Toshiba RAS-18SAV-E3, Service Manual

Page 1: ...R410A July 2011 AIR CONDITIONER SPLIT TYPE SERVICE MANUAL FILE NO SVM 11031 Outdoor Unit Heat Pump Type RAS 18SAV2 E1 RAS 18SAV E3 Indoor Unit High Wall Heat Pump Type RAS 18SKV2 E RAS 18SKV E ...

Page 2: ...5 5 WIRING DIAGRAM 17 6 SPECIFICATIONS OF ELECTRICAL PARTS 18 7 REFRIGERANT CYCLE DIAGRAM 19 8 CONTROL BLOCK DIAGRAM 21 9 OPERATION DESCRIPTION 23 10 INSTALLATION PROCEDURE 47 11 HOW TO DIAGNOSE THE TROUBLE 61 12 HOW TO REPLACE THE MAIN PARTS 83 13 EXPLODED VIEWS AND PARTS LIST 99 FILE NO SVM 11031 ...

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: ...d electrician in accordance with the Installa tion 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: ...ontroller Batteries Remote controller holder Toshiba New IAQ filter Indoor unit Accessory Remote controller holder Pan head wood screw Plasma air purifier Installation manual Owner s manual Outdoor unit Drain nipple RAS 18SKV2 E RAS 18SKV E RAS 18SAV2 E1 RAS 18SAV E3 5 0 5 0 1 1 6 0 1 1 6 0 5 8 5 8 0 8 6 3 0 8 6 3 1 Ph 50Hz 220 240V 1 Ph 60Hz 220 230V Cooling Heating Cooling Heating 0 30 0 28 0 30...

Page 6: ...pacity Ratio 100 5 0kW 2 2 Operation Characteristic Curve Cooling Heating 2 3 Capacity Variation Ratio According to Temperature Cooling Heating Capacity Ratio 100 5 8kW FILE NO SVM 11031 0 00 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 10 00 0 10 20 30 40 50 60 70 80 90 100 110 120 Compressor Speed RPS Current A 0 00 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 10 00 0 10 20 30 40 50 60 70 80 90 ...

Page 7: ... 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 with a la...

Page 8: ...ater 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 procedures a...

Page 9: ...er diameter mm mm 1 4 6 35 0 8 3 8 9 52 0 8 1 2 12 70 0 8 5 8 15 88 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 5 Conventional flare tool Clutch type Wing nut type 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 5 to 2 0 0 5 to 1 0 1 5 to 2 0 Nominal Outer diameter Thickness diameter mm mm 1 4 6 35 0 8 3 8 9 52 0 8 1 2 12 70 0 8 5 8 15 88 1 0 Dimension mm A B...

Page 10: ...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 Outer diameter Thickness diameter mm mm 1 4 6 35 0 8 3 8 9 52 0 8 1 2 12 70 0 8 5 8 15 88 1 0 3 4 19 05 ...

Page 11: ...s the tools exclusive for R410A and their interchangeability Tools exclusive for R410A The following tools for R410A are required Tools whose specifications are changed for R410A and their interchangeability Note 1 When flaring is carried out for R410A using the conventional flare tools adjustment of projection margin is necessary For this adjustment a copper pipe gauge etc are necessary Note 2 Ch...

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: ...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 in the pi...

Page 15: ...r Connecting plate 0 39m Flare Ø12 70mm Drain hose 0 5mm Connecting pipe 0 49m Flare Ø6 35mm Air inlet Knock out system Knoc k out system 19 157 Wireless remote controller 56 26 125 63 Remote controller holder 6 5 262 5 40 262 5 215 235 215 235 320 40 109 47 215 5 153 5 85 23 6 5 Hanger Hanger Hanger Cent er line Installation plat e outline For st ud bold 8 10 For st ud bold 6 Outline of indoor un...

Page 16: ...ide Flare 6 35 Ø Flare 12 7 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 11031 ...

Page 17: ...use 250V T25A Fuse T6 3A AC 250V Power Relay Relay DB01 DB02 C12 C14 C13 YEL P21 BRW P20 R220 R219 PMV Discharge 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 Heat Exchanger Sensor TC 1 2 1 2 CN42 WHI CN01 CN02 CN51 1 2 1 2 3 4 3 4 Outdoor Temp Sensor TO 2 1 2 1 R321 R320 R319 P19 P18 Reactor Reactor Coil for 4 way Valve Indoor Terminal Blo...

