FILE NO.

SVM-03016

SERVICE MANUAL

AIR-CONDITIONER
SPLIT TYPE RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E/ RAS-3M23YACV-E

R410A

June, 2003

CONTENTS
1. SPECIFICATIONS ........................................................................................................... 3 2. REFRIGERANT R410A................................................................................................... 7 3. CONSTRUCTION VIEWS .............................................................................................. 15 4. WIRING DIAGRAM ....................................................................................................... 17 5. SPECIFICATIONS OF ELECTRICAL PARTS .............................................................. 19 6. REFRIGERANT CYCLE DIAGRAM .............................................................................. 20 7. CONTROL BLOCK DIAGRAM ..................................................................................... 22 8. OPERATION DESCRIPTION ........................................................................................ 24 9. INSTALLATION PROCEDURE ..................................................................................... 36 10. HOW TO DIAGNOSE THE TROUBLE ........................................................................... 50 11. HOW TO REPLACE THE MAIN PARTS ........................................................................ 71 12. EXPLODED VIEWS AND PARTS LIST ........................................................................ 82

1. SPECIFICATIONS
1-1. Specifications
Unit model Indoor Outdoor (kW) (kW) Cooling capacity Cooling capacity range Power supply Electric characteristics Indoor RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E RAS-3M23YACV-E 6,7 2,2~7,0 220240V1Ph50Hz 220V 230V 240V RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E 0,15 30 91 87 83 RAS-3M23YACV-E 9,84 9,39 8,98 2060 95 10,29 9,84 9,43 3,12 RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E 36 39 42 33 35 39 28 28 33 RAS-3M23YACV-E 45 48 RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E 275 275 275 790 790 790 208 208 208 10 10 10 19 19 19 470 520 600 RAS-3M23YACV-E 695 780 270 48 40 2100 Flare connection RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E 6,35 6,35 6,35 9,52 9,52 12,7 RAS-3M23YACV-E 6,35 / 12,7 6,35 / 9,52 6,35 / 9,52 20 40 40 10 R410A 1,5 3 Wires : includes earth 4 Wires : includes earth 2132 1043 1 1 1 1 2 (3,1 x 16L) 1 1 2 6 (4 x 25L) 1 1 1

Outdoor

Unit model Running current Power consumption Power factor Unit model Running current Power consumption Power factor

(A) (W) (%) (A) (W) (%) (A) (dBA) (dBA) (dBA) (dBA) (dBA) (mm) (mm) (mm) (kg) (W) (m/h) (mm) (mm) (mm) (kg) (W) (m/h)

Starting current COP Operating noise Indoor Unit model High Medium Low Unit model 10-1 unit operating 3 units operating Height Width Depth

Outdoor

Indoor unit

Unit model Dimension

Net weight Fan motor output Air flow rate Outdoor unit Unit model Dimension Height Width Depth Net weight Fan motor output Air flow rate Piping connection Type Indoor unit Unit model Liquid side Gas side Outdoor unit Unit model A unit B unit C unit Maximum length (per unit) Maximum length (total) Maximum chargeless length Maximum height difference Refrigerant Name of refrigerant Weight Wiring connection Power supply Interconnection Usable temperature range Indoor Outdoor Accessory Indoor unit Installation plate Wireless remote control Label Remote control holder Pan head wood screw Purifying filter Zeodorizing filter Batteries Mounting screw Installation manual Outdoor unit Installation manual Owner's manual

(m) (m) (m) (m) (kg)

(C) (C)

For performance when each indoor unit is combined with other unit, refer to the separate table. The specifications may be subject to change without notice for purpose of improvement.

1-2. Specifications of Performance When Each Indoor Unit is Combined with Other Unit
Operating status 1 unit Power supply (V) 220 230 240 220 230 240 220 230 240 2 units 220 230 240 220 230 240 220 230 240 220 230 240 220 230 240 220 230 240 3 units 220 230 240 220 230 240 220 230 240 220 230 240 Indoor unit A 10 10 10 13 13 13 16 16 16 10 10 10 10 10 10 10 10 10 13 13 13 13 13 13 16 16 16 10 10 10 10 10 10 10 10 10 10 10 10 B 10 10 10 13 13 13 16 16 16 13 13 13 16 16 16 16 16 16 10 10 10 10 10 10 13 13 13 10 10 10 C 10 10 10 13 13 13 13 13 13 16 16 16 Unit capacity (kW) A 2,7 2,7 2,7 3,7 3,7 3,7 4,5 4,5 4,5 2,7 2,7 2,7 2,45 2,45 2,45 2,21 2,21 2,21 2,95 2,95 2,95 2,71 2,71 2,71 3,05 3,05 3,05 2,13 2,13 2,13 1,99 1,99 1,99 1,80 1,80 1,80 1,83 1,83 1,83 B 2,7 2,7 2,7 3,35 3,35 3,35 3,69 3,69 3,69 2,95 2,95 2,95 3,29 3,29 3,29 3,05 3,05 3,05 2,13 2,13 2,13 1,99 1,99 1,99 2,45 2,45 2,45 1,83 1,83 1,83 C 2,13 2,13 2,13 2,72 2,72 2,72 2,45 2,45 2,45 3,04 3,04 3,04 Cooling capacity (kW) 2,7 (1,4 to 3,2) 2,7 (1,4 to 3,2) 2,7 (1,4 to 3,2) 3,7 (1,4 to 4,4) 3,7 (1,4 to 4,4) 3,7 (1,4 to 4,4) 4,5 (1,4 to 4,9) 4,5 (1,4 to 4,9) 4,5 (1,4 to 4,9) 5,4 (1,8 to 6,0) 5,4 (1,8 to 6,0) 5,4 (1,8 to 6,0) 5,8 (1,8 to 6,3) 5,8 (1,8 to 6,3) 5,8 (1,8 to 6,3) 5,9 (1,8 to 6,4) 5,9 (1,8 to 6,4) 5,9 (1,8 to 6,4) 5,9 (1,8 to 6,4) 5,9 (1,8 to 6,4) 5,9 (1,8 to 6,4) 6,0 (1,8 to 6,4) 6,0 (1,8 to 6,4) 6,0 (1,8 to 6,4) 6,1 (1,8 to 6,5) 6,1 (1,8 to 6,5) 6,1 (1,8 to 6,5) 6,4 (2,2 to 7,0) 6,4 (2,2 to 7,0) 6,4 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) 6,7 (2,2 to 7,0) Power consumption (W) 770 (320 to 950) 770 (320 to 950) 770 (320 to 950) 1200 (320 to 1470) 1200 (320 to 1470) 1200 (320 to 1470) 1600 (320 to 1750) 1600 (320 to 1750) 1600 (320 to 1750) 1500 (360 to 1880) 1500 (360 to 1880) 1500 (360 to 1880) 1800 (360 to 1970) 1800 (360 to 1970) 1800 (360 to 1970) 1830 (360 to 2000) 1830 (360 to 2000) 1830 (360 to 2000) 1830 (360 to 2000) 1830 (360 to 2000) 1830 (360 to 2000) 1850 (360 to 2000) 1850 (360 to 2000) 1850 (360 to 2000) 1870 (360 to 2050) 1870 (360 to 2050) 1870 (360 to 2050) 1880 (420 to 2300) 1880 (420 to 2300) 1880 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) 2150 (420 to 2300) Operation current (A) 4,12 (2,08 to 5,08) 3,94 (1,99 to 4,86) 3,77 (1,90 to 4,66) 6,34 (2,08 to 7,51) 6,07 (1,99 to 7,18) 5,81 (1,90 to 6,88) 7,66 (2,08 to 8,37) 7,32 (1,99 to 8,01) 7,02 (1,90 to 7,68) 7,18 (2,34 to 9,00) 6,86 (2,24 to 8,60) 6,58 (2,14 to 8,25) 8,61 (2,34 to 9,43) 8,24 (2,24 to 9,02) 7,89 (2,14 to 8,64) 8,76 (2,34 to 9,57) 8,38 (2,24 to 9,15) 8,03 (2,14 to 8,77) 8,76 (2,34 to 9,57) 8,38 (2,24 to 9,15) 8,03 (2,14 to 8,77) 8,85 (2,34 to 9,57) 8,50 (2,24 to 9,15) 8,11 (2,14 to 8,77) 8,95 (2,34 to 9,81) 8,56 (2,24 to 9,38) 8,20 (2,14 to 8,99) 9,00 (2,73 to 11,0) 8,60 (2,61 to 10,53) 8,25 (2,50 to 10,09) 10,29 (2,73 to 11,0) 9,84 (2,61 to 10,53) 9,43 (2,50 to 10,09) 10,29 (2,73 to 11,0) 9,84 (2,61 to 10,53) 9,43 (2,50 to 10,09) 10,29 (2,73 to 11,0) 9,84 (2,61 to 10,53) 9,43 (2,50 to 10,09) Outdoor noise (dB) 45 45 45 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48

The above specification values are those under the conditions that the indoor DB/WB=27/19C and the outdoor DB=35C. Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E

1-2-1. Operation Characteristic Curve

12 11 10 9 8 Conditions Indoor : DB27C/WB19C Outdoor : DB35C Air flow : High Pipe length 5m 3 3 units operating 220V

Current (A)

7 6 5 4 3 2 1 0 0 10 20 30 40 50 60 70 80 240V

230V

90

100

Inverter output frequency (rps)

1-2-2. Capacity Variation Ratio According to Temperature

115 Conditions Indoor : DB27C Outdoor : DB35C Indoor air flow : High Pipe length 5m 3 3 units operating 105 100 95 90 Current Limited Start

110

105

Capacity ratio (%)

Capacity ratio (%)

85 80 75 70 65 60 Conditions Indoor : DB27C/WB19C Indoor air flow : High Pipe length 5m 3 3 units operating 34 36 38 40 42 43 44 46

100

95

90

85 55 0 14 16 18 20 22 24 50 32

Indoor air wet bulb temp. (C)

Outdoor temp. (C) * Capacity ratio : 100% = 6,7 kW

1-3. Electrical Data

Combination of indoor unit operation 1 unit 10 13 16 2 units 10 13 16 13 16 16 3 units 10 13 13 16 1 unit 10 13 16 2 units 10 13 16 13 16 16 3 units 10 13 13 16 1 unit 10 13 16 2 units 10 13 16 13 16 16 3 units 10 13 13 16 10 10 10 13 13 16 10 10 13 10 10 10 10 13 13 16 10 10 13 10 10 10 10 13 13 16 10 10 13 10 10 10 10 10 10 10 10 10 10 10 10 10 50 240-1 198 264 50 230-1 198 264 50 220-1 198 264 System Voltage range Min. Max. Compressor MSC 3,47 5,69 7,01 6,38 7,81 7,96 7,96 8,05 8,15 8,05 9,34 9,34 9,34 3,29 5,42 6,67 6,06 7,44 7,58 7,58 7,70 7,76 7,65 8,89 8,89 8,89 3,12 5,16 6,37 5,78 7,09 7,23 7,23 7,31 7,40 7,30 8,48 8,48 8,48 RLA 3,47 5,69 7,01 6,38 7,81 7,96 7,96 8,05 8,15 8,05 9,34 9,34 9,34 3,29 5,42 6,67 6,06 7,44 7,58 7,58 7,70 7,76 7,65 8,89 8,89 8,89 3,12 5,16 6,37 5,78 7,09 7,23 7,23 7,31 7,40 7,30 8,48 8,48 8,48 Fan motor FLA Indoor 0,15 x 1 = 0,15 0,15 x 1 = 0,15 0,15 x 1 = 0,15 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 1 = 0,15 0,15 x 1 = 0,15 0,15 x 1 = 0,15 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 1 = 0,15 0,15 x 1 = 0,15 0,15 x 1 = 0,15 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 2 = 0,30 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 3 = 0,45 0,15 x 3 = 0,45 Outdoor 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5

Hz

VoltsPh.

Power supply MOCP MCA ICF (Amps) 4,99 7,76 9,41 8,78 10,56 10,75 10,75 10,86 10,99 11,01 12,63 12,63 12,63 4,76 7,43 8,99 8,38 10,10 10,28 10,28 10,43 10,50 10,51 12,06 12,06 12,06 4,55 7,10 8,61 8,03 9,66 9,84 9,84 9,94 10,05 10,08 11,55 11,55 11,55 4,99 7,76 9,41 8,78 10,56 10,75 10,75 10,86 10,99 11,01 12,63 12,63 12,63 4,76 7,43 8,99 8,38 10,10 10,28 10,28 10,43 10,50 10,51 12,06 12,06 12,06 4,55 7,10 8,61 8,03 9,66 9,84 9,84 9,94 10,05 10,08 11,55 11,55 11,55 8,46 13,45 16,42 15,16 18,37 18,71 18,71 18,91 19,14 19,06 21,97 21,97 21,97 8,05 12,85 15,66 14,44 17,54 17,86 17,86 18,13 18,26 18,16 20,95 20,95 20,95 7,67 12,26 14,98 13,81 16,75 17,07 17,07 17,25 17,45 17,38 20,03 20,03 20,03

NOTE : Model of Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E MCA : Minimum Circuit Amps. ICF : Maximum Instantaneous Current Flow (Equivalent to MCA in case of inverter air conditioner) MOCP : Maximum Overcurrent Protection (Fuse only) MSC : Maximum Starting Current Indoor temp. C FLA : Full Load Amps. Outdoor temp. C RLA : Rated Load Amps. RLA under conditions on the right.

DB 27 35

WB 19

2. REFRIGERANT R410A
This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer. The working pressure of the new refrigerant R410A is 1,6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time. The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work. (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 large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level. If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result. (7) Be sure to carry out installation or removal according to the installation manual. Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc. (8) Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician. Improper repairs may result in water leakage, electric shock and fire, etc.

2-1. Safety During Installation/Servicing

As R410As pressure is about 1,6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration. (1) Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A. If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture. (2) Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R410A. The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R22. (3) If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire, a poisonous gas may occur. (4) When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused.

2-2. Refrigerant Piping Installation

2-2-1. Piping Materials and Joints Used
For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants. (1) Copper Pipes It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface). Otherwise, the expansion valve or capillary tube may become blocked with contaminants. As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials. Thicknesses of copper pipes used with R410A are as shown in Table 2-2-1. Never use copper pipes thinner than 0,8 mm even when it is available on the market.

Table 2-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter 1/4 3/8 1/2 5/8 Outer diameter (mm) 6,35 9,52 12,70 15,88 R410A 0,80 0,80 0,80 1,00 R22 0,80 0,80 0,80 1,00

(2) Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used. Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 2-2-3 ~ 2-2-6 below.

b) Socket Joints Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm. Thicknesses of socket joints are as shown in Table 2-2-2.

Table 2-2-2 Minimum thicknesses of socket joints Nominal diameter 1/4 3/8 1/2 5/8 Reference outer diameter of copper pipe jointed (mm) 6,35 9,52 12,70 15,88 Minimum joint thickness (mm) 0,50 0,60 0,70 0,80

2-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner 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 and Precautions a) Cutting the Pipe By means of a pipe cutter, slowly cut the pipe so that it is not deformed. b) Removing Burrs and Chips If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation.

c) Insertion of Flare Nut d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure dimension A by using a gauge for size adjustment.
D A

Fig. 2-2-1 Flare processing dimensions

Table 2-2-3 Dimensions related to flare processing for R410A A (mm) Nominal diameter Outer diameter (mm) 6,35 9,52 12,70 15,88 Thickness (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 1,0 to 1,5 1,0 to 1,5 1,0 to 1,5 1,0 to 1,5 Wing nut type 1,5 to 2,0 1,5 to 2,0 2,0 to 2,5 2,0 to 2,5

1/4 3/8 1/2 5/8

0,8 0,8 0,8 1,0

Table 2-2-4 Dimensions related to flare processing for R22 A (mm) Nominal diameter Outer diameter (mm) 6,35 9,52 12,70 15,88 Thickness (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 0,5 to 1,0 0,5 to 1,0 0,5 to 1,0 0,5 to 1,0 Wing nut type 1,0 to 1,5 1,0 to 1,5 1,5 to 2,0 1,5 to 2,0

1/4 3/8 1/2 5/8

0,8 0,8 0,8 1,0

Table 2-2-5 Flare and flare nut dimensions for R410A Nominal diameter 1/4 3/8 1/2 5/8 Outer diameter (mm) 6,35 9,52 12,70 15,88 Thickness (mm) 0,8 0,8 0,8 1,0 Dimension (mm) A 9,1 13,2 16,6 19,7 B 9,2 13,5 16,0 19,0 C 6,5 9,7 12,9 16,0 D 13 20 23 25 Flare nut width (mm) 17 22 26 29

Table 2-2-6 Flare and flare nut dimensions for R22 Nominal diameter 1/4 3/8 1/2 5/8 3/4 Outer diameter (mm) 6,35 9,52 12,70 15,88 19,05 Thickness (mm) 0,8 0,8 0,8 1,0 1,0 Dimension (mm) A 9,0 13,0 16,2 19,4 23,3 B 9,2 13,5 16,0 19,0 24,0 C 6,5 9,7 12,9 16,0 19,2 D 13 20 20 23 34 Flare nut width (mm) 17 22 24 27 36

45

~46

43

~45

Fig. 2-2-2 Relations between flare nut and flare seal surface

(2) Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 2-2-7 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 2-2-7 Tightening torque of flare for R410A [Reference values] Nominal diameter 1/4 3/8 1/2 5/8 Outer diameter (mm) 6,35 9,52 12,70 15,88 Tightening torque Nm (kgfcm) 14 to 18 (140 to 180) 33 to 42 (330 to 420) 50 to 62 (500 to 620) 63 to 77 (630 to 770) Tightening torque of torque wrenches available on the market Nm (kgfcm) 16 (160), 18 (180) 42 (420) 55 (550) 65 (650)

10

2-3. Tools
2-3-1. Required Tools
The service port diameter of packed valve of the outdoor unit in the air conditioner using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For 12,7 copper pipe) of the refrigerant piping are lengthened. The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types. (1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) (2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22) (3) Tools commonly used for R410A and for conventional refrigerant (R22) The table below shows 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
R410A air conditioner installation No. Used tool Usage Existence of new equipment for R410A Yes Yes Yes Yes Yes Yes Yes Yes (Note 2) Whether conventional equipment can be used Conventional air conditioner installation Whether new equipment can be used with conventional refrigerant

Flare tool Copper pipe gauge for adjusting projection margin Torque wrench (For 12,7) Gauge manifold Charge hose Vacuum pump adapter Electronic balance for refrigerant charging Refrigerant cylinder Leakage detector Charging cylinder

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

*(Note 1) *(Note 1)
X X X X X X X

*(Note 1)
X X

X X

(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) 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 6,35) (3) Pipe cutter (4) (5) (6) (7) (8) Reamer Pipe bender Level vial Screwdriver (+, ) Spanner or Monkey wrench (9) Hole core drill (65) (10) Hexagon wrench (Opposite side 5mm) (11) Tape measure (12) Metal saw

Also prepare the following equipments for other installation method and run check.
(1) Clamp meter (2) Thermometer (3) Insulation resistance tester (4) Electroscope

11

2-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.
Recover the refrigerant, and check no refrigerant remains in the equipment.

