Toshiba RAS-18BAVG-E, Service Manual

Page 1: ...SERVICE MANUAL SPLIT TYPE Revised on April 2016 Indoor Unit RAS 07BKV E RAS 10BKV E RAS 13BKV E Outdoor Unit RAS 07BAV E RAS 10BAV E RAS 13BAV E FILE NO SVM 16003 2 ...

Page 2: ... WIRING DIAGRAM 18 6 SPECIFICATIONS OF ELECTRICAL PARTS 19 7 REFRIGERANT CYCLE DIAGRAM 20 8 CONTROL BLOCK DIAGRAM 23 9 OPERATION DESCRIPTION 25 10 INSTALLATION PROCEDURE 47 11 HOW TO DIAGNOSE THE TROUBLE 62 12 HOW TO REPLACE THE MAIN PARTS 88 13 EXPLODED VIEWS AND PARTS LIST 101 FILE NO SVM 16003 2 ...

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 fitti...

Page 4: ... 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 g...

Page 5: ...t W 20 20 Air flow rate Cooling Heating m3 min 8 7 8 9 9 0 9 2 Outdoor unit Unit model RAS 07BAV E RAS 10BAV E Dimension Height mm 530 530 Width mm 660 660 Depth mm 240 240 Net weight kg 21 21 Compressor Motor output W 630 750 Type Model NX66F0F 20D Fan motor output W 43 Air flow rate Cooling Heating m3 min 29 30 31 31 Piping Type Flare connection connection Indoor unit Liquid side mm 6 35 6 35 Ga...

Page 6: ...ing m3 min 10 0 10 3 Outdoor unit Unit model RAS 13BAV E Dimension Height mm 530 Width mm 660 Depth mm 240 Net weight kg 22 Compressor Motor output W 750 Type Model NX89F0F 20D Fan motor output W 43 Air flow rate Cooling Heating m3 min 33 33 Piping Type Flare connection 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 15...

Page 7: ...door DB 7oC WB 6oC Indoor Air Flow High Pipe Length 5m Voltage 220V RAS 07BAV E RAS 10BAV E RAS 07BAV E RAS 10BAV E RAS 13BAV E RAS 13BAV E FILE NO SVM 16003 7 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 Cooling Capacity Ratio Outside Temperature oC Capacity ratio 100 as below 07k 2 0 kW 10k 2 5 kW 13k 3 1 kW Conditions Indoor DB 27oC WB 19oC Outdoor DB 35oC ...

Page 8: ... 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 larg...

Page 9: ... 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 w...

Page 10: ... 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 to 0...

Page 11: ...que 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 manufactur...

Page 12: ... 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 Whet...

Page 13: ...e 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 the fo...

Page 14: ...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 strength do not use it for re...

Page 15: ...ux 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 pipe i...

Page 16: ...ation plate hanger 131 131 140 131 120 24 Installation plate hanger Drain hose 0 4m Installation plate hanger Connecting pipe 0 35m Flare 9 52mm Connecting pipe 0 40m Flare 6 35mm 510 40 298 94 94 135 170 170 135 40 144 144 170 170 192 192 Installation plate outline Center line Hanger Hanger Hanger Outline of indoor unit 65 65 64 5 73 5 110 58 17 5 Wireless remote controller 25 Remote controller h...

Page 17: ...4 2 Outdoor Unit C L C L 280 400 FILE NO SVM 16003 17 ...

Page 18: ...5 WIRING DIAGRAM FILE NO SVM 16003 18 ...

Page 19: ... 20D 3 Phases 6 Poles 630W RAS 10BAV E RAS 13BAV E 2 Fan Motor WDF 340 A43 1 DC 140 340V 43W 3 Pulse Modulating Valve PMV coil PQ M10012 000313 DC 12V 4 4 Way Valve coil DXQ 939 AC 220 240V 5 Suction temp sensor TS sensor Inverter attached 6 Discharge temp sensor TD sensor Inverter attached 7 Outside air temp sensor TO sensor Inverter attached 8 Heat Exchanger temp sensor TE sensor Inverter attach...

Page 20: ...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 Pulse Modulating valve at liquid side TD 4 way valve Compressor NX66F0F 20D TS T2 Outdoor heat exchanger Temp measurement Propeller fan Refrigerant amount 0 48kg OUTDOOR UNIT Muffler Muffler Min 2m Chargeles...