Page 18: ...ion temp sensor TS sensor Discharge temp sensor TD sensor Outside air temp sensor TO sensor Heat exchanger temp sensor TE sensor Model name CH 57 ICF 140 43 4R Inverter attached Inverter attached Inverter attached Inverter attached DA131S1B 31FZ CAM MD12TCTH 5 Rating L 10mH 16A DC140V 43W 10kΩ 25 C 62kΩ 20 C 10kΩ 25 C 10kΩ 25 C 20A AC250V 3 phases 4 poles 1100W DC12V AC220 240V FILE NO SVM 11031 F...

Page 19: ...ement Indoor heat exchanger Cross flow fan 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 CAM B22YGTF 3 TD 4 way valve STF 0108Z Compressor DA131S1B 31FZ Propeller fan Refrigerant amount 1 40kg OUTDOOR UNIT TC TA Outdoor heat exchanger Spli...

Page 20: ...E Heating Tempeature Model name Standard Heat exchanger Indoor Outdoor Compressor condition C RAS pressure pipe temp fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 15 7 6 18SKV E 18SKV2 E NOTES 1 Measure surface temperature of heat exchanger pipe around center of heat exchaner path U bent Thermistor themometer 2 Connecting piping condition 7 5 m 1 to 3 High High 79 11 to 13 0 9...

Page 21: ...ng Temperature Processing Timer Serial Signal Communication Clean Function Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Initializing Circuit Power Supply Circuit Converter D C circuit Noise Filter Clock Frequency Oscillator Circuit M C U Power Supply From Outdoor Unit Serial Signal Transmitter Receiver Serial Signal Communication Operation Comman...

Page 22: ...ceive circuit Noise Filter MCC5009 P C B 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 PMV control Discharge temp control 4 way valve control Signal communication to indoor unit PMV Pulse Motor Valve M C U Micro Control Unit Outdoor Fan motor Com...

Page 23: ...tdoor 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 PMV control 4 way valve control Detection of inverter input current and current release operation Over current detection and prevention operation to IGBT module Compressor stop function Comp...

Page 24: ... ECO operation 34 10 Temporary operation 35 11 Discharge temperature control 35 FILE NO SVM 11031 12 Pulse motor valve PMV control 36 13 Self Cleaning function 37 14 Remote Controller A or B selection 38 15 QUIET mode 39 16 COMFORT SLEEP 39 17 Short Timer 39 18 One Touch Comfort 40 19 Hi POWER Mode 40 20 FILTER Indicator 40 9 3 Auto Restart Function 9 3 1 How to Set the Auto Restart Function 41 9 ...

Page 25: ...peration select COOL HEAT AUTO DRY Temperature setup Air direction Swing Air volume select AUTO LOW LOW MED MED HIGH ECO COMFORT SLEEP ON timer setup QUIET OFF timer setup PRESET Hi POWER ONE TOUCH 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: ...trolled in order to prevent lowering of the room temperature and to avoid air flow from blowing directly to persons Description 1 Detects the room temperature Ta when the operation started 2 Selects an operation mode from Ta in the left figure 3 Fan operation continues until an operation mode is selected 4 When AUTO operation has started within 2 hours after heating operation stopped and if the ro...

Page 27: ...icates one under condition of inclining downward blowing 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 ...

Page 28: ...stant 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 set temperature and room temperature 3 Min air flow rate is controlled by temperature of the indoor heat exchanger Tc as shown in Fig 4 4 Cold draft prevention the fan speed is controlled by temperature...

Page 29: ...tops 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 In cooling operation Compressor speed rps To To To During ECO QUIET and comfort sleep When To is abnormal 22 1 50 3 50 3 MIN MAX MIN MAX MIN MAX f 6 f 9 f 8 f B f A f E f 5 f 9 f 7 f ...

Page 30: ...he compressor speed so that electric power of the compressor drive circuit does not exceed the specified value Description 1 The difference between set temperature on remote controller Ts 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...

Page 31: ...n 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 the indoor ...

Page 32: ...ones 1 Stop operation of the compressor for 20 seconds 2 Invert ON 4 way valve 10 seconds after stop of the compressor 3 The outdoor fan stops at the same time when the compressor stops 4 When temperature of the indoor heat exchanger becomes 38 C or lower stop the indoor fan Finish of defrost operation Returning conditions from defrost operation to heating operation 1 Temperature of outdoor heat e...

