Toshiba RAS-10GAVP-E manual

R410A FILE NO. A05-008 PRINTED IN JAP AN, Nov .,2005 T oMo SER VICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit <High W all, Heat Pump T ype> <Heat Pump T ype> RAS-B10GKVP-E RAS-10GA VP-E RAS-B13GKVP-E RAS-13GA VP-E RAS-B16GKVP-E RAS-16GA VP-E[...]

– 2 – CONTENTS 1 . SAFETY PRECA UTIONS .......................................................................... 3 2 . SPECIFICA TIONS ..................................................................................... 5 3 . REFRIGERANT R410A ............................................................................. 7 4 . CONSTR UCTION VI[...]

– 3 – 1. SAFETY PRECA UTIONS For general public use P o wer supply cord of outdoor unit shall be more than 1.5 mm 2 (H07RN-F or 245IEC66) polychloroprene sheathed fle xib le cord. • Read this “ SAFETY PRECA UTIONS ” carefully bef ore servicing. • The precautions described below include the impor tant items regarding saf ety . Obser v e [...]

– 4 – • DO NO T INST ALL NEAR CONCENTRA TIONS OF COMBUSTIBLE GAS OR GAS V APORS. F AILURE T O FOLLO W THIS INSTR UCTION CAN RESUL T IN FIRE OR EXPLOSION. • T O PREVENT THE INDOOR UNIT FROM O VERHEA TING AND CA USING A FIRE HAZARD , PLA CE THE UNIT WELL A W A Y (MORE THAN 2 M) FR OM HEA T SOURCES SUCH AS RADIA T ORS, HEA T REGIST ORS, FURNA [...]

– 5 – 2. SPECIFICA TIONS 2-1. Specifications RAS-B10GKVP-E/RAS-B13GKVP-E/RAS-B16GKVP-E, RAS-10GA VP-E/RAS-13GA VP-E/RAS-16GA VP-E Indoor RAS-B10GKV P-E RAS-B13 GKVP-E RAS- B16GKV P-E Unit model Outdoor RAS-10GA VP-E RAS-13 GA VP- E RAS-16 GA V P-E Cooling capa city (kW) 2.5 3.5 4.5 Cooling capa city range (kW) 0.5 – 3.5 0.6 – 4.5 0.8 – 5.[...]

– 6 – * Capacity ratio : 100% = 2.5 kW (RAS-B10GKVP-E) 3.5 kW (RAS-B13GKVP-E) 4.5 kW (RAS-B16GKVP-E) 100 110 90 80 70 60 50 32 34 36 38 40 42 33 35 37 39 41 43 44 45 46 Outdoor temp. (˚C) Capacity ratio (%) 120 100 80 60 40 20 0 – 15 – 10 – 50 51 0 Capacity ratio (%) Outdoor temp. ( ˚ C) • Conditions Indoor : DB 20 ˚ C Indoor air flo[...]

– 7 – 3. REFRIGERANT R410A This air conditioner adopts the ne w refrigerant HFC (R410A) which does not damage the ozone la y er . The working pressure of the new refrigerant R410A is 1.6 times higher than con v entional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water , [...]

– 8 – T able 3-2-1 Thicknesses of annealed copper pipes Nominal diameter 1/4 3/8 1/2 5/8 Outer diameter (mm) 6.35 9.52 12.70 15.88 Thickness (mm) R410A R22 0.80 0.80 0.80 0.80 0.80 0.80 1.00 1.00 2. Joints F or copper pipes, flare joints or soc ket joints are used. Prior to use, be sure to remov e all contaminants. a) Flare Joints Flare joints [...]

– 9 – A ØD d) Flare Processing Make certain that a clamp bar and copper pipe ha v e been cleaned. By means of the clamp bar , perf orm the flare processing correctly . Use either a flare tool f or R410A or conv en- tional flare tool. Flare processing dimensions diff er according to the type of flare tool. When using a con- ventional flare tool[...]

– 10 – 43˚ to 45˚ 45˚ to 46˚ B A C D T able 3-2-6 Flare and flare nut dimensions f or R22 Nominal diameter 1/4 3/8 1/2 5/8 3/4 Outer diameter (mm) 6.35 9.52 12.70 15.88 19.05 Thickness (mm) 0.8 0.8 0.8 1.0 1.0 Dimension (mm) ABCD 9.0 9.2 6.5 13 13.0 13.5 9.7 20 16.2 16.0 12.9 20 19.7 19.0 16.0 23 23.3 24.0 19.2 34 Flare nut width (mm) 17 22[...]

– 11 – 3-3. T ools 3-3-1. Required T ools The ser vice por t diameter of pack ed v alve of the outdoor unit in the air-w ater heat pump using R410A is changed to pre v ent mixing of other refrigerant. T o reinf orce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (F or Ø 12.7 copper pipe) o[...]

– 12 – Connect the charge hose to pack ed valv e ser vice por t at the outdoor unit ’ s gas side. Recov er the refrigerant, and check no refrigerant remains in the equipment. (F or refr igerant charging, see the figure below .) Connect the charge hose to the vacuum pump adapter . Open fully both pack ed valv es at liquid and gas sides. Place [...]

– 13 – Gauge manifold [ Cylinder with siphon ] [ Cylinder without siphon ] OUTDOOR unit Gauge manifold OUTDOOR unit Refrigerant cylinder Electronic balance Refrigerant cylinder Electronic balance Siphon 1. Be sure to make setting so that liquid can be charged. 2. When using a cylinder equipped with a siphon, liquid can be charged without tur ni[...]

