Toshiba Ras 10Gavp E Service Manual
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FILE NO. A05-008 SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit
RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E RAS-10GAVP-E RAS-13GAVP-E RAS-16GAVP-E R410A PRINTED IN JAPAN, Nov.,2005 ToMo CONTENTS 1. SAFETY PRECAUTIONS .......................................................................... 3 2. SPECIFICATIONS ..................................................................................... 5 3. REFRIGERANT R410A ............................................................................. 7 4. CONSTRUCTION VIEWS ........................................................................ 15 5. WIRING DIAGRAM .................................................................................. 17 6. SPECIFICATIONS OF ELECTRICAL PARTS ......................................... 18 7. REFRIGERANT CYCLE DIAGRAM ........................................................ 19 8. CONTROL BLOCK DIAGRAM ................................................................ 22 9. OPERATION DESCRIPTION ................................................................... 24 10. INSTALLATION PROCEDURE ................................................................ 47 11. HOW TO DIAGNOSE THE TROUBLE ...................................................... 60 12. HOW TO REPLACE THE MAIN PARTS ................................................... 82 13. EXPLODED VIEWS AND PARTS LIST ................................................. 101 Cord Heater Installation Work ........................................................ Appendix-1 –2– 1. SAFETY PRECAUTIONS For general public use Power supply cord of outdoor unit shall be more than 1.5 mm 2 (H07RN-F or 245IEC66) polychloroprene sheathed flexible cord. • • • • Read this “SAFETY PRECAUTIONS” carefully before servicing. The precautions described below include the important items regarding safety. Observe them without fail. After the servicing work, perform a trial operation to check for any problem. Turn off the main power supply switch (or breaker) before the unit maintenance. CAUTION New Refrigerant Air Conditioner Installation • THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER. R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type refrigerant R410A air conditioner circuit. To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port on main unit and installation tools are different from those used for the conventional refrigerant units. Accordingly, special tools are required for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittings made for R410A only, so that water and/or dust does not enter. Moreover, do not use the existing piping because there are some problems with pressure fittings and possible impurities in existing piping. CAUTION TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY This appliance must be connected to the main power supply by 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. DANGER • ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO INSTALL/MAINTAIN THE AIR CONDITIONER. INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE. • 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. DANGER: HIGH VOLTAGE The high voltage circuit is incorporated. Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand. • CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED, ELECTRIC PARTS MAY BE DAMAGED. • CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND INSTALLATION. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK. –3– • DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION. • TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC. • WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL BECOME ABNORMALLY HIGH AND IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES. • IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE WORK AND THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY RESULT. WARNING • Never modify this unit by removing any of the safety guards or bypass 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. • After the installation work, confirm that refrigerant gas does not leak. If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may generate. • The electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive circuit. An insufficient circuit capacity or inappropriate installation may cause fire. • When wiring, use the specified cables and connect the terminals securely to prevent external forces applied to the cable from affecting the terminals. • Be sure to provide grounding. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables. • Conform to the regulations of the local electric company when wiring the power supply. Inappropriate grounding may cause electric shock. CAUTION • Exposure of unit to water or other moisture before installation may result in an electrical short. Do not store in a wet basement or expose to rain or water. • 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 or discharged air might disturb neighbors. • To avoid personal injury, be careful when handling parts with sharp edges. • Perform the specified installation work to guard against an earthquake. If the air conditioner is not installed appropriately, accidents may occur due to the falling unit. For Reference: If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan. It is recommended to procure an antifreeze heater locally for a safe installation of the air conditioner. For details, contact the dealer. –4– 2. SPECIFICATIONS 2-1. Specifications RAS-B10GKVP-E/RAS-B13GKVP-E/RAS-B16GKVP-E, RAS-10GAVP-E/RAS-13GAVP-E/RAS-16GAVP-E Unit model Indoor Outdoor Cooling capacity Cooling capacity range Heating capacity Heating capacity range Power supply Indoor Electric characteristics Outdoor COP Operating noise Indoor Outdoor Unit model Dimension Indoor unit (kW) (kW) (kW) (kW) Operation mode Running current Power consumption Power factor Operation mode Running current Power consumption Power factor Starting current (Cooling/Heating) High (Cooling/Heating) Medium (Cooling/Heating) Low (Cooling/Heating) (Cooling/Heating) Height Width Depth (A) (W) (%) (A) (W) (%) (A) (dB•A) (dB•A) (dB•A) (dB•A) (mm) (mm) (mm) (kg) (W) (Cooling/Heating) (m³/h) Net weight Fan motor output Air flow rate Unit model Height Dimension Width Depth Net weight Outdoor unit Motor output Compressor Type Model Fan motor output Air flow rate (Cooling/Heating) Type Liquid side Indoor unit Gas side Liquid side Piping Outdoor unit connection Gas side Maximum length Maximum chargeless length Maximum height difference Name of refrigerant Refrigerant Weight Power supply Wiring connection Interconnection Indoor (Cooling/Heating) Usable temperature range Outdoor (Cooling/Heating) Installation plate Wireless remote controller Batteries Remote controller holder Zeolite-plus filter Indoor unit Mounting screw Accessory Remote controller holder mounting screw Plasma pure filter Installation manual Owner’s manual Drain nipple Outdoor unit Water-proof rubber cap (mm) (mm) (mm) (kg) (W) (W) (m³/h) (m) (m) (m) (kg) (°C) (°C) RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E RAS-10GAVP-E RAS-13GAVP-E RAS-16GAVP-E 2.5 3.5 4.5 0.5–3.5 0.6–4.5 0.8–5.0 3.2 4.2 5.5 0.6–5.8 0.6–6.6 0.8–7.8 1 Ph/50Hz/220–240 V, 1 Ph/60Hz/220 V Cooling Heating Cooling Heating Cooling Heating 0.15 0.15 0.15 0.15 0.15 0.15 30 30 30 30 30 30 87 87 87 87 87 87 Cooling Heating Cooling Heating Cooling Heating 2.48/2.37/2.26 3.25/3.10/2.96 4.25/4.06/3.89 4.52/4.31/4.13 6.45/6.17/5.90 7.07/6.76/6.47 520 680 890 945 1350 1480 95 95 95 95 95 95 3.40/3.25/3.11 4.67/4.46/4.28 7.22/6.91/6.62 4.55/4.51 3.80/4.31 3.26/3.64 42/43 43/44 45/45 33/34 34/35 36/36 27/27 27/27 29/29 46/47 48/50 49/50 RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 250 250 250 790 790 790 215 215 215 9 9 9 30 30 30 550/610 560/640 640/660 RAS-10GAVP-E RAS-13GAVP-E RAS-16GAVP-E 550 550 550 780 780 780 290 290 290 35 37 37 750 750 750 Twin rotary type with DC-inverter variable speed control DA111A1F-20F1 DA111A1F-20F1 DA111A1F-20F1 43 43 43 2150/2150 2410/2410 2410/2410 Flare connection Flare connection Flare connection Ø6.35 Ø6.35 Ø6.35 Ø9.52 Ø9.52 Ø12.7 Ø6.35 Ø6.35 Ø6.35 Ø9.52 Ø9.52 Ø12.7 25 25 25 15 15 15 10 10 10 R410A R410A R410A 0.82 0.96 0.96 3 Wires : includes earth (Outdoor) 4 Wires : includes earth 21–32/0–28 21–32/0–28 21–32/0–28 5–43/–15–24 5–43/–15–24 5–43/–15–24 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 6 (Ø4 × 25L) 6 (Ø4 × 25L) 6 (Ø4 × 25L) 2 (Ø3.1 × 16L) 2 (Ø3.1 × 16L) 2 (Ø3.1 × 16L) 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 • The specifications may be subject to change without notice for purpose of improvement. –5– 2-2. Operation Characteristic Curve 10 10 9 9 8 8 7 RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 6 6 5 5 4 3 4 3 2 2 • Conditions Indoor : DB 27˚C/WB 19˚C Outdoor : DB 35˚C Air flow : High Pipe length : 7.5m Voltage : 230V 1 0 0 RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 7 Current (A) Current (A) 20 40 60 80 100 Compressor speed (rps) • Conditions Indoor : DB 20˚C Outdoor : DB 7˚C/WB 6˚C Air flow : High Pipe length : 7.5m Voltage : 230V 1 120 0 0 140 20 100 40 60 80 Compressor speed (rps) 120 140 2-3. Capacity Variation Ratio According to Temperature 110 120 100 100 80 90 80 Capacity ratio (%) Capacity ratio (%) RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 40 70 60 60 20 • Conditions Indoor : DB27˚C/WB19˚C Indoor air flow : High Pipe length : 7.5m 0 –15 50 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 • Conditions Indoor : DB 20˚C Indoor air flow : High Pipe length : 7.5m –10 –5 0 Outdoor temp. (˚C) Outdoor temp. (˚C) * Capacity ratio : 100% = 2.5 kW (RAS-B10GKVP-E) 3.5 kW (RAS-B13GKVP-E) 4.5 kW (RAS-B16GKVP-E) –6– 5 10 3. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer. The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time. The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work. 6. When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level. If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result. 7. Be sure to carry out installation or removal according to the installation manual. Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc. 8. Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician. Improper repair’s may result in water leakage, electric shock and fire, etc. 3-1. Safety During Installation/Servicing As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration. 1. Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A. If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture. 2. Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R410A. The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R22. 3. If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire, a poisonous gas may occur. 4. When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused. 5. After completion of installation work, check to make sure that there is no refrigeration gas leakage. If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur. 3-2. Refrigerant Piping Installation 3-2-1. Piping Materials and Joints Used For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants. 1. Copper Pipes It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface). Otherwise, the expansion valve or capillary tube may become blocked with contaminants. As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials. Thicknesses of copper pipes used with R410A are as shown in Table 3-2-1. Never use copper pipes thinner than 0.8 mm even when it is available on the market. –7– Table 3-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A R22 1/4 6.35 0.80 0.80 3/8 9.52 0.80 0.80 1/2 12.70 0.80 0.80 5/8 15.88 1.00 1.00 2. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used. Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-2-6 below. b) Socket Joints Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm. Thicknesses of socket joints are as shown in Table 3-2-2. Table 3-2-2 Minimum thicknesses of socket joints Nominal diameter Reference outer diameter of copper pipe jointed (mm) Minimum joint thickness (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 3-2-2. Processing of Piping Materials When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil than lubricating oils used in the installed air-water heat pump is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover. 1. Flare processing procedures and precautions a) Cutting the Pipe By means of a pipe cutter, slowly cut the pipe so that it is not deformed. b) Removing Burrs and Chips If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation. c) Insertion of Flare Nut –8– d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool. Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment. ØD A Fig. 3-2-1 Flare processing dimensions Table 3-2-3 Dimensions related to flare processing for R410A A (mm) Nominal diameter Outer diameter (mm) Thickness (mm) Conventional flare tool Flare tool for R410A clutch type Clutch type Wing nut type 1/4 6.35 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0 3/8 9.52 0.8 0 to 0.5 1.0 to 1.5 1.5 to 2.0 1/2 12.70 0.8 0 to 0.5 1.0 to 1.5 2.0 to 2.5 5/8 15.88 1.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5 Table 3-2-4 Dimensions related to flare processing for R22 A (mm) Nominal diameter Outer diameter (mm) Thickness (mm) Conventional flare tool Flare tool for R22 clutch type Clutch type Wing nut type 1/4 6.35 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5 3/8 9.52 0.8 0 to 0.5 0.5 to 1.0 1.0 to 1.5 1/2 12.70 0.8 0 to 0.5 0.5 to 1.0 1.5 to 2.0 5/8 15.88 1.0 0 to 0.5 0.5 to 1.0 1.5 to 2.0 Table 3-2-5 Flare and flare nut dimensions for R410A Dimension (mm) Nominal diameter Outer diameter (mm) Thickness (mm) A B C D Flare nut width (mm) 1/4 6.35 0.8 9.1 9.2 6.5 13 17 3/8 9.52 0.8 13.2 13.5 9.7 20 22 1/2 12.70 0.8 16.6 16.0 12.9 23 26 5/8 15.88 1.0 19.7 19.0 16.0 25 29 –9– Table 3-2-6 Flare and flare nut dimensions for R22 Dimension (mm) Nominal diameter Outer diameter (mm) Thickness (mm) A B C D Flare nut width (mm) 1/4 6.35 0.8 9.0 9.2 6.5 13 17 3/8 9.52 0.8 13.0 13.5 9.7 20 22 1/2 12.70 0.8 16.2 16.0 12.9 20 24 5/8 15.88 1.0 19.7 19.0 16.0 23 27 3/4 19.05 1.0 23.3 24.0 19.2 34 36 45˚ 6˚ to 4 B A C 43˚ D to 4 5˚ Fig. 3-2-2 Relations between flare nut and flare seal surface 2. Flare Connecting Procedures and Precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur. When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 3-2-7 shows reference values. NOTE : When applying oil to the flare surface, be sure to use oil designated by the manufacturer. If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out. Table 3-2-7 Tightening torque of flare for R410A [Reference values] Nominal diameter Outer diameter (mm) Tightening torque N•m (kgf•cm) Tightening torque of torque wrenches available on the market 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) – 10 – 3-3. Tools 3-3-1. Required Tools The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened. The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types. 1. Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) 2. Tools exclusive for R410A, but can be also used for conventional refrigerant (R22) 3. Tools commonly used for R410A and for conventional refrigerant (R22) The table below shows the tools exclusive for R410A and their interchangeability. Tools exclusive for R410A (The following tools for R410A are required.) Tools whose specifications are changed for R410A and their interchangeability R410A air-water heat pump installation No. Used tool Usage Existence of new equipment for R410A Whether conventional equipment can be used Conventional air-water heat pump installation Whether new equipment can be used with conventional refrigerant 1 Flare tool Pipe flaring Yes *(Note 1) ¡ 2 Copper pipe gauge for adjusting projection margin Flaring by conventional flare tool Yes *(Note 1) *(Note 1) 3 Torque wrench (For Ø12.7) Connection of flare nut Yes × × 4 Gauge manifold Charge hose Evacuating, refrigerant charge, run check, etc. Yes 5 × × 6 Vacuum pump adapter Vacuum evacuating Yes ¡ 7 Electronic balance for refrigerant charging Refrigerant charge Yes 8 Refrigerant cylinder Refrigerant charge Yes 9 Leakage detector Gas leakage check Yes 10 Charging cylinder Refrigerant charge (Note 2) × × × × × ¡ × ¡ × (Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary. (Note 2) Charging cylinder for R410A is being currently developed. General tools (Conventional tools can be used.) In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools. 1. Vacuum pump Use vacuum pump by attaching vacuum pump adapter. 2. Torque wrench (For Ø6.35, Ø9.52) 3. Pipe cutter 4. 5. 6. 7. 8. Reamer Pipe bender Level vial Screwdriver (+, –) Spanner or Monkey wrench 9. Hole core drill (Ø65) 10. Hexagon wrench (Opposite side 4mm) 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 – 11 – 3-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment. When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch. Connect the charge hose to packed valve service port at the outdoor unit’s gas side. Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return. Connect the charge hose to the vacuum pump adapter. Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant. Open fully both packed valves at liquid and gas sides. (For refrigerant charging, see the figure below.) 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. 1. Never charge refrigerant exceeding the specified amount. 2. If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode. 3. Do not carry out additional charging. When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury. (Water heat exchanger unit) (Outdoor unit) Opened Refrigerant cylinder (with siphon) Check valve Opened Opened Open/close valve for charging Closed Service port Electronic balance for refrigerant charging Fig. 3-4-1 Configuration of refrigerant charging – 12 – 1. Be sure to make setting so that liquid can be charged. 2. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon. [ Cylinder with siphon ] [ Cylinder without siphon ] Gauge manifold Gauge manifold OUTDOOR unit OUTDOOR unit Refrigerant cylinder Refrigerant cylinder Electronic balance Electronic balance Siphon R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies. Fig. 3-4-2 3-5. Brazing of Pipes 1. Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint. 2. When performing brazing again at time of servicing, use the same type of brazing filler. 3-5-1. Materials for Brazing 1. Silver brazing filler Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability. 2. Phosphor bronze brazing filler Phosphor bronze brazing filler is generally used to join copper or copper alloy. 3. Low temperature brazing filler Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes. 3-5-2. Flux 1. Reason why flux is necessary • By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler. • In the brazing process, it prevents the metal surface from being oxidized. • By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal. – 13 – 2. Characteristics required for flux • Activated temperature of flux coincides with the brazing temperature. • Due to a wide effective temperature range, flux is hard to carbonize. • It is easy to remove slag after brazing. • The corrosive action to the treated metal and brazing filler is minimum. • It excels in coating performance and is harmless to the human body. As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc. 3. Types of flux • Noncorrosive flux Generally, it is a compound of borax and boric acid. It is effective in case where the brazing temperature is higher than 800°C. • Activated flux Most of fluxes generally used for silver brazing are this type. It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound. 4. Piping materials for brazing and used brazing filler/flux Piping material Used brazing filler Used flux Copper - Copper Phosphor copper Do not use Copper - Iron Silver Paste flux Iron - Iron Silver Vapor flux 3-5-3. Brazing As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified. In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow. Never use gas other than Nitrogen gas. 1. Brazing method to prevent oxidation 1) Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder. 2) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder. 3) Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas. 4) When the Nitrogen gas is flowing, be sure to keep the piping end open. 5) Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 MPa (0.2kgf/cm2) by means of the reducing valve. 6) After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands). 7) Remove the flux completely after brazing. M Flow meter Stop valve Nitrogen gas cylinder 1. Do not enter flux into the refrigeration cycle. 2. When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine. 3. When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water). 4. Remove the flux after brazing. From Nitrogen cylinder Pipe Nitrogen gas Rubber plug Fig. 3-5-1 Prevention of oxidation during brazing – 14 – 4. CONSTRUCTION VIEWS 4-1. Indoor Unit RAS-B10GKVP-E RAS-B13GKVP-E RAS-B16GKVP-E 790 Plasma pure filter Indoor heat exchanger Front panel Air filter 215 60 60 250 790 53 Knockout system 7 7 53 Knockout system Zeolite-plus filter 53 53 Air ionizer 54.5 60 60 54.5 Remote controller holder 64 5 125.5 Installation plate hanging section Wireless remote controller 58 19 Connecting pipe (Outside length:0.4m) Flare Ø9.52 (RAS-B16GKVP-E : Ø12.7) Connecting pipe (Outside length:0.45m) Flare Ø6.35 163 Drain hose (Outside length:0.54m) 290 Installation plate hanging section Parts name of remote controller 10 674 450 288 10 10 25 Stud bolt hole for Ø6 10 Minimum distance to ceilinfg Stud bolt hole for Ø8 to Ø10 Minimum distance to wall Minimum distance to wall 74 or more 42 140 or more Lower part hanging section 3 250 42 167.5 Hanging section 47 or more 91 Outline of installation plate Center line of main unit 91 Center line of installation plate 304 304 790 – 15 – 91 WH-H03JE 4-2. Outdoor Unit RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E 60 108 Ø25 drain hole 125 90 54 RAS-13GAVP-E) (Pipe dia. Ø9.52:RAS-10GAVP-E, Ø12.7:RAS-16GAVP-E 290 Connecting pipe port (Pipe dia. Ø6.35) 30 20 8-Ø7 hole (for fixing outdoor unit) Ø11x14 long hole (for Ø8-Ø10 anchor bolt) B leg part 257 483 Packed valve cover 157 79 21 6 147 21 108 69.5 Ø11-14U-shape hole (for Ø8-Ø10 anchor bolt) Connecting pipe port 145.5 320 (Anchor bort long hole pitch) 306 Ø7 hole pitch 2-Ø20x88 drain long hole 600 30 A leg part 483 449 Z 25 22 35 52 8 32 143 54 93 31 137 550 145 71 500 342 780 Charging port 4-Ø4.5 embossment Fan guard Fin guard Detailed A leg part 600 54 38 When installing the outdoor unit, leave open in at least two of directions (A), (B), (C) and (D) shown in the figure below. 11 5 R1 hole 2-Ø7 320 Z view Mounting dimensions of anchor bolt 2-Ø11x14U- Shape hole (for Ø8-Ø10 anchor bolt) D 50 or more Outside line of product .5 R5 600 Intake 250 or more A 11 C 100 or more Outside line of product 200 or more B Outlet Minimum distance from wall 2-Ø11x14 long hole (for Ø8-Ø10 anchor bolt) Outside line of product 320 320 Intake 38 54 600 Detailed B leg part – 16 – 2-Ø 7h ole R1 5 R5 .5 5. WIRING DIAGRAM 5-1. Outdoor Unit RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E Color Identification 220-240V 220V RED : RED WHI : WHITE BLK : BLACK BLU : BLUE BRW : BROWN ORN : ORANGE PUR : PURPUL YEL : YELLOW GRY : GRAY PNK : PINK GRN& GREEN& YEL : YELLOW ~50Hz ~60Hz 5-2. