Toshiba RAS-3M18SACV-E, Service Manual

Page 1: ...A FILE NO A06 013 PRINTED IN JAPAN May 2007 ToMo SERVICE MANUAL AIR CONDITIONER SPLIT TYPE RAS B10SKVP E RAS B13SKVP E RAS B16SKVP E RAS 3M18SAV E RAS M10SKCVP E RAS M13SKCVP E RAS M16SKCVP E RAS 3M18SACV E ...

Page 2: ...N VIEWS 20 5 WIRING DIAGRAM 22 6 SPECIFICATIONS OF ELECTRICAL PARTS 24 7 REFRIGERANT CYCLE DIAGRAM 25 8 CONTROL BLOCK DIAGRAM 29 9 OPERATION DESCRIPTION 32 10 INSTALLATION PROCEDURE 57 11 HOW TO DIAGNOSE THE TROUBLE 73 12 HOW TO REPLACE THE MAIN PARTS 93 13 EXPLODED VIEWS AND PARTS LIST 112 ...

Page 3: ...unit and 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 pressu...

Page 4: ... qualified 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...

Page 5: ...nly Outdoor unit RAS 3M18SAV E RAS 3M18SACV E Indoor unit RAS B10SKVP E RAS B13SKVP E RAS B16SKVP E RAS M10SKV E RAS M13SKV E RAS M16SKV E RAS M10GDV E RAS M13GDV E RAS M16GDV E RAS M10SMUV E RAS M13SMUV E RAS M16SMUV E RAS M10SKCVP E RAS M13SKCVP E RAS M16SKCVP E RAS M10SKCV E RAS M13SKCV E RAS M16SKCV E RAS M10GDCV E RAS M13GDCV E RAS M16GDCV E RAS M10SMUCV E RAS M13SMUCV E RAS M16SMUCV E Type H...

Page 6: ... m Maximum chargeless length m Additional refrigerant Maximum height difference m Name of refrigerant Weight kg Wiring connection Power supply Interconnection Usable temperature range Indoor Cooling Heating C Outdoor Cooling Heating C Installation plate Wireless remote controller Label Remote controller holder Indoor unit Pan head wood screw Purifying filter Accessory Deodorizing filter Batteries ...

Page 7: ...nnection Minimum length per unit m Maximum length total m Maximum chargeless length m Additional refrigerant Maximum height difference m Name of refrigerant Weight kg Wiring connection Power supply Interconnection Usable temperature range Indoor Cooling Heating C Outdoor Cooling Heating C Installation plate Wireless remote controller Label Remote controller holder Indoor unit Pan head wood screw A...

Page 8: ... 5 0 1 8 to 6 2 5 0 1 8 to 6 2 5 1 2 2 to 6 3 5 2 2 2 to 6 5 5 2 2 2 to 6 5 5 2 2 2 to 6 5 Power consumption W 600 320 to 850 1070 320 to 1520 1670 320 to 1780 1320 360 to 1800 1320 360 to 1800 1370 360 to 1820 1370 360 to 1820 1340 420 to 1970 1340 420 to 2100 1340 420 to 2100 1340 420 to 2100 600 320 to 850 1070 320 to 1520 1670 320 to 1780 1320 360 to 1800 1320 360 to 1800 1370 360 to 1820 1370...

Page 9: ... 8 2 2 to 7 7 6 8 2 2 to 7 7 6 8 2 2 to 7 7 Power consumption W 1050 300 to 1500 1470 300 to 1600 1850 300 to 2050 1720 360 to 2140 1720 360 to 2140 1840 360 to 2200 1840 360 to 2200 1580 420 to 1950 1600 420 to 2030 1600 420 to 2030 1600 420 to 2030 1050 300 to 1500 1470 300 to 1600 1850 300 to 2050 1720 360 to 2140 1720 360 to 2140 1840 360 to 2200 1840 360 to 2200 1580 420 to 1950 1600 420 to 2...

