Toshiba RAS-3M23GACV-E, Service Manual

Page 1: ...R410A FILE NO A05 014 PRINTED IN JAPAN Jan 2006 ToMo SERVICE MANUAL SPLIT TYPE Cooling OnlyType Indoor Unit RAS M10GKCVP E RAS M13GKCVP E RAS M16GKCVP E Outdoor Unit RAS 3M23GACV E ...

Page 2: ...N VIEWS 17 5 WIRING DIAGRAM 19 6 SPECIFICATIONS OF ELECTRICAL PARTS 21 7 REFRIGERANT CYCLE DIAGRAM 22 8 CONTROL BLOCK DIAGRAM 24 9 OPERATION DESCRIPTION 26 10 INSTALLATION PROCEDURE 47 11 HOW TO DIAGNOSE THE TROUBLE 64 12 HOW TO REPLACE THE MAIN PARTS 84 13 EXPLODED VIEWS AND PARTS LIST 101 ...

Page 3: ... 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 fittings and possible impurities in existin...

Page 4: ...a qualified electrician in accordance with the Installation Manual Make sure the air conditioner uses an exclusive circuit An insufficient circuit capacity or inappropriate installation may cause fire When wiring use the specified cables and connect the terminals securely to prevent external forces applied to the cable from affecting the terminals Be sure to provide grounding Do not connect ground...

Page 5: ...AS M13GKCVP E and RAS M16GKCVP E For other indoor units that can also be used in combination see the service manual of each indoor unit Type Cooling only Outdoor unit RAS 3M23GACV E Indoor unit RAS M10GKCVP E RAS M13GKCVP E RAS M16GKCVP E RAS M10GKCV E RAS M13GKCV E RAS M16GKCV E RAS M10GDCV E RAS M13GDCV E RAS M16GDCV E Indoor unit RAS M10GDV E RAS M10GDCV E RAS M13GDV E RAS M13GDCV E RAS M16GDV ...

Page 6: ... Air flow rate m h High 3000 Medium 2800 Outdoor unit Type Flare connection Unit model RAS M10GKCVP E RAS M13GKCVP E RAS M16GKCVP E Indoor unit Liquid side Gas side Ø6 35 Ø9 52 Ø6 35 Ø9 52 Ø6 35 Ø12 7 Unit model RAS 3M23GACV E A unit Liquid side Gas side Ø6 35 Ø12 7 B unit Liquid side Gas side Ø6 35 Ø9 52 Outdoor unit C unit Liquid side Gas side Ø6 35 Ø9 52 Maximum length per unit m 20 Maximum len...

Page 7: ...8 76 2 34 to 9 57 48 230 13 13 2 95 2 95 5 9 1 8 to 6 4 1830 360 to 2000 8 38 2 24 to 9 15 48 240 13 13 2 95 2 95 5 9 1 8 to 6 4 1830 360 to 2000 8 03 2 14 to 8 77 48 220 13 16 2 71 3 29 6 0 1 8 to 6 4 1850 360 to 2000 8 85 2 34 to 9 57 48 230 13 16 2 71 3 29 6 0 1 8 to 6 4 1850 360 to 2000 8 50 2 24 to 9 15 48 240 13 16 2 71 3 29 6 0 1 8 to 6 4 1850 360 to 2000 8 11 2 14 to 8 77 48 220 16 16 3 05...

Page 8: ... 12 Current A Inverter output frequency rps 0 10 20 30 40 50 60 70 80 90 100 90 100 95 105 85 80 75 70 65 60 55 50 32 34 36 38 40 42 43 44 46 Conditions Indoor DB 27 C WB 19 C Outdoor DB 35 C Air flow High Pipe length 5m 3 3 units operating 220V 230V 240V Conditions Indoor DB 27 C Outdoor DB 35 C Indoor air flow High Pipe length 5m 3 3 units operating Current Limited Start Conditions Indoor DB 27 ...

Page 9: ...e pressure in the refrig eration cycle may become abnormally high so that a rupture or personal injury may be caused 5 After completion of installation work check to make sure that there is no refrigeration gas leakage If the refrigerant gas leaks into the room coming into contact with fire in the fan driven heater space heater etc a poisonous gas may occur 6 When an air conditioning system charge...

