FILE NO. A00-T004
SERVICE MANUAL
AIR-CONDITIONER
SPLIT TYPE
RAS-10YKV-E/RAS-10YAV-E
RAS-13YKV-E/RAS-13YAV-E
R410A
PRINTED IN JAPAN, Aug.,2000 ToMo
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1. SPECIFICATIONS
1-1. Specifications
RAS-10YKV-E/RAS-10YAV-E
Unit model
Indoor
RAS-10YKV-E
Outdoor
RAS-10YAV-E
Current limited
—
Cooling capacity
Cooling capacity range
Heating capacity
Heating capacity range
Power supply
(kW)
(kW)
(kW)
(kW)
2,7
0,8 – 3,4
3,6
0,8 – 6,2
220 – 230 –240V – 1Ph – 50/60Hz
Electric
characteristics
Indoor
Operation mode
Cooling
0,15
Heating
0,15
Running current
Power consumption
Power factor
Operation mode
Running current
Power consumption
Power factor
(A)
(W)
(%)
30
30
87
Cooling
3,39 / 3,23 / 3,09
670
87
Heating
4,40 / 4,20 / 4,02
870
Outdoor
(A)
(W)
(%)
(A)
90
90
Starting current
4,55 / 4,35 / 4,17
COP (Cooling/Heating)
3,86 / 4,00
Operating noise
Indoor
High
Medium (Cooling / Heating) (dB•A)
Low (Cooling / Heating) (dB•A)
(Cooling / Heating) (dB•A)
38 / 39
34 / 35
30 / 30
Outdoor
(Cooling / Heating)
(dB•A)
45 / 46
Indoor unit
Unit model
Dimension
RAS-10YKV-E
Height
Width
Depth
(mm)
(mm)
(mm)
(kg)
265
790
189
8
Net weight
Fan motor output
(W)
19
Air flow rate (Cooling / Heating)
Unit model
(m³/h)
480 / 520
RAS-10YAV-E
Outdoor unit
Dimension
Height
Width
Depth
(mm)
(mm)
(mm)
(kg)
550
780
270
38
Net weight
Compressor Motor output
Type
(W)
750
Twin rotary type with DC-inverter variable speed control
Model
DA91A1F-44F
Fan motor output
Air flow rate (Cooling / Heating)
(W)
(m³/h)
40
2120 / 2120
Piping connection Type
Indoor unit
Flare connection
Liquid side
Gas side
Ø6,35
Ø9,52
Outdoor unit Liquid side
Gas side
Ø6,35
Ø9,52
Maximum length (Per unit)
Maximum chargeless length
Maximum height difference
Name of refrigerant
Weight
(m)
(m)
(m)
15
15
10
R410A
Refrigerant
(kg)
0,8
Wiring connection
Power supply
3 Wires : includes earth
Interconnection
4 Wires : includes earth
Usable temperature range
Accessory Indoor unit
Indoor (Cooling / Heating)
Outdoor (Cooling / Heating)
Installation plate
(°C)
(°C)
21 – 32 / 0 – 28
10 – 43 / –10 – 21
1
Wireless remote control
Label
1
2
Remote controller holder
Pan head wood screw
Purifying filter
1
2 (Ø3,1 x 16L)
1
Deodorizing filter
Batteries
1
2
Mounting screw
6 (Ø4 x 25L)
Installation manual
Owner's manual
Outdoor unit Drain nipple
1
1
1
• The specifications may be subject to change without notice for purpose of improvement.
– 3 –
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RAS-13YKV-E/RAS-13YAV-E
Unit model
Indoor
RAS-13YKV-E
Outdoor
RAS-13YAV-E
Current limited
—
Cooling capacity
Cooling capacity range
Heating capacity
Heating capacity range
Power supply
(kW)
(kW)
(kW)
(kW)
3,7
0,8 – 4,0
4,8
0,8 – 6,6
220 – 230 –240V – 1Ph – 50/60Hz
Electric
characteristics
Indoor
Operation mode
Running current
Power consumption
Power factor
Operation mode
Running current
Power consumption
Power factor
Cooling
0,15
Heating
0,15
(A)
(W)
(%)
30
30
87
Cooling
5,59 / 5,34 / 5,11
1170
87
Heating
7,03 / 6,71 / 6,43
1470
Outdoor
(A)
(W)
(%)
(A)
95
95
Starting current
7,18 / 6,86 / 6,58
COP (Cooling/Heating)
3,08 / 3,20
Operating noise
Indoor
High
Medium (Cooling / Heating) (dB•A)
Low (Cooling / Heating) (dB•A)
(Cooling / Heating) (dB•A)
41 / 41
36 / 36
30 / 30
Outdoor
(Cooling / Heating)
(dB•A)
48 / 50
Indoor unit
Unit model
Dimension
RAS-13YKV-E
Height
Width
Depth
(mm)
(mm)
(mm)
(kg)
265
790
189
8
Net weight
Fan motor output
(W)
19
Air flow rate (Cooling / Heating)
Unit model
(m³/h)
530 / 560
RAS-13YAV-E
Outdoor unit
Dimension
Height
Width
Depth
(mm)
(mm)
(mm)
(kg)
550
780
270
38
Net weight
Compressor Motor output
Type
(W)
750
Twin rotary type with DC-inverter variable speed control
Model
DA91A1F-44F
Fan motor output
Air flow rate (Cooling / Heating)
(W)
(m³/h)
40
2520 / 2520
Piping connection Type
Indoor unit
Flare connection
Liquid side
Gas side
Ø6,35
Ø9,52
Outdoor unit Liquid side
Gas side
Ø6,35
Ø9,52
Maximum length (Per unit)
Maximum chargeless length
Maximum height difference
Name of refrigerant
Weight
(m)
(m)
(m)
15
15
10
R410A
Refrigerant
(kg)
0,8
Wiring connection
Power supply
3 Wires : includes earth
Interconnection
4 Wires : includes earth
Usable temperature range
Accessory Indoor unit
Indoor (Cooling / Heating)
Outdoor (Cooling / Heating)
Installation plate
(°C)
(°C)
21 – 32 / 0 – 28
10 – 43 / –10 – 21
1
Wireless remote control
Label
1
2
Remote controller holder
Pan head wood screw
Purifying filter
1
2 (Ø3,1 x 16L)
1
Deodorizing filter
Batteries
1
2
Mounting screw
6 (Ø4 x 25L)
Installation manual
Owner's manual
Outdoor unit Drain nipple
1
1
1
• The specifications may be subject to change without notice for purpose of improvement.
– 4 –
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1-2. Operation Characteristic Curve
<Cooling>
<Heating>
7
7
6
6
5
4
3
2
1
RAS-10YKV-E
RAS-13YKV-E
RAS-10YKV-E
RAS-13YKV-E
5
4
3
2
• Conditions
Indoor : DB 27˚C/WB 19˚C
Outdoor : DB 35˚C
Air flow : High
Pipe length : 5m
230V
• Conditions
Indoor : DB 20˚C
Outdoor : DB 7˚C/WB 6˚C
Air flow : High
1
0
Pipe length : 5m
230V
0
0
0
20
40
60
80
100
20
40
60
80
100
Compressor speed (rps)
Compressor speed (rps)
1-3. Capacity Variation Ratio According toTemperature
<Cooling>
105
100
95
90
85
80
75
70
65
60
55
50
120
110
100
90
80
70
60
50
40
30
20
10
0
Current Limited Start
RAS-10YKV-E
RAS-13YKV-E
RAS-10YKV-E
RAS-13YKV-E
• Conditions
• Conditions
Indoor : DB27˚C/WB19˚C
Indoor air flow : High
Pipe length 5m
Indoor : DB 20˚C
Indoor air flow : High
Pipe length : 5m
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
0 1 2 3 4 5 6 7 8 9 10
32 33 34 35 36 37 38 39 40 41 42 43
Outdoor temp. (˚C)
Outdoor temp. (˚C)
Capacity ratio : 100% = 2,7 kW (RAS-10YKV-E)
100% = 3,7 kW (RAS-13YKV-E)
*
– 5 –
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2. REFRIGERANT R410A
This air conditioner adopts the new refrigerant HFC
(R410A) which does not damage the ozone layer.
(5) After completion of installation work, check to
make sure that there is no refrigeration gas
leakage.
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 refrigerat-
ing oil are not entered in the refrigerant cycle of the
air conditioner using the new refrigerant during
installation work or servicing time.
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.
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.
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.
2-1. Safety During Installation/Servicing
Improper installation may cause refrigeration
trouble, water leakage, electric shock, fire, etc.
As R410A’s pressure is about 1,6 times higher than
that of R22, improper installation/servicing may
cause a serious trouble. By using tools and materi-
als exclusive for R410A, it is necessary to carry out
installation/servicing safely while taking the following
precautions into consideration.
(8) Unauthorized modifications to the air conditioner
may be dangerous. If a breakdown occurs
please call a qualified air conditioner technician
or electrician.
Improper repair’s may result in water leakage,
electric shock and fire, etc.
(1) Never use refrigerant other than R410A in an air
conditioner which is designed to operate with
R410A.
2-2. Refrigerant Piping Installation
2-2-1. Piping Materials and Joints Used
If other refrigerant than R410A is mixed, pres-
sure in the refrigeration cycle becomes abnor-
mally high, and it may cause personal injury, etc.
by a rupture.
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.
(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 condi-
tioner using R410A as refrigerant.To prevent
mischarging, the diameter of the service port
differs from that of R22.
(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 discol-
ored portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube
may become blocked with contaminants.
(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.
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.
– 6 –
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Table 2-2-1 Thicknesses of annealed copper pipes
Thickness (mm)
Nominal diameter
Outer diameter (mm)
R410A
0,80
R22
0,80
0,80
0,80
1,00
1/4
3/8
1/2
5/8
6,35
9,52
0,80
12,70
15,88
0,80
1,00
(2) Joints
b) Socket Joints
For copper pipes, flare joints or socket joints are
used. Prior to use, be sure to remove all con-
taminants.
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.
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 to 2-
2-6 below.
Table 2-2-2 Minimum thicknesses of socket joints
Reference outer diameter of
copper pipe jointed (mm)
Minimum joint thickness
(mm)
Nominal diameter
1/4
3/8
1/2
5/8
6,35
9,52
0,50
0,60
0,70
0,80
12,70
15,88
(1) Flare Processing Procedures and Precautions
a) Cutting the Pipe
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.
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.
– 7 –
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c) Insertion of Flare Nut
d) Flare Processing
Flare processing dimensions differ according
to the type of flare tool. When using a con-
ventional flare tool, be sure to secure “dimen-
sion A” by using a gauge for size adjustment.
Make certain that a clamp bar and copper
pipe have been cleaned.
ØD
By means of the clamp bar, perform the flare
processing correctly.
A
Use either a flare tool for R410A or conven-
tional flare tool.
Fig. 2-2-1 Flare processing dimensions
Table 2-2-3 Dimensions related to flare processing for R410A
A (mm)
Conventional flare tool
Outer
diameter
(mm)
Nominal
diameter
Thickness
(mm)
Flare tool for R410A
clutch type
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
1/4
3/8
1/2
5/8
6,35
9,52
0,8
0,8
0,8
1,0
0 to 0,5
0 to 0,5
0 to 0,5
0 to 0,5
1,5 to 2,0
12,70
15,88
2,0 to 2,5
2,0 to 2,5
Table 2-2-4 Dimensions related to flare processing for R22
A (mm)
Outer
diameter
(mm)
Nominal
diameter
Thickness
(mm)
Conventional flare tool
Flare tool for R410A
clutch type
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
1/4
3/8
1/2
5/8
6,35
9,52
0,8
0,8
0,8
1,0
0 to 0,5
0 to 0,5
0 to 0,5
0 to 0,5
1,0 to 1,5
12,70
15,88
1,0 to 2,0
1,0 to 2,0
Table 2-2-5 Flare and flare nut dimensions for R410A
Outer
diameter
(mm)
Dimension (mm)
Flare nut
width
(mm)
Nominal
diameter
Thickness
(mm)
A
B
C
D
1/4
3/8
1/2
5/8
6,35
9,52
0,8
0,8
0,8
1,0
9,1
9,2
6,5
9,7
13
20
23
25
17
22
26
29
13,2
16,6
19,7
13,5
16,0
19,0
12,70
15,88
12,9
16,0
– 8 –
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Table 2-2-6 Flare and flare nut dimensions for R22
Outer
diameter
(mm)
Dimension (mm)
Thickness
Flare nut
width
(mm)
Nominal
diameter
(mm)
A
B
C
D
1/4
3/8
1/2
5/8
3/4
6,35
9,52
0,8
0,8
0,8
1,0
1,0
9,0
9,2
6,5
9,7
13
20
20
23
34
17
22
24
27
36
13,0
16,2
19,7
23,3
13,5
16,0
19,0
24,0
12,70
15,88
19,05
12,9
16,0
19,2
D
B
A
C
Fig. 2-2-2 Relations between flare nut and flare seal surface
(2) Flare Connecting Procedures and Precautions
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.
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.
Note:
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 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]
Tightening torque of torque
wrenches available on the market
N•m (kgf•cm)
Nominal
diameter
Outer diameter
(mm)
Tightening torque
N•m (kgf•cm)
1/4
3/8
1/2
5/8
6,35
9,52
14 to 18 (140 to 180)
33 to 42 (330 to 420)
50 to 62 (500 to 620)
63 to 77 (630 to 770)
16 (160), 18 (180)
42 (420)
12,70
15,88
55 (550)
65 (650)
– 9 –
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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 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. 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
Conventional air
conditioner installation
Existence of
Whether
Whether new equip-
ment can be used with
No.
Used tool
Usage
new equipment conventional
for R410A
equipment can conventional refriger-
be used ant
‚
Flare tool
Pipe flaring
Yes
(Note 1)
¡
*
*
Copper pipe gauge for Flaring by
adjusting projection
margin
conventional flare
tool
Yes
(Note 1)
(Note 1)
*
Torque wrench
(For Ø12,7)
Connection of flare
nut
ƒ
„
Yes
Yes
X
X
X
X
Evacuating, refriger-
ant charge, run
check, etc.
Gauge manifold
Charge hose
ꢀ
†
Vacuum pump adapter Vacuum evacuating
Electronic balance for
Yes
Yes
X
X
¡
¡
‡
Refrigerant charge
refrigerant charging
ˆ
‰
Š
Refrigerant cylinder
Leakage detector
Charging cylinder
Refrigerant charge
Gas leakage check
Refrigerant charge
Yes
Yes
X
X
X
X
¡
X
(Note 2)
(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.
(4) Reamer
(9) Hole core drill (Ø65)
(1) Vacuum pump
(5) Pipe bender
(10) Hexagon wrench
(Opposite side 5mm)
Use vacuum pump by
attaching vacuum pump adapter.
(6) Level vial
(11) Tape measure
(12) Metal saw
(2) Torque wrench (For Ø6,35)
(7) Screwdriver (+, –)
(8) Spanner or Monkey wrench
(3) Pipe cutter
Also prepare the following equipments for other installation method and run check.
(1) Clamp meter
(2) Thermometer
(3) Insulation resistance tester
(4) Electroscope
– 10 –
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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.
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.
Keep the status as it is for 1 to 2 minutes, and ensure
that the compound gauge’s pointer does not return.
Connect the charge hose of the vacuum pump
adapter.
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.
Open fully both packed valves at liquid and gas
sides.
Place the handle of the gauge manifold Low in the
fully opened position, and turn on the vacuum pump’s
power switch. Then, evacuating the refrigerant in the
cycle.
(For refrigerant charging, see the figure below.)
Never charge refrigerant exceeding the specified amount.
‚
ƒ
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
Closed
(Gas side)
Refrigerant cylinder
(With siphon pipe)
Check valve
Open/Close valve
for charging
Service port
Electronic balance for refrigerant charging
Fig. 2-4-1 Configuration of refrigerant charging
– 11 –
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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 ]
[ Cylinder without siphon ]
Gauge manifold
Gauge manifold
OUTDOOR unit
OUTDOOR unit
c y l i n d e r
a n t i g e r R e f r
Refrigerant
cylinder
Electronic
balance
Electronic
balance
Siphon
R410A refrigerant is HFC mixed refrigerant.