– 14 – Nitrogen gas cylinder Pipe Flow meter M Stop valv e F rom Nitrogen cylinder Nitrogen gas Rubber plug 2. Characteristics required for flux • Activated temper ature of flux coincides with the brazing temperature . • Due to a wide eff ective temper ature range, flux is hard to carbonize . • It is easy to remov e slag after brazing. ?[...]

– 15 – 4. CONSTR UCTION VIEWS 4-1. Indoor Unit RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E P ar ts name of remote controller WH-H03JE Connecting pipe (Outside length:0.4m) Flare Ø 9.52 (RAS-B16GKVP-E : Ø 12.7) Minimum distance to ceilinfg Minimum distance to wall Minimum distance to wall Hanging section F ront panel Plasma pure filter 53 790 79[...]

– 16 – 4-2. Outdoor Unit RAS-10GA VP-E, RAS-13GA VP-E, RAS-16GA VP-E Pipe dia. Ø 9.52:RAS-10GAVP-E, RAS-13GAVP-E Ø 12.7:RAS-16GAVP-E 2- Ø 20x88 drain long hole leg par t Ø 25 drain hole Ø 11-14U-shape hole (for Ø 8- Ø 10 anchor bolt) Connecting pipe por t Connecting pipe por t (Pipe dia. Ø 6.35) 8- Ø 7 hole (for fixing outdoor unit) Ø[...]

– 17 – 5. WIRING DIA GRAM 5-1. Outdoor Unit RAS-10GA VP-E, RAS-13GA VP-E, RAS-16GA VP-E 5-2. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E MAIN P .C. BO ARD (MCC-5020) HEA T EXCHANGER SENSOR (TC) CN07 (WHI) CN13 (WHI) CN100 (WHI) CN08 (WHI) MCC-899 Wireless Unit Assembly POWER SUPPL Y CIRCUIT 2 1 4 3 BLK 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 [...]

– 18 – 6. SPECIFICA TIONS OF ELECTRICAL P A RTS 6-1. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E 6-2. Outdoor Unit RAS-10GA VP-E, RAS-13GA VP-E, RAS-16GA VP-E No. 1 2 3 4 P ar ts name F an motor (f or indoor) Room temp . sensor (T A-sensor) Heat e xchanger temp . sensor (TC-sensor) Louv er motor T ype MF-280-30-5R ( – ) ( – ) MP[...]

– 19 – 7. REFRIGERANT CYCLE DIA GRAM 7-1. Refrigerant Cycle Dia gram RAS-B10GKVP-E/RAS-10GA VP-E NO TE : • The maximum pipe length of this air conditioner is 25 m. When the pipe length exceeds 15m, the additional charging of refrigerant, 20g per 1m f or the part of pipe exceeded 15m is required. (Max. 200g) Deo xidized copper pipe Outer dia. [...]

– 20 – RAS-B13GKVP-E/RAS-13GA VP-E, RAS-B16GKVP-E/RAS-16GA VP-E NO TE : • The maximum pipe length of this air conditioner is 25 m. When the pipe length exceeds 15m, the additional charging of refrigerant, 20g per 1m f or the part of pipe exceeded 15m is required. (Max. 200g) Max. : 25m Min. : 2m Chargeless : 15m Charge : 20g/m (16 to 25m) Deo[...]

– 21 – 7-2. Operation Data <Cooling> <Heating> T emperature condition (°C) Indoor Outdoor 27/19 35/ – Model name RAS- B10GKVP-E B13GKVP-E B16GKVP-E Standar d pressure P (MP a) 0.9 to 1.1 0.8 to 1.0 0.7 to 0.9 Heat exc hanger pipe temp. T1 (°C) T2 (°C) 13 to 15 42 to 44 11 to 14 42 to 45 8 to 11 43 to 47 Indoor fan mode High Hig[...]

– 22 – 8. CONTR OL BLOCK DIA GRAM 8-1. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E M.C.U. Indoor Unit Control Unit From Outdoor Unit 220-240V ~ 50Hz 220V ~ 60Hz Serial Signal Communication (Operation Command and Information) Serial Signal Transmitter/Receiver Micro Switch Converter (D.C circuit) Noise Filter Indoor Fan Motor Air pur[...]

– 23 – 8-2. Outdoor Unit (In verter Assembly) RAS-10GA VP-E, RAS-13GA VP-E, RAS-16GA VP-E 220 – 240 V ~ 50Hz 220 V ~ 60Hz MICRO-COMPUTER BLOCK DIA GRAM Driver circuit of P.M.V. Heat exchanger temp.sensor Suction temp. sensor Outdoor air temp. sensor Discharge temp. sensor Indoor unit send/receive circuit Relay circuit Noise Filter Converter ([...]

– 24 –    9. OPERA TION DESCRIPTION 9-1. Outline of Air Conditioner Contr ol This air conditioner is a capacity-v ariable type air conditioner , which uses DC motor f or the indoor f an motor and the outdoor f an motor . And the capacity- propor tional control compressor which can change the motor speed in the range from 13 to 115 rps [...]

– 25 – 9-2. Operation Description 9-2. 1. Basic oper ation ........................................................................................................... 26 1. Operation control ................................................................................................... 26 2. Cooling/Heating operation .......................[...]