Page 21: ... heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attaching port Vacuum pump connecting port Pulse Modulating valve at liquid side TD 4 way valve Compressor NX89F0F 20D TS T2 Outdoor heat exchanger Temp measurement Propeller fan 13k Refrigerant amount 0 58kg OUTDOOR UNIT Muffler Muffler TE TC TA Min 2m Chargeless 15m TO Strainer RAS 10BKV E RAS 10BA...

Page 22: ...E 0 9 to 1 1 12 to 13 47 to 48 High High 60 10BKV E 0 8 to 1 0 11 to 12 52 to 53 High High 60 13BKV E 0 7 to 0 9 11 to 12 49 to 50 High High 84 condition C Tempeature Heat exchanger pipe temp Model name Standard Indoor Outdoor Compressor RAS pressure fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 7 6 2 3 to 2 4 35 to 36 0 to 1 High High 69 2 5 to 2 7 42 to 43 0 to 1 High High 6...

Page 23: ...l Processing Temperature Processing Timer LED brightness dim Serial Signal Communication Functions M C U Indoor Unit Control Panel Power Supply Remote Control Heat Exchanger Sensor Temperature Sensor Infrared Rays Signal Receiver Infrared Rays Initiallizing Circuit Clock Frequency Oscillator Circuit Louver Motor 36 7KHz Power Supply Circuit Noise Filter Indoor Fan Motor Timer Display Operation Dis...

Page 24: ...nt Detector PWM synthesis function Input current release control IPM 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 Inverte...

Page 25: ...to indoor unit controller The following signals are sent from the outdoor unit controller The current operation mode The current compressor revolution Outdoor temperature Existence of protective circuit operation For transferring of these signals the indoor unit controller monitors the contents of signals and judges existence of trouble occurrence Contents of judgment are described below Whether d...

Page 26: ... 2 Air direction adjustment 35 3 Swing 35 9 ECO operation 36 10 Temporary operation 37 11 12 Discharge temperature control 37 13 Pulse Modulating valve P M V control 38 Self Cleaning function 39 14 Remote A or B selection 40 9 3 Auto Restart Function 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 9 4 Remo...

Page 27: ...te controller ON OFF Air conditioner Air purifier Operation select COOL HEAT AUTO DRY Temperature setup Air direction Swing Air volume select AUTO LOW LOW MED MED HIGH ECO 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 preve...

Page 28: ...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 when t...

Page 29: ...n speed M L x 1 4 L Linear approximation from M and L RAS 07BKV E RAS 10BKV E Cooling Heating Cooling Heating Fan speed Air flow rate rpm m 3 hr Fan speed Air flow rate rpm m 3 hr Fan speed Air flow rate rpm m 3 hr Fan speed Air flow rate rpm m 3 hr WF UH 1080 540 1080 540 1110 580 1110 580 WE UH H 1080 540 1080 540 1110 580 1110 580 WD H M UH 1050 520 1030 510 1080 530 1060 525 WC M H 1000 490 94...

Page 30: ...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 WB 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 Limited to Min WD tap Fan speed TC W8 W8 No limit FAN AUTO FAN Manual In starting Until 12 minutes passed after operat...

Page 31: ... is selected 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 Compressor speed rps To 38 C To 28 C To To 15 C To 5 5 C To 0 ...

Page 32: ...at 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 Capacity control continues Detection of electromotive force of compressor motor winding Detection of motor speed and rotor position Inverter output change Commutation timing change Change of c...

Page 33: ...ssor speed is kept Q zone When temperature of the indoor heat exchanger drops in the range from 48 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 52 C or when it drops below to 48 C the capacity control operation return...

Page 34: ... 2 TE 25 C SH SH0 2 More than 90 minutes accumulated heating operation time condition TE 2 C Table 1 In normal To In abnormal To TE0 TE 2 C SH SH0 2 TE0 TE TO0 TO 2 C SH SH0 2 Returning from defrost operation 1 Stop operation of the compressor for approx 40 seconds 2 Invert ON 4 way valve approx 30 seconds after stop of the compressor 3 The outdoor fan starts rotating at the same time when the com...

Page 35: ...puter The angle of the louver is indicated as the louver closes fully is 0 1 Louver position in cooling operation mode COOL HEAT and the louver returns to the stored position when the next operation is performed Cooling Heating memory position The louver position can be arbitrarily set up by pressing FIX button Swing operation is perfor in range 35 with the Fixed position as the center If the swin...