Therefore, if it is charged with gas, the compo-
sition of the charged refrigerant changes and
the characteristics of the equipment varies.
Fig. 2-4-2
Phosphor bronze brazing filler tends to react
with sulfur and produce a fragile compound
water solution, which may cause a gas leak-
age.Therefore, use any other type of brazing
filler at a hot spring resort, etc., and coat the
surface with a paint.
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 expen-
sive though it excels in solderability.
When performing brazing again at time of
servicing, use the same type of brazing filler.
(2) Phosphor bronze brazing filler
2-5-2. Flux
Phosphor bronze brazing filler is generally used
to join copper or copper alloy.
(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 filler’s surface tension,
the brazing filler adheres better to the treated
metal.
(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.
– 12 –
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(2) Characteristics required for flux
2-5-3. Brazing
• 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.
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.
• It excels in coating performance and is
harmless to the human body.
Never use gas other than Nitrogen gas.
(1) Brazing method to prevent oxidation
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.
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.
‚
(3) Types of flux
• Noncorrosive flux
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.
Generally, it is a compound of borax and boric
acid.
It is effective in case where the brazing
temperature is higher than 800°C.
ƒ
When the Nitrogen gas is flowing, be sure to
keep the piping end open.
• 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 chlo-
ride and sodium fluoride to the borax-boric
acid compound.
„
ꢀ
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).
†
‡
(4) Piping materials for brazing and used braz-
ing filler/flux
Remove the flux completely after brazing.
Piping
material
Used brazing
filler
Used
flux
Copper - Copper Phosphor copper Do not use
M
Flow meter
Copper - Iron
Iron - Iron
Silver
Silver
Paste flux
Vapor flux
Stop valve
Nitrogen gas
cylinder
Do not enter flux into the refrigeration cycle.
‚
From Nitrogen cylinder
When chlorine contained in the flux remains
within the pipe, the lubricating oil deterio-
rates. Therefore, use a flux which does not
contain chlorine.
Pipe
Nitrogen
gas
When adding water to the flux, use water
which does not contain chlorine (e.g. distilled
water or ion-exchange water).
ƒ
„
Rubber plug
Remove the flux after brazing.
Fig. 2-5-1 Prevention of oxidation during brazing
– 13 –
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3. CONSTRUCTION VIEWS
3-1. Indoor Unit
RAS-10YKV-E, RAS-13YKV-E
Heat exchanger
Air inlet
Air filter
189
790
Air outlet
47
Knock out system
50 94
790
326
Front panel
Back body
Hanger
232
232
47
Drain hose (0,54m)
321
Knock out system
External
Connecting pipe (0,39m)
(Flare ø9,52)
Connecting pipe (0,49m)
Hanger
length reference
(Flare ø6,35)
65,5
65,5
659
450
344
326
Hanger
For stud bolt
(ø8~ø10)
Hanger
For stud bolt
(ø6)
Minimum
distance
to ceiling
Minimum
distance to wall
Minimum
distance
to wall
120 or more
120 or more
Wireless
remote controller
Hanger
Hanger
Installation
60,5
126
plate outline
55
16
10,5
76
Center line
269
319
790
– 14 –
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3-2. Outdoor Unit
RAS-10YAV-E
RAS-13YAV-E
600
Ø25 drain hole
90
A leg part
Ø11 x 17U-shape hole
50
(For Ø8-Ø10 anchor bolt)
115
8-Ø6 hole
(For fixing outdoor unit)
B leg part
Ø11 x 17 long hole
(For Ø8-Ø10 anchor bolt)
Ø4,5 embossing (Ø4STS used)
(For sunshade roof attaching)
Valve cover
157
Fan guard
59
49,5
147
115,5
Hanger
Z
Charging
port
780
61
322
Earth terminal
Connecting pipe port
(Pipe dia.Ø6,35)
Detailed A leg part
600
50
R15
36
11
Connecting pipe port
(Pipe dia.Ø9,52)
Z
view
Outside line
of product
2-Ø6 hole
Mounting dimensions of anchor bolt
600
4 x Ø11 x 17U-shape hole
(For Ø8-Ø10 anchor bolt)
D
Intake
2-Ø6 hole
A
11
250 or more
Intake
Outside line
of product
100 or
more
C
(Minimum distance
from wall)
Outside line
of product
36
50
R15
200 or more
600
Outlet
4 x Ø11 × 17 long hole
(For Ø8-Ø10 anchor bolt)
Detailed B leg part
B
– 15 –
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4. WIRING DIAGRAM
FAN MOTOR
DC MOTOR
4-1. Indoor Unit
RAS-10YKV-E, RAS-13YKV-E
LOUVER
MOTOR
6 5 4 3 2 1
6 5 4 3 2 1
5 4 3 2 1
5 4 3 2 1
CN10
CN07
R109
VARISTOR
5
6
R116
BLK
P04
IC04
J04
SG01 DSA
L01
R01
T6,3A 250V
DB01
TO1
F01 FUSE
DC35V
DC12V
DC7V
R21
3
INDOOR
TERMINAL
BLOCK
C02
C01
C15
2
BLK
1
DC0V
CN30
WHI
2
MAIN P.C. BOARD
(MCC-772)
C06
RED
3
IC02
GRN & YEL
IC
IC01
CN23
4
CN13
CN03
1 2
1 2
CN01
1 2
1 2
OUTDOOR INDOOR
UNIT UNIT
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
INFRARED RAYS RECEIVE
AND INDICATION PARTS
HEAT
EXCHANGER
SENSOR
(TC)
1
CN25
THERMO
SENSOR
(TA)
Table 4-1-1 Simple check points for diagnosing faults
COLOR
IDENTIFICATION
Check items
Diagnosis result
BRW : BROWN
RED : RED
WHI : WHITE
YEL : YELLOW
BLU : BLUE
Check to see if the OPERATION indicator goes on and off when the main
switch or breaker is turned on, or the power cord is plugged in the wall
outlet. (Check the primary and secondary voltage of transformer.)
OPERATION
indicator
Check for power supply voltage between
–
. (Refer to the name
‚
Terminal
block
BLK : BLACK
GRY : GRAY
PNK : PINK
plate.) (Check the primary and secondary voltage of transformer.)
Check for fluctuate voltage between . (DC 15 to 60V)
–
‚ ƒ
Fuse
6,3A
Check to determine if the fuse is open.
(Check Varistor : R109, R21)
ORN : ORANGE
GRN : GREEN &
&YEL YELLOW
Check for voltage at the pink lead of the infrared rays receive parts.
(Check the transformer and the rated voltage power supply circuit.)
DC 5V
Check for voltage at the
lead of louver motor.
ƒ
DC 12V
DC 35V
(Check the transformer and the rated voltage power supply circuit.)
Check for voltage at the CN10 connector side point.
(Check the transformer and the rated voltage power supply circuit.)
For detailed diagnostic procedure, refer to the service data.
DSA : Surge Absorber
– 16 –
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4-2. Outdoor Unit
RAS-10YAV-E, RAS-13YAV-E
P.M.V. : Pulse Modulating Valve
COIL
THERMOSTAT
FOR
POWER
SUPPLY
FOR
To
4WAY VALVE
COMPRESSOR 220/240V~
50/60Hz
INDOOR
UNIT
TE
TD
TO
TS
FAN MOTOR
FM
~ ~ ~
~ ~ ~ ~
REACTOR
P. M . V.
L
N
1
2
3
1
1
2
2
1
1
2
2
1
1
2
2
3
3
1
1
2
2
1
1
2
2
3
3
5
5
4
4
3
3
2
2
1
1
1
1
2
2
3
3
1
1
2
2
3
3
6
6
5
5
4
4
3
3
2
2
1
1
1
1
2
2
BLK
P06
CN600
CN601
CN602
CN603
P08 P07
CN301
CN300
CN701
CN703
CN500 P01 P02
P03
P.C. BOARD
MCC-808
F01
FUSE
25A
SURGE
ABSORBER
RELAY
VARISTOR
CT
P09
P10
ORN
P11
1
2
1
2
POWER RELAY
P12
P13
REACTOR
C13
G
E
A
~
PUR
P14
ELECTRONIC
STARTER
F03
FUSE
15A
–
C12 C14
F04
FUSE
3,15A
~
+
DB01
RELAY
P19
YEL
P20
+
BU
EU
BV
EV
BW
EW
BX
BY
BZ
Q200
BLU
P21 RED
P22 WHI
P23 BLK
1
2
3
1
2
3
–
COLOR IDENTIFICATION
CM
P18
P17
COMPRESSOR
BLK : BLACK
BLU : BLUE
RED : RED
GRY : GRAY
PNK : PINK
WHI : WHITE
BRW : BROWN
ORN : ORANGE
YEL :YELLOW
PUR : PURPLE
– 17 –
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5. SPECIFICATIONS OF ELECTRICAL PARTS
5-1. Indoor Unit
RAS-10YKV-E, RAS-13YKV-E
No.
1
Parts name
Fan motor (for indoor)
Thermo. sensor (TA-sensor)
DC-DC transformer (T01)
Microcomputer
Type
TICF-35-19-4
Specifications
DC35V, 19W
2
( – )
10kΩ at 25°C
3
SWT-34 or SWT-46
TMP87PM40AF or TMP87CM40AF
DC390V, Secondary DC35V, 12V, 7V
4
Heat exchanger temp. sensor
(TC-sensor)
5
( – )
10kΩ at 25°C
6
7
8
9
Line filter (L01)
Diode (DB01)
Capacitor (C02)
Fuse (F01)
UF-253Y0R7
RBV-406 or D3SBA60
KMH450VNSN100M25B
TSCR6,3A
25mH, AC0,7A
4A, 600V
100µF, 450V
T6,3A, 250V
10 Power supply IC (IC01)
11 Varistor (R21, R109)
12 Resistor (R01)
MA2830-FJ
4A, 600V
15G561K
560V
ERF-5TK5R6
5,6Ω, 5W
13 Louver motor
MP35EA7
Output (Rated) 2W, 10poles, 1phase DC12V
5-2. Outdoor Unit
RAS-10YAV-E, RAS-13YAV-E
No.
Parts name
Model name
SC-15-S06J
SC-20-01J
Rating
15A, 0,6mH
L03
L01
SC coil
(Noise filter)
1
20A, 150µH
Primary side DC280V, Secondary side
7,5V x 1, 13V x 1, 26,5V x 3, 16V x 1, 15V x 1
2
DC-DC transformer
SWT-43
3
4
Reactor
CH38Z-K
L=10mH, 16A x 2
DC140V, 40W
Outside fan motor
ICF-140-40-7
Coil DC12V
Contact AC125V, 3A
5
6
7
8
9
Fan control relay
AJQ1341
Suction temp. sensor
(TS sensor)
(Inverter attached)
(Inverter attached)
(Inverter attached)
(Inverter attached)
10kΩ (25°C)
62kΩ (20°C)
10kΩ (25°C)
10kΩ (25°C)
Discharge temp. sensor
(TD sensor)
Outside air temp. sensor
(TO sensor)
Heat exchanger temp.
sensor (TE sensor)
10 Terminal block (9P)
——
20A, AC250V
For protection of switching power source
3,15A, AC250V
11 Fuse
For protection of transistor module breakage 15A, AC250V
For protection of inverter input overcurrent
LLQ2G501KHUATF, 400LISN500K35F
25A, AC250V
12 Electrolytic capacitor
13 Transistor module
14 Compressor
500µF, DC400V X 3 pieces
6MBI25GS-060-01 or 6MBI25GS-060-01A 25A, 600V
DA91A1F-44F
US-622KXTMQO-SS
MP7003
3-phases 4-poles 750W
15 Compressor thermo.
16 Converter module
OFF: 125 4°C, ON: 90 5° C
Diode: 25A, 600V, IGBT: 40A, 600V
– 18 –
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6. REFRIGERANT CYCLE DIAGRAM
6-1. Refrigerant Cycle Diagram
RAS-10YKV-E/RAS-10YAV-E
RAS-13YKV-E/RAS-13YAV-E
T1 Temp. measurement
INDOOR UNIT
Indoor heat
exchanger
Cross flow fan
P
Pressure measurement
Deoxidized copper pipe
Outer dia. : 6,35mm
Thickness : 0,8mm
Max. : 15m
Gauge attaching port
Vacuum pump connecting port
Sectional shape
of heat insulator
Deoxidized copper pipe
Outer dia. : 9,52mm
Thickness : 0,8mm
Strainer
Muffler
4-way valve
(CHV-0213)
Pulse modulating
valve at liquid side
(SEV15RC2)
Muffler
TD
Compressor
DA91A1F-44F
TS
Outdoor heat
exchanger
Split capillary
Ø1,5 x 200
Ø1,5 x 200
TE
Temp. measurement
T2
Refrigerant amount : 0,8kg
Propeller fan
Gas leak check position
Refrigerant flow (Cooling)
Refrigerant flow (Heating)
OUTDOOR UNIT
NOTE :
NOTE :
• The maximum pipe length of this air conditioner is 15 m. The additional charging of refrigerant is unneces-
sary because this air conditioner is designed with charge-less specification.
– 19 –
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6-2. Operation Data
<Cooling>
Temperature
condition (°C)
Heat exchanger
pipe temp.
Standard
pressure
P (MPa)
Compressor
revolution
(rps)
Indoor fan Outdoor fan
Model name
mode
mode
Indoor Outdoor
T1 (°C)
9 to 11
8 to 10
T2 (°C)
42 to 44
46 to 48
10YKV-E
13YKV-E
0,8 to 1,0
0,8 to 1,0
High
High
High
High
56
85
27/19
35/–
<Heating>
Temperature
condition (°C)
Heat exchanger
pipe temp.
Standard
pressure
P (MPa)
Compressor
revolution
(rps)
Indoor fan Outdoor fan
Model name
mode
mode
Indoor Outdoor
T1 (°C)
42 to 44
50 to 52
T2 (°C)
2 to 4
0 to 3
10YKV-E
13YKV-E
3,5 to 3,7
2,5 to 2,7
High
High
High
High
70
97
20/–
7/6
NOTES :
(1) Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent.
(Thermistor themometer)
(2) Connecting piping condition : 5 m
– 20 –
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7. CONTROL BLOCK DIAGRAM
7-1. Indoor Unit
RAS-10YKV-E, RAS-13YKV-E
Indoor Unit Control Panel
M.C.U
Heat Exchanger Sensor
Temperature Sensor
Functions
Operation
Display
• Louver Control
Timer
Display
Infrared Rays Signal Receiver
• 3-minute Delay at Restart for Compressor
ECONO.
Initializing Circuit
• Motor Revolution Control
Infrared
Rays
Sign Display
Clock Frequency
Oscillator Circuit
• Processing
(Temperature Processing)
PRE DEF.
Sign Display
• Timer
Indoor
Fan Motor
• Serial Signal Communication
Power Supply
Circuit
Louver ON/OFF Signal
Remote
Controller
Louver
Motor
Noise Filter
Louver Driver
Serial Signal Transmitter/Receiver
From Outdoor Unit
Serial Signal Communication
REMOTE CONTROLLER
Infrared
Rays
Remote Controller
Operation (START/STOP)
Operation Mode Selection
AUTO, COOL, DRY, HEAT
Thermo. Setting
Fan Speed Selection
ON TIMER Setting
OFF TIMER Setting
Louver AUTO Swing
Louver Direction Setting
ECONO.
– 21 –
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MICRO-COMPUTER BLOCK DIAGRAM
For INDOOR UNIT
220–230–240 V
~ 50/60 Hz
MCC808 (P.C.B)
OUTDOOR UNIT
Inddor unit
send/receive
circuit
Rotor position
detect circuit
M.C.U
• PWM synthesis function
Rotor position
detect circuit
• Input current release control
• IGBT over-current detect control
• Outdoor fan control
Discharge
temp. sensor
Gate drive
circuit
• High power factor correction control
• Inverter output frequency control
• A/D converter function
Outdoor air
temp. sensor
Gate drive
circuit
• P.M.V. control
• Discharge temp. control
• 4-way valve control
Suction temp.
sensor
Over current
detect circuit
• Signal communication to indoor unit
Heat exchanger
temp.sensor
Over current
sensor
High Power
factor Correction
circuit
Clock
frequency
16MHz
Noise
Filter
Input current
sensor
Converter
Outdoor
Over current
sensor
Inverter
(DC AC)
(AC
DC)
Fan motor
Driver circuit
of P.M.V.