– 26 – Item 1. Basic operation Operation flow and applicable data, etc. 1. Operation control Description Receiving the user ’ s operation condition setup , the operation statuses of indoor/outdoor units are controlled. 1) The operation conditions are selected by the remote controller as shown in the belo w . 2) A signal is sent by ON button o[...]

– 27 – Operation ON Setup of remote controller Indoor f an motor control / Louver control Indoor unit control Sending of operation command signal Outdoor unit control [ ] Compressor re volution control / Outdoor f an motor control / 4-wa y valv e control In cooling operation: ON In heating operation: OFF Pulse motor valv e control Item 1. Basic[...]

– 28 – Item 2. Indoor f an motor control Operation flow and applicable data, etc. <In cooling operation> (This operation controls the f an speed at indoor unit side.) The indoor f an (cross flow f an) is operated b y the phase- control induction motor . The fan rotates in 5 stages in MANU AL mode, and in 5 stages in A UT O mode , respec- [...]

– 29 – Item 2. Indoor f an motor control Operation flow and applicable data, etc. <In heating operation> Description 1) When setting the f an speed to L, L+, M, M+ or H on the remote controller , the operation is per- f or med with the constant speed shown in Fig. 3 and T able 1. 2) When setting the fan speed to A UT O on the remote contr[...]

– 30 – Item 3. Outdoor fan motor control Operation flow and applicable data, etc. The blo wing air volume at the outdoor unit side is controlled. Receiving the operation command from the controller of indoor unit, the controller of outdoor unit controls f an speed. * For the f an motor , a DC motor with non-stage v ar iable speed system is used[...]

– 31 – Item 4. Capacity control Operation flow and applicable data, etc. The cooling or heating capacity depending on the load is adjusted. According to diff erence between the setup value of tempera- ture and the room temperature, the capacity is adjusted b y the compressor re volution. Description 1) The difference betw een set temperature on[...]

– 32 – Item 6. Release protective control by tempera- ture of indoor heat e xchanger Operation flow and applicable data, etc. <In cooling/dry operation> (Pre vent-freezing control f or indoor heat e xchanger) In cooling/dr y operation, the sensor of indoor heat e xchanger detects ev aporation temperature and controls the compressor speed [...]

– 33 – Item 7. Quick heating control Operation flow and applicable data, etc. This function quick ens the star ting of heating opera- tion when indoor/outdoor temperature is lo w . (A v ailable only in heating operation) When indoor temperature is lo w , this function stores the heat by heating winding depended on the outdoor temperature and th[...]

– 34 – Horizontal blowing Inclined blowing Blowing downward Air direction Inclined blowing Horizontal blowing Powerful Room temp. (Ta) < Set temp. (Tsc) + 3.5 Room temp. (Ta) ≥ Set temp. (Tsc) + 3.5 Initial setting of “ Cooling storage position ” Louver : Directs downward (9 ˚ ) Initial setting of “ Cooling storage position ” Louv[...]

– 35 – Item 10. ECO operation Operation flow and applicable data, etc. When pressing [ECO] button on the remote controller , a quiet and mild operation is perf or med by reducing the f an speed and the compressor speed. <Cooling operation> This function operates the air conditioner with the diff erence between the set and the room tempera[...]

– 36 – Item 11. T emporary operation Operation flow and applicable data, etc. Pressing [RESET] button starts the temporar y opera- tion of [A UT O] operation. When k eeping [RESET] button pressed f or 10 seconds or more, the tempor ar y [COOL] operation is perf or med. Description 1) When pressing [RESET] button, the temporary [A UT O] operatio[...]

– 37 – Item Operation flow and applicable data, etc. Description 1. Purpose The air purifying control function is to aler t the user to trouble in the ionizing or air purifying operation. 2. Description T rouble is determined to hav e occurred (indicated by the FIL TER indicator) in the f ollowing f our cases. 1) When a count of 1000H has been [...]

– 38 – Item 14. Pulse motor valv e (P .M.V .) control Operation flow and applicable data, etc. This function controls throttle amount of the refrigerant in the refr igerating cycle. According to operating status of the air conditioner , this function also controls the open degree of v alve with an e xpansion valv e with pulse motor . Descriptio[...]

– 39 – Item 15. Clean operation Operation flow and applicable data, etc. • During clean operations: The louv er opens slightly . The indoor f an operates continuously at a speed of 260 r pm. Clean operation times • T o stop an ongoing clean operation at any time Press the star t/stop button on the remote controller twice during the clean op[...]

– 40 – Item 16. Clean operation release Operation flow and applicable data, etc. Setting the clean operation release Description * J04 will be near the MCU so take steps to ensure that it will not be e xposed to excessiv e le vels of heat. Also take care to a v oid solder bridging with the surrounding components. Setting the clean operation Ind[...]

– 41 – Both indoor units start operation. Unnecessary set [Remote controller select] Press the operation button on the remote controller. YES NO CLOCK CHECK RESET CLR SET SWING FIX FAN ON OFF HiPOWER ECO MEMO SLEEP 1 . 3 . 5 . 9H When switching between settings “ A ” and “ B ” , always switch the indoor unit board and the remote control[...]

– 42 – Operation Press [RESET] b utton f or more than three seconds. (Less than 10 seconds) Motions The unit is on standb y . ↓ The unit star ts to operate. The green indicator is on. ↓ After appro x. three seconds, The unit beeps three times The green indicator flashes and continues to operate . for 5 seconds. If the unit is not required t[...]