Page 10: ... 6 3 5 2 2 2 to 6 5 5 2 2 2 to 6 5 5 2 2 2 to 6 5 Power consumption W 600 320 to 850 1070 320 to 1520 1670 320 to 1780 1320 360 to 1800 1320 360 to 1800 1370 360 to 1820 1370 360 to 1820 1340 420 to 1970 1340 420 to 2100 1340 420 to 2100 1340 420 to 2100 600 320 to 850 1070 320 to 1520 1670 320 to 1780 1320 360 to 1800 1320 360 to 1800 1370 360 to 1820 1370 360 to 1820 1340 420 to 1970 1340 420 to...

Page 11: ... 80 75 70 65 60 55 50 Outdoor temp C Capacity ratio 60 50 40 30 20 10 0 110 105 100 95 90 85 80 Total pipe length m 110 100 90 80 70 60 50 40 Outdoor temp C Capacity ratio Conditions Indoor DB27 C WB19 C Outdoor DB35 C WB24 C Indoor air flow High 3 units operating Conditions Indoor DB20 C WB15 C Outdoor DB7 C WB6 C Indoor air flow High Pipe length 5m 3 3 units operating Conditions Indoor DB20 C WB...

Page 12: ...se 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 charge...

Page 13: ...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 14: ... 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 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 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 15: ... 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 16: ... 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 17: ...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 18: ... 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 19: ...efore 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 20: ...10 10 10 10 790 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 M16SKCVP E Ø12 7 Connecting pipe Outside length 0 45m Flare Ø6 35 47 or ...

Page 21: ... 21 4 2 Outdoor Unit RAS 3M18SAV E RAS 3M18SACV E ...

Page 22: ...or R01 Line Filter 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 Indoor Terminal Block To outdoor unit Wireless Unit Assembly MCC 5052 3 2 1 WHI YEL YEL 1 2 3 1 2 3 YEL 4 1 2 3 4 4 YEL 5 5 CN22 WHI CN32 WHI CN31 WHI Louver Motor Fan Motor Micro SW 1 2 3 1 2 3 4 4 5 5 RED BLK 1 2 3 1 2 3 WHI 4 4 ...

Page 23: ... EW BW EV BV EU BU CN20 CN22 CN21 CN607 TGc 3 1 3 1 GRN BLK WHI RED RED Compressor Fan motor 4 way valve coil 3 1 3 1 3 1 3 1 BLU YEL 2 1 2 1 2 1 2 1 2 1 2 1 PUR ORN 2 1 2 1 2 1 2 1 PNK RED 3 3 3 3 BLU 4 4 4 4 WHI 5 5 5 5 BLK CN802 2 1 2 1 2 1 2 1 Fan circuit CM FM PMV C PMV B PMV A T04 CT T03 CT 2 1 2 1 Q200 Q404 DB02 DB01 IGBT module IGBT PFC Diode block PFC Diode block Power supply circuit For ...

Page 24: ...E sensor Suction temp sensor TS sensor Terminal block 9P Fuse Electrolytic capacitor Transistor module Compressor Compressor thermo Diode block Rectifire Reactor Main Reactor Sub Model name SC 15 06J B SC 20 03J SWT 75 ICF 140 43 2R G5NB 1A G4A 1A PE CA Inverter attached Inverter attached Inverter attached Inverter attached Inverter attached Inverter attached Inverter attached For protection of sw...

Page 25: ...R UNIT A T1 Temp measurement To C room To B room Indoor heat exchanger Cross flow fan Sectional shape of heat insulator To C room To B room Allowable height difference 10m Allowable pipe length Per 1 unit Max 20m Min 2m Total Max 50m P Strainer Pulse motor valve at liquid side UKV 18D64 TGa TGb TGc TD Accumulating tank 54 370 Compressor DA130A1F 25F T2 Outdoor heat exchanger Temp measurement Prope...

Page 26: ...k check position Refrigerant flow INDOOR UNIT A T1 Temp measurement To C room To B room Indoor heat exchanger Cross flow fan Sectional shape of heat insulator To C room To B room Allowable height difference 10m Allowable pipe length Per 1 unit Max 20m Min 2m Total Max 50m P Strainer Pulse motor valve at liquid side UKV 18D64 TGa TGb TGc TD Accumulating tank 54 370 Compressor DA130A1F 25F T2 Outdoo...