Page 33: ...tion mode COOL HEAT The set louver position is stored in memory by the microcomputer and the louver returns to the stored position when the next operation is performed Cooling heating memory position The angle of the louver is indicated as the horizontal angle is 0 1 Louver position in cooling operation 2 Louver position in heating operation Swing operation is performed in width 35 with the stop p...

Page 34: ...equency Dry Max FAN Min Hz Fan speed depend on presetting and can change every speed 6 5 6 0 5 5 5 0 4 5 4 0 3 5 3 0 2 5 2 0 1 5 1 0 0 5 TSC 0 5 1 0 2 0 A B C A B C 0 5 0 1 0 1 5 2 0 2 5 3 0 4 0 5 0 5 5 11 0 11 5 Room temp Set temp Compressor speed 0Hz A zone aHz B zone a to cHz C zone cHz 30 minutes Time FILE NO SVM 11031 12 DRY max COOL min 6 5 COOL min 11 DRY max COOL min 6 4 COOL min 10 DRY ma...

Page 35: ... more Pi sound is heard and the temporary COOL operation starts 4 If the filter lamp goes on push RESET button to go off the filter lamp and then push RESET button again 5 To stop the temporary operation push the button again FILE NO SVM 11031 11 Discharge temperature control Td value 117 C 112 C 108 C 105 C 98 C Control operation Judges as an error and stops the compressor Reduce the compressor s...

Page 36: ...t the open degree of valve by super heat amount SH control 3 If the discharge temperature was excessively up adjust the open degree of valve so that it is in the range of set temperature Discharge temp control 4 When defrost operation is performed the open degree of valve is adjusted according to each setup conditions during preparation for defrost or during defrost operation 4 way valve is invers...

Page 37: ...the specified period based on duration of the operation which was performed prior to the shutdown after which the Self Cleaning operation stops The Self Cleaning operation is not performed after a heating operation 2 Operation 1 When the stop signal from the remote controller or timer off function is received only the timer indicator light 2 The period of the Self Cleaning operation is determined ...

Page 38: ...setting display Setting the remote controller To separate using of remote controller for each indoor unit in case of 2 air conditioner are installed nearly Remote Controller B Setup 1 Push RESET button on the indoor unit to turn the air conditioner ON 2 Point the remote controller at the indoor unit 3 Push and hold CHK button on the Remote Controller by the tip of the pencil 00 will be shown on th...

Page 39: ...ours 1hr 3hr 5hr or 9hr If the COMFORT SLEEP button is pushed again means cancel comfort sleep mode Heating mode The preset temperature will drop down as shown on ECO operation Item No 9 Push the COMFORT SLEEP button to choose the operating hours Repeat pushing to setect the hours 1hr 3hr 5hr or 9hr If the COMFORT SLEEP button is pushed again means cancel comfort sleep mode 16 COMFORT SLEEP 17 Sho...

Page 40: ...is in Auto Cooling or Heating operation Hi 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 The preset temperature drops 1 degree The value of the preset temperature on the remote controller does not change The indoor unit s fan speed level increa...

Page 41: ...unit is stand by Not operating When the unit is in operation Operation Push RESET button for more than 3 seconds Less than 10 seconds Motions The unit is in operation The green indicator is on The unit stops operating The green indicator is turned off After approx 3 seconds The unit beeps 3 times The green indicator flashes for 5 seconds If the unit is required to operate at this time push RESET b...

Page 42: ... remote controller to turn it off When the system is operating Operation Push RESET button for more than 3 seconds Less than 10 seconds Motions The unit is in operation The green indicator is on The unit stops operating The green indicator is turned off After approx 3 seconds The unit beeps 3 times If the unit is required to operate at this time push RESET button once more or use the remote contro...

Page 43: ...erences 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 functions of your TOSHIBA unit Push ONE TOUCH Start the operaton 2 AUTOMATIC OPERATION To automatically select cooling heating o...

Page 44: ...on the set temperature will decrease 7 TEMPORARY OPERATION In case of the misplaced or discharged remote controller Pushing the RESET button the unit can start or stop without using the remote controller Operation mode is set on AUTOMATIC operation preset temperature is 24 C and fan operation is automatic speed 8 TIMER OPERATION Daily timer allows the user to set both the ON and OFF timers and wil...