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E RED BRW BRW BRW 1 2 3 4 5 6 HEAT EXCHANGER SENSOR (TC) CN03 (WHI) BLK 1 1 BLK BLK WHI RED 3 CN22 CN33 (WHI) 2 2 INDOOR TERMINAL 1 2 3 BLOCK Ion electrode 1 2 3 4 1 2 3 4 CN01 (BLU) BLK 1 1 BLK Air purifier Electrode 1 2 3 4 1 2 3 4 1 2 3 4 5 6 High-voltage Power supply BLK BLK Heat exchanger GRN & YEL 1 CN23 CN21 1 1 CN34 2 2 (RED) FUSE F01 AC 250V T3.15A CN10 (WHI) 1 1 2 2 THERMO SENSOR (TA) 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 MCC-899 10 10 BLU BLU BLU BLU BLU BLU BLU BLU WHI CN13 (WHI) 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 MAIN P.C. BOARD 1 (MCC-5020) LINE FILTER DC5V DB01 DC12V TNR CN08 (WHI) POWER SUPPLY CIRCUIT Wireless Unit Assembly CN100 (WHI) 3 4 5 6 Micro SW BLU FAN MOTOR RED BLK 3 WHI 4 YEL 5 BLU 6 CN07 (WHI) 1 2 3 4 5 BRW 1 2 3 4 5 WHI YEL YEL YEL YEL DC MOTOR 1 2 3 4 5 1 2 3 4 5 LOUVER MOTOR 1 2 3 4 – 17 – 6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E Parts name No. Type MF-280-30-5R Specifications 1 Fan motor (for indoor) DC280–340V, 30W 2 Room temp. sensor (TA-sensor) (–) 10kΩ at 25°C 3 Heat exchanger temp. sensor (TC-sensor) (–) 10kΩ at 25°C 4 Louver motor MP24Z Output (Rated) 1W, 16 poles, DC12V Model name Rating 6-2. Outdoor Unit RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E Parts name No. 1 Reactor CH-57 2 Outside fan motor 3 Suction temp. sensor (TS sensor) (Inverter attached) 10kΩ (25°C) 4 Discharge temp. sensor (TD sensor) (Inverter attached) 62kΩ (20°C) 5 Outside air temp. sensor (TO sensor) (Inverter attached) 10kΩ (25°C) 6 Heat exchanger temp. sensor (TE sensor) (Inverter attached) 10kΩ (25°C) 7 Terminal block (6P) —— 20A, AC250V 8 Compressor 9 Coil for P.M.V. 10 Coil for 4-way valve ICF-140-43-4R DA111A1F-20F1 CAM-MD12TF VHV – 18 – L = 10mH, 16A × 2 DC140V, 43W 3-phases 4-poles 750W DC12V AC220–240V 7. REFRIGERANT CYCLE DIAGRAM 7-1. Refrigerant Cycle Diagram RAS-B10GKVP-E/RAS-10GAVP-E INDOOR UNIT T1 Temp. measurement Indoor heat exchanger P Pressure measurement Gauge attaching port Vacuum pump connecting port TA Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm Sectional shape of heat insulator Deoxidized copper pipe Outer dia. : 9.52mm Thickness : 0.8mm Allowable pipe length Cross flow fan Allowable height difference : 10m TC Max. : 25m Min. : 2m Chargeless : 15m Charge : 20g/m (16 to 25m) Strainer Muffler 4-way valve (STF-0108Z) Pulse motor valve at liquid side (CAM-B22YGTF-3) Muffler TD Compressor DA111A1F-20F1 Strainer TS TO Outdoor heat exchanger Temp. measurement T2 TE Refrigerant amount : 0.82kg Propeller fan OUTDOOR UNIT NOTE : Gas leak check position Refrigerant flow (Cooling) Refrigerant flow (Heating) NOTE : • 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 for the part of pipe exceeded 15m is required. (Max. 200g) – 19 – RAS-B13GKVP-E/RAS-13GAVP-E, RAS-B16GKVP-E/RAS-16GAVP-E INDOOR UNIT T1 Temp. measurement Indoor heat exchanger P Pressure measurement Gauge attaching port Vacuum pump connecting port TA Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm Sectional shape of heat insulator Deoxidized copper pipe Outer dia. : 9.52mm(13), 12.7mm(16) Thickness : 0.8mm Allowable pipe length Cross flow fan Allowable height difference : 10m TC Max. : 25m Min. : 2m Chargeless : 15m Charge : 20g/m (16 to 25m) Strainer Muffler 4-way valve (STF-0108Z) Pulse motor valve at liquid side (CAM-B22YGTF-3) Muffler TD Compressor DA111A1F-20F1 TS TO Outdoor heat exchanger Split capillary Ø1.2 x 80 Ø1.2 x 80 Temp. measurement T2 TE Refrigerant amount : 0.96kg Propeller fan OUTDOOR UNIT NOTE : Gas leak check position Refrigerant flow (Cooling) Refrigerant flow (Heating) NOTE : • 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 for the part of pipe exceeded 15m is required. (Max. 200g) – 20 – 7-2. Operation Data Temperature condition (°C) Indoor 27/19 Model name RAS- Outdoor 35/– Standard pressure P (MPa) Heat exchanger pipe temp. T1 (°C) T2 (°C) Indoor fan mode Outdoor fan mode Compressor revolution (rps) B10GKVP-E 0.9 to 1.1 13 to 15 42 to 44 High High 37 B13GKVP-E 0.8 to 1.0 11 to 14 42 to 45 High High 59 B16GKVP-E 0.7 to 0.9 8 to 11 43 to 47 High High 82 Model name RAS- Standard pressure P (MPa) Indoor fan mode Outdoor fan mode Compressor revolution (rps) Temperature condition (°C) Indoor 20/– Outdoor 7/6 Heat exchanger pipe temp. T1 (°C) T2 (°C) B10GKVP-E 2.2 to 2.4 37 to 39 0 to 3 High High 54 B13GKVP-E 2.5 to 2.7 42 to 45 0 to 2 High High 65 B16GKVP-E 2.8 to 3.0 48 to 49 0 to 2 High High 86 NOTES : 1. Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent. (Thermistor themometer) 2. Connecting piping condition : 7.5 m – 21 – 8. CONTROL BLOCK DIAGRAM 8-1. Indoor Unit RAS-B10GKVP-E, RAS-B13GKVP-E, RAS-B16GKVP-E Indoor Unit Control Unit M.C.U. Heat Exchanger Sensor (Tc) Louver Motor Functions • Cold draft preventing Function Room Temperature Sensor (Ta) • 3-minute Delay at Restart for Compressor Infrared Rays Signal Receiver and Indication Initializing Circuit Clock Frequency Oscillator Circuit Louver Motor Drive Control • Fan Motor Starting Control Indoor Fan Motor Control • Processing (Temperature Processing) Indoor Fan Motor • Timer • Serial Signal Communication • Clean Function Power Supply Circuit Air purifier unit Converter (D.C circuit) Micro Switch Noise Filter From Outdoor Unit 220-240V ~50Hz 220V ~60Hz Serial Signal Transmitter/Receiver Serial Signal Communication (Operation Command and Information) Remote Controller REMOTE CONTROLLER Operation (START/STOP) Operation Mode Selection AUTO, COOL, DRY, HEAT Thermo. Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver AUTO Swing Louver Direction Setting ECO Hi-POWER Air Purifier SLEEP – 22 – Infrared Rays, 36.7kHz ~50Hz ~60Hz MCC5009 (P.C.B) Indoor unit send/receive circuit Outdoor air temp. sensor – 23 – Suction temp. sensor Heat exchanger temp.sensor Noise Filter Current detect M.C.U • • • • • • • • • • • Discharge temp. sensor OUTDOOR UNIT PWM synthesis function Input current release control IGBT over-current detect control Outdoor fan control High power factor correction control Inverter output frequency control A/D converter function P.M.V. control Discharge temp. control 4-way valve control Signal communication to indoor unit High Power factor Correction circuit Clock frequency 4MHz Input current sensor Converter (AC → DC) Driver circuit of P.M.V. P.M.V. Gate drive circuit Current detect Gate drive circuit Inverter (DC → AC) Relay circuit 4-way valve Inverter (DC → AC) P.M.V. : Pulse Motor Valve M.C.U. : Micro Control Unit Outdoor Fan motor Compressor 8-2. Outdoor Unit (Inverter Assembly) 220–240 V 220 V RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E MICRO-COMPUTER BLOCK DIAGRAM For INDOOR UNIT 9. OPERATION DESCRIPTION • Detection of inverter input current and current release operation • Over-current detection and prevention operation to IGBT module (Compressor stop function) • Compressor and outdoor fan stop function when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system) • Transferring of operation information (Serial signal) from outdoor unit controller to indoor unit controller • Detection of outdoor temperature and operation revolution control • Defrost control in heating operation (Temp. measurement by outdoor heat exchanger and control for 4-way valve and outdoor fan) 9-1. Outline of Air Conditioner Control This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor fan motor and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 13 to 115 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control fan motor are mounted to the outdoor unit. The entire air conditioner is mainly controlled by the indoor unit controller. The indoor unit controller drives the indoor fan motor based upon command sent from the remote controller, and transfers the operation command to the outdoor unit controller. The outdoor unit controller receives operation command from the indoor unit side, and controls the outdoor fan and the pulse motor valve. (P.M.V) Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors drive according to the operation command. And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller. 3. Contents of operation command signal (Serial signal) from indoor unit controller to outdoor unit controller The following three types of signals are sent from the indoor unit controller. • Operation mode set on the remote controller • Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.) • Temperature of indoor heat exchanger • For these signals ([Operation mode] and [Compressor revolution] indoor heat exchanger temperature), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value. As the compressor adopts four-pole brushless DC motor, the frequency of the supply power from inverter to compressor is two-times cycles of the actual number of revolution. 1. Role of indoor unit controller The indoor unit controller judges the operation commands from the remote controller and assumes the following functions. • Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor. (TA sensor) • Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor) (Prevent-freezing control, etc.) • Louver motor control • Indoor fan motor operation control • LED (Light Emitting Diode) 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) to the outdoor unit and judgment/display of error • Air purifier operation control 4. Contents of operation command signal (Serial signal) from outdoor unit controller to indoor unit controller 2. Role of outdoor unit controller The following signals are sent from the outdoor unit controller. • The current operation mode • The current compressor revolution • Outdoor temperature • Existence of protective circuit operation For transferring of these signals, the indoor unit controller monitors the contents of signals, and judges existence of trouble occurrence. Contents of judgment are described below. • Whether distinction of the current operation status meets to the operation command signal • Whether protective circuit operates When no signal is received from the outdoor unit controller, it is assumed as a trouble. Receiving the operation command signal (Serial signal) from the indoor unit controller, the outdoor unit performs its role. • Compressor operation control • Operation control of outdoor fan motor Operations followed to judgment of serial signal from indoor side. • P.M.V. control • 4-way valve control – 24 – 9-2. Operation Description 9-2. 1. Basic operation ........................................................................................................... 26 1. Operation control ................................................................................................... 26 2. Cooling/Heating operation ..................................................................................... 27 3. AUTO operation ..................................................................................................... 27 4. DRY operation ........................................................................................................ 27 2. Indoor fan motor control ............................................................................................. 28 3. Outdoor fan motor control........................................................................................... 30 4. Capacity control .......................................................................................................... 31 5. Current release control ............................................................................................... 31 6. Release protective control by temperature of indoor heat exchanger ........................ 32 7. Quick heating control .................................................................................................. 33 8. Defrost control (Only in heating operation) ................................................................ 33 9. Louver control ............................................................................................................. 34 1) Louver position ....................................................................................................... 34 2) Air direction adjustment ......................................................................................... 34 3) Swing ..................................................................................................................... 34 10. ECO operation ............................................................................................................ 35 11. Temporary operation ................................................................................................... 36 12. Air purifying control [Detection of abnormality] .......................................................... 37 13. Discharge temperature control ................................................................................... 37 14. Pulse motor valve (P.M.V.) control .............................................................................. 38 15. Clean operation .......................................................................................................... 39 16. Clean operation release ............................................................................................ 40 17. Select switch on remote controller ............................................................................. 41 9-3. Auto Restart Function............................................................................................. 42 9-3-1. How to Set the Auto Restart Function .................................................................... 42 9-3-2. How to Cancel the Auto Restart Function ............................................................. 43 9-3-3. Power Failure During Timer Operation ................................................................... 43 9-4. FILTER Indicator ...................................................................................................... 43 9-4-1. How to Turn Off FILTER Indicator ............................................................................ 43 9-5. Remote Controller and Its Fuctions ...................................................................... 44 9-5-1. Parts Name of Remote Controller ........................................................................... 44 9-5-2. Name and Functions of Indications on Remote Controller ................................. 45 9-6. Hi-POWER Mode ([Hi-POWER] button on the remote controller is pressed) .................................. 46 – 25 – Item Operation flow and applicable data, etc. 1. Basic operation Description 1. Operation control Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are controlled. 1) The operation conditions are selected by the remote controller as shown in the below. 2) A signal is sent by ON button of the remote controller. 3) The signal is received by a sensor of the indoor unit and processed by the indoor controllers as shown in the below. 4) The indoor controller controls the indoor fan motor and louver motor. 5) The indoor controller sends the operation command to the outdoor controller, and sends/receives the control status with a serial signal. 6) The outdoor controller controls the operation as shown in the left, and also controls the compressor, outdoor fan motor, 4-way valve and pulse motor valve. Remote controller Selection of operation conditions ON/OFF Control contents of remote controller • ON/OFF (Air conditioner/Air purifier) • Operation select (COOL/HEAT/AUTO/DRY) • Temperature setup • Air direction • Swing • Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH) • ECO • ON timer setup • OFF timer setup • High power Indoor unit Signal receiving Indoor unit control Operation command Serial signal send/receive Indoor unit control • Command signal generating function of indoor unit operation • Calculation function (temperature calculation) • Activation compensation function of indoor fan • Cold draft preventive function • Timer function • Indoor heat exchanger release control ~ Outdoor unit Serial signal send/receive Outdoor unit control Outdoor unit control • Frequency control of inverter output • Waveform composite function • Calculation function (Temperature calculation) • AD conversion function • Quick heating function • Delay function of compressor reactivation • Current release function • GTr over-current preventive function • Defrost operation function – 26 – • Indoor fan motor • Louver motor Inverter • Compressor • Outdoor fan motor • 4-way valve • Pulse motor valve (P.M.V.) Item 1. Basic operation Operation flow and applicable data, etc. Description 2. Cooling/Heating operation The operations are performed in the following parts by controls according to cooling/heating conditions. 1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal starts being transferred form the indoor controller to the outdoor unit. 2) At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan motor control” and the louver according to the contents of “9. Louver control”, respectively. 3) The outdoor unit controls the outdoor fan motor, compressor, pulse motor valve and 4-way valve according to the operation signal sent from the indoor unit. *1. The power coupler of 4-way valve is usually turned off, and it is turned on during defrost operation. (Only in heating) Operation ON Indoor unit control Setup of remote controller Indoor fan motor control / Louver control Sending of operation command signal Outdoor unit control Compressor revolution control / Outdoor fan motor control / 4-way valve control In cooling operation: ON In heating operation: OFF Pulse motor valve control [ 3. AUTO operation Selection of operation mode As shown in the following figure, the operation starts by selecting automatically the status of room temperature (Ta) when starting AUTO operation. *1. When reselecting the operation mode, the fan speed is controlled by the previous operation mode. Ta Cooling operation Ts + 1 Monitoring (Fan) Ts – 1 Heating operation ] 1) Detects the room temperature (Ta) when the operation started. 2) Selects an operation mode from Ta in the left figure. 3) Fan operation continues until an operation mode is selected. 4) When AUTO operation has started within 2 hours after heating operation stopped and if the room temperature is 20°C or more, the fan operation is performed with ”Super Ultra LOW” mode for 3 minutes. Then, select an operation mode. 5) If the status of compressor-OFF continues for 15 minutes the room temperature after selecting an operation mode (COOL/HEAT), reselect an operation mode. 4. DRY operation 1) Detects the room temperature (Ta) when the DRY operation started. DRY operation is performed according to the difference between room temperature and the setup temperature as 2) Starts operation under conditions in the shown below. left figure according to the temperature difference between the room temperaIn DRY operation, fan speed is controlled in order to ture and the setup temperature (Tsc). prevent lowering of the room temperature and to avoid air Setup temperature (Tsc) flow from blowing directly to persons. = Set temperature on remote controller (Ts) + (0.0 to 1.0) [˚C] 3) When the room temperature is lower Ta L– (W5) 1°C or less than the setup temperature, turn off the compressor. +1.0 (W5+W3) / 2 +0.5 SL (W3) Tsc Fan speed – 27 – Item Operation flow and applicable data, etc. 2. Indoor fan motor control Description (This operation controls the fan speed at indoor unit side.) The indoor fan (cross flow fan) is operated by the phasecontrol induction motor. The fan rotates in 5 stages in MANUAL mode, and in 5 stages in AUTO mode, respectively. (Table 1) UH H M+ M L+ L LUL SUL COOL ON Fan speed setup MANUAL (Fig. 1) Fan speed Indication AUTO L W6 L+ (L + M) / 2 M W9 M+ (M + H) / 2 H WC (Fig. 2) Air volume AUTO Ta [˚C] M+(WB) +2.5 +2.0 a *3 *3 : Fan speed = (M + –L) x 3/4 + L +1.5 b *4 *4 : Fan speed = (M + –L) x 2/4 + L +1.0 c *5 *5 : Fan speed = (M + –L) x 1/4 + L +0.5 d Tsc e L(W6) * Symbols : Ultra High : High : Medium+ : Medium : Low+ : Low : Low– : Ultra Low : Super Ultra Low * The fan speed broadly varies due to position of the louver, etc. The described value indicates one under condition of inclining downward blowing. 1) When setting the fan speed to L, L+, M, M+ or H on the remote controller, the operation is performed with the constant speed shown in Fig. 1. 2) When setting the fan speed to AUTO on the remote controller, revolution of the fan motor is controlled to the fan speed level shown in Fig. 2 and Table 1 according to the setup temperature, room temperature, and heat exchanger temperature. (Linear approximation from M+ and L) (Table 1) Indoor fan air flow rate Fan speed COOL HEAT level WF WE WD WC WB WA W9 W8 W7 W6 W5 W4 W3 W2 W1 UH H M+ M L+ L L– UL SUL RAS-B10GKVP-E DRY UH H M+ M L+ L L– UL SUL L+ L L– UL SUL RAS-B13GKVP-E RAS-B16GKVP-E Fan speed (rpm) Air flow rate (m3/h) Fan speed (rpm) Air flow rate (m3/h) Fan speed (rpm) Air flow rate (m3/h) 1630 1480 1400 1350 1200 1110 980 910 900 890 880 730 580 430 400 684 609 569 544 468 423 358 323 318 313 308 232 157 82 67 1650 1530 1440 1390 1240 1150 1010 910 900 890 880 730 580 430 400 694 634 589 564 488 443 373 323 318 313 308 232 157 82 67 1650 1580 1550 1530 1380 1230 1080 970 960 950 940 790 640 490 400 694 659 644 634 559 483 408 353 348 343 338 263 187 112 67 – 28 – Item Operation flow and applicable data, etc. 2. Indoor fan motor control Description 1) When setting the fan speed to L, L+, M, M+ or H on the remote controller, the operation is performed with the constant speed shown in Fig. 3 and Table 1. 2) When setting the fan speed to AUTO on the remote controller, revolution of the fan motor is controlled to the fan speed level shown in Fig. 5 according to the set temperature and room temperature. 3) Min air flow rate is controlled by temperature of the indoor heat exchanger (Tc) as shown in Fig. 4. 4) Cold draft prevention, the fan speed is controlled by temperature of the indoor heat exchanger (Tc) as shown in Fig. 6. HEAT ON Fan speed setup MANUAL (Fig. 3) Indication AUTO Fan speed L W8 L+ (L + M) / 2 M WA M+ (M + H) / 2 H WE YES TC ≥ 42˚C Min air flow rate control NO Limited to Min WD tap Tc 52 51 * 42 41 (Fig. 4) No limit * Fan speed = (TC – – W8) + W8 Cold draft preventive control Basic fan control Fan speed AUTO TA [˚C] TSC –0.5 –1.0 –1.5 –2.0 –2.5 b L (W8) 46 45 Tc 46 45 34 33 33 32 33 32 21 20 *A+4 *A+4 *A+4 *A-4 *A-4 *A-4 H (WE) c d *1 e *2 Line-approximate H and SUL with Tc. SUL (W2) f *3 Stop g –5.0 Fan speed MANUAL in starting Fan speed AUTO in stability Fan speed AUTO in starting M+ (WD) –5.5 H (WE) *1: *2: 4+L 4+L * No limitation while fan speed MANUAL mode is in stability. * A: When Tsc ≥ 24, A is 24, and when Tsc < 24, A is Tsc Tsc: Set value – (Fig. 6) (Fig. 5) [In starting and in stability] In starting FAN AUTO In stability • Until 12 minutes passed after operation start • When 12 to 25 minutes passed after operation start and room temp. is higher than (set temp. –3°C) • When 12 to 25 minutes passed after operation start and room temp. is 3°C or lower than set temp. • When 25 minutes or more passed after operation start • Room temp. ≥ Set temp. –3.5°C FAN Manual • Room temp. < Set temp. –4°C – 29 – Item 3. Outdoor fan motor control Operation flow and applicable data, etc. Description The blowing air volume at the outdoor unit side is controlled. Receiving the operation command from the controller of indoor unit, the controller of outdoor unit controls fan speed. * For the fan motor, a DC motor with non-stage variable speed system is used. However, it is limited to 8 stages for reasons of controlling. 