poles must be included in the fixed wiring Be sure to use an approved circuit breaker or switch NOTE Make sure the wire length is sufficient before performing wiring work 10 3 4 Wiring Connection How to connect the connecting ...

Page 60: ...el slit Cut out the slit on the left or right side of the front panel for the left or right connection and the slit on the bottom left or right side of the front panel for the bottom left or right connection with a pair of nippers 2 Changing drain hose For left connection left bottom connection and rear left connection s piping it is necessary to relocate the drain hose and drain cap How to remove...

Page 61: ...hey are posi tioned within 43 mm above the wall surface If the connecting pipes are positioned more than 43 mm above the wall surface the indoor unit may be unstable When bending the connecting pipe make sure to use a spring bender to avoid crushing the pipe Refer to the table below for the bending radius of each connection pipe Fig 10 3 17 NOTE If the pipe is incorrectly bent the indoor unit may ...

Page 62: ...firmly 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 pa...

Page 63: ...ater does not cause any problems Precautions for adding refrigerant Use a scale having at least 10 g per index line precision 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 refrigerant gradu...

Page 64: ...nside diam eter and 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 with very little slack to the hose Do not use ordinary garden hose which can flatten and prevent drainage Fig 10 4 3 Commercially available drain h...

Page 65: ...heck for gas leaks at all connections Use a vacuum pump Be sure to use a vacuum pump with counter flow prevention function so that oil inside 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 manifol...

Page 66: ...2 3 L N Terminal block Connecting cable Power cord 30 30 10 L N 10 1 2 3 10 10 40 40 Earth line Earth line Connecting cable Power cord CAUTION Incorrect wiring connection may cause electrical 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...

Page 67: ...ting B The default setting for both units is A If the indoor unit and remote controller settings are different the remote controller signal is not accepted 1 Setting the remote controller 1 Slide open the remote controller cover and remove the batteries 2 Cut the jumper wire inside the battery compartment using nippers The jumper wire should not remain in contact after being cut Also be careful no...

Page 68: ... unit 3DV 3 shunt Discrete Vector control u The control circuitry has an uninsulated construction Fig 11 1 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 70 71 71 72 75 No 6 7 8 9 10 Troubleshooting Procedure How to Check Simply the Main Parts Troublesho...

Page 69: ... in damage to the components Sensor leads Do NOT lay the circuit board assembly flat u 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 powe...

Page 70: ...rated Increasing 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...

Page 71: ...hen air conditioner 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 F...

Page 72: ...ntroller Push ON or OFF button If there is no fault with a code the indoor unit will beep once Beep 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 Push ON or OFF button to change the check code backward If there is a fault the indoor unit...

Page 73: ...ion started 1 Defective wiring of connecting cable 2 Operation of compres sor thermo Gas shortage Gas leak Air conditioner status Operation continues Operation continues Operation continues All off Operation continues Operation continues Remarks Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error i...

Page 74: ... when error is detected Displayed when error is detected Flashes when trouble is detected on return serial signal and normal status when signal is reset Displayed when error is detected Displayed when error is detected Displayed when error is detected Judgment and action Even if trying operation again all operations stop immediately Replace P C board 1 Even if connecting lead wire of compressor is...

Page 75: ...ontroller 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 Is DC310 340V supplied between CN31 1 3 Does fan motor connector between CN31 1 3 short circuit Item by symptoms Operation Check Item Considerable principle cause Measures Parts R01 R02 DB01 C01 C03 IC11 and T101 are def...

Page 76: ... detect DC 1V or more between 5 and 3 of motor connector CN31 Is it possible to detect DC 1V or more between 5 and 3 of motor connector CN31 Is it possible to detect DC 310 340V between 1 and 3 of motor connector CN31 Motor connection condition Is it possible to detect DC 15V between 4 and 3 of motor connector CN31 Is it possible to detect DC 15V between 4 and 3 of motor connector CN31 Is it possi...

Page 77: ...ace motor 4 Indoor fan motor automatically starts to rotate by turning on power supply Cause The IC is built in the indoor fan motor Therefore the P C board is also mounted to inside of the motor If the P C board is soldered imperfectly or the IC is defective the fan motor may automatically rotate by turning on power supply Inspection procedure 1 Remove the front panel Remove 2 screws 2 Remove the...

Page 78: ... Batteries 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 resta...