Page 10: ...ure that water or dust does not enter the pipe interior that no other oil than lubricating oils used in the installed air water heat pump is used and that refrigerant does not leak When using lubricating oils in the piping processing use such lubricating oils whose water content has been removed When stored be sure to seal the container with an airtight cap or any other cover 1 Flare processing pr...

Page 11: ...4 3 8 1 2 5 8 Outer diameter mm 6 35 9 52 12 70 15 88 Thickness mm 0 8 0 8 0 8 1 0 A mm Flare tool for R410A clutch type 0 to 0 5 0 to 0 5 0 to 0 5 0 to 0 5 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 m...

Page 12: ... designated by manufacturers Table 3 2 7 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufacturer If any other oil is used the lubricating oils may deteriorate and cause the compressor to burn out Table 3 2 7 Tightening torque of flare for R410A Reference values Nominal diameter 1 4 3 8 1 2 5 8 3 4 Outer diameter mm 6 35 9 52 12 70 15 88 ...

Page 13: ...2 Charging cylinder for R410A is being currently developed General tools Conventional tools can be used In addition to the above exclusive tools the following equipments which serve also for R22 are necessary as the general tools 1 Vacuum pump Use vacuum pump by attaching vacuum pump adapter 2 Torque wrench For Ø6 35 Ø9 52 3 Pipe cutter 4 Reamer 5 Pipe bender 6 Level vial 7 Screwdriver 8 Spanner o...

Page 14: ...and the connecting port of the electronic balance and charge liquid refrigerant Water heat exchanger unit Outdoor unit Opened Opened Refrigerant cylinder with siphon Check valve Open close valve for charging Electronic balance for refrigerant charging Opened Closed Service port 3 4 Recharging of Refrigerant When it is necessary to recharge refrigerant charge the specified amount of new refrigerant...

Page 15: ... composed of silver and copper It is used to join iron copper or copper alloy and is relatively expensive though it excels in solderability 2 Phosphor bronze brazing filler Phosphor bronze brazing filler is generally used to join copper or copper alloy 3 Low temperature brazing filler Low temperature brazing filler is generally called solder and is an alloy of tin and lead Since it is weak in adhe...

Page 16: ...ore 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 i...

Page 17: ...88 91 290 19 125 5 163 250 167 5 42 42 3 47 or more 74 or more 140 or more 7 Knockout system Knockout system Zeolite plus filter Air ionizer Installation plate hanging section Remote controller holder Wireless remote controller Stud bolt hole for Ø6 Stud bolt hole for Ø8 to Ø10 Outline of installation plate Lower part hanging section Center line of installation plate Center line of main unit Drain...

Page 18: ...ide line of product Outside line of product 600 310 B C A D 4 Ø11 17 U shape hole For Ø8 to Ø10 anchor bolt Mounting dimensions of anchor bolt 50 or more Intake Intake 100 or more 250 or more 200 or more Minimum distance from wall Outside line of product Outlet 4 Ø11 17 long hole For Ø8 to Ø10 anchor bolt 8 687 695 Hanger 123 8 332 86 2 53 53 53 53 53 Z Charging port Valve cover For installation o...

Page 19: ...1 2 WHI 1 2 3 4 5 1 2 3 4 5 1 2 1 2 1 2 3 4 5 1 2 3 4 5 LOUVER MOTOR FAN MOTOR INDOOR TERMINAL BLOCK DC MOTOR WHI YEL YEL YEL YEL FUSE F01 1 3 4 5 1 3 4 5 RED BLK WHI YEL 6 6 BLU DC5V DC12V DB01 CN21 CN23 CN34 CN22 AC 250V BLK WHI 2 1 3 1 3 RED GRN YEL T3 15A Heat exchanger Micro SW BRW BLU RED LINE FILTER TNR CN33 WHI BLK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 RED BRW BRW BRW Ion electrode High voltage ...

Page 20: ...B To Indoor unit C Power supply 220 240V 50Hz 220 220V 60Hz 3 1 3 1 TGa 3 1 3 1 YEL CN606 TGb 3 1 3 1 BRW BLU BRW RED YEL BZ BY BX EW BW EV BV EU BU CN09 CN10 CN11 CN607 TGc 3 1 3 1 GRN BLK WHI RED RED Compressor Fan motor 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 L N...