Page 45: ... time sec for 5 seconds Do not operate ON timer and OFF timer 2 Push and hold the RESET button on the indoor unit for 3 seconds to cancel the operation 3 beep sound but OPERATION lamp does not flash 11 QUIET OPERATION To operate at super low fan speed for quiet operation except in DRY mode Push QUIET Start and stop the operation Note Under certain conditions QUIET operation may not provide adequat...

Page 46: ... is set B appears in the remote controller display When the remote controller setting is A there is no indication at this position 10 Comfort sleep Indicates when comfort sleep is activaled Push comfort sleep button to select 11 Quiet Indicates when quiet is activated Push quiet button to start and push it again to stop operation 12 One Touch Indicates when one touch comfort is activated Push one ...

Page 47: ...ion Cut the piping hole sloped slightly Bottom right Bottom left Do not allow the drain hose to get slack Loading Batteries 1 Remove the battery cover 2 Insert 2 new batteries AAA type following the and positions Before installing the wireless remote controller 3 Batteries 2 Wireless remote controller Shield pipe Attach to the front panel 3 Batteries 5 6 2 Wireless remote control TOSHIBA New IAQ f...

Page 48: ...2 5 m m Æ 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 12 7 mm Pipe insulating material polyethylene foam 8 mm thick Putty PVC tapes FILE NO SVM 11031 48 If it is necessary to drain the defrost water attach drain nipple to the base plate of the base pl...

Page 49: ...ntrol x 1 Battery x 2 Part name Q ty Remote control holder x 1 TOSHIBA New IAQ filter x 2 TOSHIBA New IAQ filter x 2 Part No 4 5 6 Part No Others Name Owner s manual Installation manual Part name Q ty Pan head wood screw 3 1 x 16 x 2 l Screw 4 x 10 x 2 l 10 11 Drain nipple 1 Water proof rubber cap 2 Mounting screw 4 x 25 x 6 l 7 8 9 ...

Page 50: ...ter 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 be sure to...

Page 51: ...terference The location of the remote controller should be determined as shown below Fig 10 3 1 10 3 2 Drilling a Hole and Mounting Installation Plate Drilling a hole When install the refrigerant pipes from the rear Fig 10 3 2 1 After determining the pipe hole position on the installation plate ð drill the pipe hole Ø65 mm at a slight downward slant to the outdoor side NOTE When drilling into a wa...

Page 52: ...itioner NOTE Wire type More than 1 5 mm 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 disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring An approved circuit breaker or switch must be used 2 Connection ...

Page 53: ...nd drain cap How to remove the drain cap Clip drain cap with needle nose pliers and pull out Fig 10 3 9 How to remove the drain hose The drain hose is secured in place by a screw Remove the screw securing the drain hose then pull out the drain hose Die cutting Front panel slit Changing drain hose Piping preparation Rear right Rear left Bottom left Left Bottom right Right Fig 10 3 10 CAUTION Be sur...

Page 54: ...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 15 NOTE If the pipe is incorrectly bent the indoor unit may be u...

Page 55: ...e for pipes Wall Drain guide Fig 10 3 21 FILE NO SVM 11031 Carefully arrange the pipes so that none of the pipes stick out of the rear plate of the indoor unit Carefully connect the auxiliary pipes and connecting pipes to each other and cut off the insulating tape wound on the connecting pipe to avoid double taping at the joint moreover seal the joint with the vinyl tape etc Since condensation can...

Page 56: ...rain 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 refr...

Page 57: ...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 58: ... 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 pressure side handle of the gauge manifold valve 4 Operate the vacuum pump to begin evacuating Perform evacuating for about 15 minutes if the piping length...

Page 59: ...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 incomplete wiring is carried out fire or smoke may result Prepare the power supply for the exclusive use of the air conditioner This product can be connected to the main breaker Co...

Page 60: ... In this case the operation can be preserved by setting either one indoor unit or remote controller to B setting Both are set to A setting in factory shipment The remote controller signal is not received when the settings of indoor unit and remote controller are different There is no relation between A setting B setting and A room B room when connecting the piping and cables Remote controller A B ...

