Manual Split Toshiba

SERVICE MANUAL

FILE NO. SVM-03016

AIR-CONDITIONERSPLIT TYPE

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E /RAS-3M23YACV-E

R410A June, 2003

– 2 –

CONTENTS

1. SPECIFICATIONS ........................................................................................................... 3

2. REFRIGERANT R410A................................................................................................... 7

3. CONSTRUCTION VIEWS.............................................................................................. 15

4. WIRING DIAGRAM ....................................................................................................... 17

5. SPECIFICATIONS OF ELECTRICAL PARTS .............................................................. 19

6. REFRIGERANT CYCLE DIAGRAM.............................................................................. 20

7. CONTROL BLOCK DIAGRAM ..................................................................................... 22

8. OPERATION DESCRIPTION ........................................................................................ 24

9. INSTALLATION PROCEDURE ..................................................................................... 36

10. HOW TO DIAGNOSE THE TROUBLE ........................................................................... 50

11. HOW TO REPLACE THE MAIN PARTS ........................................................................ 71

12. EXPLODED VIEWS AND PARTS LIST ........................................................................ 82

– 3 –

1. SPECIFICATIONS

1-1. Specifications

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

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-ERAS-3M23YACV-E

6,72,2~7,0

220–240V–1Ph–50Hz220V 230V 240V

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E0,1530

91 87 83RAS-3M23YACV-E

9,84 9,39 8,982060

9510,29 9,84 9,43

3,12RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E

36 39 4233 35 3928 28 33

RAS-3M23YACV-E4548

RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-E275 275 275790 790 790208 208 208 10 10 1019 19 19

470 520 600RAS-3M23YACV-E

6957802704840

2100Flare connection

RAS-M10UKCV-E RAS-M13UKCV-E RAS-M16UKCV-EØ6,35 Ø6,35 Ø6,35Ø9,52 Ø9,52 Ø12,7

RAS-3M23YACV-EØ6,35 / Ø12,7Ø6,35 / Ø9,52Ø6,35 / Ø9,52

20404010

R410A1,5

3 Wires : includes earth4 Wires : includes earth

21–3210–43

1111

2 (Ø3,1 x 16L)112

6 (Ø4 x 25L)111

Unit model IndoorOutdoor

Cooling capacity (kW)Cooling capacity range (kW)Power supplyElectriccharacteristics Indoor Unit model

Running current (A)Power consumption (W)Power factor (%)

Outdoor Unit modelRunning current (A)Power consumption (W)Power factor (%)

Starting current (A)COPOperating noise Indoor Unit model

High (dB•A)Medium (dB•A)Low (dB•A)

Outdoor Unit model10-1 unit operating (dB•A)

3 units operating (dB•A)Indoor unit Unit model

Dimension Height (mm)Width (mm)Depth (mm)

Net weight (kg)Fan motor output (W)Air flow rate (m³/h)

Outdoor unit Unit modelDimension Height (mm)

Width (mm)Depth (mm)

Net weight (kg)Fan motor output (W)Air flow rate (m³/h)

Piping connection TypeIndoor unit Unit model

Liquid sideGas side

Outdoor unit Unit modelA unitB unitC unit

Maximum length (per unit) (m)Maximum length (total) (m)Maximum chargeless length (m)Maximum height difference (m)

Refrigerant Name of refrigerantWeight (kg)

Wiring connection Power supplyInterconnection

Usable temperature range Indoor (°C)Outdoor (°C)

Accessory Indoor unit Installation plateWireless remote controlLabelRemote control holderPan head wood screwPurifying filterZeodorizing filterBatteriesMounting screwInstallation manual

Outdoor unit Installation manualOwner's manual

– 4 –

• The above specification values are those under the conditions that the indoor DB/WB=27/19°C and theoutdoor DB=35°C.

• Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E

Operating Powerstatus supply

(V)1 unit 220

230

240

220

230

240

220

230

240

2 units 220

230

240

220

230

240

220

230

240

220

230

240

220

230

240

220

230

240

3 units 220

230

240

220

230

240

220

230

240

220

230

240

Indoor unit Unit capacity (kW)

A B C A B C

10 — — 2,7 — —

10 — — 2,7 — —

10 — — 2,7 — —

13 — — 3,7 — —

13 — — 3,7 — —

13 — — 3,7 — —

16 — — 4,5 — —

16 — — 4,5 — —

16 — — 4,5 — —

10 10 — 2,7 2,7 —

10 10 — 2,7 2,7 —

10 10 — 2,7 2,7 —

10 13 — 2,45 3,35 —

10 13 — 2,45 3,35 —

10 13 — 2,45 3,35 —

10 16 — 2,21 3,69 —

10 16 — 2,21 3,69 —

10 16 — 2,21 3,69 —

13 13 — 2,95 2,95 —

13 13 — 2,95 2,95 —

13 13 — 2,95 2,95 —

13 16 — 2,71 3,29 —

13 16 — 2,71 3,29 —

13 16 — 2,71 3,29 —

16 16 — 3,05 3,05 —

16 16 — 3,05 3,05 —

16 16 — 3,05 3,05 —

10 10 10 2,13 2,13 2,13

10 10 10 2,13 2,13 2,13

10 10 10 2,13 2,13 2,13

10 10 13 1,99 1,99 2,72

10 10 13 1,99 1,99 2,72

10 10 13 1,99 1,99 2,72

10 13 13 1,80 2,45 2,45

10 13 13 1,80 2,45 2,45

10 13 13 1,80 2,45 2,45

10 10 16 1,83 1,83 3,04

10 10 16 1,83 1,83 3,04

10 10 16 1,83 1,83 3,04

Cooling Power Operation Outdoorcapacity consumption current noise

(kW) (W) (A) (dB)2,7 770 4,12 45

(1,4 to 3,2) (320 to 950) (2,08 to 5,08)2,7 770 3,94 45

(1,4 to 3,2) (320 to 950) (1,99 to 4,86)2,7 770 3,77 45

(1,4 to 3,2) (320 to 950) (1,90 to 4,66)3,7 1200 6,34 48

(1,4 to 4,4) (320 to 1470) (2,08 to 7,51)3,7 1200 6,07 48

(1,4 to 4,4) (320 to 1470) (1,99 to 7,18)3,7 1200 5,81 48

(1,4 to 4,4) (320 to 1470) (1,90 to 6,88)4,5 1600 7,66 48

(1,4 to 4,9) (320 to 1750) (2,08 to 8,37)4,5 1600 7,32 48

(1,4 to 4,9) (320 to 1750) (1,99 to 8,01)4,5 1600 7,02 48

(1,4 to 4,9) (320 to 1750) (1,90 to 7,68)5,4 1500 7,18 48

(1,8 to 6,0) (360 to 1880) (2,34 to 9,00)5,4 1500 6,86 48

(1,8 to 6,0) (360 to 1880) (2,24 to 8,60)5,4 1500 6,58 48

(1,8 to 6,0) (360 to 1880) (2,14 to 8,25)5,8 1800 8,61 48

(1,8 to 6,3) (360 to 1970) (2,34 to 9,43)5,8 1800 8,24 48

(1,8 to 6,3) (360 to 1970) (2,24 to 9,02)5,8 1800 7,89 48

(1,8 to 6,3) (360 to 1970) (2,14 to 8,64)5,9 1830 8,76 48

(1,8 to 6,4) (360 to 2000) (2,34 to 9,57)5,9 1830 8,38 48

(1,8 to 6,4) (360 to 2000) (2,24 to 9,15)5,9 1830 8,03 48

(1,8 to 6,4) (360 to 2000) (2,14 to 8,77)5,9 1830 8,76 48

(1,8 to 6,4) (360 to 2000) (2,34 to 9,57)5,9 1830 8,38 48

(1,8 to 6,4) (360 to 2000) (2,24 to 9,15)5,9 1830 8,03 48

(1,8 to 6,4) (360 to 2000) (2,14 to 8,77)6,0 1850 8,85 48

(1,8 to 6,4) (360 to 2000) (2,34 to 9,57)6,0 1850 8,50 48

(1,8 to 6,4) (360 to 2000) (2,24 to 9,15)6,0 1850 8,11 48

(1,8 to 6,4) (360 to 2000) (2,14 to 8,77)6,1 1870 8,95 48

(1,8 to 6,5) (360 to 2050) (2,34 to 9,81)6,1 1870 8,56 48

(1,8 to 6,5) (360 to 2050) (2,24 to 9,38)6,1 1870 8,20 48

(1,8 to 6,5) (360 to 2050) (2,14 to 8,99)6,4 1880 9,00 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)6,4 1880 8,60 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)6,4 1880 8,25 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)6,7 2150 10,29 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)6,7 2150 9,84 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)6,7 2150 9,43 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)6,7 2150 10,29 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)6,7 2150 9,84 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)6,7 2150 9,43 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)6,7 2150 10,29 48

(2,2 to 7,0) (420 to 2300) (2,73 to 11,0)6,7 2150 9,84 48

(2,2 to 7,0) (420 to 2300) (2,61 to 10,53)6,7 2150 9,43 48

(2,2 to 7,0) (420 to 2300) (2,50 to 10,09)

1-2. Specifications of Performance When Each Indoor Unit is Combined with Other Unit

– 5 –

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

1-2-1. Operation Characteristic Curve

12

11

10

9

8

7

6

5

4

3

2

1

0100 20 30 40 50 60 70 80 90 100

Inverter output frequency (rps)

Cur

rent

(A

)

• ConditionsIndoor : DB27˚C/WB19˚COutdoor : DB35˚CAir flow : HighPipe length 5m × 33 units operating

220V

240V

230V

105115

110100

105

100

95

90

85

0

95

90

85

80

75

70

65

60

55

5032 34 36 38 40 42 44 4614 16 4318 20 22 24

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

Indoor air wet bulb temp. (˚C)

Cap

acity

rat

io (

%)

Cap

acity

rat

io (

%)

• ConditionsIndoor : DB27˚COutdoor : DB35˚CIndoor air flow : HighPipe length 5m × 33 units operating

• ConditionsIndoor : DB27˚C/WB19˚CIndoor air flow : HighPipe length 5m × 33 units operating

Current Limited Start

– 6 –

DB WB

Indoor temp. °C 27 19

Outdoor temp. °C 35 —

NOTE :Model of Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-EMCA : Minimum Circuit Amps.ICF : Maximum Instantaneous Current Flow

(Equivalent to MCA in case of inverter air conditioner)MOCP : Maximum Overcurrent Protection (Fuse only)MSC : Maximum Starting CurrentFLA : Full Load Amps.RLA : Rated Load Amps. RLA under conditions on the right.

Combination ofindoor unit operation

1 unit 10 — —

13 — —

16 — —

2 units 10 10 —

13 10 —

16 10 —

13 13 —

16 13 —

16 16 —

3 units 10 10 10

13 10 10

13 13 10

16 10 10

1 unit 10 — —

13 — —

16 — —

2 units 10 10 —

13 10 —

16 10 —

13 13 —

16 13 —

16 16 —

3 units 10 10 10

13 10 10

13 13 10

16 10 10

1 unit 10 — —

13 — —

16 — —

2 units 10 10 —

13 10 —

16 10 —

13 13 —

16 13 —

16 16 —

3 units 10 10 10

13 10 10

13 13 10

16 10 10

SystemVoltage range Power supply

Hz Volts-Min. Max. MCA ICF MOCPPh. (Amps)

4,99 4,99 8,46

7,76 7,76 13,45

9,41 9,41 16,42

8,78 8,78 15,16

10,56 10,56 18,37

50 220-1 198 264 10,75 10,75 18,71

10,75 10,75 18,71

10,86 10,86 18,91

10,99 10,99 19,14

11,01 11,01 19,06

12,63 12,63 21,97

12,63 12,63 21,97

12,63 12,63 21,97

4,76 4,76 8,05

7,43 7,43 12,85

8,99 8,99 15,66

8,38 8,38 14,44

10,10 10,10 17,54

50 230-1 198 264 10,28 10,28 17,86

10,28 10,28 17,86

10,43 10,43 18,13

10,50 10,50 18,26

10,51 10,51 18,16

12,06 12,06 20,95

12,06 12,06 20,95

12,06 12,06 20,95

4,55 4,55 7,67

7,10 7,10 12,26

8,61 8,61 14,98

8,03 8,03 13,81

9,66 9,66 16,75

50 240-1 198 264 9,84 9,84 17,07

9,84 9,84 17,07

9,94 9,94 17,25

10,05 10,05 17,45

10,08 10,08 17,38

11,55 11,55 20,03

11,55 11,55 20,03

11,55 11,55 20,03

Compressor Fan motor FLA

MSC RLA Indoor Outdoor

3,47 3,47 0,15 x 1 = 0,15 0,5

5,69 5,69 0,15 x 1 = 0,15 0,5

7,01 7,01 0,15 x 1 = 0,15 0,5

6,38 6,38 0,15 x 2 = 0,30 0,5

7,81 7,81 0,15 x 2 = 0,30 0,5

7,96 7,96 0,15 x 2 = 0,30 0,5

7,96 7,96 0,15 x 2 = 0,30 0,5

8,05 8,05 0,15 x 2 = 0,30 0,5

8,15 8,15 0,15 x 2 = 0,30 0,5

8,05 8,05 0,15 x 3 = 0,45 0,5

9,34 9,34 0,15 x 3 = 0,45 0,5

9,34 9,34 0,15 x 3 = 0,45 0,5

9,34 9,34 0,15 x 3 = 0,45 0,5

3,29 3,29 0,15 x 1 = 0,15 0,5

5,42 5,42 0,15 x 1 = 0,15 0,5

6,67 6,67 0,15 x 1 = 0,15 0,5

6,06 6,06 0,15 x 2 = 0,30 0,5

7,44 7,44 0,15 x 2 = 0,30 0,5

7,58 7,58 0,15 x 2 = 0,30 0,5

7,58 7,58 0,15 x 2 = 0,30 0,5

7,70 7,70 0,15 x 2 = 0,30 0,5

7,76 7,76 0,15 x 2 = 0,30 0,5

7,65 7,65 0,15 x 3 = 0,45 0,5

8,89 8,89 0,15 x 3 = 0,45 0,5

8,89 8,89 0,15 x 3 = 0,45 0,5

8,89 8,89 0,15 x 3 = 0,45 0,5

3,12 3,12 0,15 x 1 = 0,15 0,5

5,16 5,16 0,15 x 1 = 0,15 0,5

6,37 6,37 0,15 x 1 = 0,15 0,5

5,78 5,78 0,15 x 2 = 0,30 0,5

7,09 7,09 0,15 x 2 = 0,30 0,5

7,23 7,23 0,15 x 2 = 0,30 0,5

7,23 7,23 0,15 x 2 = 0,30 0,5

7,31 7,31 0,15 x 2 = 0,30 0,5

7,40 7,40 0,15 x 2 = 0,30 0,5

7,30 7,30 0,15 x 3 = 0,45 0,5

8,48 8,48 0,15 x 3 = 0,45 0,5

8,48 8,48 0,15 x 3 = 0,45 0,5

8,48 8,48 0,15 x 3 = 0,45 0,5

1-3. Electrical Data

– 7 –

2. REFRIGERANT R410A

(5) After completion of installation work, check tomake sure that there is no refrigeration gasleakage.

If the refrigerant gas leaks into the room, cominginto contact with fire in the fan-driven heater,space heater, etc., a poisonous gas may occur.

(6) When an air conditioning system charged with alarge volume of refrigerant is installed in a smallroom, it is necessary to exercise care so that,even when refrigerant leaks, its concentrationdoes not exceed the marginal level.

If the refrigerant gas leakage occurs and itsconcentration exceeds the marginal level, anoxygen starvation accident may result.

(7) Be sure to carry out installation or removalaccording to the installation manual.

Improper installation may cause refrigerationtrouble, water leakage, electric shock, fire, etc.

(8) Unauthorized modifications to the air conditionermay be dangerous. If a breakdown occursplease call a qualified air conditioner technicianor electrician.

Improper repair’s may result in water leakage,electric shock and fire, etc.

2-2. Refrigerant Piping Installation

2-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipesand joints are mainly used. Copper pipes and jointssuitable for the refrigerant must be chosen andinstalled. Furthermore, it is necessary to use cleancopper pipes and joints whose interior surfaces areless affected by contaminants.

(1) Copper Pipes

It is necessary to use seamless copper pipeswhich are made of either copper or copper alloyand it is desirable that the amount of residual oilis less than 40 mg/10 m. Do not use copperpipes having a collapsed, deformed or discol-ored portion (especially on the interior surface).Otherwise, the expansion valve or capillary tubemay become blocked with contaminants.

As an air conditioner using R410A incurspressure higher than when using R22, it isnecessary to choose adequate materials.

Thicknesses of copper pipes used with R410Aare as shown in Table 2-2-1. Never use copperpipes thinner than 0,8 mm even when it isavailable on the market.

This air conditioner adopts the new refrigerant HFC(R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410Ais 1,6 times higher than conventional refrigerant(R22). The refrigerating oil is also changed inaccordance with change of refrigerant, so be carefulthat water, dust, and existing refrigerant or refrigerat-ing oil are not entered in the refrigerant cycle of theair conditioner using the new refrigerant duringinstallation work or servicing time.

The next section describes the precautions for airconditioner using the new refrigerant. Conforming tocontents of the next section together with thegeneral cautions included in this manual, performthe correct and safe work.

2-1. Safety During Installation/Servicing

As R410A’s pressure is about 1,6 times higher thanthat of R22, improper installation/servicing maycause a serious trouble. By using tools and materi-als exclusive for R410A, it is necessary to carry outinstallation/servicing safely while taking the followingprecautions into consideration.

(1) Never use refrigerant other than R410A in an airconditioner which is designed to operate withR410A.

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.

(2) Confirm the used refrigerant name, and usetools and materials exclusive for the refrigerantR410A.

The refrigerant name R410A is indicated on thevisible place of the outdoor unit of the air condi-tioner using R410A as refrigerant. To preventmischarging, the diameter of the service portdiffers from that of R22.

(3) If a refrigeration gas leakage occurs duringinstallation/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 therefrigeration cycle. Otherwise, pressure in therefrigeration cycle may become abnormally highso that a rupture or personal injury may becaused.

– 8 –

(2) Joints

For copper pipes, flare joints or socket joints areused. Prior to use, be sure to remove all con-taminants.

a) Flare Joints

Flare joints used to connect the copper pipescannot be used for pipings whose outerdiameter exceeds 20 mm. In such a case,socket joints can be used.

Sizes of flare pipe ends, flare joint ends andflare nuts are as shown in Tables 2-2-3 ~ 2-2-6below.

b) Socket Joints

Socket joints are such that they are brazedfor connections, and used mainly for thickpipings whose diameter is larger than 20 mm.Thicknesses of socket joints are as shown inTable 2-2-2.

Table 2-2-2 Minimum thicknesses of socket joints

Nominal diameterReference outer diameter of Minimum joint thickness

copper pipe jointed (mm) (mm)

1/4 6,35 0,50

3/8 9,52 0,60

1/2 12,70 0,70

5/8 15,88 0,80

2-2-2. Processing of Piping Materials

When performing the refrigerant piping installation,care should be taken to ensure that water or dustdoes not enter the pipe interior, that no other oilother than lubricating oils used in the installed airconditioner is used, and that refrigerant does notleak. When using lubricating oils in the pipingprocessing, use such lubricating oils whose watercontent has been removed. When stored, be sure toseal the container with an airtight cap or any othercover.