Page 21: ...r Compressor thermo Diode block Rectifire Reactor Main Reactor Sub Model name ADR25H200RBTB SC 20 S03J SWT 75 ICF 140 43 2R G4A 1A PE Inverter attached Inverter attached Inverter attached Inverter attached Inverter attached For protection of switching power source F04 For protection of power factor converter circuit breakage For protection of inverter input overcurrent For protection of switching ...

Page 22: ...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 40m P Strainer Pulse motor valve at liquid side CAM B22YGTF TGa TGb TGc TD Accumulating tank Ø51 x 300 460cc Compressor DA130A1F 25F T2 Outdoor heat exchanger Temp measurement Pro...

Page 23: ...16 10 10 13 10 16 10 13 13 16 13 16 16 10 10 10 13 10 10 16 10 10 13 13 10 Standard pressure P MPa 0 92 0 85 0 73 0 96 0 92 0 92 0 92 0 92 0 92 1 04 0 98 0 98 0 98 Surface temp of heat exchanger T1 C T2 C 11 42 09 47 8 50 10 5 to 11 5 49 11 to 12 51 11 to 12 51 11 to 12 51 11 to 12 51 11 to 12 51 12 5 to 13 5 51 12 to 13 52 12 to 13 52 12 to 13 52 Fan speed Indoor Outdoor High Med High High High H...

Page 24: ...kHz 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 Operation Mode Selection AUTO COOL DRY REMOTE CONTROLLER ECO Air Purifier Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Functions Cold draft preventing Function 3 minute Delay at...

Page 25: ... Output current release control A D converter function M C U Discharge temp Sensor Gas side pipe 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 Signal communication to MCU Inverter DC AC Over current sensor Compressor B unit P M V C unit P M V Noise filter Over current sensor Inverter DC AC Output current sensor Input curre...

Page 26: ...p data to the outdoor unit and judgment display of error Air purifier operation control 2 Role of outdoor unit controller Receiving the operation command signal Serial signal from the indoor unit controller the outdoor unit performs its role Compressor operation control Operation control of outdoor fan motor P M V control Operations followed to judgment of serial signal from indoor side Detection ...

Page 27: ...orary operation 35 10 Air purifying control 36 Air purifying control Detection of abnormality 37 11 Discharge temperature control 38 12 Pulse motor valve P M V control 38 13 Clean operation 39 14 Clean operation release 40 15 Select switch on remote controller 41 9 3 Auto Restart Function 42 9 3 1 How to Set the Auto Restart Function 42 9 3 2 How to Cancel the Auto Restart Function 43 9 3 3 Power ...

Page 28: ...ite function Calculation function Temperature calculation AD conversion function Delay function of compressor reactivation Current release function GTr over current preventive function Compressor Outdoor fan motor 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...

Page 29: ... the indoor controller to the outdoor unit 2 At the indoor unit side the indoor fan is operated according to the contents of 2 Indoor fan motor control and the louver according to the contents of 9 Louver control respectively 3 The outdoor unit controls the outdoor fan motor compressor and pulse motor valve according to the operation signal sent from the indoor unit No 1 2 3 4 5 6 7 8 9 Indoor uni...

Page 30: ...ing 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 the DRY operation started 2 Starts operation under conditions in the left figure according to the temperature difference bet...

Page 31: ...n in Fig 2 and Table 1 according to the setup tempera ture room temperature and heat exchanger temperature Fig 1 Fig 2 Table 1 Indoor fan air flow rate 2 5 Ta C 2 0 1 5 1 0 0 5 Tsc a b c d e M WB 3 4 5 L W6 Air volume AUTO L L M M H W6 L M 2 W9 M H 2 WC Indication Fan speed Fan speed setup COOL ON AUTO MANUAL 3 Fan speed M L x 3 4 L 4 Fan speed M L x 2 4 L 5 Fan speed M L x 1 4 L Linear approximat...

Page 32: ... 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 Cooling operation dry operation TO Outdoor sensor Compressor revolution rps Outdoor temp sensor TO 38 C TO 38 C 1 to 2 units TO 1 to 2 units Econo operation TO 38 C TO 38 C TO is abnormal 20 3 50 3 62 8 63 4 390 rpm 670 rpm 670 rpm 740 rpm 390 rp...