– 43 – Operation Press [RESET] b utton f or more than three seconds. (Less than 10 seconds) Motions The unit is on standb y . ↓ The unit star ts to operate. The green indicator is on. ↓ After appro x. three seconds, The unit beeps three times and continues to operate . If the unit is not required to operate at this time , press [RESET] b ut[...]

– 44 – 9-5. Remote Contr oller and Its Fuctions 9-5-1. P ar ts Name of Remote Controller 1 Infrared signal emitter T ransmits signal to the indoor unit. 2 b utton Press the button to star t operation. (A receiving beep is heard.) Press the button again to stop oper ation. (A receiving beep is heard.) If no receiving sound is heard from the indo[...]

– 45 – AU T O A U T O 3 95 76 1 2 8 4 10 9-5-2. Name and Functions of Indications on Remote Controller [Displa y] All indications, e xcept f or the cloc k time indicator , are displa yed b y pressing the button. 1 T ransmission mark This transmission mark indicates when the remote controller transmits signals to the indoor unit. 2 Mode indicato[...]

– 46 – 9-6. Hi-PO WER Mode ([Hi-PO WER] button on the remote contr oller is pressed) When [Hi-PO WER] button is pressed while the indoor unit is in A uto , Cooling or Heating operation, Hi-PO WER mark is indicated on the display of the remote controller and the unit oper ates as f ollo w s . 1. A utomatic operation • The indoor unit operates [...]

– 47 – 10. INST ALLA TION PR OCEDURE 10-1. Safety Cautions 1 Installation plate Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better installation work. Make sure the drain hose is sloped downward. The auxiliary piping can be connected at the left, rear left, rear right, right, bottom right or bottom left as s[...]

– 48 – 10-2. Optional P arts, Accessories and T ools 10-2-1. Optional Installation Parts P ar t Code Y Z P ar ts name Refrigerant piping Indoor unit name Liquid side (Outer diameter) Gas side (Outer diameter) RAS-B10GKVP-E, B13GKVP-E 6.35 mm 9.52 mm RAS-B16GKVP-E 6.35 mm 12.7 mm Shield pipe (f or extension dr ain hose) (polyeth ylene f oam, 6 m[...]

– 49 – 10-2-3. Installation/Ser vicing T ools Changes in the product and components In the case of an air conditioner using R410A, in order to pre v ent an y other refrigerant from being charged accidentally , the ser vice por t diameter of the outdoor unit control valve (3 w a y v alv e) has been changed. (1/2 UNF 20 threads per inch) • In o[...]

– 50 – 10-3. Indoor Unit 10-3-1. Installation Place • A place which provides enough spaces around the indoor unit as shown in the diagr am. • A place where there are no obstacle near the air inlet and outlet. • A place which allows easy installation of the piping to the outdoor unit. • A place which allows the front panel to be opened. [...]

– 51 – When the installation plate is directly mounted on the wall 1. Securely fit the installation plate onto the wall by scre ws with the upper and lower catches , that hold the indoor unit, f acing out. 2. T o mount the installation plate on a concrete wall use anchor bolts. Drill the anchor bolt holes as illustrated in the abo v e figure . [...]

– 52 – CA UTION • Be sure to ref er to the wiring system diagr am labeled inside the front panel. • Chec k local electrical regulations f or any specific wiring instr uctions or limitations. 10-3-5. Piping and Drain Hose Installation Piping and drain hose f orming • Since condensation results in machine troubl e , make sure to insulate bo[...]

– 53 – 4 mm No gap Insert a hexagon wrench ( Ø 4mm) Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. If applied, deterioration and drain leakage of the drain plug may occur. How to attac h the drain cap 1. Inser t hexagonal wrench (4 mm). Fig. 10-3-13 2. Fir mly inser t drain cap. Fig. 10-3-14 How to attac h[...]

– 54 – CA UTION • Bind the auxiliar y pipes (two) and connecting cab le with f acing tape tightly . In case of leftward piping and rear-leftward piping, bind the auxiliar y pipes (two) only with f acing tape . Fig. 10-3-18 • Carefully arrange the pipes so that none of the pipes stick out of the rear plate of the indoor unit. • Carefully c[...]

– 55 – 10-4. Outdoor Unit 10-4-1. Installation Place • A place which provides enough space around the outdoor unit as shown in the diagr am. • A place which can bear the weight of the outdoor unit and does not allow an increase in noise le v el and vibration. • A place where the operation noise and discharged air do not disturb neighbors.[...]

– 56 – Base plate 9 Drain nipple 10 Water-proof rubber caps (supplied with the outdoor unit) 10-4-2. Draining the W ater • Holes are provided on the base plate of the outdoor unit to ensure that the defrost water produced during heating operations is drained off efficiently . If a centralized dr ain is required when installing the unit on a b[...]

– 57 – Tightening Connection Align the centers of the connecting pipes and tighten the flare nut as much as possib le with y our fingers . Then tighten the nut with a wrench and torque wrench as shown in the figure. Fig. 10-4-7 CA UTION • Do not apply e xcessiv e f orce . Otherwise, the n ut may break. (Unit : N · m) • Tightening torque f [...]

– 58 – P acked V alve handling precautions • Open the v alv e stem all the w ay; but do not try to open it be y ond the stopper . • Securely tighten the v alve stem cap with torque in the f ollo wing tab le: He xagonal wrench is required. Fig. 10-4-10 10-4-5. Wiring Connection 1 . Remov e the v alv e co ve r , the electr ic par ts cov er an[...]

