FILE NO. A05-008 SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E RAS-10GAVP-E RAS-13GAVP-E RAS-16GAVP-E R410A PRINTED IN JAPAN, Nov.
CONTENTS 1. SAFETY PRECAUTIONS .......................................................................... 3 2. SPECIFICATIONS ..................................................................................... 5 3. REFRIGERANT R410A ............................................................................. 7 4. CONSTRUCTION VIEWS ........................................................................ 15 5. WIRING DIAGRAM .................................................................................
1. SAFETY PRECAUTIONS For general public use Power supply cord of outdoor unit shall be more than 1.5 mm 2 (H07RN-F or 245IEC66) polychloroprene sheathed flexible cord. • • • • Read this “SAFETY PRECAUTIONS” carefully before servicing. The precautions described below include the important items regarding safety. Observe them without fail. After the servicing work, perform a trial operation to check for any problem. Turn off the main power supply switch (or breaker) before the unit maintenance.
• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION. • TO PREVENT THE INDOOR UNIT FROM OVERHEATING 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.
2. SPECIFICATIONS 2-1.
2-2. Operation Characteristic Curve 10 10 9 9 8 8 7 RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 6 6 5 5 4 3 4 3 2 2 • Conditions Indoor : DB 27˚C/WB 19˚C Outdoor : DB 35˚C Air flow : High Pipe length : 7.5m Voltage : 230V 1 0 0 RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 7 Current (A) Current (A) 20 40 60 80 100 Compressor speed (rps) • Conditions Indoor : DB 20˚C Outdoor : DB 7˚C/WB 6˚C Air flow : High Pipe length : 7.
3. 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).
Table 3-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A R22 1/4 6.35 0.80 0.80 3/8 9.52 0.80 0.80 1/2 12.70 0.80 0.80 5/8 15.88 1.00 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.
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. ØD A Fig.
Table 3-2-6 Flare and flare nut dimensions for R22 Dimension (mm) Nominal diameter Outer diameter (mm) Thickness (mm) A B C D Flare nut width (mm) 1/4 6.35 0.8 9.0 9.2 6.5 13 17 3/8 9.52 0.8 13.0 13.5 9.7 20 22 1/2 12.70 0.8 16.2 16.0 12.9 20 24 5/8 15.88 1.0 19.7 19.0 16.0 23 27 3/4 19.05 1.0 23.3 24.0 19.2 34 36 45˚ 6˚ to 4 B A C 43˚ D to 4 5˚ Fig. 3-2-2 Relations between flare nut and flare seal surface 2.
3-3. Tools 3-3-1. Required Tools The service port diameter of packed valve of the outdoor unit in the air-water heat pump 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 Ø12.7 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.
3-4. 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. When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch. Connect the charge hose to packed valve service port at the outdoor unit’s gas side.
1. Be sure to make setting so that liquid can be charged. 2. 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.
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.
4. CONSTRUCTION VIEWS 4-1. Indoor Unit RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 790 Plasma pure filter Indoor heat exchanger Front panel Air filter 215 60 60 250 790 53 Knockout system 7 7 53 Knockout system Zeolite-plus filter 53 53 Air ionizer 54.5 60 60 54.5 Remote controller holder 64 5 125.5 Installation plate hanging section Wireless remote controller 58 19 Connecting pipe (Outside length:0.4m) Flare Ø9.52 (RAS-B16GKVP-E : Ø12.7) Connecting pipe (Outside length:0.
4-2. Outdoor Unit RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E 60 108 Ø25 drain hole 125 90 54 RAS-13GAVP-E) (Pipe dia. Ø9.52:RAS-10GAVP-E, Ø12.7:RAS-16GAVP-E 290 Connecting pipe port (Pipe dia. Ø6.35) 30 20 8-Ø7 hole (for fixing outdoor unit) Ø11x14 long hole (for Ø8-Ø10 anchor bolt) B leg part 257 483 Packed valve cover 157 79 21 6 147 21 108 69.5 Ø11-14U-shape hole (for Ø8-Ø10 anchor bolt) Connecting pipe port 145.
5. WIRING DIAGRAM 5-1. Outdoor Unit RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E Color Identification 220-240V 220V RED : RED WHI : WHITE BLK : BLACK BLU : BLUE BRW : BROWN ORN : ORANGE PUR : PURPUL YEL : YELLOW GRY : GRAY PNK : PINK GRN& GREEN& YEL : YELLOW ~50Hz ~60Hz 5-2.
6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E Parts name No. Type MF-280-30-5R Specifications 1 Fan motor (for indoor) DC280–340V, 30W 2 Room temp. sensor (TA-sensor) (–) 10kΩ at 25°C 3 Heat exchanger temp. sensor (TC-sensor) (–) 10kΩ at 25°C 4 Louver motor MP24Z Output (Rated) 1W, 16 poles, DC12V Model name Rating 6-2. Outdoor Unit RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E Parts name No.