Connect the charge hose to packed valve service port at the outdoor units gas side.

When the compound gauges pointer has indicated 0,1 Mpa (76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pumps power switch.

Connect the charge hose of the vacuum pump adapter.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauges pointer does not return.

Open fully both packed valves at liquid and gas sides.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant. (For refrigerant charging, see the figure below.)

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pumps power switch. Then, evacuating the refrigerant in the cycle.

Never charge refrigerant exceeding the specified amount. If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode. Do not carry out additional charging. When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

(INDOOR unit)

(Liquid side)

(OUTDOOR unit)

Opened (Gas side) Refrigerant cylinder (With siphon pipe) Check valve Closed

Open/Close valve for charging

Service port Electronic balance for refrigerant charging

Fig. 2-4-1 Configuration of refrigerant charging

12

Be sure to make setting so that liquid can be charged. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.
[ Cylinder with siphon ]
Gauge manifold OUTDOOR unit

[ Cylinder without siphon ]

Gauge manifold OUTDOOR unit

Refrigerant cylinder Electronic balance

R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

Fig. 2-4-2

2-5. Brazing of Pipes

2-5-1. Materials for Brazing
(1) Silver brazing filler Silver brazing filler is an alloy mainly 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 adhesive strength, do not use it for refrigerant pipes.

2-5-2. Flux
(1) Reason why flux is necessary By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler. In the brazing process, it prevents the metal surface from being oxidized. By reducing the brazing fillers surface tension, the brazing filler adheres better to the treated metal.

13

Refrigerant cylinder Electronic balance Siphon

Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint. When performing brazing again at time of servicing, use the same type of brazing filler.

(2) Characteristics required for flux Activated temperature of flux coincides with the brazing temperature. Due to a wide effective temperature range, flux is hard to carbonize. It is easy to remove slag after brazing. The corrosive action to the treated metal and brazing filler is minimum. It excels in coating performance and is harmless to the human body. As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc. (3) Types of flux Noncorrosive flux Generally, it is a compound of borax and boric acid. It is effective in case where the brazing temperature is higher than 800C. Activated flux Most of fluxes generally used for silver brazing are this type. It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound. (4) Piping materials for brazing and used brazing filler/flux

2-5-3. Brazing
As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified. In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitrogen gas.

(1) Brazing method to prevent oxidation

Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder. Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder. Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas. When the Nitrogen gas is flowing, be sure to keep the piping end open. Adjust the flow rate of Nitrogen gas so that it is lower than 0,05 m3/Hr or 0,02 MPa (0,2kgf/ cm2) by means of the reducing valve. After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands). Remove the flux completely after brazing.

Piping material Copper - Copper Copper - Iron Iron - Iron

Used brazing filler Phosphor copper Silver Silver

Used flux Do not use Paste flux Vapor flux

Stop valve Nitrogen gas cylinder From Nitrogen cylinder

M Flow meter

Do not enter flux into the refrigeration cycle. When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine. When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water). Remove the flux after brazing.

Pipe Nitrogen gas Rubber plug

Fig. 2-5-1 Prevention of oxidation during brazing

14

3. CONSTRUCTION VIEWS
3-1. Indoor Unit RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

Front panel Back body

Air inlet

Air filter 790

Heat exchanger

208

60

275

Air outlet Knock out system

48

Knock out system

64 53 120 590 Hanger 80

Drain hose (0.54m) Hanger

320

Connecting pipe (0.43m) (Flare 6.35) Connecting pipe (0.33m) (For 10,13 series ; Flare 9.52 For 16 series ; Flare 12.7) 235 215 For stud bolt (8~10) For stud bolt (6)

620 235 215

Minimum distance to ceiling

65 or more

Hanger

26

48

45

275

190

Minimum distance to ceiling

Minimum distance to ceiling

45

170 or more

170 or more

Hanger 90 150 160 160

Hanger

32

40

57

18

90 150 Installation plate outline Center line

Wireless remote control

15

160

60

3-2. Outdoor Unit

RAS-3M23YACV-E
(Anchor bolt long hole pitch)

A leg part

600 50

90

11 17U-shape hole (For 8-10 anchor bolt)

(6 hole pitch)

310

296

270

8-6 hole (For fixing outdoor unit) 11 17 long hole (For 8-10 anchor bolt)
18 115,5

B leg part Fan guard

Hanger
687 695

Valve cover
53

Charging port

53

53

780

68,5

123,8 332

Connecting pipe port (Pipe dia.6,35)

Detailed A leg part

600 Connecting pipe port (Pipe dia.9,52) Connecting pipe port (Pipe dia.12,7) 50 36 11 R15

Z view
310
R5,5

Outside line of product 296 2-6 hole

Mounting dimensions of anchor bolt 600 50 or more 4 11 17U-shape hole (For 8-10 anchor bolt) Intake D A

2-6 hole 310 296 11 Outside line of product

Intake 310

250 or more

C 100 or more 200 or more Outside line of product Outlet B

(Minimum distance from wall) 36 50

R15
,5 R5

For installation of the outdoor unit, open (60cm or more) two directions at least of A , B , C , and D directions.

4 11 17 long hole (For 8-10 anchor bolt)

600

Detailed B leg part

16

86,2

53

53

4. WIRING DIAGRAM
4-1. Indoor Unit
RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E

Table 4-1-1 Simple check points for diagnosing faults

Check items Diagnosis result
Check to see if the OPERATION indicator goes on and off when the main switch or breaker is turned on. (Check the primary and secondary voltage of transformer.)

1 2
3 4 5 6

OPERATION INDICATOR TERMINAL BLOCK FUSE 6.3A DC 5V DC 12V DC 35V

(DC310 ~ 340V)

Check for power supply voltage between and . (Refer to the name plate.) (Check the primary and secondary voltage of transformer.) Check for fluctuate voltage between . (DC 15 ~ 60V) Check to see if the fuse blows out. (Check the R04 of the varistor.) Check the voltage at the No.4 pin on CN13 connector of the infrared receiver. (Check the transformer and the power supply circuit of the rated voltage.) Check for voltage at the while lead of louver motor. (Check the transformer and the power supply circuit of the rated voltage.) Check the voltage at the No.1 pin on CN10 connector. (Check the DB01, R05 and C03.)

Color Identification BRW : BROWN RED : RED WHI : WHITE YEL : YELLOW BLU : BLUE BLK : BLACK GRY : GRAY PNK : PINK ORN : ORANGE GRN : GREEN & &YEL YELLOW GRN : GREEN

Refer to the service data for the detailed failure diagnosis.

17

4-2. Outdoor Unit

RAS-3M23YACV-E

POWER To SUPPLY INDOOR 220230240V~ UNIT 50Hz A

To INDOOR UNIT B

To INDOOR UNIT C

~~~
L N

~~~~
1 2 3

~~~~
1 2 3

~~~~
1 2 3 4

FAN MOTOR REACTOR

FM
REACTOR REACTOR
GRY PNK
1 2 1 2

5 4 3 2 1 5 4 3 2 1

RED WHI BLK

1 2 3 1 2 3

YEL

BLK P06

P08

P07

CN301 CN300

WHI SURGE ABSORBER

BLK

THERMOSTAT for COMPRESSOR PNK P03 ORN P04 RED P05 WHI P06 BRW 1 1 RED 2 2 ORN 3 3 CN15 YEL 4 4 CN08 2 2
1 1 1 1

ORN TD

P.C. BOARD MCC-758

P09 ORN P10 POWER RELAY
CONVERTER MODULE

F01 FUSE 25A CT VARISTOR

1 BRW 2 RED CN704 3 ORN 4 YEL 1 1

BLK

CN02 2 2
3 3

C13

C15 F03 FUSE 15A CN501

F01 FUSE 6,3A

CN03 1 1 2 2
1 1

BLK

TO

G E A ~ ~ + P19 P20

BLK P02 GRY P01 YEL

BLK YEL BLK BRW BLK GRN GRY RED BLU ORN YEL WHI GRY RED BLU ORN YEL WHI GRY RED BLU ORN YEL WHI

TGa

3 3

CN05 2 2
3 3

ELECTRONIC STARTER C12 C14

P11 P12 P13 P14

DB01 YEL

F04 FUSE 3,15A RELAY

1 1 2 2

TGb

1 1

YEL REACTOR PUR PHOTO COUPLER

CN06 2 2
3 3

TGc

1 1

CN07 2 2
3 3 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1

+ BU EU BV EV BW EW BX BY BZ P18 P17

IGBT MODULE

CN14

P.M.V. A UNIT

SUB P.C. BOARD MCC-775

CN13

P.M.V. B UNIT

Q200 BLU

P21 RED 1 1 P22 WHI 2 2 P23 BLK 3 3

CM

CN12

P.M.V. C UNIT

COMPRESSOR

COLOR IDENTIFICATION
BLK BLU ORN GRY PNK SKB : BLACK : BLUE : ORANGE : GRAY : PINK : SKY-BLUE WHI BRW RED YEL PUR GRN : WHITE : BROWN : RED : YELLOW : PURPLE : GREEN

P.M.V. : PULSE MODULATING VALVE

18

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor Unit
RAS-M10YKCV-E, RAS-M13YKCV-E, RAS-M16YKCV-E
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Parts name Fan motor (for indoor) Thermo. sensor (TA-sensor) DC-DC transformer (T01) Microcomputer Heat exchanger sensor (TC-sensor) Line filter (L01) Diode (DB01) Capacitor (C03) Fuse (F01) Power supply IC (IC01) Varistor (R21, R109) Resistor (R01) Louver motor Type ICF-340-30-2 () SWT-70 () () SS11V-06270 D3SBA60 KMH450VNSN120M25C FCU250V3.15A STR-L472 15G561K RF-5TK5R6 MP24GA 10k at 25C 27mH, AC0,64A 4A, 600V 120F, 450V T3,15A, 250V 560V 4,7, 5W Output (Rated) 1W, 16poles, 1phase DC12V Specifications DC340V, 30W 10k at 25C DC390V, Secondary DC15V, 12V, 7V

5-2. Outdoor Unit

RAS-3M23YACV-E
No. 1 2 3 4 5 6 7 8 9 10 11 Parts name SC coil (Noise filter) DC-DC transformer Reactor Outside fan motor Fan control relay Discharge temp. sensor (TD sensor) Outside air temp. sensor (TO sensor) Temp. sensor at A room gas side (TGa sensor) Temp. sensor at B room gas side (TGb sensor) Temp. sensor at C room gas side (TGc sensor) Terminal block (9P) Model name SC-15-S06J SC-20-01J SWT-43 CH38Z-K ICF-140-40-8 AJQ1341 (Inverter attached) (Inverter attached) (Inverter attached) (Inverter attached) (Inverter attached) For protection of switching power source For protection of transistor module breakage For protection of inverter input overcurrent LLQ2G501KHUATF 400LISN500K35F 6MBI25GS-060-01 DA130A1F-21F PW-2AL MP7002 CH43Z-K Rating 15A, 0,6mH 20A, 150H Primary side DC280V Secondary side 7,5V x 1, 13V x 1 26,5V x 3, 16V x 1, 15V x 1 L=10mH, 16A x 2 DC140V, 40W Coil DC12V Contact AC125V, 3A 62k (20C) 10k (25C) 10k (25C) 10k (25C) 10k (25C) 20A, AC250V (9P x 2)

3,15A, AC250V 15A, 25A, AC250V AC250V

12

Fuse

13 14 15 16 17 18

Electrolytic capacitor Transistor module Compressor Compressor thermo. Converter module Reactor

500F, DC400V X 4 pieces 25A, 600V 3-phases 4-poles 1100W OFF: 125 4C, ON: 90 5C Diode: 25A, 600V, IGBT: 40A, 600V L = 10mH, 1A x 2

19

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram
INDOOR UNIT A
Indoor heat exchanger
T1

Temp. measurement

To To C room B room

To To C room B room

Cross flow fan

Allowable height difference : 10m

Connecting pipe Thickness : 0,8 mm 9,52 : RAS-M10UKCV-E RAS-M13UKCV-E 12,7 : RAS-M16UKCV-E

Pressure measurement Gauge attaching port Vacuum pump connecting port
P

Allowable pipe length

Per 1 unit Max. : 20m Min. : 2m Total Max. : 40m

Connecting pipe Thickness : 0,8 mm 6,35

Sectional shape of heat insulator

(9,52) (9,52) (12,7) (6,35) (6,35) (6,35)

Strainer
TGc TGb TGa

Pulse modulating valve at liquid side (SEV15RC2)

Accumulating tank 51 x 300 (460cc)
TD

Compressor DA130A1F-21F

Outdoor heat exchanger

Temp. measurement T2

Propeller fan Refrigerant amount : 1,5kg (R410A)

OUTDOOR UNIT

NOTE :

Gas leak check position Refrigerant flow

NOTE : The maximum pipe length of this air conditioner is 40 m. The additional charging of refrigerant is unnecessary because this air conditioner is designed with charge-less specification.

20

6-2. Operation Data

No. of operating Indoor Outdoor units Temperature condition (C) Combinations of indoor units 10 1 unit 13 16 10 13 16 2 units 27/19 35/ 13 16 16 10 13 3 units 16 13 10 13 10 10 0,98 0,98 12 to 13 12 to 13 52 52 High High High High 89 89 13 13 16 10 10 10 10 0,92 0,92 0,92 1,04 0,98 11 to 12 11 to 12 11 to 12 12,5 to 13,5 12 to 13 51 51 51 51 52 High High High High High High High High High High 78 78 78 81 89 10 10 10 Standard pressure P (Mpa) 0,92 0,85 0,73 0,96 0,92 0,92 Surface temp. of heat exchanger T1 (C) 11 9 8 10,5 to 11,5 11 to 12 11 to 12 T2 (C) 42 47 50 49 51 51 Compressor revolution (rps) Indoor Outdoor High High High High High High Med. High High High High High 37 57 73 69 78 78 Fan speed

NOTE : Model of Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E NOTES : (1) Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent. (Thermistor themometer) (2) Connecting piping condition : 5 meters x 3 units (5m / each unit)

21

7. CONTROL BLOCK DIAGRAM

7-1. Indoor Unit RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E
Indoor Unit Control Panel M.C.U. Heat Exchanger Sensor Functions Louver Control 3-minute Delay at Restart for Compressor Motor Revolution Control Infrared Rays Signal Receiver Processing (Temperature Processing) Timer Filter Sign Display Operation Display Timer Display

Temperature Sensor

Infrared Rays

Initiallizing Circuit Clock Frequency Oscillator Circuit

Fan Only Sign Display

Indoor Fan Motor Power Supply Circuit

Remote Control

Outdoor unit ON/OFF Signal

Louver ON/OFF Signal

Noise Filter

Relay Driver Relay RY04

Louver Driver

Louver Motor

From Outdoor Unit

Outdoor Unit

REMOTE CONTROL
Remote Control Operation (START/STOP) Operation Mode Selection AUTO, COOL, DRY, FAN ONLY Temperature Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver Auto Swing Louver Direction Setting ECONO.

Infrared Rays

22

For Indoor unit

220230240V ~ 50Hz

MCC-775 (SUB P.C.B)

C unit send/receive circuit

MCC-758 (MAIN P.C.B)

M.C.U
PWM synthesis function Input current release control IGBT over-current detect control Outdoor fan control High power factor correction control Signal communication to MCU Over current detect circuit Gate drive circuit Rotor position detect circuit Rotor position detect circuit

7-2. Outdoor Unit (Inverter Assembly)

A unit send/receive circuit

B unit send/receive circuit

Discharge temp. sensor

M.C.U

Inverter output frequency control

23
High power factor correction circuit Over current detect circuit Noise filter Input current Sensor Converter DC) (AC C unit P.M.V.

A/D converter function

Gas side A, B, C pipe temp. sensor

P.M.V. control Gate drive circuit

Discharge temp. control

Error display

Outdoor air temp. sensor

Signal communication to MCU Over current sensor Inverter (DC AC)

Outdoor fan motor

Driver circuit of P.M.V.