– 59 – 10-5. T est Operation 10-5-1. Gas Leak T est • Chec k the flare nut connections f or gas leaks with a gas leak detector and/or soap y water . Fig. 10-5-1 10-5-2. T est Operation T o test the system, press and hold RESET button f or 10 sec. (There will be one shor t beep .) Fig. 10-5-2 10-5-3. Auto Restart Setting This product is design[...]

– 60 – 11. HO W T O DIA GNOSE THE TR OUBLE The pulse motor circuits are mounted to both indoor and outdoor units. Theref ore, diagnose troub les according to the troub le diagnosis procedure as described below . (Refer to the chec k points in ser vicing written on the wiring diagrams attached to the indoor/outdoor units.) T able 11-1 K Precauti[...]

– 61 – CA UTION A high v oltage (equivalent to the suppl y v oltage) is also ener gized to ground through the sensor s, PMV and other low-v oltage cir cuits. The sensor leads and other wires are covered with insulated tubes f or protection. Ne ver theless, care must be taken to ensure that these wires are not pinched. T ake sufficient care to a[...]

– 62 – 11-1. First Confirmation 11-1-1. Confirmation of P ower Supply Confir m that the pow er breaker oper ates (ON) normally . 11-1-2. Confirmation of P o wer V oltage Confir m that power v oltage is A C 220 – 230 – 240 ± 10%. If power v oltage is not in this range , the unit ma y not oper ate nor mally . 11-1-3. Operation Which is not a[...]

– 63 – 11-2. Primary Judgment T o diagnose the troubles , use the f ollo wing methods . 1) Judgment b y flashing LED of indoor unit 2) Self-diagnosis by ser vice check remote controller 3) Judgment of troub le by e v er y symptom Firstly use the method 1) f or diagnosis. Then, use the method 2) or 3) to diagnose the details of troubles . 11-3. [...]

– 64 – 11-4. Self-Diagnosis b y Remote Contr oller (Check Code) 1. If the lamps are indicated as sho wn B to E in T able 11-3-1, e x ecute the self-diagnosis b y the remote controller . 2. When the remote controller is set to the ser vice mode, the indoor controller diagnoses the oper ation condi- tion and indicates the inf or mation of the sel[...]

– 65 – Check code Check code Judgment and action 1. Chec k the room temp . sensor. 2. When the room temp . sensor is normal, check P .C . board. 1. Chec k heat e xchanger sensor . 2. When heat e xchanger sensor is normal, check P .C . board. 1. Chec k the motor . 2. When the motor is normal, check P .C. board. Replace P .C . board. 1. When the [...]

– 66 – Check code Check code Block distinction Judgment and action Even if trying operation again, all operations stop immediately . : Replace P .C . board. 1. Even if connecting lead wire of compressor is remov ed, position-detect circuit error occurred. : Replace P .C. board. 2. Measure resistance between wires of compressor , and perf or m s[...]

– 67 – 11-5. J udgment of T r ouble b y Every Symptom 11-5-1. Indoor Unit (Including Remote Controller) (1) P ower is not turned on (Does not operate entirel y) <Primary check> 1. Is the supply voltage normal? 2. Is the nor mal voltage provided to the outdoor unit? 3. Is the crossover cab le connected properly? 4. Is the fuse (F01) blown?[...]

– 68 – Turn off power supply once, and turn it on again. Start to operate indoor unit in cooling operation at airflow level “ LOW ” . Turn off indoor unit and remove connector from motor. Then start to operate indoor unit with remote controller. Turn off indoor unit and remove connector from motor. Then push START/STOP button on remote cont[...]

– 69 – Indoor fan starts rotating when power supply is turned on. (Check output DC voltage of fan motor on P.C. board.) Measure voltage between 3 (GND : BLACK) and 5 (V line : YELLOW) of motor connector (CN10) while indoor fan motor is rotating. DC 1.0V or more P.C. board is defective. 6 (Blue) 5 (Yellow) 4 (White) 3 (Black) 2 – 1 (Red) Motor[...]

– 70 – NO YES Push the START/STOP button. Is transmission mark indicated? The unit does not beep at all. Operation lamp on indoor unit is not indicated. NOTE : After replacing batteries, push the RESET button with a tip of a pencil. Is receiver on indoor unit exposed to direct sunlight? Avoid direct sunlight. Is there any thyristor fluorescent [...]

– 71 – Refer to the chart in 11-6. Gas leak P.M.V. is defective. Miswiring of connecting wires of indoor/outdoor units Clogging of pipe and coming-off of TC sensor Gas circulation amount is down. Measure gas pressure. Gas shortage Gas leak Pipe clogging Thermo. operation of compressor Red White T er minal block S5277G T ester 3 2 1 T er minal b[...]

– 72 – NO NO NO NO YES YES YES YES YES Gas leakage, disconnection of TS/TC sensors (Check code 02, 1C) Discharge temp . error , gas leakage (Check code 03, 1E) 1C 1E Gas amount check and v alve clogging chec k Remov e TC sensor connector from the P .C. board in indoor unit. (Remov e connector from the P .C. board.) Operate the air conditioner i[...]