Page 27: ...8 6 to 8 49 to 51 13 to 14 48 to 50 13 to 14 48 to 50 13 to 14 48 to 50 13 to 14 48 to 50 16 to 18 48 to 50 16 to 18 48 to 50 16 to 18 48 to 50 16 to 18 48 to 50 Indoor fan Manual High High High High High High High High High High High Outdoor fan MED MED MED MED MED MED MED MED MED MED MED Compressor revolution rps 32 52 75 63 63 65 65 62 62 62 62 Temperature condition Indoor Outdoor 20 C 7 6 C No...

Page 28: ... 10 10 13 10 10 16 10 10 13 13 10 Standard pressure P MPa 0 8 to 1 0 0 7 to 0 9 0 6 to 0 8 0 8 to 1 0 0 8 to 1 0 0 8 to 1 0 0 8 to 1 0 0 8 to 1 0 0 8 to 1 0 0 8 to 1 0 0 8 to 1 0 Heat exchanger pipe temp T1 C T2 C 11 to 13 42 to 44 8 to 10 46 to 48 6 to 8 49 to 51 13 to 14 48 to 50 13 to 14 48 to 50 13 to 14 48 to 50 13 to 14 48 to 50 16 to 18 48 to 50 16 to 18 48 to 50 16 to 18 48 to 50 16 to 18 ...

Page 29: ...Hz Remote Controller Operation START STOP Thermo Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver AUTO Swing Louver Direction Setting Hi POWER SLEEP MODE Operation Mode Selection AUTO COOL DRY HEAT REMOTE CONTROLLER Air Purifier Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Functions Cold draft preventing Function 3 minute Del...

Page 30: ...rcuit Clock Frequency Oscillator Circuit Power Supply Circuit Infrared Rays 36 7kHz Remote Controller Operation START STOP Thermo Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver AUTO Swing Louver Direction Setting Hi POWER SLEEP MODE Operation Mode Selection AUTO COOL DRY REMOTE CONTROLLER Air Purifier Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal R...

Page 31: ...as side pipe temp Sensor Suction temp Sensor Evaporator temp Sensor Outdoor air temp Sensor MCC 818 SUB P C B MCC 1438 MAIN P C B 220 240V 50Hz 220V 60Hz Driver circuit of P M V P M V Pulse motor valve PWM Pulse width modulation IGBT Insulated gate bipolar transistor A unit send receive circuit B unit send receive circuit C unit send receive circuit Inverter DC AC Over current detect circuit Clock...

Page 32: ...eration control 2 Role of outdoor unit controller Receiving the operation command signal Serial signal from the indoor unit controller the outdoor unit performs its role Compressor operation control Operation control of outdoor fan motor P M V control 4 way valve control Operations followed to judgment of serial signal from indoor side Detection of inverter input current and current release operat...

Page 33: ...10 SLEEP MODE operation 44 Cooling operation 44 Heating operation 44 11 Temporary operation 45 12 Air purifying control 45 Air purifying control Detection of abnormality 46 13 Discharge temperature control 46 14 Pulse motor valve PMV control 47 15 Clean operation 48 16 Clean operation cancel 49 17 Select switch on remote controller 50 18 Set temp correction 51 9 3 Auto Restart Function 52 9 3 1 Ho...

Page 34: ...ation function Compressor Outdoor fan motor 4 way valve Pulse motor valve P M V 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 operation condition setup the operati...

Page 35: ... to the operation signal sent from the indoor unit 1 The power of 4 way valve is turned on in heating time and turned off in cooling time and defrosting time respectively Description No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Indoor unit Pressed first Pressed last Pressed first Pressed last Pressed first Pressed last Pressed first Pressed last Pressed first Pressed last Pressed first Pressed last P...