Relay
circuit
Over current
sensor
Inverter
(DC AC)
Compressor
4-way
valve
P.M.V.
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8. OPERATION DESCRIPTION
(1) Role of indoor unit controller
8-1. Outline of Air Conditioner Control
The indoor unit controller judges the operation
commands from the remote controller and
assumes the following functions.
This air conditioner is a capacity-variable type air
conditioner, which uses DC motor for the indoor fan
motor and the outdoor fan motor. And the capacity-
proportional 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.
• Judgment of suction air temperature of the
indoor heat exchanger by using the indoor
temp. sensor.
• Temperature setting of the indoor heat ex-
changer by using heat exchanger sensor
(Prevent-freezing control)
• Louver motor control
The indoor unit controller drives the indoor fan motor
based upon command sent from the remote control-
ler, and transfers the operation command to the
outdoor unit controller.
• Indoor fan motor operation control
• LED display control
• Transferring of operation command signal
(Serial signal) to the outdoor unit
The outdoor unit controller receives operation
command from the indoor unit side, and controls the
outdoor fan and the pulse modulating valve.
• Reception of information of operation status
(Serial signal including outside temp. data) to
the outdoor unit and judgment/display of error
Besides, detecting revolution position of the com-
pressor 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.
(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
Operations followed
to judgment of serial
signal from indoor
side.
• Operation control of
outdoor fan motor
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.
• P.M.V. control
• Detection of inverter input current and current
release operation
• Over-current detection and prevention opera-
tion 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 opera-
tion revolution control
• Defrost control in heating operation (Temp.
measurement by outdoor heat exchanger and
control for four-way valve and outdoor fan)
– 23 –
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(3) Contents of operation command signal (Serial
signal) from indoor unit controller to outdoor unit
controller
8-1-1. Capacity Control
The cooling and heating capacity is varied by
changing compressor motor speed.The inverter
changes compressor motor speed by changing AC
220–230–240V 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 electromo-
tive 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.
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.
Detection of the revolution position for controlling is
performed 12 times per 1 revolution of compressor.
The range of supply power frequency to the com-
pressor differs according to the operation status
(COOL, HEAT, DRY).
• Temperature of indoor heat exchanger by indoor
heat exchanger sensor
(Minimum revolution control)
(4) Contents of operation command signal (Serial
signal) from outdoor unit controller to indoor unit
controller
Table 8-1-1 Compressor revolution range
Operation
mode
Compressor
revolution (rps)
Model name
The following signals are sent from the outdoor
unit controller.
10YKV-E
13YKV-E
10YKV-E
13YKV-E
13 to 74
13 to 94
16 to 110
16 to 114
COOL
HEAT
• The current operation mode
• The current compressor revolution
• Outdoor temperature
• Existence of protective circuit operation
8-1-2. Current Release Control
For transferring of these signals, the indoor
unit controller monitors the contents of signals,
and judges existence of trouble occurrence.
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 reduc-
ing motor speed so that value becomes closest to
the command within the limited value.
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.
8-1-3. Power Factor Improvement Control
Power factor improvement control is performed
mainly aiming to reduce the current on much power
consumption of cooling/heating operation. Control-
ling 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.
– 24 –
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8-1-4. Prevent-Freezing Control
8-1-6. Louver Control
The indoor heat exchanger sensor detects refriger-
ant vapor temperature in COOL/DRY operation.
If the temperature is below the specified value,
compressor motor speed is reduced so that opera-
tion is performed in temperature below the specified
value to prevent-freezing of indoor heat exchanger.
(1) Vertical air flow louvers
Positions of vertical air flow louvers are auto-
matically controlled according to the operation
status (AUTO, COOL, DRY, HEAT). 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.
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 two P.M.V. corresponds to
difference of pipe length, fan speed, and unit tem-
perature.
(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.
After the power has been turned on, when a serial
operation signal is received from indoor at the first
time, or when PMV alarm is detected and the
equipment is reactivated, move the valve once until
it hits on the stopper for positioning of the valve.
In this case, ticktack sound may be heard.
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 8-1-2. It is not selected by relay, so selecting
sound does not generate.
Table 8-1-2
RAS-10YKV-E
RAS-13YKV-E
Operation
mode
Fan mode
Motor speed
(rpm)
Air flow rate
(m³/h)
Motor speed
Air flow rate
(m³/h)
(rpm)
1210
1020
850
H
M
L
1120
980
480
400
330
320
520
450
380
530
420
330
320
560
470
380
COOL
DRY
850
—
H
M
L
820
820
1200
1070
930
1270
1100
930
HEAT
– 25 –
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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.
<COOL, DRY>
Table 8-1-3
Model name
Compressor revolution (rps)
TO ≥ 38°C
RAS-10YAV-E
To 34,1
800
RAS-13YAV-E
To 34,1
940
To 13,2
450
From 34,7
800
To 13,2
450
From 34,7
940
Outdoor temp. sensor
TO < 38°C
450
630
800
450
700
940
TO
TO < 15°C
390
390
TO ≥ 38°C
450
450
630
800
630
450
450
700
940
700
ECONO. operation
TO is abnormal
<HEAT>
TO < 38°C
450
450
TO < 15°C
390
390
630
630
800
700
700
940
Table 8-1-4
Model name
Compressor revolution (rps)
RAS-10YAV-E
To 44,3
580
RAS-13YAV-E
To 44,3
650
To 16,2
390
From 44,9
800
To 16,2
390
From 44,9
900
TO ≥ 5°C
TO < 5°C
TO ≥ 5°C
TO < 5°C
Outdoor temp. sensor
TO
580
580
800
650
650
940
390
390
580
390
390
650
ECONO. operation
TO is abnormal
390
580
580
390
650
650
390
580
800
390
650
900
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.
– 26 –
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(1) Cooling capacity control
8-2-1. Cooling Operation
(The Remote Controller MODE Button
• 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.
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.
• When compressor has been activated or
reactivated, it operates with Max. 41 rps for 2
minutes, with Max. 91 rps from 2 minute to 3
minutes, and with Max. 94 rps after 3 minutes
passed.
• The indoor fan motor operates as shown in Fig.
8-2-1 when FAN button is set to AUTO.
• The motor operates with a constant air flow when
the FAN button is set to LOW, MED, or HIGH.
• When room temperature is lower than set
temperature, indoor fan motor is operated at
fan speed L– as shown in Fig. 8-2-1 while the
outdoor unit stops.
• 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.
(2) Prevent-freezing control
If temperature of indoor heat exchanger de-
tected by the indoor heat exchanger sensor is
5°C or lower, compressor motor speed is
gradually lowered to prevent freezing of the
indoor heat exchanger. If temperature is 7°C or
higher, return the operation to the above item
(1).
˚C
+3
M+
+2,5
*1
+2
*1
+1,5
(3) Current release control
*1
+1
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
9,0A if current value exceeds 9,0A. When the
current value lowers to 8,5A, return the opera-
tion to the above item (1).
L–
+0,5
Set
0
In normal
operation
temp.
–0,5
NOTE :
1: Calculated from difference in motor speed of
M+ and L–, and controlled.
*
Comp. motor
speed down
9,0
Fig. 8-2-1 Setting of air flow [Fan AUTO]
Comp. motor
speed keep
8,5
Normal control
Fig. 8-2-2
(4) Outdoor temperature release control
The outdoor temperature release is controlled by
changing the current release points 9,0 and 8,5
in the above item according to temperature
detected by the outdoor temperature sensor.
For example, if the outdoor temperature is 43°C,
the value of current release point becomes 8,0A.
– 27 –
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(5) Limit for maximum compressor motor speed
by indoor fan speed
(7) Discharge temperature control
(Common control to cooling and heating)
When outdoor temperature sensor detected
32°C or lower, and indoor heat exchanger
sensor detected 17°C or lower, the maximum
compressor motor speed is limited by the indoor
fan speed.
The discharge temperature of refrigerant gas
from the compressor is detected by the dis-
charge temperature sensor, and controls operat-
ing compressor motor speed.
1) Control 1 (A zone) : Normal operation zone
For example, the compressor motor speed is
limited as described in the table below.
When TD detect value is 98°C or lower, the
operation is performed with operating motor
speed instructed by the serial signal.
Table 8-2-1
2) Control 2 (B zone) : Slow-up zone of motor
speed
RAS-10YKV-E RAS-13YKV-E
Air flow rate
(rps)
56
(rps)
85
When TD detect value is 98°C or higher,
operating motor speed is slowly up.
HIGH
M+
49
71
3) Control 3 (C zone) : Keep zone
MED.
L–, L
43
57
When TD detect value is 105°C or higher,
operating motor speed is not changed if
raising operation speed.
36
44
UL, SUL
30
30
4) Control 4 (D zone) : Slow down zone of motor
speed
When TD detect value is 108°C or higher,
operating motor speed is slowly down.
(6) Louver control
The vertical air flow louvers are automatically set
to horizontal or cool memory position.
5) Control 5 (E zone) : Normal down of motor
speed
When temperature of indoor heat exchanger
becomes 5°C 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.
When TD detect value is 112°C or higher,
operating motor speed is down.
6) Control 6 (F zone) : Operation stop zone
If TD detect value exceeds 117°C during
operation, stop the operation immediately.
Then, restart the operation when TD detect
value becomes 105°C or lower.
TD
(˚C)
Zone
F
Operation stop zone
117
112
108
E
D
Normal down zone of motor speed
Slow down of motor speed
Release of motor speed
C
B
Keep zone : Motor speed is not changed.
Slow-up zone of motor speed
105
98
A
Normal operation zone
Fig. 8-2-3 Compressor motor speed control
– 28 –
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(8) ECONO. operation control
2) Setting 10 at 16 rps and 13 at 20 rps as the
maximum operating compressor motor
When the ECONO. button of the remote control-
ler is pushed, quiet and mild operation is per-
formed by restraining air flow and operating
motor speed.
speed, the minimum capacity operation range
is widened every 1 hour and 2 hours have
passed after ECONO. operation had started.
1) Indoor air flow is controlled between SUL
and L– (Low air (–)).
Compressor motor speed
10
13
Air volume
L–
16 rps
15 rps
20 rps
17 rps
3,5
3
{(L–) + (SUL)}/2
2,5
2
SUL
13 rps
13 rps
1,5
1
0,5
1H
2H
Time
Fig. 8-2-4
8-2-2. DRY Operation
(The Remote Controller MODE Button
is Set to the DRY Position)
+2,5
+2,0
+1,5
+1,0
+0,5
0
• 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.
L–
*1
• Dry operation signal is transmitted to outdoor
unit.
SUL
• The Cooling operation giving priority to dehumidi-
fying, which restrains the indoor fan speed and
compressor motor speed, is performed.
Set
temp.
• The indoor fan motor operates as shown in Fig.
8-2-5. (Fan speed is AUTO only.)
–0,5
• 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.
NOTE :
*1 : Middle motor speed between L– and SUL
Fig. 8-2-5 Setting of air flow
– 29 –
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[In starting and in stability]
8-2-3. Heating Operation
Transferring of heating operation signal from indoor
unit to outdoor unit starts.
In starting
In stability
• Until 12 minutes
passed after
operation start
• When 12 to 25
minutes passed
after operation start
and room temp. is
higher than (set
temp. –3°C)
The indoor fan motor operates by the room tempera-
ture when selecting “AUTO” of “FAN” as shown in
Fig. 8-2-6, and operates with a set air flow when
selecting “Low” to “High”.
• When 12 to 25
FAN
minutes passed
AUTO
However, to prevent cold draft, revolution speed of
the fan is restricted by indoor heat exchanger when
air flow is AUTO (Fig. 8-2-7) and starting of FAN
Manual.
after operation start
and room temp. is
3°C or lower than
set temp.
• When 25 minutes or
more passed after
operation start
FAN
Manual
• Room temp. < Set
temp. –4°C
• Room temp. ≥ Set
temp. –3,5°C
[Basic control]
LOW
Set
temp.
0
–0,5
–1
–1,5
–2
The outdoor unit controls the outdoor fan based
upon the operation signal sent from the indoor unit,
and also controls revolution speed of the compres-
sor motor.
1
*
2
*
M+
The power coupler (IC20) for four-way valve is
turned on, and turned off in defrost operation.
–5,0
–5,5
(1) Heating capacity control
HIGH
[FAN AUTO]
Calculate the difference between temperature
detected by room temp. sensor every minute and
the set temp. set on “Temp. indicator” and
variation amount of room temp.
*1, *2 : Approximate revolution speed of M+ and L to
linear according to temperature.
Fig. 8-2-6 Setting of air flow
Then, obtain the correction amount of the
command signal, and correct the current fre-
quency command signal.
[Cold draft preventing control]
The upper limit of fan revolution speed is shown
below.
(2) High-temp. release control
If temperature of the indoor heat exchanger
detected by the indoor heat exchanger sensor is
55°C or higher, compressor motor speed is
gradually lowered to prevent over-temp. rising of
compressed pressure.
HIGH
44
43
33
32
Approximate
revolution speed
of HIGH and SUL
linear by Tc.
If temperature becomes below 48°C, return to
above item (1).
31
30
20
19
3
*
SUL
(3) Current release control
2
*
A
A + 4
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.
The compressor motor speed is lowered gradu-
ally according to the range of TO (outside air
temp.) if the input current exceeds the current
value determined in each zone as shown in Fig.
8-2-8 so that the input current does not exceed
the set value.
( NOTE : 1)
SUL
Stop
*
A – 8 A – 8
Starting
FAN
of FAN
AUTO
Manual
Fig. 8-2-7 Cold draft preventing control
NOTES :
(1) Stops for 2 minutes after thermostat-OFF.
(2) 24°C when the set temp. is 24°C or more
Set temp. when the set temp. is below 24°C
In case that the current lowered by approx. 0,5A
than each set value, return to above item (1).
(3) SUL : Super ultra low
– 30 –
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2) Defrost operation
Operation of the compressor is stopped
once, turn off power coupler for four-way
valve after 10 seconds, and then exchange
the four-way valve.
TO
10,8A
10,3A
9,8A
16,0
15,5
11,0
10,5
After 20 seconds, restart operation of the
compressor. Turn off the outdoor fan just
when the compressor stopped.
If temperature of the indoor heat exchanger
lowered than 38°C, stop the indoor fan.
3) Defrost reset
Fig. 8-2-8
Resetting operation from defrost to heating is
performed when any one of the following
conditions is satisfied.
(4) Defrost control
1) Detection of frost
a. Temperature of the outdoor heat ex-
changer rose to +8°C or higher.
In heating operation, time duration while the
compressor operates is counted, and defrost
operation starts by any condition described
below.
b. A status that temperature of the outdoor
heat exchanger is +5°C or higher contin-
ued for 80 seconds.
a. The counted time is 28 minutes or more,
and status that temperature of the outdoor
heat exchanger detected by the outdoor
heat exchanger is –20°C or lower contin-
ued for 2 minutes or more.
c. Defrost operation continued for 10 min-
utes.
In resetting defrost operation, the compressor
stops for 50 seconds if defrost has started
under condition a. to c. in item 1), but the
compressor is reset to heating operation
keeping operated if defrost has started under
condition d. in item 1).
b. The counted time is 28 minutes or more,
and status that temperature of the outdoor
heat exchanger detected by the outdoor
heat exchanger is –7°C or lower and
temperature lowered by 2,5 °C than the
minimum value of the outdoor heat ex-
changer during 10 to 15-minutes count
time continued for 2 minutes or more.
(5) Louver control
The vertical air flow louvers are automatically set
to heating position or heat memory position.
When the compressor is turned off by high-temp.
release control, the vertical air flow louvers close
once and then return to the position of previous
time.
c. The counted time is 34 minutes or more,
and status that temperature of the outdoor
heat exchanger detected by the outdoor
heat exchanger is –5°C or lower and
temperature lowered by 3,0 °C than the
minimum value of the outdoor heat ex-
changer during 10 to 15-minutes count
time continued for 2 minutes or more.
d. If the following three conditions are satis-
fied, defrost operation (Timer defrost)
starts after heating operation for 37
minutes.
Setting on remote control, HEAT
(mode), HIGH (Fan), 30°C (temp.).
‚ Room temp. is 19°C to 24°C, and
outside air temp. is 5°C or lower.