(1) Flare Processing Procedures and Precautions

a) Cutting the Pipe

By means of a pipe cutter, slowly cut the pipeso that it is not deformed.

b) Removing Burrs and Chips

If the flared section has chips or burrs,refrigerant leakage may occur. Carefullyremove all burrs and clean the cut surfacebefore installation.

Table 2-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter Outer diameter (mm) R410A R22

1/4 6,35 0,80 0,80

3/8 9,52 0,80 0,80

1/2 12,70 0,80 0,80

5/8 15,88 1,00 1,00

– 9 –

AØD

Flare nutwidth(mm)

Flare processing dimensions differ accordingto 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.

Fig. 2-2-1 Flare processing dimensions

Table 2-2-3 Dimensions related to flare processing for R410A

Nominal Outer Thicknessdiameterdiameter (mm) (mm)

1/4 6,35 0,8

3/8 9,52 0,8

1/2 12,70 0,8

5/8 15,88 1,0

A (mm)

Flare tool for Conventional flare tool

R410A clutch type Clutch type Wing nut type

0 to 0,5 1,0 to 1,5 1,5 to 2,0

0 to 0,5 1,0 to 1,5 1,5 to 2,0

0 to 0,5 1,0 to 1,5 2,0 to 2,5

0 to 0,5 1,0 to 1,5 2,0 to 2,5

Table 2-2-4 Dimensions related to flare processing for R22

Nominal Outer Thicknessdiameterdiameter (mm) (mm)

1/4 6,35 0,8

3/8 9,52 0,8

1/2 12,70 0,8

5/8 15,88 1,0

A (mm)

Flare tool for Conventional flare tool

R22 clutch type Clutch type Wing nut type

0 to 0,5 0,5 to 1,0 1,0 to 1,5

0 to 0,5 0,5 to 1,0 1,0 to 1,5

0 to 0,5 0,5 to 1,0 1,5 to 2,0

0 to 0,5 0,5 to 1,0 1,5 to 2,0

Table 2-2-5 Flare and flare nut dimensions for R410A

Nominal Outer diameter Thicknessdiameter (mm) (mm)

1/4 6,35 0,8

3/8 9,52 0,8

1/2 12,70 0,8

5/8 15,88 1,0

Dimension (mm)

A B C D

9,1 9,2 6,5 13 17

13,2 13,5 9,7 20 22

16,6 16,0 12,9 23 26

19,7 19,0 16,0 25 29

c) Insertion of Flare Nut

d) Flare Processing

Make certain that a clamp bar and copperpipe have been cleaned.

By means of the clamp bar, perform the flareprocessing correctly.

Use either a flare tool for R410A or conven-tional flare tool.

– 10 –

43˚~45˚

45˚~46˚

B A C D

Flare nutwidth(mm)

Nominal Outer diameter Thicknessdiameter (mm) (mm)

1/4 6,35 0,8

3/8 9,52 0,8

1/2 12,70 0,8

5/8 15,88 1,0

3/4 19,05 1,0

Dimension (mm)

A B C D

9,0 9,2 6,5 13 17

13,0 13,5 9,7 20 22

16,2 16,0 12,9 20 24

19,4 19,0 16,0 23 27

23,3 24,0 19,2 34 36

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

(2) Flare Connecting Procedures and Precautions

a) Make sure that the flare and union portionsdo not have any scar or dust, etc.

b) Correctly align the processed flare surfacewith the union axis.

c) Tighten the flare with designated torque bymeans of a torque wrench. The tighteningtorque for R410A is the same as that forconventional R22. Incidentally, when thetorque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack andmay be made non-removable. When choos-ing the tightening torque, comply with valuesdesignated by manufacturers. Table 2-2-7shows reference values.

Note:When applying oil to the flare surface, be sure to useoil designated by the manufacturer. If any other oil isused, the lubricating oils may deteriorate and causethe compressor to burn out.

Table 2-2-7 Tightening torque of flare for R410A [Reference values]

Nominal Outer diameter Tightening torque Tightening torque of torquewrenches available on the market

diameter (mm) N•m (kgf•cm) N•m (kgf•cm)

1/4 6,35 14 to 18 (140 to 180) 16 (160), 18 (180)

3/8 9,52 33 to 42 (330 to 420) 42 (420)

1/2 12,70 50 to 62 (500 to 620) 55 (550)

5/8 15,88 63 to 77 (630 to 770) 65 (650)

Table 2-2-6 Flare and flare nut dimensions for R22

– 11 –

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

No. Used tool

Flare tool

Copper pipe gauge for adjusting projection

margin

Torque wrench(For Ø12,7)

Gauge manifold

Charge hose

Vacuum pump adapter

Electronic balance forrefrigerant charging

Refrigerant cylinder

Leakage detector

Charging cylinder

Usage

Pipe flaring

Flaring byconventional flaretool

Connection of flarenut

Evacuating, refriger-ant charge, runcheck, etc.

Vacuum evacuating

Refrigerant charge

Refrigerant charge

Gas leakage check

Refrigerant charge

R410A air conditionerinstallation

Existence of Whethernew equipment conventionalfor R410A equipment can

be used

Yes *(Note 1)

Yes *(Note 1)

Yes X

Yes X

Yes X

Yes XYes XYes X

(Note 2) X

Conventional airconditioner installation

Whether new equip-ment can be used withconventional refriger-ant

*(Note 1)

X

X

XX

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projectionmargin 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 necessaryas the general tools.

(1) Vacuum pumpUse vacuum pump byattaching vacuum pump adapter.

(2) Torque wrench (For Ø6,35) (3) Pipe cutter

(4) Reamer (5) Pipe bender (6) Level vial (7) Screwdriver (+, –) (8) Spanner or Monkey wrench

(9) Hole core drill (Ø65)(10) Hexagon wrench

(Opposite side 5mm)(11) Tape measure

(12) Metal saw

Also prepare the following equipments for other installation method and run check.

(1) Clamp meter (2) Thermometer

(3) Insulation resistance tester

(4) Electroscope

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 preventmixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite sidedimension 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.

– 12 –

(INDOOR unit) (Liquid side)

Refrigerant cylinder (With siphon pipe)

Check valve

(Gas side)

Open/Close valvefor charging

Electronic balance for refrigerant charging

Opened

(OUTDOOR unit)

Closed

Service port

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

Recover the refrigerant, and check no refrigerant remains in the equipment.

(For refrigerant charging, see the figure below.)

Connect the charge hose of the vacuum pump adapter.

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.

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.

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

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.

Never charge refrigerant exceeding the specified amount.

If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

Do not carry out additional charging.When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in therefrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the speci-fied amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pres-sure, and may cause a rupture or personal injury.

Fig. 2-4-1 Configuration of refrigerant charging

2-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to thefollowing steps.

– 13 –

Gauge manifold

[ Cylinder with siphon ] [ Cylinder without siphon ]

OUTDOOR unitGauge manifold

OUTDOOR unit

Refrigerantcylinder

Electronicbalance

Refrigerantcylinder

Electronicbalance

Siphon

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 thecylinder upside down if cylinder is not equipped with siphon.

R410A refrigerant is HFC mixed refrigerant.Therefore, if it is charged with gas, the compo-sition of the charged refrigerant changes andthe characteristics of the equipment varies.

Fig. 2-4-2

2-5. Brazing of Pipes

2-5-1. Materials for Brazing

(1) Silver brazing filler

Silver brazing filler is an alloy mainly composedof silver and copper. It is used to join iron,copper or copper alloy, and is relatively expen-sive though it excels in solderability.

(2) Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally usedto join copper or copper alloy.

(3) Low temperature brazing filler

Low temperature brazing filler is generally calledsolder, and is an alloy of tin and lead. Since it isweak in adhesive strength, do not use it forrefrigerant pipes.

Phosphor bronze brazing filler tends to reactwith sulfur and produce a fragile compoundwater solution, which may cause a gas leak-age. Therefore, use any other type of brazingfiller at a hot spring resort, etc., and coat thesurface with a paint.

When performing brazing again at time ofservicing, use the same type of brazing filler.

2-5-2. Flux

(1) Reason why flux is necessary

• By removing the oxide film and any foreignmatter on the metal surface, it assists the flowof brazing filler.

• In the brazing process, it prevents the metalsurface from being oxidized.

• By reducing the brazing filler’s surface tension,the brazing filler adheres better to the treatedmetal.

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.

– 14 –

Nitrogen gascylinder

Pipe

Flow meterM

Stop valve

From Nitrogen cylinder

Nitrogengas

Rubber plug

Pipingmaterial

Copper - Copper

Copper - Iron

Iron - Iron

Used brazing Usedfiller flux

Phosphor copper Do not use

Silver Paste flux

Silver Vapor flux

Do not enter flux into the refrigeration cycle.

When chlorine contained in the flux remainswithin the pipe, the lubricating oil deterio-rates. Therefore, use a flux which does notcontain chlorine.

When adding water to the flux, use waterwhich does not contain chlorine (e.g. distilledwater or ion-exchange water).

Remove the flux after brazing.

2-5-3. Brazing

As brazing work requires sophisticated techniques,experiences based upon a theoretical knowledge, itmust be performed by a person qualified.

In order to prevent the oxide film from occurring inthe pipe interior during brazing, it is effective toproceed with brazing while letting dry Nitrogen gas(N2) flow.

Never use gas other than Nitrogen gas.

(1) Brazing method to prevent oxidation

Attach a reducing valve and a flow-meter tothe Nitrogen gas cylinder.

Use a copper pipe to direct the pipingmaterial, and attach a flow-meter to thecylinder.

Apply a seal onto the clearance between thepiping material and inserted copper pipe forNitrogen in order to prevent backflow of theNitrogen gas.

When the Nitrogen gas is flowing, be sure tokeep the piping end open.

Adjust the flow rate of Nitrogen gas so that itis 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 theNitrogen gas flowing until the pipe coolsdown to a certain extent (temperature atwhich pipes are touchable with hands).

Remove the flux completely after brazing.

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

(2) Characteristics required for flux

• Activated temperature of flux coincides withthe brazing temperature.

• Due to a wide effective temperature range,flux is hard to carbonize.

• It is easy to remove slag after brazing.• The corrosive action to the treated metal and

brazing filler is minimum.• It excels in coating performance and is

harmless to the human body.

As the flux works in a complicated manner asdescribed above, it is necessary to select anadequate type of flux according to the type andshape of treated metal, type of brazing filler andbrazing method, etc.

(3) Types of flux

• Noncorrosive fluxGenerally, it is a compound of borax and boricacid.It is effective in case where the brazingtemperature is higher than 800°C.

• Activated fluxMost of fluxes generally used for silver brazingare this type.It features an increased oxide film removingcapability due to the addition of compoundssuch as potassium fluoride, potassium chlo-ride and sodium fluoride to the borax-boricacid compound.

(4) Piping materials for brazing and used braz-ing filler/flux

– 15 –

3. CONSTRUCTION VIEWS

3-1. Indoor Unit

Connecting pipe (0.33m)(For 10,13 series ; Flare ∅9.52 For 16 series ; Flare ∅12.7)

Knock out system

Back body

Front panel

Air outlet

Air inlet Air filter Heat exchanger

Knock out system

660

275

790 208

48

4826

4519

040

32

64

590

320

620235 235

215 215

9090

275

45

150150 160160

120 80

53

660

Hanger

Hanger

Hanger

Hanger Hanger

Drain hose (0.54m) Connecting pipe (0.43m)(Flare ∅6.35)

For stud bolt (∅8~∅10)

For stud bolt (∅6)

Installation plate outline

Center line

Minimumdistanceto ceiling

170 or more


170 or more

65 o

r m

ore


Wireless remote control

57 18

160

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

– 16 –

3-2. Outdoor Unit

RAS-3M23YACV-E

115,5

780 68,5

Fan guard

(For ø8-ø10 anchor bolt)ø11 × 17U-shape hole

8-ø6 hole(For fixing outdoor unit)

ø11 × 17 long hole(For ø8-ø10 anchor bolt)

90

50

600

310

296

270

18B leg part

(ø6

hole

pitc

h)

(Anc

hor b

olt l

ong

hole

pitc

h)

A leg part

2-ø6 hole

2-ø6 hole

600

50

11

R1536

310

296

600

50

11

R1536

310

296

R5,5

R5,

5

Detailed A leg part

Detailed B leg part

Outside line of product


600

310

B

C

AD

4 × ø11 × 17U-shape hole(For ø8-ø10 anchor bolt)

Mounting dimensions of anchor bolt

50 o

r m

ore

Intake

Intake

100 or more

250 or more

200

or m

ore

(Minimum distance from wall)


Outlet 4 × ø11 × 17 long hole(For ø8-ø10 anchor bolt)

868

769

5

Hanger

123,8332

86,2

5353

5353

53

ZChargingport

Valve cover

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

Connecting pipe port

(Pipe dia.ø6,35)

Connecting pipe port(Pipe dia.ø9,52)

Connecting pipe port(Pipe dia.ø12,7)

viewZ

– 17 –

4. WIRING DIAGRAM

4-1. Indoor Unit

RAS-M10UKCV-ERAS-M13UKCV-ERAS-M16UKCV-E

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

Diagnosis result

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

Check for power supply voltage between and . (Refer to the name plate.)(Check the primary and secondary voltage of transformer.)Check for fluctuate voltage between – . (DC 15 ~ 60V)

Check to see if the fuse blows out.(Check the R04 of the varistor.)

Check the voltage at the No.4 pin on CN13 connector of the infrared receiver. (Check the transformer and the power supply circuit of the rated voltage.)

Check for voltage at the while lead of louver motor.(Check the transformer and the power supply circuit of the rated voltage.)

Check the voltage at the No.1 pin on CN10 connector.(Check the DB01, R05 and C03.)

Refer to the service data for the detailed failure diagnosis.

Check items

OPERATIONINDICATOR

TERMINALBLOCK

FUSE6.3A

DC 5V

DC 12V

DC 35V

1

2

3

4

5

6

ColorIdentification

BRW : BROWNRED : REDWHI : WHITEYEL : YELLOWBLU : BLUEBLK : BLACKGRY : GRAYPNK : PINKORN : ORANGEGRN : GREEN &&YEL YELLOW

(DC310 ~ 340V)

GRN : GREEN

– 18 –

4-2. Outdoor Unit

RAS-3M23YACV-E

REACTOR

1 12 2

COLOR IDENTIFICATION

BLK : BLACKBLU : BLUEORN : ORANGEGRY : GRAYPNK : PINK

WHI : WHITEBRW : BROWNRED : REDYEL : YELLOWPUR : PURPLEGRN : GREENSKB : SKY-BLUE

CN08

P.M.V.A UNIT

POWER SUPPLY

220–230–240V~50Hz

SURGEABSORBER

CN300

FAN MOTOR

P.C. BOARDMCC-758

REACTOR

CN301

CT

CO

NV

ER

TE

RM

OD

ULE

IGB

T M

OD

ULE

ELECTRONICSTARTER

POWER RELAY

GEA~–

~+

+

BUEUBVEVBWEWBXBYBZ–

C15C13

C14C12

P07P08

ORN P10

YEL

DB01

P20

BLU

Q200

P18P17

P19

P09

P06

F01FUSE25A

VARISTOR

ToINDOOR

UNITA

ToINDOOR

UNITB

TD

WHIYELORNBLUREDGRY

P.M.V.B UNIT

WHIYELORNBLUREDGRY

ORNPNK

WHI

CN501

P12

P13

P11

P14

YEL

YEL

PUR

CN704

BLKBLK

PN

K

YE

L

RE

DW

HI

BLK

GR

Y

P04RED P05WHI

BRWREDORNYEL

BLK

BRWREDORNYEL

P06

CN15

P02

GRY

ORN

BLK

BLK

BLK

BLK

BLK

P01

L

321321

123123

44

55

22

11

N 1 2 3 1 2 3

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

P03 1 12 2

CN02

CN03

CN05

CN14

CN13

1 12 23 3

1 12 2

1 12 23 3

6 65 54 43 32 21 1

6 65 54 43 32 21 1

P.M.V. : PULSE MODULATING VALVE

P.M.V.C UNIT

WHIYELORNBLUREDGRY

CN12

6 65 54 43 32 21 1

THERMOSTAT for COMPRESSOR

PHOTOCOUPLER

F03FUSE15A

F04FUSE3,15A

F01FUSE 6,3A

3

1

3

1

4321

4321

4321

TO

YEL

TGa

CN061 12 23 3

BRW

TGb

CN071 12 23 3

GRN

TGc

RELAY

BLKP23WHIP22REDP21

FM

ToINDOOR

UNITC

1 2 3 4

~ ~ ~ ~

SUBP.C. BOARD

MCC-775

321

321

COMPRESSOR

CM

REACTOR

REACTOR

– 19 –

5. SPECIFICATIONS OF ELECTRICAL PARTS

5-1. Indoor UnitRAS-M10YKCV-E, RAS-M13YKCV-E, RAS-M16YKCV-E

No. Parts name Type Specifications1 Fan motor (for indoor) ICF-340-30-2 DC340V, 30W2 Thermo. sensor (TA-sensor) ( – ) 10kΩ at 25°C3 DC-DC transformer (T01) SWT-70 DC390V, Secondary DC15V, 12V, 7V

4 Microcomputer ( – )

5 Heat exchanger sensor ( – ) 10kΩ at 25°C(TC-sensor)6 Line filter (L01) SS11V-06270 27mH, AC0,64A7 Diode (DB01) D3SBA60 4A, 600V8 Capacitor (C03) KMH450VNSN120M25C 120µF, 450V9 Fuse (F01) FCU250V3.15A T3,15A, 250V

10 Power supply IC (IC01) STR-L47211 Varistor (R21, R109) 15G561K 560V12 Resistor (R01) RF-5TK5R6 4,7Ω, 5W13 Louver motor MP24GA Output (Rated) 1W, 16poles, 1phase DC12V

5-2. Outdoor UnitRAS-3M23YACV-E

No. Parts name Model name Rating

1 SC coil (Noise filter)SC-15-S06J 15A, 0,6mHSC-20-01J 20A, 150µH

Primary side DC280V2 DC-DC transformer SWT-43 Secondary side 7,5V x 1, 13V x 1

26,5V x 3, 16V x 1, 15V x 13 Reactor CH38Z-K L=10mH, 16A x 24 Outside fan motor ICF-140-40-8 DC140V, 40W

5 Fan control relay AJQ1341 Coil DC12VContact AC125V, 3A

6 Discharge temp. sensor (Inverter attached) 62kΩ (20°C)(TD sensor)

7 Outside air temp. sensor (Inverter attached) 10kΩ (25°C)(TO sensor)

8 Temp. sensor at A room (Inverter attached) 10kΩ (25°C)gas side (TGa sensor)

9 Temp. sensor at B room (Inverter attached) 10kΩ (25°C)gas side (TGb sensor)

10 Temp. sensor at C room (Inverter attached) 10kΩ (25°C)gas side (TGc sensor)11 Terminal block (9P) ——— 20A, AC250V (9P x 2)