Page 36: ... 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 change every speed 1 The control target tem...

Page 37: ... 3 seconds or more Did you press RESET button for 10 seconds or more Switch to AUTO RESTART control YES NO NO YES Temporary AUTO operation Temporary COOL Operation 11 Discharge temperature control 1 Purpose This function detects error on the refrigerating cycle or error on the com pressor and performs protective control 2 Operation Control of the compressor speed The speed control is performed as ...

Page 38: ... 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 th...

Page 39: ...eration 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 ind...

Page 40: ...ation prevents the remote controller signal from being received simultaneously by both units thus preventing both units from operating 3 Operation The indoor unit on which the remote 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 Setti...

Page 41: ... 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 increase 1 tap The preset temperature drops 1ºC The value of the preset temperature on the 3 Heating operation remote controller does not change The indoor unit s fan speed level increase 1 tap The preset temperature increases...

Page 42: ...s indoor unit is 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...

Page 43: ...te at this time press 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 st...

Page 44: ...rt or stop without using the remote control Operation mode is set on AUTOMATIC operation preset temperature is 25 C and fan operation is automatic speed 7 AUTO RESTART OPERATION To automatically restart the conditioner after the power failure Power of the unit must be on 1 Press and hold the RESET button on the indoor unit for 3 seconds to set the operation 3 beep sound and OPERATION lamp blink 5 ...

Page 45: ...HEATING FAN ONLY OPERATION To automatically select cooling or fan only operation 1 Press Select Cool Heat or Fan only 2 Press Set the desired temperature Cooling Heating Min 17 C Max 30 C Fan Only No temperature indication 3 Press Select AUTO LOW LOW MED MED or HIGH MODE MODE FAN 2 Press Set the desired temperature 3 DRY OPERATION COOLING ONLY For dehumidification a moderate cooling performance is...

Page 46: ...icator remote controller When the remote controller switching function is set B appears in the remote controller display When the remote controller setting is A there is no indication at this position Press swing button to start the swing operation and press it again to stop the swing operation 9 Swing 5 OFF TIMER indicator Indicates when the OFF timer is setting press the OFF timer button and sel...

Page 47: ...drain 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 Flat head wood screw Remote control holder Vinyl tape Apply after carrying out...

Page 48: ... 7 to the bottom plate of the outdoor unit before installing it 10 2 1 Optional installation parts 10 2 Installation Fixing bolt arrangement of outdoor unit Drain outlet Air inlet Air outlet 280 mm 500 mm 53 mm 97 mm Ø25 mm Part Code A B C Parts name Refrigerant piping Liquid side 6 35 mm Gas side 9 52 mm Pipe insulating material polyethylene foam 6 mm thick Putty PVC tapes Q ty One each 1 One eac...

Page 49: ...te control holder x 1 Part No 4 5 6 Part No 7 Others Name Owner s manual Installation manual Part name Q ty 10 2 2 Accessory and installation parts The part marked with asterisk is packaged with the outdoor unit Mounting screw 4 x 25 s x 6 Flat head wood screw 3 1 x 16 s x 2 Drain nipple x 1 FILE NO SVM 16003 49 ...

Page 50: ...ze 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 incr...

Page 51: ...hole and mounting installation Cutting a hole When installing the refrigerant pipes from the rear 1 After determining the pipe hole position on the mounting plate A drill the pipe hole 65 mm at a slight downward slant to the outdoor side NOTE When drilling a wall that contains a metal lath wire lath or metal plate be sure to use a pipe hole brim ring sold separately Mounting the installation plate...

Page 52: ...hose installation Piping and Drain Hose Forming Since dewing results in a machine trouble make sure to insulate both the connecting pipes Use polyethylene foam as insulating material Fig 10 3 6 Fig 10 3 7 How to remove the drain hose Fig 10 3 8 The drain hose can be removed by removing the screw securing the drain hose and then pulling out the drain hose When removing the drain hose be careful of ...

Page 53: ...s side Outward form of indoor unit R 30 mm Use polisin polyethylene core or the like for bending pipe Liquid side CAUTION Bind the auxiliary pipes two and connecting cable with facing tape tightly In case of leftward piping and rear leftward piping bind the auxiliary pipes two only with facing tape Carefully arrange pipes so that any pipe does not stick out of the rear plate of the indoor unit Car...