7. REFRIGERANT CYCLE DIAGRAM 7-1. Refrigerant Cycle Diagram RAS-B10GKVP-E/RAS-10GAVP-E INDOOR UNIT T1 Temp. measurement Indoor heat exchanger P Pressure measurement Gauge attaching port Vacuum pump connecting port TA Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm Sectional shape of heat insulator Deoxidized copper pipe Outer dia. : 9.52mm Thickness : 0.8mm Allowable pipe length Cross flow fan Allowable height difference : 10m TC Max. : 25m Min.
RAS-B13GKVP-E/RAS-13GAVP-E, RAS-B16GKVP-E/RAS-16GAVP-E INDOOR UNIT T1 Temp. measurement Indoor heat exchanger P Pressure measurement Gauge attaching port Vacuum pump connecting port TA Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm Sectional shape of heat insulator Deoxidized copper pipe Outer dia. : 9.52mm(13), 12.7mm(16) Thickness : 0.8mm Allowable pipe length Cross flow fan Allowable height difference : 10m TC Max. : 25m Min.
7-2. Operation Data Temperature condition (°C) Indoor 27/19 Model name RAS- Outdoor 35/– Standard pressure P (MPa) Heat exchanger pipe temp. T1 (°C) T2 (°C) Indoor fan mode Outdoor fan mode Compressor revolution (rps) B10GKVP-E 0.9 to 1.1 13 to 15 42 to 44 High High 37 B13GKVP-E 0.8 to 1.0 11 to 14 42 to 45 High High 59 B16GKVP-E 0.7 to 0.
8. CONTROL BLOCK DIAGRAM 8-1. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E Indoor Unit Control Unit M.C.U.
~50Hz ~60Hz MCC5009 (P.C.B) Indoor unit send/receive circuit Outdoor air temp. sensor – 23 – Suction temp. sensor Heat exchanger temp.sensor Noise Filter Current detect M.C.U • • • • • • • • • • • Discharge temp. sensor OUTDOOR UNIT PWM synthesis function Input current release control IGBT over-current detect control Outdoor fan control High power factor correction control Inverter output frequency control A/D converter function P.M.V. control Discharge temp.
9.
9-2. Operation Description 9-2. 1. Basic operation ........................................................................................................... 26 1. Operation control ................................................................................................... 26 2. Cooling/Heating operation ..................................................................................... 27 3. AUTO operation .........................................................................................
Item Operation flow and applicable data, etc. 1. Basic operation Description 1. Operation control Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are controlled. 1) The operation conditions are selected by the remote controller as shown in the below. 2) A signal is sent by ON button of the remote controller. 3) The signal is received by a sensor of the indoor unit and processed by the indoor controllers as shown in the below.
Item 1. Basic operation Operation flow and applicable data, etc. Description 2. Cooling/Heating operation The operations are performed in the following parts by controls according to cooling/heating conditions. 1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal starts being transferred form the indoor controller to the outdoor unit. 2) At the indoor unit side, the indoor fan is operated according to the contents of “2.
Item Operation flow and applicable data, etc. 2. Indoor fan motor control Description (This operation controls the fan speed at indoor unit side.) The indoor fan (cross flow fan) is operated by the phasecontrol induction motor. The fan rotates in 5 stages in MANUAL mode, and in 5 stages in AUTO mode, respectively. (Table 1) UH H M+ M L+ L LUL SUL COOL ON Fan speed setup MANUAL (Fig. 1) Fan speed Indication AUTO L W6 L+ (L + M) / 2 M W9 M+ (M + H) / 2 H WC (Fig.
Item Operation flow and applicable data, etc. 2. Indoor fan motor control Description 1) When setting the fan speed to L, L+, M, M+ or H on the remote controller, the operation is performed with the constant speed shown in Fig. 3 and Table 1. 2) When setting the fan speed to AUTO on the remote controller, revolution of the fan motor is controlled to the fan speed level shown in Fig. 5 according to the set temperature and room temperature.
Item 3. Outdoor fan motor control Operation flow and applicable data, etc. Description The blowing air volume at the outdoor unit side is controlled. Receiving the operation command from the controller of indoor unit, the controller of outdoor unit controls fan speed. * For the fan motor, a DC motor with non-stage variable speed system is used. However, it is limited to 8 stages for reasons of controlling.
Item 4. Capacity control Operation flow and applicable data, etc. Description The cooling or heating capacity depending on the load is adjusted. According to difference between the setup value of temperature and the room temperature, the capacity is adjusted by the compressor revolution. 1) The difference between set temperature on remote controller (Ts) and room temperature (Ta) is calculated.