For protection of 3,15A, AC250Vswitching power source

12 Fuse For protection of transistor 15A, AC250Vmodule breakageFor protection of 25A, AC250Vinverter input overcurrent

13 Electrolytic capacitor LLQ2G501KHUATF 500µF, DC400V X 4 pieces400LISN500K35F14 Transistor module 6MBI25GS-060-01 25A, 600V15 Compressor DA130A1F-21F 3-phases 4-poles 1100W16 Compressor thermo. PW-2AL OFF: 125 ± 4°C, ON: 90 ± 5°C17 Converter module MP7002 Diode: 25A, 600V, IGBT: 40A, 600V18 Reactor CH43Z-K L = 10mH, 1A x 2

– 20 –

6. REFRIGERANT CYCLE DIAGRAM

6-1. Refrigerant Cycle Diagram

NOTE :

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

Connecting pipeThickness : 0,8 mmØ9,52 : RAS-M10UKCV-E RAS-M13UKCV-EØ12,7 : RAS-M16UKCV-E

NOTE : Gas leak check position

Refrigerant flow

INDOOR UNIT AT1 Temp. measurement

To C room

To B roomIndoor heat

exchanger

Cross flow fan

Sectional shapeof heat insulator

To C room

To B room

Allo

wab

le h

eigh

tdi

ffere

nce

: 10m

Allo

wab

le p

ipe

leng

th

Per 1 unitMax. : 20mMin. : 2m

TotalMax. : 40m

P

Strainer

Pulse modulating valve at liquid side(SEV15RC2)

TGaTGbTGc

TDAccumulating tankØ51 x 300(460cc)

CompressorDA130A1F-21F

T2

Outdoor heat exchanger

Temp. measurementPropeller fan

Refrigerant amount : 1,5kg (R410A)

OUTDOOR UNIT

Connecting pipeThickness : 0,8 mmØ6,35 Pressure

measurementGauge attaching portVacuum pump connecting port

(Ø9,52) (Ø9,52) (Ø12,7) (Ø6,35) (Ø6,35) (Ø6,35)

– 21 –

6-2. Operation Data

NOTE :

Model of Indoor unit 10 : RAS-M10UKCV-E, 13 : RAS-M13UKCV-E, 16 : RAS-M16UKCV-E

NOTES :

(1) Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent.(Thermistor themometer)

(2) Connecting piping condition : 5 meters x 3 units (5m / each unit)

TemperatureNo. ofcondition (°C)

operatingIndoor Outdoor units

1 unit

2 units27/19 35/–

3 units

Combinationsof indoor units

10 — —

13 — —

16 — —

10 10 —

13 10 —

16 10 —

13 13 —

16 13 —

16 16 —

10 10 10

13 10 10

16 10 10

13 13 10

StandardSurface temp. of

pressureheat exchanger

P (Mpa) T1 (°C) T2 (°C)

0,92 11 42

0,85 9 47

0,73 8 50

0,96 10,5 to 11,5 49

0,92 11 to 12 51

0,92 11 to 12 51

0,92 11 to 12 51

0,92 11 to 12 51

0,92 11 to 12 51

1,04 12,5 to 13,5 51

0,98 12 to 13 52

0,98 12 to 13 52

0,98 12 to 13 52

Fan speed Compressorrevolution

Indoor Outdoor (rps)

High Med. 37

High High 57

High High 73

High High 69

High High 78

High High 78

High High 78

High High 78

High High 78

High High 81

High High 89

High High 89

High High 89

– 22 –

7. CONTROL BLOCK DIAGRAM

7-1. Indoor Unit

Remote Control

Operation (START/STOP)

Operation Mode SelectionAUTO, COOL, DRY, FAN ONLY

Temperature Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver Auto Swing

Louver Direction Setting

ECONO.

InfraredRaysREMOTE CONTROL

Indoor Unit Control Panel

Heat Exchanger Sensor

Temperature Sensor

Infrared Rays Signal Receiver

Initiallizing Circuit

Clock FrequencyOscillator Circuit

Power SupplyCircuit

Noise Filter

From Outdoor Unit

M.C.U.

Functions• Louver Control

• 3-minute Delay at Restart for Compressor

• Motor Revolution Control

• Processing(Temperature Processing)

• Timer

Louver ON/OFF Signal

Louver Driver

Relay RY04

Outdoor Unit

OperationDisplay

TimerDisplay

Filter SignDisplay

Indoor FanMotor

Fan OnlySign Display

Louver Motor

InfraredRays

RemoteControl

Outdoor unitON/OFF Signal

Relay Driver

RAS-M10UKCV-E, RAS-M13UKCV-E, RAS-M16UKCV-E

– 23 –

7-2. Outdoor Unit (Inverter Assembly)

MC

C-7

75 (

SU

B P

.C.B

)M

CC

-758

(M

AIN

P.C

.B)

220–

230–

240V

~ 5

0Hz

For

Indo

or u

nit

Out

door

air

tem

p. s

enso

r

Dis

char

gete

mp.

sen

sor

Gas

sid

e A

, B, C

pip

ete

mp.

sen

sor

C u

nit

send

/rec

eive

circ

uit

A u

nit

send

/rec

eive

circ

uit

B u

nit

send

/rec

eive

circ

uit

Com

pres

sor

Out

door

fan

mot

or

• P

WM

syn

thes

is fu

nctio

n

• In

put c

urre

nt r

elea

se c

ontr

ol

• IG

BT

ove

r-cu

rren

t det

ect c

ontr

ol

• O

utdo

or fa

n co

ntro

l

• H

igh

pow

er fa

ctor

cor

rect

ion

cont

rol

• S

igna

l com

mun

icat

ion

to M

CU

M.C

.U

Inpu

t cur

rent

Sen

sor

Ove

r cur

rent

sens

or

Ove

r cur

rent

sens

or

Con

vert

er(A

C D

C)

Inve

rter

(DC

AC

)

Inve

rter

(DC

AC

)N

oise

filte

r

Hig

h po

wer

fact

orco

rrec

tion

circ

uit

Ove

r cu

rren

tde

tect

circ

uitOve

r cu

rren

tde

tect

circ

uit

Rot

or p

ositi

onde

tect

circ

uit

Rot

or p

ositi

onde

tect

circ

uit

Gat

e dr

ive

circ

uit

Gat

e dr

ive

circ

uit

• In

vert

er o

utpu

t fre

quen

cy c

ontr

ol

• A

/D c

onve

rter

func

tion

• P

.M.V

. con

trol

• D

isch

arge

tem

p. c

ontr

ol

• E

rror

dis

play

• S

igna

l com

mun

icat

ion

to M

CU

M.C

.U

Driv

er c

ircui

t of P

.M.V

. C u

nit

P.M

.V.

P.M

.V.

: Pul

se M

odul

atin

g V

alve

PW

M

: Pul

se W

idth

Mod

ulat

ion

IGB

T

: Ins

ulat

ed G

ate

Bip

olar

Tra

nsis

tor

A u

nit

P.M

.V.

B u

nit

P.M

.V.

– 24 –

8. OPERATION DESCRIPTION

8-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type airconditioner, which uses DC motor for the indoor fanmotors and the outdoor fan motor. And the capacity-proportional control compressor which can changethe motor speed in the range from 13 to 120 rps ismounted. The DC motor drive circuit is mounted tothe indoor unit. The compressor and the inverter tocontrol fan motor are mounted to the outdoor unit.The entire air conditioner is mainly controlled by theindoor unit controller.

The indoor unit controller drives the indoor fan motorbased upon command sent from the remote control,and transfers the operation command to the outdoorunit controller.

The outdoor unit controller receives operationcommand from the indoor unit side, and controls theoutdoor fan and the pulse modulating valve.Besides, detecting revolution position of the com-pressor motor, the outdoor unit controller controlsspeed of the compressor motor by controlling outputvoltage of the inverter and switching timing of thesupply power (current transfer timing) so that motorsdrive according to the operation command. Andthen, the outdoor unit controller transfers reverselythe operating status information of the outdoor unitto control the indoor unit controller.

As the compressor adopts four-pole brushlessDC motor, the frequency of the supply powerfrom inverter to compressor is two-timescycles of the actual number of revolution.

(1) Role of indoor unit controller

The indoor unit controller judges the operationcommands from the remote control and as-sumes the following functions.

• Judgment of suction air temperature of theindoor heat exchanger by using the indoortemp. sensor.

• Temperature setting of the indoor heat ex-changer by using heat exchanger sensor(Prevent-freezing control)

• Louver motor control

• Indoor fan motor operation control

• LED display control

• Transferring of operation command signal(Serial signal) to the outdoor unit

• Reception of information of operation status(Serial signal including outside temp. data) tothe outdoor unit and judgment/display of error

(2) Role of outdoor unit controller

Receiving the operation command signal (Serialsignal) from the indoor controller, the outdoorunit performs its role.

• Compressor operationcontrol

• Operation control ofoutdoor fan motor

• P.M.V. control

Operations followedto judgment of serialsignal from indoorside.

• Detection of inverter input current and currentrelease operation

• Over-current detection and prevention opera-tion to transistor module (Compressor stopfunction)

• Compressor and outdoor fan stop functionwhen serial signal is off (when the serial signaldoes not reach the board assembly of outdoorcontrol by trouble of the signal system)

• Transferring of operation information (Serialsignal) from outdoor unit to indoor unit

• Detection of outdoor temperature and opera-tion revolution control

(3) Contents of operation command signal (Serialsignal) from indoor unit controller to outdoor unitcontroller

The following three types of signals are sentfrom the indoor unit controller.

• Operation mode set on the remote control

• Compressor revolution command signal definedby indoor temperature and set temperature(Correction along with variation of roomtemperature and correction of indoor heatexchanger temperature are added.)

• For these two types of signals ( [Operationmode] and [Compressor revolution] ), theoutdoor unit controller monitors the inputcurrent to the inverter, and performs thefollowed operation within the range thatcurrent does not exceed the allowable value.

• Temperature of indoor heat exchanger by indoorheat exchanger sensor(Minimum revolution control)

– 25 –

(4) Contents of operation command signal (Serialsignal) from outdoor unit controller to indoor unitcontroller

The following signals are sent from the outdoorunit controller.

• The current operation mode

• The current compressor revolution

• Outdoor temperature

• Existence of protective circuit operation

For transferring of these signals, the indoorunit controller monitors the contents of signals,and judges existence of trouble occurrence.

Contents of judgment are described below.

• Whether distinction of the current operationstatus meets to the operation commandsignal

• Whether protective circuit operates

When no signal is received from theoutdoor unit controller, it is assumed as atrouble.

8-1-1. Capacity Control

The cooling capacity is varied by changing compres-sor motor speed. The inverter changes compressormotor speed by changing AC 220–230–240V powerto DC once, and controls capacity by changingsupply power status to the compressor with transis-tor module (includes 6 transistors). The outline of thecontrol is as follows: The revolution position andrevolution speed of the motor are detected bydetecting winding electromotive force of the com-pressor motor under operation, and the revolutionspeed is changed so that the motor drives basedupon revolution speed of the operation command bychanging timing (current transfer timing) to ex-change inverter output voltage and supply powerwinding.

Detection of the revolution position for controlling isperformed 12 times per 1 revolution of compressor.The range of supply power frequency to the com-pressor differs according to the operation status(COOL, DRY).

Table 8-1-1 Compressor revolution range

No. of Combination of Compressoroperating unit indoor units revolution (rps)

RAS-M16UKCV-E 16 to 771 unit RAS-M13YKCV-E 16 to 72

RAS-M10YKCV-E 16 to 452 units * 19 to 843 units * 23 to 92

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

8-1-2. Current Release Control

The outdoor main circuit control section (Inverterassembly) detects the input current to the outdoorunit. If the current value with compressor motorspeed instructed from indoor side exceeds thespecified value, the outdoor main circuit controlsection controls compressor motor speed by reduc-ing motor speed so that value becomes closest tothe command within the limited value.

8-1-3. Power Factor Improvement Control

Power factor improvement control is performedmainly aiming to reduce the current on much powerconsumption of cooling operation. Controlling startsfrom the time when input power has reached at acertain point. To be concrete, IGBT of the powerfactor improvement circuit is used, and the powerfactor is improved by keeping IGBT on for an arbi-trary period to widen electro-angle of the inputcurrent.

8-1-4. Prevent-Freezing Control

The indoor heat exchanger sensor detects refriger-ant vapor temperature in COOL/DRY operation. Ifthe temperature is below the specified value, com-pressor motor speed is reduced so that operation isperformed in temperature below the specified valueto prevent-freezing of indoor heat exchanger.

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

Using P.M.V., refrigerant flow of refrigeration cycle isvaried for the optimum temperature. Controllingeach unit separately by three P.M.V. corresponds todifference of pipe length, fan speed, and unit tem-perature.

If an error occurs on cycle temperature when powersource of the air conditioner has been turned on,and if start/stop times of the outdoor unit are 30times, move the valve once until it hits on thestopper for positioning of the valve. In this case,ticktack sound may be heard.

– 26 –

8-1-6. Louver Control

(1) Vertical air flow louvers

Positions of vertical air flow louvers are auto-matically controlled according to the operationstatus (COOL, AUTO, DRY, FAN ONLY). Be-sides, positions of vertical air flow louvers can bearbitrarily set by pressing the [SET] button. Thelouver position which has been set by the [SET]button is stored in microcomputer, and the louveris automatically set at the stored position in thenext operation.

(2) Swing

If the [AUTO] button is pressed during runningoperation, vertical air flow louvers start swinging.When the [AUTO] button is pressed again,swinging stops.

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

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

Table 8-1-3

NOTE : UL : Ultra Low, SUL : Super Ultra Low

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

Although the outdoor fan motor drives the outdoor fan by non-step variable system of the revolution speed, therevolution 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 orderto protect the outdoor fan motor.

If a fan lock occurred due to entering of foreign matter, the air conditioner stops and an alarm is displayed.

Table 8-1-4

Compressor revolution (rps) ~ 17,4 ~ 38,9 39 ~

Outdoor temp. sensorTO ≥ 38°C 500 (rpm) 800 (rpm) 800 (rpm)

TO38°C > TO ≥ 15°C 500 (rpm) 700 (rpm) 800 (rpm)

15°C > TO 390 (rpm) 390 (rpm) 390 (rpm)

TO ≥ 38°C 500 (rpm) 700 (rpm) 800 (rpm)

ECONO. operation 38°C > TO ≥ 15°C 500 (rpm) 500 (rpm) 700 (rpm)

15°C > TO 390 (rpm) 390 (rpm) 390 (rpm)

TO is abnormal 700 (rpm) 700 (rpm) 800 (rpm)

Remote Motor speed Air flow rate Motor speed Air flow rate Motor speed Air flow ratemode mode Control ( rpm ) ( m3/h ) ( rpm ) ( m3/h ) ( rpm ) ( m3 /h )

H HIGH 1190 560 1210 590 1350 670M 1080 510 1130 530 1250 610

MED 1100 510 1130 530 1250 610M MED 1000 460 1050 490 1150 550

LOW 960 440 990 460 1070 500L 950 430 950 430 1050 490L LOW 910 400 910 400 980 450L 850 370 850 370 920 410L 950 430 950 430 1050 490L 910 400 910 400 980 450L 850 370 850 370 920 410

UL 720 300 750 310 920 410SUL 660 260 700 280 800 340

RAS-M13UKCV-E RAS-M16UKCV-E

DRY

Coolingand Fan

only

RAS-M10UKCV-EFanOperation

+

-+

-+

++

– 27 –

0Settemp.

+0,5

+1

+1,5

+2

+2,5

+3

(Set temp.) 25˚C

˚C

M+

*1

*1

*1

L–

(Roo

m te

mp.

) –

(Set

tem

p.)

NOTE :

*1: Calculated from difference in motor speed of M+and L–, and controlled.

Fig. 8-2-1 Auto setting of air flow

8-2. Description of Operation Circuit

• Turning [ON] the breaker flashes the operationlamp.

This is the display of power-ON (or notification ofpower failure).

• When pushing [START/STOP] button of theremote control, receive sound is issued from themain unit, and the next operations are performedtogether with opening the vertical air flow louvers.

8-2-1. Fan Only Operation(The Remote Control MODE Button isSet to the FAN ONLY Operation)

• Once the setting is made, the operation mode ismemorized in the microcomputer so that thesame operation can be effected thereafter simplyby pushing [START/STOP] button.

• When the FAN button is set to the AUTO position,the indoor fan motor operates as shown in Fig. 8-2-1. When the FAN SPEED button is set toLOW, MED, or HIGH, the motor operates with aconstant air flow.

• ECONO. mode cannot be set.

8-2-2. Cooling Operation(The Remote Control MODE Button isSet to the COOL Position)


• A cooling operation signal is transmitted tooutdoor unit.

• The indoor fan motor operates as shown in Fig.8-2-2 when FAN button is set to AUTO.

• The motor operates with a constant air flow whenthe FAN button is set to LOW, MED, or HIGH.

• The outdoor unit controls the outdoor fan relayR01, R02 and R03, and the compressor motorspeed according to the operation commandsignal sent from the indoor unit.

Settemp.

+3M+

*1

*1

*1

L–

+2,5

+2

+1,5

+1

+0,5

0

–0,5

˚C

(Roo

m te

mp.

) –

(Set

tem

p.)

In normaloperation

NOTE :

*1: Calculated from difference in motor speed of M+and L–, and controlled.

Fig. 8-2-2 Setting of air flow [FAN AUTO]

– 28 –

(1) Cooling capacity control

• The cooling capacity and room temperatureare controlled by changing the compressormotor speed according to both the differencebetween the temperature detected by theroom temperature sensor and the temperatureset by TEMP button and also any change inroom temperature.

• When compressor has been activated orreactivated, it operates with Max. 33 rps for 2minute, with Max. 57 rps from 2 to 4 minutes,with Max. 91 rps from 4 to 7 minutes, and withMax. 92 rps after 7 minutes passed.

• When room temperature is lower than settemperature, indoor fan motor is operated atfan speed L– as shown in Fig. 8-2-2 while theoutdoor unit stops.

(2) Prevent-freezing control

If temperature of indoor heat exchanger de-tected by the indoor heat exchanger sensor is5°C or lower, compressor motor speed isgradually lowered to prevent freezing of theindoor heat exchanger. If temperature is 7°C orhigher, return the operation to the above item (1).

(3) Current release control

The input current of compressor and outdoor fanmotor (Precisely inverter main circuit controlsection) which occupy most of air conditionerinput is detected by the outdoor current sensor,and compressor motor speed is graduallylowered so that current value does not exceed1A if current value exceeds 1A. When thecurrent value lowers to 2A, return the operationto the above item (1).

Normal control

Cur

rent

val

ue (

A) Comp. motor

speed down

Comp. motor speed keep

I1

I2

Fig. 8-2-3

Table 8-2-1

Current value Current limit

1 9.5

2 9,0

(4) Outdoor temperature release control

The outdoor temperature release is controlled bychanging the current release points 1 and 2 inthe above item according to temperature de-tected by the outdoor temperature sensor.

For example, if the outdoor temperature is over40°C, the value of current release point be-comes 7,7A.

(5) Limit for maximum compressor motor speedby indoor fan speed

When outdoor temperature sensor detected32°C or lower, and indoor heat exchangersensor detected 17°C or lower, the maximumcompressor motor speed is limited by the indoorfan speed.

For example, when 1 unit only operates, thecompressor motor speed is limited as describedin the table below.