Page 54: ...TE Hole should be made at a slight downward slant on the outdoor side Fig 10 3 16 2 Put water in the drain pan and make sure that the water is drained out of doors 3 When connecting extension drain hose insulate the connecting part of extension drain hose with shield pipe Fig 10 3 17 CAUTION Arrange the drain pipe for proper drainage from the unit Improper drainage can result in dew dropping This ...

Page 55: ...o not use the supplied drain nipple for draining water Drain the water from all the drain holes directly hood and plate Do not use a double stacked design To protect the outdoor unit from snow accumulation install a holding frame and attach a snow protection Snow protection plate Snow protection hood At least 50 cm Snow accumulation line Holding frame Front Anchor bolts Install at least 50 cm abov...

Page 56: ...art evacuating Perform evacuating for about 15 minutes if the piping length is 20 meters 15 minutes for 20 meters assuming a pump capacity of 27 liters per minute Then confirm that the compound pressure gauge reading is 101 kPa 76 cmHg 5 Close the low pressure side valve handle of gauge manifold 6 Open fully the valve stem of the packed valves both side of Gas and Liquid 7 Remove the charging hose...

Page 57: ...ce Port Cap H17 H19 H22 H30 H14 H17 14 18 N m 1 4 to 1 8 kgf m 33 42 N m 3 3 to 4 2 kgf m 8 12 N m 0 8 to 1 2 kgf m 14 18 N m 1 4 to 1 8 kgf m A H Hexagon wrench is required Service Port Cap Valve Rod Cap CAUTION KEEP IMPORTANT 5 POINTS FOR PIPING WORK 1 Take away dust and moisture Inside of the connecting pipes 2 Tight connection between pipes and unit 3 Evacuate the air in the connecting pipes u...

Page 58: ...the pipe hole on the wall 4 Take out the connecting cable through the cable slot on the rear panel so that it protrudes about 20 cm from the front 5 Insert the connecting cable fully into the terminal block and secure it tightly with screws 6 Tightening torque 1 2 N m 0 12 kgf m 7 Secure the connecting cable with the cord clamp 8 Fix the terminal cover and air inlet grille on the indoor unit Cord ...

Page 59: ...ble Connecting cable Stripping length of the connecting cable 3 2 L Earth line 50 mm 10 mm 70 mm 10 mm Connecting cable Earth line Earth line Connecting cable Power cord Terminal block Power cord 1 The power supply must be same as the rated of air conditioner 2 Prepare the power source for exclusive use with air conditioner 3 Circuit breaker must be used for the power supply line of this air condi...

Page 60: ...Outdoor Terminal Block INDOOR UNIT OUTDOOR UNIT CHASSIS CHASSIS EARTH Power supply input at Outdoor unit Terminal Block Optional Indoor Terminal Block Power supply input Outdoor Terminal Block INDOOR UNIT OUTDOOR UNIT CHASSIS CHASSIS EARTH 10 5 3 Power supply input wiring diagram FILE NO SVM 16003 60 ...

Page 61: ... the display and 00 will disappear and the air conditioner will turn OFF The Remote Control B NOTE 1 Repeat above step to reset Remote Control to be A 2 Remote Control A has not A display 3 Default setting of Remote Control from factory is A 10 6 2 Remote Control A B Selection is memorized Picture Picture 1 2 10 6 3 Test operation To switch the TEST RUN COOL mode press RESET button for 10 sec The ...

Page 62: ...ce as the electric shock may be caused in case of touching parts on the P C board by hand The new inverter will be incorporated starting with this unit 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 No 6...

Page 63: ...lt in damage to the components 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...

Page 64: ...creasing 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 fl...

Page 65: ...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 Flashing display 1 Hz OPERATION TIMER Flashing display 5 Hz OPERATION Flashing display 5 Hz OPERATION TIMER White Flashing display 5 Hz OPERATION Flashing display 5 Hz Protective circuit operation for indoor P C board Protective circuit op...

Page 66: ... 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 Press TEMP or TEMP button to change the check code backward If there is a fault the indoor unit will beep for 10 s...

Page 67: ...oom Operation Flashes when 1 Check the sensor TA and connection board temperature sensor is continues error is detected 2 In case of the sensor and its short Circuit or disconnection connection is normal check the P C board TC sensor The heat Operation Flashes when 1 Check the sensor TC and connection exchanger temperature continues error is detected 2 In case of the sensor and its sensor of the i...