Page 36: ...y 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 room temperature is 20 C or more the fan operation is performed with Super Ultra LOW mode for 3 minutes T...

Page 37: ...d 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 and heat exchanger temperature Fan speed level ...

Page 38: ...ing operation Heat pump model 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 ...

Page 39: ...e of 1 1 In the following cases the outdoor fan is driven at MAX speed 1 minute from start of compressor 2 The fan speed changes by the TE outdoor heat exchanger sensor temperature or TD compressor discharge sensor temperature as shown in the table below Zone M 1000rpm Fixed 1 Zone L MAX taps Zone N Not controlled by TD temperature Usual control RAS 3M18SAV E RAS 3M18SACV E To Outdoor sensor temp ...

Page 40: ...nsor temp C Description 4 Capacity control 1 Four indoor units from A to D determine the respective instruction revolutions from the difference between the remote controller setting temperature Ts and the indoor temperature Ta and transmit this to the outdoor unit 2 The outdoor unit receives the instructions from the indoor units and the inverter operates the compressor at the calculated revolutio...

Page 41: ...e In heating operation the sensor of indoor heat ex changer detects condensation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value Description 1 The input current of the outdoor unit is detected in the inverter section of the outdoor unit 2 According to the detected outdoor temperature the specified value of the current is s...

Page 42: ...s shown in the left figure The necessity of defrost operation is detected by the outdoor heat exchanger temperature The conditions to detect the necessity of defrost operation differ in A B or C zone each Table 1 Defrost operation Defrost operation in A to C zones 1 Stop operation of the compressor for 20 seconds 2 Invert OFF 4 way valve 10 seconds after stop of the compressor 3 The outdoor fan st...

Page 43: ... Directs downward 23 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...

Page 44: ... air conditioner with the difference between the set and the room temperature Tsc and Ta as shown in the following figure The time correction is performed for 8 minutes each Heating operation Description Cooling operation 1 The indoor fan speed is con trolled between L and SUL The compressor speed in control as shown in the left figure 2 The set temperature increased 0 5 C per hour up to 2 C start...

Page 45: ...s received 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 pressing RESET button the temporary AUTO operation starts 2 When keeping RESET button pressed for 3 seconds or more Pi Pi Pi sound is heard and AUTO RESTART control is changed 3 When keeping RESET button pre...

Page 46: ...ptom such as the build up of dirt has been detected while the air purifier is ON 4 When the electric dust collector has not been installed correctly Trouble case 2 or 3 is deemed to have occurred when the action concerned continues for more than one second 3 Operation The sequence that FILTER indicator is turned on are described in the left flowchart 1 When 1000H timer counts up the FILTER indicat...

Page 47: ...er temperature at evaporation side PMV Pulse Motor Valve Description 1 When starting the operation move the valve once 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 range of set tempera ture Dischar...

Page 48: ...r 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 indicator ...

Page 49: ...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 50: ...ote 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 Slide and open the remote controller cover and remove the batteries Cut the jumper wire inside the battery compartment using nippers The jumper wire sho...

Page 51: ...urpose 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 J umper wire setup J 801 J 802 HEAT ...

Page 52: ...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 53: ...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 54: ... adjust the air flow direction A receiving beep is heard 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...

Page 55: ...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 56: ...nd thermo off occurred the following operations start Refer to the figure below 1 The indoor unit of the room A room in which thermo off did not occur starts a continuous operation with the setup number of revolution 2 The indoor unit of the room B room in which thermo off occurred starts intermittent operation of the indoor fan The indoor fan operates with number of revolution of UL or SUL Fan ON...

Page 57: ...es separately not together When installing 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 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 cont...

Page 58: ...CVP E RAS M16SKCVP 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 M10SKCVP E M13SKCVP E RAS B16SKVP E M16SKCVP E 6 35 mm 12 7 mm Shield pipe for extension drain hose polyethylene foam...

Page 59: ... 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 60: ...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 61: ...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 c...