Table 8-2-2

Air flow M10UKCV-E M13UKCV-E M16UKCV-Erate (rps) (rps) (rps)

HIGH 45 72 77

M+ 42 59 66

MED. 34 40 54

L–, L 31 31 43

UL, SUL 31 31 31

(6) Louver control

The vertical air flow louvers are automatically setto horizontal or cool memory position.

When temperature of indoor heat exchangerbecomes 5°C or lower by the prevent-freezingcontrol and the compressor is turned off, thevertical air flow louvers close once and thenreturn to the position of previous time.

(7) Discharge temperature control

The discharge temperature of refrigerant gasfrom 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

When TD detect value is 101°C or lower, theoperation is performed with operating motorspeed instructed by the serial signal.

2) Control 2 (B zone) : Slow-up zone of motorspeed

When TD detect value is 101°C or higher,operating motor speed is slowly up.

– 29 –

3) Control 3 (C zone) : Keep zone

When TD detect value is 108°C or higher,operating motor speed is not changed ifraising operation speed.

4) Control 4 (D zone) : Slow down zone of motorspeed

When TD detect value is 111°C or higher,operating motor speed is slowly down.

5) Control 5 (E zone) : Normal down of motorspeed

When TD detect value is 115°C or higher,operating motor speed is down.

6) Control 6 (F zone) : Operation stop zone

If TD detect value exceeds 120°C duringoperation, stop the operation immediately.

Then, restart the operation when TD detectvalue becomes 108°C or lower.

Fig. 8-2-4 Compressor motor speed control

(8) ECONO. operation control

When the ECONO. button of the remote controlis pushed, quiet and mild operation is performedby restraining air flow and operating motorspeed.

1) Indoor air flow is controlled between SULand L– (Low air (–)).

2) Setting M10UKCV-E at 16 rps, M13UKCV-Eat 20 rps and M16UKCV-E at 26 rps as themaximum operating compressor motorspeed, the minimum capacity operation rangeis widened every 1 hour and 2 hours havepassed after ECONO. operation had started.

3) Maximum operating compressor motor speedlowers up to 37 rps when the ECONO.instruction is sent from even a room.

Fig. 8-2-5

Zone

Operation stop zone

Normal down zone of motor speed

Slow down of motor speed

Keep zone : Motor speed is not changed.

Slow-up zone of motor speed

Normal operation zone

F120

TD(˚C)

115

111

108

101

E

D

C

B

A

Release of motor speed

0,5

1

1,5

2

2,5

3

3,5

(Roo

m te

mp.

) –

(Set

tem

p.)

Air volumeCompressor motor speed

16 rps 16 rps 19 rps 23 rps16 rpsSUL

20 rps16 rpsL–

16 to 20 rps

26 rps

16 to 26 rps

37 rps

19 to 37 rps

37 rps

23 to 37 rps16 rps(L– + SUL)/2

M13UKCV-E M16UKCV-EM10UKCV-E

1 unit2 units 3 units

Time2H1H

– 30 –

32

22

Outdoortemp.(˚C)

Powerful Cool mode

Cool mode

Fan Only mode

–0,5

0

+0,5

+1,0

+1,5

+2,0

+2,5

*1

L–

SUL

(Roo

m te

mp.

) –

(Set

tem

p.)

Settemp.

8-2-3. DRY Operation(The Remote Control MODE Button isSet to the DRY Position)


• Dry operation signal is transmitted to outdoorunit.

• The Cooling operation giving priority to dehumidi-fying, which restrains the indoor fan speed andcompressor motor speed, is performed.

• The indoor fan motor operates as shown in Fig.8-2-6. (Fan speed is AUTO only.)

• The outdoor unit controls the outdoor fan relayR01, R02 and R03, and the compressor motorspeed according to the operation commandsignal sent from the indoor unit.

NOTE :

*1 : Middle motor speed between L– and SUL

Fig. 8-2-6 Setting of air flow

(1) Dehumidifying-preferential Cooling capacitycontrol

• The cooling capacity and room temperatureare controlled by changing the compressormotor speed according to both the differencebetween the temperature detected by theroom temperature sensor and the temperatureset by TEMP button and also any change inroom temperature.

• The compressor operates with maximum 28rps for 1 minute when started and restarted.

• When the air conditioner operates in Drymode, the maximum compressor motor speedis restricted.

M10UKCV-E : Max. 22 rpsM13UKCV-E : Max. 28 rpsM16UKCV-E : Max. 32 rps

While multiple indoor units operate, compres-sor motor speed is calculated in the outdoorunit to operate.

• When room temperature is lower than settemperature, indoor fan motor is operated atfan speed SUL as shown in Fig. 8-2-6 whilethe outdoor unit stops.

• ECONO. mode cannot be set.

• Other controls than the above-mentionedcontrols are common to those of Coolingoperation.

8-2-4. Auto Operation

• The operation mode is selected according to theoutdoor temperature when Auto operation hasstarted, as shown in Fig. 8-2-7. The Fan onlymode will continue until the operation mode isselected. The air flow display on the remotecontrol becomes AUTO.

Fig. 8-2-7

• If the compressor is turned off by room tempera-ture or outdoor temperature for 15 minutesconsecutively after operation mode has beenselected, the operation mode is selected again.

• In Powerful Cool mode, the louver directs down-ward, and air flow increases. When room tem-perature comes close to the set temperature, thelouver returns to Cooling operation position.

• The other controls than the above-mentionedcontrols follow that of each operation.

– 31 –

8-3. Temporary Operation

• Temporary Auto operation, existence of AutoRestart, and Temporary Cooling operation can beset by the TEMPORARY button of the indoorcontroller.

8-3-1. Temporary Auto Operation

• When the TEMPORARY button is pushed, theAuto operation with set temperature fixed at 24°Cstarts. Controlling is same as that of Auto opera-tion by the remote control.

• When the TEMPORARY button is pushed again,the operation stops.

• During Temporary Auto operation, operation bythe remote control is accepted.

• Using the Auto Restart function, the TemporaryAuto operation starts when power failure is reset.

8-3-2. Temporary Cooling Operation

• When the TEMPORARY operation button keepspushed for 10 seconds, Cooling operation ofwhich compressor motor speed and the indoorfan speed are fixed starts.

Compressor motor speed : 28 rps

Indoor fan speed : Low

• When the TEMPORARY operation button ispushed again, the operation stops.

• Auto Restart function is unavailable.

TEMPORARY button Control

OFF →→→→→ ON Temporary Auto operation start

After pushing button Auto Restart control selectfor 3 seconds

After pushing button Temporary Coolingfor 10 seconds operation start

TEMPORARY button

0

3S

Fig. 8-3-1

Table 8-3-1

– 32 –

8-4. Auto Restart Function

This unit is equipped with an Automatic restartingfacility which allows the unit to restart and resumethe set operating conditions in the event of a powersupply shutdown without the use of the hand control.

The operation will resume without warning threeminutes after the power is restored.

The Auto Restart function is set not to work onshipment from the factory, and so it is necessary toset it to function as required.

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

To set the Auto Restart function, proceed as follows:

Access the TEMPORARY button located in the lowerright hand corner beneath the hinged front panel ofthe indoor unit (please refer to Fig. 8-3-1). Thepower supply to the unit must be on - the functionwill not be set if the power is off.

To enable the Auto Restart function, push theTEMPORARY button continuously for threeseconds.

The unit will acknowledge the setting and beep threetimes. The system will now restart automatically.

The above Auto Restart settings can be carried out:

• When the system is stand-by (not operating)

• When the system is operating

Operation

Push the TEMPORARY buttoncontinuously more than threeseconds.

Motion

Stand-by

↓The system starts to operate. The green light goes on.

↓ about three seconds after

The unit beeps three times. The orange light goes on.

↓The system is operating.

If the system is not required to run at this time, push the TEMPORARYbutton once more or use the remote control and the unit will stop.

Operation


Motion

Operating The green light goes on.

↓The system stops to operate. The green light goes off.


The unit beeps three times.

↓The system stops.

If the system is not required to stop at this time, use the remote controland to restart.

During subsequent operation, the orange light goes on.

• The Auto Restart function will not accept aninstruction if timer operation with the remotecontrol is selected.

• During louver swing (AUTO) operation, afterrestart by the Auto Restart function the louverswing stops.

TEMPORARY button

0

3S

TEMPORARY button

0

3S

– 33 –

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

To cancel the Auto Restart function, proceed asfollows:

Repeat the setting procedure: the unit willacknowledge the instruction and beep three times.

The system will now be required to manually restartwith the remote control after the main supply isturned off.

Cancellation is carried out:

• When the system is stand-by (not operating)

Operation


Motion

Stand-by

↓The system starts to operate. The orange light goes on.


The unit beeps three times. The green light goes on.

↓The system is operating.

If the system is not required to run at this time, push the TEMPORARYbutton once more or use the remote control and the unit will stop.

• When the system is operating

Operation


Motion

Operating The orange light goes on.

↓The system stops to operate. The orange light goes off.


The unit beeps three times.

↓The system stops.

If the system is not required to stop at this time, use the remote controland to restart.

During subsequent operation, the green light goes on.

(2) If OFF-TIMER operation is reserved withoutsetting of Auto Restart operation, the reservationis cancelled with power failure.(The OPERATION lamp on the main unit goeson and off to inform of power failure.) In thatcase, try to reserve OFF-TIMER operation.When Auto Restart operation is set, OFF-TIMERreservation is also cancelled with power failure.

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

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

TEMPORARY button

0

3S

TEMPORARY button

0

3S

– 34 –

11111 Infrared signal emitterTransmits a signal to the indoor unit.

22222 START/STOP buttonPress the button to start operation.(A receiving beep is heard.)Press the button again to stop operation.(A receiving beep is heard.)If no receiving sound is heard from the indoor unit,press the button twice.

33333 Mode select button (MODE)Press this button to select a mode.Each time you press the button, a mode isselected in a sequence that goes from A : Autochangeover control, : Cool, : Dry,

: Heat, : Fan only, and back to A.(A receiving beep is heard.)

44444 Temperature button ( ),.......The set temperature is increased up to 30°C.9.......The set temperature is dropped down to 17°C.

(A receiving beep is heard.)55555 Fan speed button (FAN)

Press this button to select fan speed. When youselect AUTO, the fan speed is automaticallyadjusted according to the room temperature.You can also manually select the desired fanspeed from among five settings.(LOW , LOW+ , MED ,MED+ , HIGH )(A receiving beep is heard.)

66666 Auto louver button (SWING)Press this button to swing the louver.(A receiving beep is heard.)Press the FIX button to stop the louver swinging.(A receiving beep is heard.)

77777 Set louver button (FIX)Press this button to adjust the air flow direction.(A receiving beep is heard.)

88888 Off timer button (OFF)Press this button to set the OFF timer.

99999 On timer button (ON)Press this button to set the ON timer.

!!!!! Reserve button (SET)Press this button to reserve time settings.(A receiving beep is heard.)

""""" Cancel button (CLR)Press this button to cancel ON timer and OFFtimer. (A receiving beep is heard.)

##### High power button (Hi POWER)Press this button to start the high poweroperation.

$$$$$ Memory button (MEMO)Press this button to stand by memorizing thesettings.Press the button again for more than 4 secondsto memorize the setting indicated on the remotecontrol and mark is indicated.

%%%%% Automatic operation button (AUTO)Press this button to operate the air conditionerautomatically.(A receiving beep is heard.)

&&&&& ECO timer button (ECO)Press this button to start the ECO timer (OFFtimer) operation.You can select the OFF timer time from amongfour settings (1,3,5 or 9 hours).

((((( FILTER buttonPress this button to turn off the filter cleaninglamp on the indoor unit.Press this button after cleaning the air filter.