Page 33: ... C 10 1A 8 0A 16 C 39 C 11 C 15 5 C 10 5 C Cooling current release value Current decrease Outdoor unit inverter main circuit control current High Low Reduce compressor speed Operating current Setup value 6 Release protec tive control by temperature of indoor heat exchanger In cooling dry operation Prevent freezing control for indoor heat exchanger In cooling dry operation the sensor of indoor heat...

Page 34: ... function controls the air direction of the indoor unit Description Swing operation is performed in width 35 with the stop position as the center If the stop position exceeds either upper or lower limit position swing operation is performed in width 35 from the limit which the stop position exceeded 3 Swing Swing When pressing SWING button during operation the louver starts swinging The position i...

Page 35: ... 8 COOL min OFF Zone 12 11 10 9 8 7 6 5 4 3 2 1 0 TA C 4 0 3 5 3 0 2 5 2 0 1 5 1 0 0 5 TSC 0 5 1 0 2 0 12 DRY max COOL min 6 x 5 COOL min 11 DRY max COOL min 6 x 4 COOL min 10 DRY max COOL min 6 x 3 COOL min 9 DRY max COOL min 6 x 2 COOL min 8 DRY max COOL min 6 x 1 COOL min 9 Temporary operation Pressing RESET button starts the temporary operation of AUTO operation When keeping RESET button press...

Page 36: ...er close All stop Air conditioner operates Sending air purifier OFF 1 2 3 1 2 3 4 4 Air conditioner operates Air conditioner stops Air purifier operates Air conditioner Air purifier operate 1 2 Present status Stop Air purifier only Air conditioner Joint use of AC and air purifier Operation button PURE button Air conditioner Air purifier AC operation Stop All AC Air purifier AC Air purifier All sto...

Page 37: ...eared by filter RESET button on the indoor unit or a power failure FILTER indicator goes off 2 A trouble detected within 1 minute after activation of the air is immedi ately judged as an error and the FILTER indicator goes on 3 In case that 1 minute passed after activation of the purifier the purifier is turned off while the PURE indicator keeps ON After 10 minutes passed restart the purifier and ...

Page 38: ...tatus of the air conditioner this function also controls the open degree of valve with an expansion valve with pulse motor 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 ...

Page 39: ...ation 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 green on the main body lights and the clean operation starts Neither the OPERATION indicator nor the TIMER indicator light 2 The period of the clean operat...

Page 40: ... function Hold down the auto operation switch on the indoor unit for at least 3 seconds but not more than 10 seconds The indoor unit s buzzer emits three beeps and the OPERATION indicator flashes at 5 Hz intervals This completes the clean operation release setting Cut J04 of the indoor P C board This step may be skipped if the auto restart function is not required Hold down the auto operation swit...

Page 41: ...ion 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 Setting the remote controller Switching between A and B is enabled by cutting the jumper wire inside the battery box using pliers 1 Slide open the r...

Page 42: ...erating When the unit is in operation When the unit is turned on by this function the louver will not swing even though it was swinging automatically before shutting down While the filter check indicator is on the RESET button has the function of filter reset button Operation Press RESET button for more than three seconds Less than 10 seconds Motions The unit is on standby The unit starts to opera...

Page 43: ... FILTER indicator 9 4 1 How to Turn Off FILTER Indicator Press RESET button on the indoor unit NOTE If RESET button is pushed while the FILTER indica tor is not lit the indoor unit will start the automatic operation When you want a temporary operation while the FILTER lamp lights press RESET button to turn off the FILTER lamp Operation Press RESET button for more than three seconds Less than 10 se...

Page 44: ...k and ON timer times To move up the time press of the ON ON button To move down the time press of the ON ON button 9 OFF timer button OFF Use this button to change the OFF timer times To move up the time press of the OFF OFF button To move down the time press of the OFF OFF button 10 Reserve button SET Press this button to store the time settings A receiving beep is heard 11 Cancel button CLR Pres...

Page 45: ... time setting 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 Press the Hi POWER button to start and press it again to stop the operation 8 MEMORY indicator Flashes for 3 seconds when the MEMO button is pressed during operation The mark is shown when holding down ...

Page 46: ...n The indoor unit operates in according to the current operation 2 Cooling operation The preset temperature drops 1 C The value of the preset temperature on the remote controller does not change If the difference between the preset temperature and the room temperature is big the horizontal louver moves to the Hi POWER position automatically Then when the difference between them gets smaller the ho...