Page 68: ...or unit open 4 The outdoor unit abnormal stop at circuit of signal some time Signal circuit of indoor If the other check codes are found P C board or outdoor concurrently check them together P C board is failure Check protector hardware such in some period as Hi Pressure switch Thermal Relay etc Check refrigerant amount or any possibility case which may caused high temperature or high pressure Che...

Page 69: ...resistance of compressor winding If circuit is shortage replace the compressor Current detect circuit of All OFF Flashes after Even if trying to operate again all inverter P C board error error is detected operations stop replace inverter 4 times P C board TE sensor The heat All OFF Flashes after 1 Check sensors TE TS and connection exchanger temperature error is detected 2 In case of the sensors ...

Page 70: ...rror count comes 4 or 8 times record error to check code But after re starting operation if no error is detected and air conditioner can operate more than 6 minutes error count is cleared The others Return signal of the outdoor Indoor unit Flashes when 1 Check power supply Rate 10 including unit has been sent when operates error is detected 2 If the air conditioner repeat operates compressor opera...

Page 71: ...Flashes after 1 Check sensors TD exceeded 117o C error is detected 2 Check refrigerant amount 4 times 3 Check P M V by measure the resistance of the coil and confirm its operation sound of initial operation etc 4 Observe any possibility cause which may affect high temperature of compressor Compressor is high current All OFF Flashes after 1 Check installation conditions such as though operation Hz ...

Page 72: ... the indo unit by using diode Measure voltage at terminal block of the indoor unit between No 2 and No 3 or L2 and S If signal is varied 15 60V continuously replace inverter P C board If signal is not varied replace indoor P C board 4 Check and clean heat exchanger area Indoor and Outdoor unit Instantaneous power failure Some protector hardware of the outdoor unit open circuit of signal Signal cir...

Page 73: ...O YES NO NO YES YES Is it possible to turn on power supply by pressing button on remote control Does transmission mark on remote control flash normally and is its signal transmitted properly Remote control is defective Refer to 4 Remote Control Is fuse F01 of indoor control board blown Is voltage DC 12V or 5V indicated on rear of indoor control board normal Microcomputer is defective Replace main ...

Page 74: ...laced Confirmation procedure YES YES NO NO Turn on power supply Does operation lamp flash Is it wired as shown in Figure below Return the wiring of the power relay is returned to the normal procedure To the paragraph of No Power turns on FILE NO SVM 16003 74 ...

Page 75: ...e Change the setting of cooling to high fan Operation stops Shut off the power supply Motor control circuit failure IC03 Q39 and D01 or 12 V Switching power supply failure Does the cross flow fan rotate normally Is the rotation signal DC 5 V 0 V output between 2 gray lead wire and 3 brown lead wire of the motor connector CN11 when rotating the cross flow fan by hand in no operating status 1 pulse ...

Page 76: ...thin test rod of Judgment of Trouble by Every Symptom SJM 240 25 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 operate 1 3 5 1 2 3 2 1 3 2 1 3 2 1 3 2 1 3 CN10 CN11 P C board WHI BLK RED BRW GRY YEL Resistance value Position P C board Between 3 Black 1 Red Between 3 Black 5 White Between 1 Red 5 White 120 6 8 4 Ω 244...

Page 77: ... a transistor radio when transmitting within 5 cm distance from the radio P C board is failure Replace P C board Is operation possible when the transmitter is moved nearer to the infrared signal receiver of the air conditioner Battery life Replace the batteries Dose the transmission indicator light Is there any beep and operation Normal Remote control is failure Replace remote control Push the but...

Page 78: ...nsmission 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 7 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while after operat...

Page 79: ...s 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 indo...

Page 80: ...R 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 760µF of C07 with printed WARNING ELECTRIC SHOCK on P C board OK if 760µF DC290 to 400V Remove CN31 while pushing the part indicated by an by an arrow because CN31 is a connector with l...

Page 81: ... Main Parts 11 8 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 Inspec...

Page 82: ...ION TIMER are lit for 3 seconds and they return to normal 3 seconds later 1 Check whether or not the compressor operates 2 Check whether or not the OPERATION indicator flashes 1 Check whether or not the compressor operates 2 Check whether or not the OPERATION indicator flashes 1 Check it is impossible to detect the voltage AC120V or higher voltage between red and black 2 The motor does not operate...