))))) PRESET buttonPress this button to operate the air conditioneraccording to settings memorized by the MEMObutton.

~~~~~ TIMER buttonUse this button to change the clock, ON timer,and OFF timer times.To forward the time, press the “TIMER ” button.To set back the time, press the “TIMER ” button.

PRESET

FAN MODE

Hi-POWER

ON OFF SET CLR

ECO

AUTO

TIMER

CLOCK CHECKRESETFILTER

1

444

FIX

SWING

MEMO

START/STOP

13

1144

11

3

115512

101188

1713

14

11

3

1512

1018

172

5

6

77988

1166

2

5

6

798

16

AB

AUTOA

RAS-M10UKCV, RAS-M13UKCV, RAS-M16UKCV

8-5. Remote control8-5-1. Remote control and its functions

– 35 –

8-5-2. Names and functions of indications on remote control

DisplayAll indications, except for clock time indication, are indicated by pressing the START/STOP button.

11111 Transmission markThis transmission mark (,) indicates when the remote control transmits signals to the indoor unit.

22222 Mode displayIndicates the current operation mode.(AUTO : Automatic control, A : Auto changeover control, : Cool,

: Dry, : Heat, : Fan only)33333 Temperature display

Indicates the temperature setting (17°C to 30°C).When you set the operating mode to : Fan only, no temperaturesetting is indicated.

44444 Louver operation displayIndicates the louver positioning and operation.Five selectable positions , , , , Automatic Swing

55555 FAN speed displayIndicates the selected fan speed. AUTO or one of five fan speed levels

(LOW , LOW+ , MED , MED+ , HIGH )can be indicated.Indicates AUTO when the operating mode is either AUTO or : Dry.

66666 TIMER and clock time displayThe time set for timer operation or clock time is indicated.The present time is always indicated except for TIMER operation.

77777 Hi POWER displayIndicates when the Hi POWER operation starts.Press the Hi POWER button to start and press it again to stopthe operation.

88888 (MEMORY) displayFlashes for 4 seconds when the MEMO button is pressed duringoperation.

mark is indicated when keeping the button depressed for morethan 4 seconds while the mark is flashing.Press another button to turn off the mark.

99999 ECO TIMER displayIndicates when the ECO TIMER is in operation.Each time you press the ECO button, the display changes in the sequence of 1,3,5 or 9h.

• In the illustration, all indicationsare indicated for explanation.During operation, only therelevant indications will beindicated on the remote control.

13 2 8

9 67 5

AB

AUTOA

4

AB

A

– 36 –

9. INSTALLATION PROCEDURE

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

CAUTION

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

New Refrigerant Air Conditioner Installation

9-1. Safety Cautions

DANGER• FOR USE BY QUALIFIED PERSONS ONLY.• TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF.

FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.• CONNECT THE CONNECTING CABLE CORRECTLY. IF THE CONNECTING CABLE IS CONNECTED BY WRONG WAY, ELECTRIC PARTS

MAY BE DAMAGED.• CHECK THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE INSTALLATION.• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS.

FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.• TO PREVENT OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M)

FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC.• WHEN MOVING THE AIR-CONDITIONER FOR INSTALLING IT IN ANOTHER PLACE AGAIN, BE VERY CAREFUL NOT TO GET THE

SPECIFIED REFRIGERANT WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CYCLE. IF AIR OR ANY OTHER GAS ISMIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CYCLE BECOMES ABNORMALLY HIGH AND ITRESULTINGLY 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 LETFRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSES GENERATION OFPOISONOUS GAS.

WARNING• Never modify this unit by removing any of the safety guards or by by-passing any of the safety interlock switches.• Do not install in a place which cannot bear the weight of the unit.

Personal injury and property damage can result if the unit falls.• Before doing the electrical work, attach an approved plug to the power supply cord.

And, make sure the equipment to be earthed.• Appliance shall be installed in accordance with national wiring regulations.

If you detect any damage, do not install the unit. Contact your Toshiba dealer immediately.

CAUTION• Exposure of unit to water or other moisture before installation will result in an electrical short.

Do not store in a wet basement or expose to rain or water.• After unpacking the unit, examine it carefully for possible damage.• Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise level of the unit or where

noise and discharged air might disturb neighbors.• To avoid personal injury, be careful when handling parts with sharp edges.• Please read this installation manual carefully before installing the unit. It contains further important instructions for proper installation.

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

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY.

9-1-1. Installation/Servicing Tools

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

has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)

New tools for R-410A

Changes in the product and components

New tools for R-410A Applicable to R-22 model Changes

Gauge manifold

Charge hose

Electronic balance forrefrigerant charging

Torque wrench(nominal diam. 1/2, 5/8)

Flare tool(clutch type)

Gauge for projection adjustment

Vacuum pump adapter

Gas leakage detector

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 diameterhas been changed.

In order to increase pressure resisting strength, hose materials and port sizehave been changed (to 1/2 UNF 20 threads per inch).When purchasing a charge hose, be sure to confirm the port size.

As pressure is high and gasification speed is fast, it is difficult to read theindicated value by means of charging cylinder, as air bubbles occur.

The size of opposite sides of flare nuts have been increased. Incidentally,a common wrench is used for nominal diameters 1/4 and 3/8.

By increasing the clamp bar's receiving hole, strength of spring in the tool hasbeen improved.

Used when flare is made by using conventional flare tool.

Connected to conventional vacuum pump. It is necessary to use an adapter toprevent vacuum pump oil from flowing back to the charge hose.The charge hose connecting part has two ports-one for conventional refrigerant(7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil(mineral) mixes with R-410A a sludge may occur and damage the equipment.

Exclusive for HFC refrigerant.

• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R-410A) and protector coating in the U.S's ARI specified rose color(ARI color code: PMS 507).

• Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to the charge hose's port size.

– 37 –

– 38 –

Shield pipe

Air filter

Hook

Hook

(Attach to the front panel)

2 Wireless remotecontrol

65 m

m o

r m

ore

170 mmor more

170 mmor more 1 Installationplate

6 Purifying filter

5 Zeolite filter

4 Remote control holder

For the rear left and left piping

Wall

Insert the cushion betweenthe indoor unit and wall,and tilt the indoor unit for betteroperation.

RAS-M10UKCV-E

Before installing the wirelessremote control

• With the remote control coveropen, load the batteries suppliedcorrectly, observing theirpolarity.

2 Wireless remote control

3 Batteries

Cover

The auxiliary piping can beconnected the left, rear left,rear right, right, bottom right orbottom left.

Left

Rear left

Right

Rear right

Bottom right

Bottom left

Do not allow the drain hose toget slack.

Cut the piping holesloped slightly

Make sure to run the drain hosesloped downward.

8 Flat head wood screw

RAS-M13UKCV-E

9-2. Indoor unit

RAS-M16UKCV-E

Insulate the refrigerantpipes separately with insulation,not together.

6 mm thick heat resistingpolyethylene foam

Part name (Q'ty)

Mounting screw ∅4 x 25 s x 6

Flat head wood screw ∅3.1 x 16 s x 2

B Label x 1

PartNo.

1

2

3

Part name (Q'ty)

Installation plate x 1

Wireless remote control x 1

Battery x 2

Part name (Q'ty)

Remote control holder x 1

Zeolite filter x 1

Purifying filter x 1

This model is not equipped with an extension drain hose.

Option :For the extension drain hose, use an optionally availableRB-821SW or commercially available one.

Name

Owner's manual

Installation manual

Others

PartNo.

4

5

6

PartNo.

7

8

9

9-2-1. Accessory and Installation Parts

B

– 39 –

9-2-2. Installation Place

• A place which provides the spaces around the indoor unit as shown inthe above diagram.

• A place where there is no obstacle near the air inlet and outlet.• A place which allows easy installation of the piping to the outdoor unit.• A place which allows the front panel to be opened.• The indoor unit shall be installed as top of the indoor unit comes to at

least 2m height.Also it must be avoided to put anything on the top of the indoor unit.

62

85

82.5

170

∅65 mm

100 mm

5 m

5 m

45° 45°

75°

* 7

m

7 m

When install the refrigerant pipes from the rear.

Cutting a Hole

The center of the pipehole is above the arrow.

Pipehole

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

1. After determining the pipe hole position on the mounting plate (A)drill the pipe hole (∅65 mm) at a slight downward slant to the outdoorside.

NOTE

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

7 Mounting screw

Pipe holePipe hole

Indoor unit

Thread

Weight

Hook

Hook

Mounting the Installation Plate

For installation of the indoor unit, use the paper pattern on the back.

1Installationplate

Remote controller

• A place where there are no obstacles such as a curtain that may blockthe signal from the indoor unit.

• Do not install the remote control in a place exposed to direct sunlightor close to a heating source, such as a stove.

• Keep the remote control at least 1 m apart from the nearest TV set orstereo equipment. (This is necessary to prevent image disturbances ornoise interference.)

• The location of the remote control should be determined as shownbelow.

CAUTION• Direct sunlight to the indoor unit wireless receiver should be

avoided.• The microprocessor in the indoor unit should not be too close to

r-f noise sources.(For details, see the owner's manual.)

(Top view)

Indoor unit

* : Axial distance

Receptionrange

Reception rangeRemotecontrol

Ind

oo

r u

nit

Remote control

(Side view)

Hook

Anchor bolt holes

2 m

or

mo

re f

rom

flo

or

Fig. 9-2-1

Fig. 9-2-2

When the installation plate is directly mounted on the wall

1. Securely fit the installation plate onto the wall by screwing it in theupper and lower parts to hook up the indoor unit.

2. To mount the installation plate on a concrete wall with anchor bolts,utilize the anchor bolt holes as illustrated in the above figure.

3. Install the installation plate horizontally in the wall.

CAUTIONWhen installing the installation plate with a mounting screw, do notuse the anchor bolt hole. Otherwise the unit may fall down and resultin personal injury and property damage.

CAUTIONFailure to firmly install the unit may result in personal injury andproperty damage if the unit falls.

• In case of block, brick, concrete or similar type walls, make 5 mm dia.holes in the wall.

• Insert clip anchors for appropriate 7 mounting screws.

NOTE

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

Projection15 mm or less

7 Mountingscrew∅4 x 25 s

Clip anchor(local parts)

5 mm dia. hole

Anchor bolt

Fig. 9-2-3

Fig. 9-2-4

9-2-4. Electrical Work

1. The supply voltage must be the same as the rated voltage of the airconditioner.

2. Prepare the power source for exclusive use with the air conditioner.

NOTE

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

– 40 –

Piping and Drain Hose Forming

* Since dewing results in a machine trouble, make sure to insulate boththe connecting pipes. (Use polyethylene foam as insulating material.)

Rear right

Rear left

Die

-cut

ting

Fron

t pan

el s

lit Cha

ngin

gdr

ain

hose

Pip

ing

prep

arat

ion

Bottom left

Left

Bottom right

Right

Heat insulator

Drain hose

Do not apply lubricating oil (refrigerantmachine oil) when inserting the drain cap.Application causes deterioration anddrain leakage of the plug.

Insert a hexagon wrench (4 mm)

No gap

CAUTION

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

CAUTION• This appliance can be connected to the mains in either of the

following two ways.(1) Connection to fixed wiring :

A switch or circuit breake which disconnects all poles andhas a contact separation of at least 3 mm must be incorpo-rate in the fixed wiring. An approved circuit breaker orswitches must used.

(2) Connection with power supply plug :Attach power supply plug with power cord and plug it intowall outlet. An approved power supply cord and plug mustbe used.

NOTE

• Perform wiring works so as to allow a generous wiring capacity.

CAUTION• Be sure to refer to the wiring system diagram labeled inside the

front panel.• Check local electrical cords and also any specific wiring instruc-

tions or limitations.

How to connect the connecting cable

Wiring of the connecting cable can be carried out withoutremoving the front panel.

1. Remove the air inlet grille.Open the air inlet grille upward and pull it toward you.

2. Remove the terminal cover and cord clamp.3. Insert the connecting cable (according to the local cords) into the pipe

hole on the wall.4. Take out the connecting cable through the cable slot on the rear panel

so that it protrudes about 15 cm from the front.5. Insert the connecting cable fully into the terminal block and secure it

tightly with screws.6. Tightening torque :1.2 N·m (0.12 kgf·m)7. Secure the connecting cable with the cord clamp.8. Fix the terminal cover, rear plate bushing and air inlet grille on the

indoor unit.

Terminal coverCord clamp Teminal block

Earth wire

Connecting cable

Screw

Screw

Screw

Connecting cable

Earth line

4 mm

9-2-5. Wiring Connection

NOTE

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

10mm10mm

10mm

80 mm

50 mm

3

2

1

9-2-6 Piping and Drain Hose Installation

Fig. 9-2-5

1. Die-cutting Front panel slitCut out the slit on the left or right side of the front panel for the left orright connection and the slit on the bottom left or right side of the frontpanel for the bottom left or right connection with a pair of nippers.

2. Changing drain hoseFor left connection, left-bottom connection and rear-left connection’spiping, it is necessary to change the drain hose and drain cap.

How to remove the Drain CapClip drain cap by needle-nose plier, and pull out.

Fig. 9-2-6

How to install the Drain HoseFirmly insert drain hose connecting part until hitting on a heat insulator.

Fig. 9-2-7

How to fix the Drains Cap1)Insert hexagonal wrench (4 mm) in a center head.

Fig. 9-2-8

2)Firmly insert drains cap.

Fig. 9-2-9

about 15 cm

– 41 –

9-2-6 Indoor Unit Fixing

1. Pass the pipe through the hole in the wall, and hook the indoor unit onthe installation plate at the upper hooks.

2. Swing the indoor unit to right and left to confirm that it is firmly hookedup on the installation plate.

3. While pressing the indoor unit onto the wall, hook it at the lower parton the installation plate. Pull the indoor unit toward you to confirm thatit is firmly hooked up on the installation plate.

Fig. 9-2-14

• For detaching the indoor unit from the installation plate pull the indoorunit toward you while pushing its bottom up at the specified parts.

Fig. 9-2-15

80°

270 mm

170 mm

43 m

m

50 mmor more

Do not put thedrain hose endinto water.

Do not put thedrain hose endin the drainageditch.

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

Extension drain hoseInside the roomDrain hose

Shield pipe

Hook

1 Installation plate

Hook here

Press(unhook)

Push

Wall

Drainguide

Space for pipes

This air conditioner has the structuredesigned to drain water collected fromdew, which forms on the back of theindoor unit, to the drain pan.Therefore, do not store the power cordand other parts at a height above thedrain guide.

Push

CAUTION

• Bind the auxiliary pipes (two) and connecting cable with facing tapetightly. In case of leftward piping and rear-leftward piping, bind theauxiliary pipes (two) only with facing tape.

Fig. 9-2-13

• Carefully arrange pipes so that any pipe does not stick out of therear plate of the indoor unit.

• Carefully connect the auxiliary pipes and connecting pipes to eachother and cut off the insulating tape wound on the connecting pipeto avoid double-taping at the joint, moreover, seal the joint with thevinyl tape, etc.

• Since dewing results in a machine trouble, make sure to insulateboth the connecting pipes. (Use polyethylene foam as insulatingmaterial.)

• When bending a pipe, carefully do it not to crush it.

NOTE

If the pipe is bent incorrectly, the indoor unit may unstably be set on thewall.After passing the connecting pipe through the pipe hole, connect theconnecting pipe to the auxiliary pipes and wrap the facing tape aroundthem.

Installation plate

Auxiliary pipes

Indoor unit

Connecting cable

(To the forefront of flare)

Liquid side

Outward form of indoor unit

Use the handle of screwdriver, etc.

1

2Slit

In case of right or left piping

• After scribing slits of the front panelwith a knife or a making-off pin, cutthem with a pair of nippers or anequivalent tool.

In case of bottom right or bottom left piping

• After scribing slits of the front panelwith a knife or a making-off pin, cutthem with a pair of nippers or anequivalent tool.

Left-hand connection with piping

Bend the connecting pipe so that it is laid within 43 mm above the wallsurface. If the connecting pipe is laid exceeding 43 mm above the wallsurface, the indoor unit may unstably be set on the wall. When bendingthe connecting pipe, make sure to use a spring bender so as not tocrush the pipe.

Bend the connection pipe within a radius of 30 mm (Ø6.35) 40 mm(Ø9.52).

To connect the pipe after installation of the unit (figure)

Slit

Gas side

R30 or less (Ø6.35) R40 or less (Ø9.52) (Use polisin(polyethylene core or the like for bending pipe.)

Fig. 9-2-12

Fig. 9-2-10

Fig. 9-2-11

9-2-7 Drainage

1. Run the drain hose sloped downwards.

NOTE

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

Fig. 9-2-16

2. Put water in the drain pan and make sure that the water is drained outof doors.

3. When connecting extension drain hose, insulate the connecting partof extension drain hose with shield pipe.

Fig. 9-2-17

CAUTIONArrange the drain pipe for proper drainage from the unit.Improper drainage can result in dew-dropping.

Fig. 9-2-18

9-2-8. Setting of Remote Controller SelectorSwitch

When two indoor units are installed in theseparated rooms, there is no need to changethe select switches.

Remote Controller Selector Switch

• When two indoor units are installed in thesame room or adjacent two rooms, if operatinga unit, two units may receive the remotecontroller signal simultaneously and operate. Inthis case, the operation can be preserved bysetting either one indoor unit and remotecontroller to B setting(Both are set to A setting in factory shipment).

• The remote control signal is not receivedwhen the settings of indoor unit and remotecontroller are different.

• There is no relation between A setting/Bsetting and A room/B room when connectingthe piping and cables.

1. Setting of remote controller switch at theindoor unit side

Fig. 9-2-19

How to remove the front cabinet

(1) Stop the operation of the air conditioner and turnturn off its main power supply.

(2) Pull the air inlet grille toward you to open it and

remove the air inlet grille.(3) First open the horizontal louver and then remove

the front panel from the back body by pulling it

toward you.

Position of Remote Control Selector Switch

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

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

How to mount the front panelPush the front panel back in and make sure all hookare locked.

Fig. 9-2-20

Fig. 9-2-21

– 42 –

– 43 –

2. Setting of remote controller selector at theremote controller side

[B] of the remote controller is displayed withliquid crystal only when it is set to [B].

There is no display of [A].

• Enter the batter.

• Push the [CHK] button by something with thinedge. ([00] is displayed.)

• If [MODE] button is pushed while pushing [CHK]button, the small [B] is displayed at the right of thesetting temperature indication section.

* To reset [A] setting, push the [MODE] buttonagain while pusing the [CHK] button.

3. Confirm the indoor unit can operate withthe changed setting of the remote control-ler.

9-2-9. Check and Test Operation

1. Check the unit is firmly hooked up on theinstallation plate.

2. Check the connecting pipes tightenedsecurely.

Confirm that there is no gas leakage.

3. Confirm that all connecting cables aresecured and correct.

4. Check the pipes insulation.

5. Check the drainage.

6. Connection of the grounding wire.

7. To switch the TEST RUN (COOL) mode, turnthe switch on.

To switch the TEST RUN (COOL) mode,press TEMPORARY button for 10 sec.(The beeper will make a short beep.)

* The above remote controller is one for coolingonly model.

[CHK] button

Fig. 9-2-23

8. Operate the unit at cooling operation modefor fifteen minutes or more.

Measure the temperature of the intake anddischarge air. Ensure the difference betweenthe intake temperature and the discharge oneis more, than 8°C.

NOTE: Three-minutes protection feature

A protection feature prevents the airconditioner from being activated for about 3minutes when it is restarted immediatelyafter operation or when the power switch isturned on.

9. Check the remote controller operation.