ƒ Defrost operation has been already
performed once.
– 31 –
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(2) After selecting the operation mode (COOL, DRY,
HEAT), select an operation mode again when a
status that the compressor was turned off by the
room temperature or outside air temperature
continues for 15 minutes.
8-2-4. Automatic Operation
(1) As shown in Fig. 8-2-9, the operation mode
(COOL, DRY, HEAT) is selected according to the
outside temperature and room temperature
when the operation has started.
(3) Powerful Cool mode control
The operation in Fan mode continues until an
operation mode is selected.
When the outside temperature is above 32°C
and indoor temperature is above 28°C, select
Cool mode control. In Cool mode, the air flow
louver directs downward. When the room tem-
perature gains access to the set temperature, it
becomes cool memory position.
If the room temperature is 20°C or higher when
“AUTO” operation started within 2 hours after
“HEAT” operation had stopped, select an opera-
tion mode after Fan operation of ultra low fan.
In AUTO operation, the set temperature of each
operation can be corrected by the remote
controller in the range of 17 to 30°C.
Powerful Cooling/Drying with
setting on remote controller
Ts = 25˚C
TA
28
Cooling/Drying with setting on remote controller
Ts = 25˚C
26
24
23
Monitoring
(Follow to the Fan control in previous
mode when being selected again.)
Heating with setting
on remote controller
Ts = 25˚C
20
Ts correction by outside
temperature ( To)
5
15 18
–1
24
32
To
–2
0
+1
Fig. 8-2-9
8-3-1. Temporary Auto Operation
8-3. Temporary Operation
• When the TEMPORARY button is pushed, the
Auto operation with set temperature fixed at 25°C
starts. Controlling is same as that of Auto opera-
tion by the remote controller.
• Temporary Auto operation, existence of Auto
Restart, and Temporary Cooling operation can be
set by the TEMPORARY button of the indoor
controller.
• When the TEMPORARY button is pushed again,
the operation stops.
• During Temporary Auto operation, operation by
the remote controller is accepted.
• Using the Auto Restart function, the Temporary
Auto operation starts when power failure is reset.
8-3-2. Temporary Cooling Operation
TEMPORARY
button
TEMPORARY
• 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.
Table 8-3-1
Compressor motor speed :
10 : 30 rps
TEMPORARY button
Control
13 : 30 rps
OFF → ON
Temporary Auto operation start
Indoor fan speed : Low
After pushing button
for 3 seconds
Auto Restart control select
• When the TEMPORARY operation button is
pushed again, the operation stops.
After pushing button
for 10 seconds
Temporary Cooling
operation start
• Auto Restart function is unavailable.
– 32 –
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8-4-1. How to Set the Auto Restart
8-4. Auto Restart Function
To set the Auto Restart function, proceed as follows:
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.
Access the TEMPORARY button located in the lower
right hand corner beneath the hinged front panel of
the indoor unit (please refer to Fig. 8-2-9). The
power supply to the unit must be on - the function
will not be set if the power is off.
The operation will resume without warning three
minutes after the power is restored.
To enable the Auto Restart function, push the
TEMPORARY button continuously for three
seconds.
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.
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
Motion
Push the TEMPORARY button
continuously more than three
seconds.
Stand-by
↓
The system starts to operate.
↓ about three seconds after
The unit beeps three times.
↓
The green light goes on.
The orange light goes on.
0
3S
The system is operating.
TEMPORARY
If the system is not required to run at this time, push the TEMPORARY
button once more or use the remote controller and the unit will stop.
• When the system is operating
Operation
Motion
Push the TEMPORARY button
continuously more than three
seconds.
Operating
The green light goes on.
The green light goes off.
↓
The system stops to operate.
↓ about three seconds after
The unit beeps three times.
↓
0
3S
The system stops.
TEMPORARY
If the system is not required to stop at this time, use the remote
controller and to restart.
During subsequent operation, the orange light goes on.
• During louver swing (AUTO) operation, after
restart by the Auto Restart function the louver
swing stops.
• The Auto Restart function will not accept an
instruction if timer operation with the remote
controller is selected.
– 33 –
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The system will now be required to manually restart
with the remote controller after the main supply is
turned off.
8-4-2. How to Cancel the Auto Restart
To cancel the Auto Restart function, proceed as
follows:
Cancellation is carried out:
Repeat the setting procedure: the unit will
acknowledge the instruction and beep three times.
• When the system is stand-by (not operating)
Operation
Motion
Push the TEMPORARY button
continuously more than three
seconds.
Stand-by
↓
The system starts to operate.
↓ about three seconds after
The unit beeps three times.
↓
The orange light goes on.
The green light goes on.
0
3S
The system is operating.
TEMPORARY
If the system is not required to run at this time, push the TEMPORARY
button once more or use the remote controller and the unit will stop.
• When the system is operating
Operation
Motion
Push the TEMPORARY button
continuously more than three
seconds.
Operating
The orange light goes on.
The orange light goes off.
↓
The system stops to operate.
↓ about three seconds after
The unit beeps three times.
↓
0
3S
The system stops.
TEMPORARY
If the system is not required to stop at this time, use the remote control
ler and to restart.
During subsequent operation, the green light goes on.
(2) If OFF-TIMER operation is reserved without
setting of Auto Restart operation, the reservation
is cancelled with power failure.
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.
(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.
– 34 –
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8-5. Remote Controller
8-5-1. Parts Name of Remote Controller
Transmitter
TEMP.
MODE
FAN
AUTO
LOW
MED.
HIGH
AUTO
COOL
DRY
˚C
HEAT
Hr.ON OFF TIMER
TEMP. (Temperature) buttons
Push this button to set a desired
temperature.
START/STOP button
Push this button to start/stop the air
conditioner.
TEMP.
FAN (Fan speed) button
START/STOP
Push this button to change air flow.
AUTO (Auto louver) button
Push this button to swing the vertical air
flow louvers automatically.
SET button
AUTO
MODE
SET
CHK
FAN
Push this button to change wind direction.
MODE (Mode select) button
Push this button to select an operation
mode.
ECONO.
ECONO. (Economy) button
Push this button to operate economically.
TIMER
ON (On timer) button
CHK (Check) button
ON
OFF
RSV
CNL
Push this button to start the unit at the
time set by the timer.
Service man pushes this button to check
the location of a problem.
OFF (Off timer) button
CNL (Cancel) button
Push this button to stop the unit at the
time set by the timer.
Push this button to cancel reservation of
timer operation.
RSV (Reserve) button
Push this button to reserve timer
operation.
8-5-2. Name of Indications on Remote Controller
All indication that appear on the remote controller are shown for explanation.
Transmission indicator
This mark is indicated when a button is pushed.
Set temperature is indicated
(17˚C to 30˚C).
Selected operation mode with
the MODE button is indicated.
Selected degree of air flow
(HIGH, MED., LOW or AUTO) is indicated.
MODE
AUTO
COOL
DRY
TEMP.
FAN
AUTO
LOW
MED.
HIGH
˚C
Hr.ON OFF TIMER
HEAT
This mark is indicated when
the ECONO. button is pushed.
Set time for timer
operation is indicated.
– 35 –
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Power supply cord of parts of appliance for outdoor use shall be more
than polychloroprene sheathed flexible cord (design H07 RN-F), or
cord designation 245 IEC 66. (2,0mm² or more)
9. INSTALLATION PROCEDURE
For general public use
9-1. Safety Cautions
Remark per EMC Directive 89/336/EEC
CAUTION
New Refrigerant Air Conditioner Installation
For to prevent flicker impressions during the start of the compressor (technical process) following installation
conditions do apply.
•
This air conditioner adopts the new HFC refrigerant (R410A) which does not destroy ozone layer.
1. The power connection for the air conditioner has to be done at the main power distribution.
This distribution has to be of an impedance.
Normally the required impedance is reached at a 32A fusing point. Air conditioner fuse has to be 16A max.!
2. No other equipment has to be connected to this power line.
R410A refrigerant is apt to be affected by impurity such as water, oxidizing membrane, and oils because pressure of
R410A refrigerant is approx. 1,6 times of refrigerant R22. 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 of new-refrigerant air conditioner.
To prevent mixing 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 conventional refrigerant. Accordingly, the exclusive tools are
required for the new refrigerant (R410A) as shown below.
For connecting pipes, use new and clean piping materials with high pressure-tight force, which were made for R410A
only, so that water or dust does not enter. Moreover, do not use the existing piping because there are problems about
pressure-tight force and inner impurity in the existing piping.
3. For detailed installation acceptance please refer to your contact with the power supplier, it restriction do apply
for products like washing machines, air conditioners or electrical ovens.
4. For power details of the air conditioner refer to the rating plate of the product.
9-1-1. Installation Diagram of Indoor and Outdoor Units
CAUTION
To Disconnect the Appliance from the Mains Supply.
For the rear left and left piping
This appliance must be connected to the mains by means of a circuit breaker or a switch with a contact separation of at
least 3 mm.
Clip anchor
Wall
Hook
If this is not possible, a power supply plug with earth must be used. This plug must be easily accessible after
installation. The plug must be disconnected from the power supply socket in order to disconnect the appliance
completely from the mains.
Hook
Front cabinet
1
Installation
plate
Insert the cushion between
the indoor unit and wall,
and lift indoor unit to make
work easier.
Front panel
DANGER
Hook
•
•
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.
Do not allow the drain hose to
get slack.
5
Mounting screw
•
CONNECT THE CONNECTING CABLE CORRECTLY. IF THE CONNECTING CABLE IS CONNECTED BY WRONG
WAY, ELECTRIC PARTS MAY BE DAMAGED.
Cut the piping hole
sloped slightly
•
•
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.
Shield pipe
•
•
TO PREVENT OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY
(MORE THAN 2M.) 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 (R-22) WITH ANY OTHER GASEOUS BODY INTO THE REFRIG-
ERATION 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.
Pan head
Make sure to run the drain
hose sloped downward.
wood screw
8
7
Deodorizing
filter
The auxiliary piping can be
connected the left, rear left,
rear, right or bottom.
6
Purifying
filter
4
Remote
controller
holder
•
2
Wireless
remote controller
Right
WARNING
Rear
•
•
Never modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches.
Rear left
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.
Left
Bottom
Before install the wireless
remote controller
•
•
Insulation of refrigerant pipes
insulates the pipes separately,
not together.
•
With the remote controller
cover open, load the batteries
supplied correctly, observing
their polarity.
ore
or m
m
200m
2
Wireless remote controller
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.
3
Batteries
•
•
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 user’s neighbors.
6 mm thick heat resisting
polyethylene foam
Cover
•
•
To avoid personal injury, be careful when handling parts with sharp edges.
Please read the installation manual carefully before installing the unit. It contains further important instructions for
proper installation.
As shown in the figure, hang power cord
and connecting cable downward, and
take out it along piping connection port.
Fig. 9-1-1
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9-1-2. Optional Installation Parts
9-2. Indoor Unit
9-2-1. 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 an easy installation of the
piping to the outdoor unit.
Mounting the Installation Plate
Fixing bolt arrangement of outdoor unit
For installation of the indoor unit, use the
paper pattern on the back.
Part
code
• Secure the outdoor unit with the fixing bolts and nuts if the
Parts name
Q’ty
unit is likely to be exposed
to a strong wind.
• Use ø8 mm or ø10 mm
anchor bolts and nuts.
Anchor bolt hole
600
40mm
66mm
Suction side
Refrigerant piping
Liquid side : Ø6,35
Gas side : Ø9,52
Each
one
115
A
120mm
65,5mm
• If it is necessary to drain
the defrost water attach
65,5mm
Pipe insulating material
(Polyethylene foam, 6mm thick)
B
C
1
Pipe
hole
drain nipple to the bottom
• A place which allows the front panel to be
opened.
Drain hole
Diffuser
plate of the outdoor unit
before installing it.
Pipe hole
1
Each
one
Putty, PVC tapes
Fig. 9-1-2
Installation
plate
Thread
Weight
5
Mounting
screw
Indoor unit
CAUTION
• Direct sunlight to the indoor unit wireless
receiver should be avoided.
Fig. 9-2-3
9-1-3. Accessory and Installation Parts
When the installation plate is directly
mounted on the wall
• The microprocessor in the indoor unit should not
be too close to r-f noise sources.
Part
No.
Part
No.
Part name (Q'ty)
Part name (Q'ty)
Name
(For details, see the owner's manual.)
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.
1
2
3
4
Owner’s manual
5
6
7
8
Others
Mounting screw Ø4 x 25 x 6
Installation plate x 1
Remote controller
Installation manual
• 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 controller in a place
exposed to direct sunlight or close to a heating
source, such as a stove.
• Keep the remote controller at least 1 m apart from
the nearest TV set or stereo equipment.
(This is necessary to prevent image disturbances
or noise interference.)
Purifying filter x 1
Wireless remote controller x 1
This model is not equipped with
an extention drain hose.
Deodorizing filter x 1
Battery x 2
Option :
3. Install the installation plate horizontally in
the wall.
For the extention drain hose, use
an optionally available RB-821SW
or commercially available one.
Pan head wood screw Ø3,1x 16 x 2
Remote controller holder x 1
CAUTION
9-1-4. 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, to 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)
When installing the installation plate with
mounting screw, do not use the anchor
bolt hole. Otherwise the unit may fall down
and result in personal injury and property
damage.
• The location of the remote controller should be
determined as shown below.
(Side view)
(Top view)
Indoor unit
˚
5
4
Anchor bolt
New tools for R410A
Reception
range
Remote
controller
Remote
controller
Reception
range
Projection
New tools for R410A
Applicable to R22 model
Changes
: Axial distance
*
15mm or less
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.
Fig. 9-2-1
Gauge manifold
×
Fig. 9-2-4
5 mm dia. hole
9-2-2. Cutting a Hole and Mounting
Installation Plate
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.
Charge hose
×
5
Mounting screw
Ø4 x 25
Cutting a Hole
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.
Electronic balance
for refrigerant charging
¡
When install the
refrigerant pipes
from the rear.
Clip anchor
(local parts)
Fig. 9-2-5
Torque wrench
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.
The center of the piping slot
is above the arrow.
The center of the pipe
hole is above the arrow.
(nominal diam. 1/2, 5/8)
×
CAUTION
By increasing the clamp bar’s receiving hole, strength of spring in the
tool has been improved.
Flare tool (clutch type)
Pipe hole
¡
Failure to firmly install the unit may result
in personal injury and property damage if
the unit falls.
80mm
Gauge for projection adjustment ——
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 R410A a sludge
may occur and damage the equipment.
Fig. 9-2-2
• In case of block, brick, concrete or similar
type walls, make 5 mm dia. holes in the
wall.
Vacuum pump adapter
¡
1. After determining the pipe hole position on the
mounting plate (80 mm ), drill the pipe hole
(ø65 mm) at a slight downward slant to the
outdoor side.
• Insert clip anchors for appropriate ꢀ
Gas leakage detector
Exclusive for HFC refrigerant.
Exclusive for HFC refrigerant.
mounting screws.
×
NOTE
NOTE
• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) 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 correspond-
ing to the charge hose’s port size.
• When drilling the wall that contains a metal lath,
wire lath or metal plate, be sure to use a pipe
hole brim ring sold separately.
• Install the installation plate using 4 to 6
pieces of mounting screw securing four
corners with screws.
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9-2-3. 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.
9-2-5. Piping and Drain Hose Installation
In case of rightward piping
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.
How to connect the connecting cable
Wiring of the connecting cable can be carried out
without removing of the front cabinet.
Slit
• After scribing slits of the
(front cabinet)
1. Remove the front cabinet.
front cabinet and the rear
panel by a knife or a
Fully open the front cabinet. Disengage the
support arm located in the upper center while
pushing its handle leftwards, and then remove
the panel toward you.
marking-off pin, cut them by
NOTE
a pair of nippers or the like.
Slit (rear panel)
• Wire type : More than H07RN-F or 245IEC66
(2,0mm² or more)
Fig. 9-2-12
2. Remove the terminal cover and cord clamp.
3. Insert the connecting cable (according to local
cords) into pipe hole on the wall.
4. Take out the connecting cable through the cable
slot on the rear panel so that it is exploded by
about 15 cm long in the front side.
5. Insert the connecting cable fully into the
terminal block and secure it by screw tightly.