A unit P.M.V.

B unit P.M.V.

Over current sensor

Inverter (DC AC)

Compressor

P.M.V. : Pulse Modulating Valve PWM : Pulse Width Modulation IGBT : Insulated Gate Bipolar Transistor

8. OPERATION DESCRIPTION
8-1. Outline of Air Conditioner Control
This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor fan motors and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 13 to 120 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control fan motor are mounted to the outdoor unit. The entire air conditioner is mainly controlled by the indoor unit controller. The indoor unit controller drives the indoor fan motor based upon command sent from the remote control, and transfers the operation command to the outdoor unit controller. The outdoor unit controller receives operation command from the indoor unit side, and controls the outdoor fan and the pulse modulating valve. Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors drive according to the operation command. And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller. As the compressor adopts four-pole brushless DC motor, the frequency of the supply power from inverter to compressor is two-times cycles of the actual number of revolution. (1) Role of indoor unit controller The indoor unit controller judges the operation commands from the remote control and assumes the following functions. Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor. Temperature setting of the indoor heat exchanger by using heat exchanger sensor (Prevent-freezing control) Louver motor control Indoor fan motor operation control LED display control Transferring of operation command signal (Serial signal) to the outdoor unit Reception of information of operation status (Serial signal including outside temp. data) to the outdoor unit and judgment/display of error (2) Role of outdoor unit controller Receiving the operation command signal (Serial signal) from the indoor 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 of inverter input current and current release operation Over-current detection and prevention operation to transistor module (Compressor stop function) Compressor and outdoor fan stop function when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system) Transferring of operation information (Serial signal) from outdoor unit to indoor unit Detection of outdoor temperature and operation revolution control (3) Contents of operation command signal (Serial signal) from indoor unit controller to outdoor unit controller The following three types of signals are sent from the indoor unit controller. Operation mode set on the remote control Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.) For these two types of signals ( [Operation mode] and [Compressor revolution] ), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value. Temperature of indoor heat exchanger by indoor heat exchanger sensor (Minimum revolution control)

24

(4) Contents of operation command signal (Serial signal) from outdoor unit controller to indoor unit controller The following signals are sent from the outdoor unit controller. The current operation mode The current compressor revolution Outdoor temperature Existence of protective circuit operation For transferring of these signals, the indoor unit controller monitors the contents of signals, and judges existence of trouble occurrence. Contents of judgment are described below. Whether distinction of the current operation status meets to the operation command signal Whether protective circuit operates When no signal is received from the outdoor unit controller, it is assumed as a trouble.

8-1-2. Current Release Control

The outdoor main circuit control section (Inverter assembly) detects the input current to the outdoor unit. If the current value with compressor motor speed instructed from indoor side exceeds the specified value, the outdoor main circuit control section controls compressor motor speed by reducing motor speed so that value becomes closest to the command within the limited value.

8-1-3. Power Factor Improvement Control

Power factor improvement control is performed mainly aiming to reduce the current on much power consumption of cooling operation. Controlling starts from the time when input power has reached at a certain point. To be concrete, IGBT of the power factor improvement circuit is used, and the power factor is improved by keeping IGBT on for an arbitrary period to widen electro-angle of the input current.

8-1-1. Capacity Control

The cooling capacity is varied by changing compressor motor speed. The inverter changes compressor motor speed by changing AC 220230240V power to DC once, and controls capacity by changing supply power status to the compressor with transistor module (includes 6 transistors). The outline of the control is as follows: The revolution position and revolution speed of the motor are detected by detecting winding electromotive force of the compressor motor under operation, and the revolution speed is changed so that the motor drives based upon revolution speed of the operation command by changing timing (current transfer timing) to exchange inverter output voltage and supply power winding. Detection of the revolution position for controlling is performed 12 times per 1 revolution of compressor. The range of supply power frequency to the compressor differs according to the operation status (COOL, DRY). Table 8-1-1 Compressor revolution range
No. of operating unit 1 unit 2 units 3 units Combination of indoor units RAS-M16UKCV-E RAS-M13YKCV-E RAS-M10YKCV-E Compressor revolution (rps) 16 to 77 16 to 72 16 to 45 19 to 84 23 to 92

8-1-4. Prevent-Freezing Control

The indoor heat exchanger sensor detects refrigerant vapor temperature in COOL/DRY operation. If the temperature is below the specified value, compressor motor speed is reduced so that operation is performed in temperature below the specified value to prevent-freezing of indoor heat exchanger.

8-1-5. P. M. V. (Pulse Modulating Valve)

Using P.M.V., refrigerant flow of refrigeration cycle is varied for the optimum temperature. Controlling each unit separately by three P.M.V. corresponds to difference of pipe length, fan speed, and unit temperature. If an error occurs on cycle temperature when power source of the air conditioner has been turned on, and if start/stop times of the outdoor unit are 30 times, move the valve once until it hits on the stopper for positioning of the valve. In this case, ticktack sound may be heard.

* *

* : In case that any multiple indoor units are combined.

25

8-1-6. Louver Control

(1) Vertical air flow louvers Positions of vertical air flow louvers are automatically controlled according to the operation status (COOL, AUTO, DRY, FAN ONLY). Besides, positions of vertical air flow louvers can be arbitrarily set by pressing the [SET] button. The louver position which has been set by the [SET] button is stored in microcomputer, and the louver is automatically set at the stored position in the next operation. (2) Swing If the [AUTO] button is pressed during running operation, vertical air flow louvers start swinging. When the [AUTO] button is pressed again, swinging stops.

8-1-7. Indoor Fan Control (DC Fan Motor)

The indoor fan is operated by motor speed non-step variable DC drive system motor. For flow rate, motor speed is controlled manually in three steps (LOW, MED, HIGH), and with the unit of 10 rpm from upper limit to lower limit in AUTO mode as described in Table 8-1-3. It is not selected by relay, so selecting sound does not generate.

Operation mode Cooling and Fan only

Fan mode H M+ M L+ L LL+ L LUL SUL

Remote Control HIGH MED+ MED LOW+ LOW

Motor speed ( rpm )

RAS-M10UKCV-E 560 510 510 460 440 430 400 370 430 400 370 300 260

Table 8-1-3

DRY

1190 1080 1100 1000 960 950 910 850 950 910 850 720 660

Air flow rate ( m3/h )

Motor speed ( rpm )

RAS-M13UKCV-E 590 530 530 490 460 430 400 370 430 400 370 310 280

1210 1130 1130 1050 990 950 910 850 950 910 850 750 700

Air flow rate ( m3/h )

Motor speed ( rpm )

RAS-M16UKCV-E 670 610 610 550 500 490 450 410 490 450 410 410 340

1350 1250 1250 1150 1070 1050 980 920 1050 980 920 920 800

Air flow rate ( m3 /h )

NOTE : UL : Ultra Low,

SUL : Super Ultra Low

8-1-8. Outdoor Fan Control (DC Fan Motor)

Although the outdoor fan motor drives the outdoor fan by non-step variable system of the revolution speed, the revolution speed is restricted to three steps on the convenience of controlling. If a strong wind is lashing outside of the room, the operation may be continued as the outdoor fan stops in order to protect the outdoor fan motor. If a fan lock occurred due to entering of foreign matter, the air conditioner stops and an alarm is displayed. Table 8-1-4
Compressor revolution (rps) TO 38C Outdoor temp. sensor TO 38C > TO 15C 15C > TO TO 38C ECONO. operation 38C > TO 15C 15C > TO TO is abnormal

~ 17,4
500 (rpm) 500 (rpm) 390 (rpm) 500 (rpm) 500 (rpm) 390 (rpm) 700 (rpm)

~ 38,9
800 (rpm) 700 (rpm) 390 (rpm) 700 (rpm) 500 (rpm) 390 (rpm) 700 (rpm)

39 ~ 800 (rpm) 800 (rpm) 390 (rpm) 800 (rpm) 700 (rpm) 390 (rpm) 800 (rpm)

26

8-2. Description of Operation Circuit

Turning [ON] the breaker flashes the operation lamp. This is the display of power-ON (or notification of power failure). When pushing [START/STOP] button of the remote control, receive sound is issued from the main unit, and the next operations are performed together with opening the vertical air flow louvers.

8-2-2. Cooling Operation (The Remote Control MODE Button is Set to the COOL Position)
Once the setting is made, the operation mode is memorized in the microcomputer so that the same operation can be effected thereafter simply by pushing [START/STOP] button. A cooling operation signal is transmitted to outdoor unit. The indoor fan motor operates as shown in Fig.82-2 when FAN button is set to AUTO.

8-2-1. Fan Only Operation (The Remote Control MODE Button is Set to the FAN ONLY Operation)
Once the setting is made, the operation mode is memorized in the microcomputer so that the same operation can be effected thereafter simply by pushing [START/STOP] button. When the FAN button is set to the AUTO position, the indoor fan motor operates as shown in Fig. 82-1. When the FAN SPEED button is set to LOW, MED, or HIGH, the motor operates with a constant air flow. ECONO. mode cannot be set.
C +3 +2,5 +2 +1,5 +1 +0,5 0 M+ *1 *1 *1 L

The motor operates with a constant air flow when the FAN button is set to LOW, MED, or HIGH. The outdoor unit controls the outdoor fan relay R01, R02 and R03, and the compressor motor speed according to the operation command signal sent from the indoor unit.

(Room temp.) (Set temp.)

(Room temp.) (Set temp.)

C +3 +2,5 +2 +1,5 +1 +0,5 0 0,5 M+ *1 *1 *1 L In normal operation

Set temp.

(Set temp.) 25C

Set temp.

NOTE : *1: Calculated from difference in motor speed of M+ and L, and controlled. Fig. 8-2-1 Auto setting of air flow

NOTE : *1: Calculated from difference in motor speed of M+ and L, and controlled. Fig. 8-2-2 Setting of air flow [FAN AUTO]

27

(1) Cooling capacity control The cooling capacity and room temperature are controlled by changing the compressor motor speed according to both the difference between the temperature detected by the room temperature sensor and the temperature set by TEMP button and also any change in room temperature. When compressor has been activated or reactivated, it operates with Max. 33 rps for 2 minute, with Max. 57 rps from 2 to 4 minutes, with Max. 91 rps from 4 to 7 minutes, and with Max. 92 rps after 7 minutes passed. When room temperature is lower than set temperature, indoor fan motor is operated at fan speed L as shown in Fig. 8-2-2 while the outdoor unit stops. (2) Prevent-freezing control If temperature of indoor heat exchanger detected by the indoor heat exchanger sensor is 5C or lower, compressor motor speed is gradually lowered to prevent freezing of the indoor heat exchanger. If temperature is 7C or higher, return the operation to the above item (1). (3) Current release control The input current of compressor and outdoor fan motor (Precisely inverter main circuit control section) which occupy most of air conditioner input is detected by the outdoor current sensor, and compressor motor speed is gradually lowered so that current value does not exceed 11A if current value exceeds 11A. When the current value lowers to 12A, return the operation to the above item (1).
Current value (A) Comp. motor speed down

(4) Outdoor temperature release control The outdoor temperature release is controlled by changing the current release points 11 and 12 in the above item according to temperature detected by the outdoor temperature sensor. For example, if the outdoor temperature is over 40C, the value of current release point becomes 7,7A. (5) Limit for maximum compressor motor speed by indoor fan speed When outdoor temperature sensor detected 32C or lower, and indoor heat exchanger sensor detected 17C or lower, the maximum compressor motor speed is limited by the indoor fan speed. For example, when 1 unit only operates, the compressor motor speed is limited as described in the table below. Table 8-2-2
Air flow rate HIGH M+ MED. L, L UL, SUL M10UKCV-E M13UKCV-E M16UKCV-E (rps) (rps) (rps) 45 42 34 31 31 72 59 40 31 31 77 66 54 43 31

(6) Louver control The vertical air flow louvers are automatically set to horizontal or cool memory position. When temperature of indoor heat exchanger becomes 5C or lower by the prevent-freezing control and the compressor is turned off, the vertical air flow louvers close once and then return to the position of previous time. (7) Discharge temperature control The discharge temperature of refrigerant gas from the compressor is detected by the discharge temperature sensor, and controls operating compressor motor speed. 1) Control 1 (A zone) : Normal operation zone When TD detect value is 101C or lower, the operation is performed with operating motor speed instructed by the serial signal. 2) Control 2 (B zone) : Slow-up zone of motor speed When TD detect value is 101C or higher, operating motor speed is slowly up.

I1

I2 Normal control

Comp. motor speed keep

Fig. 8-2-3 Table 8-2-1 Current value 11 12 Current limit 9.5 9,0

28

3) Control 3 (C zone) : Keep zone When TD detect value is 108C or higher, operating motor speed is not changed if raising operation speed. 4) Control 4 (D zone) : Slow down zone of motor speed When TD detect value is 111C or higher, operating motor speed is slowly down.
TD (C) 120 115 111 Zone F E D

5) Control 5 (E zone) : Normal down of motor speed When TD detect value is 115C or higher, operating motor speed is down. 6) Control 6 (F zone) : Operation stop zone If TD detect value exceeds 120C during operation, stop the operation immediately. Then, restart the operation when TD detect value becomes 108C or lower.

Operation stop zone Normal down zone of motor speed Release of motor speed Slow down of motor speed

108 101

C B A

Keep zone : Motor speed is not changed.

Slow-up zone of motor speed Normal operation zone

Fig. 8-2-4 Compressor motor speed control (8) ECONO. operation control When the ECONO. button of the remote control is pushed, quiet and mild operation is performed by restraining air flow and operating motor speed. 1) Indoor air flow is controlled between SUL and L (Low air ()). 2) Setting M10UKCV-E at 16 rps, M13UKCV-E at 20 rps and M16UKCV-E at 26 rps as the maximum operating compressor motor speed, the minimum capacity operation range is widened every 1 hour and 2 hours have passed after ECONO. operation had started. 3) Maximum operating compressor motor speed lowers up to 37 rps when the ECONO. instruction is sent from even a room.
1 unit 2 units 3 units 37 rps

Compressor motor speed

3,5
(Room temp.) (Set temp.)

Air volume M10UKCV-E M13UKCV-E M16UKCV-E L (L + SUL)/2 16 rps 16 rps 20 rps 26 rps 37 rps

16 to 20 rps 16 to 26 rps 19 to 37 rps 23 to 37 rps

3 2,5 2 1,5 1 0,5 1H 2H Time SUL 16 rps 16 rps 16 rps 19 rps 23 rps

Fig. 8-2-5

29

8-2-3. DRY Operation (The Remote Control MODE Button is Set to the DRY Position)
Once the setting is made, the operation mode is memorized in the microcomputer so that the same operation can be effected thereafter simply by pushing [START/STOP] button. Dry operation signal is transmitted to outdoor unit. The Cooling operation giving priority to dehumidifying, which restrains the indoor fan speed and compressor motor speed, is performed. The indoor fan motor operates as shown in Fig. 8-2-6. (Fan speed is AUTO only.) The outdoor unit controls the outdoor fan relay R01, R02 and R03, and the compressor motor speed according to the operation command signal sent from the indoor unit.

When the air conditioner operates in Dry mode, the maximum compressor motor speed is restricted. M10UKCV-E : Max. 22 rps M13UKCV-E : Max. 28 rps M16UKCV-E : Max. 32 rps While multiple indoor units operate, compressor motor speed is calculated in the outdoor unit to operate. When room temperature is lower than set temperature, indoor fan motor is operated at fan speed SUL as shown in Fig. 8-2-6 while the outdoor unit stops. ECONO. mode cannot be set. Other controls than the above-mentioned controls are common to those of Cooling operation.

8-2-4. Auto Operation

+2,5 (Room temp.) (Set temp.) +2,0 +1,5 *1 +1,0 SUL +0,5 0 0,5 L

The operation mode is selected according to the outdoor temperature when Auto operation has started, as shown in Fig. 8-2-7. The Fan only mode will continue until the operation mode is selected. The air flow display on the remote control becomes AUTO.

Outdoor temp. (C) Powerful Cool mode 32 Cool mode 22

Set temp.

NOTE : *1 : Middle motor speed between L and SUL Fig. 8-2-6 Setting of air flow Fig. 8-2-7 (1) Dehumidifying-preferential Cooling capacity control The cooling capacity and room temperature are controlled by changing the compressor motor speed according to both the difference between the temperature detected by the room temperature sensor and the temperature set by TEMP button and also any change in room temperature. The compressor operates with maximum 28 rps for 1 minute when started and restarted. If the compressor is turned off by room temperature or outdoor temperature for 15 minutes consecutively after operation mode has been selected, the operation mode is selected again. In Powerful Cool mode, the louver directs downward, and air flow increases. When room temperature comes close to the set temperature, the louver returns to Cooling operation position. The other controls than the above-mentioned controls follow that of each operation.
Fan Only mode

30

8-3. Temporary Operation

Temporary Auto operation, existence of Auto Restart, and Temporary Cooling operation can be set by the TEMPORARY button of the indoor controller.

8-3-1. Temporary Auto Operation

When the TEMPORARY button is pushed, the Auto operation with set temperature fixed at 24C starts. Controlling is same as that of Auto operation by the remote control. When the TEMPORARY button is pushed again, the operation stops. During Temporary Auto operation, operation by the remote control is accepted.
0

Using the Auto Restart function, the Temporary Auto operation starts when power failure is reset.
3S

TEMPORARY button

8-3-2. Temporary Cooling Operation

When the TEMPORARY operation button keeps pushed for 10 seconds, Cooling operation of which compressor motor speed and the indoor fan speed are fixed starts. Compressor motor speed : 28 rps
Control

Fig. 8-3-1

Table 8-3-1
TEMPORARY button OFF ON After pushing button for 3 seconds After pushing button for 10 seconds

Indoor fan speed : Low When the TEMPORARY operation button is pushed again, the operation stops. Auto Restart function is unavailable.