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

10. Explain to the customer on the correct usageof air conditioner simple layman’s terms.

ON OFF SET CLR

AUTO

TIMER


B

PRESET

START/STOP

B

MODEFAN

SWING ECO Hi-POWER

FIX MEMO

MODE button

TEMPORARY button

INFORMATION

TEMPORARY button

Fig. 9-2-22

– 44 –

Outdoor unit installation manual x 1

Specifications x 1

Owner's manual x 1

SPECIFICATIONS

1

2

3

9-3-2. Refrigerant Piping

• Piping kit used for the conventional refrigerantcannot be used.

• Use copper pipe with 0.8 mm or more thick-ness.

• Flare nut and flare works are also different fromthose of the conventional refrigerant. Take out theflare nut attached to the main unit of the air condi-tioner, and use it.

9-3-3. Installation Place

• A place which provides the spaces around theoutdoor unit.

• A place where the operation noise and dischargedair do not disturb your neighbors.

• A place which is not exposed to a strong wind.

• A place which does not block a passage.

• When the outdoor unit is to be installed in anelevated position, be sure to secure its feet.

• There must be sufficient spaces for carrying theunit into and out of the site.

• A place where the drain water does not raise anyproblem.

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

CAUTION1. Install the outdoor unit without anything

blocking the air discharging.

2. When the outdoor unit is installed in a placeexposed always to a strong wind like a coastor on a high story of a building, secure thenormal fan operation using a duct or a windshield.

3. Specially in windy area, install the unit toprevent the admission of wind.

A

B

C

Parts name

Refrigerant pipingLiquid side : Ø6.35 mmGas side : Ø9.52 mm or Ø12.7 mm

Pipe insulating material(polyethylene foam, 6 mm thick)

Putty, PVC tapes

Q’ty

Each one

1

Each one

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

Parts name

RB-M43RE Reducer (Ø12.7 → Ø9.52)

RB-M34EE Expander (Ø9.52 → Ø12.7)

Strong wind

Fig. 9-3-1

4. Installation in the following places may resultin trouble. Do not install the unit in suchplaces.

• A place full of machine oil.

• A place full of sulfide gas.

• A place where high-frequency waves arelikely to be generated as from audioequipment, welders, and medical equip-ment.

9-3. Outdoor Unit

9-3-1. Accessory and Installation Parts

– 45 –

9-3-6. Refrigerant Piping Connection

CAUTIONKEEP IMPORTANT 4 POINTS FOR PIPINGWORK

1. Take away dust and moisture.(Inside of the connecting pipes)

2. Tight connection (between pipes and unit)

3. Evacuate the air in the connecting pipes usingVACUUM PUMP.

4. Check gas leak. (connected points)

Flaring

1. Cut the pipe with a pipe cutter.

Fig. 9-3-2

2. Insert a flare nut into the pipe, and flare the pipe.

As the flaring sizes of R410A differ from those ofrefrigerant R22, the flare tools newly manufac-tured for R410A are recommended.

However, the conventional tools can be used byadjusting projection margin of the copper pipe.

90˚ Obliquity Roughness Warp

B

Outer dia. ofcopper pipe

6.35

9.52

12.7

R410A tool used

R410A R22

0 to 0.5 (Same as left)



Conventional tool used

R410A R22

1.0 to 1.5 0.5 to 1.0

1.0 to 1.5 0.5 to 1.0

1.0 to 1.5 0.5 to 1.0

Imperial (Wing nut type)

Outer dia. of copper pipe

6.35

9.52

12.7

R410A R22

1.5 to 2.0 1.0 to 1.5

1.5 to 2.0 1.0 to 1.5

2.0 to 2.5 1.5 to 2.0

• Flaring size : A (Unit : mm)


6.35

9.52

12.7

A

R410A R22

9.1 9.0

13.2 13.0

16.6 16.2

+0-0.4

* In the case of flaring for R410A with the conven-tional flare tool, pull out it approx.0.5 mm more than that for R22 toadjust to the specified flare size.The copper pipe gauge is usefulfor adjusting projection margin size.

Fig. 9-3-4

A

9-3-7. Installation

NOTE : For installation, at least 3 dimensions shouldbe kept free from obstacles (walls).

Fig. 9-3-5

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

Fixing bolt arrangement of outdoor unit

• Secure the outdoor unit with the fixing boltsand nuts if the unit is likely to be exposed to astrong wind.

• Use Ø8 mm or Ø10 mm anchor bolts and nuts.

Fig. 9-3-3

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

250mm or

more from wall200mm or m

ore

600m

m o

r m

ore

50mm or more

from wall

100mm or

more from wall

600

115Suction side

Diffuser

310

76

Drain hole

Fig. 9-3-6

– 46 –

Outdoorunit

10 m

or l

ess

A

B

C

Half union Flare nut

Externallythreaded side

Internallythreaded side

Use a wrench to secure. Use a torque wrench to tighten.

Flare at indoorunit side

Flare at outdoorunit side

1. Piping connections to the outdoor unit should bearranged in the sequence A, B, C starting fromthe bottom.(For each piping connection, the gas pipe is onthe bottom and the liquid pipe is on the top.)

2. When multiple indoor units are to be connected tothe outdoor unit, make the ends of the pipes andwires from each indoor unit to ensure that theywill be connected to the outdoor unit correctly.(Problems caused by indoor units being con-nected to the outdoor unit incorrectly are verycommon in multiple-unit installations.)

3. The length and height difference of the connect-ing pipes between the indoor and outdoor unitsmust be within the ranges indicated below.• Total piping length :

4 units (A + B + C) Multi, Non. Additional refrigerant :40 m or less

• Minimum piping length :A or B or C = 2 m or more

• Maximum indoor piping length :A or B or C = 20 m or less

• Maximum piping height difference :A or B or C = 10 m or less

• Maximum piping/heightdifference between 2 rooms = 10 m or less

Fig. 9-3-7

4. If the outdoor units is to be mounted on a wall,make sure that the platform supporting it issufficiently strong. The platform should bedesigned and manufactured to maintain itsstrength over a long period of time, and sufficientconsideration should be given to ensuring that theoutdoor unit will not fall.

5. When the outdoor unit is to be mounted high on awall, take particular care to ensure that parts donot fall installer is protected.

6. When doing installation work on level ground, it isusual to wiring and piping connections to theindoor units. And/then make to the outdoor unit.However if outdoor work is difficult it is possibleinstead to make changes to the procedure.For example by making adjustments to the wiringand piping length on the inside (rather than theoutside).

How to remove the side panel1. Remove a screws

of the value.2. Pull the value cover

downward.

Tightening connectionAlign the centers of the connecting pipes and tightenthe flare nut as far as possible with your fingers.Then tighten the nut with a spanner and torquewrench as shown in the figure.

CAUTION• Do not apply excess torque. Otherwise, the

nut may crack depending on the conditions.

(Unit : N·m)


Ø6.35 mm

Ø9.52 mm

Ø12.7 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)

• Tightening torque of flare pipe connectionsPressure of R410A becomes higher than that of R22.(Approx. 1.6 times) Therefore, using a torquewrench, tighten firmly the flarepipe connecting sectionswhich connect the indoorand outdoor units up to thespecified tightening torque.Incorrect connections maycause not only a gasleakage, but also a troubleof the refrigeration cycle.

Fig. 9-3-9

Fig. 9-3-10

Fig. 9-3-11

Valvecover

Fig. 9-3-8

Outdoor unitIndoor unit

C C UNIT

ø6,35

ø9,52

A A UNIT

ø6,35

ø12,7

B B UNIT

ø6,35

ø9,52

Connectable capacity class

A B C Total

10, 13 16 163M23 (withreducer) (with expander) (with expander) 36

16 10, 13 10, 13

– 47 –

9-3-8. EvacuatingAfter the piping has been connected to all indoorunit(s), you can perform the air purge together atonce.

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

Use a vacuum pumpBe sure to use a vacuum pump with counter-flowprevention function so that inside oil of the pumpdoes not flow backward into pipes of the air condi-tioner when the pump stops.(If inside oil of the vacuum pump enters into the airconditioner which adopts R410A, a trouble of therefrigeration cycle may be caused.)1. Connect the charge hose from the manifold valve

to the service port of the gas side packed valve.2. Connect the charge hose to the port of vacuum

pump.3. Open fully the low pressure side handle of the

gauge manifold valve.4. Operate the vacuum pump to start for evacuating.

Perform evacuating for about 15 minutes if thepiping length is total 20 meters. (15 minutes fortotal 20 meters) (assuming a pump capacity of 27liters per minute.)Then confirm that the compound pressure gaugereading is –101 kPa ( –76 cmHg).

5. Close the low pressure side valve handle ofgauge manifold.

6. Open fully the valve stem of the packed valves(both sides of Gas and Liquid).

7. Remove the charging hose from the service port.8. Securely tighten the caps on the packed valves.

Fig. 9-3-12

Packed valve handling precautions

• Open the valve stem all the way out ; do not try toopen it beyond the stopper.

• Securely tighten the valve stem cap in torque is asfollows :

Gas side (Ø12.7 mm)

Gas side (Ø9.52 mm)

Liquid side (Ø6.35 mm)

Service port

50 to 62 N•m (5.0 to 6.2 kgf•m)

33 to 42 N•m (3.3 to 4.2 kgf•m)

14 to 18 N•m (1.4 to 1.8 kgf•m)

14 to 18 N•m (1.4 to 1.8 kgf•m)

Hexagonal wrench is required.

Fig. 9-3-13

9-3-9. Electrical Work

For the air conditioner that has no power cord,connect a power cord to it as mentioned below.

Power supply

Maximum running current

Installation fuse rating

Power cord

220 – 240 VSingle phase 50/60 Hz

11 A

15 A

How to wire

1. Connect the connecting cable to the terminal asidentified with their respective matched numberson the terminal block of indoor and outdoor unit.(1.0 mm2 AWG 18 or more)

2. When connecting the connecting cable to theoutdoor unit terminal, prevent water coming in theoutdoor unit.

3. Insulate the unused cords (conductors) strippedthe sheath of connecting cable with PVC tape.

Process them so that they do not touch anyelectrical or metal parts.

4. For inter-unit wiring, do not use a cut wire jointedto another on the way.

Use wires long enough to cover the entire length.

Compound pressure gauge Pressure gauge

Manifold valve

Handle Hi(Keep full closed)

Charge hose(For R410A only)

Vacuum pump adapter for counter-flow prevention(For R410A only)

Packed valve at liquid side

Packed valve at gas sideService port (Valve core (Setting pin))

Connectingpipe

Handle Lo

Charge hose(For R410A only)

-101kPa (-76cmHg)

Vacuum pump

B

A

2,0 mm2 (AWG-14) or more

– 48 –

9-3-10. Check and Test Operation

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

* The conventional leak detector for HCFC refriger-ant (R22, etc.) cannot be used because its sensi-tivity for HFC refrigerant lowers to approx. 1/40.

• Pressure of R410A becomes approx. 1.6 times ofthat of R22. If installation work is incompletelyfinished, a gas leakage may occur in the casessuch as pressurerise during operation. Therefore, be sure to testthe piping connections for leaking.

Fig. 9-3-15

Connectingcable

Power cord

Earth line Earth line

1010

L N

30

10

3040

10

40

1 2 3

Fig. 9-3-16

• Check the flare nut connections, valve stem capconnections and service port cap connections forgas leak with a leak detector or soap water.

CAUTION• Use a circuit breaker of a type that is not

tripped by shock waves.

• If incorrect/incomplete wiring is carried out, itwill cause an electrical fire or smoke.

• Prepare the power supply for exclusive usewith the air conditioner.

• This product can be connected to the mains.

Connection to fixed wiring :

A switch or circuit breaker which disconnectsall poles and has a contact separation of atleast 3 mm must be incorporate in the fixedwiring.

An approved short circuit breaker or switchesmust be used.

* (A breaker having a sensitivity of approxi-mately 0.1 second or less and a capacity ofapproximately 30 mA is usually used.)

Three room (A + B + C) Multi

Fig. 9-3-14

CAUTION• Wrong wiring connection may cause some

electrical parts burn out.

• Be sure to use the cord clamps specifiedpositions with attached to the product.

• Do not damage or scratch the conductive coreand inner insulator of power and inter-connect-ing cables when peeling them.

• Be sure to comply with local cords on runningthe wire from outdoor unit to indoor unit (size ofwire and wiring method etc.)

• Use the power cord and Inter-connecting cablewith specified thickness, specified type, andprotective devices specified.

Stripping length power cord and connecting cable

Terminal block(Connecting cable)

Connecting cable(A unit)

Connecting cable(C unit)

ScrewPower cord Connecting cable

(B unit)

• Flare nut connections(Outdoor unit)

• Valve stem cap connection• Service port cap connection

Flare nut connections(Indoor unit)

9-3-12. Miswiring (Mispiping) Check

Make sure that the wiring and piping for each roomhave the same alphabetical codes (A, B, C).

Connect and secure the power cord.

Use the power cord/cables with thickness, type andprotective devices specified in this manual.

Insulate the unused cords (conductors) with PVCtape.

1. Turn on the power breaker.

2. Open side panel of the outdoor unit.

3. Start the check.

• Run the indoor unit in A room, and confirm cool

air blow out.• Conform the indoor unit in B,C rooms do not run,

also check flowing sound of refrigerant is not heard.)

• Stop operation of the indoor unit in A room, andexecute the same checks on the indoor unit in B and C rooms.

– 49 –

9-3-11. Useful Functions

• For this outdoor unit, the self-diagnonsis is possible

by using five LEDs (Red).• Refer to the table in page 68 for more details.

* LEDs (Red) (D11 to D15) locate on the sub-controlborad underneath of the inverter.

1. If a trouble occurs, LED (Red) goes on according to

the contents of trouble as shown in the table in

page 68.

2. When two or more troubles occur, LEDs go on

3. Usually, LEDs (Red) go off.

Self-Diagnosis by LED Indication

cyclically (alternately).

Wiring port

D11 D12 D13 D14 D15

LED (Red)

Fig. 9-3-14

For Singapore only y

IMPORTANT INSTRUCTIONS

T o All Installers :

1) Please be reminded that all air conditionerinstalled at HDB flat are subjected to amp.restriction of either 8,5A or 11,0A.

2) It is the installer's responsibility to have thecurrent release control set correctly for thetype of HDB flat in which the IES unit is installed.

3) Figure below shows how the connector canbe arranged for the appropriate setting.

Wiring portCONNECTOR

(CN600)

Connector No.

Full operation11A(Delivery )

8,5A

CN600

Short

Open

– 50 –

10. HOW TO DIAGNOSE THE TROUBLE

The pulse modulating circuits are mounted to both indoor and outdoor units. Therefore, diagnose troublesaccording to the trouble diagnosis procedure as described below. (Refer to the check points in servicing writtenon the wiring diagrams attached to the indoor/outdoor units.)

Table 11-1

No.

1

2

3

4

5

6

7

8

9

Troubleshooting Procedure

First Confirmation

Primary Judgment

Judgment by Flashing LED of Indoor Unit

Self-Diagnosis by Remote Controller (Check Code)

Judgment of Trouble by Every Symptom

Trouble Diagnosis by Outdoor LED

How to Diagnose Trouble in Outdoor Unit

How to Check Simply the Main Parts

How to Simply Judge Whether Outdoor Fan Motor is Good or Bad

Page

51

51

52

53

56

62

63

64

70

NOTE :

A large-capacity electrolytic capacitor is used in theoutdoor unit controller (inverter). Therefore, if thepower supply is turned off, charge (charging voltageDC280V) remains and discharging takes a lot oftime. After turning off the power source, if touchingthe charging section before discharging, an electricalshock may be caused. Discharge the electrolyticcapacitor completely by using soldering iron, etc.

< Discharging method >(1) Remove the inverter cover (plating) by opening

four mounting claws.

(2) As shown below, connect the dischargeresistance (approx. 100Ω/40W) or plug of thesoldering iron to voltage between + – terminals ofthe C13 (“CAUTION HIGH VOLTAGE 320V” isindicated.) electrolytic capacitor (760µF/400V) onP.C. board, and then perform discharging.

Fig. 11-1

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Inverter cover

P. C. board (Soldered surface)

– 51 –

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

For controlling the air conditioner, the programoperations are built in the microcomputer as de-scribed in the following table. If a claim is made forrunning operation, check whether or not it meets tothe contents in the following table. When it does, weinform you that it is not trouble of equipment, but it isindispensable for controlling and maintaining of airconditioner.

10-2. Primary Judgment

To diagnose the troubles, use the following methods.

(1) Judgment by flashing LED of indoor unit

(2) Self-diagnosis by service check remote controller

(3) Judgment of trouble by every symptom

Firstly use the method (1) for diagnosis. Then, use the method (2) or (3) to diagnose the details of troubles.

For any trouble occurred at the outdoor unit side, detailed diagnosis is possible by 5-serial LED on the inverterP.C. board.

No.

1

2

3

4

5

Operation of air conditioner

When power breaker is turned “ON”, theoperation lamp (Green) of the indoor unitflashes.

Compressor may not operate even if theroom temperature is within range ofcompressor-ON.

In DRY and ECONO. mode, FAN (air flow)display does not change even though FAN(air flow select) button is operated.

Increasing of compressor motor speedstops approx. 30 seconds after operationstarted, and then compressor motor speedincreases again approx. 30 seconds after.

The set value of the remote control shouldbe below the room temperature.

Description

The OPERATION lamp of the indoor unit flashes whenpower source is turned on. If “START/STOP” button isoperated once, flashing stops. (Flashes also in powerfailure)

The compressor does not operate while compressorrestart delay timer (3-minutes timer) operates.The same phenomenon is found after power source hasbeen turned on because 3-minutes timer operates.

The air flow indication is fixed to [AUTO].

For smooth operation of the compressor, the compressormotor speed is restricted to Max. 33 rps for 2 minutes andMax. 57 rps for 2 minutes to 4 minutes, respectively afterthe operation has started.

If the set value is above the room temperature, Coolingoperation is not performed. And check whether battery ofthe remote control is consumed or not.

10-1. First Confirmation

10-1-1. Confirmation of Power Supply

Confirm that the power breaker operates (ON) nor-mally.

10-1-2. Confirmation of Power Voltage

Confirm that power voltage is AC 220–240V ± 10%.If power voltage is not in this range, the unit may notoperate normally.

Table 10-1-1

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, thecontents of self-diagnosis are displayed with block on the indoor unit indication section.

Table 10-3-1

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.

Lamps Self-diagnosis

A OPERATION lamp is blinking. (1Hz)

B OPERATION lamp is blinking. (5Hz)

C OPERATION lamp is blinking. (5Hz)

D OPERATION lamp is blinking. (5Hz)

E OPERATION lamp is blinking. (5Hz)

F OPERATION and TIMER lamps are blinking.(5Hz)

G OPERATION, TIMER and FAN ONLY lampsare blinking.

H OPERATION, TIMER and FAN ONLY lampsare blinking.

Power failure (when the power supply is turning on)

Thermo sensor (TA) short or break

Heat exchanger sensor (TC) short or break

Indoor fan motor lock or failure

Indoor P.C. board failure

Wrong wiring of connecting cable

• Gas shortage or other refrigerant cycle trouble• Heat exchanger sensor open, break or short• Overload relay or thermostat trouble of compressor

Cycle failure

(4) When connecting the changing kit, first-push priority control is executed. The secondary operation lampcontinues flashing. For details, refer to the section 10. Changing Kit.

– 52 –

– 53 –

PRESET

FAN MODE

Hi-POWER

ON OFF SET CLR

ECO

AUTO

TIMER


FIX

SWING

MEMO

START/STOP

AB

AUTOA

SET CLR

CLOCK CHECKRESET

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

(1) If the lamps are indicated as shown B to H in Table11-3-1, exchanger the self-diagnosis by theremote control.

(2) When the remote control is set to the servicemode, the indoor controller diagnoses the opera-tion condition and indicate the information of theself-diagnosis on the display of the remote controlwith the check codes. If a fault is detected, alllamps on the indoor unit will blink at 5Hz and it willbeep for 10 seconds (Pi, Pi, Pi....). The timer lampusually blinks (5Hz) during the self-diagnosis.

(1) Press [CHECK] button with a tip of pencil to setthe remote control to the service mode.• “00” is indicated on the display of the remote

control.• The timer lamp on the indoor unit blinks

continuously. (5 times per 1 sec.)

(4) Press [START/STOP] button to release the servicemode.• The display of the remote control returns to as it

was before service mode was engaged.

(2) Press [TIMER 8] button.If there is no fault with a code, the indoor unit willbeep once (Pi) and the display of the remotecontrol will change as follows:

; 00 ; 01 ; 02 ··· 1d ; 1E ; 22

• Check the unit with all 35 check codes (00 to22). as shown in Table 10-4-1.

• Press [TIMER 9] button to change the checkcode backwards.

If there is a fault, the indoor unit will beep for 10seconds (Pi, Pi, Pi...).Note the check code on the display of the remotecontrol.• 2-digits alphanumeric will be indicated on the

display.• All lamps on the indoor unit will blink. (5 times

per 1 sec.)

(3) Press [CLR] button. After service finish for clearservice code in memory.• “7F” is indicated on the display of the remote

control.

• Alphanumeric characters are used for the checkcode.

is 5. is 6.is A. is B.is C. is D.