– 73 – Primar y check Operation chec k T urn off the power breaker once , and turn on again after 10 seconds. Does the OPERA TION indicator flash? T urn off the power breaker and remo v e CN34 (Micro switch connector). Shor t-circuit between and pin of CN34 at PC side, and turn on the power break er after 10 seconds. 1) Check operation while sh[...]

– 74 – 11-7-2. How to Chec k Whether the Minus Ion Generator is Good or Not 1) Check operation while short-circuiting CN34 of the main P .C. board. 2) P erform air purifying operation by the remote controller . • In this time, check that the remote controller is in status which is shortened by time on the reactivation pre ventiv e timer and a[...]

– 75 – 11-8. H ow to Dia gnose T r ouble in Outdoor Unit 11-8 -1. Summarized Inner Diagnosis of In verter Assembly T able 11-8-1 Diagnosis/Pr ocess flowchart Item Preparation Check Check Operation Measure- ment Check Stop Check Measure- ment Contents Tu r n “ OFF ” the power supply breake r , and remov e 3P connector which connects inv er t[...]

– 76 – Diagnosis/Pr ocess flowchart Item Check Operation Contents Check winding resistance between phases of compres- sor , and resistance between outdoor frames by using a tester . • Is not grounded. • Is not shor t-circuited between windings . • Winding is not opened. Remov e connector CN300 of the outdoor f an motor , tur n on the pow [...]

– 77 – (3) Check pr ocedures T able 11-9-1 No. 1 2 3 4 5 6 7 Procedure T ur n off the power supply break er and remov e the P .C. board assembly from electronic par ts base. Remove the connecting cables from the terminal bloc k. Remov e the connector of the motor and turn on the power supply breaker . If OPERA TION indicator flashes (once per s[...]

– 78 – 11-9-2. P.C. Board Layout GND +12V +5V 100 30 40 50 60 70 80 90 20 10 0 01 0 2 0 3 0 4 0 5 0 Resistance value (k ) Temperature (˚C) TD : Discharge temp. sensor TA : Room temp. sensor TC : Heat exchanger temp. sensor TO : Outdoor temp. sensor TE : Outdoor heat exchanger temp. sensor TS : Suction temp. sensor TA, TC, TO, TE, TS TD [1] Sen[...]

– 79 – 11-9-3. Indoor Unit (Other Parts) 11-9-4. Outdoor Unit No. 1 P ar t name Room temp . (T A) sensor Heat e xchanger (TC) sensor Checking pr ocedure Disconnect the connector and measure the resistance v alue with tester . (Nor mal temp .) No. 1 P ar t name Compressor (Model : D A111A1F-20F1) Checking pr ocedure Measure the resistance v alue[...]

– 80 – 11-9-5. Chec king Method for Eac h P ar t No. 1 P ar t name Electrolytic capacitor (F or boost, smoothing) Checking pr ocedure 1. T ur n OFF the power supply break er . 2. Discharge all three capacitors completely . 3. Chec k that saf ety valv e at the bottom of capacitor is not brok en. 4. Chec k that v essel is not sw ollen or exploded[...]

– 81 – 11-10. Ho w to Simply J udge Whether Outdoor Fan Motor is Good or Bad 1. Symptom • Outdoor f an motor does not rotate. • Outdoor f an motor stops within se v eral tens seconds though it star ted rotating. • Outdoor f an motor rotates or does not rotate according to the position where the fan stopped, etc. Remote controller chec k c[...]

– 82 – 12. HO W T O REPLA CE THE MAIN P AR TS W ARNING • Since high v oltages pass through the electrical par ts, tur n off the power without f ail bef ore proceeding with the repairs. Electric shocks ma y occur if the pow er plug is not disconnected. • After the repairs ha v e been completed (after the front panel and cabinet ha v e been i[...]

– 83 – No.  P a rt name F ront panel Procedures 4) Press “ ” part under the front panel and remov e hooks of the front panel from the installation plate. Remarks Pull here Press here Press here Press Front panel Installation plate Holder Holder Protrusion Protrusion Electric dust Electric dust collector collector Holder Holder Protrusion[...]

– 84 – Air ionizer Connector Drain guide Press the claw here Press the claw here Pull here Screw No.  P ar t name High v oltage generator Procedures 1) F o llo w to the procedure in the item  . 2) Remov e the drain guide . 3) T o remove the air ioniz er from the bac k body , pull it tow ard you while pressing do wn on its left and right c[...]

– 85 – No.  P a rt name Electric par ts bo x assembly Procedures 1) Fo llo w the procedure up to 4) in  abov e. 2) Remov e screw of earth lead attached to the end plate of the e v apor ator . 3) Remov e the lead wire cov er , and remo ve connector (5P) f or the f an motor and connec- tor (5P) f or the louv er motor from the electric par t[...]

– 86 – No.  P a rt name Horizontal louver Procedures 1) Remov e shaft of the hor izontal louv er from the bac k body . (First remov e the left shaft, and then remov e other shafts while sliding the horizontal louv er leftward.)  Evapor ator (Heat e xchanger) 1) Follo w to the procedure in the item  . 2) Remov e the pipe holder from the[...]

– 87 – Screw Bearing base Screw Raise the left side Remove in this direction Bearing base Bearing Drain pipe Bearing base Drain pipe No.  P a rt name Bearing Procedures 1) F o llo w to the procedure in the items  . 2) Remov e the two fixing scre ws used to secure the left edge panel of the heat e xchanger , and remov e the two scre ws use[...]