Temporary Auto operation start Auto Restart control select Temporary Cooling operation start

31

8-4. Auto Restart Function

This unit is equipped with an Automatic restarting facility which allows the unit to restart and resume the set operating conditions in the event of a power supply shutdown without the use of the hand control. The operation will resume without warning three minutes after the power is restored. The Auto Restart function is set not to work on shipment from the factory, and so it is necessary to set it to function as required.

8-4-1. How to Set the Auto Restart

To set the Auto Restart function, proceed as follows: Access the TEMPORARY button located in the lower right hand corner beneath the hinged front panel of the indoor unit (please refer to Fig. 8-3-1). The power supply to the unit must be on - the function will not be set if the power is off. To enable the Auto Restart function, push the TEMPORARY button continuously for three seconds. The unit will acknowledge the setting and beep three times. The system will now restart automatically. The above Auto Restart settings can be carried out:

When the system is stand-by (not operating) Operation Push the TEMPORARY button continuously more than three seconds. Motion Stand-by The system starts to operate. The green light goes on. about three seconds after The unit beeps three times. The orange light goes on. The system is operating. If the system is not required to run at this time, push the TEMPORARY button once more or use the remote control and the unit will stop.

3S

TEMPORARY button

When the system is operating Operation Push the TEMPORARY button continuously more than three seconds. Motion Operating The green light goes on. The system stops to operate. The green light goes off. about three seconds after The unit beeps three times. The system stops. If the system is not required to stop at this time, use the remote control and to restart.

3S

TEMPORARY button

During subsequent operation, the orange light goes on. The Auto Restart function will not accept an instruction if timer operation with the remote control is selected.

During louver swing (AUTO) operation, after restart by the Auto Restart function the louver swing stops.

32

8-4-2. How to Cancel the Auto Restart

To cancel the Auto Restart function, proceed as follows: Repeat the setting procedure: the unit will acknowledge the instruction and beep three times. When the system is stand-by (not operating) Operation Push the TEMPORARY button continuously more than three seconds.

The system will now be required to manually restart with the remote control after the main supply is turned off. Cancellation is carried out:

Motion Stand-by The system starts to operate. The orange light goes on. about three seconds after The unit beeps three times. The green light goes on. The system is operating. If the system is not required to run at this time, push the TEMPORARY button once more or use the remote control and the unit will stop.

3S

TEMPORARY button

When the system is operating Operation Push the TEMPORARY button continuously more than three seconds. Motion Operating The orange light goes on. The system stops to operate. The orange light goes off. about three seconds after The unit beeps three times. The system stops. If the system is not required to stop at this time, use the remote control and to restart.

3S

TEMPORARY button

During subsequent operation, the green light goes on.

8-4-3. In Case of Power Failure during the Timer Operation

(1) If ON-TIMER operation is reserved with setting of Auto Restart operation, it is cancelled with power failure. (The OPERATION lamp on the main unit goes on and off to inform of power failure.) In that case, try to reserve ON-TIMER operation once again.

(2) If OFF-TIMER operation is reserved without setting of Auto Restart operation, the reservation is cancelled with power failure. (The OPERATION lamp on the main unit goes on and off to inform of power failure.) In that case, try to reserve OFF-TIMER operation. When Auto Restart operation is set, OFF-TIMER reservation is also cancelled with power failure.

33

8-5. Remote control

8-5-1. Remote control and its functions

RAS-M10UKCV, RAS-M13UKCV, RAS-M16UKCV

1 Infrared signal emitter Transmits a signal to the indoor unit. 2 START/STOP button Press the button to start operation. (A receiving beep is heard.) Press the button again to stop operation. (A receiving beep is heard.) If no receiving sound is heard from the indoor unit, press the button twice. 3 Mode select button (MODE) Press this button to select a mode. Each time you press the button, a mode is selected in a sequence that goes from A : Auto changeover control, : Cool, : Dry, : Heat, : Fan only, and back to A. (A receiving beep is heard.) ) 4 Temperature button ( ,.......The set temperature is increased up to 30C. 9.......The set temperature is dropped down to 17C. (A receiving beep is heard.) 5 Fan speed button (FAN) Press this button to select fan speed. When you select AUTO, the fan speed is automatically adjusted according to the room temperature. You can also manually select the desired fan speed from among five settings. , MED , (LOW , LOW+ MED+ , HIGH ) (A receiving beep is heard.) 6 Auto louver button (SWING) Press this button to swing the louver. (A receiving beep is heard.) Press the FIX button to stop the louver swinging. (A receiving beep is heard.) 7 Set louver button (FIX) Press this button to adjust the air flow direction. (A receiving beep is heard.) 8 Off timer button (OFF) Press this button to set the OFF timer. 9 On timer button (ON) Press this button to set the ON timer. ! Reserve button (SET) Press this button to reserve time settings. (A receiving beep is heard.) " Cancel button (CLR) Press this button to cancel ON timer and OFF timer. (A receiving beep is heard.) # High power button (Hi POWER) Press this button to start the high power operation.

&

Memory button (MEMO) Press this button to stand by memorizing the settings. Press the button again for more than 4 seconds to memorize the setting indicated on the remote control and mark is indicated. Automatic operation button (AUTO) Press this button to operate the air conditioner automatically. (A receiving beep is heard.) ECO timer button (ECO) Press this button to start the ECO timer (OFF timer) operation. You can select the OFF timer time from among four settings (1,3,5 or 9 hours). FILTER button Press this button to turn off the filter cleaning lamp on the indoor unit. Press this button after cleaning the air filter. PRESET button Press this button to operate the air conditioner according to settings memorized by the MEMO button. TIMER button Use this button to change the clock, ON timer, and OFF timer times. To forward the time, press the TIMER button. To set back the time, press the TIMER button.

AUTOA
A B

4
PRESET

13 17
2
5
FAN
SWING FIX

START/STOP

MODE ECO TIMER

AUTO Hi-POWER
MEMO

6 7 9 8
16 16

ON

OFF
FILTER

SET

CLR

RESET CLOCK CHECK

3 14 14 15 15 12 13 17 11 10 18 18

34

8-5-2. Names and functions of indications on remote control Display All indications, except for clock time indication, are indicated by pressing the START/STOP button. 1 Transmission mark This transmission mark (,) indicates when the remote control transmits signals to the indoor unit. 2 Mode display Indicates the current operation mode. 4 2 8 3 1 (AUTO : Automatic control, A : Auto changeover control, : Cool, : Dry, : Heat, : Fan only) 3 Temperature display Indicates the temperature setting (17C to 30C). AUTOA When you set the operating mode to : Fan only, no temperature A B setting is indicated. 4 Louver operation display Indicates the louver positioning and operation. Swing Five selectable positions , , , , Automatic 5 FAN speed display Indicates the selected fan speed. AUTO or one of five fan speed levels 5 6 9 7 (LOW , LOW+ , MED+ , HIGH ) , MED can be indicated. In the illustration, all indications Indicates AUTO when the operating mode is either AUTO or : Dry. are indicated for explanation. 6 TIMER and clock time display During operation, only the The time set for timer operation or clock time is indicated. relevant indications will be The present time is always indicated except for TIMER operation. indicated on the remote control. 7 Hi POWER display Indicates when the Hi POWER operation starts. Press the Hi POWER button to start and press it again to stop A A the operation. B (MEMORY) display 8 Flashes for 4 seconds when the MEMO button is pressed during operation. mark is indicated when keeping the button depressed for more than 4 seconds while the mark is flashing. Press another button to turn off the mark. 9 ECO TIMER display Indicates when the ECO TIMER is in operation. Each time you press the ECO button, the display changes in the sequence of 1,3,5 or 9h.

35

9. INSTALLATION PROCEDURE
9-1. Safety Cautions

For general public use

Power supply cord of parts of appliance for Outdoor use shall be more than polychloroprene sheathed flexible cord (design H07RN-F), or cord designation 245IEC66. (1.5 mm2 or more)

CAUTION

New Refrigerant Air Conditioner Installation

THIS AIR CONDTIONER ADOPTS THE NEW HFC REFRIGERANT (R-410A) WHICH DOES NOT DESTROY OZONE LAYER. R-410A refrigerant is apt to be affected by impurity such as water, oxidizing membrane, and oils because pressure of R-410A refrigerant is approx. 1,6 times of refrigerant R-22. Accompanied with adoption of the new refrigerant, refrigerating machine oil has been also changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating machine oil does not enter into the refrigerating cycle or new-refrigerant air coditioner. To prevent mixin of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port of the main unit or installation tools are different from those for the coventional refrigerant. Accordingly, the exclusive tools are required for the new refrigerant (R-410A) as shown below. For conecting pipes, use new and clean piping materials with high pressure-tight force, which were made fro R-410A only, so that water or dust does not enter. Moreover, do not use the existing piping because there are problems about pressure-tight forec and inner impurity in the existing piping.

CAUTION

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY.

This appliance must be connected to the main power supply by means of a circuit breaker or a switch with a contact separation of at least 3 mm. The installation fuse (25A D type ) must be used for the power supply line of this air conditioner. (RAS-13UKV-E only)

DANGER
FOR USE BY QUALIFIED PERSONS ONLY. TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK. CONNECT THE CONNECTING CABLE CORRECTLY. IF THE CONNECTING CABLE IS CONNECTED BY WRONG WAY, ELECTRIC PARTS MAY BE DAMAGED. CHECK THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE INSTALLATION. DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION. TO PREVENT OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC. WHEN MOVING THE AIR-CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT TO GET THE SPECIFIED REFRIGERANT WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CYCLE. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CYCLE BECOMES ABNORMALLY HIGH AND IT RESULTINGLY CAUSES BURST OF THE PIPE AND INJURIES ON PERSONS. IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSES GENERATION OF POISONOUS GAS.

WARNING
Never modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches. Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls. Before doing the electrical work, attach an approved plug to the power supply cord. And, make sure the equipment to be earthed. Appliance shall be installed in accordance with national wiring regulations. If you detect any damage, do not install the unit. Contact your Toshiba dealer immediately.

CAUTION
Exposure of unit to water or other moisture before installation will result in an electrical short. Do not store in a wet basement or expose to rain or water. After unpacking the unit, examine it carefully for possible damage. Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise level of the unit or where noise and discharged air might disturb neighbors. To avoid personal injury, be careful when handling parts with sharp edges. Please read this installation manual carefully before installing the unit. It contains further important instructions for proper installation.

36

9-1-1. Installation/Servicing Tools

Changes in the product and components

In the case of an air condition using R-410A, in order to prevent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads per inch) In order to increase the pressure resisting strength of the refrigerant piping, flare processing diameter and size of opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)

New tools for R-410A

New tools for R-410A
Gauge manifold

Applicable to R-22 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 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 increasing the clamp bar's receiving hole, strength of spring in the tool has been improved. Used when flare is made by using conventional flare tool. Connected to conventional vacuum pump. It is necessary to use an adapter to prevent vacuum pump oil from flowing back to the charge hose. The charge hose connecting part has two ports-one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R-410A a sludge may occur and damage the equipment. Exclusive for HFC refrigerant.

Charge hose Electronic balance for refrigerant charging Torque wrench (nominal diam. 1/2, 5/8) Flare tool (clutch type) Gauge for projection adjustment

Vacuum pump adapter

Gas leakage detector

Incidentally, the refrigerant cylinder comes with the refrigerant designation (R-410A) and protector coating in the U.S's ARI specified rose color (ARI color code: PMS 507). Also, the charge port and packing for refrigerant cylinder require 1/2 UNF 20 threads per inch corresponding to the charge hose's port size.

37

9-2. Indoor unit

RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E
65 mm or more

For the rear left and left piping

Hook

170 or m mm ore

1 Installation
plate

Wall

Hoo

170 or m mm ore

Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better operation.

Air

filte

(At

Do not allow the drain hose to get slack.

tac h to

Shield pipe
the fron t pa

5 Zeolite filter

nel

Cut the piping hole sloped slightly

6 Purifying filter
Before installing the wireless remote control
With the remote control cover open, load the batteries supplied correctly, observing their polarity. 2 Wireless remote control Cover

8 Flat head wood screw

Make sure to run the drain hose sloped downward.

2 Wireless remote
control

4 Remote control holder

The auxiliary piping can be connected the left, rear left, rear right, right, bottom right or bottom left.

3 Batteries

Insulate the refrigerant pipes separately with insulation, not together.

Right

Rear right

Rear left Left Bottom left

Bottom right

6 mm thick heat resisting polyethylene foam

9-2-1. Accessory and Installation Parts

Part No. Part name (Q'ty) Part No. Part name (Q'ty) Part No. Part name (Q'ty)

1
Installation plate x 1

4
Remote control holder x 1

7
Mounting screw 4 x 25 s x 6

2
Wireless remote control x 1

5
Zeolite filter x 1

8
Flat head wood screw 3.1 x 16 s x 2

3
Battery x 2 Others Name
Owner's manual Installation manual

6
Purifying filter x 1 This model is not equipped with an extension drain hose. Option : For the extension drain hose, use an optionally available RB-821SW or commercially available one.

9
B Label x 1

38

9-2-2. Installation Place

A place which provides the spaces around the indoor unit as shown in the above diagram. A place where there is no obstacle near the air inlet and outlet. A place which allows easy installation of the piping to the outdoor unit. A place which allows the front panel to be opened. The indoor unit shall be installed as top of the indoor unit comes to at least 2m height. Also it must be avoided to put anything on the top of the indoor unit.

Mounting the Installation Plate

For installation of the indoor unit, use the paper pattern on the back.
Anchor bolt holes
62 82.5

Hook

170 85

CAUTION
Direct sunlight to the indoor unit wireless receiver should be avoided. The microprocessor in the indoor unit should not be too close to r-f noise sources. (For details, see the owner's manual.)

Hook Hook Thread Pipe hole Indoor unit Weight Pipe hole

Installation plate

7 Mounting screw

Remote controller
A place where there are no obstacles such as a curtain that may block the signal from the indoor unit. Do not install the remote control in a place exposed to direct sunlight or close to a heating source, such as a stove. Keep the remote control at least 1 m apart from the nearest TV set or stereo equipment. (This is necessary to prevent image disturbances or noise interference.) The location of the remote control should be determined as shown below.
(Side view) (Top view)
5

Fig. 9-2-3

When the installation plate is directly mounted on the wall

1. Securely fit the installation plate onto the wall by screwing it in the upper and lower parts to hook up the indoor unit. 2. To mount the installation plate on a concrete wall with anchor bolts, utilize the anchor bolt holes as illustrated in the above figure. 3. Install the installation plate horizontally in the wall.

CAUTION
When installing the installation plate with a mounting screw, do not use the anchor bolt hole. Otherwise the unit may fall down and result in personal injury and property damage.

Indoor unit

7m

Indoor unit 5

m
45
45

75

Reception range

Remote control

Reception range Remote control * : Axial distance 5 mm dia. hole

*7m

Anchor bolt Projection 15 mm or less 7 Mounting screw 4 x 25 s Clip anchor (local parts)

Fig. 9-2-1

9-2-3. Cutting a Hole and Mounting Installation Plate Cutting a Hole

When install the refrigerant pipes from the rear.

Fig. 9-2-4

CAUTION
Failure to firmly install the unit may result in personal injury and property damage if the unit falls. In case of block, brick, concrete or similar type walls, make 5 mm dia. holes in the wall. Insert clip anchors for appropriate 7 mounting screws.

Pipe hole
65 mm

NOTE
The center of the pipe hole is above the arrow.
100 mm

Install the installation plate using 4 to 6 pieces of mounting screw securing four corners with screws.

Fig. 9-2-2 1. After determining the pipe hole position on the mounting plate (A) drill the pipe hole (65 mm) at a slight downward slant to the outdoor side.

9-2-4. Electrical Work

1. The supply voltage must be the same as the rated voltage of the air conditioner. 2. Prepare the power source for exclusive use with the air conditioner.

NOTE
When drilling a wall that contains a metal lath, wire lath or metal plate, be sure to use a pipe hole brim ring sold separately.

NOTE
Wire type : More than H07RN-F or 245IEC66 (1.0 mm2 or more)

39

2 m or more from floor

CAUTION
This appliance can be connected to the mains in either of the following two ways. (1) Connection to fixed wiring : A switch or circuit breake which disconnects all poles and has a contact separation of at least 3 mm must be incorporate in the fixed wiring. An approved circuit breaker or switches must used. (2) Connection with power supply plug : Attach power supply plug with power cord and plug it into wall outlet. An approved power supply cord and plug must be used.

9-2-6 Piping and Drain Hose Installation Piping and Drain Hose Forming
* Since dewing results in a machine trouble, make sure to insulate both the connecting pipes. (Use polyethylene foam as insulating material.) Rear right

Bottom left Left

NOTE
Perform wiring works so as to allow a generous wiring capacity. Bottom right Right

9-2-5. Wiring Connection How to connect the connecting cable Wiring of the connecting cable can be carried out without removing the front panel.
1. Remove the air inlet grille. Open the air inlet grille upward and pull it toward you. 2. Remove the terminal cover and cord clamp. 3. Insert the connecting cable (according to the local cords) into the pipe hole on the wall. 4. Take out the connecting cable through the cable slot on the rear panel so that it protrudes about 15 cm from the front. 5. Insert the connecting cable fully into the terminal block and secure it tightly with screws. 6. Tightening torque :1.2 Nm (0.12 kgfm) 7. Secure the connecting cable with the cord clamp. 8. Fix the terminal cover, rear plate bushing and air inlet grille on the indoor unit.