Item Indoor heat exchanger temperature 6. Release protective control by temperature of indoor heat exchanger Operation flow and applicable data, etc. (Prevent-freezing control for indoor heat exchanger) In cooling/dry operation, the sensor of indoor heat exchanger detects evaporation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value.
Item Operation flow and applicable data, etc. 7. Quick heating control This function quickens the starting of heating operation when indoor/outdoor temperature is low. (Available only in heating operation) When indoor temperature is low, this function stores the heat by heating winding depended on the outdoor temperature and then it enables the hot air blowing out quickly. The previous operation was heating and 2 hours passed after the operation had stopped. NO YES Winding is not heated.
Item Description Operation flow and applicable data, etc. 9. Louver control 1) Louver position This function controls the air direction of the indoor unit. • The position is automatically controlled according to the operation mode (COOL/HEAT). • The set louver position is stored in memory by the microcomputer, and the louver returns to the stored position when the next operation is performed. (Cooling/heating memory position) The angle of the louver is indicated as the horizontal angle is 0°.
Item 10. ECO operation Operation flow and applicable data, etc. Description When pressing [ECO] button on the remote controller, a quiet and mild operation is performed by reducing the fan speed and the compressor speed. This function operates the air conditioner with the difference between the set and the room temperature as shown in the following figure. The time correction is performed for 8 minutes each.
Item Operation flow and applicable data, etc. 11. Temporary operation Description Pressing [RESET] button starts the temporary operation of [AUTO] operation. When keeping [RESET] button pressed for 10 seconds or more, the temporary [COOL] operation is performed. YES Filter lamp ON Press RESET button.
Item Operation flow and applicable data, etc. 1. Purpose The air purifying control function is to alert the user to trouble in the ionizing or air purifying operation. 12. Air purifying control [Detection of abnormality] Purifying operation YES 2. Description Trouble is determined to have occurred (indicated by the FILTER indicator) in the following four cases. 1) When a count of 1000H has been reached on the timer 2) When the panel switch has been set to OFF by the opening of the air inlet grile, etc.
Item 14. Pulse motor valve (P.M.V.) control Operation flow and applicable data, etc. Description This function controls throttle amount of the refrigerant in the refrigerating cycle. According to operating status of the air conditioner, this function also controls the open degree of valve with an expansion valve with pulse motor. 1) When starting the operation, move the valve once until it fits to the stopper. (Initialize) * In this time, “Click” sound may be heard.
Item Operation flow and applicable data, etc. 15. Clean operation Unit now performing cooling or dry operation Press “STOP” button Only S.CLEAN indicator lights, and clean operation starts Time set now elapses Operation stops • During clean operations: The louver opens slightly. The indoor fan operates continuously at a speed of 260 rpm. Clean operation times Operation mode Cooling: Auto (cooling) Dry Operation time Description 1.
Item Operation flow and applicable data, etc. Description 16. Clean operation Setting the clean operation release release Add J04 of the indoor P.C. board assembly. * This cancels the auto restart function. Hold down the auto operation switch on the indoor unit for at least 3 seconds but not more than 10 seconds. * J04 will be near the MCU so take steps to ensure that it will not be exposed to excessive levels of heat. Also take care to avoid solder bridging with the surrounding components.
Item Operation flow and applicable data, etc. 17. Select switch on remote controller 1. Purpose This operation is to operate only one indoor unit using one remote controller. Press the operation button on the remote controller. YES Both indoor units start operation. Select “B” as the setting for one of the two indoor units and for the remote controller. (See below for details.) NO Unnecessary set [Remote controller select] HiPOWER ECO MEMO 1.3.5.
9-3. Auto Restart Function This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored. This function is not set to work when shipped from the factory. Therefore it is necessary to set it to work. 9-3-1.
9-3-2. How to Cancel the Auto Restart Function To cancel auto restart function, proceed as follows : Repeat the setting procedure : the unit receives the signal and beeps three times. The unit will be required to be turned on with the remote controller after the main power supply is turned off. • When the system is on stand-by (not operating) Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) Motions The unit is on standby. ↓ The unit starts to operate.
9-5. Remote Controller and Its Fuctions 9-5-1. Parts Name of Remote Controller 1 2 3 4 5 6 7 8 9 11 Infrared signal emitter Transmits signal to the indoor unit. 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. 13 Mode select button (MODE) Press this button to select a mode.
9-5-2. Name and Functions of Indications on Remote Controller [Display] All indications, except for the clock time indicator, are displayed by pressing the 1 2 3 4 5 6 Transmission mark This transmission mark indicates when the remote controller transmits signals to the indoor unit. Mode indicator Indicates the current operation mode. (AUTO : Automatic control, A : Auto changeover : Cool, : Dry, : Heat) control, 7 Temperature indicator Indicates the temperature setting.