– 88 – No.  P a rt name F an motor Procedures 1) F ollo w to the procedure in the item  . 2) Loosen the set screw of the cross flo w f an. 3) Remov e two fixing scre ws of the motor band (Right), and then remov e the motor band (Right). 4) Pull the f an motor outw ard. In assemb ling w ork, install the f an motor as f ollows . • When as[...]

– 89 – No.  P a rt name Cross flow f an Procedures <Caution at reassembling> 1) At assembling wo rk of the bearing base, check that the drain pipe is surely incorpo- rated in the back body . (Otherwise, water leak is caused.) 2) T o incor porate the f an motor , remo v e the f an motor rubber (at shaft core side), incor porate the moto[...]

– 90 – No.  P a rt name Common procedure Procedure 1) T ur n the pow er supply off to stop the operation of air-conditioner . 2) Remov e the front panel. • Remov e the 2 fixing scre w s. 3) Remov e the electrical par t base. Remarks Replace ter minal bloc k, microcomputer ass’y and the P .C . board ass’ y. 12-2. Micr ocomputer <P .C[...]

– 91 – 12-3. Outdoor Unit No.  P a rt name Common procedure Procedure 1. Detachment NO TE W ear gloves f or this job. Otherwise, you ma y injure your hands on the parts, etc. 1) Stop operation of the air conditioner , and tur n off the main s witch of the breaker f or air conditioner . 2) Remov e the v alv e cov er . (ST1TØ 4 × 8L 1 pc.) ?[...]

– 92 – No.  P a rt name F ront cabinet Procedure 1. Detachment 1) P erf orm step 1 in  . 2) Remov e the fixing screws (ST1TØ 4 × 8L 2 pcs.) used to secure the front cabinet and in ver ter cov er , the scre ws (ST1T Ø4 × 8L 3 pcs.) used to secure the front cabinet at the bottom, and the fixing screws (ST1T Ø 4 × 8L 2 pcs.) used to se[...]

– 93 – No.  P a rt name In ve r ter assemb ly Procedure 1) P erf orm work of item 1 in  . 2) Remov e screw (ST1T Ø 4 × 8L 2 pcs.) of the upper par t of the front cabinet. • If removing the in v er ter cover in this condition, P .C . board can be chec k ed. • If there is no space abov e the unit, perf or m work of 1 in  . Be caref[...]

– 94 – No.  P a rt name Control board assemb ly Procedure 1. Disconnect the leads and connectors connected to the other par ts from the control board assemb ly . 1) Leads • 3 leads (b lac k, white, or ange) connected to ter minal bloc k. • Lead connected to compressor : Disconnect the connector (3P). • Lead connected to reactor : Disco[...]

– 95 – No.  P a rt name Side cabinet Procedure 1. Side cabinet (right) 1) P erf orm step 1 in  and all the steps in  . 2) Remov e the fixing scre w (ST1TØ 4 × 8L 5 pcs.) used f or securing the side cabinet to the bottom plate and v alv e fixing panel. 2. Side cabinet (left) 1) P erf orm step 1 in  . 2) Remov e the fixing scre w (S[...]

– 96 – No.  P ar t name Compressor Procedure 1) P erf orm work of item 1 of  and  ,  ,  ,  . 2) Extract refrigerant gas. 3) Remov e the par tition board. (ST1TØ 4 × 8L 3 pcs.) 4) Remov e the sound-insulation material. 5) Remov e ter minal cov er of the compressor , and disconnect lead wire of the compressor from the ter mina[...]

– 97 – No.  P a rt name Electronic e xpansion v alv e coil Procedure 1. Detachment 1) P erf orm step 1 in  , all the steps in  and 1 in  . 2) Remov e the coil by pulling it up from the electronic control v alv e body . 2. Attachment 1) When assembling the coil into the v alv e body , ensure that the coil anti-tur n lock is installed[...]

– 98 – No. 11 P art name Pr ocedure Remarks TE sensor (outdoor heat e xchanging temperature sensor) • Attachment With the leads pointing downw ard and the sensor leads pointing in the direction shown in the figure , install the sensor onto the straight pipe par t of the condenser output pipe. CA UTION During the installation wor k (and on its[...]

– 99 – No. 15 P ar t name Replacement of temperature sensor f or ser vicing only Common ser vice par ts of sensor T O , TS , TE, TD Procedure 1) Cut the sensor 100 mm longer than old one. 2) Cut the protective tube after pulling out it (200 mm). 3) Mov e the protectiv e tube toward the ther mal sensor side and tear the tip of lead wire in two t[...]

– 100 – MCC-5009[...]

– 101 – Location Pa r t Description No. No. 201 43005633 P anel Ass ’ y , F ront 202 43005610 Grille, Air Inlet 203 4301V052 Plate, Fix 204 43080512 Filter , Air , Right 205 43080521 Filter , Air , Left 206 43009675 Louv er , Hor izontal 207 43009682 Louv er , V er tical 209 4302C067 Motor , F an 210 4302C063 Motor , Louver 211 4306A024 Cord,[...]

– 102 – Location Pa r t Description No. No. 401 4306A123 T er minal Block, 2P 402 43062263 Cov er , E-P ar ts 403 43050425 Sensor , TC (F6) 404 43050426 Sensor , T A 405 4306S728 P .C. Board Ass ’ y , WRS-LED 406 43051346 SW -Micro Ass ’y Location Pa r t Description No. No. 407 4306S709 P .C. Board Ass ’y (B10GKVP-E) 408 4306S710 P .C. Bo[...]