Page 79: ...rm that transmission from indoor unit to outdoor unit is correctly performed based upon the following 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 af...

Page 80: ... gas if pressure 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 i...

Page 81: ...board MCC5045 Micro switch is stuck Micro switch malfunction To item Power supply is not turned on Replace the main P C board MCC5045 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 b...

Page 82: ... which connects inverter and compressor Check whether 25A fuse on the control board assembly is blown or not F01 Turn on the power breaker and operate the air condi tioner in COOL mode by time shortening Measure terminal voltage of the electrolytic capacity 500µF 400WV 3 After operation turn off the power breaker after 2 minutes 20 seconds passed and discharge the electrolytic capacitor by solderi...

Page 83: ... Indoor fan motor control circuit CPU and peripheral circuits buzzer and Driving circuit of louver b Indication unit of infrared ray receiving infrared ray receiving circuit LED To check defect of the P C board follow the procedure described below NG OK B A Replace control board assembly Replace control board Replace compressor Check compressor winding resistance Diagnosis Process flowchart Item C...

Page 84: ...0V Check whether or 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 DC 15V between...

Page 85: ...0 0 0 10 20 30 40 50 Resistance value k 9 Temperature C TD Discharge temp sensor TA Room temp sensor TC TCJ Heat exchanger temp sensor TO Outdoor temp sensor TE Outdoor heat exchanger temp sensor TS Suction temp sensor TA TC TCJ TO TE TS TD 1 Sensor characteristic table ...

Page 86: ... Model STF 01AJ502E1 Pulse motor valve coil Model CAM MD12TF 10 Outdoor temperature sensor TO discharge temperature sensor TD suction temperature sensor TS outdoor heat exchanger temperature sensor TE Checking procedure Measure the resistance value of each winding by using the tester Position Red White White Black Black Red Resistance value 1 02 to 1 12Ω Under 20 C Measure the resistance value of ...

Page 87: ...loded 5 Check that electrolytic liquid does not blow off 6 Check that the normal charging characteristics are shown in continuity test by the tester 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 1 Turn OFF the power supply breaker 2 Completely discharge the four electrolytic c...

Page 88: ...e inside 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...

Page 89: ...may ignite 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 circ...

Page 90: ...ric parts box with the right thumb while pulling the both sides of the front panel toward you How to assemble the front panel 1 Push three center positions and two lower center positions of the air outlet and then hang the hanging hooks 4 pcs at the top side of the front panel to the rear plate 2 Insert the electric dust collector and left and right air filters Push in the electric dust collector ...

Page 91: ...tor and disconnect the four leads from where they are fitted into the other components 3 Remove the fixing screw which secures the high voltage generator and remove the high voltage generator from the evaporator How to assemble the high voltage generator 1 Put the high voltage generator on the evaporator and then fix it with two screws 2 Pass the leads of the high voltage generator through the are...

Page 92: ... 5P for the louver motor from the electric parts box assembly 4 Pull out TC and TCJ sensors from sensor holder of the evaporator 5 Disengage the two claws at the top of the display unit They can be easily disengaged by pushing the drain pan above the claws and at the same time pulling the display unit toward you 6 Remove the fixing screw that secures the electric parts box assembly and remove the ...

Page 93: ...emove other shafts while sliding the horizontal louver leftward 1 Follow to the procedure in the item 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 4 Remove the heat exchanger fixing holder by removing the two fixing screws used to secure it 5 Remove right side of the end plate from two fixing ribs wh...

Page 94: ...d to secure the left edge panel of the heat exchanger and remove the two screws used to secure the bearing base 3 Raise the left side of the heat exchanger slightly and 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 After assembling the bearing base check that it is fitted into the st...

Page 95: ... work install 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 hooking claws of the motor band right into the main body position the fan motor insert it and then secure the motor band right using the two fixing screws 1 Follow to the procedure in...

Page 96: ...o that the right end of the 1st joint from the right of the cross flow fan is set keeping 70 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 f...

Page 97: ...81 J201 T101 C03 DB01 No Part name Common procedure Procedure 1 Turn the power supply 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 ...

Page 98: ...Attachment 1 Attach the water proof cover NOTE The water proof cover must be attached without fail in order to prevent rain water etc from entering inside the indoor unit 2 Attach the upper cabinet ST1TØ4 8L 5 pcs 3 Perform cabling of connecting cable and attach the wiring cover Place the wiring cover over the opening used to work on the con necting wires of the side cabinet and secure it using th...