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 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 connections piping, it is necessary to change the drain hose and drain cap.

How to remove the Drain Cap

Clip drain cap by needle-nose plier, and pull out.

CAUTION
Be sure to refer to the wiring system diagram labeled inside the front panel. Check local electrical cords and also any specific wiring instructions or limitations.
Terminal cover Screw Cord clamp Teminal block

How to install the Drain Hose

Firmly insert drain hose connecting part until hitting on a heat insulator.
Heat insulator

How to fix the Drains Cap

Screw Earth wire
4 mm

1) Insert hexagonal wrench (4 mm) in a center head.

Connecting cable Screw

NOTE
Wire type : More than H07RN-F or 245IEC66 (1.0 mm2 or more)
80 mm
10mm 10mm

2) Firmly insert drains cap.

No gap Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. Application causes deterioration and drain leakage of the plug. Insert a hexagon wrench (4 mm)

Earth line

Connecting cable
3

abou

t 15

cm

1
10mm

50 mm

Fig. 9-2-5

CAUTION
Firmly insert the drain hose and drain cap; otherwise, water may leak.

40

Die-cutting Front panel slit

Fig. 9-2-6

Drain hose

Fig. 9-2-7

Fig. 9-2-8

Fig. 9-2-9

Piping preparation

Changing drain hose

Rear left

In case of right or left piping

After scribing slits of the front panel with a knife or a making-off pin, cut them with a pair of nippers or an equivalent tool.
Slit

9-2-6 Indoor Unit Fixing

1. Pass the pipe through the hole in the wall, and hook the indoor unit on the installation plate at the upper hooks. 2. Swing the indoor unit to right and left to confirm that it is firmly hooked up on the installation plate. 3. While pressing the indoor unit onto the wall, hook it at the lower part on the installation plate. Pull the indoor unit toward you to confirm that it is firmly hooked up on the installation plate.
Hook here
1

Fig. 9-2-10

In case of bottom right or bottom left piping

After scribing slits of the front panel with a knife or a making-off pin, cut them with a pair of nippers or an equivalent tool.

1 Installation plate

Slit

Hook

Press (unhook)

Fig. 9-2-11

Fig. 9-2-14 For detaching the indoor unit from the installation plate pull the indoor unit toward you while pushing its bottom up at the specified parts.

Left-hand connection with piping

Bend the connecting pipe so that it is laid within 43 mm above the wall surface. If the connecting pipe is laid exceeding 43 mm above the wall surface, the indoor unit may unstably be set on the wall. When bending the connecting pipe, make sure to use a spring bender so as not to crush the pipe. Bend the connection pipe within a radius of 30 mm (6.35) 40 mm (9.52). To connect the pipe after installation of the unit (figure)
(To the forefront of flare)
270 mm 170 mm

Push

Push

Fig. 9-2-15

Liquid side Gas side

9-2-7 Drainage
1. Run the drain hose sloped downwards.

NOTE
Outward form of indoor unit
43 mm

Hole should be made at a slight downward slant on the outdoor side.

Do not rise the drain hose. Do not form the drain hose into the waved shape.

R30 or less (6.35) R40 or less (9.52) (Use polisin (polyethylene core or the like for bending pipe.)

80

Use the handle of screwdriver, etc.

50 mm or more

Fig. 9-2-12

NOTE
If the pipe is bent incorrectly, the indoor unit may unstably be set on the wall. After passing the connecting pipe through the pipe hole, connect the connecting pipe to the auxiliary pipes and wrap the facing tape around them.
Do not put the drain hose end into water. Do not put the drain hose end in the drainage ditch.

Fig. 9-2-16 2. Put water in the drain pan and make sure that the water is drained out of doors. 3. When connecting extension drain hose, insulate the connecting part of extension drain hose with shield pipe.
Shield pipe

CAUTION
Bind the auxiliary pipes (two) and connecting cable with facing tape tightly. In case of leftward piping and rear-leftward piping, bind the auxiliary pipes (two) only with facing tape.
Indoor unit Auxiliary pipes Connecting cable Installation plate

Drain hose

Inside the room

Extension drain hose

Fig. 9-2-17

CAUTION
Fig. 9-2-13 Arrange the drain pipe for proper drainage from the unit. Improper drainage can result in dew-dropping. This air conditioner has the structure designed to drain water collected from dew, which forms on the back of the indoor unit, to the drain pan. Therefore, do not store the power cord and other parts at a height above the drain guide. Space for pipes
Wall Drain guide

Carefully arrange pipes so that any pipe does not 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 dewing results in a machine trouble, make sure to insulate both the connecting pipes. (Use polyethylene foam as insulating material.) When bending a pipe, carefully do it not to crush it.

Fig. 9-2-18

41

9-2-8. Setting of Remote Controller Selector Switch

When two indoor units are installed in the separated rooms, there is no need to change the select switches.

(1) Stop the operation of the air conditioner and turn turn off its main power supply. (2) Pull the air inlet grille toward you to open it and remove the air inlet grille. (3) First open the horizontal louver and then remove the front panel from the back body by pulling it toward you.

Remote Controller Selector Switch

When two indoor units are installed in the same room or adjacent two rooms, if operating a unit, two units may receive the remote controller signal simultaneously and operate. In this case, the operation can be preserved by setting either one indoor unit and remote controller to B setting (Both are set to A setting in factory shipment). The remote control 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.

Position of Remote Control Selector Switch

1. Setting of remote controller switch at the indoor unit side

How to remove the front cabinet

Fig. 9-2-20

How to mount the front panel

Push the front panel back in and make sure all hook are locked.

Adhesion of B label (When setting to [B])

Be sure to affix the B label on the front panel same as the below figure.

Fig. 9-2-21

Fig. 9-2-19

42

2. Setting of remote controller selector at the remote controller side

[B] of the remote controller is displayed with liquid crystal only when it is set to [B]. There is no display of [A]. Enter the batter. Push the [CHK] button by something with thin edge. ([00] is displayed.) INFORMATION If [MODE] button is pushed while pushing [CHK] button, the small [B] is displayed at the right of the setting temperature indication section. * To reset [A] setting, push the [MODE] button again while pusing the [CHK] button.

9-2-9. Check and Test Operation

1. Check the unit is firmly hooked up on the

installation plate.

2. Check the connecting pipes tightened

securely. Confirm that there is no gas leakage. 3. Confirm that all connecting cables are secured and correct. 4. Check the pipes insulation. 5. Check the drainage. 6. Connection of the grounding wire. 7. To switch the TEST RUN (COOL) mode, turn the switch on. To switch the TEST RUN (COOL) mode, press TEMPORARY button for 10 sec. (The beeper will make a short beep.)

3. Confirm the indoor unit can operate with the changed setting of the remote controller.

B
B

TEMPORARY button
TEMPORARY button

PRESET

Fig. 9-2-23

START/STOP

8. Operate the unit at cooling operation mode

for fifteen minutes or more. Measure the temperature of the intake and discharge air. Ensure the difference between the intake temperature and the discharge one is more, than 8C.
[CHK] button

FAN

MODE ECO TIMER

AUTO Hi-POWER MEMO

SET

MODE button

SWING FIX
ON OFF
FILTER

CLR

NOTE: Three-minutes protection feature

A protection feature prevents the air conditioner from being activated for about 3 minutes when it is restarted immediately after operation or when the power switch is turned on. 9. Check the remote controller operation.

RESET

CLOCK CHECK

Fig. 9-2-22

* The above remote controller is one for cooling

only model.

When finished the check and test operation, make sure to return to REMOTE CONTROLLER. (Push the temporary switch with once again.)

10. Explain to the customer on the correct usage

of air conditioner simple laymans terms.

43

9-3. Outdoor Unit

9-3-1. Accessory and Installation Parts

CAUTION
1. Install the outdoor unit without anything blocking the air discharging. 2. When the outdoor unit is installed in a place exposed always to a strong wind like a coast or on a high story of a building, secure the normal fan operation using a duct or a wind shield. 3. Specially in windy area, install the unit to prevent the admission of wind.

1
Owner's manual x 1

2
Outdoor unit installation manual x 1

Strong wind

SPECIFICATIONS

Fig. 9-3-1 4. Installation in the following places may result in trouble. Do not install the unit in such places. A place full of machine oil. A place full of sulfide gas. A place where high-frequency waves are likely to be generated as from audio equipment, welders, and medical equipment.

3
Specifications x 1

9-3-2. Refrigerant Piping

Piping kit used for the conventional refrigerant cannot be used. Use copper pipe with 0.8 mm or more thickness. Flare nut and flare works are also different from those of the conventional refrigerant. Take out the flare nut attached to the main unit of the air conditioner, and use it.

9-3-4. Optional Installation Parts (Local Supply)

Parts name A B Refrigerant piping Liquid side : 6.35 mm Gas side : 9.52 mm or 12.7 mm Pipe insulating material (polyethylene foam, 6 mm thick) Putty, PVC tapes Qty Each one 1 Each one

9-3-3. Installation Place

A place which provides the spaces around the outdoor unit. A place where the operation noise and discharged air do not disturb your neighbors. A place which is not exposed to a strong wind. A place which does not block a passage. 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.
C

9-3-5. Optional Installation Parts (Separate Sold)

Parts name RB-M43RE RB-M34EE Reducer (12.7 9.52) Expander (9.52 12.7)

44

9-3-6. Refrigerant Piping Connection

Flaring size : A (Unit : mm)

Outer dia. of copper pipe A +0 - 0.4 R410A 6.35 9.52 12.7 9.1 13.2 16.6 R22 9.0 13.0 16.2

CAUTION
KEEP IMPORTANT 4 POINTS FOR PIPING WORK 1. Take away dust and moisture. (Inside of the connecting pipes) 2. Tight connection (between pipes and unit) 3. Evacuate the air in the connecting pipes using VACUUM PUMP . 4. Check gas leak. (connected points)

* In the case of flaring for R410A with the conventional 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 adjusting projection margin size.
A

Fig. 9-3-4

Flaring
1. Cut the pipe with a pipe cutter.

9-3-7. Installation
NOTE : For installation, at least 3 dimensions should be kept free from obstacles (walls).

mo 100 re mm fro m wor all

600mm or more

90

Obliquity

Roughness

Warp

ore or m ll mmom wa 50 fr

Fig. 9-3-2 2. Insert a flare nut into the pipe, and flare the pipe. As the flaring sizes of R410A differ from those of refrigerant R22, the flare tools newly manufactured for R410A are recommended. However, the conventional tools can be used by adjusting projection margin of the copper pipe.
B

200

mm

or

re mo

mo 250 re mm fro m wor all

As shown in the figure, hang power cord and connecting cable downward, and take out it along piping connection port.

Fig. 9-3-3

Fig. 9-3-5

Projection margin in flaring : B (Unit : mm) Rigid (Clutch type)

R410A tool used Outer dia. of copper pipe R410A R22 6.35 9.52 12.7 0 to 0.5 (Same as left) 0 to 0.5 (Same as left) 0 to 0.5 (Same as left) Conventional tool used R410A 1.0 to 1.5 1.0 to 1.5 1.0 to 1.5 R22 0.5 to 1.0

Fixing bolt arrangement of outdoor unit

600 115 310 Suction side

0.5 to 1.0 0.5 to 1.0

Fig. 9-3-6
76

Imperial (Wing nut type)

Outer dia. of copper pipe 6.35 9.52 12.7 R410A 1.5 to 2.0 1.5 to 2.0 2.0 to 2.5 R22 1.0 to 1.5 1.0 to 1.5 1.5 to 2.0

Diffuser

Drain hole

Secure the outdoor unit with the fixing bolts and nuts if the unit is likely to be exposed to a strong wind. Use 8 mm or 10 mm anchor bolts and nuts.

45

10 m or less

1. Piping connections to the outdoor unit should be arranged in the sequence A, B, C starting from the bottom. (For each piping connection, the gas pipe is on the bottom and the liquid pipe is on the top.) 2. When multiple indoor units are to be connected to the outdoor unit, make the ends of the pipes and wires from each indoor unit to ensure that they will be connected to the outdoor unit correctly. (Problems caused by indoor units being connected to the outdoor unit incorrectly are very common in multiple-unit installations.) 3. The length and height difference of the connecting pipes between the indoor and outdoor units must be within the ranges indicated below. Total piping length : 4 units (A + B + C) Multi, Non. Additional refrigerant :40 m or less Minimum piping length : A or B or C = 2 m or more Maximum indoor piping length : A or B or C = 20 m or less Maximum piping height difference : C A A or B or C = 10 m or less Maximum piping/height Outdoor difference between 2 rooms unit = 10 m or less Fig. 9-3-7
B

Tightening connection
Align the centers of the connecting pipes and tighten the flare nut as far as possible with your fingers. Then tighten the nut with a spanner and torque wrench as shown in the figure.

CAUTION
Do not apply excess torque. Otherwise, the nut may crack depending on the conditions. (Unit : Nm)
Outer dia. of copper pipe 6.35 mm 9.52 mm 12.7 mm Tightening torque 14 to 18 (1.4 to 1.8 kgfm) 33 to 42 (3.3 to 4.2 kgfm) 50 to 62 (5.0 to 6.2 kgfm)

Tightening torque of flare pipe connections Pressure of R410A becomes higher than that of R22. (Approx. 1.6 times) Therefore, using a torque wrench, tighten firmly the flare Flare at pipe connecting sections indoor unit side which connect the indoor and outdoor units up to the specified tightening torque. Incorrect connections may cause not only a gas leakage, but also a trouble Flare at of the refrigeration cycle.
Fig. 9-3-9
Half union Externally threaded side Use a wrench to secure. Flare nut Internally threaded side Use a torque wrench to tighten.
outdoor unit side

4. 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. 5. When the outdoor unit is to be mounted high on a wall, take particular care to ensure that parts do not fall installer is protected. 6. When doing installation work on level ground, it is usual to wiring and piping connections to the indoor units. And/then make to the outdoor unit. However if outdoor work is difficult it is possible instead to make changes to the procedure. For example by making adjustments to the wiring and piping length on the inside (rather than the outside).

Fig. 9-3-10
6,35 C 9,52 6,35 B 9,52 6,35 A 12,7 A UNIT B UNIT C UNIT

How to remove the side panel

1. Remove a screws of the value. 2. Pull the value cover downward.

Indoor unit Outdoor unit

Fig. 9-3-11
Connectable capacity class A
Valve cover

B 16 10, 13

C 16

Total 36

10, 13 3M23
(withreducer)

(with expander) (with expander)

Fig. 9-3-8

16

10, 13

46

9-3-8. Evacuating
After the piping has been connected to all indoor unit(s), you can perform the air purge together at once.

Packed valve handling precautions

Open the valve stem all the way out ; do not try to open it beyond the stopper. Securely tighten the valve stem cap in torque is as follows :
Gas side (12.7 mm) Gas side (9.52 mm) Liquid side (6.35 mm) Service port 50 to 62 Nm (5.0 to 6.2 kgfm) 33 to 42 Nm (3.3 to 4.2 kgfm) 14 to 18 Nm (1.4 to 1.8 kgfm) 14 to 18 Nm (1.4 to 1.8 kgfm)

AIR PURGE Evacuate the air in the connecting pipes and in the indoor unit using vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the manual of vacuum pump.

Use a vacuum pump

Be sure to use a vacuum pump with counter-flow prevention function so that inside oil of the pump does 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 handle of the gauge manifold valve. 4. Operate the vacuum pump to start for evacuating. Perform evacuating for about 15 minutes if the piping length is total 20 meters. (15 minutes for total 20 meters) (assuming a pump capacity of 27 liters per minute.) Then confirm that the compound pressure gauge reading is 101 kPa ( 76 cmHg). 5. Close the low pressure side valve handle of gauge manifold. 6. Open fully the valve stem of the packed valves (both sides of Gas and Liquid). 7. Remove the charging hose from the service port. 8. Securely tighten the caps on the packed valves.
Compound pressure gauge -101kPa (-76cmHg) Manifold valve Handle Lo Charge hose (For R410A only) Connecting pipe Handle Hi (Keep full closed) Charge hose (For R410A only) Vacuum pump adapter for counter-flow prevention (For R410A only) Pressure gauge

Hexagonal wrench is required.

Fig. 9-3-13

9-3-9. Electrical Work

For the air conditioner that has no power cord, connect a power cord to it as mentioned below.
Power supply Maximum running current Installation fuse rating Power cord
2

220 240 V Single phase 50/60 Hz 11 A 15 A 2,0 mm (AWG-14) or more

How to wire
1. Connect the connecting cable to the terminal as identified with their respective matched numbers on the terminal block of indoor and outdoor unit. (1.0 mm2 AWG 18 or more) 2. When connecting the connecting cable to the outdoor unit terminal, prevent water coming in the outdoor unit. 3. Insulate the unused cords (conductors) stripped the sheath of connecting cable with PVC tape. Process them so that they do not touch any electrical or metal parts. 4. For inter-unit wiring, do not use a cut wire jointed to another on the way. Use wires long enough to cover the entire length.

B A

Vacuum pump

Packed valve at liquid side Service port (Valve core (Setting pin)) Packed valve at gas side

Fig. 9-3-12

47

Three room (A + B + C) Multi

Terminal block (Connecting cable)

9-3-10. Check and Test Operation

For R410A, use the leak detector exclusively manufactured for HFC refrigerant (R410A, R134a, etc.).