9-6. Hi-POWER Mode ([Hi-POWER] button on the remote controller is pressed) When [Hi-POWER] button is pressed while the indoor unit is in Auto, Cooling or Heating operation, Hi-POWER mark is indicated on the display of the remote controller and the unit operates as follows. 1. Automatic operation • The indoor unit operates in according to the current operation. 2. Cooling operation • The preset temperature drops 1°C. (The value of the preset temperature on the remote controller does not change.
10. INSTALLATION PROCEDURE 10-1. Safety Cautions For the rear left and left piping Hook 47 mm or more 1 Installation plate Wall Hook 140 mm or more 74 mm or more Hook Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better installation work. 7 Mounting screw Do not allow the drain hose to become slack. Cut the piping hole slightly sloped 5 Zeolite-plus filter Z Shield pipe (for extension drain hose) Make sure the drain hose is sloped downward.
10-2. Optional Parts, Accessories and Tools 10-2-1. Optional Installation Parts Part Code Parts name Q’ty Refrigerant piping Indoor unit name Liquid side (Outer diameter) Gas side (Outer diameter) RAS-B10GKVP-E, B13GKVP-E 6.35 mm 9.52 mm RAS-B16GKVP-E 6.35 mm 12.7 mm 1 ea.
10-2-3. Installation/Servicing Tools Changes in the product and components In the case of an air conditioner using R410A, 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.
10-3-2. Drilling a Hole and Mounting Installation Plate 10-3. Indoor Unit 10-3-1. Installation Place Drilling a hole When install the refrigerant pipes from the rear. The center of the pipe hole Pipe hole 65 42 mm • A place which provides enough spaces around the indoor unit as shown in the diagram. • A place where there are 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.
When the installation plate is directly mounted on the wall 1. Securely fit the installation plate onto the wall by screws with the upper and lower catches, that hold the indoor unit, facing out. 2. To mount the installation plate on a concrete wall use anchor bolts. Drill the anchor bolt holes as illustrated in the above figure. 3. Install the installation plate horizontally and level. 10-3-3. Electrical Work 1. The supply voltage must be the same as the rated voltage of the air conditioner. 2.
10-3-5. Piping and Drain Hose Installation CAUTION • Be sure to refer to the wiring system diagram labeled inside the front panel. • Check local electrical regulations for any specific wiring instructions or limitations. Piping and drain hose forming • Since condensation results in machine trouble, make sure to insulate both the connecting pipes separately. (Use polyethylene foam as insulating material.
How to attach the drain cap In case of bottom right or bottom left piping 1. Insert hexagonal wrench (4 mm). • After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool. Slit Fig. 10-3-16 4 mm Fig. 10-3-13 Left-hand connection with piping 2. Firmly insert drain cap. No gap Insert a hexagon wrench (Ø4mm) Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap.
10-3-7. Drainage CAUTION 1. Run the drain hose at a downward sloped angle. • 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. NOTE : • Hole should be made at a slight downward slant on the outdoor side. Do not rise the drain hose. Indoor unit Auxiliary pipes Connecting cable Do not form the drain hose into the waved shape. 50 mm or more Installation plate Fig.
10-4. Outdoor Unit Precautions for adding refrigerant 10-4-1. Installation Place • A place which provides enough space around the outdoor unit as shown in the diagram. • A place which can bear the weight of the outdoor unit and does not allow an increase in noise level and vibration. • A place where the operation noise and discharged air do not disturb neighbors. • A place which is not exposed to a strong wind. • A place free of combustible gases. • A place which does not block a passageway.
10-4-2. Draining the Water 10-4-3. Refrigerant Piping Connection • Holes are provided on the base plate of the outdoor unit to ensure that the defrost water produced during heating operations is drained off efficiently. If a centralized drain is required when installing the unit on a balcony or wall, follow the steps below to drain off the water. 1. Proceed with water-proofing by installing the water-proof rubber caps in the 2 elongated holes on the base plate of the outdoor unit.
Tightening Connection Use a vacuum pump Align the centers of the connecting pipes and tighten the flare nut as much as possible with your fingers. Then tighten the nut with a wrench and torque wrench as shown in the figure. Half union Flare nut Externally threaded side Internally threaded side Use a wrench to secure. Use a torque wrench to secure. Fig. 10-4-7 CAUTION • Do not apply excessive force. Otherwise, the nut may break. (Unit : N·m) Outer dia. of copper pipe Tightening torque Ø6.
Packed Valve handling precautions • Open the valve stem all the way; but do not try to open it beyond the stopper. • Securely tighten the valve stem cap with torque in the following table: 1 2 3 10 10 40 Gas side (Ø12.7 mm) 50 to 62 N•m (5.0 to 6.2 kgf•m) Gas side (Ø9.52 mm) 33 to 42 N•m (3.3 to 4.2 kgf•m) Liquid side (Ø6.35 mm) 14 to 18 N•m (1.4 to 1.8 kgf•m) Service port 14 to 18 N•m (1.4 to 1.8 kgf•m) 10 L N 10 30 Earth line Connecting cable 40 30 Power cord Earth line Fig.