Page 47: ... C and D shown in the right figure Ensure sufficient space to allow drainage A B C D Power cord Y Wall Bottom right Rear right Right Left Bottom left Rear left As shown in the figure position power cord and connecting cable downward and lead out along piping connection port Before installing the wireless remote controller With the remote controller cover removed correctly load the supplied batteri...

Page 48: ...or extension drain hose polyethylene foam 6 mm thick Q ty 1 ea 1 Part No Part name Q ty Installation plate 1 Wireless remote control 1 Battery 2 Part No Part name Q ty Remote control holder 1 Zeolite plus filter 1 Plasma pure filter 1 Part No Part name Q ty Mounting screw Ø4 25L 6 Remote control holder mounting screw Ø3 1 16L 2 This model is not equipped with an extension drain hose Others Name Ow...

Page 49: ...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 b...

Page 50: ...to direct sunlight or close to a heating source such as a stove Keep the remote controller at least 1 m away from the nearest TV set or stereo equipment This is necessary to prevent image disturbances or noise interference The location of the remote controller should be determined as shown below Fig 10 3 1 10 3 2 Drilling a Hole and Mounting Instal lation Plate Drilling a hole When install the ref...

Page 51: ...e use of the air conditioner NOTE Wire type More than H07RN F or 245IEC66 1 0mm CAUTION This appliance can be connected to a main circuit breaker in either of the following two ways 1 Connection to fixed wiring A switch or circuit breaker which discon nects all poles and has a contact separa tion of at least 3 mm must be incorporated in the fixed wiring An approved circuit breaker or switch must b...

Page 52: ...e 70 mm 10 mm 10 mm 50 mm Fig 10 3 10 1 Die cutting front panel 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 side of thefront 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 ...

Page 53: ...they 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 54: ...s 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 ...

Page 55: ...arts Part No Part name Q ty Outdoor unit installation manual 1 Part No Part name Q ty Specifications 1 Part name Refrigerant piping 1 Putty PVC tapes 10 4 2 Which Models can be Combined Table of models that can be connected Others Name Important information and warning B W strips Energy efficiency labels Type Cooling only Outdoor unit RAS 3M23GACV E Indoor unit RAS M10GKCVP E RAS M13GKCVP E RAS M1...

Page 56: ...m or less Maximum piping height difference A or B or C 10 m or less Maximum piping height difference between 2 units 10 m or less If the outdoor unit is to be mounted on a wall make sure the platform supporting it is sturdy enough The platform should be designed and manufac tured to maintain its strength over a long period of time and sufficient consideration should be given to ensuring that the o...

Page 57: ...io equipment welders and medical equip ment Strong wind 10 5 2 Fixing Bolt Arrangement of Outdoor Unit Fig 10 5 3 Suction side Diffuser 600 mm 310 mm 10 5 3 Refrigerant Piping Connection Flaring 1 Cut the pipe with a pipe cutter Fig 10 5 4 2 Insert a flare nut into the pipe and flare the pipe Projection margin in flaring A Unit mm Rigid Clutch type Fig 10 5 5 Imperial Wing nut type Flaring size B ...

Page 58: ...kgf m 50 to 62 5 0 to 6 2 kgf m All combinations that do not exceed the Total number can be installed Note that expanders and reducers may be required depending on the combination method Outdoor unit Indoor unit Unit A Ø9 52 Ø6 35 Unit B Unit C Ø9 52 Ø6 35 Ø12 7 Ø6 35 Tightening torque for connection of flare pipe The pressure of R410A is higher than R22 Approx 1 6 times Therefore securely tighten...

Page 59: ... Use a vacuum pump Be sure to use a vacuum pump with counter flow prevention function so that oil inside the pump does not flow back into the air conditioner pipes when the pump stops If oil inside the vacuum pump enters into the air conditioner circuit which uses R410A trouble with the refrigeration system may develop 1 Connect the charge hose from the manifold valve to the service port of the ga...

Page 60: ...eaker circuit Terminal block Connecting cable Connecting cable A unit Connecting cable C unit Connecting cable B unit Power cord Screw Model Power source Maximum running current Installation fuse rating Power cord Connection cable 3 units Multi 220 240 V 50 Hz 220 V 60 Hz 11 A 25A D type H07RN F or 245IEC66 1 5 mm H07RN F or 245IEC66 1 0 mm 10 5 5 Wiring Connection 1 Remove the valve cover the ele...