* The conventional leak detector for HCFC refrigerant (R22, etc.) cannot be used because its sensitivity for HFC refrigerant lowers to approx. 1/40. Pressure of R410A becomes approx. 1.6 times of that of R22. If installation work is incompletely finished, a gas leakage may occur in the cases such as pressure rise during operation. Therefore, be sure to test the piping connections for leaking.

Screw Po wer cord Connecting cable (A unit) Connecting cable (C unit) Connecting cable (B unit)

Fig. 9-3-14

CAUTION
Wrong wiring connection may cause some electrical parts burn out. Be sure to use the cord clamps specified positions with attached to the product. Do not damage or scratch the conductive core and inner insulator of power and inter-connecting cables when peeling them. Be sure to comply with local cords on running the wire from outdoor unit to indoor unit (size of wire and wiring method etc.) Use the power cord and Inter-connecting cable with specified thickness, specified type, and protective devices specified.

Flare nut connections (Indoor unit) Flare nut connections (Outdoor unit) Valve stem cap connection Service port cap connection
Fig. 9-3-16 Check the flare nut connections, valve stem cap connections and service port cap connections for gas leak with a leak detector or soap water.

CAUTION
Stripping length power cord and connecting cable Use a circuit breaker of a type that is not tripped by shock waves. If incorrect/incomplete wiring is carried out, it will cause an electrical fire or smoke. Prepare the power supply for exclusive use with the air conditioner. This product can be connected to the mains. 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 incorporate in the fixed wiring. An approved short circuit breaker or switches must be used. * (A breaker having a sensitivity of approximately 0.1 second or less and a capacity of approximately 30 mA is usually used.)

L N 10

10 10

1 2 3

10

30

40

30

40

Earth line Power cord

Earth line Connecting cable

Fig. 9-3-15

48

9-3-11. Useful Functions Self-Diagnosis by LED Indication

For this outdoor unit, the self-diagnonsis is possible by using five LEDs (Red). Refer to the table in page 68 for more details. * LEDs (Red) (D11 to D15) locate on the sub-control borad underneath of the inverter. 1. If a trouble occurs, LED (Red) goes on according to the contents of trouble as shown in the table in page 68. 2. When two or more troubles occur, LEDs go on cyclically (alternately). 3. Usually, LEDs (Red) go off.
Wiring port

9-3-12. Miswiring (Mispiping) Check

Make sure that the wiring and piping for each room have the same alphabetical codes (A, B, C). Connect and 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. Start the check. Run the indoor unit in A room, and confirm cool air blow out. Conform the indoor unit in B,C rooms do not run, also check flowing sound of refrigerant is not heard.) Stop operation of the indoor unit in A room, and execute the same checks on the indoor unit in B and C rooms.

LED (Red)
D11 D12 D13 D14 D15

Fig. 9-3-14

For Singapore only

T o All Installers :

IMPORT ANT INSTRUCTIONS

1) Please be reminded that all air conditioner installed at HDB flat are subjected to amp. restriction of either 8,5A or 11,0A. 2) It is the installer's responsibility to hav e the current release control set correctly for the type of HDB flat in which the IES unit is installed. 3) Figure below shows how the connector can be arranged for the appropriate setting.
Wiring port CONNECTOR (CN600)

Connector No. Full operation 11A (Delivery ) 8,5A

CN600 Short Open

49

10. HOW TO DIAGNOSE THE TROUBLE

The pulse modulating circuits are mounted to both indoor and outdoor units. Therefore, diagnose troubles according to the trouble diagnosis procedure as described below. (Refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.) Table 11-1 No. 1 2 3 4 5 6 7 8 9 First Confirmation Primary Judgment Judgment by Flashing LED of Indoor Unit Self-Diagnosis by Remote Controller (Check Code) Judgment of Trouble by Every Symptom Trouble Diagnosis by Outdoor LED How to Diagnose Trouble in Outdoor Unit How to Check Simply the Main Parts How to Simply Judge Whether Outdoor Fan Motor is Good or Bad Troubleshooting Procedure Page 51 51 52 53 56 62 63 64 70

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 electrical shock may be caused. Discharge the electrolytic capacitor completely by using soldering iron, etc.

< Discharging method > (1) Remove the inverter cover (plating) by opening four mounting claws.
(2) As shown below, connect the discharge resistance (approx. 100/40W) or plug of the soldering iron to voltage between + terminals of the C13 (CAUTION HIGH VOLTAGE 320V is indicated.) electrolytic capacitor (760F/400V) on P board, and then perform discharging. .C.

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Inverter cover

P C. board . (Soldered surface)

Fig. 11-1

50

10-1. First Confirmation

10-1-1. Confirmation of Power Supply
Confirm that the power breaker operates (ON) normally.

10-1-3. Operation Which is not a Trouble (Program Operation)

For controlling the air conditioner, the program operations are built in the microcomputer as described in the following table. If a claim is made for running operation, check whether or not it meets to the contents in the following table. When it does, we inform you that it is not trouble of equipment, but it is indispensable for controlling and maintaining of air conditioner.

10-1-2. Confirmation of Power Voltage

Confirm that power voltage is AC 220240V 10%. If power voltage is not in this range, the unit may not operate normally.

Table 10-1-1 No. 1 Operation of air conditioner When power breaker is turned ON, the operation lamp (Green) of the indoor unit flashes. 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 flow indication is fixed to [AUTO].

Compressor may not operate even if the room temperature is within range of compressor-ON.

In DRY and ECONO. mode, FAN (air flow) display does not change even though FAN (air flow select) button is operated. Increasing of compressor motor speed stops approx. 30 seconds after operation started, and then compressor motor speed increases again approx. 30 seconds after. The set value of the remote control should be below the room temperature.

For smooth operation of the compressor, the compressor motor speed is restricted to Max. 33 rps for 2 minutes and Max. 57 rps for 2 minutes to 4 minutes, respectively after the operation has started. If the set value is above the room temperature, Cooling operation is not performed. And check whether battery of the remote control is consumed or not.

10-2. Primary Judgment

To diagnose the troubles, use the following methods. (1) Judgment by flashing LED of indoor unit (2) Self-diagnosis by service check remote controller (3) Judgment of trouble by every symptom Firstly use the method (1) for diagnosis. Then, use the method (2) or (3) to diagnose the details of troubles. For any trouble occurred at the outdoor unit side, detailed diagnosis is possible by 5-serial LED on the inverter P board. .C.

51

10-3. Judgment by Flashing LED of Indoor Unit

While the indoor unit monitors the operation status of the air conditioner, if the protective circuit operates, the contents of self-diagnosis are displayed with block on the indoor unit indication section.

Table 10-3-1 Lamps A B C D E F G OPERATION lamp is blinking. (1Hz) OPERATION lamp is blinking. (5Hz) OPERATION lamp is blinking. (5Hz) OPERATION lamp is blinking. (5Hz) OPERATION lamp is blinking. (5Hz) OPERATION and TIMER lamps are blinking. (5Hz) OPERATION, TIMER and FAN ONLY lamps are blinking. OPERATION, TIMER and FAN ONLY lamps are blinking. Self-diagnosis Power failure (when the power supply is turning on) Thermo sensor (TA) short or break Heat exchanger sensor (TC) short or break Indoor fan motor lock or failure Indoor P.C. board failure Wrong wiring of connecting cable Gas shortage or other refrigerant cycle trouble Heat exchanger sensor open, break or short Overload relay or thermostat trouble of compressor Cycle failure

NOTES:
(1) (2) (3) (4) The contents of items B and C and a part of item E are displayed when air conditioner operates. When item B and C, and item B and a part of item E occur concurrently, priority is given to the block of item B. The check codes can be confirmed on the remote controller for servicing. When connecting the changing kit, first-push priority control is executed. The secondary operation lamp continues flashing. For details, refer to the section 10. Changing Kit.

52

10-4. Self-Diagnosis by Remote Control (Check Code)

(1) If the lamps are indicated as shown B to H in Table 11-3-1, exchanger the self-diagnosis by the remote control. (2) When the remote control is set to the service mode, the indoor controller diagnoses the operation condition and indicate the information of the self-diagnosis on the display of the remote control with the check codes. If a fault is detected, all lamps on the indoor unit will blink at 5Hz and it will beep for 10 seconds (Pi, Pi, Pi....). The timer lamp usually blinks (5Hz) during the self-diagnosis. 10-4-1. How to use remote control in service mode

SET

CLR

RESET CLOCK CHECK

AUTOA
A B

(1) Press [CHECK] button with a tip of pencil to set the remote control to the service mode. 00 is indicated on the display of the remote control. The timer lamp on the indoor unit blinks continuously. (5 times per 1 sec.) (2) Press [TIMER 8] button. If there is no fault with a code, the indoor unit will beep once (Pi) and the display of the remote control will change as follows: ; 00 ; 01 ; 02 1d ; 1E ; 22 Check the unit with all 35 check codes (00 to 22). as shown in Table 10-4-1. Press [TIMER 9] button to change the check code backwards. If there is a fault, the indoor unit will beep for 10 seconds (Pi, Pi, Pi...). Note the check code on the display of the remote control. 2-digits alphanumeric will be indicated on the display. All lamps on the indoor unit will blink. (5 times per 1 sec.) (3) Press [CLR] button. After service finish for clear service code in memory. 7F is indicated on the display of the remote control.

PRESET

START/STOP

FAN SWING FIX ON OFF

FILTER

MODE ECO TIMER

AUTO Hi-POWER MEMO SET CLR

RESET CLOCK CHECK

Alphanumeric characters are used for the check code. is 5. is A. is C. is 6. is B. is D.

(4) Press [START/STOP] button to release the service mode. The display of the remote control returns to as it was before service mode was engaged.

53

10-4-2. Operation Control by Rated Frequency in Service Mode

In the service mode, pushing ON or OFF operates the air conditioner by rated frequency of COOL mode for 30 minutes.

10-4-3. Caution at Servicing

(1) After servicing, push the START/STOP button to return to the normal mode. (2) After servicing by the check code, turn off breaker of the power supply, and turn on breaker of the power supply again so that memory in the microcomputer 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.

Table 10-4-1
Block distinction Check code Check code Operation of diagnosis function Air conditioner status Judgment and action Condition

Block

Cause of operation

Indoor P.C. board etc.

Short-circuit or disconnec- Operation Displayed when tion of the room tempera- continues. error is detected. ture sensor (TA sensor). Coming-off, Operation Displayed when disconnection, continues. error is detected. short-circuit, or migration of heat exchanger sensor (TC sensor) Lock of indoor fan or trouble on the indoor fan circuit All off Displayed when error is detected.

1. Check the room temp. sensor. 2. When the room temp. sensor is normal, check P.C. board. 1. Check heat exchanger sensor. 2. When heat exchanger sensor is normal, check P.C. board.

1. Check P.C. board. 2. When P.C. board is normal, check the motor. Replace P.C. board.

Not displayed Connecting cable and serial signal

Trouble on other indoor P.C. boards

Operation Displayed when continues. error is detected.

Return serial signal is not Operation sent to indoor side from continues. operation started. (1) Defective wiring of connecting cable (2) Operation of compressor thermo. Gas shortage Gas leak

1. When the outdoor unit never Flashes when operate: trouble is detected (1) Check connecting cable, and on Return serial correct if defective wiring. signal, and normal (2) Check 25A ( or 30A) fuse (F01) status when signal of outdoor main P.C. board. is reset. (3) Check 3.15A fuse (F04) of outdoor main P.C. board. 2. To display [Other] block during operation, check compressor thermo. operation and supply gas (check gas leak also). 3. Unit operates normally during check. If Return serial signal does not stop between indoor terminal board 2 and 3, replace inverter P .C. board. If signal stops between indoor terminal board 2 and 3, replace indoor P.C. board. If Operation command signal does not stop between indoor terminal board 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal board 2 and 3, replace indoor P.C. board.

Operation command signal is not sent to outdoor side.

Operation Flashes when continues. trouble is detected on Operation command signal, and normal status when signal is reset.

54

Block distinction Check Block code Outdoor P.C. board code Check

Operation of diagnosis function Air conditioner status Judgment and action Remarkes

Cause of operation

Inverter over-current All off protective circuit operates. (Short time) Position-detect circuit error or short-circuit between windings of compressor All off

Displayed when Even if trying operation again, all error is detected. operations stop immediately. : Replace P board. .C. Displayed when 1. Even if connecting lead wire of error is detected. compressor is removed, positiondetect circuit error occurred. : Replace P.C. board. 2. Measure resistance between wires of compressor, and perform shortcircuit. : Replace compressor. Displayed when Even if trying operation again, all error is detected. operations stop immediately. : Replace P board. .C. Displayed when Check 5-serial LED. error is detected. 1. Check P.C. board.

Current-detect circuit error

All off

Being out of place, disconnection or shortcircuit of outdoor temp. sensor Disconnection or shortcircuit of discharge temp. sensor

All off

All off

Displayed when 1. Check discharge temp. sensor (TD). error is detected. 2. Check P.C. board.

Outdoor fan drive system All off error

Displayed when Position-detect error, over-current error is detected. protective operation of outdoor fan drive system, fan lock, etc. : Replace P.C. board or fan motor. 1. Check outdoor temp. sensor (TO). 2. Check P.C. board.

Not displayed Outdoor P.C. board

Outdoor temp. sensor error Compressor drive output error, Compressor error (lock, missing, etc.), Break down Error exclusive for multiple type

Operation continues. All off

Displayed when Check 5-serial LED. error is detected. When 20 seconds passed after start-up, position-detect circuit error occurred. : Replace compressor. Displayed when Check 5-serial LED. error is detected. 1. Miswiring of connecting wire of A/B/ C/D rooms in indoor/outdoor units 2. Check gas leakage. 3. Check disconnection of sensor. 4. Electronic control valve error Displayed when 1. Trouble on compressor error is detected. 2. Trouble on wiring of compressor (Missed phase)

All off

Others (including compressor)

Compressor does not All off rotate. (Current protective circuit does not operate when a specified time passed after compressor had been activated.) Discharge temp. exceeded 120C. All off

Displayed when 1. Check dischage temp. sensor (TD). error is detected. 2. Degassing 3. Trouble on P.M.V. Displayed when 1. Check power voltage. (220240 V 10%) error is detected. 2. Overload operation of refrigeration cycle Check installation condition (Short-circuit of outdoor diffuser).

Break down of compressor

All off

55

10-5. Judgement of Trouble by Every Symptom

10-5-1. Indoor unit (Including remote controller) (1) Power is not turned on (Does not operate entirely)
Turn off power supply once, and 5 second later, turn it on again.

Operation Check item Conceivable principle cause

NO

Is OPERATION lamp blinking? YES Is it possible to turn on power supply by pressing [START/STOP] button on remote control? YES Does transmission mark on remote control flash normally, and is its signal transmitted properly? YES

Measure Item by symptoms

NO

NO

Remote control is defective.

Refer to (5) Troubleshooting for Remote Control. Unit operates normally.

Is fuse (F01) YES of indoor control board blown? NO

Parts (R04, C01, DB01, C03, R01 IC01 and T01) are defective.

Does fan motor connector between 1 and 2 short-circuit? NO Microcomputer is defective.

YES

NO

Is voltage (DC 12V or 5V) YES indicated on rear of indoor control board normal? Refer to <Primary check> or this problem is one step short of power P.C. board block. Are DC 15V, DC 12V or DC 7V supplied to secondary side of transfer switch? YES

Replace main P.C. board.

Is DC 310 340V NO suppalied to primary side of transfer switch? YES Are DC 15V, DC 12V and DC 7V supplied to secondary side of transfer switch? YES

NO

Turn off breaker once and turn it on again after removing motor.

NO

Transfer switch, IC (IC01) for power supply or fan motor is defective.

Replace motor.

Be sure to disconnect the motor connector CN10 after shut off the power supply, or it will be a cause of damage of the motor.

56

(2) Power is not turned on though Indoor P.C. board is replaced <Confirmation procedure>
Turn on power supply. NO Does operation lamp flash? YES NO Correct wiring.

Is wired correctly to white and black lead wires of terminal board? YES

To item of Power is not turned on.

57

(3) Only indoor fan motor does not operate. <Preliminary check> 1 Is it possible to detect the power supply voltage (200 240V) between 1 and 2 on the terminal block? 2 Does the indoor fan motor operate in cooling operation? (In heating operation, the indoor fan motor does not operate for Operation approximately 5 minutes after it is turned on, to prevent a cold air Check item from blowing in.)
Conceivable principle cause

Turn off power supply once, and turn it on again.

Measure Item by symptoms

Does compressor continue to operate? NO Start to operate indoor unit in cooling operation at airflow level LOW.

YES

Is it possible to detect DC 1V or more between 5e and 3dof motor connector (CN10). YES

NO Replace indoor fan motor.

Does indoor fan operate? YES Change airflow level to High.

NO

Is it possible to detect DC 310 340V between 1e and 3d of motor connector (CN10). YES (Motor connection condition) Is it possible to detect DC 15V between 4e and 3d of motor connector (CN10). YES Start to operate the indoor unit. At this time, is it possible to detect DC 1V or more between 5e and 3d of motor connector (CN10)?

NO Turn off indoor unit and remove connector from motor. Then press START/STOP button on remote control to stop blinking lamp on indoor unit.

NO

NO

Is it possible to detect DC 15V between 4e and 3d of motor connector (CN10).

NO

Replace main P.C. board.

Is it possible to change airflow level to High? YES

NO

Is it possible to rotate cross- NO flow fan by hand properly?

Turn off indoor unit and remove connector from motor. Then start to operate indoor unit with remote control.

Fan motor operates normally.

