FILE NO. A05-014 SERVICE MANUAL SPLIT TYPE Indoor Unit RAS-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-E Outdoor Unit RAS-3M23GACV-E R410A PRINTED IN JAPAN, Jan.
CONTENTS 1. SAFETY PRECAUTIONS .......................................................................... 3 2. SPECIFICATIONS ..................................................................................... 5 3. REFRIGERANT R410A ............................................................................. 9 4. CONSTRUCTION VIEWS ........................................................................ 17 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 RESISTORS, FURNACE, STOVES, ETC.
2. SPECIFICATIONS The indoor and outdoor units that can be used in combination are shown in the tables below.
2-1.
2-2. Specifications of Performance When Each Indoor Unit is Combined with Other Unit Operating status 1 unit Power supply (V) A B C A B C 220 10 — — 2.7 — — 230 10 — — 2.7 — — 240 10 — — 2.7 — — 220 13 — — 3.7 — — 230 13 — — 3.7 — — 240 13 — — 3.7 — — 220 16 — — 4.5 — — 230 16 — — 4.5 — — 240 16 — — 4.5 — — 220 10 10 — 2.7 2.7 — 230 10 10 — 2.7 2.7 — 240 10 10 — 2.7 2.7 — 220 10 13 — 2.45 3.
2-2-1. Operation Characteristic Curve 12 • Conditions Indoor : DB 27˚C/WB 19˚C Outdoor : DB 35˚C Air flow : High Pipe length : 5m × 3 3 units operating 11 10 9 8 Current (A) 220V 7 230V 6 5 240V 4 3 2 1 0 0 10 20 30 40 50 60 70 80 90 100 Inverter output frequency (rps) 2-2-2.
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-M10GKCVP-E RAS-M13GKCVP-E RAS-M16GKCVP-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 64 5 125.5 Installation plate hanging section Remote controller holder Wireless remote controller 58 19 Connecting pipe (Outside length:0.4m) Flare Ø9.52 (RAS-M16GKCVP-E : Ø12.7) Connecting pipe (Outside length:0.
4-2. Outdoor Unit RAS-3M23GACV-E 600 A leg part 90 Ø11 × 17 U-shape hole (For Ø8 to Ø10 anchor bolt) 270 296 (ø6 hole pitch) 310 (Anchor bolt long hole pitch) 50 8-Ø6 hole (For fixing outdoor unit) Ø11 × 17 long hole (For Ø8 to Ø10 anchor bolt) 18 B leg part Fan guard 115.5 Hanger 53 53 687 695 Valve cover 8 86.2 53 53 53 Charging port 123.8 68.5 780 332 Connecting pipe port (Pipe dia.Ø6.35) Detailed A leg part 600 Connecting pipe port (Pipe dia.Ø9.
BLK BLK HEAT EXCHANGER SENSOR (TC) CN03 (WHI) BLK 1 1 BLK BLK WHI RED 3 CN22 CN33 (WHI) Heat exchanger GRN & YEL 1 CN23 CN21 1 1 CN34 2 2 (RED) FUSE F01 AC 250V T3.15A CN10 (WHI) 1 1 2 2 THERMO SENSOR (TA) CN100 (WHI) BLU BLU BLU BLU BLU BLU BLU BLU WHI CN13 (WHI) 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 LINE FILTER DC5V DB01 DC12V MAIN P.C.
5-2. Outdoor Unit Color Identification BLK BLU RED GRY PNK GRN RAS-3M23GACV-E : BLACK : BLUE : RED : GRAY : PINK : GREEN WHI BRW ORN YEL PUR : WHITE : BROWN : ORANGE : YELLOW : PURPLE NOTE IGBT PMV TD TGa to TGc TO : Insulated Gate Bipolar Transistor : Pulse Motor Valve : Discharge Temp. sensor : Temp. sensor at A to C unit gas side : Outdoor Temp.
6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E No. Parts name Type MF-280-30-5R Specifications 1 Fan motor (for indoor) 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 DC280–340V, 30W Output (Rated) 1W, 16 poles, DC12V 6-2. Outdoor Unit RAS-3M23GACV-E Parts name Model name SC coil (Noise filter) (L01) ADR25H200RBTB AC 250V, 20A, 0.
7. REFRIGERANT CYCLE DIAGRAM 7-1. Refrigerant Cycle Diagram INDOOR UNIT A To To C room B room Connecting pipe Thickness : 0.8 mm Ø9.52 : RAS-M10GKCVP-E RAS-M13GKCVP-E Ø12.7 : RAS-M16GKCVP-E Indoor heat exchanger T1 Temp. measurement To To C room B room Connecting pipe Thickness : 0.8 mm Ø6.35 Pressure measurement Gauge attaching port Vacuum pump connecting port P Allowable pipe length Allowable height difference : 10m Cross flow fan Per 1 unit Max. : 20m Min. : 2m Total Max.