1) The operation command sent from the remote controller is processed by the indoor unit controller and transferred to the controller of the outdoor unit. 2) When strong wind blows at outdoor side, the operation of air conditioner continues with the fan motor stopped. 3) Whether the fan is locked or not is detected, and the operation of air conditioner stops and an alarm is displayed if the fan is locked. 4) According to each operation mode, by the conditions of outdoor temperature (To) and compressor revolution, the speed of the outdoor fan shown in the table is selected. Air conditioner ON (Remote controller) Indoor unit controller 1) Outdoor unit operation command (Outdoor fan control) 2) Fan speed ≥ 400 when the motor stopped. YES OFF status of fan motor continues. YES Air conditioner OFF NO Fan motor ON 3) Fan lock Alarm display NO 4) Motor operates as shown in the table below. In Heating operation In cooling operation Compressor speed (rps) ~ 13.8 ~ 31.7 32.3 ~ MAX MIN MAX MIN MAX MIN MAX To > 38°C To > 28°C f2 f3 fC fD fE fF f2 f3 fB fC fE fF To > 15°C To > 5.5°C f2 f3 f8 f9 fA fB f2 f3 f6 f7 f8 To > 0°C To > 38°C f1 f2 f4 f5 f6 f2 f3 fB fC fC fD To < 38°C f2 f3 f2 f3 fB fC When To is abnormal fD fF fD fF fD fF To During ECO mode Compressor speed (rps) ~16.8 ~47.9 48.5 ~ MAX To > 15°C f3 f8 f9 To < 15°C f3 f9 fA To < 5.5°C f8 fA fD To < –5.0°C To > 15°C fB fC fD f9 f3 f3 f6 f7 To < 15°C f3 f3 f8 To < 5.5°C f5 f9 f9 To < –5.5°C f7 fA fB fA fB fD To During ECO mode When To is abnormal Outdoor fan speed (rpm) Tap 10GAVP-E 13GAVP-E 16GAVP-E Tap 10GAVP-E 13GAVP-E 16GAVP-E f1 200 200 200 f9 700 700 700 f2 300 300 300 fA 700 700 700 f3 390 390 390 fB 700 700 700 f4 450 450 450 fC 700 700 700 f5 500 500 500 fD 750 840 920 f6 500 500 500 fE 750 840 920 f7 600 600 600 fF 750 840 920 f8 600 600 600 – 30 – Item 4. Capacity control Operation flow and applicable data, etc. Description The cooling or heating capacity depending on the load is adjusted. According to difference between the setup value of temperature and the room temperature, the capacity is adjusted by the compressor revolution. 1) The difference between set temperature on remote controller (Ts) and room temperature (Ta) is calculated. 2) According to the temperature difference, the correction value of Hz signal which determines the compressor speed is set up. 3) The rotating position and speed of the motor are detected by the electromotive force occurred on the motor winding with operation of the compressor. 4) According to the difference resulted from comparison of the correction value of Hz signal with the present operation Hz, the inverter output and the commutation timing are varied. 5) Change the compressor motor speed by outputting power to the compressor. * The contents of control operation are same in cooling operation and heating operation Remote controller Indoor unit Set temp. (Ts) Room temp. (Ta) Ts –Ta Correction of Hz signal Detection of electromotive force of compressor motor winding Detection of motor speed and rotor position Correction value of Hz signal ≤ Operating Hz Inverter output change Commutation timing change Change of compressor speed 5. Current release control This function prevents troubles on the electronic parts of the compressor driving inverter. This function also controls drive circuit of the compressor speed so that electric power of the compressor drive circuit does not exceed the specified value. Outdoor temp. To Outdoor unit inverter main circuit control current Setup of current release point Operating current ≤ Setup value High Reduce compressor speed Low Current decrease Capacity control continues. Cooling current release value Outdoor temp. Heating current release value 6.45A 45˚C 40˚C 44˚C 16˚C 39˚C 11˚C 15.5˚C 6.75A 7.72A 8.47A 9.22A 10.5˚C 10.80A – 31 – 1) The input current of the outdoor unit is detected in the inverter section of the outdoor unit. 2) According to the detected outdoor temperature, the specified value of the current is selected. 3) Whether the current value exceeds the specified value or not is judged. 4) If the current value exceeds the specified value, this function reduces the compressor speed and controls speed up to the closest one commanded from the indoor unit within the range which does not exceed the specified value. Item Indoor heat exchanger temperature 6. Release protective control by temperature of indoor heat exchanger Operation flow and applicable data, etc. (Prevent-freezing control for indoor heat exchanger) In cooling/dry operation, the sensor of indoor heat exchanger detects evaporation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value. Usual cooling capacity control R When the value is in Q zone, the compressor speed is kept. 7˚C Q 6˚C 1) When temperature of the indoor heat exchanger drops below 5°C, the compressor speed is reduced. (P zone) 2) When temperature of the indoor heat exchanger rises in the range from 6°C to under 7°C, the compressor speed is kept. (Q zone) 3) When temperature of the indoor heat exchanger rises to 7°C or higher, the capacity control operation returns to the usual control in cooling operation. (R zone) P 5˚C Reduction of compressor speed (Prevent-overpressure control for refrigerating cycle) In heating operation, the sensor of indoor heat exchanger detects condensation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value. Indoor heat exchanger temperature Description Reduction of compressor speed P 55˚C 50˚C Q When the value is in Q zone, the compressor speed is kept. 46˚C R Usual heating capacity control – 32 – 1) When temperature of the indoor heat exchanger rises in the range from 50°C to 55°C, the compressor speed is kept. (Q zone) When temperature of the indoor heat exchanger drops in the range from 46°C to under 55°C, the compressor speed is kept. (Q zone) 2) When temperature of the indoor heat exchanger rises to 55°C or higher, the compressor speed is reduced. (P zone) 3) When temperature of the indoor heat exchanger does not rise to 50°C, or when it drops below to 46°C, the capacity control operation returns to the usual control in heating operation. (R zone) Item Operation flow and applicable data, etc. 7. Quick heating control This function quickens the starting of heating operation when indoor/outdoor temperature is low. (Available only in heating operation) When indoor temperature is low, this function stores the heat by heating winding depended on the outdoor temperature and then it enables the hot air blowing out quickly. The previous operation was heating and 2 hours passed after the operation had stopped. NO YES Winding is not heated. Outdoor heat exchanger temperature Indoor temperature Heating output for winding –1˚C –3˚C OFF –6˚C –8˚C 20W or equivalent (This function removes frost adhered to the outdoor heat exchanger.) The temperature sensor of the outdoor heat exchanger (Te sensor) judges the frosting status of the outdoor heat exchanger and the defrost operation is performed with 4-way valve reverse defrost system. Start of heating operation Outdoor heat exchanger temperature Condition 1 : The previous operation was heating. Condition 3 : The room temperature is 20°C or lower. The indoor temperature sensor detects the room temperature. If the detected room temperature is 20°C or lower, the outdoor heat exchanger temperature sensor detects the outdoor heat exchanger temperature. As shown in the left figure, winding of the compressor is heated for each division of the temperature ( for each outdoor temperature) and the heat is stored. 20W or equivalent 8. Defrost control (Only in heating operation) 0’ When the following conditions are satisfied, winding is heated by output varied by the outdoor heat exchanger temperature. Condition 2 : 2 hours passed after operation stop. In case of operation stop 20˚C Description 10’ 15’ 27’40” 34’ Operation time (Minute) –5˚C C zone –7˚C A zone –20˚C B zone * * The minimum value of Te sensor 10 to 15 minutes after start of operation is stored in memory as Te0. Table 1 A zone When Te0 - TE ≥ 2.5 continued for 2 minutes in A zone, defrost operation starts. B zone When the operation continued for 2 minutes in B zone, defrost operation starts. C zone When Te0 - TE ≥ 3 continued for 2 minutes in C zone, defrost operation starts. – 33 – The necessity of defrost operation is detected by the outdoor heat exchanger temperature. The conditions to detect the necessity of defrost operation differ in A, B, or C zone each. (Table 1) • Defrost operation in A to C zones 1) Stop operation of the compressor for 20 seconds. 2) Invert (ON) 4-way valve 10 seconds after stop of the compressor. 3) The outdoor fan stops at the same time when the compressor stops. 4) When temperature of the indoor heat exchanger becomes 38°C or lower, stop the indoor fan. • Returning conditions from defrost operation to heating operation 1) Temperature of outdoor heat exchanger rises to +8°C or higher. 2) Temperature of outdoor heat exchanger is kept at +5°C or higher for 80 seconds. 3) Defrost operation continues for 15 minutes. 1) Stop operation of the compressor for approx. 50 seconds. 2) Invert (OFF) 4-way valve approx. 40 seconds after stop of the compressor. 3) The outdoor fan starts rotating at the same time when the compressor starts. Item Description Operation flow and applicable data, etc. 9. Louver control 1) Louver position This function controls the air direction of the indoor unit. • The position is automatically controlled according to the operation mode (COOL/HEAT). • The set louver position is stored in memory by the microcomputer, and the louver returns to the stored position when the next operation is performed. (Cooling/heating memory position) The angle of the louver is indicated as the horizontal angle is 0°. When the louver closes fully, it directs approx. 49° upward. Horizontal (0˚) Louver angle 1) Louver position in cooling operation Powerful Initial setting of “Cooling storage position” Louver : Directs downward (9˚) 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˚) “Inclined blowing” Louver : Directs downward (14˚) Powerful YES operation Cooling/AUTO (COOL)/DRY operation NO Room temp. ≥ NO Set temp. +3.5 Cooling memory position NO Room temp. ≥ Set temp. +3.5 YES Cooling memory position YES Inclined blowing 2) Louver position in heating operation ECO operation Heating operation/ AUTO (HEAT) Room temp. (Ta) < Set temp. (Tsc) – 3 or 25 minutes after start of operation Initial setting of “Heating storage position” Louver : Directs downward (76˚) “Heating storage position” Louver : Directs downward (76˚) YES ECO operation Heating operation NO Room temp. ≥ NO Set temp. –3.0 Horizontal blowing 3) Swing Inclined blowing “Cooling storage position” Louver : Directs downward (9˚) Horizontal position YES Heating memory position YES • The louver position can be arbitrarily set up by pressing [FIX] button. Air direction Blowing downward NO Room temp. ≥ Set temp. –3.0 Heating memory position 2) Air direction adjustment Room temp. (Ta) ≥ Set temp. (Tsc) – 3 Inclined blowing Horizontal blowing • Swing operation is performed in width 35° with the stop position as the center. • If the stop position exceeds either upper or lower limit position, swing operation is performed in width 35° from the limit which the stop position exceeded. – 34 – • Swing When pressing [SWING] button during operation, the louver starts swinging. Item 10. ECO operation Operation flow and applicable data, etc. Description When pressing [ECO] button on the remote controller, a quiet and mild operation is performed by reducing the fan speed and the compressor speed. This function operates the air conditioner with the difference between the set and the room temperature as shown in the following figure. The time correction is performed for 8 minutes each. (However, the first correction is performed 150 seconds after start of the operation.) TA [˚C] +4.0 +3.5 +3.0 +2.5 +2.0 +1.5 +1.0 +0.5 TSC –0.5 –1.0 –2.0 Zone 12 11 10 9 8 7 6 5 4 3 2 1 Frequency DRY max *12 *11 *10 *9 *8 COOL min 0 OFF Fan L+ (W7) L (W6) Time correction +1 1) The room temperature (Tao) at the start time of DRY operation is detected. 2) According to difference between the room temperature and the set temperature (Tsc), the operation starts with the conditions shown in the left figure. Set temp. (Tsc) = Set temp. on remote controller (Ts) + (0.0 to 1.0) 3) If the room temperature is down by 2°C or more, turn off the compressor. L– (W5) ±0 UL (W4) –1 zone: min 1 * 12 (DRY max - COOL min) /6 x 5 + COOL min * 11 (DRY max - COOL min) /6 x 4 + COOL min * 10 (DRY max - COOL min) /6 x 3 + COOL min * 9 (DRY max - COOL min) /6 x 2 + COOL min * 8 (DRY max - COOL min) /6 x 1 + COOL min → Time Compressor speed 0Hz (Room temp. – Set temp.) 30 minutes 0 –0.5 –1.0 –1.5 –2.0 –2.5 –3.0 –4.0 –5.0 –6.0 –7.0 –8.0 –9.0 –10.0 –11.0 A B C A A zone 16Hz B B zone 16 to 52Hz C zone 52Hz C – 35 – 1) The indoor fan speed is controlled within (W7) as maximum value. 2) Setting the compressor speed to Max. 52Hz, the temperature zone in which the operation can be performed with Max. 16Hz is gradually widened after 30 minutes passed when starting ECO operation. 3) The louver position is set horizontally (Standard cooling position) when the room temperature comes close to the set temperature or when 25 minutes passed after starting ECO operation. Item Operation flow and applicable data, etc. 11. Temporary operation Description Pressing [RESET] button starts the temporary operation of [AUTO] operation. When keeping [RESET] button pressed for 10 seconds or more, the temporary [COOL] operation is performed. YES Filter lamp ON Press RESET button. NO NO Did you press [RESET] button for 3 seconds or more? Temporary [AUTO] operation YES YES Did you press [RESET] button for 10 seconds or more? 1) When pressing [RESET] button, the temporary [AUTO] operation starts. 2) When keeping [RESET] button pressed for 3 seconds or more, Pi, Pi, Pi sound is heard and [AUTO RESTART] control is changed. 3) When keeping [RESET] button pressed for 10 seconds or more, “Pi” sound is heard and the temporary [COOL] operation starts. 4) If the filter lamp goes on, press [RESET] button to go off the filter lamp, and then press [RESET] button again. 5) To stop the temporary operation, press the button again. NO Switch to [AUTO RESTART] control. 12. Air purifying control Temporary [COOL] Operation This function generates nagative ion while cleaning the air in the room. If air purifier-ON signal is received while the air conditioner stops, the air purifier starts operation, and if it is received while the air conditioner operates, the air conditioner and the air purifier start operation. The air ion generator operates linked with the air purifying operation. Operation button Present status PURE button Air conditioner Stop Air purifier AC operation* Air purifier only Stop (All) AC + Air purifier Air conditioner AC + Air purifier All stop AC operation All stop Joint use of AC and air purifier Air purifying operation Louver*1 Fan speed *2 Cooling position AUTO, L, L+, M, M+, H * When the previous operation was the operation of air conditioner + air purifier, an operation of air conditioner + air purifier starts by pushing AC button on the remote controller. (Operation of air conditioner + air purifier is stored in memory.) *1 Swing is available *2 Fan speed is Fan Auto mode varies in order, (M + 1) → (L) → (L–) → (SL). AC + Air purifying operation Follows to AC operation Follows to AC operation Sending air purifier-ON 1 1 , 2 Sending air purifier-OFF 2 3 Air conditioner stops Air conditioner operates Operation lamp ON Start of air purifier-ON *1 Memory position of louver/COOL Air conditioner + air purifier operate Air purifier operates , 4 4 Air conditioner + Air purifier operate Operation lamp OFF Filter-OFF Fan stop Air conditioner operates *2 Fan ON Air purifier-OFF Air purifier ON Louver close Air purifying operation All stop – 36 – 3 Item Operation flow and applicable data, etc. 1. Purpose The air purifying control function is to alert the user to trouble in the ionizing or air purifying operation. 12. Air purifying control [Detection of abnormality] Purifying operation YES 2. Description Trouble is determined to have occurred (indicated by the FILTER indicator) in the following four cases. 1) When a count of 1000H has been reached on the timer 2) When the panel switch has been set to OFF by the opening of the air inlet grile, etc. 3) When an abnormal discharge caused by a symptom such as the build-up of dirt has been detected while the air purifier is ON 4) When the electric dust collector has not been installed correctly * Trouble case (2) or (3) is deemed to have occurred when the action concerned continues for more than one second. Total operation time 1000H NO Purifier power ON NO Error input YES Purifier power ON 1 minute or less NO Filter lamp-OFF continues. YES Filter lamp ON Purifier power OFF Purifier power OFF Purifier power ON after 10 minutes from the error input. Filter lamp ON Error input NO YES Purifier power OFF Purifier power OFF 1 2 3 1) Reset by RESET button. 2) Reset by RESET button or by the stop direction from the remote controller. * When the breaker is turned [ON] (In restart time after power failure) or RESET button is pressed while the FILTER indicator is turned on, the air purifier is not turned on until the integrated operation time of the indoor fan exceeds 1 hour after operation start (It is nor the air purifier operation time). It is the safety measures considering an incomplete drain when electric dust collector has been cleaned with water. 13. Discharge temperature control Td value 117°C 112°C 108°C 105°C 98°C Description Control operation Judges as an error and stops the compressor. Reduce the compressor speed. Reduce slowly compressor speed. Keeps the compressor speed. If the operation is performed with lower speed than one commanded by the serial signal, speed is slowly raised up to the commanded speed. Operates with speed commanded by the serial signal. – 37 – 3. Operation The sequence that FILTER indicator is turned on are described in the left flowchart. 1) When 1000H timer counts up, the FILTER indicator keeps lighting even if the operation is stopped by the remote controller. The timer is stored in memory of the microcomputer, and the operation time is cleared by filter RESET button on the indoor unit or a power failure. (FILTER indicator goes off.) 2) A trouble detected within 1 minute after activation of the air is immediately judged as an error and the FILTER indicator goes on. 3) In case that 1 minute passed after activation of the purifier, the purifier is turned off while the PURE indicator keeps ON. After 10 minutes passed, restart the purifier and an error is judged again. 1. Purpose This function detects error on the refrigerating cycle or error on the compressor, and performs protective control. 2. Operation • Control of the compressor speed The speed control is performed as described in the left table based upon the discharge temperature. Item 14. Pulse motor valve (P.M.V.) control Operation flow and applicable data, etc. Description This function controls throttle amount of the refrigerant in the refrigerating cycle. According to operating status of the air conditioner, this function also controls the open degree of valve with an expansion valve with pulse motor. 1) When starting the operation, move the valve once until it fits to the stopper. (Initialize) * In this time, “Click” sound may be heard. 2) Adjust the open degree of valve by super heat amount. (SH control) 3) If the discharge temperature was excessively up, adjust the open degree of valve so that it is in the range of set temperature. (Discharge temp. control) 4) When defrost operation is performed, the open degree of valve is adjusted according to each setup conditions during preparation for defrost and during defrost operation (4-way valve is inversed.). 5) To turn off the compressor while the air conditioner stops by control of the thermostat or by remote controller, adjust the open degree of valve to the setup value before stop of the compressor. Starting up Initialize Move to initial position Compressor ON SH control Td release control PMV open degree control Stop by remote controller Power OFF Room temp. sensor (Ta sensor) control Defrost * SH (Super Heat amount) = Ts (Temperature of suction pipe of the compressor) – Tc or Te (Heat exchanger temperature at evaporation side) * PMV: Pulse Motor Valve – 38 – Item Operation flow and applicable data, etc. 15. Clean operation Unit now performing cooling or dry operation Press “STOP” button Only S.CLEAN indicator lights, and clean operation starts Time set now elapses Operation stops • During clean operations: The louver opens slightly. The indoor fan operates continuously at a speed of 260 rpm. Clean operation times Operation mode Cooling: Auto (cooling) Dry Operation time Description 1. Purpose The clean operation is to minimize the growth of mold, bacteria etc. by running the fan and drying so as to keep the inside of the air conditioner clean. Clean operation When the cooling or dry operation shuts down, the unit automatically starts the clean operation which is then performed for the specified period based on duration of the operation which was performed prior to the shutdown, after which the clean operation stops. (The clean operation is not performed after a heating operation.) 2. Operation 1) When the stop signal from the remote controller is received, the S.CLEAN indicator (green) on the main body lights, and the clean operation starts. (Neither the OPERATION indicator nor the TIMER indicator light.) 