Turn off indoor unit and rotate cross-flow fan by hand when the unit is on standby. At this time, NO is it possible to detect DC 1V or more between 5e and 3d of motor connector (CN10).

Start to operate the indoor unit in except heating operation. At this time, is it possible to detect DC 1V or more between 5e and 3d of motor connector (CN10)? (Check this condition within 15 seconds after starting unit.)

NO

YES YES Replace bearing.

58

(4) Indoor fan motor starts rotating by turning on power supply alone <Cause> The IC is built in the indoor fan motor. Therefore the P board is also mounted to the inside of the motor. .C. If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turning on power supply. <Confirmation procedure> (1) Remove the front panel.(Remove 4 screws.) (2) Remove cover of the fan motor lead wires. (3) Check DC voltage with CN10 connector while the fan rotating. NOTE : Do not disconnect the connector while the fan rotates. Use a thin tester rod.
P.C. board CN10

Indoor fan starts rotating when power supply breaker is turned ON.

(Check output voltage (DC) of the fan motor on P.C. board.)

Yellow
Measure the voltage of the motor connector CN10 pin 2 (GND : Black) and pin 3 (V line : Yellow) under condition that the indoor fan rotates.

6 (Blue) 5 (Yellow)
4 (Blue) 3 (Yellow) 2 1 (Red)

Black

Above DC 0.4V

Below DC 0.4V

P.C. board is defective.

Motor is defective.

DC

59

(5) How to examine whether remote controller is good or bad Does setting (A/B) of the remote controller selection match with that indoor unit?

Operation Check Items Considerable main cause Measures Item by symptom

Press the START/STOP button.

There is no beep from the indoor unit. The operation lamp of the air conditioner main unit does not light.

Does the transmission indicator of remote controller light? YES

NO

Is there direct sunlight on the receptor of the air conditioner? YES

Short-circuit ACL switch with a coin or others at rear side of remote controller. NO

Is there any thyristor fluorescent light near by? YES

NO

NO

Is operation possible when the transmitter is moved nearer to the infrared signal receiver of the air conditioner? YES Battery life

Push the START/ STOP button

Is Temporary Cool operation possible when NO keeping the temporary switch of the air conditioner main unit pushed for 10 seconds or more? YES NO

Does the transmission indicator light? YES

NO

Is there any receiving sound and operation? YES

Can any signal tone be heard in a transistor radio when transmitting within 5cm distance from the radio? YES

NO

Avoid direct sunlight.

Keep the air conditioner away from thyristor fluorescent light.

Replace P.C. board.

Replace the battery.

Normal

Remote controller is failure.

60

10-5-2. Wiring Failure (Interconnecting and Serial Signal Wire)

(1) Outdoor unit does not operate 1) Is the voltage between R and S of the indoor terminal block varied? Confirm that transmission from indoor to outdoor is correctly performed based upon the following diagram. NOTE: Measurement should be performed 2 minutes and 30 seconds after starting of the operation. Be sure to prepare a diode for judgment.
Terminal block at indoor side
Red White

3
S5277G

S5277G or equivalent (G or J type) (Diode with rated voltage of 400V or more is acceptable.)
Tester

Terminal block

Fig. 11-5-1 Normal time : Voltage swings between DC15 and 60V. Abnormal time : Voltage does not vary. (2) Outdoor unit stops in a little while after operation started <Check procedure> Select phenomena described below. (1) The outdoor unit stops 10 to 20 minutes after operation started, and 10 minutes or more are required to restart the unit.

Gas circulation amount is down. Measure gas pressure. Thermo. operation of compressor

Gas shortage Gas leak Pipe clogging

(2) If the unit stops once, it does not operate until the power will be turned on again.

To item of Compressor does not operate.

(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) Gas leak P.M.V. is defective. Miswiring of connecting wires of indoor/outdoor units Clogging of pipe and coming-off of TG, TC sensors

61

10-6. Trouble Diagnosis by Outdoor LED

For the outdoor unit, the self-diagnosis is possible by five LEDs (Red). LEDs (Red) (D11 to D15) are provided on the sub-control board under surface of the inverter, and as shown below, they are checked from the wiring port when removing the wiring cover. 1. If a trouble occurs, LED (Red) goes on according to the trouble as described in the table below. 2. When two or more troubles occur, LEDs go on cyclically. 3. Usually, LEDs (Red) go off.

Wiring port

LED (Red)
D11 D12 D13 D14 D15

Fig. 11-6-1

: LED ON, l : LED OFF

LED display D11 D12 D13 D14 D15 Indoor check code None 07 14 16 17 19 1A 1B 1C 1C 1D 1E 1F During normal operation

P.M.V. : Pulse modulating valve

Description

l l

l l l l

l l l l l l l

l l l l l l l l l l

Compressor thermo. operation, instantaneous power failure, gas leak IGBT short circuit, compressor motor rear short Position-detect circuit error Current-detect circuit error Discharge temp. sensor (TD) error Outdoor fan error Outside temp. sensor (TO) error Compressor system error A room gas side temp. sensor (TGa) error B room gas side temp. sensor (TGb) error C room gas side temp. sensor (TGc) error Gas leakage, P.M.V. sensor error Indoor heat exchanger sensor (TC) disconnection, P.M.V. sensor error Indoor/outdoor miswiring, gas leakage, TC sensor disconnection, P.M.V. sensor error Communication error between MCU Compressor lock Discharge temp. error, gas leakage Compressor break down

l l

l l

*2 *2 *2 *1 *1

l l

l l l l

l l l l l

l l l

*1 Back-up operation is performed without block display of the indoor unit. *2 Operated normally when the air conditioners in other rooms are driven.
62

10-7. How to Diagnose Trouble in Outdoor Unit

10-7-1. Summarized Inner Diagnosis of Inverter Assembly
Diagnosis/Process flowchart Item Preparation
Remove connector of compressor.

Contents Turn OFF the power breaker, and remove 3P connector which connects inverter and compressor. Check whether 25A fuse on the control board assembly is blown or not. (F01)

Summary

Check 25A fuse (Part No.F01). OK

NG

Check

If fuse was blown, be sure to check the electrolytic capacitor and diode block. (DB01) Connect discharge resistance (approx. 10040W) or soldering iron (plug) between +, terminals of the electrolytic capacitor (500F) of C15 (with printed CAUTION HIGH VOLTAGE) on P.C. board.
Plug of soldering iron

Replace fuse.

Check electrolytic capacitor, diode block, etc.

Check

Check whether 15A fuse on the control board assembly is blown or not. (F03)

Check 15A fuse (Part No.F03). OK

NG

Replace control board assembly.

15A fuse (F03) on the control board is provided for power factor improvement control circuit. The operation continues even if fuse is blown.

Discharging position (Discharging period 10 seconds or more)

Check terminal voltage of electrolytic capacitor. OK

NG

Check electrolytic capacitor, diode block, etc.

If 15A fuse is blown, discharge both edges of the electrolytic capacitor with soldering iron. Turn on power breaker, and operate the air conditioner in COOL mode by short-circuit of OK if 500F DC280V the timer. Measurement Measure terminal voltage of Remove CN300 while the electrolytic capacity. pushing the part indicated 500F:400WV x 4 by an arrow. After operation, turn off the power breaker after 2 minutes 20 seconds passed, and Stop discharge the electrolytic capacity by soldering iron. Check voltage between motor Check phases. Measurement Is not winding between QR, R-S, or Q-S opened Resistance between or short-circuited? phases should be approx. Is not frame grounded with 55 to 77. Q, R, or S? Should be 10M or more. Check Operation

Does outdoor fan rotate? YES

NO

Does LED on control board flash or go on? NO Remove connector CN300 of outdoor fan NG motor, and using a tester, check resistance value between every phases at motor side. OK Replace outdoor fan motor.

YES

63

Diagnosis/Process flowchart

Item Check

Contents Check winding resistance between phases of compressor, and resistance between outdoor frames by using a tester. Is not grounded. Is not short-circuited between windings. Winding is not opened. Remove connector CN300 of the outdoor fan motor, turn on the power breaker, and perform the operation. (Stops though activation is prompted.) Check operation within 2 minutes 20 seconds after activation stopped.

Summary

Check winding of compressor.

OK

NG

OK if 10M or more

OK if 0,51 0,57 (Check by a digital tester.)

NG

Check fan motor position detect signal.

OK

Replace compressor.

Operation

Replace outdoor fan motor.

Check
Replace control board assembly.

Check compressor winding resistance.

OK

NG

Replace control board.

Replace compressor.

<Output check of fan motor a) One or two of three voltages should be 5V, position detect signal> and others should be 0V. While connecting connector (When all are 0V or 5V, it 5P (CN301) for position is not accepted.) detection, using a tester, measure voltage between Q b) When rotating the fan - U. Between U - T : 5V slowly with hands, the voltage between pins should move from 0V to 5V. (Check it with an analog tester.)

10-8. How to Check Simply the Main Parts

10-8-1. How to Check the P.C. Board (Indoor Unit)
(1) Operating precautions 1) When removing the front panel or the P.C. board, be sure to shut off the power supply breaker. 2) When removing the P.C. board, hold the edge of the P.C. board and do not apply force to the parts. 3) When connecting or disconnecting the connectors on the P.C. board, hold the whole housing. Do not pull at the lead wire.

(2) Inspection procedures 1) When a P.C. board is judged to be defective, check for disconnection, burning, or discoloration of the copper foil pattern or this P.C. board. 2) The P.C. board consists of the following 2 parts a. Main P.C. board part: DC power supply circuit (5V, 12V, 35V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer, and Driving circuit of top/bottom louvers b. Indication unit of infrared ray receiving Infrared ray receiving circuit, LED: To check defect of the P.C. board, follow the procedure described below.

64

(3) Check procedures Table 10-8-1

No. 1 Procedure Shut off the power supply and remove the P.C. board assembly from the electronic parts base. Remove the connecting cable from the terminal block. Remove the connector for the motor, and turn the power on. If the OPERATION lamp flashes (0,5 sec. :ON, 0,5 sec. :OFF) when the power turning on, the checking points described as 1-5 of right column are not necessary to perform. Check point (Symptom) 1. Is the fuse blown? Causes 1. * Application of shock voltage. * Overload by short-circuit of the parts.

Voltage check 1. Between TP1 and TP2 (220230240V AC) 2. Between TP2 and pin 1 of CN04 (220230240V AC) 3. Between TP2 and pin 3 of CN04 (220230240V AC) 4. Between + and of C02 (310 ~ 340V DC) 5. Between 35V and GND 6. Between 12V and GND 7. Between 5 V and GND

1. * AC power cord is defective. * Poor contact of the terminal plate. * Miss wiring of the power relay. 2. Fuse is defective. 3. Operation of the thermal fuse. 4. * Capacitor (C01, C15) is defective. * Line filter (L01) is defective. * Resistor (R01) is defective. * Diode (DB01) is defective. 5. IC01, IC02, T01 are defective. 6. IC01, IC02, T01, F03 are defective. 7. IC01, IC02, T01, F02, Q29, IC03 are defective. 1. Breaking wire of the relay coil, defective relay driver. (IC31) 2. Poor contact of relay.

Make the operation status by pushing once the START/STOP button, except the status of [FAN ONLY], [ON TIMER].

Voltage check 1. Voltage of relay coil. (DC 12V) Between pin 10 of IC31 and GND Between pin 11 of IC31 and GND 2. Between No. 1 and 2 of connecting cable terminal block. (220230240V AC) 1. All indicators light for 3 sec. 2. Indicators do not indicate normally after approximate 3 sec.

Start the operation with the system which the time of the restart delay timer is shortened.

Defective indicator, or poor housing assembly. (CN13)

Make the operation status by pressing 1. Compressor does not operate. once the START/STOP button. 2. OPERATION lamp flashes. 1. The time of the restart delay timer is shortened. 2. Cool operation 3. Air volume [AUTO] 4. Make the setting temperature lower enough than room temperature. 5. Continuous operation.

1. The temperature of the indoor heat exchanger is abnormally low. 2. Poor contact of the heat exchanger sensor. (The connector is disconnected.) (CN01) 3. Heat exchanger sensor, main P.C. board are defective. 4. Main P.C. board is defective.

Turn the power on after connecting 1. The voltage of DC 35V is not 1. Indoor fan motor is defective. the motor connector. (Protecting operation on the P.C. measured between the red and board.) black of the motor terminals. Start the operation with the following condition. 2. Poor contact of the motor 2. Motor does not rotate. connector. (The key operation is accepted.) 1. Operation [Cooling] 3. The motor rotates, but it vibrates too 3. P.C. board is defective. 2. Airflow [High fan] much. 3. Continuous operation

65

10-8-2. P.C. Board Layout

<Top View>

<Bottom View>

66

<Sensor characteristic table>

100 90
Resistance value (k )

80 70 60 50 40 30 20 10 0 0 10 20

TD

TA, TC, TO, TGa, TGb, TGc, TGd

30

40

50

Temperature (C)

TD TA TC TO TGa TGb TGc TGd

: Discharge temp. sensor : Room temp. sensor : Heat exchanger temp. sensor : Outdoor temp. sensor : Gas side temp. sensor : Gas side temp. sensor : Gas side temp. sensor : Gas side temp. sensor

67

10-8-3. Indoor Unit (Other Parts)

No. 1 Part name Room temp. (TA) sensor Heat exchanger (TC) sensor Checking procedure Disconnect the connector and measure the resistance value with tester. (Normal temp.)
Temperature Sensor TA, TC (k) 10C 20,7 20C 12,6 25C 10,0 30C 7,9 40C 4,5

Remote control

To item of How to judge whether remote control is good or bad of the Judgment of trouble by symptom. Measure the resistance value of each winding coil by using the tester. (Under normal temp. 25C) Position Resistance value
White Yellow Yellow Yellow Yellow 1 2 3 4 5

Louver motor MP24GA

1 to 4 1 to 6 2 to 3 2 to 5

130 10

Indoor fan motor

Since judgment of DC motor is difficult on the single motor, refer to 115-1. (3).

11-8-4. Outdoor Unit

No. 1 Part name Compressor (Model : DA130A1F-21F)
Red

Checking procedure Measure the resistance value of each winding by using the tester.
Position Red - White White - Black Black - Red
Black

White

Resistance value 0,51 to 0,57 0,51 to 0,57 0,51 to 0,57 Under 20C

Outdoor fan motor (Model : ICF-140-40-8)

Measure the resistance value of winding by using the tester.

Red
1 Yellow 4 Pink 5 Gray

Position Yellow - Pink

Resistance value 5 to 20 k

White

Black

For details, refer to Section 11-9.

Compressor thermo. Bimetal type (Model : PW - 2AL)

Check conduction by using the tester.

Outdoor temperature sensor Disconnect the connector, and measure resistance value with the (TO), pipe temperature sensor tester. (Normal temperature) (TGa, TGb, TGc), discharge Temperature temperature sensor (TD)
Sensor TD (k) TO, TGa, TGb, TGc (k) 10C 105 20,7 20C 64 12,6 30C 41 10,0 40C 27 7,9

50C 18 4,5

68

10-8-5. Checking Method for Each Part

No. 1 Part name Electrolytic capacitor (For raising pressure, smoothing) 1. 2. 3. 4. 5. 6. Checking procedure Turn OFF the power supply breaker. Discharge all four capacitors completely. Check that safety valve at the bottom of capacitor is not broken. Check that vessel is not swollen or exploded. Check that electrolytic liquid does not blow off. Check that the normal charging characteristics are shown in continuity test by the tester.
Heat sink IGBT side

C12

C13

C14

C15

Case that product is good

Pointer swings once, and returns slowly. When performing test once again under another polarity, the pointer should return.

MCC-758 Soldered surface

C12, C13, C14, C15 500F/400V 2 Converter module

1. Turn OFF the power supply breaker. 2. Discharge all four capacitors completely. 3. Check that the normal rectification characteristics are shown in continuity test by the tester.

Mark

~1

~2

Diode check
Tester rod

+ ~1 ~2 +
E

~1 ~2 ~1 ~2

Resistance value in good product

~1

~2

IGBT check
50kW or more (0 in trouble) Tester rod

+ ~2
G

E E

Resistance value in good product 50kW or more (0 in trouble)

IGBT module

1.Turn OFF the power supply switch. 2. Discharge all four electrolytic capacitors completely. 3. Execute continuity test with a tester.

+
BU BV BW

BZ BY BX W BW V BV U BU

BX

BY

BZ

Tester rod

+
U V W

W U

V W 200k

U to 300k

Case that product is good

1M or more 100k to 300k

69

10-9. How to Simply Judge Whether Outdoor Fan Motor is Good or Bad
1. Symptom
Outdoor fan motor does not rotate. Outdoor fan motor stops within several tens seconds though it started rotating. Outdoor fan motor rotates or does not rotate according to the position where the fan stopped., etc. Remote control check code 02 : Outdoor block, 1A : Outdoor fan drive system error

2. Cause
The following causes are considered when the outdoor fan motor does not normally rotate. 1) Mechanical lock of the outdoor fan motor 2) Winding error of the outdoor fan motor 3) Position-detect circuit error inside of the outdoor fan motor or 4) Motor drive circuit error of the outdoor P.C. board

3. How to simply judge whether outdoor fan motor is good or bad

Turn OFF the breaker.

Disconnect two connectors (CN300 and CN301) of the outdoor fan motor from the inverter.