Page 61: ...ng the product to the mains power 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 into the fixed wiring Utilize only approved short circuit breakers and switches A breaker having sensitivity of approximately 0 1 second or less and capacity of approximately 30 mA is usually used 10 7 1 Miswiring Mi...

Page 62: ...l l l l l l l l l l l l Description Normal operation no error Checking A unit Checking B unit Checking C unit Crush Clog of pipe A Crush Clog of pipe B Crush Clog of pipe C Miswiring Mis piping or Crush Clog of pipe A B Miswiring Mis piping or Crush Clog of pipe A C Miswiring Mis piping or Crush Clog of pipe B C A B C Miswiring Mis piping LED Light Emitting Diode LED ON l LED OFF LED Flash Check m...

Page 63: ...hort Trouble on position detecting circuit Trouble on current detecting circuit Discharge pipe temp sensor TD fault Trouble on outdoor fan Outdoor temp sensor TO fault Trouble on compressor system Gas side pipe temp sensor a TGa fault Gas side pipe temp sensor b TGb fault Gas side pipe temp sensor b TGc fault Gas leakage P M V fault Sensor fault Indoor evaporator pipe sensor TC out of place P M V ...

Page 64: ...66 69 74 75 77 78 83 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 DC280V 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 electrolytic capacitor complete...

Page 65: ...r Dry operation 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 operate...

Page 66: ...e mode is indicated on the display of the remote controller Press 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 3 1 Press ON or OFF button to change the ch...

Page 67: ...rocomputer returns the initial status However the check codes are not deleted even if the power supply is turned off because they are stored in the fixed memory 3 After servicing press CLR button under check mode status and then send the check code 7F to the indoor unit The error code stored in memory is cleared Table 11 3 1 Block distinction Operation of diagnosis function Block Indoor P C board ...

Page 68: ...ion of refrigera tion cycle Check installation condition Short circuit of outdoor diffuser Block Outdoor P C board Not displayed Outdoor P C board Others including compressor Operation of diagnosis function Cause of operation Inverter over current protective circuit operates Short time Position detect circuit error or short circuit between windings of compressor Current detect circuit error Being ...

Page 69: ...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 CN10 1 3 Does fan motor connector between CN10 1 3 short circuit Item by symptoms Operation Check Item Considerable principle cause Measures Parts R04 R05 DB01 C01 C03 IC01 and T01 are def...

Page 70: ... detect DC 1V or more between 5 and 3 of motor connector CN10 Is it possible to detect DC 1V or more between 5 and 3 of motor connector CN10 Is it possible to detect DC 310 340V between 1 and 3 of motor connector CN10 Motor connection condition Is it possible to detect DC 15V between 4 and 3 of motor connector CN10 Is it possible to detect DC 15V between 4 and 3 of motor connector CN10 Is it possi...

Page 71: ...ace motor 4 Indoor fan motor automatically starts to rotate by turning on power supply Cause The IC is built in the indoor fan motor Therefore the P C board is also mounted to inside of the motor If the P C board is soldered imperfectly or the IC is defective the fan motor may automatically rotate by turning on power supply Inspection procedure 1 Remove the front panel Remove 2 screws 2 Remove the...

Page 72: ... Batteries are exhausted Does radio sound is affected by remote controller when a signal is transmitted at distance of 5 cm from radio Is transmission mark indicated P C board is defective Replace P C board Replace batteries Replace remote controller Normal operation Remote controller is defective NO YES NO YES NO YES NO YES NO YES NO YES NO YES Does indoor unit start to operate by automatic resta...

Page 73: ...m that transmission from indoor unit to outdoor unit is correctly performed based upon the follow ing diagram NOTE Measurement should be performed 2 minutes and 30 seconds after starting of the operation Be sure to prepare a diode for judgment Normal time Voltage swings between DC15 and 60V Inverter Assembly check 11 9 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while af...

Page 74: ... 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 check code 14 16 17 1C 19 1A 1B 1D 1E 1F 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 Discharg...

Page 75: ...board MCC5020 Micro switch is stuck Micro switch malfunction To item Power supply is not turned on Replace the main P C board MCC5020 Replace micro switch Does the PURE indicator go off within 2 seconds after it was ON and does the FILTER indicator Orange go on Are the electric dust collector and ionizer dried Electrode check Dry the electric dust collector and ionizer Is DC 5V to DC 10V applied b...