10-5-4. Remote Controller Selector Switch Setting 10-5. Test Operation 10-5-1. Gas Leak Test • Check the flare nut connections for gas leaks with a gas leak detector and/or soapy water. Check places for flare nut connections (indoor unit) Remote controller selector switch Valve cover Electric parts Check places for outdoor unit Fig. 10-5-1 10-5-2. Test Operation To test the system, press and hold RESET button for 10 sec. (There will be one short beep.
11. HOW TO DIAGNOSE THE TROUBLE The pulse motor 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. Troubleshooting Procedure Page No.
CAUTION A high voltage (equivalent to the supply voltage) is also energized to ground through the sensors, PMV and other low-voltage circuits. The sensor leads and other wires are covered with insulated tubes for protection. Nevertheless, care must be taken to ensure that these wires are not pinched. Take sufficient care to avoid directly touching any of the circuit parts without first turning off the power.
11-1. First Confirmation 11-1-1. Confirmation of Power Supply Confirm that the power breaker operates (ON) normally. 11-1-2. Confirmation of Power Voltage Confirm that power voltage is AC 220–230–240 ± 10%. If power voltage is not in this range, the unit may not operate normally. 11-1-3. 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.
11-2. 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. 11-3.
11-4. Self-Diagnosis by Remote Controller (Check Code) 1. If the lamps are indicated as shown B to E in Table 11-3-1, execute the self-diagnosis by the remote controller. 2. When the remote controller is set to the service mode, the indoor controller diagnoses the operation condition and indicates the information of the self-diagnosis on the display of the remote controller with the check codes.
11-4-2. Caution at Servicing 1. After servicing, press 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. 3.
Operation of diagnosis function Block distinction Check code Block Outdoor P.C. board Check code Air conditioner status Cause of operation Remarks Judgment and action Inverter over-current protective circuit operates. (Short time) All off Displayed when error is detected. Even if trying operation again, all operations stop immediately. : Replace P.C. board. Position-detect circuit error or short-circuit between windings of compressor All off Displayed when error is detected. 1.
11-5. Judgment of Trouble by Every Symptom 11-5-1. Indoor Unit (Including Remote Controller) (1) Power is not turned on (Does not operate entirely) 1. Is the supply voltage normal? 2. Is the normal voltage provided to the outdoor unit? 3. Is the crossover cable connected properly? 4. Is the fuse (F01) blown? Operation Check Item Considerable principle cause Turn off power supply once, and 5 second later, turn it on again.
(3) Only the indoor motor fan does not operate 1. Is it possible to detect the power supply voltage (AC220–240V) between Q and R 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 approximately 10 minutes after it is turned on, to prevent a cold air from blowing in.) Turn off power supply once, and turn it on again.
(4) Indoor fan motor automatically starts to rotate by turning on power supply The IC is built in the indoor fan motor. Therefore the P.C. board is also mounted to inside of the motor. If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turning on power supply. 1. Remove the front panel. (Remove 2 screws.) 2. Remove the cover of the fan motor lead wires. 3.
(5) Troubleshooting for remote controller Check that A or B selected on the main unit is matched with A or B selected on the remote controller. The unit does not beep at all. Push the START/STOP button. Operation lamp on indoor unit is not indicated. NO Is transmission mark indicated? YES Is receiver on indoor unit exposed to direct sunlight? Push RESET button on remote controller with tip of pencil.
11-5-2. 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 unit to outdoor unit 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.
11-6. Check Code 1C (Miswiring in indoor/outdoor units) and 1E 1C 1E Gas leakage, disconnection of TS/TC sensors (Check code 02, 1C) Discharge temp. error, gas leakage (Check code 03, 1E) Valve drive check Is coil of the pulse motor valve (P.M.V.) correctly set? NO Set it correctly. YES Is connecter of coil connected to inverter? NO Set it correctly.
11-7. Troubleshooting 11-7-1. How to Check Whether the Air Purifier is Good or Not Turn off the power breaker once, and turn on again after 10 seconds. Does the OPERATION indicator flash? NO To item “Power supply is not turned on” Primary check YES Turn off the power breaker and remove CN34 (Micro switch connector). Short-circuit between 1 and 2 pin of CN34 at PC side, and turn on the power breaker after 10 seconds.
11-7-2. How to Check Whether the Minus Ion Generator is Good or Not Turn off the power breaker once, and turn on again after 10 seconds. Does the OPERATION indicator flash? NO To item “Power supply is not turned on” Primary check YES Turn off the power breaker and remove CN34 (Micro switch connector). Short-circuit between 1 and 2 pin of CN34 at PC side, and turn on the power breaker after 10 seconds.