2) The period of the clean operation is determined by the duration of the operation performed prior to the reception of the stop code. 3) After the clean operation has been performed for the specified period, the unit stops operating. Clean operation time Up to 10 minutes No clean operation performed (0 minutes) From 10 minutes up to 1 hour 2 hours 1 hour or longer 4 hours Heating: Auto (heating) Auto (fan only) No clean operation performed Shutdown • To stop an ongoing clean operation at any time Press the start/stop button on the remote controller twice during the clean operation. (After pressing the button for the first time, press it for the second time without delay (within 10 minutes).) – 39 – Item Operation flow and applicable data, etc. Description 16. Clean operation Setting the clean operation release release Add J04 of the indoor P.C. board assembly. * This cancels the auto restart function. Hold down the auto operation switch on the indoor unit for at least 3 seconds but not more than 10 seconds. * J04 will be near the MCU so take steps to ensure that it will not be exposed to excessive levels of heat. Also take care to avoid solder bridging with the surrounding components. The indoor unit’s buzzer emits three beeps, and the OPERATION indicator flashes at 5 Hz intervals. This completes the clean operation release setting. Setting the clean operation Cut J04 of the indoor P.C. board * This step may be skipped if the auto restart function is not required. Hold down the auto operation switch on the indoor unit for at least 3 seconds but not more than 10 seconds. The indoor unit’s buzzer emits three beeps, and the OPERATION indicator flashes at 5 Hz intervals. This completes the clean operation setting. Indoor P.C. board J04 – 40 – Item Operation flow and applicable data, etc. 17. Select switch on remote controller 1. Purpose This operation is to operate only one indoor unit using one remote controller. Press the operation button on the remote controller. YES Both indoor units start operation. Select “B” as the setting for one of the two indoor units and for the remote controller. (See below for details.) NO Unnecessary set [Remote controller select] HiPOWER ECO MEMO 126.96.36.199H SWING FIX FAN CLR CLOCK SLEEP SET ON Description OFF RESET CHECK Cutting direction Jumper wire 2. Description When operating one indoor unit in a situation where two indoor units have been installed in the same room or nearby rooms, this operation prevents the remote controller signal from being received simultaneously by both units, thus preventing both units from operating. 3. Operation The indoor unit on which the remote controller selection has been set to B receives the signal of the remote controller also set to B. (At the factory the remote controller selection is set to A on all the indoor units. There is no A setting display.) Setting the remote controller Switching between A and B is enabled by cutting the jumper wire inside the battery box using pliers. 1) Slide open the remote controller cover and remove the batteries. 2) Cut the jumper wire inside the battery compartment using nippers. • The jumper wire should not remain in contact after being cut. Also, be careful not to let plastic scraps, jumper wire cuttings or other debris enter the inside of the remote controller. 3) Insert the batteries. “B” appears in the remote controller display. * Even after the jumper wire has been cut, switching between A and B is still possible by pressing the CHECK button and FIX button together. The A or B setting, which was switched by pressing the CHECK button and FIX button together, is restored to the setting established prior to the switching when the battery is replaced or the RESET button is pressed. Setting the selector switch on the main unit • Remove the front panel, and then set the selector switch to “B”. • After making the switch setting, remount the front panel. Position of remote controller selector switch When switching between settings “A” and “B”, always switch the indoor unit board and the remote controller as a pair. (Otherwise, the indoor unit will not accept the remote controller’s signals.) Selector switch – 41 – 9-3. Auto Restart Function This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored. This function is not set to work when shipped from the factory. Therefore it is necessary to set it to work. 9-3-1. How to Set the Auto Restart Function To set the auto restart function, proceed as follows: The power supply to the unit must be on ; the function will not set if the power is off. Press the [RESET] button located in the center of the front panel continuously for three seconds. The unit receives the signal and beeps three times. The unit then restarts operating automatically in the event of power supply being accidentally shut down. • When the unit is standby (Not operating) Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) Motions The unit is on standby. ↓ The unit starts to operate. ↓ The green indicator is on. After approx. three seconds, The unit beeps three times and continues to operate. The green indicator flashes for 5 seconds. If the unit is not required to operate at this time, press [RESET] button once more or use the remote controller to turn it off. • When the unit is in operation Motions Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) The unit is in operation. The green indicator is on. ↓ The unit stops operating. ↓ The green indicator is turned off. After approx. three seconds, The unit beeps three times. The green indicator flashes for 5 seconds. If the unit is required to operate at this time, press [RESET] button once more or use the remote controller to turn it on. • When the unit is turned on by this function, the louver will not swing even though it was swinging automatically before shutting down. • While the filter check indicator is on, the RESET button has the function of filter reset button. – 42 – 9-3-2. How to Cancel the Auto Restart Function To cancel auto restart function, proceed as follows : Repeat the setting procedure : the unit receives the signal and beeps three times. The unit will be required to be turned on with the remote controller after the main power supply is turned off. • When the system is on stand-by (not operating) Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) Motions The unit is on standby. ↓ The unit starts to operate. ↓ The green indicator is on. After approx. three seconds, The unit beeps three times and continues to operate. If the unit is not required to operate at this time, press [RESET] button once more or use the remote controller to turn it off. • When the system is operating Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) Motions The unit is in operation. The green indicator is on. ↓ The unit stops operating. ↓ The green indicator is turned off. After approx. three seconds, The unit beeps three times. If the unit is required to operate at this time, press [RESET] button once more or use the remote controller to turn it on. 9-3-3. Power Failure During Timer Operation 9-4. FILTER Indicator When the unit is turned off because of power failure during timer operation, the timer operation is cancelled. In that case, set the timer operation again. When the elapsed time reaches 1000 hours after air purifier operation, the FILTER indicator lights. After cleaning the filters, turn off the FILTER indicator. NOTE : The Everyday Timer is reset while a command signal can be received from the remote controller even if it stopped due to a power failure. 9-4-1. How to Turn Off FILTER Indicator Press [RESET] button on the indoor unit. NOTE : If [RESET] button is pushed while the FILTER indicator is not lit, the indoor unit will start the automatic operation. When you want a temporary operation while the FILTER lamp lights, press [RESET] button to turn off the FILTER lamp. (See page 36) – 43 – 9-5. Remote Controller and Its Fuctions 9-5-1. Parts Name of Remote Controller 1 2 3 4 5 6 7 8 9 11 Infrared signal emitter Transmits signal to the indoor unit. button Press the button to start operation. (A receiving beep is heard.) Press the button again to stop operation. (A receiving beep is heard.) If no receiving sound is heard from the indoor unit, press the button twice. 13 Mode select button (MODE) Press this button to select a mode. Each time you press the button, the modes cycle in order from A : Auto changeover control, : Cool, : Dry, : Heat and back to A. (A receiving beep is heard.) Temperature button ( TEMP ) .. The temperature setting is increased to 30°C. .. The temperature setting is reduced to 17°C. (A receiving beep is heard.) 14 15 16 Fan speed button (FAN) Press this button to select the fan speed. When you select AUTO, the fan speed is automatically adjusted according to the room temperature. You can also manually select the desired fan speed from five available settings. (LOW , LOW+ , MED , MED+ , HIGH ) (A receiving beep is heard.) 17 High power button (Hi POWER) Press this button to start high power operation. Memory button (MEMO) Press this button to ready for storing the settings. Hold down the button for more than 3 seconds to store the setting indicated on the remote controller mark is displayed. and until the Automatic operation button (AUTO) Press this button to operate the air conditioner automatically. (A receiving beep is heard.) Economy button (ECO) Press this button to operate the air conditioner economically. PRESET button Press this button to operate the air conditioner to the settings stored using the MEMO button. PURE button (PURE) Press this button to start the electrical air purifying operation. Press the button again to stop operation. 18 Sleep time button (SLEEP) Press this button to start the sleep timer (OFF timer) operation. You can select the OFF timer time from among four settings (1, 3, 5 or 9 hours). Auto louver button (SWING) Press this button to swing the louver. (A receiving beep is heard.) Press this button again to stop the louver from swinging. (A receiving beep is heard.) 1 Set louver button (FIX) Press this button again to adjust the air flow direction. (A receiving beep is heard.) ON timer button (ON) Use this button to change the clock and ON timer times. To move up the time, press of the “ON ON ” button. To move down the time, press of the “ON ON ” button. OFF timer button (OFF) Use this button to change the OFF timer times. To move up the time, press of the “OFF ” button. To move down the time, press of the “OFF OFF ” button. OFF 10 12 Cancel button (CLR) Press this button to cancel the ON timer and OFF timer. (A receiving beep is heard.) Reserve button (SET) Press this button to store the time settings. (A receiving beep is heard.) 4 17 TEMP 3 2 7 12 6 11 8 – 44 – AUTO PURE MODE PRESET HiPOWER ECO MEMO 188.8.131.52H SWING FIX FAN CLR CLOCK SLEEP SET ON RESET CHECK OFF 14 16 15 5 13 18 10 9 9-5-2. Name and Functions of Indications on Remote Controller [Display] All indications, except for the clock time indicator, are displayed by pressing the 1 2 3 4 5 6 Transmission mark This transmission mark indicates when the remote controller transmits signals to the indoor unit. Mode indicator Indicates the current operation mode. (AUTO : Automatic control, A : Auto changeover : Cool, : Dry, : Heat) control, 7 Temperature indicator Indicates the temperature setting. (17°C to 30°C) 8 PURE indicator Shows that the electrical air purifying operation is in progress. FAN speed indicator Indicates the selected fan speed. AUTO or five fan speed levels (LOW , LOW+ , MED , MED+ HIGH ) can be shown. Indicates AUTO when the operating mode is : Dry. either AUTO or 1 3 , 10 TIMER and clock time indicator The time setting for timer operation or the clock time is indicated. The current time is always indicated except during TIMER operation. Hi-POWER indicator Indicates when the Hi-POWER operation starts. Press the Hi-POWER button to start and press it again to stop the operation. (MEMORY) indicator Flashes for 3 seconds when the MEMO button is pressed during operation. mark is shown when holding down the The button for more than 3 seconds while the mark is flashing. Press another button to turn off the mark. ECO indicator Indicates when the ECO is in activated. Press the ECO button to start and press it again to stop operation. A, B change indicator remote controller When the remote controller switching function is set, “B” appears in the remote controller display. (When the remote controller setting is “A”, there is no indication at this position.) 10 2 4 9 button. 8 AUTO 9 7 5 6 • In the illustration, all indications are shown for purposes of explanation. During operation, only the relevant indicators are shown on the remote controller. – 45 – 9-6. Hi-POWER Mode ([Hi-POWER] button on the remote controller is pressed) When [Hi-POWER] button is pressed while the indoor unit is in Auto, Cooling or Heating operation, Hi-POWER mark is indicated on the display of the remote controller and the unit operates as follows. 1. Automatic operation • The indoor unit operates in according to the current operation. 2. Cooling operation • The preset temperature drops 1°C. (The value of the preset temperature on the remote controller does not change.) • If the difference between the preset temperature and the room temperature is big, the horizontal louver moves to the Hi-POWER position automatically. Then when the difference between them gets smaller, the horizontal louver returns automatically. 3. Heating operation • The preset temperature increases 2°C. (The value of the preset temperature on the remote controller does not change.) 4. The Hi-POWER mode can not be set in Dry operation – 46 – 10. INSTALLATION PROCEDURE 10-1. Safety Cautions For the rear left and left piping Hook 47 mm or more 1 Installation plate Wall Hook 140 mm or more 74 mm or more Hook Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better installation work. 7 Mounting screw Do not allow the drain hose to become slack. Cut the piping hole slightly sloped 5 Zeolite-plus filter Z Shield pipe (for extension drain hose) Make sure the drain hose is sloped downward. 6 Plasma pure filter The auxiliary piping can be connected at the left, rear left, rear right, right, bottom right or bottom left as shown below. Air filters Y 80 mm or more only when unobstructed to the front and both sides 2 Wireless remote controller 100 mm or more from wall In principle, leave open (C) Right 50 mm or more from wall Rear right (D) 4 Remote controller holder (Mounting holes on both left and right sides) Left Bottom left Bottom right Rear left As shown in the figure, position power cord and connecting cable downward, and lead out along piping connection port. 200 mm or more (B) (A) 8 Remote controller holder mounting screw 250 mm or more from wall When installing the outdoor unit, leave open in at least two of directions (A), (B), (C) and (D) shown in the right figure. Ensure sufficient space to allow drainage Insulate the refrigerant pipes separately, not together. Power cord Extension drain hose (Option: RB-821SW) 6 mm thick heat resisting polyethylene foam Before installing the wireless remote controller • With the remote controller cover removed, correctly load the supplied batteries while observing their polarity. Cover 3 Batteries 2 Wireless remote controller – 47 – 10-2. Optional Parts, Accessories and Tools 10-2-1. Optional Installation Parts Part Code Parts name Q’ty Refrigerant piping Indoor unit name Liquid side (Outer diameter) Gas side (Outer diameter) RAS-B10GKVP-E, B13GKVP-E 6.35 mm 9.52 mm RAS-B16GKVP-E 6.35 mm 12.7 mm 1 ea. Y Z Shield pipe (for extension drain hose) (polyethylene foam, 6 mm thick) Attachment bolt arrangement of outdoor unit • Secure the outdoor unit with the attachment bolts and nuts if the unit is likely to be exposed to a strong wind. • Use Ø8 mm or Ø10 mm anchor bolts and nuts. If it is necessary to drain the defrost water, attach drain nipple to the base plate of the outdoor unit before installing it. Elongated drain hole 1 Suction side () Diffuser Drain hole () 10-2-2. Accessory and Installation Parts Part No. Part name (Q’ty) Part No. Part name (Q’ty) Installation plate × 1 Part No. Zeolite-plus filter × 1 Wireless remote control × 1 Plasma pure filter × 1 Part name (Q’ty) Drain nipple* × 1 (RAS-10GAVP-E, 13GAVP-E, 16GAVP-E) Water-proof rubber cap* × 2 (RAS-10GAVP-E, 13GAVP-E, 16GAVP-E) Parts marked with asterisk (*) are packaged with the outdoor unit. Battery × 2 Mounting screw Ø4 × 25L × 6 Name Remote control holder × 1 Owner’s manual Remote control holder mounting screw Ø3.1 × 16L × 2 This model is not equipped with an extension drain hose. – 48 – Installation manual Important information and warning* B/W strips* (Energy efficiency labels) 10-2-3. Installation/Servicing Tools Changes in the product and components In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads per inch) • In order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of opposite side of flare nuts has been changed. (for copper pipes with nominal dimensions 1/2 and 5/8) New tools for R410A New tools for R410A Applicable to R22 model Changes Gauge manifold × As pressure is high, it is impossible to measure by means of conventional gauge. In order to prevent any other refrigerant from being charged, each port diameter has been changed. Charge hose × In order to increase pressure resisting strength, hose materials and port size have been changed (to 1/2 UNF 20 threads per inch). When purchasing a charge hose, be sure to confirm the port size. Electronic balance for refrigerant charging ¡ As pressure is high and gasification speed is fast, it is difficult to read the indicated value by means of charging cylinder, as air bubbles occur. Torque wrench (nominal diam. 1/2, 5/8) × 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 has been improved. Flare tool (clutch type) Gauge for projection adjustment — — Used when flare is made by using conventional flare tool. Vacuum pump adapter ¡ Connected to conventional vacuum pump. It is necessary to use an adapter to prevent vacuum pump oil from flowing back to the charge hose. The charge hose connecting part has two ports-one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R410A a sludge may occur and damage the equipment. Gas leakage detector × Exclusive for HFC refrigerant. • Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the U. S’s ARI specified rose color (ARI color code: PMS 507). • Also, the “charge port and packing for refrigerant cylinder” require 1/2 UNF 20 threads per inch corresponding to the charge hose’s port size. – 49 – 10-3-2. Drilling a Hole and Mounting Installation Plate 10-3. Indoor Unit 10-3-1. Installation Place Drilling a hole When install the refrigerant pipes from the rear. The center of the pipe hole Pipe hole 65 42 mm • A place which provides enough spaces around the indoor unit as shown in the diagram. • A place where there are no obstacle near the air inlet and outlet. • A place which allows easy installation of the piping to the outdoor unit. • A place which allows the front panel to be opened. • The indoor unit shall be installed so that the top of the indoor unit is positioned at least 2m in height. • Also, avoid putting anything on the top of the indoor unit. CAUTION • Direct sunlight on the indoor unit wireless receiver should be avoided. • The microprocessor in the indoor unit should not be too close to r-f sources. (For details, see the owner's manual.) mm Fig. 10-3-2 1. After determining the pipe hole position on the installation plate ( ð ) drill the pipe hole (Ø65 mm) at a slight downward slant to the outdoor side. Remote controller • Should be placed where there are no obstacles, such as curtains, that may block the signal. • Do not install the remote controller in a place exposed to direct sunlight or close to a heating source, such as a stove. • Keep the remote controller at least 1 m away from the nearest TV set or stereo equipment. (This is necessary to prevent image disturbances or noise interference.) • The location of the remote controller should be determined as shown below. NOTE : • When drilling into a wall that contains a metal lath, wire lath or metal plate, be sure to use a pipe hole brim ring sold separately. Mounting the installation plate Indoor unit Anchor bolt holes (Side view) (Top view) 25 mm Indoor unit 91 mm Pipe hole Reception range Remote controller Reception range Pipe hole Indoor unit Remote controller 7 Mounting screw *: Axial distance Fig. 10-3-3 Fig. 10-3-1 – 50 – 1 Installation plate When the installation plate is directly mounted on the wall 1. Securely fit the installation plate onto the wall by screws with the upper and lower catches, that hold the indoor unit, facing out. 2. To mount the installation plate on a concrete wall use anchor bolts. Drill the anchor bolt holes as illustrated in the above figure. 3. Install the installation plate horizontally and level. 10-3-3. Electrical Work 1. The supply voltage must be the same as the rated voltage of the air conditioner. 2. Prepare a power source for the exclusive use of the air conditioner. NOTE : • Wire type : More than H07RN-F or 245IEC66 (1.0mm²) CAUTION CAUTION • This appliance can be connected to a main circuit breaker in either of the following two ways. 1. Connection to fixed wiring: A switch or circuit breaker which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring. An approved circuit breaker or switch must be used. 2. Connection with power supply plug: Attach power supply plug with power cord and plug it into wall outlet. An approved power supply cord and plug must be used. When installing the installation plate with mounting screw, do not use the anchor bolt hole. Otherwise the unit may fall down and result in personal injury and property damage. Anchor bolt Projection 15mm or less NOTE : • Perform wiring work being sure the wire length is long enough. Fig. 10-3-4 10-3-4. Wiring Connection 5 mm dia. hole How to connect the connecting cable 7 Mounting screw Ø4 × 25L Clip anchor (local parts) Fig. 10-3-5 CAUTION Failure to securely install the unit may result in personal injury and/or property damage if the unit falls. • In case of block, brick, concrete or similar type walls, drill 5 mm dia. holes in the wall. • Insert clip anchors for the mounting screws. NOTE : • Install the installation plate using mounting screws between 4 to 6, being sure to secure all four corners. Wiring the connecting cable can be carried out without removing 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 (or as according to local regulations/codes) into the pipe hole on the wall. 4. Pull the connecting cable through the cable slot on the rear panel so that it protrudes about 15 cm out of 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. Attach the terminal cover, rear plate bushing and air inlet grille on the indoor unit. – 51 – 10-3-5. Piping and Drain Hose Installation CAUTION • Be sure to refer to the wiring system diagram labeled inside the front panel. • Check local electrical regulations for any specific wiring instructions or limitations. Piping and drain hose forming • Since condensation results in machine trouble, make sure to insulate both the connecting pipes separately. (Use polyethylene foam as insulating material.) Terminal cover Rear left Die-cutting Front panel slit Bottom left Cord clamp Left Terminal block Bottom right Right Earth wire Fig. 10-3-10 Connecting cable Fig. 10-3-6 Terminal block Piping preparation Screw Changing drain hose Rear right Screw 1. Die-cutting front panel slit Cut out the slit on the left or right side of the front panel for the left or right connection and the slit on the bottom left or side of thefront panel for the bottom left or right connection with a pair of nippers. 