10-4-1. How to use remote control in service mode

– 54 –

CheckCause of operationcode

Short-circuit or disconnec-tion of the room tempera-ture sensor (TA sensor).

Coming-off,disconnection,short-circuit, or migrationof heat exchanger sensor(TC sensor)

Lock of indoor fan ortrouble on the indoor fancircuit

Trouble on other indoorP.C. boards

Return serial signal is notsent to indoor side fromoperation started.(1) Defective wiring of

connecting cable(2) Operation of

compressor thermo.Gas shortageGas leak

Operation commandsignal is not sent tooutdoor side.

Block distinction

CheckBlockcode

Indoor P.C.board etc.

Notdisplayed

Connectingcable andserial signal

Operation of diagnosis function

Operationcontinues.

Operationcontinues.

All off

Operationcontinues.

Operationcontinues.

Operationcontinues.

Judgment and action

1. Check the room temp. sensor.2. When the room temp. sensor is

normal, check P.C. board.

1. Check heat exchanger sensor.2. When heat exchanger sensor is

normal, check P.C. board.

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

the motor.

Replace P.C. board.

1. When the outdoor unit neveroperate:(1) Check connecting cable, and

correct if defective wiring.(2) Check 25A ( or 30A) fuse (F01)

of outdoor main P.C. board.(3) Check 3.15A fuse (F04) of

outdoor main P.C. board.2. To display [Other] block during

operation, check compressorthermo. operation and supply gas(check gas leak also).

3. Unit operates normally duringcheck.If Return serial signal does notstop between indoor terminalboard 2 and 3, replace inverter P.C.board.If signal stops between indoorterminal board 2 and 3, replaceindoor P.C. board.

If Operation command signal does notstop between indoor terminal board 2and 3, replace inverter P.C. board.If signal stops between indoorterminal board 2 and 3, replace indoorP.C. board.

Airconditioner

statusCondition

Displayed whenerror is detected.




Flashes whentrouble is detectedon Return serialsignal, and normalstatus when signalis reset.

Flashes whentrouble is detectedon Operationcommand signal,and normal statuswhen signal isreset.

Table 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 mode for30 minutes.

10-4-3. Caution at Servicing

(1) After servicing, push the START/STOP button to return to the normal mode.

(2) After servicing by the check code, turn off breaker of the power supply, and turn on breaker of the powersupply again so that memory in the microcomputer returns the initial status. However, the check codes arenot deleted even if the power supply is turned off because they are stored in the fixed memory.

– 55 –

Block distinction

CheckBlock

code

Outdoor P.C.board

Notdisplayed

Outdoor P.C.board

Others(includingcompressor)

Operation of diagnosis function

CheckCause of operation

code

Inverter over-currentprotective circuit operates.(Short time)

Position-detect circuiterror or short-circuitbetween windings ofcompressor

Current-detect circuiterror

Being out of place,disconnection or short-circuit of outdoor temp.sensor

Disconnection or short-circuit of discharge temp.sensor

Outdoor fan drive systemerror

Outdoor temp. sensorerror

Compressor drive outputerror, Compressor error(lock, missing, etc.),Break down

Error exclusive formultiple type

Compressor does notrotate. (Current protectivecircuit does not operatewhen a specified timepassed after compressorhad been activated.)

Discharge temp. ex-ceeded 120°C.

Break down ofcompressor

Airconditioner

status

All off

All off

All off

All off

All off

All off

Operationcontinues.

All off

All off

All off

All off

All off

Remarkes







——






Judgment and action

Even if trying operation again, alloperations stop immediately. : ReplaceP.C. board.

1. Even if connecting lead wire ofcompressor is removed, position-detect circuit error occurred. :Replace P.C. board.

2. Measure resistance between wires ofcompressor, and perform short-circuit. : Replace compressor.

Even if trying operation again, alloperations stop immediately. : ReplaceP.C. board.

Check 5-serial LED.1. Check P.C. board.

1. Check discharge temp. sensor (TD).2. Check P.C. board.

Position-detect error, over-currentprotective operation of outdoor fan drivesystem, fan lock, etc. : Replace P.C.board or fan motor.

1. Check outdoor temp. sensor (TO).2. Check P.C. board.

Check 5-serial LED.When 20 seconds passed after start-up,position-detect circuit error occurred. :Replace compressor.

Check 5-serial LED.1. Miswiring of connecting wire of A/B/

C/D rooms in indoor/outdoor units2. Check gas leakage.3. Check disconnection of sensor.4. Electronic control valve error

1. Trouble on compressor2. Trouble on wiring of compressor

(Missed phase)

1. Check dischage temp. sensor (TD).2. Degassing3. Trouble on P.M.V.

1. Check power voltage.(220–240 V ±10%)

2. Overload operation of refrigerationcycleCheck installation condition(Short-circuit of outdoor diffuser).

– 56 –

10-5. Judgement of Trouble by Every Symptom

10-5-1. Indoor unit (Including remote controller)

Turn off powersupply once, and 5second later, turn it

on again.

Is OPERATIONlamp blinking?

NO

YES

NO NO

YESYES

Is it possible toturn on power

supply bypressing

[START/STOP]button on

remote control?

Doestransmission

mark onremote controlflash normally,and is its signal

transmittedproperly?

Remote control isdefective.

Refer to (5)“Troubleshooting for

Remote Control.”

Is fuse (F01)of indoor control

board blown?

Is voltage(DC 12V or 5V)

indicated onrear of indoorcontrol board

normal?

Microcomputeris defective.

Replace mainP.C. board.

Refer to<Primary check>or this problem

is one step shortof power P.C.board block.

Is DC310 – 340Vsuppalied to

primary side oftransfer switch?

Are DC 15V,DC 12V and

DC 7Vsupplied tosecondary

side oftransferswitch?

Turn off breakeronce and turn iton again after

removing motor.

Transfer switch,IC (IC01) for

power supply orfan motor isdefective.

Replace motor.

YES

YESNO

NO

NO NO

YES

YES YES

NO

NO

YES

Doesfan motorconnector

between 1and 2

short-circuit?

Unit operatesnormally.

Are DC 15V,DC 12V or

DC 7Vsupplied tosecondary

side oftransferswitch?

Operation

Measure

Item by symptoms

Check item

Conceivable principle cause

Parts(R04, C01,

DB01, C03, R01IC01 and T01)are defective.

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

(1) Power is not turned on (Does not operate entirely)

(2) Power is not turned on though Indoor P.C. board is replaced

<Confirmation procedure>

YES YES

NO NO

To item of “Power is not turned on”.

Turn on power supply.

Does operation lamp flash? Is wired correctly to white and black lead wires of terminal board?

Correct wiring.

– 57 –

– 58 –

1 Is it possible to detect the power supply voltage (200 – 240V) between 1 and 2 on the terminal block?2 Does the indoor fan motor operate in cooling operation?

(In heating operation, the indoor fan motor does not operate forapproximately 5 minutes after it is turned on, to prevent a cold airfrom blowing in.)

Operation

Measure

Item by symptoms

Check item

Conceivable principle cause

Turn off powersupply once, andturn it on again.

Doescompressorcontinue tooperate?

Is it possible to detectDC 1V or more between5e and 3dof motor

connector (CN10).

Start to operateindoor unit in

cooling operationat airflow

level “LOW”.

Does indoorfan operate?

Is it possible to detect DC310 – 340V between

1e and 3d of motorconnector (CN10).

Change airflowlevel to “High”. (Motor connection condition)

Is it possible to detect DC 15Vbetween 4e and 3d ofmotor connector (CN10).

Turn off indoor unitand remove connectorfrom motor. Then pressSTART/STOP buttonon remote control tostop blinking lamp on

indoor unit.

Replace indoorfan motor.

Replace mainP.C. board.

Is it possible to detectDC 15V between 4e

and 3d of motorconnector (CN10).

Turn off indoor unitand remove connector

from motor.Then start to operate

indoor unit withremote control.

Start to operate theindoor unit. At this time, is itpossible to detect DC 1V or

more between 5e and 3dof motor connector (CN10)?

Is it possible tochange airflowlevel to “High”?

Is it possible to rotate cross-flow fan by hand properly?

Turn off indoor unit and rotatecross-flow fan by hand when theunit is on standby. At this time,

is it possible to detect DC 1V ormore between 5e and 3dof motor connector (CN10).

Fan motoroperates normally.

Start to operate the indoorunit in except heating

operation. At this time, is itpossible to detect DC 1V

or more between 5e and3d of motor connector

(CN10)? (Check thiscondition within 15 seconds

after starting unit.)

Replace bearing.

NO

NO

YES

NO NO

YES

YES

YES

NO

NO

NO

YES

NO

YES

YES

YES

NONO

NO

(3) Only indoor fan motor does not operate.

<Preliminary check>

<Cause>The IC is built in the indoor fan motor. Therefore the P.C. board is also mounted to the inside of the motor.

If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turningon power supply.

<Confirmation procedure>

(1) Remove the front panel.(Remove 4 screws.)

(2) Remove cover of the fan motor lead wires.

(3) Check DC voltage with CN10 connector while the fan rotating.

NOTE :

• Do not disconnect the connector while the fan rotates.

• Use a thin tester rod.

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

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

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

P.C. board is defective.

5 (Yellow)

4 (Blue)

3 (Yellow)

2 —

1 (Red)

Motor is defective.

Below DC 0.4V

(4) Indoor fan motor starts rotating by turning on power supply alone

– 59 –

Yellow

Black

CN10P.C. board

DC

6 (Blue)

– 60 –

NO

YES

Press the START/STOP button.

Does the transmission indicator of remote

controller light?

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

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

Avoid direct sunlight.

Is there any thyristor

fluorescent light near by?

Keep the air conditioner away

from thyristor fluorescent light.

Is operation possible when the

transmitter is moved nearer to the infrared signal receiver of the

air conditioner?

Battery life

Can any signal tone be heard in a transistor radio when transmitting

within 5cm distance from the radio?

Does the transmission

indicator light?

Is there any receiving sound and operation?

Short-circuit ACL switch with a coin or others at rear side of remote controller.

ReplaceP.C. board.

Replace the battery. Normal

Remote controller is failure.

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

Is Temporary Cool operation possible when keeping the temporary

switch of the air conditioner main unit pushed for 10 seconds or more?

Push the START/STOP button

Item by symptom

Operation

Check Items

Considerable main cause

Measures

(5) How to examine whether remote controller is good or bad

• Does setting (A/B) of the remote controller selection match with that indoor unit?

– 61 –

Gas circulation amount is down.

Measure gas pressure.

Gas shortage

Gas leak

Pipe clogging

Thermo. operation of compressor

Red

White

Terminal block

S5277G

Tester

3

2

1

Terminal block at indoor side

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

To item of Compressor does not operate.

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?

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.

Fig. 11-5-1

Normal time : Voltage swings between DC15 and 60V.

Abnormal time : Voltage does not vary.

(2) Outdoor unit stops in a little while after operation started

<Check procedure> Select phenomena described below.

(1) The outdoor unit stops 10 to 20 minutes after operation started, and 10 minutes or more are required torestart the unit.

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

(3) The outdoor unit stops 10 minutes to 1 hour after operation started, and an alarm is displayed.(Discharge temp. error check code 03, 1E)

Gas leak

P.M.V. is defective.

Miswiring of connecting wires of indoor/outdoor units

Clogging of pipe and coming-off of TG, TC sensors

– 62 –

Wiring port

D11 D12 D13 D14 D15LED (Red)

10-6. Trouble Diagnosis by Outdoor LED

For the outdoor unit, the self-diagnosis is possible byfive LEDs (Red).

• LEDs (Red) (D11 to D15) are provided on thesub-control board under surface of the inverter,and as shown below, they are checked from thewiring port when removing the wiring cover.

1. If a trouble occurs, LED (Red) goes on accord-ing to the trouble as described in the table below.

2. When two or more troubles occur, LEDs go oncyclically.

3. Usually, LEDs (Red) go off.

Fig. 11-6-1

¤ : LED ON, : LED OFF P.M.V. : Pulse modulating valve

LED display

D11 D12 D13 D14 D15

¤

¤

¤ ¤

¤

¤ ¤

¤ ¤ ¤

¤

¤ ¤

*2 ¤ ¤ ¤ ¤

*2 ¤ ¤*2 ¤ ¤ ¤*1 ¤ ¤ ¤*1 ¤ ¤ ¤ ¤

¤ ¤

¤ ¤ ¤ ¤¤ ¤

¤ ¤

¤ ¤ ¤

Indoorcheckcode

None

07

14

16

17

19

1A

1B

1C

––

––

––

––

––

—

1C

1D

1E

1F

Description

During normal operation

Compressor thermo. operation, instantaneous power failure,gas leak

IGBT short circuit, compressor motor rear short

Position-detect circuit error

Current-detect circuit error

Discharge temp. sensor (TD) error

Outdoor fan error

Outside temp. sensor (TO) error

Compressor system error

A room gas side temp. sensor (TGa) error

B room gas side temp. sensor (TGb) error

C room gas side temp. sensor (TGc) error

Gas leakage, P.M.V. sensor error

Indoor heat exchanger sensor (TC) disconnection, P.M.V.sensor error

Indoor/outdoor miswiring, gas leakage, TC sensordisconnection, P.M.V. sensor error

Communication error between MCU

Compressor lock

Discharge temp. error, gas leakage

Compressor break down

*1 Back-up operation is performed without block display of the indoor unit.

*2 Operated normally when the air conditioners in other rooms are driven.

– 63 –

Diagnosis/Process flowchart Item

Preparation

Check

Check

Operation

Measurement

Check

Stop

CheckMeasurement

Contents

Turn “OFF” the power breaker,and remove 3P connectorwhich connects inverter andcompressor.

• Check whether 25A fuse onthe control board assemblyis blown or not. (F01)

Check whether 15A fuse onthe control board assemblyis blown or not. (F03)

• 15A fuse (F03) on thecontrol board is provided forpower factor improvementcontrol circuit. The operationcontinues even if fuse isblown.

Turn on power breaker, andoperate the air conditioner inCOOL mode by short-circuit ofthe timer.Measure terminal voltage ofthe electrolytic capacity.

500µF:400WV x 4

After operation, turn off thepower breaker after 2 minutes20 seconds passed, anddischarge the electrolyticcapacity by soldering iron.Check voltage between motorphases.

• Is not winding between -, -, or - openedor short-circuited?

• Is not frame grounded with, , or ?

Summary

If fuse was blown, be sure tocheck the electrolyticcapacitor and diode block.(DB01)

• Connect dischargeresistance (approx.100Ω40W) or solderingiron (plug) between +, –terminals of the electro-lytic capacitor (500µF) ofC15 (with printed CAU-TION HIGH VOLTAGE) onP.C. board.

If 15A fuse is blown,discharge both edges ofthe electrolytic capacitorwith soldering iron.

OK if 500µF →→→→→ DC280V

Remove CN300 whilepushing the part indicatedby an arrow.

→→→→→ Resistance betweenphases should be approx.55 to 77Ω.

→→→→→ Should be 10MΩ or more.

Replaceoutdoorfan motor.

Remove connector of compressor.

NG

NG

NG

NG

NO

NO

OK

OK

OK

OK

YES

YES

Check 25A fuse(Part No.F01).

Does outdoor fan rotate?

Replace fuse.

Check electrolytic

capacitor, diodeblock, etc.

Check electrolytic

capacitor, diode block, etc.

Replace control board assembly.

Remove connector CN300 of outdoor fan

motor, and using a tester, check resistance

value between every phases at motor side.

Check15A fuse

(Part No.F03).

Check terminal voltageof electrolytic

capacitor.

Does LED on control board flash or go on?

CBA



10-7. How to Diagnose Trouble in Outdoor Unit

10-7-1. Summarized Inner Diagnosis of Inverter Assembly

– 64 –

Diagnosis/Process flowchart Item

Check

Operation

Check

Contents

Check winding resistancebetween phases of compres-sor, and resistance betweenoutdoor frames by using atester.• Is not grounded.• Is not short-circuited

between windings.• Winding is not opened.

Remove connector CN300 ofthe outdoor fan motor, turnon the power breaker, andperform the operation.(Stops though activation isprompted.)Check operation within 2minutes 20 seconds afteractivation stopped.

<Output check of fan motorposition detect signal>While connecting connector5P (CN301) for positiondetection, using a tester,measure voltage between - . Between - : 5V

Summary

→→→→→ OK if 10MΩ or more

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

a) One or two of threevoltages should be 5V,and others should be 0V.(When all are 0V or 5V, itis not accepted.)

b) When rotating the fanslowly with hands, thevoltage between pinsshould move from 0V to5V.(Check it with an analogtester.)

NG

NG

NG

OK

OK

OK

Check winding of

compressor.

Check fan motorpositiondetectsignal.

Replacecom-pressor.

CBA

Replaceoutdoorfan motor.

Replace control board assembly.

Replacecontrol board.

Replacecompressor.

Check compressor

windingresistance.

10-8. How to Check Simply the MainParts

10-8-1. How to Check the P.C. Board(Indoor Unit)

(1) Operating precautions

1) When removing the front panel or the P.C.board, be sure to shut off the power supplybreaker.

2) When removing the P.C. board, hold the edgeof the P.C. board and do not apply force tothe parts.

3) When connecting or disconnecting theconnectors on the P.C. board, hold the wholehousing. Do not pull at the lead wire.

(2) Inspection procedures

1) When a P.C. board is judged to be defective,check for disconnection, burning, or discol-oration of the copper foil pattern or this P.C.board.

2) The P.C. board consists of the following 2parts

a. Main P.C. board part:

DC power supply circuit (5V, 12V, 35V),Indoor fan motor control circuit, CPU andperipheral circuits, buzzer, and Driving circuitof top/bottom louvers

b. Indication unit of infrared ray receiving

Infrared ray receiving circuit, LED:

To check defect of the P.C. board, follow theprocedure described below.

– 65 –

No.

1

2

3

4

5

6

Procedure

Shut off the power supply andremove the P.C. board assemblyfrom the electronic parts base.

Remove the connecting cable fromthe terminal block.

Remove the connector for themotor, and turn the power on.

If the OPERATION lamp flashes(0,5 sec. :ON, 0,5 sec. :OFF) whenthe power turning on, the checkingpoints described as 1-5 of rightcolumn are not necessary toperform.

Make the operation status bypushing once the START/STOPbutton, except the status of [FANONLY], [ON TIMER].

Start the operation with the systemwhich the time of the restart delaytimer is shortened.

Make the operation status by pressingonce the START/STOP button.

1. The time of the restart delay timeris shortened.

2. Cool operation

3. Air volume [AUTO]

4. Make the setting temperature lowerenough than room temperature.

5. Continuous operation.

Turn the power on after connectingthe motor connector.

Start the operation with the followingcondition.

1. Operation [Cooling]

2. Airflow [High fan]

3. Continuous operation

Check point (Symptom)

1. Is the fuse blown?

Voltage check

1. Between TP1 and TP2(220–230–240V AC)

2. Between TP2 and pin 1 of CN04(220–230–240V AC)

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

Voltage check

1. Voltage of relay coil. (DC 12V)

Between pin 10 of IC31 and GND

Between pin 11 of IC31 and GND

2. Between No. 1 and 2 of connectingcable terminal block.

(220–230–240V AC)

1. All indicators light for 3 sec.

2. Indicators do not indicate normallyafter approximate 3 sec.

1. Compressor does not operate.

2. OPERATION lamp flashes.

1. The voltage of DC 35V is notmeasured between the red andblack of the motor terminals.

2. Motor does not rotate.(The key operation is accepted.)

3. The motor rotates, but it vibrates toomuch.

Causes

1. * Application of shock voltage.

* Overload by short-circuit of theparts.

1. * AC power cord is defective.

* Poor contact of the terminal plate.

* Miss wiring of the power relay.

2. Fuse is defective.

3. Operation of the thermal fuse.

4. * Capacitor (C01, C15) is defective.

* Line filter (L01) is defective.

* Resistor (R01) is defective.

* Diode (DB01) is defective.

5. IC01, IC02, T01 are defective.

6. IC01, IC02, T01, F03 are defective.

7. IC01, IC02, T01, F02, Q29, IC03are defective.

1. Breaking wire of the relay coil,defective relay driver. (IC31)

2. Poor contact of relay.

Defective indicator, or poorhousing assembly. (CN13)

1. The temperature of the indoor heatexchanger is abnormally low.

2. Poor contact of the heat exchangersensor. (The connector isdisconnected.) (CN01)

3. Heat exchanger sensor, main P.C.board are defective.

4. Main P.C. board is defective.

1. Indoor fan motor is defective.(Protecting operation on the P.C.board.)

2. Poor contact of the motorconnector.

3. P.C. board is defective.

(3) Check procedures

Table 10-8-1

– 66 –

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

<Top View>

<Bottom View>

– 67 –

100

30

40

50

60

70

80

90

20

10

00 10 20 30 40 50

Res

ista

nce

valu

e (k

)

Temperature (˚C)

TD : Discharge temp. sensorTA : Room temp. sensorTC : Heat exchanger temp. sensorTO : Outdoor temp. sensorTGa : Gas side temp. sensorTGb : Gas side temp. sensorTGc : Gas side temp. sensorTGd : Gas side temp. sensor

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

TD

<Sensor characteristic table>

– 68 –

Checking procedure

Disconnect the connector and measure the resistance value with tester.(Normal temp.)

To item of How to judge whether remote control is good or bad of theJudgment of trouble by symptom.