6. Tightening torque : 1,2 N•m (0,12 kgf•cm)
7. Secure the connecting cable with the cord clamp.
8. Fix the wiring cover, rear plate bushing and
front cabinet on the indoor unit.
In case of downward piping
CAUTION
• Use power specified above table.
• This appliance can be connected to the mains
in either of the following two ways.
(1) Connection to fixed wiring :
Hook here
1
• After scribing the slit of the front
1
cabinet and slit in the lower part
Installation
plate
Slit
(front cabinet)
of the rear panel by a knife or a
marking-off pin, cut them by a
2
Fig. 9-2-16
pair of nippers or the like.
Press (unhook)
Hook
Slit
(rear panel)
Fig. 9-2-13
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 circuit breaker or switches
must be used.
• For detaching the
indoor unit from the
installation plate pull
the indoor unit toward
you while pushing its
bottom up at the
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 spring bender so as not to crush the pipe.
Push
Push
CAUTION
specified parts.
(2) Connection with power supply plug :
• 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 limitation.
Fig. 9-2-17
Attach power supply plug with power cord
and plug it into wall outlet. An approved
power supply cord and plug must be used.
9-2-7. Drainage
1. Run the drain hose sloping downwards.
Bend the connection pipe within a radius of 30 mm.
To connect pipe after installation of unit (figure)
(To the forefront of flare)
NOTE
196mm
Terminal block
Cord
NOTE
Liquid side
96mm
• Hole should be made at a slight downward slant
on the outdoor side.
Gas side
• Perform wiring works so as to allow a generous
wiring capacity.
Terminal
clamp
Connecting
cable
Earth line
cover
Screw
Outward form
of indoor unit
Do not rise the drain hose.
Do not form the drain hose
into the waved shape.
Screw
R 30mm (Use polisin (polyethylene core)
or the like for bending pipe.)
Fig. 9-2-8
Connecting
cable
9-2-4. Wiring Connection
How to remove the front cabinet
50 mm
Screw
or more
80˚
Use the handle of screwdriver,etc.
Stripping length of connecting cable
Fig. 9-2-14
NOTE
If the pipe is bent incorrectly, the indoor unit may
unstably be set on the wall.
1
2
3
Do not put the
Do not put the drain
hose end in the
drainage ditch.
10mm
1
2
3
drain hose end
(4)
10mm
into water.
(4)
50mm
Fig. 9-2-18
40mm
After passing the connecting pipe through the pipe
hole, connect the connecting pipe to the auxiliary
pipes and wrap the facing tape around them.
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
(1) (2)
(3)
(1) (2)
Earth
line
Vertical air flow louver
NOTE
NOTE
Connect the earth line to the
metallic part ( mark) located
at the side of 3P terminal.
Use stranded wire only.
WIRE TYPE : more than
H05 RN-F
CAUTION
shield pipe.
Fig. 9-2-6
Shield pipe
• Bind the auxiliary pipes (two) and connecting
Fig. 9-2-9
cable with facing tape
How to open the screw cap
Indoor unit
tightly. In case of
Connecting
How to install the front cabinet on the indoor unit
• Install the front cabinet through the opposite
order of “How to remove the front cabinet”.
When the panel is removed and mounted again,
take the following actions:
After fastening the two screws, one each at the left
and right of the air outlet be sure to push the upper
center , right end ‚, left end ƒ and the lower
center „ of the air outlet, and confirm that no gap
is left between the front cabinet and the rear plate.
Auxiliary
• Place your finger on the lower part and push
to open the screw cap.
cable
leftward piping and
Drain hose Inside the room
Extension drain hose
pipes
rear-leftward piping,
Fig. 9-2-19
bind the auxiliary
Installation
plate
pipes (two) only with
facing tape.
CAUTION
Fig. 9-2-15
• Carefully arrange pipes so that any pipe does
not stick out of the rear plate of the indoor unit.
Arrange the drain pipe for proper drainage from
the unit.
Improper drainage can result in dew-dropping.
• 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.)
Fig. 9-2-7
This air conditioner has the structure designed to
drain water collected from dew,
1 Open the screw caps and remove the two
screws securing the front cabinet.
2 Close the screw caps as behind.
3 Open the vertical air flow louver horizontally by
hand.
4 Slightly open the lower part of the front cabinet
then pull the upper part of the front cabinet
toward you to remove it from the rear plate.
• If cooling (dry) operation is made without pushing
the air outlet, dew can be
Wall
which forms on the back of the
Push
3
Push
1
Push
2
deposited on the front
cabinet surface. In addition
a gap between the front
cabinet and the rear plate
will become wilder,
indoor unit, to the drain pan.
Drain
guide
Therefore, do not store the
power cord and other parts
at a height above the drain
guide.
4
Space for
pipes
• When bending a pipe, carefully do it not to
crush it.
Push
spoiling the apperance.
Fig. 9-2-20
Fig. 9-2-10
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9-3-5. Gas Leak Test
9-3. Outdoor Unit
9-3-1. Installation Place
• A place which provides the spaces around the
outdoor unit as shown in the left diagram.
Tightening Connection
CAUTION
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.
•
KEEP IMPORTANT 4 POINTS FOR PIPING WORK
1. Take away dust and moisture
(Inside of the connecting pipes.)
• 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 your neighbors.
• A place which is not exposed to a strong wind.
• A place free of a leakage of combustible gases.
• 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.
2. Tight connection (between pipes and unit)
3. Evacuate the air in the connecting pipes using
VACUUM PUMP.
CAUTION
Flare nut connections
(Indoor unit)
• Do not apply excess torque. Otherwise, the nut
may crack depending on the conditions.
• Flare nut connections
(Outdoor unit)
• Valve stem cap connection
4. Check gas leak (connected points)
(Unit : N·m)
PackedValve Handling Precautions
• Open the valve stem all the way out; but do not try
to open it beyond the stopper.
• Service port cap connection
Outer dia. of copper pipe
ø6,35 mm
Tightening torque
14 to 18 (1,4 to 1,8 kgf•m)
33 to 42 (3,3 to 4,2 kgf•m)
50 to 62 (5,0 to 6,2 kgf•m)
Fig. 9-3-9
ø9,52 mm
ø12,7 mm
• Securely tighten the valve stem cap with torque in
• Check the flare nut connections, valve
stem cap connections and service port cap
connections for gas leak with a leak
detector or soap water.
the following table :
• Tightening torque of flare pipe connections
Hexagonal
wrench is
required.
•
An allowable length of the connecting pipe is up 15m.
Gas side
50 to 62 N•m
Pressure of R410A becomes higher than that of R22.
(Approx. 1,6 times) Therefore, using a torque wrench,
tighten firmly the flare pipe connecting sections 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
of the refrigeration cycle.
(ø12,7 mm) (5,0 to 6,2 kgf•m)
Gas side 33 to 42 N•m
• An allowable height level is up to 10 m.
• A place where the drain water does not raise
any problem.
(ø9,52 mm) (3,3 to 4,2 kgf•m)
Flare at
indoor
Liquid side
14 to 18 N•m
9-3-6. Test Operation
unit side
(ø6,35 mm) (1,4 to 1,8 kgf•m)
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.
4. Installation in the following places may result
trouble. Do not install the unit such places.
• A place full of machine oil.
• A saline-place such as coast.
• A place full of sulfide gas.
• A place where high-frequency waves are
likely to be generated
as from audio
To switch the TEST RUN (COOL) mode,
press TEMPORARY button for 10 sec.
(The beeper will make a short beep.)
14 to 18 N•m
Service port
(1,4 to 1,8 kgf•m)
Fig. 9-3-7
Half union
Flare nut
9-3-4. Wiring Connection
1. Remove the electric parts cover from the outdoor
unit.
2. Connect the connecting cable to the terminal as
identified with their respective matched numbers
on the terminal block of indoor and outdoor unit.
3. When connecting the connecting cable to the
outdoor unit terminal, make a loop as shown
installation diagram of indoor and outdoor unit, to
prevent water coming in the outdoor unit.
Flare at
outdoor
unit side
Externally
threaded side
Use a wrench
to secure.
Internally
threaded side
Use a torque wrench
to secure.
Fig. 9-3-4
Fig. 9-3-5
9-3-3. Evacuating
After the piping has been connected to all indoor unit(s),
you can perform the air purge together at once.
TEMPORARY
button
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.
TEMPORARY
4. Insulate the unused cords (conductors) with water
coming in the outdoor unit. Process them so that
they do not touch any electrical or metal parts.
Use a vacuum pump
Fig. 9-3-10
equipment,
Stripping length of connecting cable
Strong
welders, and
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.
wind
Terminal block (Connecting cable)
medical
equipment.
10
10
L
N
1
2
3
9-3-7. Auto Restart Setting
Fig. 9-3-1
10
10
This product is designed so that, after a
power failure, it can restart automatically in
the same operating mode as before the
power failure,
40
40
9-3-2. Refrigerant Piping Connection
30
30
Flaring 1. Cut the pipe with a pipe cutter.
Earth line
Connecting cable
Connecting
cable
Power Power
cord cord
Fig. 9-3-8
90˚
Obliquity Roughness
Warp
3. Open fully the low pressure side handle of the gauge
manifold valve.
Information
Model
RAS-10YKV-E/RAS-13YKV-E
The product was shipped with Auto
Restart function in the off position.
Turn it on as required.
4. Operate the vacuum pump to start for evacuating.
Perform evacuating for about 15 minutes if the piping
length is 20 meters. (15 minutes for 20 meters)
(assuming a pump capacity of 27 liters per minute.)
Then confirm that the compound pressure gauge
reading is –101 kPa ( –76 cmHg).
Power source
50/60 Hz, 220 – 240 V Single phase
Fig. 9-3-2
Maximum running current
Plug socket & fuse rating
Power cord
8,5A
2. Insert a flare nut into the pipe, and flare the pipe.
• Projection margin in flaring : A (Unit : mm)
Rigid (Clutch type)
10A
H07RN-F or 245IEC66 (2,0mm² or more)
How to Set the Auto Restart
Compound
Pressure gauge
Outer dia. of
R410A
Conventional
pressure
CAUTION
• Wrong wiring connection may cause some
electrical parts burn out.
• Be sure to comply with local codes on running
the wire from outdoor unit to indoor unit (size of
wire and wiring method etc.)
5. Close the low pressure side
valve handle of gauge manifold.
• Press and hold down the TEMPORARY
button for about 3 seconds. After 3
seconds, the electronic beeper makes
three short beeps to tell you the Auto
Restart has been selected.
• To cancel the Auto Restart, follow the
steps described in the section Auto Restart
Function of the Owner’s Manual.
copper pipe
tool used
tool used
gauge
-101kPa
Manifold valve
(-76cmHg)
6,35
9,52
12,7
0 to 0,5
0 to 0,5
0 to 0,5
1,0 to 1,5
1,0 to 1,5
1,0 to 1,5
6. Open fully the valve stem of
Handle Hi
(Keep full closed)
Charge hose
(For R410A only)
Handle Lo
the packed valves (both side
Charge hose
(For R410A only)
of Gas and Liquid).
Vacuum pump
adapter for
7. Remove the charging hose
from the service port.
8. Securely tighten the caps
on the packed valves.
counter-flow
prevention
Imperial (Wing nut type)
Connecting
pipe
A
(For R410A only)
Outer dia. of
• Every wire must be connected firmly.
R410A
copper pipe
6,35
Vacuum
pump
1,5 to 2,0
1,5 to 2,0
2,0 to 2,5
NOTE : Connecting cable
• Wire type : More than H07RN-F or 245IEC66
(2,0mm² or more)
Die
Pipe
Packed valve at liquid side
Packed valve at gas side
Service port
(Valve core (Setting pin))
9,52
12,7
Fig. 9-3-3
Fig. 9-3-6
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10. HOW TO DIAGNOSETHE TROUBLE
The pulse modulating circuits are mounted to both
NOTE :
indoor and outdoor units. Therefore, diagnose
troubles according to the trouble diagnosis proce-
dure as described below. (Refer to the check points
in servicing written on the wiring diagrams attached
to the indoor/outdoor units.)
A large-capacity electrolytic capacitor is used in the
outdoor unit controller (inverter).Therefore, if the
power supply is turned off, charge (charging voltage
DC280V) remains and discharging takes a lot of
time. After turning off the power source, if touching
the charging section before discharging, an electri-
cal shock may be caused. Discharge the electrolytic
capacitor completely by using soldering iron, etc.
Table 10-1
No.
1
Troubleshooting Procedure
First Confirmation
Page
40
< Discharging method >
2
Primary Judgment
41
(1) Remove the inverter cover (plating) by opening
four mounting claws.
3
Judgment by Flashing LED of Indoor Unit
42
(2) As shown below, connect the discharge resis-
tance (approx. 100Ω40W) or plug of the solder-
ing iron to voltage between + – terminals of the
C14 (“CAUTION HIGH VOLTAGE 320V” is
indicated.) electrolytic capacitor (500µF/400V)
on P.C. board, and then perform discharging.
Self-Diagnosis by Service Check Remote
Controller
4
43
5
6
Judgment of Trouble by Every Symptom
How to Check Simply the Main Parts
46
53
Inverter cover
P. C. board
(Soldered surface)
Discharging position
(Discharging period
10 seconds or more)
Plug of
soldering iron
MCC-808
Fig. 10-1
10-1-2. Confirmation of Power Voltage
10-1. First Confirmation
Confirm that power voltage is AC 220–230–240
10%. If power voltage is not in this range, the unit
may not operate normally.
10-1-1. Confirmation of Power Supply
Confirm that the power breaker operates (ON)
normally.
– 40 –
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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 control-
ling and maintaining of air conditioner.
Table 10-1-1
No.
Operation of air conditioner
Description
1
When power breaker is turned “ON”, the
operation lamp (Green) of the indoor unit
flashes.
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)
2
Compressor may not operate even if the
room temperature is within range of
compressor-ON.
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.
3
4
In Dry and ECONO. mode, FAN (air flow)
display does not change even though FAN
(air flow select) button is operated.
The air flow indication is fixed to [AUTO].
Increasing of compressor motor speed
stops approx. 30 seconds after operation
For smooth operation of the compressor, the compressor
motor speed is restricted to Max. 41 rps for 2 minutes, and
started, and then compressor motor speed Max.91 rps for 2 minutes to 3 minutes, respectively after
increases again approx. 30 seconds after. the operation has started.
5
6
7
The set value of the remote controller
should be below the room temperature.
If the set value is above the room temperature, Cooling
operation is not performed. And check whether battery of
the remote controller is consumed or not.
In AUTO mode, the operation mode is
changed.
After selecting Cool or Heat mode, select an operation
mode again if the compressor keeps stop status for 15
minutes.
In HEAT mode, the compressor motor
speed does not increase up to the maxi-
mum speed or decreases before the
temperature arrives at the set tempera-
ture.
The compressor motor speed may decrease by high-temp.
release control (Release protective operation by temp.-up
of the indoor heat exchanger) or current release control.
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.
– 41 –
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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
Check
code
Item
A
Block display
Description for self-diagnosis
OPERATION
ECONO.
TIMER
OPERATION (Green)
Power failure (when power is ON)
Flashing display (1 Hz)
Indoor
PRE DEF.
indication
lamp flashes.
OPERATION
ECONO.
TIMER
OPERATION (Green)
Flashing display (5 Hz)
Protective circuit operation for
indoor P.C. board
B
Which lamp
does flash?
PRE DEF.
OPERATION
ECONO.
TIMER
OPERATION (Green)
TIMER (Yellow)
Protective circuit operation for
connecting cable and serial signal
system
C
D
Flashing display (5 Hz)
PRE DEF.
OPERATION (Green)
PRE DEF. (Orange)
Flashing display (5 Hz)
OPERATION
ECONO.
TIMER
Protective circuit operation for
outdoor P.C. board
PRE DEF.
OPERATION
ECONO.
TIMER
Protective circuit operation for others
(including compressor)
OPERATION (Green)
TIMER (Yellow)
PRE DEF. (Orange)
Flashing display (5 Hz)
E
PRE DEF.
NOTES :
(1) The contents of items B and C and a part of item E are displayed when air conditioner operates.
(2) 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.
(3) The check codes can be confirmed on the remote controller for servicing.