2. Changing drain hose For left connection, left-bottom connection and rear-left connection’s piping, it is necessary to relocate the drain hose and drain cap. Fig. 10-3-7 How to remove the drain cap Clip drain cap with needle-nose pliers, and pull out. Connecting cable About 15 cm Fig. 10-3-8 Fig. 10-3-11 70 mm 10 mm How to remove the drain hose Earth line The drain hose is secured in place by a screw. Remove the screw securing the drain hose, then pull out the drain hose. 10 mm 50 mm Fig. 10-3-9 NOTE : WIRE TYPE : more than H07 RN-F or 245 IEC 66. (1.0mm²) Screw Drain hose Fig. 10-3-12 – 52 – How to attach the drain cap In case of bottom right or bottom left piping 1. Insert hexagonal wrench (4 mm). • After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool. Slit Fig. 10-3-16 4 mm Fig. 10-3-13 Left-hand connection with piping 2. Firmly insert drain cap. No gap Insert a hexagon wrench (Ø4mm) Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. If applied, deterioration and drain leakage of the drain plug may occur. Bend the connecting pipes so that they are positioned within 43 mm above the wall surface. If the connecting pipes are positioned more than 43 mm above the wall surface, the indoor unit may be unstable. When bending the connecting pipe, make sure to use a spring bender to avoid crushing the pipe. Refer to the table below for the bending radius of each connection pipe. Fig. 10-3-14 How to attach the drain hose Always use the original screw that secured the drain hose to the unit. If using a different screw may cause water to leak. Insert the drain hose firmly until the connector contacts with the insulation, then secure it in place using the original screw. Outer diameter Bending radius 6.35 mm 30 mm 9.52 mm 40 mm 12.7 mm 50 mm To connect the pipe after installation of the unit (figure) (To the front flare) 220 mm Gas side 170 mm CAUTION Liquid side Securely insert the drain hose and drain cap; otherwise, water may leak. 43 mm R30 or less (Ø6.35), R40 or less (Ø9. 52), R50 or less (Ø12. 7) Use polishing (polyethylene core or the like for bending pipe). In case of right or left piping • After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool. Outward form of indoor unit Use a screwdriver handle, etc. Fig. 10-3-17 Slit Fig. 10-3-15 NOTE : If the pipe is incorrectly bent, the indoor unit may be unstable on the wall. After passing the connecting pipe through the pipe hole, connect the connecting pipe to the auxiliary pipes and wrap the facing tape around them. – 53 – 10-3-7. Drainage CAUTION 1. Run the drain hose at a downward sloped angle. • Bind the auxiliary pipes (two) and connecting cable with facing tape tightly. In case of leftward piping and rear-leftward piping, bind the auxiliary pipes (two) only with facing tape. NOTE : • Hole should be made at a slight downward slant on the outdoor side. Do not rise the drain hose. Indoor unit Auxiliary pipes Connecting cable Do not form the drain hose into the waved shape. 50 mm or more Installation plate Fig. 10-3-18 Do not put the drain hose end into water. • Carefully arrange the pipes so that none of the pipes stick out of the rear plate of the indoor unit. • Carefully connect the auxiliary pipes and connecting pipes to each other and cut off the insulating tape wound on the connecting pipe to avoid double-taping at the joint, moreover, seal the joint with the vinyl tape, etc. • Since condensation can result in machine performance trouble, be sure to insulate both connecting pipes. (Use polyethylene foam as insulating material.) • When bending a pipe, be careful not to crush it. Do not put the drain hose end in the drainage ditch. Fig. 10-3-21 2. Put water in the drain pan and make sure that the water is being drained outside. 3. When connecting extension drain hose, insulate the connection part of extension drain hose with shield pipe. Shield pipe 10-3-6. Indoor Unit Installation Drain hose Inside the room 1. Pass the pipe through the hole in the wall, and hook the indoor unit on the installation plate at the upper hooks. 2. Swing the indoor unit to right and left to confirm that it is firmly hooked on the installation plate. 3. While pressing the indoor unit onto the wall, hook it at the lower part on the installation plate. Pull the indoor unit toward you to confirm that it is firmly hooked on the installation plate. 1 Fig. 10-3-22 CAUTION Install the drain pipe for proper drainage. Improper drainage can result in water dripping inside the room. Hook here 1 Installation plate 2 Push (unhook) Hook Fig. 10-3-19 Extension drain hose This air conditioner has been designed to drain water collected from condensation which forms on the back of the indoor unit, to the drain pan. Therefore, do not locate the power cord and other parts at a high place than the drain guide. • For detaching the indoor unit from the installation plate pull the indoor unit toward you while pushing the bottom up at the specified places. Wall Drain guide Space for pipes Push Push Fig. 10-3-23 Fig. 10-3-20 – 54 – 10-4. Outdoor Unit Precautions for adding refrigerant 10-4-1. Installation Place • A place which provides enough space around the outdoor unit as shown in the diagram. • A place which can bear the weight of the outdoor unit and does not allow an increase in noise level and vibration. • A place where the operation noise and discharged air do not disturb neighbors. • A place which is not exposed to a strong wind. • A place free of combustible gases. • A place which does not block a passageway. • When the outdoor unit is to be installed in an elevated position, be sure to secure its feet. • This air conditioner accepts a connection piping length of up to 25 m. • There is no need to add refrigerant as long as the length of the connection piping is 15 m or less. • You will need to add 20 g of refrigerant per meter of added connection piping for installations requiring connection piping to be between 16 m to 25 m. • An allowable height level is up to 10 m. • A place where the drain water does not cause any problems. • Use a scale having a precision with at least 10 g per index line when adding the refrigerant. Do not use a bathroom scale or similar instrument. • Use liquid refrigerant when refilling the refrigerant. Since the refrigerant is in liquid form, it can fill quickly. Therefore, perform the filling operation carefully and insert the refrigerant gradually. CAUTION 1. Install the outdoor unit without anything blocking the discharging air. 2. When the outdoor unit is installed in a place always exposed to strong winds like on the coast or on a high story of a building, secure the normal fan operation using a duct or a wind shield. 3. Especially in windy areas, install the unit to prevent the admission of wind. 4. Installation in the following places may result in trouble. Do not install the unit in such places. • A place full of machine oil. • A saline-place such as the coast. • A place full of sulfide gas. • A place where high-frequency waves are likely to be generated, such as from audio equipment, welders, and medical equipment. Strong wind Fig. 10-4-1 – 55 – 10-4-2. Draining the Water 10-4-3. Refrigerant Piping Connection • Holes are provided on the base plate of the outdoor unit to ensure that the defrost water produced during heating operations is drained off efficiently. If a centralized drain is required when installing the unit on a balcony or wall, follow the steps below to drain off the water. 1. Proceed with water-proofing by installing the water-proof rubber caps in the 2 elongated holes on the base plate of the outdoor unit. [How to install the water-proof rubber caps] 1) Place four fingers into each cap, and insert the caps into the water drain holes by pushing them into place from the underside of the base plate. 2) Press down on the outer circumferences of the caps to ensure that they have been inserted tightly. (Water leaks may result if the caps have not been inserted properly, if their outer circumferences lift up or the caps catch on or wedge against something.) 10 Water-proof rubber caps (supplied with the outdoor unit) Flaring 1. Cut the pipe with a pipe cutter. 90˚ Obliquity Roughness Fig. 10-4-4 2. Insert a flare nut into the pipe, and flare the pipe. • Projection margin in flaring : A (Unit : mm) Rigid (Clutch type) Outer dia. of copper pipe R410A tool used Conventional tool used 6.35 0 to 0.5 1.0 to 1.5 9.52 0 to 0.5 1.0 to 1.5 12.7 0 to 0.5 1.0 to 1.5 Imperial (Wing nut type) Base plate 9 Drain nipple A Outer dia. of copper pipe R410A 6.35 1.5 to 2.0 9.52 1.5 to 2.0 12.7 2.0 to 2.5 Die Pipe Fig. 10-4-5 Fig. 10-4-2 B • Flaring size : B (Unit : mm) 2. Install the drain nipple and a commercially available drain hose (with 16 mm inside diameter), and drain off the water. (For the position where the drain nipple is installed, refer to the installation diagram of the indoor and outdoor units.) • Check that the outdoor unit is horizontal, and route the drain hose at a downward sloped angle while ensuring that it is connected tautly. Base plate Warp Fig. 10-4-6 B +0 –0.4 Outer dia. of copper pipe R410A R22 6.35 9.1 9.0 9.52 13.2 13.0 12.7 16.6 16.2 9 Drain nipple Commercially available drain hose Do not use ordinary garden hose, but one can flatten and prevent water from draining. • In case of flaring for R410A with the conventional flare tool, pull it out approx. 0.5 mm more than that of R22 to adjust to the specified flare size. The copper pipe gauge is useful for adjusting projection margin size. Fig. 10-4-3 – 56 – Tightening Connection Use a vacuum pump Align the centers of the connecting pipes and tighten the flare nut as much as possible with your fingers. Then tighten the nut with a wrench and torque wrench as shown in the figure. Half union Flare nut Externally threaded side Internally threaded side Use a wrench to secure. Use a torque wrench to secure. Fig. 10-4-7 CAUTION • Do not apply excessive force. Otherwise, the nut may break. (Unit : N·m) Outer dia. of copper pipe Tightening torque Ø6.35 mm 14 to 18 (1.4 to 1.8 kgf•m) Ø9.52 mm 33 to 42 (3.3 to 4.2 kgf•m) Ø12.7 mm 50 to 62 (5.0 to 6.2 kgf•m) Be sure to use a vacuum pump with counter-flow prevention function so that oil inside the pump does not flow back into the air conditioner pipes when the pump stops. (If oil inside the vacuum pump enters into the air conditioner circuit which uses R410A, trouble with the refrigeration system may develop.) 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 the vacuum pump. 3. Open fully the low pressure side handle of the gauge manifold valve. 4. Operate the vacuum pump to begin evacuating. Perform evacuating for about 15 minutes if the piping length is 20 meters (15 minutes for 20 meters) (assuming a pump capacity of 27 liters per minute). Confirm that the compound pressure gauge reading is –101 kPa (–76 cmHg). 5. Close the low pressure valve handle of gauge 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. • Tightening torque for connection of flare pipe The pressure of R410A is higher than R22. (Approx. 1.6 times.) Therefore securely tighten the flare pipes which connect the outdoor unit and the indoor unit with the specified tightening torque using a torque wrench. If any flare pipe is Flare at indoor unit incorrectly connected, side it may cause not only a gas leakage but also trouble in the refrigeration cycle. Compound pressure gauge -101kPa (-76cmHg) Pressure gauge Handle Lo Charge hose (For R410A only) Connecting pipe Manifold valve Handle Hi (Keep full closed) Charge hose (For R410A only) Vacuum pump adapter for counter-flow prevention (For R410A only) Vacuum pump Packed valve at liquid side Packed valve at gas side Service port (Valve core (Setting pin)) Flare at outdoor unit side Fig. 10-4-8 Fig. 10-4-9 CAUTION 10-4-4. Evacuating After the piping has been connected to the indoor unit, perform the air purge. • IMPORTANT POINTS FOR PIPING WORK 1. Keep dust and moisture from entering the pipes. 2. Tighten connections carefully (between pipes and unit). 3. Evacuate the air in the connecting pipes using a VACUUM PUMP. 4. Check for gas leaks at all connections. AIR PURGE Evacuate the air in the connecting pipes and in the indoor unit using a vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the vacuum pump manual. – 57 – Packed Valve handling precautions • Open the valve stem all the way; but do not try to open it beyond the stopper. • Securely tighten the valve stem cap with torque in the following table: 1 2 3 10 10 40 Gas side (Ø12.7 mm) 50 to 62 N•m (5.0 to 6.2 kgf•m) Gas side (Ø9.52 mm) 33 to 42 N•m (3.3 to 4.2 kgf•m) Liquid side (Ø6.35 mm) 14 to 18 N•m (1.4 to 1.8 kgf•m) Service port 14 to 18 N•m (1.4 to 1.8 kgf•m) 10 L N 10 30 Earth line Connecting cable 40 30 Power cord Earth line Fig. 10-4-12 Hexagonal wrench is required. m 4m Model RASPower source 10GAVP-E 13GAVP-E 220 – 240 V ~50 Hz 220 V ~60 Hz Maximum running current Fig. 10-4-10 Installation fuse rating 16GAVP-E 12 A 25A (D type ) 10-4-5. Wiring Connection Power cord H07RN-F or 245IEC66 (1.5 mm²) 1. Remove the valve cover, the electric parts cover and the cord clamp from the outdoor unit. 2. Connect the connecting cable to the terminal as identified by the matching numbers on the terminal block of indoor and outdoor unit. 3. Insert the power cord and the connecting cable fully into the terminal block and secure it tightly with screws. 4. Insulate the unused cords (conductors) from water entering in the outdoor unit. Locate them so that they do not touch any electrical or metal parts. 5. Secure the power cord and the connecting cable with the cord clamp. 6. Attach the electric parts cover and the valve cover on the outdoor unit. Connection cable H07RN-F or 245IEC66 (1.0 mm²) CAUTION • Incorrect wiring connection may cause electrical parts to burn out. • Be sure to comply with local regulations/codes when running the wire from outdoor unit to indoor unit. (Size of wire and wiring method etc.) • Every wire must be securely connected. • This installation fuse (25A D type ) must be used for the power supply line. • If incorrect or incomplete wiring is carried out, fire or smoke may result. • Prepare the power supply for the exclusive use of the air conditioner. • This product can be connected to the main breaker. Connection to fixed wiring: A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring when connecting to a main breaker circuit. Stripping length of connecting cable Terminal block 1 2 3 L N Connecting cable Power cord Fig. 10-4-11 – 58 – 10-5-4. Remote Controller Selector Switch Setting 10-5. Test Operation 10-5-1. Gas Leak Test • Check the flare nut connections for gas leaks with a gas leak detector and/or soapy water. Check places for flare nut connections (indoor unit) Remote controller selector switch Valve cover Electric parts Check places for outdoor unit Fig. 10-5-1 10-5-2. Test Operation To test the system, press and hold RESET button for 10 sec. (There will be one short beep.) • If two indoor units are installed in the same room or adjoining rooms, the second unit can inadvertently receive a remote controller signal and start operation when operating the first unit. This can be prevented by setting one of the indoor units and the corresponding remote controller to the B setting (the A setting is the default setting). 1. Setting the selector switch on the main unit • Remove the front panel, and then set the selector switch to “B”. • After making the switch setting, remount the front panel. 2. Setting the remote controller 1) Slide open the remote controller cover and remove the batteries. 2) Cut the jumper wire inside the battery compartment using nippers. • The jumper wire should not remain in contact after being cut. Also, be careful not to let plastic scraps, jumper wire cuttings or other debris enter the inside of the remote controller. 3) Insert the batteries. “B” appears in the remote controller display. 3. Check that the indoor unit can be operated by the modified remote controller. Position of remote controller selector switch Fig. 10-5-2 10-5-3. Auto Restart Setting This product is designed so that, after a power failure, it can restart automatically in the same operating mode as before the power failure. Selector switch Fig. 10-5-3 Information The product was shipped with Auto Restart function in the OFF position. Turn it ON as required. Cutting direction ECO HiPOWER MEMO Jumper wire 184.108.40.206H SWING FIX FAN CLR CLOCK How to Set the Auto Restart SET ON RESET CHECK • Press and hold the RESET button for about 3 seconds. After 3 seconds, three short electric beeps will be heard to inform you that the Auto Restart has been selected. • To cancel the Auto Restart, follow the steps described in the section Auto Restart Function on Owner’s Manual. SLEEP OFF When switching between settings “A” and “B”, always switch the indoor unit board and the remote controller as a pair. (Otherwise, the indoor unit will not accept the remote controller’s signals.) Fig. 10-5-4 – 59 – 11. HOW TO DIAGNOSE THE TROUBLE The pulse motor circuits are mounted to both indoor and outdoor units. Therefore, diagnose troubles according to the trouble diagnosis procedure as described below. (Refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.) Table 11-1 No. Troubleshooting Procedure Page No. Troubleshooting Procedure Page 1 First Confirmation 62 6 How to Check Simply the Main Parts 72 2 Primary Judgment 63 7 Troubleshooting 73 3 Judgment by Flashing LED of Indoor Unit 63 8 How to Diagnose Trouble in Outdoor Unit 75 4 Self-Diagnosis by Remote Controller 64 9 How to Check Simply the Main Parts 76 5 Judgment of Trouble by Every Symptom 67 10 How to Simply Judge Whether Outdoor Fan Motor is Good or Bad 81 K Precautions when handling the new inverter (3DV Inverter) CAUTION: HIGH VOLTAGEN The high voltage circuit is incorporated. Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand. The new inverter (3DV inverter) will be incorporated starting with this unit. (3DV: 3-shunt Discrete Vector control) K The control circuitry has an uninsulated construction. G-Tr Compressor Fan motor Photocoupler Shared potential FET (6IN1) MCU Hall device Photocoupler JAVP-E series (insulated type) IGBT × 6 Compressor Fan motor Shared potential Driver MCU Amplifier FET × 6 Driver Amplifier GAVP-E, EAVP-E series (uninsulated type) Fig. 11-1 – 60 – CAUTION A high voltage (equivalent to the supply voltage) is also energized to ground through the sensors, PMV and other low-voltage circuits. The sensor leads and other wires are covered with insulated tubes for protection. Nevertheless, care must be taken to ensure that these wires are not pinched. Take sufficient care to avoid directly touching any of the circuit parts without first turning off the power. At times such as when the circuit board is to be replaced, place the circuit board assembly in a vertical position. Laying the board flat on an electrically conductive object (such as the top panel of the air conditioner's outdoor unit) while a charge is still retained by the electrolytic capacitors of the inverter's main circuit may cause short-circuiting between the electrolytic capacitors and secondary circuit components and result in damage to the components. Sensor leads Fig. 11-2 Do NOT lay the circuit board assembly flat. K Precautions when inspecting the control section of the outdoor unit NOTE : A large-capacity electrolytic capacitor is used in the outdoor unit controller (inverter). Therefore, if the power supply is turned off, charge (charging voltage DC280 to 380V) remains and discharging takes a lot of time. After turning off the power source, if touching the charging section before discharging, an electrical shock may be caused. Discharge the electrolytic capacitor 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 discharge resistance (approx. 100Ω40W) or plug of the soldering iron to voltage between + – terminals of the C14 (“CAUTION HIGH VOLTAGE” is indicated.) electrolytic capacitor (500µF/400V) on P.C. board, and then perform discharging. Discharging position (Discharging period 10 seconds or more) Plug of soldering iron Inverter cover P. C. board (Soldered surface) Fig. 11-3 – 61 – 11-1. First Confirmation 11-1-1. Confirmation of Power Supply Confirm that the power breaker operates (ON) normally. 11-1-2. Confirmation of Power Voltage Confirm that power voltage is AC 220–230–240 ± 10%. If power voltage is not in this range, the unit may not operate normally. 11-1-3. Operation Which is not a Trouble (Program Operation) For controlling the air conditioner, the program operations are built in the microcomputer as described in the following table. If a claim is made for running operation, check whether or not it meets to the contents in the following table. When it does, we inform you that it is not trouble of equipment, but it is indispensable for controlling and maintaining of air conditioner. Table 11-1-1 No. Operation of air conditioner Description 1 When power breaker is turned “ON”, the operation indicator (Green) of the indoor unit flashes. The OPERATION lamp of the indoor unit flashes when power source is turned on. If [START/STOP] button is operated once, flashing stops. (Flashes also in power failure) 2 Compressor may not operate even if the room temperature is within range of compressor-ON. The compressor does not operate while compressor restart delay timer (3-minutes timer) operates. The same phenomenon is found after power source has been turned on because 3-minutes timer operates. 3 In Dry and ECO mode, FAN (air flow) display does not change even though FAN (air flow select) button is operated. The air flow indication is fixed to [AUTO]. 4 Increasing of compressor motor speed stops approx. 30 seconds after operation started, and then compressor motor speed increases again approx. 30 seconds after. For smooth operation of the compressor, the compressor motor speed is restricted to Max. 41 rps for 2 minutes, and Max.91 rps for 2 minutes to 3 minutes, respectively after the operation has started. 5 In AUTO mode, the operation mode is changed. After selecting Cool or Heat mode, select an operation mode again if the compressor keeps stop status for 15 minutes. 6 In HEAT mode, the compressor motor speed does not increase up to the maximum speed or decreases before the temperature arrives at the set temperature. The compressor motor speed may decrease by hightemp. release control (Release protective operation by temp.-up of the indoor heat exchanger) or current release control. – 62 – 11-2. Primary Judgment To diagnose the troubles, use the following methods. 1) Judgment by flashing LED of indoor unit 2) Self-diagnosis by service check remote controller 3) Judgment of trouble by every symptom Firstly use the method 1) for diagnosis. Then, use the method 2) or 3) to diagnose the details of troubles. 11-3. Judgment by Flashing LED of Indoor Unit While the indoor unit monitors the operation status of the air conditioner, if the protective circuit operates, the contents of self-diagnosis are displayed with block on the indoor unit indication section. Table 11-3-1 Item Check code Block display Description for self-diagnosis A OPERATION (Green) Flashing display (1 Hz) Power failure (when power is ON) B OPERATION (Green) Flashing display (5 Hz) Protective circuit operation for indoor P.C. board C OPERATION (Green) TIMER (Yellow) Flashing display (5 Hz) Protective circuit operation for connecting cable and serial signal system D OPERATION (Green) FILTER (Orange) Flashing display (5 Hz) Protective circuit operation for outdoor P.C. board E OPERATION (Green) TIMER (Yellow) FILTER (Orange) Flashing display (5 Hz) Protective circuit operation for others (including compressor) Indoor indication lamp flashes. Which lamp does flash? 