Measure the resistance value of each winding coil by using the tester.(Under normal temp. 25°C)

Since judgment of DC motor is difficult on the single motor, refer to 11-5-1. (3).

No. Part name

1 Room temp. (TA) sensorHeat exchanger (TC) sensor

2 Remote control

3 Louver motorMP24GA

4 Indoor fan motor

Position Resistance value

1 to 41 to 6

130 ± 10 Ω2 to 32 to 5

Temperature10°C 20°C 25°C 30°C 40°CSensor

TA, TC (kΩ) 20,7 12,6 10,0 7,9 4,5

No. Part name

1 Compressor(Model : DA130A1F-21F)

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

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

4 Outdoor temperature sensor(TO), pipe temperature sensor(TGa, TGb, TGc), dischargetemperature sensor (TD)

Checking procedure

Measure the resistance value of each winding by using the tester.

Measure the resistance value of winding by using the tester.

For details, refer to Section 11-9.

Check conduction by using the tester.

Disconnect the connector, and measure resistance value with thetester. (Normal temperature)

Temperature10°C 20°C 30°C 40°C 50°CSensor

TD (kΩ) 105 64 41 27 18

TO, TGa, TGb, TGc (kΩ) 20,7 12,6 10,0 7,9 4,5

Position Resistance valueRed - White 0,51 to 0,57 Ω

White - Black 0,51 to 0,57 ΩBlack - Red 0,51 to 0,57 Ω

Under 20°C

Position Resistance valueYellow - Pink 5 to 20 k Ω

Red

White Black

Red

1 Yellow

4 Pink5 Gray

White Black

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

11-8-4. Outdoor Unit

12345

WhiteYellowYellowYellowYellow

– 69 –

No. Part name

1 Electrolytic capacitor(For raising pressure,smoothing)

2 Converter module

3 IGBT module

Checking procedure

1. Turn OFF the power supply breaker.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 → 500µF/400V

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

continuity test by the tester.

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

MCC-758SolderedsurfaceH

eat s

ink

IGB

T s

ide

C12 C13 C14 C15 Case that product is good

Pointer swings once, andreturns slowly. Whenperforming test once againunder another polarity, thepointer should return.

10-8-5. Checking Method for Each Part

+ ~ – ~ A21

+ ~1

– ~2

A

Mark

E G

E G

Resistance value in good product

Diode checkTester rod

+ –~ 1

~ 2

+

–

~ 1

~ 2

E~ 1

~ 2

50kW or more(0 in trouble)

Tester rodU V W U V W

WVU WVU

1M or more 100k to 300k 200k to 300kCase that product is good

IGBT check

Resistance value in good product

50kW or more(0 in trouble)

BZ BY BX BW

BW

BZ

BV BU

Tester rod

+ –~ 2

G

E

E

++

+–

+ +

–

––

– W V U

W

BV

BY

V

BU

BX

U

– 70 –

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.

If the resistance value between 1 (Red lead) – 2 (White lead)2 (White lead) – 3 (Black lead)3 (Black lead) – 1 (Red lead)

of the connector (CN300 : Motor winding) is 50 to 80 , it is normal.

CN300

Turn OFF the breaker.

Fan motor is normal.

Does the fan rotate without trouble when rotating it with hands?

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

(Outdoor P.C. board error)

Fan motor error

YES

YES

NO

NO

NO

YES

10-9. How to Simply Judge Whether Outdoor Fan Motor is Good or Bad

1. Symptom

• Outdoor fan motor does not rotate.

• Outdoor fan motor stops within several tens seconds though it started rotating.

• Outdoor fan motor rotates or does not rotate according to the position where the fan stopped., etc.

Remote control check code “02 : Outdoor block, 1A : Outdoor fan drive system error”

2. Cause

The following causes are considered when the outdoor fan motor does not normally rotate.

1) Mechanical lock of the outdoor fan motor

2) Winding error of the outdoor fan motor

3) Position-detect circuit error inside of the outdoor fan motor

or

4) Motor drive circuit error of the outdoor P.C. board

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

NOTE :

However, GND circuit error inside of the motor may be accepted in some cases when the above check isperformed.

When the fan motor does not become normal even if P.C. board is replaced, replace the outdoor fan motor.

– 71 –

11-1. Indoor Unit

11. HOW TO REPLACE THE MAIN PARTS

No. Part name Procedures Remarks

How to remove the front panel1) Stop operation of the air conditioner and

turn off its main power supply.2) Pull the air inlet grille toward you to open it

and remove the air inlet grille.Then remove the 4 screws fixing the frontpanel.

3) First open the horizontal louver, and thenremove the front panel from the back bodyby pulling it toward you.

How to mount the front panelPush the front panel back in and makesure all hooks are locked.

How to remove the electrical part.1) Remove the front panel with procedure 1.2) Remove the screw holding the electrical

part cover.3) Remove the drain guide.4) Disconnect the 2 connectors (3P) for the

fan motor and the connector (5P) for thelouver motor from the P.C. board assembly.

5) Pull out the TC sensor from the sensorholder.

6) Remove the screw for the groundconnection, remove the 2 screws for theelectrical part box and remove the screwfrom the LED unit. Then remove the LEDunit and the electrical part box from themain unit.

How to mount the electrical part.1) To put back the electrical part box, lock it

to the upper hook of the back body.2) Tighten the 2 screws on the electrical part

box.3) Connect the 3 connectors and arrange the

wiring same as original condition and thentighten the screw from the LED unit to theback body.

4) Attach the TC sensor to the holder.5) Tighten the screw for the ground connection.6) Assemble the drain guide (the TC sensor

wire should be covered by the drain guide).7) Tighten the screw on the electrical part cover.

1) Remove the front panel and the electricalpart following procedure 2.

2) Remove the center shaft of the horizontallouver from the back body.

3) Remove the left shaft from the back body.4) Remove the horizontal louver from the

back body.

1 Front panel

2 Electrical part

3 Horizontallouver

6 2-Screws

2 4-Screws

2

2 2

3

2 Screws

3 Drain guide

5 TC Sensor

6 Screws 4 3-Connectors

3 Left shaft 2 Center shaft

– 72 –

No. Part name Procedures Remarks

1) Remove the front panel, electrical partand the horizontal louver followingprocedure 3.

2) Remove the pipe holder at the rear side ofmain unit.

3) Remove the 2 screws on the heatexchanger at the base bearing.

4) Remove the 2 screws on the heatexchanger at the 2 fixed plates (upper andlower) from the back body, and then pullout the upper side of the heat exchangerslowly.

1) Remove the front panel, electrical part,horizontal louver and the heat exchangerfollowing procedure 4.

2) Remove the 2 screws on the band motor(L) and remove the 2 screws on the bandmotor (R) and then remove the cross flowfan.

3) Loosen the set screw of the cross flow fanthen separate the fan and the fan motor.

NoticeTo assemble cross flow fan and fan motor tothe unit, please turn the fan motor unit thecenter of its terminal meets the lowest pointof band motor (R) (point A).Fix the cross flow fan with the set screw atthe position where the gap between the backbody and the right surface of the cross flowfan is 4 mm.

1) Remove the front panel, electrical part,horizontal louver, heat exchanger and thecross flow fan following procedure 5.

2) Remove the 2 screws fixing the basebearing.

3) Remove the bearing from the basebearing. If the housing protrudes from thebase bearing, put the housing in positionand attach the bearing to the basebearing.

4 Heat exchanger

5 Cross flow fan

6 Base bearing

2 Pipe holder

3 2-Screws

4 2-Screws

2 2-Screws (R)

2 2-Screws (L)

4 mm

3 Set screws

2 2-Screws

Middle of the fan motor terminal

– 73 –

Procedure

1) Turn the power supply off to stop the operation of air-conditioner.

2) Remove the front panel.

• Remove the two fixing screws. (φ4 x 14)

3) Remove the electrical part base.

No.

Remarks

Replace the thermal fuse, terminalblock, microcomputer ass’y and theP.C. board ass’y.

Part name

Commonprocedure

11-2. Microcomputer

– 74 –

Procedure

1. Detachment1) Stop operation of the air conditioner, and remove

the power plug of the indoor unit from plugsocket.

2) Remove the valve cover. (ST1TØ4 x 10 1 pc.)• After removing screw, remove the valve cover

pulling it downward.3) Remove wiring cover (ST1TØ4 x 10 2 pcs.),

and then remove connecting cable.4) Remove the upper cabinet.

(ST1TØ4 x 10 2 pcs.)• After removing screws, remove the upper

cabinet pulling it upward.

2. Attachment1) Attach the upper cabinet.

(ST1TØ4 x 10 2 pcs.)• Hook the rear side of the upper cabinet to claw

of the rear cabinet, and then put it on the frontcabinet.

2) Perform cabling of connecting cable, and attachthe wiring cover. (ST1TØ4 x 10 2 pcs.)

3) Attach the valve cover. (ST1TØ4 x 10 1 pcs.)• 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 attachit pushing upward.

1. Detachment1) Perform work of item 1 of .2) Remove screw (ST1TØ4 x 10 1 pc.) of the front

cabinet and inverter cover and screws (ST1TØ4x 10 3 pcs.) of the front cabinet and lower partof the front cabinet and motor base (ST1TØ4 x10 2 pcs.).• The left side of the front is made to insert to

the rear cabinet, so remove it pulling upward.

2. Attachment1) Insert claw at the left side of the front into the

rear cabinet.2) Hook the lower part at the right side of the front

to concave part of the bottom plate. Insert clawof the rear cabinet into square hole of the frontcabinet.

3) Attach the removed screws to the originalpositions.

No. Part name

Commonprocedure

Front cabinet

Remarks

11-3. Outdoor Unit

Upper cabinet

Upper cabinet

Wiringcover

Valvecover

Squarehole

Concave part

Claw

– 75 –

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

Inverter cover P. C. board (Soldered surface)



P.M.V. coil (A, B, and C rooms)

Holder

TO sensor

TGa, TGb, TGc sensor

Remarks

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

No. Part name

Inverterassembly

Procedure

1. Detachment

1) Perform work of items 1. of and .

2) Remove screw (ST1TØ4 x 10 1 pc.) of theupper part of the front cabinet.• If removing the inverter cover in this condition,

P.C. board can be checked.• If there is no space in the upper part of the

upper cabinet, perform work of .

Be careful to check the inverter becausehigh-voltage circuit is incorporated in it.

3) Perform discharging by connecting + , – polarityby discharging resistance (approx. 100Ω40W) orplug of soldering iron to + , – terminals of theC15 (printed “CAUTION HIGH VOLTAGE” isattached.) electrolytic capacitor (500µF) on P.C.board.

Be careful to discharge the capacitorbecause the electrolytic capacitor cannotnaturally discharge and voltage remainsaccording to trouble type in some cases.

NOTE :This capacitor is one with mass capacity.Therefore, it is dangerous that a largespark generates if short-circuiting be-tween + , – polarity with screwdriver, etc.for discharging.

4) Remove screw (ST1TØ4 x 10 1 pc.) fixing themain body and the inverter box.

5) Remove various lead wires from the holder atupper part of the inverter box and wiring holderat right side of the terminal block.

6) Remove the lead wire from the bundled part atleft side of the terminal block.

7) Pull the inverter box upward.

8) Disconnect connectors of various lead wires.

– 76 –

No. Part name

Controlboardassembly

Rearcabinet

Remarks

CN300 and 301 at the maincontrol board assembly side andCN08 and 15 at the sub- controlboard assembly side are connec-tors with locks. Therefore,remove the connector whilepushing the part indicated by anarrow.

When mounting a new board,check that the board is correctlyset in the groove of base holderof P.C. board base.

Procedure

1) Disconnect lead wires and connectors connectedfrom the control board assembly to other parts.1. Lead wires

• Connection with terminal block : 10 wires(Black, Orange, Pink, Red, Two white wires,Four white wires (reactors))

• Connection with compressor :Remove the connector (3P).

• Connection with reactor :Remove the relay connectors fromP07, 08 (2P, White) and P11, P12 (2P, Yellow).

2. Connectors• Main control board assembly side

CN300 : Outdoor fan (3P, White)CN301 : Outdoor fan position detection (5P, White)

• Sub-control board assembly sideCN02 : TD sensor (3P, White)CN05 : TGa sensor (3P, Yellow)CN06 : TGb sensor (3P, Brown)CN07 : TGc sensor (3P, Green)CN08 : Case thermo. (2P, White)CN12 : C room pulse modulating valve (6P, Green)CN13 : B room pulse modulating valve (6P, Red)CN14 : A room pulse modulating valve (6P, Black)

2) Disconnect cable connecting the main control boardassembly side and sub-control board assembly.

• Main control board assembly sideCN704 : Connecting cable (4P, White)

• Sub.-control board assembly sideCN15 : Connecting cable (4P, White)

3) Remove the control board assembly from P.C. boardbase.1. Main control board assembly side

• Remove two claws of P.C. board base, andremove upward the heat sink with hands.

• Remove three screws fixing the heat sink andmain control board assembly side, and replacethe board with a new one.

2. Sub- control board assembly side• Remove P.C. board base from the inverter box.• Remove two claws of P.C. board base, and

replace the board with a new one.3. Be sure to use the radiating sheet between heat

sink and IGBT and also screws with tube.

1) Perform work of item 1 of , and .2) Remove fixed screws fixing to the bottom plate.

(ST1TØ4 x 10 2 pcs.)3) Remove fixed screws fixing to the heat

exchanger. (ST1TØ4 x 10 2 pcs.)4) Remove fixed screw fixing to the valve mounting

plate. (ST1TØ4 x 10 1 pc.)

CN300

CN02 CN06

CN15CN04

CN14 CN13

CN12

CN08

CN301

CN05

Main board

Sub-board

CN06 CN07

P. C. board baseP. C. board

– 77 –

No. Part name

Fan motor

Compressor

Reactor

RemarksProcedure

1) Perform work of item 1 of and .2) Remove the flange nut fixing the fan motor and

the propeller fan.• Flange nut is loosened by turning clockwise.

(To tighten the flange nut, turn counterclock-wise.)

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.

1) Perform work of item 1 of and , , , .2) Evacuate refrigerant gas.3) Remove the partition board.

(ST1TØ4 x 10 3 pcs.)4) Remove the sound-insulation material.5) Remove terminal cover of the compressor, and

disconnect lead wire of the compressor thermo.and the compressor from the terminal.

6) Remove pipe connected to the compressor witha burner.

7) Remove the fixing screw of the bottom plate andheat exchanger. (ST1TØ4 x 10 1 pc.)

8) Remove the fixing screw of the bottom plate andvalve clamping plate. (ST1TØ4 x 10 2 pcs.)

9) Pull upward the refrigeration cycle.10) Remove nut fixing the compressor to the

bottom plate.

1) Perform work of item 1 of , and .2) Remove lead wires clung in holder on the

partition board.3) Remove screws fixing the reactor.

(ST1TØ4 x 10 2 pcs.)

Fan motor

Propeller fan

Flange nut

Valve clampingplate

Compressor thermo.

Compressor

Partition board

Reactor

– 78 –

No. Part name

Pulsemodulatingvalve coil

Fan guard

RemarksProcedure

1. Detachment1) Perform work of item 1 of , and , , .2) Turn the coil clockwise or counterclockwise by

90 degrees, and remove coil from the pulsemodulating valve.

2. Attachment1) Set take-out part of the lead wire of coil to the

coil inserting position of the pulse modulatingvalve, and attach the coil.

2) Turn the coil clockwise or counterclockwise by90 degrees, set surely the concave part at lowerpart of the coil to the positioning hole of thepulse modulating valve, and then fix the coil.

The pulse modulating valve has A, B andC room side.After mounting it, check that coil at Broom side (Red marking is marked on thepulse modulating valve.) is connected toCN13.Check that coil at C room side (Greenmarking is marked on the pulse modulat-ing valve.) is connected to CN12 of thecontrol board assembly respectively.

1. Detachment1) Perform work of item 1 of , and .2) Remove the front cabinet, and put it down so

that fan guard side directs downward.

Perform work on a corrugated cardboard,cloth, etc. to prevent flaw to the product.

3) Remove the hooking claws by pushing minusscrewdriver according to the arrow mark in theright figure, and remove the fan guard.

2. Attachment1) Insert claw of the fan guard in the hole of the

front cabinet. Push the hooking claws (10positions) by hands and fix the claws.

All the attaching works have completed.Check that all the hooking claws are fixedto the specified positions.

Hooking claw

Minus screwdriver

Take-out part of lead wire

NotchCoil inserting position

Coil inserting position

Coil fix position

Positioning hole

– 79 –

No. Part name

11 Replacementof temperaturesensor forservicing only

Common serviceparts of sensorTO, TGa, TGb,TGc (without TD)

These are partsfor servicingsensors.

Please checkthat the accesso-ries shown in theright table arepacked.

RemarksProcedure

1) Cut the sensor 100 mm longer than old one.2) Cut the protective tube after pulling out it

(200 mm).3) Move the protective tube toward the thermal

sensor side and tear the tip of lead wire intwo then strip the covering part.

4) Pass the stripped part through the thermalconstringent tube.

5) Cut the old sensor 100 mm length on theconnector side, and recycle that connector.

6) Tear the lead wire in two on the connectorside and strip the covering part.

7) Twist the leads on the connector and sensorsides, and solder them.

8) Move the thermal constringent tubes towardthe soldered parts and heat them with thedryer and constring them.

9) Wind the attached color tape round the bothterminals of the protective tube when coloredprotective tube is used.

10)Fix the sensor again.

NOTES :1) Store the joint part of the sensor and the

connector in the electric parts box.2) Never joint them near the thermal sensor

part. Otherwise it would cause insulationinferiority because of dew drops.

3) When replacing the sensor using the coloredprotective tube, wind the color tape matchingthe color of that tube.

Parts name Q'ty Remarks

1 Sensor 1 Length : 3m

2 Sensor Spring (A) 1 For spare

3 Sensor Spring (B) 1 For spare

4 Thermal constringent tube 3 Including one spare

5 Color tape 1 9 colors

6 Terminal 3

Cutting here

Cutting here

Cutting here

Soldered part

Dryer

Winding the color tape

100

200

ConnectorThermal sensor part

Thermalconstringent tube

70

15

100

7015

– 80 –

CN600MCC-758

– 81 –

MCC-775

– 82 –

12. EXPLODED VIEWS AND PARTS LIST

12-1. Indoor Unit (1)

Location Part No. DescriptionNo.

401 43T69319 Temperature Sensor

402 43T60002 Terminal Block, 3P,AC 300V, 20A

403 43T69320 Temperature Sensor

404 43T69003 Cord Clamp

405 43T69079 P.C. Board Ass’y,WRS-LED


406 43T69333 P.C. Board Ass’y,MCC-867(RAS-M10UKCV-E)



406

401404

402

403

405

TC, 10kΩ, 25°C

TC, 10kΩ, 25°C

– 89 –

Indoor Unit


201 43T00352 Panel Ass’y, Front202 43T09316 Inlet Grille Assy203 43T03302 Back body Assy204 43T80301 Air Filter 205 43T09309 Horizontal Louver206 43T08350 LED Panel Assy207 13T70002 Drain Hose

Cap Drain209 43T21321 Motor Louver

Refrigeration Cycle Assy211 43T47006 Pipe Delivery

Pipe Suction(RAS-M10UKCV-E,M13UKCV-E)

212 43T47016(RAS-M16UKCV-E)

214 43T11301 Pipe Shield215 43T19302 Holder Sensor216 43T49302 Plate of EVA Seal217 43T49006 Holder Plate EVA Seal218 43T79302 Guide Drain

Bearing220 43T39301 Base Bearing221 43T20302 Fan Cross Flow222 43T39302 Band Motor - L223 43T21327 Motor Fan


226 43T69310 Remote Controller227 43T83003 Holder Remote Controller

229 43T62302 Terminal Cover231 43T60317 Cord Motor Louver232 43T60316 Cord Motor Fan233 43T07303 Holder Pipe234 43T01303 Mark208 43T79301

212 43T47305

Pipe Suction

219 43T22002

224 43T39303 Band Motor -R225 43T82301 Plate Installation

228 43T85362 Owner's Manual

202

204

204

229

228

226

227

209

Electric PartsAssembly

225

207233 222

223

224

205201

221

215

211

212

210

219

220

203

208

214

216217

217

218

206234

– 75 –

01 43005452 Cabinet, Back, Assembly 02 43005369 Cabinet, Upper, Assembly 03 43005364 Cabinet, Front, Assembly 04 4301V030 Guard, Fan 05 43042461 Base, Assembly 06 4301V029 Cover, Valve, Packed 07 43062230 Cover, Wiring, Assembly 08 4301V021 Hanger 09 43041771 Compressor, DA130A1F-21F 10 43043650 Condenser, Assembly 11 43046332 Valve, Packed, 6,35 DIA 12 43046349 Valve, Packed, 9,52 DIA 13 43046356 Valve, Packed, 12,7 DIA 14 43147196 Bonnet, 1/4 IN 15 43047401 Bonnet, 3/8 IN 16 43147195 Bonnet, 1/2 IN

Location Part DescriptionNo. No.


17 43046351 Valve, Pulse Modulating(P.M.V.), SEV15RC2

18 43046347 Coil, P.M.V. 19 43058264 Reactor, CH38Z-K 20 43050298 Thermo. Bimetal, CS-7, 125 21 4302C019 Motor, Fan, DC,

ICF-140-40-4 22 43047549 Nut, Flange 23 43020312 Fan, Propeller 24 43097166 Nut 25 43049643 Cushion, Rubber 26 43063187 Holder, Sensor 27 43049654 Holder, Sensor 28 43063195 Holder, Thermo. Bimetal 29 43019904 Holder, Sensor 30 4308N258 Manual

12-2. Outdoor Unit

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

30

18

27

1028

20

17

9

12,1511,1413,16

4

3

5

24, 25 76

23

22

21

19

81 2

4

22

23

5 26

1

29

2

– 76 –

702 43050382 Sensor, TC (Ø6)

703 43050334 Sensor, TD (Ø4)

704 43060052 Fuse, 25A, 250V, Lead Type

705 4306A027 Terminal block, 9P

706 43060726 Fuse, 15A, 250V, Lead Type

707 4306A030 Terminal block, 9P



708 43062231 Base, P.C. Board

709 43063308 Heatsink

710 4306S191 P.C. Board Assembly,MCC-758

711 4306S190 P.C. Board Assembly,MCC-775

12-3. P.C. Board Layout

44

32

1

43

21

709710

708

705 707

711

703

TO Sensor

TGb Sensor TGa Sensor

TGc Sensor

TD Sensor

702

704

706

TOSHIBA CARRIER (THAILAND) CO.,LTD.144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI,

AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

Manual Split Toshiba

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