Page 99: ...e the motor base The front cabinet 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 cab...

Page 100: ...Be careful to discharge the capacitor because the electrolytic capacitor cannot naturally discharge and voltage remains according to trouble type in some cases NOTE This capacitor is one with mass capacity Therefore it is dangerous that a large spark generates if short circuiting between polarity with screwdriver etc for discharging 4 Remove screw ST1TØ4 8L 2 pcs fixing the main body and the inver...

Page 101: ... heater 2P red NOTE These connectors have a disconnect prevention mechanism as such the lock on 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 Remov...

Page 102: ...rew ST1TØ4 8L 1 pcs used to secure the side cabinet left onto the heat exchanger 3 Remove the fixing screw ST1TØ4 8L 2 pc used for securing the side cabinet to the bottom plate and heat exchanger 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 pro...

Page 103: ... compressor with a burner Take care to keep the 4 way valve away from naked flames Otherwise it may malfunction 7 Remove the fixing screw of the bottom plate and heat exchanger ST1TØ4 8L 1 pc 8 Remove the fixing screw of the bottom plate and valve fixing plate ST1TØ4 8L 1 pc 9 Pull upward the refrigeration cycle 10 Remove BOLT 3 pcs fixing the compressor to the bottom plate Precautions when assemb...

Page 104: ...ing the coil from the valve body use your hand to secure the body in order to prevent the pipe from being bent out of shape 1 Detachment 1 Perform work of item 1 of 2 Remove the front cabinet and put it down so that fan guard side directs downward Perform work on a corrugated cardboard cloth etc to prevent flaw to the product 3 Remove the hooking claws by pushing minus screwdriver according to the...

Page 105: ...ment With its leads pointed downward install the sensor onto the vertical straight pipe part of the discharge pipe TO sensor Outside air temperature sensor Attachment Insert the outdoor air temperature sensor into the holder and install the holder onto the heat exchanger Procedure Remarks CAUTION During the installation work and on its completion take care not to damage the coverings of the sensor...

Page 106: ... and sensor sides and solder them 8 Move the thermal constringent tubes toward the soldered parts and heat them with the dryer and constring 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 NOTE 1 Store the joint part of the sensor and the connector in the electric parts box 2 Never joint them near the ...

Page 107: ... 107 MCC 5009 MCC 5009 04 F01 T25A 250V ...

Page 108: ...14 43020346 Fan Cross Flow 215 43039314 Band Motor 216 43020253 Bearing 217 4301V028 Holder Pipe 218 43049701 Pipe Shield B16SKVP E 219 43049698 Pipe Shield B10SKVP E B13SKVP E 221 43047671 Pipe Ass y Connecting Gas B10SKVP E B13SKVP E 222 43047672 Pipe Ass y Connecting Gas B16SKVP E Location Part Description No No 223 43049674 Spring B16SKVP E 224 43047673 Pipe Ass y Connecting Liquid 225 4304482...

Page 109: ...tion Part Description No No 401 4306A132 Terminal Block 3P 402 43062263 Cover E Parts 403 43050425 Sensor TC Ø6 TCJ Ø6 404 43050426 Sensor TA 405 4306S936 P C Board Ass y WRS LED 406 43051350 Switch Ass y Micro Location Part Description No No 407 4306S937 P C Board Ass y B10SKVP E 408 4306S938 P C Board Ass y B13SKVP E 409 4306S939 P C Board Ass y B16SKVP E 410 43067115 Clamp Cord ...

Page 110: ...w 215 43039314 Band Motor 216 43020253 Bearing 217 4301V028 Holder Pipe 218 43049701 Pipe Shield 16SKVP ND 219 43049698 Pipe Shield 10SKVP ND 13SKVP ND 221 43047671 Pipe Ass y Connecting Gas 10SKVP ND 13SKVP ND 222 43047672 Pipe Ass y Connecting Gas 16SKVP ND Location Part Description No No 223 43049674 Spring 16SKVP ND 224 43047673 Pipe Ass y Connecting Liquid 225 43044821 Evaporator Ass y 10SKVP...