– 103 – 13-2. Outdoor Unit 7 35 34 7 45 46 10 3 9 8 2 48 28, 29 44 30, 31 14, 15, 17, 18, 20 21, 23, 24, 25, 26 47 27 37 32 13, 16, 19, 22 35 33 34 38 43 10 11, 12 4 36 6 3 2 40 39 41 42 1 5[...]

– 104 – Location P ar t Description No. 1 43005657 Cabinet, F ront 2 43005642 Cabinet, Upper 3 43005658 Cabinet, Side, Right 4 43005634 Cabinet, Side, Left 5 4301V035 Guard, F an 6 4301V053 Guard, Fin 7 43042489 Base Ass ’y 8 43119471 Cover , V alv e, P ac k ed 9 43062262 Cov er , Wiring Ass ’y 10 43041634 Compressor , D A111A1F-20F1, RoHS [...]

– 105 – Location P ar t Description No. 701 43050422 Sensor , TE 702 43050423 Sensor , TS 703 43050427 Sensor , T O 704 43062228 Base, P .C . board Location P art Description No. 705 43160566 T er minal Block, 6P 706 43050430 Sensor , TD 707 4306S737 P .C. board Ass ’ y , MCC5009 13-3. P .C. Board La y out 704 Base, P .C. Board 707 P .C . Boa[...]

Appendix-1 Appendix No. 1 2 3 4 5 6 7 8 9 10 11 12 Cor d Heater Installation W ork Applicable Models: RAS-10GA VP-E, RAS-13GA VP-E, RAS-16GA VP-E 1. Required parts for installation work (Recommendation) The abov e products conf orm to RoHS (2002/95/EC). Therefore when procuring and using the f ollowing recom- mended par ts at local site, it is reco[...]

Appendix Appendix-2 No. Remarks Specifications/V endor Q’ ty Part name NO TE: The par ts on the abov e tab le are recommended par ts. 13 14 15 16 17 P ow er cord Thermostat fixing plate PVC tube Shield tube Bundling tie 1 1 1 1 1 2-cores x 0.75mm² or more, H05RN-F Material: SGCC-Z08, Board thickness: 0.8t Inside diameter Ø8 x outside diameter ?[...]

Appendix-3 Appendix 3. Cord heater installation wiring diagram LN Fuse Ther mostat Cord heater Outdoor unit Ear th leakage circuit breaker P ower supply f or air conditioner Ear th leakage circuit breaker P o wer supply f or cord heater * Be sure to connect the fuse and the ther mostat to LIVE side of the cord heater . NO TE: Separate the cord heat[...]

Appendix Appendix-4 4. Cord heater installation work procedure No. Photo / Explanat ory diagram Procedure 1 Remove ea ch cabinet, inv erter asse mbly , motor base a ssembly , and partit ion board as sembly . * Do not damage t he electric par ts such as c ables, connec tors, etc. w hile this w ork. Remove th e upper cabinet and the valv e cover . Re[...]

Appendix-5 Appendix No. Photo / Explanatory diagram Procedure Remove th e motor base assem bly , partition plate assembly and the soun d insulati on board. Related parts / S crews list Used screw Part na me S cre w ty pe Qua ntity Moto r base a ssemb ly (Includi ng motor and fan) Ø 4 × 82 Partition pl at e assem bly (Includi ng react or) Ø 4 × [...]

Appendix Appendix-6 No. Photo / Explanat ory diagram Procedure 2 Cord heater install ation work Drill a hol e on the outdoor unit base plate, and fix the co rd heater to the o utdoor unit base plate using P-sha pe clamp. Connect the cor d heater cables . 2-1 Using a motor drill, etc., drill Ø 3.2 hol es on the outdoor unit base plat e. (12 positio[...]

Appendix-7 Appendix No. Photo / Explanatory diagram Procedure 2-4 Rework the s ide cabinet (L) t o remove part of it. The area to be removed is indicated by the shaded lines in the left figure. After removing part of the s ide cab inet (L), deb urr the edges of the side cabi net (L). 2-5 Perform end pro cess and b undling of each cable. Using fix i[...]

Appendix Appendix-8 No. Photo / Explanat ory diagram Procedure 3 Assembly Return a set of the refrige ration cycle assembly int o the outdoor unit base plate and rea ssemble sou nd insulat ion board, part ition plate as sembly , fan motor asse mbly , and side cab inet (R/L) as or iginal. Fix the thermostat fixing plate to the side cabin et (R), bui[...]

Appendix-9 Appendix 28 24 55 11 11 18 45 18 37 56 36 46 11 11 8 5.8 3-Ø3.4 burring hole (Downw ard) 2-Ø3.4 burring hole (Upward) Material: SGCC-Z08, Thickness: 0.8t 5. Drawing of thermostat fixing plate[...]

Appendix Appendix-10 6. Diagram showing positions φ φ φ φ φ 3.2 mm holes to be additionally drilled in base plate[...]

TOSHIBA CARRIER CORPORA TION 2 CHOME 12-32, KONAN, MINA TOKU, TOK YO , 108-0075, JAP AN Cop yright © 1999 to 2005 T OSHIBA CARRIER CORPORA TION, ALL Rights Reser ved. This product is compliant with Directiv e 2002/95/EC , and cannot be disposed as unsor ted municipal waste .[...]