Page 62: ...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 63: ...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 64: ...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 65: ... disturb your neighbors A place which is not exposed to a strong wind A place which does not block a passageway When the outdoor unit is to be installed in an elevated position be sure to secure its feet There must be sufficient spaces for carrying the unit into and out of the site A place where the drain water does not raise any problem A place which can bear the weight of the outdoor unit and do...

Page 66: ...1 5 2 0 to 2 5 1 5 to 2 0 Flaring size A Unit mm Fig 10 4 4 Outer dia of copper pipe 6 35 9 52 12 7 A R410A R22 9 1 9 0 13 2 13 0 16 6 16 2 0 0 4 In the case of flaring for R410A with the conven tional flare tool pull out it approx 0 5 mm more than that for R22 to adjust to the specified flare size The copper pipe gauge is useful for adjust ing projection margin size 10 4 6 Installation NOTE For i...

Page 67: ... units for heat pump 5 If the outdoor units is to be mounted on a wall make sure that the platform supporting it is sufficiently strong The platform should be designed and manufactured to maintain its strength over a long period of time and sufficient consideration should be given to ensuring that the outdoor unit will not fall 6 When the outdoor unit is to be mounted high on a wall take particula...

Page 68: ...oes not flow backward into pipes of the air conditioner when the pump stops If inside oil of the vacuum pump enters into the air conditioner which adopts R410A a trouble of the refrigeration cycle may be caused 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 vacuum pump 3 Open fully the low pressure side ha...

Page 69: ...al block of indoor and outdoor unit 3 Insert the power cord and the connecting cable fully into the terminal block and secure it tightly with screws 4 Insulate the unused cords conductors from water entering in the outdoor unit Locate them so that they do not touch any electrical or metal parts 5 Secure the power cord and the connecting cable with the cord clamp 6 Attach the electric parts cover a...

Page 70: ...secure the power cord Use the power cord cables with thickness type and protective devices specified in this manual Insulate the unused cords conductors with PVC tape 1 Turn on the power breaker 2 Open side panel of the outdoor unit 3 Set the all indoor units to COOL mode It is unnecessary to set the temperature Miswiring check can not be executed when outdoor air temperature is 5 C or less 4 Star...

Page 71: ...y LEDs Red go off Fig 10 4 17 IGBT Insulated Gate Bipolar Transistor PMV Pulse Motor Valve LED Light Emitting Diode LED ON l LED OFF 1 Heat pump model only 1 1 LED indication D800 D801 D802 D803 D804 l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l Indoor alarm code None 14 16 17 18 18 19 1A 1B 1C 1C 1C 1C 1C 1C 1C 1C 1D 1E 1F Contents Nor...

Page 72: ...t size are 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 increa...

Page 73: ...r is Good or Bad Page 74 74 75 78 83 84 85 86 87 92 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 DC320V remains and discharging takes a lot of time After turning off the power source if touching the charging section before discharging an electri cal shock may be caused Discharge the ...

Page 74: ...ration cannot be performed Description The OPERATION lamp of the indoor unit flashes when power source is turned on If START STOP button is operated once flashing stops Flashes also in power failure The compressor does not operate while compressor restart delay timer 3 minutes timer operates The same phenomenon is found after power source has been turned on because 3 minutes timer operates The air...

Page 75: ...ush 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 will beep...

Page 76: ...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 77: ...Displayed 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 comp...

Page 78: ...rect wiring NO Turn off power supply once and 5 second later turn it on again Is OPERATION indicator flashing Is it possible to turn on power supply by pushing START STOP button on remote controller Is voltage DC12V or 5V indicated on rear of indoor control board normal Does transmission mark on remote controller flash normally and is its signal transmitted properly Is DC310 340V supplied between ...

Page 79: ...ect DC 1V or more between 5 and 3 of motor connector CN31 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 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 o...

Page 80: ...he cover of the fan motor lead wires 3 Check DC voltage with CN31 connector while the fan motor is rotating NOTE Do not disconnect the connector while the fan motor is rotating Use a thin test rod Indoor fan starts rotating when power supply is turned on Check output DC voltage of fan motor on P C board Measure voltage between 3 GND BLACK and 5 V line YELLOW of motor connector CN31 while indoor fa...