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. – 63 – 11-4. Self-Diagnosis by Remote Controller (Check Code) 1. If the lamps are indicated as shown B to E in Table 11-3-1, execute the self-diagnosis by the remote controller. 2. When the remote controller is set to the service mode, the indoor controller diagnoses the operation condition and indicates the information of the self-diagnosis on the display of the remote controller with the check codes. If a fault is detected, all lamps on the indoor unit will flash at 5Hz and it will beep for 10 seconds (Beep, Beep, Beep ... ). The timer lamp usually flashes (5Hz) during self-diagnosis. 11-4-1. How to Use Remote Controller in Service Mode 1 Press [CHECK] button with a tip of pencil to set the remote controller to the service mode. • “ ” is indicated on the display of the remote controller. 2 Press [ON ] or [OFF ] button If there is no fault with a code, the indoor unit will beep once (Beep) and the display of the remote controller will change as follows : ••• AUTO PURE TEMP MODE • The TIMER indicator of the indoor unit flashes continuously. (5 times per 1 sec.) PRESET HiPOWER ECO • Check the unit with all 52 check codes ( as shown in Table-11-4-1. MEMO 220.127.116.11H SWING FIX FAN CLR CLOCK • Press [ON ] or [OFF code backward. SLEEP SET ON to ) ] button to change the check OFF RESET If there is a fault, the indoor unit will beep for 10 seconds (Beep, Beep, Beep...). CHECK Note the check code on the display of the remote controller. Alphanumeric characters are used for the check codes. is 5. is 6. is A. is B. is C. is D. • 2-digits alphanumeric will be indicated on the display. • All indicators on the indoor unit will flash. (5 times per 1 sec.) 3 Press [START/STOP] button to release the service mode. • The display of the remote controller returns to as it was before service mode was engaged. 4 Time shortening method. 1. Press SET button while pushing CHECK button. 2. Press [START/STOP] button. Fig. 11-4-1 – 64 – 11-4-2. Caution at Servicing 1. After servicing, press the START/STOP button to return to the normal mode. 2. After servicing by the check code, turn off breaker of the power supply, and turn on breaker of the power supply again so that memory in the microcomputer returns the initial status. However, the check codes are not deleted even if the power supply is turned off because they are stored in the fixed memory. 3. After servicing, press [CLR] button under check mode status and then send the check code “7F” to the indoor unit. The error code stored in memory is cleared. Table 11-4-1 Block distinction Check code Block Indoor P.C. board etc. Operation of diagnosis function Check code Air conditioner status Cause of operation Judgment and action Remarks Short-circuit or disconnection of the room temperature sensor (TA sensor). Operation continues. Displayed when error is detected. 1. Check the room temp. sensor. 2. When the room temp. sensor is normal, check P.C. board. Being out of place, disconnection, shortcircuit, or migration of heat exchanger sensor (TC sensor) Operation continues. Displayed when error is detected. 1. Check heat exchanger sensor. 2. When heat exchanger sensor is normal, check P.C. board. Lock of indoor fan or trouble on the indoor fan circuit All off Displayed when error is detected. 1. Check the motor. 2. When the motor is normal, check P.C. board. Not displayed Trouble on other indoor P.C. boards Operation continues. Displayed when error is detected. Replace P.C. board. Connecting cable and serial signal Return serial signal is not sent to indoor side from operation started. 1) Defective wiring of connecting cable 2) Operation of compressor thermo Gas shortage Gas leak Operation continues. Flashes when trouble is detected on Return serial signal, and normal status when signal is reset. 1. When the outdoor unit never operate: 1) Check connecting cable, and correct if defective wiring. 2) Check 25A fuse of inverter P.C. board. 3) Check 3.15A of inverter P.C. board. 2. To display [Other] block during operation, check compressor thermo. operation and supply gas (check gas leak also). 3. Unit operates normally during check. If return serial signal does not stop between indoor terminal board 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal board 2 and 3, replace indoor P.C. board. – 65 – Operation of diagnosis function Block distinction Check code Block Outdoor P.C. board Check code Air conditioner status Cause of operation Remarks Judgment and action Inverter over-current protective circuit operates. (Short time) All off Displayed when error is detected. Even if trying operation again, all operations stop immediately. : Replace P.C. board. Position-detect circuit error or short-circuit between windings of compressor All off Displayed when error is detected. 1. Even if connecting lead wire of compressor is removed, position-detect circuit error occurred. : Replace P.C. board. 2. Measure resistance between wires of compressor, and perform short-circuit. : Replace compressor. Current-detect circuit error All off Displayed when error is detected. Even if trying operation again, all operations stop immediately. : Replace P.C. board. Being out of place, disconnection or shortcircuit of the outdoor heat exchanger sensor (TE) or suction temp. sensor (Ts) All off Displayed when error is detected. 1. Check sensors (TE, TS). 2. Check P.C. board. Disconnection or shortcircuit of discharge temp. sensor All off Displayed when error is detected. 1. Check discharge temp. sensor (TD). 2. Check P.C. board Outdoor fan drive system error All off Displayed when error is detected. Position-detect error, over-current protective operation of outdoor fan drive system, fan lock, etc. : Replace P.C. board or fan motor. Not displayed Outdoor heat exchanger temp. sensor error Operation continues Outdoor P.C. board Compressor drive output All off error, Compressor error (lock, missing, etc.), Break down Others (including compressor) Return serial signal has been sent when operation started, but it is not sent from halfway. 1) Compressor thermo. operation Gas shortage Gas leak 2) Instantaneous power failure Operation continues —— Displayed when error is detected. 1. Check outdoor temp. sensor (TO). 2. Check P.C. board. When 20 seconds passed after start-up, position-detect circuit error occurred. : Replace compressor. Trouble on P.M.V. Flashes when 1. Repeat Start and Stop with trouble is detected interval of approx. 10 to 40 on return serial minutes. (Code is not displayed signal, and normal during operation.) status when signal Supply gas. is reset. (Check also gas leak). 2. Unit operates normally during check. If return serial signal does not stop between indoor terminal block 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal block 2 and 3, replace indoor P.C. board. Compressor does not All off rotate. (Current protective circuit does not operate when a specified time passed after compressor had been activated.) Displayed when error is detected. 1. Trouble on compressor 2. Trouble on wiring of compressor (Missed phase) Discharge temp. exceeded 117°C All off Displayed when error is detected. 1. Check dischage temp. sensor (TD). 2. Gas leakage 3. Trouble on P.M.V. Break down of compressor All off Displayed when error is detected. 1. Check power voltage. (220–230–240 V +10%) 2. Overload operation of refrigeration cycle Check installation condition (Short-circuit of outdoor diffuser). 4-way valve inverse error Operation continues (TC sensor value lowered during heating operation.) – 66 – 1. Check 4-way valve operation. —— 11-5. Judgment of Trouble by Every Symptom 11-5-1. Indoor Unit (Including Remote Controller) (1) Power is not turned on (Does not operate entirely) 1. Is the supply voltage normal? 2. Is the normal voltage provided to the outdoor unit? 3. Is the crossover cable connected properly? 4. Is the fuse (F01) blown? Operation Check Item Considerable principle cause Turn off power supply once, and 5 second later, turn it on again. Measures NO Item by symptoms Is OPERATION indicator flashing? YES Is it possible to turn on power supply by pushing [START/STOP] button on remote controller? YES NO Does transmission mark on remote controller flash normally,and is its signal transmitted properly? YES NO Remote controller is defective. Refer to (5) “Troubleshooting for remote controller”. Unit operates normally. Is fuse (F01) of indoor control board blown? YES Parts (R04, R05, DB01, C01, C03, IC01 and T01) are defective. Does fan YES motor connector between CN10 1 – 3 short-circuit? NO NO Is voltage (DC12V or 5V) indicated on rear of indoor control board normal? Is DC310–340V supplied between CN10 1 – 3 ? NO NO YES Microcomputer is defective. Replace main P.C. board Parts of a power supply circuit defective. YES Replace fan motor. • Be sure to disconnect the motor connector CN10 after shut off the power supply, or it will be a cause of damage of the motor. (2) Power is not turned on though Indoor P.C. board is replaced Turn on power supply. NO Does OPERATION indicator flash? YES Is wired correctly to white and black lead wires of terminal block? NO Correct wiring. YES To item of “Power supply is not turned on”. – 67 – (3) Only the indoor motor fan does not operate 1. Is it possible to detect the power supply voltage (AC220–240V) between Q and R on the terminal block? 2. Does the indoor fan motor operate in cooling operation? (In heating operation, the indoor fan motor does not operate for approximately 10 minutes after it is turned on, to prevent a cold air from blowing in.) Turn off power supply once, and turn it on again. Does fan motor continue to operate? Is it possible to detect YES DC 1V or more between NO 5 + and 3 – of Peplace indoor fan motor. motor connector (CN10). NO YES Start to operate indoor unit in cooling operation at airflow level “LOW”. Does indoor fan operate? NO YES Is it possible to detect DC 310–340V between 1 + and 3 – of motor connector (CN10). NO YES (Motor connection condition) Is it possible to detect DC 15V between 4 + and 3 – of motor connector (CN10). NO Turn off indoor unit and remove connector from motor. Then push START/STOP button on remote controller to stop flashing lamp on indoor unit. YES Is it possible to detect DC 15V between 4 + and 3 – of motor connector (CN10). Change airflow level to “HIGH”. NO Peplace main P.C. board. YES Start to operate the indoor unit in except heating operation. NO At this time, is it possible to detect DC 1V or more between 5 + and 3 – of motor connector (CN10)? YES Is it possible to change airflow level to “HIGH”? Turn off indoor unit and remove connector from motor. Then start to operate indoor unit with remote controller. Start to operate the indoor unit in except heating operation. At this time, is it possible to detect DC 1V or more between 5 + and 3 – of motor connector (CN10)? (Check this condition within 15 seconds after starting unit.) NO YES NO YES Is it possible to rotate cross-flow fan by hand properly? NO Peplace bearing. YES Fan motor operates normally. Turn off indoor unit and rotate cross-flow fan by hand when the unit is on standby. At this time, is it possible to detect DC 1V or more between 5 + and 3 – of motor connector (CN10). NO YES – 68 – (4) Indoor fan motor automatically starts to rotate by turning on power supply The IC is built in the indoor fan motor. Therefore the P.C. board is also mounted to inside of the motor. If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turning on power supply. 1. Remove the front panel. (Remove 2 screws.) 2. Remove the cover of the fan motor lead wires. 3. Check DC voltage with CN10 connector while the fan motor is rotating. NOTE : • Do not disconnect the connector while the fan motor is rotating. • Use a thin test rod. Indoor fan starts rotating when power supply is turned on. P.C. board CN10 (Check output DC voltage of fan motor on P.C. board.) 6 (Blue) Yellow Measure voltage between 3 (GND : BLACK) and 5 (V line : YELLOW) of motor connector (CN10) while indoor fan motor is rotating. 5 (Yellow) 4 (White) Black 3 (Black) 2 – 1 (Red) DC 1.0V or more Under DC 1.0V DC P.C. board is defective. Motor is defective. Replace P.C. board. Replace motor. – 69 – (5) Troubleshooting for remote controller Check that A or B selected on the main unit is matched with A or B selected on the remote controller. The unit does not beep at all. Push the START/STOP button. Operation lamp on indoor unit is not indicated. NO Is transmission mark indicated? YES Is receiver on indoor unit exposed to direct sunlight? Push RESET button on remote controller with tip of pencil. NO YES Is there any thyristor fluorescent light nearby? NO NO Does indoor unit operate when moving remote controller near receiver or indoor unit? YES YES Batteries are exhausted. Push the START/ STOP button NO Does indoor unit start to operate by automatic restart function? Is transmission mark indicated? YES NO YES NO Does radio sound is affected by remote controller when a signal is transmitted at distance of 5 cm from radio? Does indoor unit beep and operate? YES NO YES Remote controller is defective. P.C. board is defective. Avoid direct sunlight. Keep indoor unit away from thyristor fluorescent light. Replace P.C. board. Replace batteries. NOTE : After replacing batteries, push the RESET button with a tip of a pencil. – 70 – Normal operation Replace remote controller. 11-5-2. Wiring Failure (Interconnecting and Serial Signal Wire) (1) Outdoor unit does not operate 1) Is the voltage between R and S of the indoor terminal block varied? Confirm that transmission from indoor unit to outdoor unit is correctly performed based upon the following diagram. NOTE: • Measurement should be performed 2 minutes and 30 seconds after starting of the operation. • Be sure to prepare a diode for judgment. Terminal block at indoor side Red 3 S5277G or equivalent (G or J type) (Diode with rated voltage of 400V or more is acceptable.) S5277G White 2 1 Terminal block Tester Normal time : Voltage swings between DC15 and 60V. ...................Inverter Assembly check (11-8-1.) Abnormal time : Voltage does not vary. (2) Outdoor unit stops in a little while after operation started Select phenomena described below. 1) The outdoor unit stops 10 to 20 minutes after operation started, and 10 minutes or more are required to restart the unit. Gas circulation amount is down. Gas shortage Gas leak Measure gas pressure. Pipe clogging Thermo. operation of compressor 2) If the unit stops once, it does not operate until the power will be turned on again. To item of Outdoor unit does not operate. 3) The outdoor unit stops 10 minutes to 1 hour after operation started, and an alarm is displayed. (Discharge temp. error check code 03, 1E Sensor temp. error check code 02, 1C) Gas leak P.M.V. is defective. Refer to the chart in 11-6. Miswiring of connecting wires of indoor/outdoor units Clogging of pipe and coming-off of TC sensor – 71 – 11-6. Check Code 1C (Miswiring in indoor/outdoor units) and 1E 1C 1E Gas leakage, disconnection of TS/TC sensors (Check code 02, 1C) Discharge temp. error, gas leakage (Check code 03, 1E) Valve drive check Is coil of the pulse motor valve (P.M.V.) correctly set? NO Set it correctly. YES Is connecter of coil connected to inverter? NO Set it correctly. YES Is positioning sound of valve (sound hitting to stopper) heard from valve when the air conditioner starts the operation after turning off power of the air conditioner once? NO Replace coil valve. YES Are temp. sensors of indoor/outdoor units correctly set to the holder? NOTE : The temperature sensors which are used to control pulse motor valve include indoor heat exchanger sensor (TC), outdoor heat exchanger temp. sensor (TE), outdoor suction temp. sensor (TS) and outdoor sensor (TO). NO Set it correctly. YES Gas amount check and valve clogging check Remove TC sensor connector from the P.C. board in indoor unit. (Remove connector from the P.C. board.) Operate the air conditioner in COOL mode by TEMP button (“Beep” sound is heard if keeping pushed for 10 seconds.). The operation enters temporary operation mode which fixes opening degree of compressor speed. Check condensation at outlet of PMV, and then check operating pressure from the service port. Existence of condensation at outlet of P.M.V. If there is condensation at outlet (1/4 inch=Ø6.35mm valve side), the valve is clogged. Check the operating pressure from service port, and add gas if pressure is low. – 72 – YES Replace valve. Add gas. 11-7. Troubleshooting 11-7-1. How to Check Whether the Air Purifier is Good or Not Turn off the power breaker once, and turn on again after 10 seconds. Does the OPERATION indicator flash? NO To item “Power supply is not turned on” Primary check YES Turn off the power breaker and remove CN34 (Micro switch connector). Short-circuit between 1 and 2 pin of CN34 at PC side, and turn on the power breaker after 10 seconds. Is DC12V applied between 1 (Red/DC12V) and (Brown/GND) of CN1 of the high-voltage generator? Is DC12V applied between 1 (+) and 2 (–) of CN33 of the main P.C. board (MCC5020)? NO YES NO YES Is there conduction of micro-switch connector under OFF status of the micro-switch (Front panel opened)? YES Replace the main P.C. board (MCC5020) Micro-switch is stuck Replace micro-switch. NO Is there conduction of micro-switch connector under ON status of the micro-switch (Front panel closed)? NO • Conduction check of micro-switch Micro-switch malfunction YES Push the switch ON → ON Release the switch → OFF 1) Check operation while short-circuiting CN34 of the main P.C. board. 2) Perform 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 preventive timer and all display indicators go on for approx. 3 seconds when a signal is received. on the reactivation preventive timer is not shortened, ( Ifthetime high-voltage is not applied to electrode of the air purifier for approx. 1 hour. ) • While the air purifier operates, check that the fan speed [AUTO] is not displayed. (Because the power ON/OFF is controlled on the program) 3) Be sure not to touch the electric dust collector, ionizer, or ionized wire unit with the human body. NO Does the indoor fan rotate? Tester To item “Only indoor fan does not operate” YES Does the PURE indicator (Blue) or the FILTER indicator (Orange) go on? NO Replace the main P.C. board (MCC5020). Operation check YES Does the PURE indicator go off within 2 seconds after it was ON, and does the FILTER indicator (Orange) go on? Is DC-5V to DC-10V applied between 4 (Brown/Negative voltage) and 2 (Brown/GND) of CN33 of the main P.C. board? NO YES NO • How to check output of the air purifier Collector output YES Are the electric dust NO collector and ionizer dried? (Electrode check) Dry the electric dust collector and ionizer. YES GND Referring to the right figure, check the high-output voltage of the air filter unit. (NOTE) Use an exclusive high voltage tester; otherwise the tester may be broken. Be sure not to come to contact to the gray part or not to touch the ionized cables. Ionizer output High-voltage tester YES Is output of the ionizer approx. 4.0 kV to 4.8 kV? Is output of the collector approx. 3.0 kV to 3.8 kV? Refer to items, cleaning and check for the electric dust collector/ionizer/ ionized wire units. When the ionized wire is disconnected or when dirt is not cleaned even cleaned, replace each unit. ( ) NO Replace the high-voltage generator. YES YES Are the electric dust collector/ionizer/ionized wire units dirty? Is an abnormal sound (cracking noise) heard from the electrode? – 73 – NO No trouble 11-7-2. How to Check Whether the Minus Ion Generator is Good or Not Turn off the power breaker once, and turn on again after 10 seconds. Does the OPERATION indicator flash? NO To item “Power supply is not turned on” Primary check YES Turn off the power breaker and remove CN34 (Micro switch connector). Short-circuit between 1 and 2 pin of CN34 at PC side, and turn on the power breaker after 10 seconds. Is DC12V applied between 1 (Red/DC12V) and 2 (Brown/GND) of CN1 of the high-voltage generator in the air purifier? YES Is there conduction of micro-switch connector under OFF status of the micro-switch (Front panel opened)? NO YES Replace the power P.C. board (MCC5020) or the housing assembly. Micro-switch is stuck Replace micro-switch. NO Is there conduction of micro-switch connector under ON status of the micro-switch (Front panel closed)? NO Micro-switch malfunction • Conduction check of micro-switch YES ON 1) Check operation while short-circuiting CN34 of the main P.C. board. 2) Perform 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 preventive timer and all display indicators go on for approx. 3 seconds when a signal is received. on the reactivation preventive timer is not shortened, ( Ifthetime high-voltage is not applied to electrode of the air purifier for approx. 1 hour. ) • While the air purifier operates, check that the fan speed [AUTO] is not displayed. (Because the power ON/OFF is controlled on the program) 3) Be sure not to touch the electrode with the human body. Does the indoor fan rotate? NO Push the switch → ON Release the switch → OFF Tester To item “Only indoor fan does not operate” YES Does the PURE indicator (Blue) or the FILTER indicator (Orange) go on? NO Replace the main P.C. board (MCC5020). Operation check YES Does the PURE indicator go off within 2 seconds after it was ON, and does the FILTER indicator (Orange) go on? YES To item “How to check whether the air purifier is good or not” NO • How to check output of minus ion Referring to the right figure, check the high-voltage output of the air ionizer. In this time, peel the thermal insulator, and attach it to the original position after check operation. NOTE : Use an exclusive high voltage tester; otherwise the tester may be broken. high-voltage unit NO Does the electrode output approx. –6kV? YES No trouble Electrode NO Replace the high-voltage generator GND High-voltage tester – 74 – 11-8. How to Diagnose Trouble in Outdoor Unit 11-8-1. Summarized Inner Diagnosis of Inverter Assembly Table 11-8-1 Diagnosis/Process flowchart Item Contents Preparation Turn “OFF” the power supply breaker, and remove 3P connector which connects inverter and compressor. Remove connector of compressor. Check 25A fuse (Part No.F01). Check NG OK Replace fuse. • Check whether 25A fuse on the control board assembly is blown or not. (F01) Check electrolytic capacitor, diode block (DB01), etc. OK Discharging position (Discharging period 10 seconds or more) NG NO Operation YES Measurement Turn on the power breaker, and operate the air conditioner in COOL mode by time shortening. Measure terminal voltage of the electrolytic capacity. 