11-8. How to Diagnose Trouble in Outdoor Unit 11-8-1. Summarized Inner Diagnosis of Inverter Assembly Table 11-8-1 Diagnosis/Process flowchart Item Contents Preparation Turn “OFF” the power supply breaker, and remove 3P connector which connects inverter and compressor. Remove connector of compressor. Check 25A fuse (Part No.F01). Check NG OK Replace fuse. • Check whether 25A fuse on the control board assembly is blown or not. (F01) Check electrolytic capacitor, diode block (DB01), etc.
Diagnosis/Process flowchart A Item Contents Check Check winding resistance between phases of compressor, and resistance between outdoor frames by using a tester. B Replace control board assembly. Check compressor winding resistance. NG • Is not grounded. → OK if 10MΩ or more • Is not short-circuited between windings. → OK if 0.51Ω → 0.57Ω (Check by a digital tester.) • Winding is not opened. OK Replace control board.
(3) Check procedures Table 11-9-1 No. Procedure Check points 1 Turn off the power supply breaker and remove the P.C. board assembly from electronic parts base. Remove the connecting cables from the terminal block. Check whether or not the fuse (F01) is blown. Impulse voltage was applied or the indoor fan motor short-circuited. 2 Remove the connector of the motor and turn on the power supply breaker.
11-9-2. P.C. Board Layout GND +12V +5V [1] Sensor characteristic table 100 Resistance value (k ) 90 80 TD 70 60 50 40 30 20 TA, TC, TO, TE, TS 10 0 0 10 20 30 40 50 Temperature (˚C) – 78 – TD TA TC TO TE TS : Discharge temp. sensor : Room temp. sensor : Heat exchanger temp. sensor : Outdoor temp. sensor : Outdoor heat exchanger temp. sensor : Suction temp.
11-9-3. Indoor Unit (Other Parts) No. Part name 1 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 (kΩ) 10°C 20°C 25°C 30°C 40°C 20.7 12.6 10.0 7.9 4.5 2 Remote controller Refer to 11-5-1. (5). 3 Louver motor MP24Z Measure the resistance value of each winding coil by using the tester. (Under normal temp.
11-9-5. Checking Method for Each Part Part name 1 Electrolytic capacitor (For boost, smoothing) Checking procedure 1. 2. 3. 4. 5. 6. Turn OFF the power supply breaker. Discharge all three 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 No.
11-10. 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 controller 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.
12. HOW TO REPLACE THE MAIN PARTS WARNING • Since high voltages pass through the electrical parts, turn off the power without fail before proceeding with the repairs. Electric shocks may occur if the power plug is not disconnected. • After the repairs have been completed (after the front panel and cabinet have been installed), perform a test run, and check for smoking, unusual sounds and other abnormalities. If this check is omitted, a fire and/or electric shocks may occur.
No. Part name Front panel Procedures Remarks 4) Press “ ” part under the front panel and remove hooks of the front panel from the installation plate. Pull here Installation plate Press here Press here Front panel Press 5) Remove the front panel fixing screws. (2 pcs.) 6) Press the electric parts box with the right thumb while pulling the both sides of the front panel toward you.
No. Part name Procedures High voltage generator 1) Follow to the procedure in the item . 2) Remove the drain guide. 3) To remove the air ionizer from the back body, pull it toward you while pressing down on its left and right claws. Disconnect the two leads (black) connected to the air ionizer from where they are fitted into the other components. (Caution: do not remove the Faston.
No. Part name Electric parts box assembly Procedures Remarks 1) Follow the procedure up to 4) in above. 2) Remove screw of earth lead attached to the end plate of the evaporator. 3) Remove the lead wire cover, and remove connector (5P) for the fan motor and connector (5P) for the louver motor from the electric parts box assembly. 4) Pull out TC sensor from sensor holder of the evaporator.
No. Part name Horizontal louver Procedures Remarks 1) Remove shaft of the horizontal louver from the back body. (First remove the left shaft, and then remove other shafts while sliding the horizontal louver leftward.) Slide the horizontal louver leftward Evaporator (Heat exchanger) 1) Follow to the procedure in the item . 2) Remove the pipe holder from the rear side of the main unit. 3) Remove two fixing screws at the left side of the end plate of the heat exchanger.
No. Part name Bearing Procedures 1) Follow to the procedure in the items . 2) Remove the two fixing screws used to secure the left edge panel of the heat exchanger, and remove the two screws used to secure the bearing base. Remarks Screw Bearing base Screw 3) Raise the left side of the heat exchanger slightly, and remove the bearing base. • If the bearing is out from the housing, push it into the specified position and then incorporate it in the main body.