Page 76: ...here conduction of micro switch connector under OFF status of the micro switch Front panel opened Is there conduction of micro switch connector under ON status of the micro switch Front panel closed Does the indoor fan rotate Does the PURE indicator Blue or the FILTER indicator Orange go on Is DC12V applied between Red DC12V and Brown GND of CN1 of the high voltage generator in the air purifier Mi...

Page 77: ...with or Summary If fuse was blown be sure to check the electrolytic capacitor and diode block Connect discharge resistance approx 100Ω 40W or soldering iron plug between terminals of the electro lytic capacitor 760µF of C14 with printed CAU TION HIGH VOLTAGE on P C board OK if 500µF DC280 to 380V Remove CN300 while pushing the part indicated by an arrow because CN300 is a connector with lock Resis...

Page 78: ...ing precautions 1 When removing the front panel or the P C board be sure to shut off the power supply breaker 2 When removing the P C board hold the edge of the P C board and do not apply force to the parts 3 When connecting or disconnecting the connectors on the P C board hold the whole housing Do not pull at the lead wire 2 Inspection procedures 1 When a P C board is judged to be defective check...

Page 79: ... 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 80: ... 50 Resistance value k W Temperature C TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor 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 TD 1 Sensor characteristic table ...

Page 81: ...ter 5 4 3 2 1 White Yellow Yellow Yellow Yellow 5 4 3 2 1 Refer to 11 4 1 5 Measure the resistance value of each winding coil by using the tester Under normal temp 25 C Refer to 11 4 1 3 and 4 2 3 Remote controller Louver motor MP24Z 4 Indoor fan motor Under 20 C Position Red White White Black Black Red Resistance value 17 25Ω 2 3 Outdoor fan motor Model ICF 140 43 2R Compressor thermo bimetal typ...

Page 82: ...al 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 C15 500µF 400V 2 IGBT module 1 Turn OFF the power supply switch 2 Discharge all four electrolytic capacitors completely 3 Execute continuity test with a tester MCC 1438 So...

Page 83: ...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 Yellow lead 4 Pink lead of the connector CN301 Motor position detect...

Page 84: ...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 inspecting the...

Page 85: ...ing screws 2 pcs 6 Press the electric parts box with the right thumb while pulling the both sides of the front panel toward you 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 Insert the electric dust collector and left and right air filters P...

Page 86: ...rom where they are fitted into the other compo nents 5 Remove the fixing screw which secures the high voltage generator and remove the high voltage generator from the evaporator Remarks How to assemble the high voltage generator 1 Insert the high voltage generator straight into the evaporator and secure it using the fixing screw Claw Claw Claw Check whether the leads have been completely inserted ...

Page 87: ...m a loop Press the drain pan Press the drain pan Pull the display unit toward you 5 Disengage the two claws at the top of the display unit They can be easily disengaged by pressing the drain pan above the claws and at the same time pulling the display unit toward you 6 Remove the fixing screw that secures the electric parts box assembly and remove the assembly How to assemble the electric parts bo...

Page 88: ...3 Remove two fixing screws at the left side of the end plate of the heat exchanger Slide the horizontal louver leftward Remarks Screw Screw Disengage the claw Pipe holder Screw Screw Heat exchanger Heat exchanger fixing holder fixing holder Screw Screw Disengage the claw Pipe holder Screw Heat exchanger fixing holder Screw Hanged part 4 Remove the heat exchanger fixing holder by removing the two f...

Page 89: ...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 90: ...ont 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 Remarks 1 Follow to the procedure in the item 6 2 Remove the heat exchanger fixing holder by removing the two fixing screws used to secure it 3 Loosen the set screw of the cross flow fan 4 Lift the left side of the h...

Page 91: ...low fan 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 t...

Page 92: ...eration of air conditioner 2 Remove the front panel Remove the 2 fixing screws 3 Remove the electrical part base Remarks Replace terminal block microcomputer ass y and the P C board ass y 12 2 Microcomputer P C board layout R05 L01 C01 CN23 FUSE R04 R01 CN10 J04 IC03 C20 IC01 T01 C03 DB01 ...