– 42 –
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10-4. Self-Diagnosis by Remote Controller (Check Code)
(1) The self-diagnosis by the check code is performed while items B to E blocks are displayed.
(2) When turning the operation mode on the remote controller to the service mode, and operating the remote
controller, the controller of the indoor unit can self-diagnose operation of the protection circuit by displayed
contents (check code) on the remote controller, by whether all the lamps flash (5Hz) and the receiving
sound (Pi, Pi, Pi ... for 10 seconds) is heard. The timer lamp usually flashes (5Hz) during self-diagnosis.
10-4-1. Self-Diagnosis
Push the CHK button by something with thin edge.
1
• Check
is displayed in the indication
part of the remote controller.
CHK
E
TIMER
Push
toward the remote controller one by one.
2
If it is normal, the receiving sound “Pi” is heard
every pushing it and check code in the indication
part of the remote controller changes.
MODE
TEMP.
FAN
AUTO
LOW
MED.
HIGH
AUTO
COOL
DRY
˚C
HEAT
Hr.ON OFF TIMER
The timer lamp of the air conditioner flashes.
(5 times for 1 second)
TEMP.
• Check all of 35 check codes (
to
).
START/STOP
• Push to return to the objective code if passed.
AUTO
MODE
SET
CHK
FAN
If a trouble occurs, the receiving sound “Pi”
changes to Pi, Pi, Pi (continues for approx.
10 seconds).
ECONO.
TIMER
Check the check code in the indication part
of the remote controller.
ON
OFF
RSV
CNL
• 2-digits alphanumeric characters are displayed in the
indication part of the remote controller.
• All the lamps of the air conditioner flash
(5 times for 1 second).
Alphanumeric characters are
used for the check codes.
START/STOP
To release the self-diagnosis function, push
button.
• Display returns to one before check.
is 5.
is A.
is C.
is 6.
is B.
is D.
3
Fig. 10-4-1
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 or HEAT
mode for 30 minutes. (Cooling function operates under condition of room temperature by 24°C or more while
heating function by 23°C or less, respectively.)
– 43 –
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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
Operation of diagnosis function
Air
Judgment and action
Check
Block
code
Check
code
Cause of operation
conditioner
status
Remarks
Indoor P.C.
board etc.
Short-circuit or
disconnection of the room continues.
temperature sensor
Operation
Displayed when
error is detected.
1. Check the room temp. sensor.
2. When the room temp. sensor is
normal, check P.C. board.
(TA sensor).
Being out of place,
disconnection, short-
circuit, or migration of
heat exchanger sensor
(TC sensor)
Operation
continues.
Displayed when
error is detected.
1. Check heat exchanger sensor.
2. When heat exchanger sensor is
normal, check P.C. board.
Lock of indoor fan or
trouble on the indoor fan
circuit
All off
Displayed when
error is detected.
1. Check P.C. board.
2. When P.C. board is normal, check
the motor.
Not
displayed
Trouble on other indoor
P.C. boards
Operation
continues.
Displayed when
error is detected.
Replace P.C. board.
Connecting
cable and
serial signal
Return serial signal is not Operation
Flashes when
1. When the outdoor unit never
operate:
sent to indoor side from
operation started.
continues.
trouble is detected
on Return serial
signal, and normal
status when signal
is reset.
(1) Check connecting cable, and
correct if defective wiring.
(1) Defective wiring of
connecting cable
(2) Check 25A fuse of inverter P.C.
board.
(2) Operation of
compressor thermo.
Gas shortage
Gas leak
(3) Check 3,15A of inverter 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.
Operation command
signal is not sent to
outdoor side.
Operation
continues
Flashes when
If Return serial signal does not stop
trouble is detected between indoor terminal board 2 and 3,
on Operation replace inverter P.C. board.
command signal, If signal stops between indoor terminal
and normal status board 2 and 3, replace indoor P.C.
when signal is
reset.
board.
– 44 –
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Block distinction
Operation of diagnosis function
Air
Judgment and action
Check
Block
code
Check
code
Cause of operation
conditioner
status
Remarks
Outdoor
P.C. board
Inverter over-current
protective circuit
operates. (Short time)
All off
All off
Displayed when
error is detected. operations stop immediately. : Replace
P.C. board.
Even if trying operation again, all
Position-detect circuit
error or short-circuit
between windings of
compressor
Displayed when
error is detected.
1. Even if connecting lead wire of
compressor is removed, position-
detect circuit error occurred. :
Replace P.C. board.
2. Measure resistance between wires
of compressor, and perform short-
circuit. : Replace compressor.
Current-detect circuit
error
All off
All off
Displayed when
error is detected. operations stop immediately. :
Replace P.C. board.
Even if trying operation again, all
Being out of place,
disconnection or short-
circuit of outdoor temp.
sensor
Displayed when
error is detected.
1. Check outdoor temp. sensors
(TE, TS).
2. Check P.C. board.
Disconnection or short-
circuit of discharge temp.
sensor
All off
Displayed when
error is detected.
1. Check discharge temp. sensor (TD).
2. Check P.C. board
Outdoor fan drive system All off
error
Displayed when
error is detected. protective operation of outdoor fan
drive system, fan lock, etc. :
Position-detect error, over-current
Replace P.C. board or fan motor.
Not
displayed
Outdoor heat exchanger Operation
1. Check outdoor heat exchanger temp.
sensor (TE).
temp. sensor error
continues
——
2. Check P.C. board.
Outdoor
P.C. board
Compressor drive output All off
error, Compressor error
(lock, missing, etc.),
Break down
Displayed when
error is detected. up, position-detect circuit error
occurred. : Replace compressor.
When 20 seconds passed after start-
Others
(including
compressor)
Return serial signal has Operation
Flashes when
1. Repeat Start and Stop with interval
of approx. 10 to 40 minutes. (Code is
not displayed during operation.)
been sent when
continues
trouble is detected
on Return serial
signal, and normal
status when signal
is reset.
operation started, but it
is not sent from halfway.
(1) Compressor thermo.
operation
Gas shortage
Gas leak
(2) Instantaneous power
failure
Supply gas. (Check also gas leak).
2. Unit operates normally during check.
If Return serial signal does not stop
between indoor terminal block 2 and
3, replace inverter P.C. board.
If signal stops between indoor
terminal block 2 and 3, replace
indoor P.C. board.
Compressor does not
rotate.
(Current protective
circuit does not operate
when a specified time
passed after compressor
had been activated.)
All off
Displayed when
error is detected.
1. Trouble on compressor
2. Trouble on wiring of compressor
(Missed phase)
Discharge temp.
exceeded 117°C
All off
All off
Displayed when
error is detected.
1. Check dischage temp. sensor (TD).
2. Degassing
3. Trouble on P.M.V.
Break down of
compressor
Displayed when
error is detected.
1. Check power voltage.
(220–30–40 V+10%)
2. Overload operation of refrigeration
cycle
Check installation condition
(Short-circuit of outdoor diffuser).
Four-way valve inverse
error
(TC sensor value
lowered during heating
operation.)
Operation
continues
1. Check four-valve operation.
——
– 45 –
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10-5. Judgment ofTrouble by Every Symptom
10-5-1. Indoor Unit (Including Remote Controller)
(1) Power is not turned on (Does not operate entirely)
Operation
Check Item
Turn off the power supply
once, and turn on it again
after 5 seconds passed.
Considerable main cause
Measures
NO
Does the operation
lamp flash?
Item by symptom
YES
Is the power supply
turned on by pressing
[START/STOP] button
on remote controller?
Does send display
of remote controller flash
normally, and is the signal
sent securely?
NO
NO
Remote controller
error
YES
YES
(No trouble)
Refer to the item of
Remote controller
check. (p.49)
Parts (R21, R109, SG01,
C15, C01, DB01, C02,
IC01, T01) are defective.
YES
YES
Is fuse of indoor control
board blown? (F01)
NO
Replace temp.
fuse set.
Check connecting
wire.
Connection of connecting
wire is defective.
Is temp. fuse blown?
NO
Is voltage indicated
on rear of indoor control
board (DC12V or 5V)
normal?
YES
NO
Microcomputer
is defective.
Replace main
board.
Is DC310 to 340V
applied to primary
side of SW trans.
(T01) applied?
NO
NO
To item of Pre-check or
trouble before power board
Is DC35V,
DC12V, DC7V
applied to secondary
side of SW trans.
(T01) applied?
Is DC35V,
Turn “OFF” breaker
once, and “ON”
again after removing
motor.
SW trans.,
IC (IC01) for
power supply, ]
or fan motor
DC12V, DC7V
applied to secondary
side of SW trans.
(T01) applied?
YES
YES
Motor is defective.
• 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.
(2) Power is not turned on though Indoor P.C. board is replaced
<Confirmation procedure>
Turn on power supply.
NO
NO
Is wired correctly to white and black
lead wires of terminal block?
Does operation lamp flash?
YES
Correct wiring.
YES
To item of “Power supply
is not turned on”.
– 46 –
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(3) Only the indoor fan does not operate
Operation
Check Item
Turn off the
power supply.
Considerable main cause
Measures
Turn on the
power supply.
Item by symptom
Does the fan
NO
Replace the board.
stop in no operating
status?
Control board is defective.
YES
Start the operation
with low fan setting
in cool operation.
Is the DC 35V
measured between
(red lead wire) and
(black lead wire)
of the motor connector
(CN10) ?
Turn off the power supply,
and turn it on after
removing the motor from
the board.
NO
NO
1
Does the fan rotate?
YES
2
YES
Turn off the power supply.
Change the setting of
cooling to high fan.
Repair the
bearing of the
cross flow fan.
Does the cross
flow fan rotate
normally?
NO
YES
Turn on the power supply.
Is the voltage of
DC35V measured
between 1 and 2 GND of
the motor connector
(CN10) ?
NO
NO
Replace
the board.
Operation
stops
Does the fan speed
become higher?
YES
YES
Is the rotation signal
(DC+5V 0V) output between
4 (blue lead wire) and (black
lead wire) of the motor connector
(CN10) when rotating the cross
flow fan by hand in no operating
status ? (2 pulses/one turn)
2
NO
YES
Replace the
control board.
Replace the
fan motor.
Normal
– 47 –
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(4) Indoor fan motor starts rotating by turning on power supply alone
(Operation may be normally performed (selected) by operation on the remote controller.)
<Cause>
IC is built in the indoor fan motor, therefore P.C. board is also mounted to inside of the motor.
If soldering of P.C. board in the motor is defective or IC is defective, the fan motor may rotate by only inputting
the power (turning on power supply).
<Confirmation procedure>
(1) Remove the front panel.(Remove 2 screws and clicks.)
(2) Remove cover of the fan motor lead wire. (1 click)
(3) Check the voltage (DC) using CN10 connector while the fan rotates.
NOTE :
• Do not disconnect the connector while the fan rotates.
• Use a thin tester rod.
Indoor fan starts rotating when power supply breaker is turned "ON".
P.C. board
CN10
(Check output voltage (DC) of the fan motor on P.C. board.)
5
4 Blue
Yellow
Black
3 Yellow
2 Black
1 Red
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.
Above DC 0.4V
Below DC 0.4V
DC
P.C. board is defective.
Motor is defective.
– 48 –
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(5) How to examine whether remote controller is good or bad
Operation
Check Items
There is no beep from
the indoor unit.
The operation lamp of
the air conditioner main
unit does not light.
Push the START/STOP button.
Considerable main cause
Measures
NO
Does the transmission
indicator of remote
controller light?
Item by symptom
YES
Is there direct
Take out the batteries and
insert them again.
(rear side of remote controller)
NO
sunlight on the
receptor of the
air conditioner?
YES
Is operation
possible when the
transmitter is moved
nearer to the infrared
signal receiver of the
air conditioner?
Is there any
thyristor
fluorescent light
near by?
NO
NO
YES
YES
Battery life
Is Temporary Cool
Push the START/
STOP button
operation possible when
keeping the temporary
switch of the air conditioner
main unit pressed for
NO
NO
Does the transmission
indicator light?
10 seconds or more?
YES
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?
NO
YES
Keep the air
conditioner away
from thyristor
Remote
controller
is failure.
Replace
P.C. board.
Avoid direct
sunlight.
Replace the
battery.
Normal
fluorescent light.
– 49 –
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10-5-2. 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?
‚
ƒ
Confirm that transmission from indoor to outdoor is correctly performed based upon the following dia-
gram.
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
3
2
1
S5277G or equivalent (G or J type)
(Diode with rated voltage of 400V
or more is acceptable.)
S5277G
White
Tester
Terminal block
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.
Gas shortage
Gas leak
Pipe clogging
Thermo. operation of compressor
(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 Sensor temp. error check code 02, 1C)
Gas leak
P.M.V. is defective.
Refer to the chart in 10-6.
Miswiring of connecting wires of indoor/outdoor units
Clogging of pipe and coming-off of TC sensor
– 50 –
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10-6. Check Code 1C (Miswiring in indoor/outdoor units) and 1E
<Check procedure>
1C
1E
Operation
Check Item
Gas leakage,
Discharge temp. error,
gas leakage
(Check code 03, 1E)
disconnection of TS/TC
sensors (Check code 02, 1C)
Considerable main cause
Measures
Item by symptom
Valve drive check
NO
NO
Is coil of the pulse modulation valve
(P.M.V.) correctly set?
Set it correctly.
Set it correctly.
YES
Is connector of coil connected to inverter?
YES
Is positioning sound of valve (sound hitting to stopper) heard from valve
when the air conditioner starts the operation after turning off power of the
air conditioner once?
NOTE :
After all the operations stopped by the remote controller, the power keeps
being supplied to outdoor unit for approx. 3 minutes. If operating the air
conditioner by remote controller again just after all the operations stopped by the
remote controller, positioning of the valve is not performed when outdoor unit
is activated because supplying power to the outdoor unit is not interrupted.
After positioning of the valve, activate the compressor and the outdoor fan.
It takes approx. 7 seconds for positioning of the valve, and sound ticktack
(hitting sound to stopper) is heard for approx. 0.5 seconds at least of that
period. As the sound is low, check sound by using screwdriver, etc.
NO
Replace coil valve.
YES
Are temp. sensors of indoor/outdoor units correctly set to the holder?
NOTE :
The temperature sensors which are used to control electronic control valve
include indoor heat exchanger sensor (TC), outdoor heat exchanger temp.
sensor (TE), and outdoor suction temp. sensor (TS).
NO
Set it correctly.
YES
Gas amount check and valve clogging check
Remove TC sensor connector from the P.C. board in indoor unit.(Remove connector from the P.C. board.)
Operate the air conditioner in COOL mode by TEMP button (“Pi” sound is heard if keeping pushed for 10 seconds.).
The operation enters temporary operation mode which fixes opening degree of P.M.V. and No. of revolution of
compressor. Check condensation at outlet of P.M.V., and then check operating pressure from the service port.
Existence of condensation at outlet of P.M.V.
YES
Replace valve.
Add gas.
If there is condensation at outlet (1/4 inch=Ø6,35mm valve side),
the valve is clogged.
Check the operating pressure from service port, and add gas if pressure is low.
– 51 –
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10-7. How to DiagnoseTrouble in Outdoor Unit
10-7-1. Summarized Inner Diagnosis of Inverter Assembly
Diagnosis/Process flowchart
Item
Contents
Summary
Preparation Turn “OFF” the power breaker,
and remove 3P connector
which connects inverter and
compressor.
Remove
connector of
compressor.
If fuse was blown, be sure to
Check
• Check whether 25A fuse on check the electrolytic
the control board assembly capacitor and diode block.
NG
Check 25A fuse
(Part No.F01).
is blown or not. (F01)
(DB01)
OK
Replace fuse.
• Connect discharge
resistance (approx.
100Ω40W) or soldering
iron (plug) between +, –
terminals of the electro-
lytic capacitor (500µF) of
C14 (with printed CAU-
TION HIGH VOLTAGE) on
P.C. board.
Check
electrolytic
capacitor, diode
block (DB01),
etc.
Check
Check whether 15A fuse on
the control board assembly
is blown or not. (F03)
• 15A fuse (F03) on the
control board is provided for
power factor improvement
control circuit. The operation
continues even if fuse is
blown.
Check
15A fuse
NG
NG
Plug of
Discharging position
soldering
(Part No.F03).
(Discharging period
iron
10 seconds or more)
OK
Replace control
board assembly.