7-2. Operation Data RAS-M14GAV-E, RAS-M14GACV-E Temperature condition (°C) Indoor Outdoor No.of operating units 1 unit Standard pressure P (MPa) Combinations of indoor units Surface temp. of heat exchanger Fan speed T1 (°C) T2 (°C) Indoor Outdoor Compressor revolution (rps) 10 — — 0.92 11 42 High Med. 37 13 — — 0.85 09 47 High High 57 16 — — 0.73 8 50 High High 73 10 10 — 0.96 10.5 to 11.5 49 High High 69 13 10 — 0.
8. CONTROL BLOCK DIAGRAM 8-1. Indoor Unit RAS-M10GKCVP-E, RAS-M13GKCVP-E, RAS-M16GKCVP-E Indoor Unit Control Unit M.C.U.
8-2. Outdoor Unit (Inverter Assembly) RAS-3M23GACV-E Outdoor air temp. Sensor Gas side pipe temp. Sensor Discharge temp. Sensor MCC-818 (SUB-P.C. B) M.C.U A unit send/receive circuit • Inverter outdoor frequency control • A/D converter function A unit P.M.V. • P.M.V. control Driver circuit of P.M.V. B unit P.M.V. B unit send/receive circuit • Discharge temp. control • Error display C unit P.M.V.
9.
9-2. Operation Description 9-2. 1. Basic operation ....................................................................................................................... 1. Operation control ............................................................................................................... 2. Operating mode selection when performing 2-room operation .......................................... 3. Cooling 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 Operation flow and applicable data, etc. 1. Basic operation 2. Operating mode selection when performing 2-roomoperation Description 1) The outdoor unit operating mode conforms to the instructions of the indoor unit that was pressed first. 2) When combined operation consisting of cooling (dry) and heating, fan (air purification) and heating, or cleaning operation and heating is performed, operation conforms to the instructions of the indoor unit that was pressed first as shown in the left table.
Item Operation flow and applicable data, etc. Description 1. Basic operation 4. AUTO operation Selection of operation mode As shown in the following figure, the operation starts by selecting automatically the status of room temperature (Ta) when starting AUTO operation. 1) Detects the room temperature (Ta) when the operation started. 2) Selects an operation mode from Ta in the left figure. 3) Fan operation continues until an operation mode is selected.
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 * The fan speed broadly varies due to position of the louver, etc.
Item Description Operation flow and applicable data, etc. 3. Outdoor fan motor control The blowing air volume at the outdoor unit side is controlled. 1) The operation command sent from the remote controller is Receiving the operation command from the controller of indoor processed by the indoor unit unit, the controller of outdoor unit controls fan speed. controller and transferred to the * For the fan motor, a DC motor with non-stage variable speed controller of the outdoor unit. system is used.
Item 5. Current release control Operation flow and applicable data, etc. Description This function prevents troubles on the electronic parts of the compressor driving inverter. This function also controls drive circuit of the compressor speed so that electric power of the compressor drive circuit does not exceed the specified value. 1) The input current of the outdoor unit is detected in the inverter section of the outdoor unit.
Item Description Operation flow and applicable data, etc. 7. 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. • 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 memory position) The angle of the louver is indicated as the horizontal angle is 0°.
Item Operation flow and applicable data, etc. 8. ECO operation 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. 10. Air purifying control This function generates nagative ion while cleaning the air in the room. If air purifier-ON signal is received while the air conditioner stops, the air purifier starts operation, and if it is received while the air conditioner operates, the air conditioner and the air purifier start operation. The air ion generator operates linked with the air purifying operation.
Item Operation flow and applicable data, etc. 10. Air purifying control [Detection of abnormality] 1. Purpose The air purifying control function is to alert the user to trouble in the ionizing or air purifying operation. 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 Operation flow and applicable data, etc. 11. Discharge temperature control 1. Purpose This function detects error on the refrigerating cycle or error on the compressor, and performs protective control. Td value 117°C 112°C 108°C 105°C 98°C Description Control operation Judges as an error and stops the compressor. Reduce the compressor speed. Reduce slowly compressor speed. 2.
Item Operation flow and applicable data, etc. 13. Clean operation Description 1. Purpose The clean operation is to minimize the growth of mold, bacteria etc. by running the fan and drying so as to keep the inside of the air conditioner clean.