Page 93: ...ttach the valve cover ST1TØ4 10L 1 pc Insert the upper part to the upper cabinet set hook claw of the valve cover to square holes at three positions of the main unit and attach it pushing upward Remarks 1 Detachment 1 Perform work of item 1 of 1 2 Remove screw ST1TØ4 10L 1 pc of the front cabinet and inverter cover and screws ST1TØ4 10L 3 pcs of the front cabinet and lower part of the front cabine...

Page 94: ...ccording to trouble type in some cases NOTE This capacitor is one with mass capacity Therefore it is dangerous that a large spark generates if short circuiting be tween polarity with screwdriver etc for discharging 4 Remove screw ST1TØ4 10L 1 pc fixing the main body and the inverter box 5 Remove various lead wires from the holder at upper part of the inverter box and wiring holder at right side of...

Page 95: ... CN303 Connecting cable 2P White CN501 Connecting cable 3P Red CN800 Connecting cable 5P 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 off bundling band 4 The connecting cables of the main P C board base and the sub P C board base are fixed with bun dling band Cut off bundling ...

Page 96: ... of item 1 of 1 2 3 4 and 5 2 Evacuate refrigerant gas 3 Remove the partition board ST1TØ4 10L 3 pcs 4 Remove the sound insulation material 5 Remove terminal cover of the compressor and disconnect lead wire of the compressor thermo and the compressor from the terminal 6 Remove pipe connected to the compressor with a burner 7 Remove the fixing screw of the bottom plate and heat exchanger ST1TØ4 10L...

Page 97: ... shape Remarks 1 Detachment 1 Perform work of item 1 of and 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 claw of the fan guard in t...

Page 98: ...er and constring them 9 Wind the attached color tape round the both terminals of the protective tube when colored protective tube is used 10 Fix the sensor again 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 Therm...

Page 99: ... 99 MCC 1438 ...

Page 100: ... 100 MCC 818 ...

Page 101: ...Evaporator 2 226 43044804 Evaporator 1 227 43039324 Guide Drain 228 43049728 Guide Drain Left 229 43019904 Holder Sensor 230 43049770 Holder Evaporator Right 232 43062256 Cover Terminal 233 43062247 Cover Lead 234 43082293 Plate Installation 235 4306S577 Remote Controller 236 43083071 Holder Remote Comtroller 238 43003307 Body Ass y Back 239 43070188 Hose Drain 240 43079268 Cap Drain 245 43080516 ...

Page 102: ...43051346 SW Micro Ass y Location Part Description No No 407 4306S709 P C Board Ass y M10GKCVP E 408 4306S710 P C Board Ass y M13GKCVP E 409 4306S711 P C Board Ass y M16GKCVP E 410 43067115 Clamp Cord Indoor Unit 2 406 405 401 402 403 404 407 408 409 410 The parts in the following parts list are conformed to RoHS Therefore be sure to use the following parts for repairing and replacing ...

Page 103: ...2 DIA 13 37546846 Valve Packed 12 7 DIA 14 43147196 Bonnet 1 4 IN 15 43047401 Bonnet 3 8 IN 16 43147195 Bonnet 1 2 IN 17 37546848 Valve Pulse Motor P M V 18 43046450 Coil P M V 19 43158192 Reactor CH 43 Z T 20 43050407 Thermo Bimetal Location Part Description No No 21 4302C070 Motor Fan DC ICF 140 43 2R 22 43047669 Nut Flange 23 43020329 Fan Propeller PJ421 24 43049749 Cushion Rubber 25 43063332 H...

Page 104: ... RoHS Therefore be sure to use the following parts for repairing and replacing Location Part Description No No 700 43162042 Base P C board ABS 703 4306A130 Terminal Block 9P AC 250V 20A 704 43050424 Sensor TD Ø4 705 43050425 Sensor TO TG Ø6 Location Part Description No No 707 4316V192 Plate 709 4306S690 P C board Ass y MCC 818 3M23GACV E 713 4306V016 P C board Ass y IPDU MCC 1438 ...

Page 105: ...ON 2 CHOME 12 32 KONAN MINATOKU TOKYO 108 0075 JAPAN Copyright 1999 to 2005 TOSHIBA CARRIER CORPORATION ALL Rights Reserved This product is compliant with Directive 2002 95 EC and cannot be disposed as unsorted municipal waste ...