Check
terminal voltage
of electrolytic
capacitor.
OK
Check
electrolytic
capacitor, diode
(DB01),
If 15A fuse is blown,
discharge both edges of
the electrolytic capacitor
with soldering iron.
etc.
Operation
Turn on power breaker, and
operate the air conditioner in
COOL mode by short-circuit of OK if 500µF →
NO
Does outdoor
fan rotate?
the timer.
DC280 to 320V
Measurement Measure terminal voltage of
the electrolytic capacity.
YES
YES
Remove CN300 while
Does LED on control
board flash or go on?
500µF:400WV x 3
pushing the part indicated
by an arrow because CN01
is a connector with lock.
NO
After operation, turn off the
Remove connector
CN300 of outdoor fan
motor, and using a
tester, check resistance
value between every
phases at motor side.
Check
Stop
power breaker after 2 minutes
20 seconds passed, and
discharge the electrolytic
capacity by soldering iron.
Check voltage between motor
phases.
NG
OK
Check
Measurement • Is not winding between
-
Replace
outdoor
fan motor.
,
-
, or
-
opened
→ Resistance between
phases should be approx. 55
to 77Ω
‚ ‚ ƒ ƒ
or short-circuited?
• Is not frame grounded with
, or
,
‚
?
ƒ
A
B
C
→ Should be 10MΩ or more.
– 52 –
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Diagnosis/Process flowchart
Item
Contents
Summary
Check
Check winding resistance
between phases of compres-
sor, and resistance between
outdoor frames by using a
tester.
A
B
C
• Is not grounded.
• Is not short-circuited
between windings.
→ OK if 10MΩ or more
Check
NG
winding of
compressor.
→ OK if 0,51Ω → 0,57Ω
(Check by a digital tester.)
OK
• Winding is not opened.
Check
fan motor
position
detect
Replace
com-
Operation
Remove connector CN300 of
the outdoor fan motor, turn
on the power breaker, and
perform the operation.
(Stops though activation is
prompted.)
NG
pressor.
signal.
OK
Replace
outdoor
fan
Check operation within 2
minutes 20 seconds after
activation stopped.
motor.
Check
<Output check of fan motor a) One or two of three
position detect signal>
While connecting connector
5P (CN301) for position
detection, using a tester,
voltages should be 5V,
and others should be 0V.
(When all are 0V or 5V, it
is not accepted.)
Replace control
board assembly.
measure voltage between
b) When rotating the fan
slowly with hands, the
voltage between pins
should move from 0V to
5V.
Check
NG
-
. Between
-
ꢀ „
: 5V
ꢀ
compressor
winding
resistance.
OK
(Check it with an analog
tester.)
Replace
Replace
compressor.
control board.
(2) Inspection procedures
10-8. How to Check Simply the Main
Parts
1) When a P.C. board is judged to be defective,
check for disconnection, burning, or discol-
oration of the copper foil pattern or this P.C.
board.
10-8-1. How to Check the P.C. Board
(Indoor Unit)
2) The P.C. board consists of the following 2
parts
(1) Operating precautions
1) When removing the front panel or the P.C.
board, be sure to shut off the power supply
breaker.
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
2) When removing the P.C. board, hold the edge
of the P.C. board and do not apply force to the
parts.
b. Indication unit of infrared ray receiving
Infrared ray receiving circuit, LED:
3) When connecting or disconnecting the
connectors on the P.C. board, hold the whole
housing. Do not pull at the lead wire.
To check defect of the P.C. board, follow
the procedure described below.
– 53 –
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(3) Check procedures
Table 10-8-1
No.
Procedure
Check point (Symptom)
Causes
1
Shut off the power supply and
remove the P.C. board assembly
from the electronic parts base.
1. Is the fuse blown?
1. * Application of shock voltage.
* Overload by short-circuit of the
parts.
Remove the connecting cable from
the terminal block.
2
Remove the connector for the
motor, and turn the power on.
Voltage check
1. * AC power cord is defective.
* Poor contact of the terminal plate.
* Miss wiring of the power relay.
2. Fuse is defective.
1. Between TP1 and TP2
(220–230–240V AC)
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.
2. Between TP2 and pin 1 of CN04
(220–230–240V AC)
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.
3. Between TP2 and pin 3 of CN04
(220–230–240V 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
5. IC01, IC02, T01 are defective.
6. IC01, IC02, T01, F03 are defective.
7. IC01, IC02, T01, F02, Q29, IC03
are defective.
3
Make the operation status by
pushing once the START/STOP
button, except the status of [ON
TIMER].
Voltage check
1. Breaking wire of the relay coil,
defective relay driver. (IC31)
1. Voltage of relay coil. (DC 12V)
Between pin 10 of IC31 and GND
Between pin 11 of IC31 and GND
2. Poor contact of relay.
2. Between No. 1 and 2 of connecting
cable terminal block.
(220–230–240V AC)
4
5
Start the operation with the system
which the time of the restart delay
timer is shortened.
1. All indicators light for 3 sec.
Defective indicator, or poor
housing assembly. (CN13)
2. Indicators do not indicate normally
after approximate 3 sec.
Make the operation status by pressing
once the START/STOP button.
1. Compressor does not operate.
2. OPERATION lamp flashes.
1. The temperature of the indoor heat
exchanger is abnormally low.
1. The time of the restart delay timer
is shortened.
2. Poor contact of the heat exchanger
sensor. (The connector is
disconnected.) (CN01)
2. Cool operation
3. Heat exchanger sensor, main P.C.
board are defective.
3. Air volume [AUTO]
4. Make the setting temperature lower
enough than room temperature.
4. Main P.C. board is defective.
5. Continuous operation.
Turn the power on after connecting
the motor connector.
6
1. The voltage of DC 35V is not
measured between the red and
black of the motor terminals.
1. Indoor fan motor is defective.
(Protecting operation on the P.C.
board.)
Start the operation with the following
condition.
2. Motor does not rotate.
(The key operation is accepted.)
2. Poor contact of the motor
connector.
1. Operation [Cooling]
2. Airflow [High fan]
3. The motor rotates, but it vibrates too 3. P.C. board is defective.
much.
3. Continuous operation
– 54 –
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10-8-2. P.C. Board Layout
GND
5V
35V
12V
TP1
TP2
BottomView
(For the Top View, refer to page 61.)
[1] Sensor characteristic table
100
90
80
70
60
50
40
30
20
TD
TD : Discharge temp. sensor
TA : Room temp. sensor
TC : Heat exchanger temp. sensor
TO : Outdoor temp. sensor
TE : Outdoor heat exchanger temp. sensor
TS : Suction temp. sensor
TA, TC, TO, TE, TS
40 50
10
0
0
10
20
30
Temperature (˚C)
– 55 –
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10-8-3. Indoor Unit (Other Parts)
No.
Part name
Checking procedure
1
Room temp. (TA) sensor
Heat exchanger (TC) sensor
Disconnect the connector and measure the resistance value with tester.
(Normal temp.)
Temperature
10°C
20°C
25°C
30°C
40°C
Sensor
TA, TC (kΩ)
20,7
12,6
10,0
7,9
4,5
2
3
Remote controller
To item of How to judge whether remote controller is good or bad of the
Judgment of trouble by symptom.
Louver motor
MP35EA7
Measure the resistance value of each winding coil by using the tester.
(Under normal temp. 25°C)
Position Resistance value
1
2
3
4
5
6
Brown
Red
Orange
Yellow
Pink
1 to 4
1 to 6
2 to 3
2 to 5
130 10 Ω
Blue
4
Indoor fan motor
Since judgment of DC motor is difficult on the single motor, refer to 10-
5-1. (3).
10-8-4. Outdoor Unit
No.
Part name
Checking procedure
1
Compressor
(Model : DA91A1F-44F)
Measure the resistance value of each winding by using the tester.
Red
Position
Resistance value
0,51 to 0,57 Ω
0,51 to 0,57 Ω
0,51 to 0,57 Ω
Under 20°C
Red - White
White - Black
Black - Red
White
Black
2
Outdoor fan motor
(Model : ICF-140-40-7)
Measure the resistance value of winding by using the tester.
Red
Position
Resistance value
5 to 20 k Ω
1 Yellow
Yellow- Pink
4 Pink
5 Gray
White
Black
For details, refer to Section 10-9.
3
4
Compressor thermo. Bimetal Check conduction by using the tester.
type (Model : PW - 2AL)
Outdoor temperature sensor
(TO), discharge temperature
sensor (TD), suction
temperature sensor (TS),
outdoor heat exchanger
temperature sensor (TE)
Disconnect the connector, and measure resistance value with the tester.
(Normal temperature)
Temperature
Sensor
10°C
20°C
30°C
40°C
50°C
TD (kΩ)
105
64
41
27
18
TGa : Heat pump model only.
TO, TS, TE : Refer to the TA, TC characteristic table in Indoor (Refer to
Table 10-8-3, No. 1).
– 56 –
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10-8-5. Checking Method for Each Part
No.
Part name
Checking procedure
1. Turn OFF the power supply breaker.
1
Electrolytic capacitor
(For raising pressure,
smoothing)
2. Discharge all four capacitors completely.
3. Check that safety valve at the bottom of capacitor is not broken.
4. Check that vessel is not swollen or exploded.
5. Check that electrolytic liquid does not blow off.
6. Check that the normal charging characteristics are shown in
continuity test by the tester.
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-808
Soldered
surface
C12, C13, C14 → 500µF/400V
1. Turn OFF the power supply breaker.
2
Converter module
2. Discharge all four capacitors completely.
3. Check that the normal rectification characteristics are shown in
continuity test by the tester.
Mark
+ ~ – ~
A
E
G
1
2
+ ~ – ~
A
E
G
1
2
Diode check
IGBT check
Tester rod
Tester rod
Resistance value
in good product
Resistance value
in good product
+
~
~
–
–
+
~
G
~
~
–
1
2
2
E
50k or more
(0 in trouble)
50k or more
(0 in trouble)
~
~
~
~
1
2
1
2
1
2
+
A
E
– 57 –
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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 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.
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.
NO
Does the fan rotate without trouble
when rotating it with hands?
YES
If the resistance value between
1 (Red lead)
2 (White lead)
3 (Black lead)
– 2 (White lead)
– 3 (Black lead)
– 1 (Red lead)
CN300
NO
NO
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.
Fan motor error
(Outdoor P.C. board 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.
– 58 –
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11. HOWTO REPLACETHE MAIN PARTS
11-1. Indoor Unit
No.
Part name
Procedure
Remarks
Front panel
1) After stopping the operation of the air conditioner,
be sure to turn off the circuit breaker or disconnect
the power plug from the AC wall socket.
2) Open the screw caps and remove the two screws
fixing the front panel.
5
5
3) Close the screw caps as they were.
4) Open the horizontal louver right below by your
finger.
3 2
4
2 3
5) Open the lower side of front panel until it touches
the horizontal louver, and remove it from the indoor
unit by turning it.
<To assemble the front panel>
1) Fix the two screws to secure the front panel.
2) Close the screw caps as they were.
3
3
3
3
3) Press four places where are the center, right end,
left end and lower portions of the air outlet.
4) Check the gap between the front panel and the
main unit.
If cooling or drying operation is performed without
pressing the center of the air outlet, the surface of
the front panel may be covered with frost and have
a waterdrop.
‚
Electrical part
assembly
1) Perform the process
above.
Upper nail
Screw
2) Remove the screw securing the shield metal plate.
Drain
guide
3) Remove the electrical part cover by pressing the
nail located on upper portion of the electrical part
cover.
Screw
4) Remove the drain guide.
Electrical
part cover
5) Remove the screw securing to the end plate of the
heat exchanger.
6) Remove the connector (5p) for the fan motor and
the connector (6p) for the louver motor from the
microcomputer assembly.
Lower fixing nail
Screw
7) After unhooking the electrical part base by press-
ing the fixing nail located on its lower portion, draw
the electrical part base out toward you to remove it
from the main unit.
8) Pull the TC sensor out from the holder of the heat
exchanger.
TC
9) Dress the connecting cable securely as shown in
the right illustration.
sensor
When assembling dress the connecting
cable in loop and put it into the drain-pan.
(Improper dressing will cause water leakage.)
ƒ
Drain-pan
assembly
1) Perform the process
above.
‚
2) Remove the drain-pan by pressing the four hooks
downwards. (Keep it with the drain hose.)
Hooks
– 59 –
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No.
Part name
Horizontal grille
Note:
Procedure
1) Perform the process
Remarks
„
.
‚
2) Remove the screw fixing the louver motor, and
remove the louver motor.
The horizontal
grille can not be
removed without
removing the
3) Remove the shaft of the horizontal grille from the
drain-pan.
Louver
motor
louver motor.
Horizontal grille
Screw
Hooks
ꢀ
Heat exchanger
1) Perform the process
.
ƒ
2) Remove the pipe holder from the rear side of main
unit by removing the screw.
Pipe
holder
3) Unhook the hooks fixing the left side of the heat
exchanger and remove the screw fixing it, then
remove the right side of the end plate from the rib
fixing the main unit by sliding the heat exchanger
slightly to the right side.
Hooks fixing the
heat exchanger
Shaft bearing
base
Screw fixing the
heat exchanger
†
Cross flow fan
1) Perform the process
.
ƒ
2) Loosen the set screw of the cross flow fan.
Hook
3) Remove the screw fixing the shaft bearing base.
Screw
4) Lift slightly up the left side of the heat exchanger,
and pull the shaft bearing base out left downwards.
When assembling it, fix it with the set screw on the
position where the gap between the rear plate surface
and the left end surface of the cross flow fan is 6 to 7
Shaft
bearing
base
mm.
Cross
flow fan
6 to 7mm
Rear plate
‡
Shaft bearing
1) Perform the process
above.
†
2) Remove the shaft bearing from the shaft bearing
base.
<Caution for assembling>
• If a part of the shaft bearing is protruded from the
housing, assemble it after pushing its portion into
the correct position in the housing.
ˆ
Fan motor
1) Perform the process
above.
Mount the fan motor
asshown in figure
belowwhen
ꢀ
Ribs
2) Perform the process -2) above.
†
assembling.
3) Remove the left and right motor bands.
Put the end of lead
wire at the portion
between two ribs.
4) Remove the fan motor after pulling the cross flow
fan out sliding it left and right.
– 60 –
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11-2. Microcomputer
No.
Part name
Procedure
Remarks
Common
procedure
1) Turn the power supply off to stop the operation of
air-conditioner.
Replace the thermal fuse, terminal
block, microcomputer ass’y and the
P.C. board ass’y.
2) Remove the front panel.
• Remove the two fixing screws. (Ø4 x 14l)
3) Remove the electrical part base.
<P.C. board layout>
– 61 –
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11-3. Outdoor Unit
No.
Part name
Procedure
Remarks
Common
procedure
1. Detachment
Upper cabinet
1) Stop operation of the air conditioner, and remove
the power plug of the indoor unit from plug
socket.
Wiring
cover
2) Remove the valve cover. (ST1TØ4 x 10l 1 pc.)
• After removing screw, remove the valve cover
pulling it downward.
Valve
cover
3) Remove wiring cover (ST1TØ4 x 10l 2 pcs.),
and then remove connecting cable.
4) Remove the upper cabinet.
(ST1TØ4 x 10l 2 pcs.)
• After removing screws, remove the upper
cabinet pulling it upward.
2. Attachment
1) Attach the upper cabinet.
(ST1TØ4 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.
• Insert the upper part into the upper cabinet,
insert claw which has been hooked to the
lower part into the square hole, and then fix it
with screw. (ST1TØ4 x 10l 1 pc.)
3) Attach the valve cover. (ST1TØ4 x 10l 1 pc.)
• Insert the upper part to the upper cabinet, set
hook claw of the valve cover to square holes
(at three positions) of the main unit, and attach
it pushing upward.
Front cabinet
1. Detachment
‚
1) Perform work of item 1 of
.
2) Remove screws (ST1TØ4 x 10l 1 pc.) of the
front cabinet and inverter cover and screws
(ST1TØ4 x 10l 3 pcs.) of the front cabinet and
lower part.
• 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
Claw
Square hole
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.
Concave section
– 62 –
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No.
Part name
Procedure
Remarks
Inverter
assembly
1. Detachment
1) Perform work of item 1 of
Inverter cover
ƒ
P. C. board
(Soldered surface)
.