760µF:400WV × 3 Remove connector CN300 of outdoor fan motor, and using a tester, check resistance value between every phases at motor side. Check Stop OK Check Measurement Replace outdoor fan motor. A Plug of soldering iron Check electrolytic capacitor, diode (DB01), etc. Does outdoor fan rotate? NG If fuse was blown, be sure to check the electrolytic capacitor and diode block. (DB01) • Connect discharge resistance (approx. 100Ω, 40W) or soldering iron (plug) between +, – terminals of the electrolytic capacitor (760µF) of C14 (with printed CAUTION HIGH VOLTAGE) on P.C. board. Check Check terminal voltage of electrolytic capacitor. Summary B OK if 760µF → DC280 to 380V Remove CN300 while pushing the part indicated by an arrow because CN300 is a connector with lock. After operation, turn off the power breaker after 2 minutes 20 seconds passed, and discharge the electrolytic capacitor by soldering iron. Check voltage between motor phases. • Is not winding between QR‚ R-S, or Q-S opened or short-circuited? • Is not frame grounded with Q, R, or S? – 75 – → Resistance between phases should be approx. 55 to 77Ω → Should be 10MΩ or more. Diagnosis/Process flowchart A Item Contents Check Check winding resistance between phases of compressor, and resistance between outdoor frames by using a tester. B Replace control board assembly. Check compressor winding resistance. NG • Is not grounded. → OK if 10MΩ or more • Is not short-circuited between windings. → OK if 0.51Ω → 0.57Ω (Check by a digital tester.) • Winding is not opened. OK Replace control board. Summary Remove connector CN300 of the outdoor fan motor, turn on the power supply breaker, and perform the operation. (Stops though activation is prompted.) Operation Replace compressor. Check operation within 2 minutes 20 seconds after activation stopped. 11-9. How to Check Simply the Main Parts 11-9-1. 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 supply breaker. 2) When removing the P.C. board, hold the edge of the P.C. board and do not apply force to the parts. 3) When connecting or disconnecting the connectors on the P.C. board, hold the whole housing. 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 discoloration of the copper foil pattern or this P.C. board. 2) The P.C. board consists of the following 2 parts a. Main P.C. board part : DC power supply circuit (5V, 12V, 15V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer, and Driving circuit of louver. b. Indication unit of infrared ray receiving infrared ray receiving circuit, LED : To check defect of the P.C. board, follow the procedure described below. – 76 – (3) Check procedures Table 11-9-1 No. Procedure Check points 1 Turn off the power supply breaker and remove the P.C. board assembly from electronic parts base. Remove the connecting cables from the terminal block. Check whether or not the fuse (F01) is blown. Impulse voltage was applied or the indoor fan motor short-circuited. 2 Remove the connector of the motor and turn on the power supply breaker. If OPERATION indicator flashes (once per second), it is not necessary to check steps (1 to 3) in the right next column. Check power supply voltage : 1. Between No. 1 and No. 3 of CN23 (AC 220–240V) 2. Between and of C03 (DC 310–340V) 3. Between of C10 and output side of IC08 (DC 15V) 4. Between 12V and GND 5. Between 5V and GND 1. The terminal block or the crossover cable is connected wrongly. 2. The capacitor (C01), line filter (L01), resistor (R05), or the diode (DB01) is defective. 3. IC01, IC08 and T01 are defective. 4. IC01, IC08 and T01 are defective. 5. IC01, IC08, IC07 and T01 are defective. 3 Push [START/STOP] button once to start the unit. (Do not set the mode to On-Timer operation.) Check power supply voltage : 1. Between CN21 and No. 1 of CN23 (DC 15–60V) IC03 and IC04 are defective. 4 Shorten the restart delay timer and start unit. Check whether or not all indicators (OPERATION, TIMER, FILTER, PURE) are lit for 3 seconds and they return to normal 3 seconds later. The indicators are defective or the housing assembly (CN13) is defective. 5 Push [START/STOP] button once to start the unit, • Shorten the restart delay timer. • Set the operation mode to COOL. • Set the fan speed level to AUTO. • Set the preset temperature much lower than the room temperature. (The unit (compressor) operates continuously in the above condition.) 1. Check whether or not the compressor operates. 2. Check whether or not the OPERATION indicator flashes. 1. The temperature of the indoor heat exchanger is extremely low. 2. The connection of the heat exchanger sensor is loose. (The connector is disconnected.) (CN01) 3. The heat exchanger sensor and the P.C. board are defective. (Refer to Table 11-4-1.) 4. The main P.C. board is defective. 6 If the above condition (No. 5) still continues, start the unit in the following condition. • Set the operation mode to HEAT. • Set the preset temperature much higher than room temperature. 1. Check whether or not the compressor operates. 2. Check whether or not the OPERATION indicator flashes. 1. The temperature of the indoor heat exchanger is extremely high. 2. The connection of the heat exchanger sensor short-circuited. (CN01) 3. The heat exchanger sensor and the P.C. board are defective. (Refer to Table 11-4-1.) 4. The main P.C. board is defective 7 Connect the motor connector to 1. Check it is impossible to detect the motor and turn on the power the voltage (DC 15V) between 3 supply. and 4 of the motor terminals. Start the unit the following 2. The motor does not operate or condition. the fan motor does not rotate with • Set the fan speed level to HIGH. high speed. (The unit (compressor) operates (But it is possible to receive the continuously in the above signal from the remote controller.) condition in No. 5.) 3. The motor rotates but vibrates strongly. – 77 – Causes 1. The indoor fan motor is defective. (Protected operation of P.C. board.) 2. The P.C. board is defective. 3. The connection of the motor connector is loose. 11-9-2. P.C. Board Layout GND +12V +5V  Sensor characteristic table 100 Resistance value (k ) 90 80 TD 70 60 50 40 30 20 TA, TC, TO, TE, TS 10 0 0 10 20 30 40 50 Temperature (˚C) – 78 – TD TA TC TO TE TS : Discharge temp. sensor : Room temp. sensor : Heat exchanger temp. sensor : Outdoor temp. sensor : Outdoor heat exchanger temp. sensor : Suction temp. sensor 11-9-3. Indoor Unit (Other Parts) No. Part name 1 Room temp. (TA) sensor Heat exchanger (TC) sensor Checking procedure Disconnect the connector and measure the resistance value with tester. (Normal temp.) Temperature Sensor TA, TC (kΩ) 10°C 20°C 25°C 30°C 40°C 20.7 12.6 10.0 7.9 4.5 2 Remote controller Refer to 11-5-1. (5). 3 Louver motor MP24Z Measure the resistance value of each winding coil by using the tester. (Under normal temp. 25°C) White Yellow Yellow Yellow Yellow 4 Indoor fan motor 1 2 3 4 5 1 2 3 4 5 Position Resistance value 1 to 2 1 to 3 1 to 4 1 to 5 380 ± 40Ω Refer to 11-5-1. (3) and (4). 11-9-4. Outdoor Unit No. 1 Part name Compressor (Model : DA111A1F-20F1) Checking procedure Measure the resistance value of each winding by using the tester. Red Position Resistance value Red - White White - Black 0.88 to 0.98Ω Black - Red White 2 Outdoor fan motor (Model : ICF-140-43-4R) Black Measure the resistance value of winding by using the tester. Red White 3 4-way valve coil (Model : VHV) Under 20°C Black Position Resistance value Red - White 17 to 25kΩ White - Black 17 to 25kΩ Black- Red 17 to 25kΩ Measure the resistance value of winding by using the tester. Resistance value 1435 ± 144Ω Under 20°C 4 Pulse motor valve coil (Model : CAM-MD12TF-6) Measure the resistance value of winding by using the tester. COM 1 W Position Resistance value 6 R Red - White 42 to 50kΩ 3 O White - Orange 42 to 50kΩ Brown- Yellow 42 to 50kΩ Brown- Blue 42 to 50kΩ Y BR BL COM 2 5 4 Under 20°C 5 Outdoor temperature sensor (TO), discharge temperature sensor (TD), suction temperature sensor (TS), outdoor heat exchanger temperature sensor (TE) Disconnect the connector, and measure resistance value with the tester. (Normal temperature) Temperature 10°C 20°C 25°C 30°C 40°C 50°C TD (kW) 100 64 50 41 27 18 TO,TS,TE (kW) 20.7 12.6 10.0 7.9 4.5 — Sensor – 79 – 11-9-5. Checking Method for Each Part Part name 1 Electrolytic capacitor (For boost, smoothing) Checking procedure 1. 2. 3. 4. 5. 6. Turn OFF the power supply breaker. Discharge all three capacitors completely. Check that safety valve at the bottom of capacitor is not broken. Check that vessel is not swollen or exploded. Check that electrolytic liquid does not blow off. Check that the normal charging characteristics are shown in continuity test by the tester. Heat sink IGBT side No. C12 C13 C14 Case that product is good MCC-5009 Soldered surface Pointer swings once, and returns slowly. When performing test once again under another polarity, the pointer should return. C12, C13, C14 → 760µF/400V 2 Diode block 1. Turn OFF the power supply breaker. 2. Completely discharge the four electrolytic capacitors. 3. Remove the diode block from the PCB (which is soldered in place). 4. Use a multimeter with a pointer to test the continuity, and check that the diode block has the proper rectification characteristics. 1 + ~ Tester rod ~ 3 2 +~~– 1 2 3 4 – 4 (DBO1) + – ~2 ~3 +1 –4 ~2 ~3 Resistance value in good product ∞ 10 to 20 Ω when the multimeter probe is reversed – 80 – 11-10. How to Simply Judge Whether Outdoor Fan Motor is Good or Bad 1. Symptom • Outdoor fan motor does not rotate. • Outdoor fan motor stops within several tens seconds though it started rotating. • Outdoor fan motor rotates or does not rotate according to the position where the fan stopped, etc. Remote controller check code “02 : Outdoor block, 1A : Outdoor fan drive system error” 2. Cause The following causes are considered when the outdoor fan motor does not normally rotate. 1) Mechanical lock of the outdoor fan motor 2) Winding failure of the outdoor fan motor 3) Position-detect circuit failure inside of the outdoor fan motor 4) Motor drive circuit failure of the outdoor P.C. board 3. How to simply judge whether outdoor fan motor is good or bad Turn OFF the breaker. Disconnect two connectors (CN300) of the outdoor fan motor from the outdoor P.C. board. Does the fan rotate without trouble when rotating it with hands? NO CN300 YES 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 17 to 25Ω, it is normal. NO YES Fan motor is normal. Fan motor error (Outdoor P.C. board error) NOTE : However, GND circuit error inside of the motor may be accepted in some cases when the above check is performed. When the fan motor does not become normal even if P.C. board is replaced, replace the outdoor fan motor. – 81 – 12. HOW TO REPLACE THE MAIN PARTS WARNING • Since high voltages pass through the electrical parts, turn off the power without fail before proceeding with the repairs. Electric shocks may occur if the power plug is not disconnected. • After the repairs have been completed (after the front panel and cabinet have been installed), perform a test run, and check for smoking, unusual sounds and other abnormalities. If this check is omitted, a fire and/or electric shocks may occur. Before proceeding with the test run, install the front panel and cabinet. • Ensure that the following steps are taken when doing repairs on the refrigerating cycle. 1. Do not allow any naked flames in the surrounding area. If a gas stove or other appliance is being used, extinguish the flames before proceeding. If the flames are not extinguished, they may ignite any oil mixed with the refrigerant gas. 2. Do not use welding equipment in an airtight room. Carbon monoxide poisoning may result if the room is not properly ventilated. 3. Do not bring welding equipment near flammable objects. Flames from the equipment may cause the flammable objects to catch fire. • If keeping the power on is absolutely unavoidable while doing a job such as inspecting the circuitry, wear rubber gloves to avoid contact with the live parts. Electric shocks may be received if the live parts are touched. High-voltage circuits are contained inside this unit. Proceed very carefully when conducting checks since directly touching the parts on the control circuit board may result in electric shocks. 12-1. Indoor Unit No. Part name Front panel Procedures 1) Stop operation of the air conditioner and turn off its main power supply. 2) Open the air inlet grille, push the arm toward the outside, and remove the grille. 3) Remove the left and right air filters, and remove the electric dust collector. – 82 – Remarks No. Part name Front panel Procedures Remarks 4) Press “ ” part under the front panel and remove hooks of the front panel from the installation plate. Pull here Installation plate Press here Press here Front panel Press 5) Remove the front panel fixing screws. (2 pcs.) 6) Press the electric parts box with the right thumb while pulling the both sides of the front panel toward you. Electric dust collector Holder Electric dust collector Holder Protrusion Protrusion 1) Press three center positions and two lower center positions of the air outlet, and then hang the hanging hooks (4 pcs.) at the top side of the front panel to the rear plate. 2) Insert the electric dust collector and left and right air filters. Press in the electric dust collector until the protrusions on both sides are completely inserted into the holders. If installation is incomplete, the FILTER indicator (orange) may light. 3) Tighten two screws. • Incomplete hanging or incomplete pressing may cause a dewdrops or generation of a fluttering sound. – 83 – No. Part name Procedures High voltage generator 1) Follow to the procedure in the item . 2) Remove the drain guide. 3) To remove the air ionizer from the back body, pull it toward you while pressing down on its left and right claws. Disconnect the two leads (black) connected to the air ionizer from where they are fitted into the other components. (Caution: do not remove the Faston.) 4) Disconnect the connectors of the high-voltage generator, and disconnect the four leads from where they are fitted into the other components. 5) Remove the fixing screw which secures the high voltage generator, and remove the high voltage generator from the evaporator. Remarks Connector Drain guide Air ionizer Press the claw here Screw Press the claw here Pull here 1) Insert the high voltage generator straight into the evaporator, and secure it using the fixing screw. Check whether the completely inserted. 2) Pass the leads of the high voltage generator through the area designated and insert them into its connectors. 3) Attach the air ionizer to the back body, and pass the two leads (black) through the area designated on the electric parts box assembly. 4) Attach the drain guide. Claw Claw Claw – 84 – No. Part name Electric parts box assembly Procedures Remarks 1) Follow the procedure up to 4) in above. 2) Remove screw of earth lead attached to the end plate of the evaporator. 3) Remove the lead wire cover, and remove connector (5P) for the fan motor and connector (5P) for the louver motor from the electric parts box assembly. 4) Pull out TC sensor from sensor holder of the evaporator. TC sensor Fan motor connector Louver moter connector Screw Fixing screw 5) Disengage the two claws at the top of the display unit. (They can be easily disengaged by pressing the drain pan above the claws and at the same time pulling the display unit toward you.) 6) Remove the fixing screw that secures the electric parts box assembly, and remove the assembly. 1) Hook the top part of the electric parts box assembly onto the claws on the back body, and secure it using the fixing screw. Now attach the display unit. Connect the connectors for the fan motor and louver motor. 2) Secure the grounding wire using the fixing screw. Insert the TC sensor into the sensor holder. * Be absolutely sure to loop the grounding wire and TC sensor leads once at the bottom. – 85 – Press the drain pan Pull the display unit toward you No. Part name Horizontal louver Procedures Remarks 1) Remove shaft of the horizontal louver from the back body. (First remove the left shaft, and then remove other shafts while sliding the horizontal louver leftward.) Slide the horizontal louver leftward Evaporator (Heat exchanger) 1) Follow to the procedure in the item . 2) Remove the pipe holder from the rear side of the main unit. 3) Remove two fixing screws at the left side of the end plate of the heat exchanger. Pipe holder Disengage the claw 4) Remove the heat exchanger fixing holder by removing the two fixing screws used to secure it. Screw Heat exchanger fixing holder Screw 5) Remove right side of the end plate from two fixing ribs while sliding slightly the heat exchanger rightward. – 86 – No. Part name Bearing Procedures 1) Follow to the procedure in the items . 2) Remove the two fixing screws used to secure the left edge panel of the heat exchanger, and remove the two screws used to secure the bearing base. Remarks Screw Bearing base Screw 3) Raise the left side of the heat exchanger slightly, and remove the bearing base. • If the bearing is out from the housing, push it into the specified position and then incorporate it in the main body. • After assembling the bearing base, check that it is fitted into the stepped part of the drain pipe. Raise the left side Remove in this direction Bearing base Bearing Drain pipe Drain pipe Bearing base – 87 – No. Part name Fan motor Procedures 1) Follow to the procedure in the item . 2) Loosen the set screw of the cross flow fan. 3) Remove two fixing screws of the motor band (Right), and then remove the motor band (Right). 4) Pull the fan motor outward. In assembling work, install the fan motor as follows. • When assembling the fan motor, the fan motor must be installed in such a way that the fan motor leads will be taken out is positioned at the bottom front. • After assembling the two hooking claws of the motor band (right) into the main body, position the fan motor, insert it, and then secure the motor band (right) using the two fixing screws. Remarks Set screw Secure using the fixing g screw Screw Motor band nd (Right) Screw Secure using sing the fixing screw Fan motor leads Cross flow fan 1) Follow to the procedure in the item . 2) Remove the heat exchanger fixing holder by removing the two fixing screws used to secure it. 3) Loosen the set screw of the cross flow fan. 4) Lift the left side of the heat exchanger, and pull out the cross flow fan. Raise the left side Pull out here – 88 – No. Part name Procedures Cross flow fan 1) At assembling work of the bearing base, check that the drain pipe is surely incorporated in the back body. (Otherwise, water leak is caused.) 2) To incorporate the fan motor, remove the fan motor rubber (at shaft core side), incorporate the motor into the position in the following figure, and then install the fan motor. Remarks Bearing base Drain pipe • Install the cross flow fan so that the right end of the 1st joint from the right of the cross flow fan is set keeping 70.5 mm from wall of rear plate of the main unit. • Holding the set screw, install the cross flow fan so that U-groove of the fan motor comes to the mounting hole of the set screw. Joint 70.5mm • Perform positioning of the fan motor as follows: • When assembling the fan motor, the fan motor must be installed in such a way that the fan motor leads will be taken out is positioned at the bottom front. • After assembling the two hooking claws of the motor band (right) into the main body, position the fan motor, insert it, and then secure the motor band (right) using the two fixing screws. U groove – 89 – 12-2. Microcomputer No. Part name Common procedure Procedure Remarks 1) Turn the power supply off to stop the operation of air-conditioner. 2) Remove the front panel. • Remove the 2 fixing screws. 3) Remove the electrical part base. Replace terminal block, microcomputer ass’y and the P.C. board ass’y. R05 L01 C01 CN23 FUSE R04 R01 CN10 DB01 C03 T01 IC01 C20 IC03 – 90 – J04 12-3. Outdoor Unit No. Part name Common procedure Procedure Remarks 1. Detachment Upper cabinet NOTE Wear gloves for this job. Otherwise, you may injure your hands on the parts, etc. 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner. 2) Remove the valve cover. (ST1TØ4 × 8L 1 pc.) • After removing screw, remove the valve cover pulling it downward. 3) Remove wiring cover (ST1TØ4 × 8L 2 pcs.), and then remove connecting cable. 4) Remove the upper cabinet. (ST1TØ4 × 8L 5 pcs.) • After removing screws, remove the upper cabinet pulling it upward. Water proof cover Valve cover 2. Attachment 1) Attach the water-proof cover. NOTE The water-proof cover must be attached without fail in order to prevent rain water, etc. from entering inside the indoor unit. 2) Attach the upper cabinet. (ST1TØ4 × 8L 5 pcs.) 3) Perform cabling of connecting cable, and attach the wiring cover. • Place the wiring cover over the opening used to work on the connecting wires of the side cabinet, and secure it using the two fixing screws (ST1TØ4 × 8L 2 pcs.). At this point, the top cushion of the wiring cover must be on the inside of the opening. 4) Attach the valve cover. (ST1TØ4 × 8L 1 pc.) • Insert the upper part into the square hole of the side cabinet, set hook claws of the valve cover to square holes (at three positions) of the main unit, and attach it pushing upward. – 91 – Insert the bent part into the rear panel of the inverter Align the stitch line with the top edge of the front cabinet Bring into contact against these parts Bend downward, and align with the inside surface of the front cabinet How to mount the water-proof cover No. Part name Procedure Front cabinet 1. Detachment 1) Perform step 1 in . 2) Remove the fixing screws (ST1TØ4 × 8L 2 pcs.) used to secure the front cabinet and inverter cover, the screws (ST1TØ4 × 8L 3 pcs.) used to secure the front cabinet at the bottom, and the fixing screws (ST1TØ4 × 8L 2 pcs.) used to secure the motor base. • The front cabinet is fitted into the side cabinet (left) at the front left side so pull up the top of the front cabinet to remove it. 2. Attachment 1) Insert the claw on the front left side into the side cabinet (left). 2) Hook the bottom part of the front right side onto the concave section of the bottom plate. Insert the claw of the side cabinet (right) into the square hole in the front cabinet. 3) Return the screws that were removed above to their original positions, and attach them.the main unit, and attach it pushing upward. Remarks Front cabinet Claw Square hole Concave section – 92 – No. Part name Inverter assembly Procedure 1) Perform work of item 1 in . 2) Remove screw (ST1TØ4 × 8L 2 pcs.) of the upper part of the front cabinet. • If removing the inverter cover in this condition, P.C. board can be checked. • If there is no space above the unit, perform work of 1 in . Remarks Inverter cover P. C. board (Soldered surface) Be careful to check the inverter because high-voltage circuit is incorporated in it. 3) Perform discharging by connecting , polarity by discharging resistance (approx. 