Page 81: ...ent light nearby Keep indoor unit away from thyristor fluorescent light Does indoor unit operate when moving remote controller near receiver or indoor unit 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 contr...

Page 82: ...outdoor unit stops 10 to 20 minutes after operation started and 10 minutes or more are required to restart the unit 2 If the unit stops once it does not operate until the power will be turned on again 3 The outdoor unit stops 10 minutes to 1 hour after operation started and an alarm is displayed Discharge temp error check code 03 1E Sensor temp error check code 02 1C Red White Terminal block S5277...

Page 83: ...ort Valve drive check Check the operating 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 T...

Page 84: ...k code 14 16 17 1C 19 1A 1B 1D 1E 1F 18 18 1C 1C 1C 1C 1C 1C 1C Description During normal operation IGBT short circuit compressor motor rare short Position detect circuit error Current detect circuit error Compressor system error Discharge temp sensor TD error Outdoor fan error Outside temp sensor TO error Compressor lock Discharge temp sensor error gas leakage Compressor break down Suction temp s...

Page 85: ... the high voltage generator Is DC12V applied between and of CN42 of the main P C 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 Electro...

Page 86: ...r and remove 3P connector 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 4 After operation turn off the power breaker after 2 minutes 20 seconds passed and discharge the electrol...

Page 87: ... OK OK OK Check winding of compressor Check fan motor position detect signal Replace com pressor C B A Replace outdoor fan motor Replace control board assembly Replace control board Replace compressor Check compressor winding resistance Diagnosis Process flowchart Item Check Opera tion Check Contents Check winding resistance between phases of compres sor and resistance between outdoor frames by us...

Page 88: ... 60V 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 betwe...

Page 89: ...scharge 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 TGa A room Gas side temp sensor TGb B room Gas side temp sensor TGc C room Gas side temp sensor TA TC TO TGa TGb TGc TE TS TD 1 Sensor characteristic table GND 5V 12V ...

Page 90: ...A130A1F 25F Outdoor fan motor Model ICF 140 43 2R Compressor thermo Bimetal type Model US622KXTMQO Outdoor temperature sensor TO pipe temperature sensor TGa TGb TGc TGd discharge tempera ture sensor TD suction temperature sensor TS evaporator temperature sensor TE Heat pump model only Checking procedure Measure the resistance value of each winding by using the tester Position Red White White Black...

Page 91: ...rge all three capacitors completely 3 Check that safety valve at the bottom of capacitor is not broken 4 Check that vessel is not swollen or exploded 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 anot...

Page 92: ...r 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 CN300 Turn OFF the breaker Fan motor is normal Disconnect two connectors CN300 and CN301 of t...

Page 93: ...ay 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 circu...

Page 94: ...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 95: ...generator 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 t...

Page 96: ...or 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 th...

Page 97: ...remove other shafts while sliding the horizontal louver leftward 1 Follow to the procedure in the item S 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...

Page 98: ...sed 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 ...

Page 99: ...ng 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 ...

Page 100: ... so 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...

Page 101: ...1 J201 T101 C03 DB01 No Q 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 102: ... 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 2 pcs Hook the rear side of the upper cabinet to claw of the rear cabinet and then put it on the front cabinet 3 Perform cabling of connecting cable and attach the wiring cover ST1TØ4 8L 2 pcs Place the wiring cover...

Page 103: ... the rear cabinet left at the front left side so pull up the top of the front cabinet to remove it The left side of the front is made to insert to the rear cabinet so remove it pulling upward 2 Attachment 1 Insert the claw on the front left rear into the rear 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 rear cabinet...

Page 104: ...electrolytic capacitor 500µF on P C board 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 i 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...

Page 105: ...cting cable 2P White CN06 Connecting cable 5P Red CN13 Connecting cable 5P Red Sub control board assembly side CN302 Connecting cable 3P White CN303 Connecting cable 2P White CN800 Connecting cable 5P Red CN501 Connecting cable 3P Red 3 The connecting cable connecting compressor and P C board base and that connecting reactor and P C board base are fixed to the inverter box with bundling band Cut o...