No. Part name Fan motor Procedures 1) Follow to the procedure in the item . 2) Loosen the set screw of the cross flow fan. 3) Remove two fixing screws of the motor band (Right), and then remove the motor band (Right). 4) Pull the fan motor outward. In assembling work, install the fan motor as follows. • When assembling the fan motor, the fan motor must be installed in such a way that the fan motor leads will be taken out is positioned at the bottom front.
No. Part name Procedures Cross flow fan 1) At assembling work of the bearing base, check that the drain pipe is surely incorporated in the back body. (Otherwise, water leak is caused.) 2) To incorporate the fan motor, remove the fan motor rubber (at shaft core side), incorporate the motor into the position in the following figure, and then install the fan motor.
12-2. Microcomputer No. Part name Common procedure Procedure Remarks 1) Turn the power supply off to stop the operation of air-conditioner. 2) Remove the front panel. • Remove the 2 fixing screws. 3) Remove the electrical part base. Replace terminal block, microcomputer ass’y and the P.C. board ass’y.
12-3. Outdoor Unit No. Part name Common procedure Procedure Remarks 1. Detachment Upper cabinet NOTE Wear gloves for this job. Otherwise, you may injure your hands on the parts, etc. 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner. 2) Remove the valve cover. (ST1TØ4 × 8L 1 pc.) • After removing screw, remove the valve cover pulling it downward. 3) Remove wiring cover (ST1TØ4 × 8L 2 pcs.), and then remove connecting cable.
No. Part name Procedure Front cabinet 1. Detachment 1) Perform step 1 in . 2) Remove the fixing screws (ST1TØ4 × 8L 2 pcs.) used to secure the front cabinet and inverter cover, the screws (ST1TØ4 × 8L 3 pcs.) used to secure the front cabinet at the bottom, and the fixing screws (ST1TØ4 × 8L 2 pcs.) used to secure the motor base. • The front cabinet is fitted into the side cabinet (left) at the front left side so pull up the top of the front cabinet to remove it. 2.
No. Part name Inverter assembly Procedure 1) Perform work of item 1 in . 2) Remove screw (ST1TØ4 × 8L 2 pcs.) of the 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 above the unit, perform work of 1 in . Remarks Inverter cover P. C. board (Soldered surface) Be careful to check the inverter because high-voltage circuit is incorporated in it.
No. Part name Procedure Control board assembly 1. Disconnect the leads and connectors connected to the other parts from the control board assembly. 1) Leads • 3 leads (black, white, orange) connected to terminal block. • Lead connected to compressor : Disconnect the connector (3P). • Lead connected to reactor : Disconnect the two connectors (2P).
No. Part name Side cabinet Procedure Remarks 1. Side cabinet (right) 1) Perform step 1 in and all the steps in . 2) Remove the fixing screw (ST1TØ4 × 8L 5 pcs.) used for securing the side cabinet to the bottom plate and valve fixing panel. 2. Side cabinet (left) 1) Perform step 1 in . 2) Remove the fixing screw (ST1TØ4 × 8L 1 pcs.) used to secure the side cabinet (left) onto the heat exchanger. 3) Remove the fixing screw (ST1TØ4 × 8L 2 pc.
No. Part name Procedure Compressor 1) Perform work of item 1 of and , , , . 2) Extract refrigerant gas. 3) Remove the partition board. (ST1TØ4 × 8L 3 pcs.) 4) Remove the sound-insulation material. 5) Remove terminal cover of the compressor, and disconnect lead wire of the compressor from the terminal. 6) Remove pipe connected to the compressor with a burner. • Take care to keep the 4-way valve away from naked flames. (Otherwise, it may malfunction.
No. Part name Electronic expansion valve coil Procedure Remarks 1. Detachment 1) Perform step 1 in , all the steps in and 1 in . 2) Remove the coil by pulling it up from the electronic control valve body. Coil anti-turn lock 2. Attachment 1) When assembling the coil into the valve body, ensure that the coil anti-turn lock is installed properly in the pipe. When handling the parts, do not pull the leads.
No. 11 Part name Procedure Remarks TE sensor (outdoor heat exchanging temperature sensor) • Attachment With the leads pointing downward and the sensor leads pointing in the direction shown in the figure, install the sensor onto the straight pipe part of the condenser output pipe.
No. Part name Procedure 15 Replacement of temperature sensor for servicing only 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 two then strip the covering part. 4) Pass the stripped part through the thermal constringent tube. 5) Cut the old sensor 100 mm length on the connector side, and recycle that connector.
MCC-5009 – 100 –
13. EXPLODED VIEWS AND PARTS LIST 13-1. Indoor Unit (1) 240 238 247 216 235 213 234 217 214 225, 226 209 212 236 230 201 223 203 221, 222, 224 246 210 218, 219 207 215 211 227 205 228 206 202 239 229 245 204 232 233 ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part No. Description Location No. Part No.