Page 111: ...tion Part Description No No 401 4306A132 Terminal Block 3P 402 43062263 Cover E Parts 403 43050425 Sensor TC Ø6 TCJ Ø6 404 43050426 Sensor TA 405 4306S936 P C Board Ass y WRS LED 406 43051350 Switch Ass y Micro Location Part Description No No 410 43067115 Clamp Cord 411 4306S949 P C Board Ass y 10SKVP ND 412 4306S950 P C Board Ass y 13SKVP ND 413 4306S951 P C Board Ass y 16SKVP ND ...

Page 112: ... 112 13 2 Outdoor Unit RAS 10SAVP E RAS 13SAVP E RAS 16SAVP E 4 28 29 30 31 8 9 3 13 16 19 22 14 15 17 18 20 21 23 24 25 27 47 45 46 10 43 38 11 48 6 37 36 41 39 32 7 40 42 33 34 35 1 5 2 44 ...

Page 113: ...43047677 Nut Flare 9 52 10SAVP E 13SAVP E 21 43047655 Nut Flare 12 7 16SAVP E 22 43047679 Cap Valve Packed 6 35 23 43047680 Cap Valve Packed 9 52 10SAVP E 13SAVP E Location Part Description No No 24 43047659 Cap Valve Packed 12 7 16SAVP E 25 43047674 Cap Charge Port 27 44246239 Tube Capillary I D 1 2 28 43046444 Valve 4 Way STF 0108Z 29 43046443 Coil Solenoid VHV 01AJ503C1 30 37546848 Valve Pulse ...

Page 114: ... 114 RAS 10SAVP ND RAS 13SAVP ND RAS 16SAVP ND 4 28 29 30 31 8 9 3 13 16 19 22 14 15 17 18 20 21 23 24 25 27 47 11 48 6 37 36 41 39 32 7 40 42 49 CORD HEATER Ass y 33 34 35 1 5 2 45 46 10 43 38 44 ...

Page 115: ...VP ND 13SAVP ND 21 43047655 Nut Flare 12 7 16SAVP ND 22 43047679 Cap Valve Packed 6 35 23 43047680 Cap Valve Packed 9 52 10SAVP ND 13SAVP ND Location Part Description No No 24 43047659 Cap Valve Packed 12 7 16SAVP ND 25 43047674 Cap Charge Port 10SAVP ND 13SAVP ND 27 44246239 Tube Capillary I D 1 2 28 43046444 Valve 4 Way STF 0108Z 29 43046443 Coil Solenoid VHV 01AJ503C1 30 37546848 Valve Pulse Mo...

Page 116: ...ollowing parts for repairing and replacing 707 705 701 Sensor TE 702 Sensor TS 703 Sensor TO 704 Sensor TD Ø4 706 Location Part Description No No 701 43050422 Sensor TE 702 43050423 Sensor TS 703 43050427 Sensor TO 704 43050430 Sensor TD Location Part Description No No 705 43062228 Base P C board 706 43160566 Terminal Block 6P 20A 707 4306S914 P C board Ass y MCC5009 ...

Page 117: ...7 709 708 705 701 Sensor TE 702 Sensor TS 703 Sensor TO 704 Sensor TD Ø4 706 Location Part Description No No 701 43050422 Sensor TE 702 43050423 Sensor TS 703 43050427 Sensor TO 704 43050430 Sensor TD 705 43062228 Base P C board Location Part Description No No 706 43160566 Terminal Block 6P 707 4306S914 P C board Ass y MCC5009 708 43160571 Fuse Holder 15A 250V 709 4306A156 Fuse ET 3 15A AC250V ...

Page 118: ... J802 J806 according to each model LOCATION OF JUMPER LEAD WIRE Corresponding model Jumper lead wire J800 Jumper lead wire J801 Jumper lead wire J802 Jumper lead wire J806 ORIGINAL RAS RAS RAS RAS RAS RAS 10SAVP E 13SAVP E 16SAVP E 10SAVP ND 13SAVP ND 16SAVP ND Close Close Close Open Open Close Close Original Original Original Cut Cut Original Original Close Close Open Close Open Close Open Origin...

Page 119: ...TOSHIBA CARRIER CORPORATION 2 CHOME 12 32 KONAN MINATOKU TOKYO 108 0075 JAPAN Copyright 1999 to 2007 TOSHIBA CARRIER CORPORATION ALL Rights Reserved ...