Page 61: ...ase of touching parts on the P C board by hand The new inverter 3DV inverter will be incorporated starting with this unit 3DV 3 shunt Discrete Vector control The control circuitry has an uninsulated construction Fig 11 1 IGBT 6 FET 6 MCU Compressor Fan motor Shared potential Driver Driver Amplifier Amplifier No 1 2 3 4 5 6 7 8 9 10 Troubleshooting Procedure First Confirmation Primary Judgment Judg...

Page 62: ... the components Do NOT lay the circuit board assembly flat 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 touching the cha...

Page 63: ...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 64: ... operation of the air conditioner 3 When item B and C or item B and apart of item E occur concurrently priority is given to the block of item B 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 display 5 Hz OPERATION Green Flashing display 5 Hz Protective c...

Page 65: ...service mode is indicated on the display of the remote controller 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 th...

Page 66: ...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 67: ...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 68: ...d 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 removed position detect circuit...

Page 69: ...CN10 1 3 short circuit Item by symptoms Operation Check Item Considerable principle cause Measures Remote controller is defective Refer to 5 Troubleshooting for remote controller Unit operates normally Replace main P C board Replace fan motor Is fuse F01 of indoor control board blown Microcomputer is defective NO NO NO NO NO YES YES YES YES YES YES Point remote to digital camera Can see infrared r...

Page 70: ...connector CN31 Check this condition within 15 seconds after starting unit Start to operate the indoor unit in except heating operation At this time is it possible to detect DC 1V or more between 5 and 3 of motor connector CN31 Is it possible to detect DC 294 325V 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 CN...

Page 71: ...evel to HIGH Is it possible to rotate cross flow fan by hand properly Fan motor operates normally Replace bearing of cross flow fan YES YES YES NO NO NO Does check cross flow fan bearing normal condition Replace indoor fan motor Peplace main P C board Does check display on remote show high Change the new PC board Does fan speed change Replace remote Replace motor NO NO NO YES YES YES 71 A B FILE N...

Page 72: ...ore 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 3 2 1 Remove the grille 3 2 2 Remove the cover terminal by release one screw 3 2 3 Check DC voltage with CN31 connector while the fan motor is rotating 1 Turn on breaker 2 After Fan motor oper...

Page 73: ...tton Is transmission mark indicated Reciver P C board is defective Replace reciver 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 Push the button Does indoor unit beep and operate Reset by take off battery the push button till LCD 5 Troubleshooting for remote controller Primary check Check that ...

Page 74: ...rom 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 operation started...

Page 75: ... pressure from service port and add 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 ...

Page 76: ... failure Remove connector of compressor Replace control board Check terminal Voltage of electrolytic capacitor are in Voltage Rate Turn ON power Supply NO 10 x 1 414 Replace control board NO Cooling 17 C Connect discharge resistance approx 100Ω 40W or soldering iron plug between terminals of the electro lytic capacitor 500µF of C14 with printed CAUTION HIGH VOLTAGE on P C board Discharging positio...

Page 77: ... CN300 of outdoor fan motor Check winding resistance by ohmmeter are correct Check rotor locking by rotate Turn OFF power supply Replace outdoor fan motor NO Replace compressor Replace control board Replace compressor YES Does compresser operate normally with hand Can it rotate Turn OFF power supply Check compressor winding resistance correct is in rate A NO NO YES NO FILE NO SVM 11031 ...

Page 78: ... 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 connec tors on the P C board hold the whole housing Do not pull at the lead wire 11 8 2 How to shorten time for start the compressor 1 Turn on remote 2 Setting requirment operation 3 Push off rem...

Page 79: ... 10 20 30 40 50 Resistance value kΩ 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 FILE NO SVM 11031 ...

Page 80: ...nsor TE Checking procedure Measure the resistance value of each winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Under 20 C Disconnect the connector and measure resistance value with the tester Normal tempera...

Page 81: ...t 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 capacitors 3 Remove the diode block from the P C board which is solde...

Page 82: ...f 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 lea...

Page 83: ...shed they 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 inspectin...

Page 84: ...pcs 6 Take off four hooks of panel from rear side How to assemble the front panel 1 Press 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 Tighten four screws Incomplete hanging or incomplete pressing may cause a dewdrops or generation of a fluttering sound 2 Screws Three hooks 4 Scr...