Indoor Unit (2) 402 407, 408, 409 403 404 406 401 410 405 ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part No. Description Location No. Part No. 401 402 403 404 405 406 4306A123 43062263 43050425 43050426 4306S728 43051346 Terminal Block, 2P Cover, E-Parts Sensor, TC (F6) Sensor, TA P.C.
13-2.
∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part Description Location No.
13-3. P.C. Board Layout 704 Base, P.C. Board 706 701 702 703 Sensor, TD (Ø4) Sensor, TE Sensor, TS Sensor, TO 707 P.C. Board Ass’y 705 Terminal (6P) ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part 701 702 703 704 43050422 43050423 43050427 43062228 Description Location No. Part 705 706 707 43160566 43050430 4306S737 Sensor, TE Sensor, TS Sensor, TO Base, P.C.
Appendix Cord Heater Installation Work Applicable Models: RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E 1. Required parts for installation work (Recommendation) The above products conform to RoHS (2002/95/EC). Therefore when procuring and using the following recommended parts at local site, it is recommended to confirm each part conforms to RoHS before use. No. Part name Q’ty Specifications/Vendor 1 Cord heater 1 Drain line heaters CSC2 (1.5m, 40W/m) by Flexelec com. (Please go to the following URL.
Appendix No. Part name Q’ty Specifications/Vendor Remarks 13 Power cord 1 2-cores x 0.75mm² or more, H05RN-F Procured locally 14 Thermostat fixing plate 1 Material: SGCC-Z08, Board thickness: 0.
Appendix 3. Cord heater installation wiring diagram L N Fuse Thermostat Cord heater * Be sure to connect the fuse and the thermostat to LIVE side of the cord heater. Outdoor unit Earth leakage circuit breaker Power supply for air conditioner Earth leakage circuit breaker Power supply for cord heater NOTE: Separate the cord heater power from the air conditioner power, and connect it to its exclusive breaker.
Appendix 4. Cord heater installation work procedure No. 1 Photo / Explanatory diagram Procedure Remove each cabinet, inverter assembly, motor base assembly, and partition board assembly. * Do not damage the electric parts such as cables, connectors, etc. while this work. Remove the upper cabinet and the valve cover.
Appendix No. Photo / Explanatory diagram Procedure Motor base assembly Remove the motor base assembly, partition plate assembly and the sound insulation board. Related parts / Screws list Partition plate assembly Part name Screw type Quantity Motor base assembly (Including motor and fan) Ø4 × 8 2 Partition plate assembly (Including reactor) Ø4 × 8 3 1-5 Sound insulation board Used screw Remove the fixing screws of the heat exchanger and the valve fixing plate.
Appendix No. Photo / Explanatory diagram Procedure Cord heater installation work 2 Drill a hole on the outdoor unit base plate, and fix the cord heater to the outdoor unit base plate using P-shape clamp. Connect the cord heater cables. 2-1 Using a motor drill, etc., drill Ø3.2 holes on the outdoor unit base plate. (12 positions) See Appendix-10 for the additional hole positions. These holes are used to fix the cord heater to the outdoor unit base plate with P-shape clamp.
Appendix No. Photo / Explanatory diagram Procedure Rework the side cabinet (L) to remove part of it. Side cabinet (L) The area to be removed is indicated by the shaded lines in the left figure. After removing part of the side cabinet (L), deburr the edges of the side cabinet (L). 2-4 Delete Perform end process and bundling of each cable. Close-end connector insulation tape Using fixing screws (Self-tapping screw type-B Ø3.5 × 6mm), fix the thermostat to the thermostat fixing plate.
Appendix No. Photo / Explanatory diagram Procedure Assembly 3 Return a set of the refrigeration cycle assembly into the outdoor unit base plate and reassemble sound insulation board, partition plate assembly, fan motor assembly, and side cabinet (R/L) as original. Fix the thermostat fixing plate to the side cabinet (R), built in the inverter assembly, and then connect various cables. After then, incorporate front cabinet, upper cabinet, wiring cover, and valve cover as before.
Appendix 5.8 8 5. Drawing of thermostat fixing plate 37 2-Ø3.4 burring hole (Upward) 18 11 11 28 36 46 56 11 55 24 11 18 3-Ø3.4 burring hole (Downward) 45 Material: SGCC-Z08, Thickness: 0.
Appendix 6. Diagram showing positions φ3.
This product is compliant with Directive 2002/95/EC, and cannot be disposed as unsorted municipal waste. TOSHIBA CARRIER CORPORATION 2 CHOME 12-32, KONAN, MINATOKU, TOKYO, 108-0075, JAPAN Copyright © 1999 to 2005 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.