Page 106: ...er fan 4 Disconnect the connector for fan motor from the inverter 5 Remove the fixing screws 3 pcs holding by hands so that the fan motor does not fall 1 Perform work of item 1 of 1 2 3 4 and 5 2 Evacuate refrigerant gas 3 Remove the partition board ST1TØ4 8L 3 pcs 4 Remove the sound insulation material 5 Remove terminal cover of the compressor and disconnect lead wire of the compressor thermo and...

Page 107: ...N703 of the control board assembly respectively 1 Detachment 1 Perform work of item 1 of 1 and 1 of 2 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 Atta...

Page 108: ...nto the heat exchanger TGa TGb TGc sensor Gas side pipe temperature sensor Attachment With its leads pointing downward point the sensor in the direction of the front cabinet and install the sensor onto the straight pipe part of gas side pipe Match the sensor protective tube colors with the pipe marking colors and install the sensors TGa is yellow TGb is not marking color and TGc is green CAUTION D...

Page 109: ... and recycle that connector 6 Tear the lead wire in two on the connec tor side and strip the covering part 7 Twist the leads on the connector 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 us...

Page 110: ... 110 MCC 1438 ...

Page 111: ... 111 MCC 818 ...

Page 112: ...g 217 4301V028 Holder Pipe 218 43049701 Pipe Shield B16SKVP E M16SKCVP E 219 43049698 Pipe Shield B10SKVP E B13SKVP E M10SKCVP E M13SKCVP E 221 43047671 Pipe Ass y Connecting Gas B10SKVP E B13SKVP E M10SKCVP E M13SKCVP E 222 43047672 Pipe Ass y Connecting Gas B16SKVP E M16SKCVP E Location Part Description No No 223 43049674 Spring B16SKVP E M16SKCVP E 224 43047673 Pipe Ass y Connecting Liquid 225 ...

Page 113: ...ption 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 B10SKCVP E 408 4306S938 P C Board Ass y B13SKVP E B13SKCVP E 409 4306S939 P C Board Ass y B16SKVP E B16SKCVP E 410 43067115 Clamp Cord...

Page 114: ... 114 13 2 Outdoor Unit RAS 3M18SAV E RAS 3M18SACV E 25 38 42 26 27 29 28 24 9 11 14 17 20 12 15 18 21 23 7 8 6 2 3 45 46 10 33 32 31 30 43 41 40 36 37 4 39 35 34 44 1 5 ...

Page 115: ...47680 Cap Valve Packed 9 52 23 43047674 Cap Charge Port 24 43046449 Body PMV UKV 18D064 R410A RoHS 25 43046448 Coil PMV UKV U061E R410A RoHS 26 43046444 Valve 4 Way STF 0108Z 3M18SAV E Location Part Description No No 27 43046443 Coil Solenoid VHV 01AJ503C1 3M18SAV E 28 43050407 Thermostat Bimetal 29 43063317 Holder Thermostat 30 43047669 Nut Flange 31 43020329 Fan Propeller PJ421 32 4302C070 Motor...

Page 116: ...oard 701 4306A130 Terminal Block 9P AC250V 20A 702 4316V192 Plate 703 43050424 Sensor TD F4 704 43050425 Sensor TC F6 Ass y Service Location Part Description No No 705 43050446 Sensor TG F6 Ass y Service 3M18SAV E 706 4306S967 P C board Ass y MCC 818 3M 707 4306V021 P C board Ass y IPDU MCC 1438 702 707 706 701 704 3M18SACV E 705 3M18SAV E 704 TO Sensor TE Sensor TS Sensor TD Sensor TGa Sensor TGb...

Page 117: ...TOSHIBA CARRIER CORPORATION 2 CHOME 12 32 KONAN MINATOKU TOKYO 108 0075 JAPAN Copyright 1999 to 2007 TOSHIBA CARRIER CORPORATION ALL Rights Reserved ...