Page 85: ...ads once at the bottom 4 Disengage the display unit by simply pushing at the top of the display unit 5 Remove the fixing screw that secures the conduit mount electric parts box assembly LED assembly and remove the assembly Electric art box cover s screw TC sensor Earth Screw Fan motor connector Louver motor connector Fixing screw LED assembly Fixing screw Loof the qrunding wire p FILE NO SVM 11031...

Page 86: ...ther shafts while sliding the horizontal louver leftward Evaporator Heat exchanger 1 Follow to the procedure in the item 2 Remove the pipe holder from the rear side of the main unit Figure 1 3 Remove two fixing screws at the left side of the end plate of the heat exchanger Remarks Screw Screw FILE NO SVM 11031 Figure 1 Figure 2 Figure 3 Pipe hoolder ...

Page 87: ...ring is out from the housing push it into the specified position and then incorporate it in the main body Bearing Bearing base Two screws Bearing Bearing base FILE NO SVM 11031 One screw One screw 4 Remove three fixing screw at the right side of the heat exchanger and separate the heat exchanger from the back body Bearing Evaporator Heat exchanger Figure 5 Figure 4 5 Figure 4 n o ...

Page 88: ...ew 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 Two screws on motor cover FILE NO SVM 11031 p ...

Page 89: ...e 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 q FILE NO SVM 11031 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 hooki...

Page 90: ...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 91: ...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 92: ... 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 93: ...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 control board ...

Page 94: ...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 95: ...or from the terminal 6 Remove pipe connected to the compressor with a burner Remarks Reactor 1 Perform work of item 1 of and 2 Remove screws fixing the reactors 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 NUT 3 pcs fixing the comp...

Page 96: ...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 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 fron...

Page 97: ... 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 leads on the edges of the metal plates or other parts It is dangerous for these coverings t...

Page 98: ...em 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 Ther...

Page 99: ... 205 43T49010 PIPE SHIELD 226 43T03014 BODY ASSY BACK 206 43T83003 HOLDER REMOTE CONTROL 227 43T44030 EVAPORATOR ASSY 207 43T82008 PLATE INSTALLATION 228 43T09041 GRILLE ASSY SUB TOSHIBA 209 43T19333 HOLDER SENSOR 229 43T80331 FILTER AIR 210 43T49043 HOLDER PIPE 230 43T00052 PANEL ASSY SERVICE 212 43T39021 BASE BEARING 232 43T62031 COVER TERMINAL 218 43T79313 CAP DRAIN 238 43T69615 REMOTE CONTROLL...

Page 100: ...401 43T50308 SENSOR HEAT EXCHANGER 405 43T69736 PC BOARD ASSY WRS LED 402 43T60331 TERMINAL 3P 407 43T69721 PC BOARD ASSY 403 43T69320 TEMPERATURE SENSOR 412 43T21397 STEPPING MOTOR 404 43T62003 CORD CLAMP 413 43T60386 MOTOR CORD Description Description 402 405 401 403 412 404 407 413 411 ...

Page 101: ...ION 8 43T41446 COMPRESSOR 26 43T46343 4 WAY VALVE 9 43T43451 CONDENSER ASSEMBLY 27 43T63320 4 WAY VALVE COIL ASSEMBLY 10 43T46358 VALVE PACKED 6 35 DIA 28 43T63319 HOLDER SENSOR 11 43T46355 VALVE PACKED 12 7 DIA H4 29 43T79305 DRAIN NIPPLE 12 43T47331 BONNET 6 35 DIA 30 43T39333 MOTOR BASE CONNECTION PLATE 13 43T47333 BONNET 12 70 DIA 31 43T63318 HOLDER SENSOR 14 43T00448 FIXING PLATE VALVE 32 43T...

Page 102: ...o No 701 43T62320 HEATSINK 705 43T60377 TEMPERATURE SENSOR 702 43T69943 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60392 TERMINAL 5P 707 43T62313 BASE PLATE PC 704 43T60326 FUSE Description Description 707 704 705 703 706 702 701 TE Sensor Ø6 TS Sensor Ø6 TO Sensor Ø6 TD Sensor Ø4 ...

Page 103: ...BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND TOSHIBA CARRIER CORPORATION 23 17 TAKANAWA 3 CHOME MINATOKU TOKYO 108 0074 JAPAN Copyright 1999 to 2007 TOSHIBA CARRIER CORPORATION ALL Rights Reserved ...