Page 83: ...emperature C TA TC TO TS TE TD 1 Sensor characteristic table 11 8 2 P C Board Layout TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TS Suction temp sensor TE Outdoor heat exchanger temp sensor GND 12V 5V FILE NO SVM 16003 83 ...

Page 84: ...ack Measure the resistance value of each winding by using the tester Measure the resistance value of winding by using the tester Red White Black Measure the resistance value of winding by using the tester Resistance value 1450 150Ω Under 20 C Measure the resistance value of winding by using the tester COM COM 2 5 4 Y W GR BL 1 GR 6 O 3 Position Gray White Gray Orange Gray Yellow Gray Blue Resistan...

Page 85: ...ication characteristics are shown in continuity test by the tester 11 8 5 Checking Method for Each Part Case that product is good Pointer swings once and returns slowly When performing test once again under another polarity the pointer should return No Part name Checking procedure 5 Outdoor temperature sensor TO discharge temperature sensor TD suction temperature sensor TS exchanger temperature se...

Page 86: ... 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 lead...

Page 87: ...n LED Self cleaning flash 1 Hz function Timer LED Flash 1 Hz OFF flash 1 Hz not flash ON OFF ON OFF Setting diagnosis code 06 on remote controller See detail of setting diagnosis code in 11 4 1 Take the remote controller to direction of LED display on air conditioner press TEMP of the remote controller Fig 11 10 2 1 time to send the code 07 then air conditioner will shutdown automatically Also LED...

Page 88: ...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 cuitry wear rubber gloves to avoid contact with the live parts Electric shocks may be received if the live parts are touched High voltage cir...

Page 89: ...pper part of the front panel toward you to remove it as shown on figure 3 4 1 Follow the procedure item 3 2 Remove screw holding the electric part cover 3 Disconnect the connectors for the fan motor and louver motor from P C board assembly 4 Remove the earth screw and earth line from evaporator 5 Pull out TC sensor from sensor holder of the evaporator 6 Remove the 2 fixing screws that secures the ...

Page 90: ... the motor band and the fan motor outward 3 5 mm Cross flow fan Set screw Fan motor Body back Horizontal louver 6 1 Remove shaft of the horizontal louver from the back body First remove 2 the center shafts then remove the other shafts Horizontal louver Drain pan FILE NO SVM 16003 90 For SJM 240 25 4 5 Fan motor wires Fan motor connector To re installation Check the type name of fan motor Keep conn...

Page 91: ...screws of the unit display and remove unit display 7 5 Remove the drain pan from the back body Electric part cover Screw Connectors Louver motor connector P C board To re installation Press the drain pan into the back body Please make sure ribs of drain pan in left and right side must be install to lock position Press the center arm of drain pan to back body Center arm of drain pan Back body Drain...

Page 92: ...g figure Install the cross flow fan so that the right end of the 1st joint from the right of the Cross flow fan is keep 3 5mm from closed wall of the main unit Holding the set screw install the cross flow fan so that flat area on shaft of the fan motor comes to the mounting hole of the set screw 4 Lift up the heat exchanger follow the figure Pull out the left hand side until the cross flow fan is ...

Page 93: ... right hand side until the locking slot of heat exchanger is released from the hook of the motor cover then pull out the upper side of heat exchanger To re installation Put the evaporator hins seal on the body back before assembly the heat exchanger Please keep assembly heat exchanger follow figure as below Cross flow fan Heat exchanger Evaporator hins seal Please make sure that the hook of motor ...

Page 94: ...er 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 12 2 Microcomputer FILE NO SVM 16003 94 ...

Page 95: ...nnecting cable attach the cord clamp and wiring cover Put the wiring cover into the front cabinet and insert the claw which has been hooked to the lower part into the square hole and then fix it with screw ST2T 4 x 10s 2 pc 3 Attach the valve cover ST2T 4 x 10s 1 pc Insert the upper part to the front cabinet set the hook claw of the valve cover to square holes at three positions of the main unit a...

Page 96: ...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 Requirement As each connector has a lock mecha nism avoid to remove the connector by holding the lead wire but by holding the connector The connector is one with lock so remove it while pushing the part indicated by an arrow Be sure to remove t...