Item 14. Clean operation release Operation flow and applicable data, etc. Description Setting the clean operation 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. 15. 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. Y Z Shield pipe (for extension drain hose) (polyethylene foam, 6 mm thick) 1 10-2-2. Accessory and Installation Parts Part No. Part name (Q’ty) Part No. Part name (Q’ty) Installation plate × 1 Part No.
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 10-4-1. Optional Parts, Accessories and Tools Optional installation parts Part name Refrigerant piping *1 Specifications Q’ty Indoor unit name (Abbreviation) Liquid side (Outer diameter) Gas side (Outer diameter) RAS-M10GKCVP-E RAS-M13GKCVP-E 6.35 mm 9.52 mm RAS-M16GKCVP-E 6.35 mm 12.7 mm Putty, PVC tapes 1 ea. 1 ea. *1 Refrigerant piping covered with insulating material (polyethylene form, 6 mm thick.).
10-5. Installation of Outdoor Unit 10-5-1. Installation Location • A place which provides enough space around the outdoor unit as shown in the figure. • 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.
10-5-2. Fixing Bolt Arrangement of Outdoor Unit 10-5-3. Refrigerant Piping Connection Flaring 1. Cut the pipe with a pipe cutter. 600 mm Suction side 90˚ Roughness Warp 310 mm Obliquity Fig. 10-5-4 Diffuser 2. Insert a flare nut into the pipe, and flare the pipe. Fig. 10-5-2 • Secure the outdoor unit with fixing bolts and nuts if the unit is likely to be exposed to strong winds. • Use Ø8 mm or Ø10 mm anchor bolts and nuts.
Tightening Connection 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. • Tightening torque for connection of flare pipe The pressure of R410A is higher than R22. (Approx. 1.6 times.
10-5-4. Evacuating Use a vacuum pump After the piping has been connected to the indoor unit, perform the air purge. AIR PURGE Evacuate the air in the connecting pipes and in the indoor unit using a vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the vacuum pump manual.
10-5-5. Wiring Connection Model 1. Remove the valve cover, the electric parts cover and the cord clamp from the outdoor unit. 2. Connect the connecting cable to the terminal as identified by the matching numbers on the terminal block of indoor and outdoor unit. 3. Insert the power cord and the connecting cable fully into the terminal block and secure it tightly with screws. 4. Insulate the unused cords (conductors) from water entering in the outdoor unit.
10-6. Grounding 10-7-1. Miswiring (Mis-piping) Check This air conditioner must be grounded without fail. Grounding is necessary not only to safeguard against the possibility of receiving an electric shock but also to absorb both the static, which is generated by high frequencies and held in the surface of the outdoor unit, and noise since the air conditioner incorporates a frequency conversion device (called an inverter) in the outdoor unit.
10-7-2. Miswiring (Mis-piping) Check by LED Indication • For this outdoor unit, self-miswiring (mis-piping) checks are possible using the five LEDs (1 Yellow + 4 Red). • LEDs (D800 to D804) are provided on the inverter P.C. board.
10-8. Useful Functions 10-8-1. Self-Diagnosis by LED Indication • For this outdoor unit, by referring to the 5 LED (1 Yelow + 4 Red) indicator lights, self-diagnosis is possible. • LEDS (D800 to D804) are located on the sub-control board underneath the inverter.
11. 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 Troubleshooting Procedure No.
11-1-3. Operation Which is not a Trouble (Program Operation) 11-1. First Confirmation 11-1-1. Confirmation of Power Supply 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.
11-3. 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.
11-3-2. 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.
11-4. Judgment of Trouble by Every Symptom 11-4-1. 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 and 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. Press the START/STOP button. The unit does not beep at all. Operation lamp on indoor unit is not indicated. NO Is transmission mark indicated? YES Is receiver on indoor unit exposed to direct sunlight? Press RESET button on remote controller with tip of pencil.
11-4-2. Wiring Failure (Interconnecting and Serial Signal Wire) (1) Outdoor unit does not operate 1) Is the voltage between and 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.
11-5. Trouble Diagnosis by Outdoor LED For the outdoor unit, the self-diagnosis is possible by LED (Yel) and four LEDs (Red). • LED (Yel) (D800) and LEDs (Red) (D801 to D804) 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. LED D800D801D802D803D804 Red Yellow 1. If a trouble occurs, LED (Red or Yel) goes on according to the trouble as described in the table below. 2.
11-6. Troubleshooting 11-6-1. 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.
11-6-2. 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.
11-7. How to Diagnose Trouble in Outdoor Unit 11-7-1. Summarized Inner Diagnosis of Inverter Assembly Table 11-7-1 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 Check 25A fuse (Part No.F01). NG OK Replace fuse. • Check whether 25A fuse on the control board assembly is blown or not.