Does the fan rotate without trouble when rotating it with hands? YES If the resistance value between 1 (Red lead) 2 (White lead) 2 (White lead) 3 (Black lead) 3 (Black lead) 1 (Red lead) of the connector (CN300 : Motor winding) is 50 to 80 , it is normal. YES If the resistance value between 1 (Yellow lead) 4 (Pink lead) of the connector (CN301 : Motor position detection) is 5k to 20k , it is normal. YES Fan motor is normal. (Outdoor P.C. board error)

NO

NO

CN300

NO

Fan motor error

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.

70

11. HOW TO REPLACE THE MAIN PARTS

11-1. Indoor Unit
No. 1 Part name Front panel Procedures How to remove the front panel 1) Stop operation of the air conditioner and turn off its main power supply. 2) Pull the air inlet grille toward you to open it and remove the air inlet grille. Then remove the 4 screws fixing the front panel. 3) First open the horizontal louver, and then remove the front panel from the back body by pulling it toward you. How to mount the front panel Push the front panel back in and make sure all hooks are locked. 2 Electrical part How to remove the electrical part. 1) Remove the front panel with procedure 1. 2) Remove the screw holding the electrical part cover. 3) Remove the drain guide. 4) Disconnect the 2 connectors (3P) for the fan motor and the connector (5P) for the louver motor from the P.C. board assembly. 5) Pull out the TC sensor from the sensor holder. 6) Remove the screw for the ground connection, remove the 2 screws for the electrical part box and remove the screw from the LED unit. Then remove the LED unit and the electrical part box from the main unit. How to mount the electrical part. 1) To put back the electrical part box, lock it to the upper hook of the back body. 2) Tighten the 2 screws on the electrical part box. 3) Connect the 3 connectors and arrange the wiring same as original condition and then tighten the screw from the LED unit to the back body. 4) Attach the TC sensor to the holder. 5) Tighten the screw for the ground connection. 6) Assemble the drain guide (the TC sensor wire should be covered by the drain guide). 7) Tighten the screw on the electrical part cover. 3 Horizontal louver 1) Remove the front panel and the electrical part following procedure 2. 2) Remove the center shaft of the horizontal louver from the back body. 3) Remove the left shaft from the back body. 4) Remove the horizontal louver from the back body. 71
2 Screws

Remarks
2 2 2

2 4-Screws

3 Drain guide

5 TC Sensor

6 Screws

4 3-Connectors

6 2-Screws

3 Left shaft

2 Center shaft

No. 4

Part name Heat exchanger

Procedures 1) Remove the front panel, electrical part and the horizontal louver following procedure 3. 2) Remove the pipe holder at the rear side of main unit. 3) Remove the 2 screws on the heat exchanger at the base bearing. 4) Remove the 2 screws on the heat exchanger at the 2 fixed plates (upper and lower) from the back body, and then pull out the upper side of the heat exchanger slowly.

Remarks

2 Pipe holder

3 2-Screws

4 2-Screws

Cross flow fan

1) Remove the front panel, electrical part, horizontal louver and the heat exchanger following procedure 4. 2) Remove the 2 screws on the band motor (L) and remove the 2 screws on the band motor (R) and then remove the cross flow fan. 3) Loosen the set screw of the cross flow fan then separate the fan and the fan motor. Notice To assemble cross flow fan and fan motor to the unit, please turn the fan motor unit the center of its terminal meets the lowest point of band motor (R) (point A). Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is 4 mm.

2 2-Screws (R)

2 2-Screws (L)
4 mm

3 Set screws

Middle of the fan motor terminal

Base bearing

1) Remove the front panel, electrical part, horizontal louver, heat exchanger and the cross flow fan following procedure 5. 2) Remove the 2 screws fixing the base bearing. 3) Remove the bearing from the base bearing. If the housing protrudes from the base bearing, put the housing in position and attach the bearing to the base bearing. 72

2 2-Screws

11-2. Microcomputer
No. Part name Common procedure Procedure Remarks

1) Turn the power supply off to stop the operation of air- Replace the thermal fuse, terminal conditioner. block, microcomputer assy and the P.C. board assy. 2) Remove the front panel. Remove the two fixing screws. (4 x 14l) 3) Remove the electrical part base.

73

11-3. Outdoor Unit

No. Part name Common procedure Procedure 1. Detachment 1) Stop operation of the air conditioner, and remove the power plug of the indoor unit from plug socket. 2) Remove the valve cover. (ST1T4 x 10l 1 pc.) l After removing screw, remove the valve cover pulling it downward. 3) Remove wiring cover (ST1T4 x 10l 2 pcs.), l and then remove connecting cable. 4) Remove the upper cabinet. (ST1T4 x 10l 2 pcs.) l After removing screws, remove the upper cabinet pulling it upward. 2. Attachment 1) Attach the upper cabinet. l (ST1T4 x 10l 2 pcs.) Hook the rear side of the upper cabinet to claw of the rear cabinet, and then put it on the front cabinet. 2) Perform cabling of connecting cable, and attach the wiring cover. (ST1T4 x 10l 2 pcs.) l 3) Attach the valve cover. (ST1T4 x 10l 1 pcs.) l 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
Upper cabinet

Wiring cover Valve cover

Upper cabinet

Front cabinet

1. Detachment 1) Perform work of item 1 of . 2) Remove screw (ST1T4 x 10l 1 pc.) of the front l cabinet and inverter cover and screws (ST1T4 x 10l 3 pcs.) of the front cabinet and lower part l of the front cabinet and motor base (ST1T4 x l 10l 2 pcs.). The left side of the front is made to insert to the rear cabinet, so remove it pulling upward. 2. Attachment 1) Insert claw at the left side of the front into the rear cabinet. 2) Hook the lower part at the right side of the front to concave part of the bottom plate. Insert claw of the rear cabinet into square hole of the front cabinet. 3) Attach the removed screws to the original positions.

Square Claw hole

Concave part

74

No.

Part name Inverter assembly

Procedure 1. Detachment 1) Perform work of items 1. of and . 2) Remove screw (ST1T4 x 10l 1 pc.) of the l upper part of the front cabinet. If removing the inverter cover in this condition, P.C. board can be checked. If there is no space in the upper part of the upper cabinet, perform work of . Be careful to check the inverter because high-voltage circuit is incorporated in it. 3) Perform discharging by connecting + , polarity by discharging resistance (approx. 10040W) or plug of soldering iron to + , terminals of the C15 (printed CAUTION HIGH VOLTAGE is attached.) electrolytic capacitor (500F) 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 is one with mass capacity. Therefore, it is dangerous that a large spark generates if short-circuiting between + , polarity with screwdriver, etc. for discharging. 4) Remove screw (ST1T4 x 10l 1 pc.) fixing the l 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 the terminal block. 6) Remove the lead wire from the bundled part at left side of the terminal block. 7) Pull the inverter box upward. 8) Disconnect connectors of various lead wires.

Remarks
Inverter cover P C. board . (Soldered surface)

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Adjust length of every lead wires other than complete and case thermo., and bundle them.

Holder TO sensor

P.M.V. coil (A, B, and C rooms) TGa, TGb, TGc sensor

The connector is one with lock, so remove it while pushing the part indicated by an arrow.

75

No. Part name

Procedure

Remarks
Main board

Control 1) Disconnect lead wires and connectors connected board from the control board assembly to other parts. 1. Lead wires assembly Connection with terminal block : 10 wires (Black, Orange, Pink, Red, Two white wires, Four white wires (reactors)) Connection with compressor : Remove the connector (3P). Connection with reactor : Remove the relay connectors from P07, 08 (2P, White) and P11, P12 (2P, Yellow). 2. Connectors Main control board assembly side CN300 : Outdoor fan (3P, White) CN301 : Outdoor fan position detection (5P, White) Sub-control board assembly side CN02 : TD sensor (3P, White) CN05 : TGa sensor (3P, Yellow) CN06 : TGb sensor (3P, Brown) CN07 : TGc sensor (3P, Green) CN08 : Case thermo. (2P, White) CN12 : C room pulse modulating valve (6P Green) , CN13 : B room pulse modulating valve (6P, Red) CN14 : A room pulse modulating valve (6P, Black) 2) Disconnect cable connecting the main control board assembly side and sub-control board assembly. Main control board assembly side CN704 : Connecting cable (4P, White) Sub.-control board assembly side CN15 : Connecting cable (4P, White) 3) Remove the control board assembly from P.C. board base. 1. Main control board assembly side Remove two claws of P.C. board base, and remove upward the heat sink with hands. Remove three screws fixing the heat sink and main control board assembly side, and replace the board with a new one. 2. Sub- control board assembly side Remove P.C. board base from the inverter box. Remove two claws of P.C. board base, and replace the board with a new one. 3. Be sure to use the radiating sheet between heat sink and IGBT and also screws with tube.

CN301 CN300 CN15 CN04 CN02 CN14 CN06 CN13 CN12 CN08 CN05

CN06 CN07

Sub-board

CN300 and 301 at the main control board assembly side and CN08 and 15 at the sub- control board assembly side are connectors with locks. Therefore, remove the connector while pushing the part indicated by an arrow.

P. C. board base P. C. board

Rear cabinet

1) Perform work of item 1 of Q, and R S. 2) Remove fixed screws fixing to the bottom plate. (ST1T4 x 10l 2 pcs.) l 3) Remove fixed screws fixing to the heat exchanger. (ST1T4 x 10l 2 pcs.) l 4) Remove fixed screw fixing to the valve mounting plate. (ST1T4 x 10l 1 pc.) l

, 

When mounting a new board, check that the board is correctly set in the groove of base holder of P.C. board base.

76

No.

Part name Fan motor

Procedure 1) Perform work of item 1 of Q and R. 2) Remove the flange nut fixing the fan motor and the propeller fan. Flange nut is loosened by turning clockwise. (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 (3 pcs.) holding by hands so that the fan motor does not fall.

Remarks

Fan motor Propeller fan

Compressor

1) Perform work of item 1 of Q and R, S, T, U. 2) Evacuate refrigerant gas. 3) Remove the partition board. (ST1T4 x 10l 3 pcs.) l 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. (ST1T4 x 10l 1 pc.) l 8) Remove the fixing screw of the bottom plate and valve clamping plate. (ST1T4 x 10l 2 pcs.) l 9) Pull upward the refrigeration cycle. 10) Remove nut fixing the compressor to the bottom plate. 1) Perform work of item 1 of Q, and S. 2) Remove lead wires clung in holder on the partition board. 3) Remove screws fixing the reactor. (ST1T4 x 10l 2 pcs.) l

 

,,
Flange nut Partition board

Valve clamping plate Compressor thermo. Compressor

Reactor

, 

Reactor

77

No.

Part name Pulse modulating valve coil

Procedure 1. Detachment 1) Perform work of item 1 of , and , , . 2) Turn the coil clockwise or counterclockwise by 90 degrees, and remove coil from the pulse modulating valve. 2. Attachment 1) Set take-out part of the lead wire of coil to the coil inserting position of the pulse modulating valve, and attach the coil. 2) Turn the coil clockwise or counterclockwise by 90 degrees, set surely the concave part at lower part of the coil to the positioning hole of the pulse modulating valve, and then fix the coil. The pulse modulating valve has A, B and C room side. After mounting it, check that coil at B room side (Red marking is marked on the pulse modulating valve.) is connected to CN13. Check that coil at C room side (Green marking is marked on the pulse modulating valve.) is connected to CN12 of the control board assembly respectively.

Remarks

Take-out part of lead wire Notch Coil inserting position Coil fix position

Coil inserting position

Positioning hole

Fan guard

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.
Minus screwdriver

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 the hole of the front cabinet. Push the hooking claws (10 positions) by hands and fix the claws. All the attaching works have completed. Check that all the hooking claws are fixed to the specified positions.

Hooking claw

78

No.
11

Part name Replacement of temperature sensor for servicing only

Procedure

Remarks

1) Cut the sensor 100 mm longer than old one. 2) Cut the protective tube after pulling out it (200 mm). 3) Move the protective tube toward the thermal sensor side and tear the tip of lead wire in Common service two then strip the covering part. parts of sensor 4) Pass the stripped part through the thermal TO, TGa, TGb, constringent tube. TGc (without TD) 5) Cut the old sensor 100 mm length on the connector side, and recycle that connector. 6) Tear the lead wire in two on the connector 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 used. 10)Fix the sensor again. NOTES : 1) Store the joint part of the sensor and the connector in the electric parts box. 2) Never joint them near the thermal sensor part. Otherwise it would cause insulation inferiority because of dew drops. 3) When replacing the sensor using the colored protective tube, wind the color tape matching the color of that tube.

Thermal sensor part

Cutting here Connector 100

200

Cutting here
15 70

Thermal constringent tube Cutting here

100

15 70

Soldered part

Dryer

Winding the color tape

These are parts for servicing sensors. Please check that the accessories shown in the right table are packed.

Parts name 1 2 3 4 5 6 Sensor Sensor Spring (A) Sensor Spring (B) Thermal constringent tube Color tape Terminal

Q'ty 1 1 1 3 1 3

Remarks Length : 3m For spare For spare Including one spare 9 colors

79

MCC-758

CN600

80

MCC-775

81

12. EXPLODED VIEWS AND PARTS LIST

12-1. Indoor Unit (1)

406

405

403

402

404

401

Location Part No. No. 401 402 403 404 405 43T69319

Description

Location Part No. No. 406 406 406 43T69333

Description

Temperature Sensor TC, 10k, 25C 43T60002 Terminal Block, 3P , AC 300V, 20A 43T69320 Temperature Sensor TC, 10k, 25C 43T69003 Cord Clamp 43T69079 P Board Assy, .C. WRS-LED

P Board Assy, .C. MCC-867(RAS-M10UKCV-E) 43T69334 P Board Assy, .C. MCC-867(RAS-M13UKCV-E) 43T69335 P Board Assy, .C. MCC-867(RAS-M16UKCV-E)

82

217 216 217

Indoor Unit

214

210 211 215 212 219 220 201 205 207 233 222 223 224 221 209 218 208 203 225

204

202

Electric Parts

229 204 234 206 228

226

Assembly

227

Location Part No. No. 201 202 203 204 205 206 207 208 209 211 212 212 214 215 216 217 218 219 220 221 222 223 224 225 43T00352 43T09316 43T03302 43T80301 43T09309 43T08350 13T70002 43T79301 43T21321

Description

Location Part No. No. 226 227 228 229 231 232 233 234 43T69310 43T83003 43T85362 43T62302 43T60317 43T60316 43T07303 43T01303

Description Remote Controller Holder Remote Controller Owner's Manual Terminal Cover Cord Motor Louver Cord Motor Fan Holder Pipe Mark

Panel Assy, Front Inlet Grille Assy Back body Assy Air Filter Horizontal Louver LED Panel Assy Drain Hose Cap Drain Motor Louver Refrigeration Cycle Assy 43T47006 Pipe Delivery 43T47305 Pipe Suction
(RAS-M10UKCV-E,M13UKCV-E)

43T47016 43T11301 43T19302 43T49302 43T49006 43T79302 43T22002 43T39301 43T20302 43T39302 43T21327 43T39303 43T82301

Pipe Suction
(RAS-M16UKCV-E)

Pipe Shield Holder Sensor Plate of EVA Seal Holder Plate EVA Seal Guide Drain Bearing Base Bearing Fan Cross Flow Band Motor - L Motor Fan Band Motor -R Plate Installation

89

12-2. Outdoor Unit


,,    
10 9 4

27 18 17 12,15 11,14 13,16 28 20 23 22 19 8

21 24, 25

7 6

4 3 22 23 30

 
,  
,
Part No. 43046351 17 18 19 20 21 22 23 24 25 26 27 28 29 30

2 1

29 26

Location No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

Part No. 43005452 43005369 43005364 4301V030 43042461 4301V029 43062230 4301V021 43041771 43043650 43046332 43046349 43046356 43147196 43047401 43147195

Description Cabinet, Back, Assembly Cabinet, Upper, Assembly Cabinet, Front, Assembly Guard, Fan Base, Assembly Cover, Valve, Packed Cover, Wiring, Assembly Hanger Compressor, DA130A1F-21F Condenser, Assembly Valve, Packed, 6,35 DIA Valve, Packed, 9,52 DIA Valve, Packed, 12,7 DIA Bonnet, 1/4 IN Bonnet, 3/8 IN Bonnet, 1/2 IN

Location No.

Description

Valve, Pulse Modulating (P.M.V.), SEV15RC2 43046347 Coil, P.M.V. 43058264 Reactor, CH38Z-K 43050298 Thermo. Bimetal, CS-7, 125 4302C019 Motor, Fan, DC, ICF-140-40-4 43047549 Nut, Flange 43020312 Fan, Propeller 43097166 Nut 43049643 Cushion, Rubber 43063187 Holder, Sensor 43049654 Holder, Sensor 43063195 Holder, Thermo. Bimetal 43019904 Holder, Sensor 4308N258 Manual

No. 18 Coil, P.M.V. : For standardization of the servicing parts, one type only is provided. Therefore, color of the connector may be different in replacement work.

75

12-3. P.C. Board Layout

706 704

710 709

702

TO Sensor TGa Sensor TGb Sensor TGc Sensor TD Sensor 708 703

1 3 4

711

705

707

Location No. 702 703 704 705 706 707

Part No. 43050382 43050334 43060052 4306A027 43060726 4306A030

Description Sensor, TC (6) Sensor, TD (4) Fuse, 25A, 250V, Lead Type Terminal block, 9P Fuse, 15A, 250V, Lead Type Terminal block, 9P

Location No. 708 709 710 711

Part No.

Description

43062231 Base, P.C. Board 43063308 Heatsink 4306S191 P.C. Board Assembly, MCC-758 4306S190 P.C. Board Assembly, MCC-775

76

TOSHIBA CARRIER (THAILAND) CO.,LTD.

144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.