Page 97: ...and pinch the lead wires using the closed end splice Fan motor Compressor 1 0 0 Fan motor Propeller fan Flange nut Closed end splice 1 Perform work of item 1 of 1 1 of 2 and ƒ 2 Extract refrigerant gas 3 Remove the partition board ST2T 4 x 10s 3 pcs 4 Remove the sound insulation material 5 Remove the terminal cover of the compressor and disconnect the lead wire of the compressor thermo and the com...

Page 98: ...n guard in the hole of the front cabinet Push the hooking claws 8 positions by your hand and fix the claws Requirement This completes all the attaching work Check that all the hooking claws are fixed to the specified positions Fan guard Minus screwdriver Hooking claw 6 Pulse Modulating Valve coil 7 1 Detachment 2 Attachment 1 Insert the coil at position which perpendicular with pipe of PMV then tu...

Page 99: ...ect prevention mechanism as such the lock on their housing must be released before they are disconnected 2 Remove the control board assembly from the spacer Remove the heat sink and control board assembly while keeping them screwed together 3 Remove the two fixing screws used to secure the heat sink and control board assembly 4 Mount the new control board assembly NOTE When mounting the new contro...

Page 100: ...ind 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 Thermal co...

Page 101: ...T21462 223 43T49368 212 43T20344 224 43T62360 213 43T39365 225 43T6V672 214 43T22312 226 43T83310 215 43T39364 227 43T91305 216 43T39368 228 43T91306 217 43T39369 FRONT PANEL ASSY GRILLE OF AIR INLET ASSY AIR FILTER BACK BODY ASSY VERTICAL LOUVER ASSY DRAIN PAN ASSY HORIZONTAL LOUVER DRAIN HOSE DRAIN CAP STEPPING MOTOR MOTOR FAN CROSS FLOW FAN ASSY BASE BEARING BEARING ASSY MOLD MOTOR COVER MOTOR ...

Page 102: ...81 402 43T6V673 406 43T6V678 403 43T6V674 406 43T6V679 404 43T62340 TEMPERATURE SENSOR TERMINAL 5P TF TEMPERATURE SENSOR CORD CLAMP 406 43T6V680 PC BOARD ASSY WRS LED PC BOARD FOR RAS 07BKV E PC BOARD FOR RAS 10BKV E PC BOARD FOR RAS 13BKV E Description Description FILE NO SVM 16003 2 102 ...

Page 103: ...7 43T63360 FAN GUARD PROPELLER FAN FRONT CABINET ASSEMBLY CONDENSER ASSEMBLY TERMINAL COVER VALVE PACKED 9 52 DIA BONNET 9 52 DIA VALVE PACKED 6 35 DIA BONNET 6 35 DIA FAN MOTOR NUT FLANGE CUSHION RUBBER BODY PMV COIL PMV COMPRESSOR for RAS 10BAV E 33 43T91301 COMPRESSOR for RAS 07BAV E PACKED VALVE COVER UPPER CABINET ASSEMBLY FIXING PLATE VALVE BASE PLATE ASSEMBLY DRAIN NIPPLE 4 WAY VALVE 4 WAY ...

Page 104: ...43T46469 32 43T91302 17 43T63360 FAN GUARD PROPELLER FAN FRONT CABINET ASSEMBLY CONDENSER ASSEMBLY TERMINAL COVER VALVE PACKED 9 52 DIA BONNET 9 52 DIA VALVE PACKED 6 35 DIA BONNET 6 35 DIA FAN MOTOR NUT FLANGE CUSHION RUBBER BODY PMV COIL PMV COMPRESSOR 33 43T91301 PACKED VALVE COVER UPPER CABINET ASSEMBLY FIXING PLATE VALVE BASE PLATE ASSEMBLY DRAIN NIPPLE 4 WAY VALVE 4 WAY VALVE COIL PARTITION ...

Page 105: ...06 43T50304 702 43T6V684 707 43T95304 FUSE TEMPERATURE SENSOR SENSOR HEAT EXCHANGER SPACER KGES 703 43T60392 HEATSINK PC BOARD FOR RAS 07BAV E PC BOARD FOR RAS 10BAV E PC BOARD FOR RAS 13BAV E TERMINAL 5P Description Description TE Sensor Ø6 TS Sensor Ø6 TD Sensor Ø6 TD Sensor Ø4 701 702 703 704 705 706 707 FILE NO SVM 16003 2 105 ...

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