Diagnosis/Process flowchart A B Item Contents Check Check winding resistance between phases of compressor, and resistance between outdoor frames by using a tester. C Check winding of compressor. NG OK NG Check fan motor position detect signal. Replace compressor. Replace outdoor fan motor. Replace control board assembly. Check compressor winding resistance. → OK if 10MΩ or more • Is not short-circuited between windings. → OK if 0.2Ω (under 20°C) (Check by a digital tester.
(3) Check procedures Table 11-8-1 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.
11-8-2. P.C. Board Layout GND +12V +5V [1] Sensor characteristic table 100 Resistance value (kW) 90 80 TD 70 TD TA TC TO TGa TGb TGc 60 50 40 30 20 TA, TC, TO, TGa, TGb, TGc 10 0 0 10 20 30 40 50 Temperature (˚C) – 80 – : Discharge temp. sensor : Room temp. sensor : Heat exchanger temp. sensor : Outdoor temp. sensor : A room Gas side temp. sensor : B room Gas side temp. sensor : C room Gas side temp.
11-8-3. 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 11-4-1. (5). 3 Louver motor MP24Z Measure the resistance value of each winding coil by using the tester. (Under normal temp.
11-8-5. Checking Method for Each Part No. Electrolytic capacitor (For raising pressure, 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.
11-9. 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 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 operation, and check for smoking, unusual sounds and other abnormalities. If this check is omitted, a fire and/or electric shocks may occur.
No. 1 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 2 High voltage generator 1) Follow to the procedure in the item 1 . 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 3 Electric parts box assembly Procedures Remarks 1) Follow the procedure up to 4) in 2 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 4 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 5 Evaporator (Heat exchanger) 1) Follow to the procedure in the item 3 . 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. 6 Part name Bearing Procedures 1) Follow to the procedure in the items 1 . 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. 7 Part name Fan motor Procedures 1) Follow to the procedure in the item 3 . 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 8 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 1 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. 1 Part name Common procedure Procedure 1. Detachment 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 × 10L 1 pc.) • After removing screw, remove the valve cover pulling it downward. 3) Remove wiring cover (ST1TØ4 × 10L 2 pcs.), and then remove connecting cable. 4) Remove the upper cabinet. (ST1TØ4 × 10L 2 pcs.) • After removing screws, remove the upper cabinet pulling it upward.
No. 3 Part name Inverter assembly Procedure 1. Detachment 1) Perform work of items 1. of 1 and 2 . 2) Remove screw (ST1TØ4 × 10L 1 pc.) 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 in the upper part of the upper cabinet, perform work of 2 . Remarks Inverter cover P. C. board (Soldered surface) Be careful to check the inverter because high-voltage circuit is incorporated in it.
No. 4 Part name Control board assembly Procedure Remarks 1. Disconnect lead wires and connectors connected from the control board assembly to other parts. 1) Lead wires • Connection with terminal block : 6 wires (Red, Orange, Pink, Black and two White wires) • Connection with compressor : Disconnect the connector (3P). • Connection with reactor : Remove the connector from P08, 09 (2P, White) and P12, P13 (2P, Gray). • Connection with case thermo. : Remove the connector (2P).
;; ;; No. Part name Procedure Remarks 5 Rear cabinet 1) Perform work of item 1. of 1 , 2 and 3 . 2) Remove fixed screws fixing to the bottom plate. (ST1TØ4 × 10L 2 pcs.) 3) Remove fixed screws fixing to the heat exchanger. (ST1TØ4 × 10L 2 pcs.) 4) Remove fixed screw fixing to the valve mounting plate. (ST1TØ4 × 10L 1 pc.) 6 Fan motor 1) Perform work of item 1. of 1 and 2 . 2) Remove the flange nut fixing the fan motor and the propeller fan. • Flange nut is loosened by turning clockwise.
No. Part name Procedure 9 Pulse motor valve coil 1. Detachment 1) Perform step 1. in 2 , all the steps in 3 and 1. in 5 . 2) Release the coil by pulling it up from the electronic control valve body. Remarks 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. Part name Procedure 11 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.
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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.
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. Outdoor Unit 2 1 8 7 10 6 21 25 19 23 22 39 28 20 3 40 25 4 5 9 11,14,31,34 12,15,32,35 13,16,33,36 29 27 17 37, 38 18 Location No. Part No. Description Location No. Part No.
13-3. P.C. Board Layout RAS-3M23GACV-E 707 713 705 TO Sensor TD Sensor 700 704 705 TGa Sensor TGb Sensor TGc Sensor 709 703 ∗ 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. 700 703 43162042 4306A130 704 705 43050424 43050425 Description Location No. Part No. 707 709 4316V192 4306S690 713 4306V016 Base, P.C.
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.