2) Remove screw (ST1TØ4 x 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
.
‚
Plug of
soldering
iron
Be careful to check the inverter because
high-voltage circuit is incorporated in it.
Discharging position
(Discharging period
10 seconds or more)
3) Perform discharging by connecting + , – polarity
by discharging resistance (approx. 100Ω40W) or
plug of soldering iron to + , – terminals of the
C14 (printed “CAUTION HIGH VOLTAGE” is
attached.) electrolytic capacitor (500µF) on P.C.
board.
Be careful to discharge the capacitor
because the electrolytic capacitor cannot
naturally discharge and voltage remains
according to trouble type in some cases.
Bundled
part
NOTE :
Holder
This capacitor is one with mass capacity.
Therefore, it is dangerous that a large
spark generates if short-circuiting be-
tween + , – polarity with screwdriver, etc.
for discharging.
Terminal block
The connector is one with lock,
so remove it while pushing the
part indicated by an arrow.
4) Remove screw (ST1TØ4 x 10l 1 pc.) fixing the
main body and the inverter box.
5) Remove various lead wires from the holder at
upper part of the inverter box and wiring holder
at right side of 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.
Requirement :
As each connector has a lock mecha-
nism, avoid to remove the connector by
holding the lead wire, but by holding the
connector.
Be sure to remove the connector
by holding the connector, not by
pulling the lead wire.
– 63 –
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No.
Part name
Procedure
Remarks
Control board 1) Disconnect lead wires and connectors connected
„
assembly
from the control board assembly to other parts.
1. Lead wires
CN301
CN300
CN703
CN500
CN701
• Connection with terminal block :
3 wires (Black, White, Orange)
• Connection with compressor :
Remove the connector (3P).
CN602 CN601
CN600 CN603
• Connection with reactor :
Remove the relay connectors from P07, 08
(2P, White) and P12, 13 (2P, Yellow).
2. Connectors
CN300, CN301 and CN701, etc.
at the control board assembly
side are connectors with locks.
Therefore, remove the connector
while pushing the part indicated
by an arrow.
CN300 : Outdoor fan (3P, White)
CN301 : Outdoor fan position detection
(5P, White)
CN701 : 4 valve (3P,Yellow)
CN600 : TE sensor (2P, White)
CN601 : TD sensor (3P, White)
CN603 : TS sensor (3P, White)
CN602 : TO sensor (2P, White)
CN500 : Case thermo. (2P, White)
CN703 : Pulse modulating valve (6P, White)
2) 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.
P.C. board base
P.C. board
When mounting a new board,
check that the board is correctly
set in the groove of base holder
of P.C. board base.
Rear cabinet
1) Perform work of item 1 of , and
.
‚ ƒ
ꢀ
Reactor
2) Remove fixed screws fixing to the bottom plate.
(ST1TØ4 x 10l 3 pcs.)
3) Remove fixed screws fixing to the heat
exchanger. (ST1TØ4 x 10l 2 pcs.)
4) Remove fixed screw fixing to the valve mounting
plate. (ST1TØ4 x 10l 1 pc.)
– 64 –
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No.
Part name
Procedure
1) Perform work of item 1 of
Remarks
Fan motor
and
.
‚
†
2) Remove the flange nut fixing the fan motor and
the propeller.
Fan motor
• Flange nut is loosened by turning clockwise.
(To tighten the flange nut, turn counterclock-
wise.)
Propeller fan
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.
Flange nut
Compressor
1) Perform work of item 1 of
2) Extract refrigerant gas.
and
,
,
,
‚ ƒ „ ꢀ
.
‡
3) Remove the partition board.
(ST1TØ4 x 10l 2 pcs.)
4) Remove the sound-insulation material.
5) Remove terminal cover of the compressor, and
disconnect lead wire of the compressor thermo.
and the compressor from the terminal.
6) Remove pipe connected to the compressor with
a burner.
7) Remove the fixing screw of the bottom plate and
heat exchanger. (ST1TØ4 x 10l 1 pc.)
8) Remove the fixing screw of the bottom plate and
valve clamping plate. (ST1TØ4 x 10l 2 pcs.)
9) Pull upward the refrigeration cycle.
10) Remove nut fixing the compressor to the
bottom plate.
Partition
board
Valve
clamping
plate
Compressor
thermo.
Compressor
Reactor
1) Perform work of item 1 of , and
2) Remove lead wires clung in holder on the
partition board.
.
ƒ
ˆ
Reactor
3) Remove screws fixing the reactor.
(ST1TØ4 x 10l 2 pcs.)
– 65 –
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No.
Part name
Pulse
modulating
valve coil
Procedure
Remarks
1. Detachment
1) Perform work of item 1 of , and
‰
,
,
.
‚ ƒ ꢀ
2) Turn the coil clockwise (counterclockwise) by 90
degrees, and remove coil from the pulse modu-
lating valve.
2. Attachment
Take-out part
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 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.
of lead wire
Notch
Coil inserting
position
Coil fix
position
The pulse modulating valve has A room
side and B room side. After mounting it,
check that coil at B room side (Red
marking is marked on the pulse modulat-
ing valve.) is connected to CN13 of the
control board assembly.
Coil inserting
position
Positioning
hole
Fan guard
1. Detachment
Š
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
Hooking claw
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.
– 66 –
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No.
Part name
Procedure
Remarks
11
Replacement
of temperature
sensor for
1) Cut the sensor 100 mm longer than old one.
2) Cut the protective tube after pulling out it
(200 mm).
Cutting here
100
Thermal
servicing only
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.
Connector
sensor part
Common service
parts of sensor
TO, TS, TE, TD
Cutting here
200
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.
Thermal
constringent tube
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.
Cutting here
100
9) Wind the attached color tape round the both
terminals of the protective tube when colored
protective tube is used.
Soldered part
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.
Dryer
Winding the color tape
These are parts
for servicing
sensors.
Parts name
Q'ty
Remarks
Length : 3m
For spare
1
2
3
4
5
6
Sensor
1
1
1
3
1
3
Sensor Spring (A)
Sensor Spring (B)
Thermal constringent tube
Color tape
Please check
that the accesso-
ries shown in the
right table are
packed.
For spare
Including one spare
9 colors
Terminal
– 67 –
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MCC-808
– 68 –
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12. EXPLODED VIEWS AND PARTS LIST
12-1. Indoor Unit (1)
RAS-10YKV-E, RAS-13YKV-E
407 : RAS-10YKV-E
408 : RAS-13YKV-E
404
402
412
413
403
405
Location
No.
Part
No.
Location
No.
Part
No.
Description
Description
402
403
404
405
43T60002 Terminal Block, 3P,
AC 300V, 20A
407
408
412
413
43T69062 P.C. Board Assembly,
MCC-772 (10YKV-E)
43T69004 Sensor, Heat Exchanger
10kΩ, 25°C
43T69005 Sensor, Thermostat
10kΩ, 25°C
43T69031 P.C. Board, Assembly,
WRS-LED, MCC-766
43T69063 P.C. Board Assembly,
MCC-772 (13YKV-E)
43T61001 Base, E-Parts,
ABS, Black UL94-5V
43T62006 Base, Shield
SGCC-Z08-LUB
– 69 –
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Indoor Unit (2)
233
230
231
RAS-10YKV-E, RAS-13YKV-E
228
222
221
215
216
217
229
244
211
214
210
232
201
202
226
227
236
225
220
218
219
243
213
206
224
245
204
207
212
209
241
239
208
246
237
203
242
238
Location
No.
Part
No.
Location
No.
Part
No.
Description
Description
201
202
203
204
206
207
208
208
209
210
43T00043 Front Panel Assembly
43T00044 Grille, Suction
43T80001 Air Filter (L)
43T80002 Air Filter (R)
43T07021 Screw Cap (L)
222
224
225
226
227
228
229
230
231
232
233
236
237
238
239
241
242
243
244
245
246
43T49023 Holder of Plate of EVA-SEAL
43T79002 Drain Guide
43T39002 Motor Band (Left)
43T39001 Motor Band (Right)
43T21010 Fan Motor
43T20007 Fan, Cross Flow
43T22002 Bearing
43T39003 Base, Bearing
43T03001 Rear Plate
43T07020 Screw Cap (R)
43T08106 LED Panel (10YKV-E)
43T08107 LED Panel (13YKV-E)
43T19004 Accepted Signal Filter
43T09035 Horizontal Louver Assembly
for Service
43T09004 Louver Assembly
43T70001 Drain Hose Assembly
43T21003 Motor, Stepping
43T07001 Bushing
43T44024 Refrigerant Cycle Assembly
43T47006 Pipe, Delivery
43T47005 Pipe, Suction
43T49007 Pipe, Shield
43T07002 Pipe Holder
43T82001 Installation Plate
43T69044 Remote Controller
43T63002 Holder, Remote Controller
43T62020 Cover, E-Parts
43T62002 Cover, Up, Terminal
43T62003 Cord Clamp
43T62004 Shield Cover
43T39010 Drain Guide (UP)
43T49024 U Pipe Holder
43T01002 Mark
211
212
213
214
215
216
217
218
219
220
221
43T19003 Holder, Sensor
43T49003 Spring
43T49028 Plate, EVA-SEAL
43T85061 Manual
– 70 –
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12-2. Outdoor Unit
RAS-10YAV-E, RAS-13YAV-E
31
2
32
17, 18
1
8
11, 13
12, 14
19
7
10
28
20
23
21
9
22
24, 25
6
2
5
4
33
1
26, 27, 29
22
23
3
4
5
29
15
Location
No.
Part
No.
Location
No.
Part
No.
Description
Description
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
17
43005368 Cabinet, Back, Assembly
43005369 Cabinet, Upper, Assembly
43005401 Cabinet, Front, Assembly
4301V030 Guard, Fan
18
19
20
21
22
23
24
25
26
27
28
29
31
32
33
43046378 Coil, P.M.V.
43058264 Reactor
43050298 Thermo. Bimetal, CS-7
4302C019 Motor, Fan, DC
43047549 Nut, Flange
43020310 Fan, Propeller
43097204 Nut
43049643 Cushion, Rubber
43063274 Holder, Sensor
43063198 Holder, Sensor
43063195 Holder, Thermo. Bimetal
43019904 Holder, Sensor
43046344 Valve, 4-way
43046348 Solenoid Coil
43032441 Drain Nipple
43042461 Base, Assembly
4301V012 Cover, Valve, Packed
43062230 Cover, Wiring, Assembly
43019903 Hanger
43041607 Compressor
43043644 Condenser, Assembly
43046382 Valve, Packed, 6,35
43046383 Valve, Packed, 9,52
43147196 Bonnet, 1/4 IN
43047401 Bonnet, 3/8 IN
43047491 Tube, Capillary, I.D.1,5
43046351 Valve, Pulse Modulating
– 71 –
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12-3. P.C. Board Layout
RAS-10YAV-E, RAS-13YAV-E
704
708
707
703
701
TO Sensor (Ø6)
TE Sensor (Ø6)
TS Sensor (Ø6)
706
TD Sensor (Ø4)
702
4
4
3
2
1
4
3
2
1
705
Location
No.
Part
No.
Location
No.
Part
No.
Description
Description
701
702
703
704
43050382 Sensor, TC (F6)
43050334 Sensor, TD (F4)
705
706
707
708
4306A044 Terminal block, 9P
43062215 Base, P.C. Board
43063306 Heatsink
43060052 Fuse, 25A, 250V, Lead Type
43060726 Fuse, 15A, 250V, Lead Type
4306S230 P.C. Board Assembly,
MCC-808
– 72 –
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T O S H IB A C A R R IE R C O R P O R A T IO N
3 3 6 T A D E H A R A F U J I-S H I, S H IZ U O K A -K E N , 4 1 6 -8 5 2 1 , J A P A N
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TURN
407 (10YKV-E)
43T69062
404 43T69005
Sensor,Thermostat
10kW, 25°C
P.C. Board Assembly,
M40C7C-(71732YKV-E)
43T69063
P.C. Board Assembly,
MCC-772
402 43T60002
Terminal Block, 3P,
AC 300V, 20A
412 43T61001
Base, E-Parts,
ABS, Black UL94-5V
413 43T61001
Base, E-Parts,
ABS, Black UL94-5V
403 43T69004 Sensor,
Heat Exchanger
10kW, 25°C
405 43T69031
P.C. Board,Assembly,
WRS-LED, MCC-766
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TURN
211 43T09004
Louver Assembly
214 43T07001
Bushing
201 43T00043
210 43T09035
212 43T70001
Front Panel Assembly
Horizontal Louver
Drain Hose Assembly
Assembly for Service
202 43T00044
Grille, Suction
213 43T21003
Motor, Stepping
206 43T07021
Screw Cap (L)
239 43T62002
245
Cover, Up, Terminal
43T01002
Mark
207 43T07020
Screw Cap (R)
209 43T19004
Accepted Signal Filter
208 (10YKV-E)
43T08106
LED Panel
238 43T62020
208 (10YKV-E)
203 43T80001
Cover, E-Parts
43T08106
Air Filter (L)
LED Panel
204 43T80002
Air Filter (R)
242 43T62004
Shield Cover
246 85061
Manual
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TURN
231 43T03001
Rear Plate
233 43T82001
228 43T20007
Installation Plate
Fan, Cross Flow
230 43T39003
Base, Bearing
222
43T49023
Holder of Plate
of EVA-SEAL
221
232 43T07002
229
43T49028
Pipe Holder
43T22002
Bearing
Plate, EVA-SEAL
215
236 43T69044
43T44024
Refrigerant
Cycle Assembly
244 43T49024
Remote Controller
U Pipe Holder
226
43T39001
Motor Band (Right)
220
216
227 43T21010
43T49003
Spring
43T47006
Pipe, Delivery
Fan Motor
225 43T39002
Motor Band (Left)
241 43T62003
243
Cord Clamp
43T39010
237
Drain Guide (UP)
43T63002
Holder, Remote
Controller
224 43T79002
217 43T47005
Drain Guide
218 43T49007
Pipe, Suction
219 43T19003
Pipe, Shield
Holder, Sensor
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TURN
1
43005368
2
43005369
Cabinet, Back, Assembly
Cabinet, Upper,
Assembly
8
43019903
Hanger
7
19
43062230
43058264
Reactor
Cover, Wiring,
Assembly
21 4302C019
Motor, Fan, DC
23 43020310
Fan, Propeller
22 43047549
Nut, Flange
24
43097204
6
4301V012
N25ut
Cover, Valve, Packed
43049643
Cushion, Rubber
5
43042461
Base, Assembly
33 43032441
Drain Nipple
3
43005401
Cabinet, Front, Assembly
4
4301V030
Guard, Fan
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TURN
31 43046344
17 43046351
Valve, 4-way
Valve, Pulse Modulating
18 43046378
32 43046348
Solenoid Coil
Coil, P.M.V.
11 43046382
Valve, Packed, 6,35
13 43147196
Bonnet, 1/4 IN
12 43046383
10
Valve, Packed, 9,52
14 43047401
43043644
Condenser,
Assembly
28 43063195
Holder, Thermo. Bimetal
Bonnet, 3/8 IN
20 43050298
Thermo. Bimetal, CS-7
2
43005369
9
43041607
Cabinet, Upper,
Assembly
Compressor
1
43005368
Cabinet, Back,
Assembly
4
4301V030
Guard, Fan
26 43063274
22 43047549
H27old4e3r0, 6S3e1n9s8or
Nut, Flange
23 43020310
H29old4e3r0, 1S9e9n0s4or
Fan, Propeller
Holder, Sensor
5
43042461
15 43047491
Tube, Capillary, I.D.1,5
29 43019904
Base, Assembly
Holder, Sensor
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TURN
704 43060726
Fuse, 15A, 250V, Lead Type
708 4306S230
P.C. Board Assembly,
MCC-808
707 43063306
703 43060052
Heatsink
Fuse, 25A, 250V, Lead Type
701 43050382
Sensor, TC (F6)
TO Sensor (Ø6)
TE Sensor (Ø6)
706 43062215
TS Sensor (Ø6)
Base, P.C. Board
TD Sensor (Ø4)
702 43050334
Sensor, TD (F4)
4
4
3
2
1
4
3
2
1
705 4306A044
Terminal block, 9P
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