100Ω40W) or plug of soldering iron to , terminals a of the C14 (printed “CAUTION HIGH VOLTAGE” is attached.) electrolytic capacitor (760µF) on P.C. board. Be careful to discharge the capacitor because the electrolytic capacitor cannot naturally discharge and voltage remains according to trouble type in some cases. Discharging position (Discharging period 10 seconds or more) A screw (STIT-4X8MSZN) Plug of soldering iron Terminal block NOTE This capacitor is one with mass capacity. Therefore, it is dangerous that a large spark generates if short-circuiting between , polarity with screwdriver, etc. for discharging. 4) Remove screw (ST1TØ4 × 8L 2 pcs.) fixing the main body and the inverter box. 5) Remove the front cabinet by performing step 1 in , and remove the fixing screws (ST1TØ4 × 8L) for securing the main body and inverter box. 6) Remove various lead wires from the holder at upper part of the inverter box. 7) Pull the inverter box upward. 8) Disconnect connectors of various lead wires. Put the compressor Put each leads leads through through the hole the hole The connector is one with lock, so remove it while pushing the part indicated by an arrow. Requirement As each connector has a lock mechanism, avoid to remove the connector by holding the lead wire, but by holding the connector. Be sure to remove the connector by holding the connector, not by pulling the lead wire. – 93 – No. Part name Procedure Control board assembly 1. Disconnect the leads and connectors connected to the other parts from the control board assembly. 1) Leads • 3 leads (black, white, orange) connected to terminal block. • Lead connected to compressor : Disconnect the connector (3P). • Lead connected to reactor : Disconnect the two connectors (2P). 2) Connectors (×8) CN300 : Outdoor fan motor (3P: white)* (See NOTE) CN701 : 4-way valve (2P: yellow)* CN600 : TE sensor (2P: white)* CN700 : PMW (6P: white) CN603 : TS sensor (3P: white)* CN601 :TD sensor (3P: white)* CN602 : TO sensor (2P: white) Remarks CN603 CN601 CN600 CN701 CN700 CN602 CN300 CN300, CN701, CN600 and CN603 are connectors with locking mechanisms: as such, to disconnect them, they must be pressed in the direction of the arrow while pulling them out. NOTE These connectors have a disconnect prevention mechanism: as such, the lock on their housing must be released before they are disconnected. 2. Remove the control board assembly from the P.C. board base. (Remove the heat sink and control board assembly while keeping them screwed together.) NOTE Disengage the four claws of the P.C. board base, hold the heat sink, and lift to remove it. 3. Remove the two fixing screws used to secure the heat sink and control board assembly. 4. Mount the new control board assembly. NOTE When mounting the new control board assembly, ensure that the P.C. board is inserted properly into the P.C. board support groove. – 94 – P.C. board base P.C. board No. Part name Side cabinet Procedure Remarks 1. Side cabinet (right) 1) Perform step 1 in and all the steps in . 2) Remove the fixing screw (ST1TØ4 × 8L 5 pcs.) used for securing the side cabinet to the bottom plate and valve fixing panel. 2. Side cabinet (left) 1) Perform step 1 in . 2) Remove the fixing screw (ST1TØ4 × 8L 1 pcs.) used to secure the side cabinet (left) onto the heat exchanger. 3) Remove the fixing screw (ST1TØ4 × 8L 2 pc.) used for securing the side cabinet to the bottom plate and heat exchanger. Hook the claw onto the bottom plate here. A B C The back body section is hooked onto the bottom plate here. Detail A Fan motor Detail B 1) Perform work of item 1 of and . 2) Remove the flange nut fixing the fan motor and the propeller. • Flange nut is loosened by turning clockwise. (To tighten the flange nut, turn counterclockwise.) 3) Remove the propeller fan. 4) Disconnect the connector for fan motor from the inverter. 5) Remove the fixing screws (2 pc.) holding by hands so that the fan motor does not fall. * Precautions when assembling the fan motor Tighten the flange nut using a tightening torque of 4.9 N•m. – 95 – Detail C Propeller fan Fan motor Flange nut No. Part name Procedure Compressor 1) Perform work of item 1 of and , , , . 2) Extract refrigerant gas. 3) Remove the partition board. (ST1TØ4 × 8L 3 pcs.) 4) Remove the sound-insulation material. 5) Remove terminal cover of the compressor, and disconnect lead wire of the compressor from the terminal. 6) Remove pipe connected to the compressor with a burner. • Take care to keep the 4-way valve away from naked flames. (Otherwise, it may malfunction.) 7) Remove the fixing screw of the bottom plate and heat exchanger. (ST1TØ4 × 8L 1 pc.) 8) Remove the fixing screw of the bottom plate and valve fixing plate. (ST1TØ4 × 8L 1 pc.) 9) Pull upward the refrigeration cycle. 10) Remove BOLT (3 pcs.) fixing the compressor to the bottom plate. * Precautions when assembling the compressor. Tighten the compressor bolts using a tightening torque of 4.9 N•m. Reactor Remarks Partition board Compressor Valve fixing plate 1) Perform work of item 1 of , and . 2) Remove screws fixing the reactor. (ST1TØ4 × 8L 4 pcs.) Reactor – 96 – No. Part name Electronic expansion valve coil Procedure Remarks 1. Detachment 1) Perform step 1 in , all the steps in and 1 in . 2) Remove the coil by pulling it up from the electronic control valve body. Coil anti-turn lock 2. Attachment 1) When assembling the coil into the valve body, ensure that the coil anti-turn lock is installed properly in the pipe. When handling the parts, do not pull the leads. When removing the coil from the valve body, use your hand to secure the body in order to prevent the pipe from being bent out of shape. Fan guard 1. Detachment 1) Perform work of item 1 of . 2) Remove the front cabinet, and put it down so that fan guard side directs downward. Coil anti-turn lock position Coil inserting position Minus screwdriver Hooking claw Perform work on a corrugated cardboard, cloth, etc. to prevent flaw to the product. 3) Remove the hooking claws by pushing minus screwdriver according to the arrow mark in the right figure, and remove the fan guard. 2. Attachment 1) Insert claws of the fan guard in the holes of the front cabinet. Push the hooking claws (9 positions) by hands and fix the claws. All the attaching works have completed. Check that all the hooking claws are fixed to the specified positions. – 97 – No. 11 Part name Procedure Remarks TE sensor (outdoor heat exchanging temperature sensor) • Attachment With the leads pointing downward and the sensor leads pointing in the direction shown in the figure, install the sensor onto the straight pipe part of the condenser output pipe. Detail C for 10GAVP-E 12 Detail C for 13, 16GAVP-E TS sensor (Suction pipe temperature sensor) TD sensor (Discharge pipe temperature sensor) • Attachment With its leads pointed downward, install the sensor onto the vertical straight pipe part of the discharge pipe. 14 Detail B Detail C • Attachment With its leads pointing downward, point the sensor in the direction of the packed valve, and install it onto the straight pipe part of the suction pipe. 13 Detail A Arrow D • Shown in the above figure is the model 13GAVP-E. • The sensor mounting positions in the model 10GAVP-E are all the same with the sole exception of the TE sensor. Refer to the figure shown on the left. TO sensor (Outside air temperature sensor) • Attachment Insert the outdoor air temperature sensor into the holder, and install the holder onto the heat exchanger. Detail B TS sensor Detail A TD sensor Arrow D TO sensor CAUTION During the installation work (and on its completion), take care not to damage the coverings of the sensor leads on the edges of the metal plates or other parts. It is dangerous for these coverings to be damaged since damage may cause electric shocks and/or a fire. CAUTION After replacing the parts, check whether the positions where the sensors were installed are the proper positions as instructed. The product will not be controlled properly and trouble will result if the sensors have not been installed in their proper positions. – 98 – No. Part name Procedure 15 Replacement of temperature sensor for servicing only 1) Cut the sensor 100 mm longer than old one. 2) Cut the protective tube after pulling out it (200 mm). 3) Move the protective tube toward the thermal sensor side and tear the tip of lead wire in two then strip the covering part. 4) Pass the stripped part through the thermal constringent tube. 5) Cut the old sensor 100 mm length on the connector side, and recycle that connector. 6) Tear the lead wire in two on the connector side and strip the covering part. 7) Twist the leads on the connector and sensor sides, and solder them. 8) Move the thermal constringent tubes toward the soldered parts and heat them with the dryer and constring them. 9) Wind the attached color tape round the both terminals of the protective tube when colored protective tube is used. 10) Fix the sensor again. Common service parts of sensor TO, TS, TE, TD Remarks Cutting here Connector 100 Thermal sensor part Cutting here 200 15 Thermal constringent tube 70 Cutting here 100 15 70 Soldered part Dryer Winding the color tape NOTE 1) Store the joint part of the sensor and the connector in the electric parts box. 2) Never joint them near the thermal sensor part. Otherwise it would cause insulation inferiority because of dew drops. 3) When replacing the sensor using the colored protective tube, wind the color tape matching the color of that tube. These are parts for servicing sensors. Please check that the accessories shown in the right table are packed. 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 – 99 – MCC-5009 – 100 – 13. EXPLODED VIEWS AND PARTS LIST 13-1. Indoor Unit (1) 240 238 247 216 235 213 234 217 214 225, 226 209 212 236 230 201 223 203 221, 222, 224 246 210 218, 219 207 215 211 227 205 228 206 202 239 229 245 204 232 233 ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part No. Description Location No. Part No. Description 201 202 203 204 205 206 207 209 210 211 212 213 214 215 216 217 218 219 43005633 43005610 4301V052 43080512 43080521 43009675 43009682 4302C067 4302C063 4306A024 43039363 43039321 43020346 43039314 43020253 4301V028 43049701 43049698 223 43049674 224 225 43047673 43044803 221 43047671 226 227 228 229 230 232 233 234 235 236 238 239 240 245 246 247 43044804 43039324 43049728 43019904 43049770 43062256 43062247 43082293 4306S577 43083071 43003307 43070188 43079268 43080516 43080527 4308N732 Spring, Suction (B16GKVP-E) Pipe, Inlet Evaporator (B10GKVP-E, B13GKVP-E) Evaporator (B16GKVP-E) Guide, Drain Guide, Drain, Left Holder, Sensor Holder, Evaporator, Right Cover, Terminal Cover, Lead Plate, Installation Remote Controller Holder, Remote, Comtroller Body Ass’y, Back Hose, Drain Cap, Drain Electrical Air Purifying Filter Generator Ass’y, HV Owner’s Manual 222 43047672 Panel Ass’y, Front Grille, Air Inlet Plate, Fix Filter, Air, Right Filter, Air, Left Louver, Horizontal Louver, Vertical Motor, Fan Motor, Louver Cord, Motor, Louver Band, Motor, Left Base, Bearing Fan, Cross Flow Band, Motor Bearing Holder, Pipe Pipe, Shield (B16GKVP-E) Pipe, Shield (B10GKVP-E, B13GKVP-E) Pipe, Outlet (B10GKVP-E, B13GKVP-E) Pipe, Outlet (B16GKVP-E) – 101 – Indoor Unit (2) 402 407, 408, 409 403 404 406 401 410 405 ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part No. Description Location No. Part No. 401 402 403 404 405 406 4306A123 43062263 43050425 43050426 4306S728 43051346 Terminal Block, 2P Cover, E-Parts Sensor, TC (F6) Sensor, TA P.C. Board Ass’y, WRS-LED SW-Micro Ass’y 407 4306S709 408 4306S710 409 4306S711 410 43067115 – 102 – Description P.C. Board Ass’y (B10GKVP-E) P.C. Board Ass’y (B13GKVP-E) P.C. Board Ass’y (B16GKVP-E) Clamp, Cord 13-2. Outdoor Unit 4 44 10 2 28, 29 30, 31 47 6 27 14, 15, 17, 18, 20 21, 23, 24, 25, 26 11, 12 48 36 43 38 33 34 13, 16, 19, 22 8 9 3 35 37 2 32 40 39 41 35 7 34 42 5 3 1 7 45 46 10 – 103 – ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part Description Location No. Part Description 1 2 3 4 5 6 7 8 9 10 43005657 43005642 43005658 43005634 4301V035 4301V053 43042489 43119471 43062262 43041634 24 43047681 25 43047674 26 43047675 27 44246239 28 43046444 29 30 43046443 37546848 11 43043749 12 43043751 13 14 37546845 43046442 15 37546846 16 17 43147196 43047401 18 19 20 43147195 43047676 43047677 21 22 23 43047678 43047679 43047680 Cabinet, Front Cabinet, Upper Cabinet, Side, Right Cabinet, Side, Left Guard, Fan Guard, Fin Base Ass’y Cover, Valve, Packed Cover, Wiring Ass’y Compressor, DA111A1F-20F1, RoHS Condenser Ass’y (10GAVP-E) Condenser Ass’y (13GAVP-E, 16GAVP-E) Valve, Packed, 6.35 Valve, Packed, 9.52 (10GAVP-E, 13GAVP-E) Valve, Packed, 12.7 (16GAVP-E) Bonnet, 1/4 IN Bonnet, 3/8 IN (10GAVP-E, 13GAVP-E) Bonnet, 1/2 IN (16GAVP-E) Nut, Flare, 6.35 Nut, Flare, 9.52 (10GAVP-E, 13GAVP-E) Nut, Flare, 12.7 (16GAVP-E) Cap, Valve, Packed, 6.35 Cap, Valve, Packed, 9.52 (10GAVP-E, 13GAVP-E) 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 37546849 43058277 4302C068 43020329 43047669 43039392 43004233 4301V064 43032441 43089160 4301P703 4301P702 43049749 43062176 43063321 43063322 43063325 43063339 Cap, Valve, Packed, 12.7 (16GAVP-E) Cap, Charge, Port (10GAVP-E, 13GAVP-E) Cap, Charge, Port (16GAVP-E) Tube, Capillary, I.D 1.2 (13GAVP-E, 16GAVP-E) Valve, 4-Way, STF-0108Z, RoHS Coil, 4-Way valve Valve, Pulse, Motor, CAM-B22YGTF-3 Coil, PMV, CAM-MD12TF-6 Reactor Motor, Fan, ICF-140-43-4R Fan, Propeller, PJ421 Nut, Flange Base, Motor Ass’y Plate, Partition Plate, Fix, Valve, Packed Nipple, Drain Cap, Waterproof Mark, TOSHIBA Mark, DAISEIKAI Rubber, Cushion Sleeve, Flag Holder, Sensor (TD) Holder, Sensor (TS) Holder, Sensor (TE) Holder, Sensor (TO) – 104 – 13-3. P.C. Board Layout 704 Base, P.C. Board 706 701 702 703 Sensor, TD (Ø4) Sensor, TE Sensor, TS Sensor, TO 707 P.C. Board Ass’y 705 Terminal (6P) ∗ The parts in the following parts list are conformed to RoHS. Therefore be sure to use the following parts for repairing and replacing. Location No. Part 701 702 703 704 43050422 43050423 43050427 43062228 Description Location No. Part 705 706 707 43160566 43050430 4306S737 Sensor, TE Sensor, TS Sensor, TO Base, P.C. board – 105 – Description Terminal Block, 6P Sensor, TD P.C. board Ass’y, MCC5009 Appendix Cord Heater Installation Work Applicable Models: RAS-10GAVP-E, RAS-13GAVP-E, RAS-16GAVP-E 1. Required parts for installation work (Recommendation) The above products conform to RoHS (2002/95/EC). Therefore when procuring and using the following recommended parts at local site, it is recommended to confirm each part conforms to RoHS before use. No. Part name Q’ty Specifications/Vendor 1 Cord heater 1 Drain line heaters CSC2 (1.5m, 40W/m) by Flexelec com. (Please go to the following URL.) http://www.flexelec.com Procured locally 2 Thermostat 1 US-622AXRLQE by ASAHI KEIKI Operating temperature: on 4 ± 4°C, off 15 ± 3°C A thermostat holder is incorporated with a thermostat in the package. (Please go to the following URL.) http://www.asahikeiki.co.jp/product/product.html On self-responsibility, you can use a product manufactured by other company (For example, Texas Instruments) if its characteristics are equivalent to those of ASAHI KEIKI. However, when the shape of the thermostat holder is different from that of ASAHI KEIKI, apply some treatment to No.14 thermostat fixing plate and then fix the holder. Procured locally 3 Fuse 1 ES3-5000, 250V / 5A by NAGASAWA Electric Co. (Please go to the following URL.) http://www.nagasawa-el.co.jp/ On self-responsibility, you can use a product manufactured by other company if its characteristics are equivalent to those of NAGASAWA Electric Co. Procured locally 4 Fuse holder 1 GM1H-02 by NAGASAWA Electric Co. (Please go to the following URL.) http://www.nagasawa-el.co.jp/ On self-responsibility, you can use a product manufactured by other company if its characteristics are equivalent to those of NAGASAWA Electric Co. 5 P-shape clamp 13 Use heat-resistance, weatherproof and non-hydrolytic type. Material: 4-fluorinated ethylene copolymer Harness diameter: Ø5.9 Use equivalence with the above specifications. 11 pieces are used to fix the cord heater to the outdoor unit base plate. One piece is used to fix the power cord to the thermostat fixing plate . One piece is used to fix the power cord to the terminal fixing plate. Procured locally 6 P-shape clamp 1 Use heat-resistance, weatherproof and non-hydrolytic type. Material: 4-fluorinated ethylene copolymer Harness diameter: Ø9.1 Use equivalence with the above specifications. One piece is used to fix the cord heater to the outdoor unit base plate. Procured locally 7 Screw 12 Self-tapping screw type-B Ø4 × 6mm, truss head, stainless These screws are used to fix the cord heater to the outdoor unit base plate with P-shape clamp. Procured locally 8 Screw 4 Self-tapping screw type-B Ø4 × 8mm, truss head, stainless Two screws are used to fix the thermostat fixing plate to the side cabinet (R). One screw is used to fix the power cord to the thermostat fixing plate. One screw is used to fix the power cord to the terminal fixing plate. Procured locally 9 Screw 2 Self-tapping screw type-B Ø3.5 × 6mm, pan head These screws are used to fix the thermostat to the thermostat fixing plate with the thermostat holder. Procured locally 10 Faston 2 #250 Procured locally 11 Sleeve for Faston 2 UL sleeve for #250 Procured locally 12 Close-end connector 2 Use the most appropriate connector with the power cord diameter. Procured locally They are used for the connecting part to the thermostat. Appendix-1 Remarks Procured locally Appendix No. Part name Q’ty Specifications/Vendor Remarks 13 Power cord 1 2-cores x 0.75mm² or more, H05RN-F Procured locally 14 Thermostat fixing plate 1 Material: SGCC-Z08, Board thickness: 0.8t Procured locally (Drawing attached) 15 PVC tube 1 Inside diameter Ø8 x outside diameter Ø11 x 70 mm Procured locally 16 Shield tube 1 Inside diameter Ø18 x outside diameter Ø26 x 70 mm Material: Polyethylene foam Procured locally 17 Bundling tie 1 Bundling tie for securing the wires Material: 6/6 nylon Procured locally NOTE: The parts on the above table are recommended parts. 2. Required tools for installation work No. Part name Usage Specifications 1 Plus screwdriver It is used for disassembling and assembling of each cabinet. 2 Wrench It is used for disassembling and assembling of compressor fixing nuts. 3 Motor drill Drill diameter: Ø3.2 and Ø5.0 4 Faston crimping tool Fixing jig for #250 5 Close-end connector crimping tool 6 Cutting plier 7 Stripper 8 Cutter knife 9 Insulation tape 10 Metal-cutting shears It is used to make the additional holes on the base or the side cabinet (R). It is used to process the side cabinet (L). Appendix-2 Appendix 3. Cord heater installation wiring diagram L N Fuse Thermostat Cord heater * Be sure to connect the fuse and the thermostat to LIVE side of the cord heater. Outdoor unit Earth leakage circuit breaker Power supply for air conditioner Earth leakage circuit breaker Power supply for cord heater NOTE: Separate the cord heater power from the air conditioner power, and connect it to its exclusive breaker. By doing so, the power consumption can be decreased because the breaker can be turned off if there is no possibility of freezing of the base plate in cooling operation, etc. When the cord heater power is connected to the inverter P.C. board assembly or others without connected to the exclusive breaker, the control P.C. board of the inverter assembly may cause a failure. When the cord heater has been mounted on a base plate, do not mount the water-proof cap and drain nipple which are provided with the outdoor unit on the base plate. Appendix-3 Appendix 4. Cord heater installation work procedure No. 1 Photo / Explanatory diagram Procedure Remove each cabinet, inverter assembly, motor base assembly, and partition board assembly. * Do not damage the electric parts such as cables, connectors, etc. while this work. Remove the upper cabinet and the valve cover. Upper cabinet Related parts / Screws list Part name 1-1 Used screw Screw type Quantity Upper cabinet Ø4 × 8 5 Valve cover Ø4 × 1 1 Valve cover Water-proof cover Remove the front cabinet, the wiring cover and the water-proof cover. Related parts / Screws list Wiring cover Part name 1-2 Used screw Screw type Quantity Front cabinet Ø4 × 8 7 Wiring cover Ø4 × 8 2 Front cabinet Side cabinet (L) Inverter assembly Side cabinet (R) Remove the side cabinet (R/L) and the inverter assembly. Related parts / Screws list Part name 1-3 Used screw Screw type Quantity Side cabinet (R) Ø4 × 8 7 Side cabinet (L) Ø4 × 8 3 Inverter assembly Ø4 × 8 1 Remove the inverter assembly. 1-4 No. Part name Connector No. 1 TE sensor CN600 White 2 TD sensor CN601 White 3 TO sensor CN602 White 4 TS sensor CN603 White CN701 Yellow 6 PMV coil CN700 White 7 CN300 White 5 4-way valve coil Fan motor Compressor (Intermediate connector) 8 lead 9 Appendix-4 Reactor (2 pieces.) (Intermediate connector) Connector color White White Appendix No. Photo / Explanatory diagram Procedure Motor base assembly Remove the motor base assembly, partition plate assembly and the sound insulation board. Related parts / Screws list Partition plate assembly Part name Screw type Quantity Motor base assembly (Including motor and fan) Ø4 × 8 2 Partition plate assembly (Including reactor) Ø4 × 8 3 1-5 Sound insulation board Used screw Remove the fixing screws of the heat exchanger and the valve fixing plate. Remove the compressor fixing bolt. Valve fixing plate Heat exchanger Related parts / Screws list Part name 1-6 Used screw Screw type Quantity Heat exchanger Ø4 × 8 1 Valve fixing plate Ø4 × 8 1 Compressor bolt 3 Compressor As shown in the left figure, remove the set of refrigeration cycle assembly from the outdoor unit base plate. * In this time, work attentively so that the cycle pipes are not damaged by dent or deformation. Apply protective measures to pipes if necessary. 1-7 Appendix-5 Appendix No. Photo / Explanatory diagram Procedure Cord heater installation work 2 Drill a hole on the outdoor unit base plate, and fix the cord heater to the outdoor unit base plate using P-shape clamp. Connect the cord heater cables. 2-1 Using a motor drill, etc., drill Ø3.2 holes on the outdoor unit base plate. (12 positions) See Appendix-10 for the additional hole positions. These holes are used to fix the cord heater to the outdoor unit base plate with P-shape clamp. Insert the PVC tube into the cord heater. This tube is designed to protect the cord heater from the fixing screws used to secure the anchoring feet. As shown in the left figure, install the cord heater (1.5m) to the outdoor unit base plate by using Pshape clamp and screws (Self-tapping screw type-B Ø4 × 6mm, stainless). 2-2 PVC tube Ø9.1 P-shape clamp The PVC tube must be inserted into the cord heater between the fixing screws in order to protect the cord heater from these screws. Under no circumstances must the tube be allowed to ride over the tip of the fixing screws. Pay attention to the direction of P-shape clamp so that it is set to the same direction in the left figure. * If the drain port is frozen due to installation status, etc., draw around the cord heater so that the end part of the heater is inserted into the drain port. In this case, add some fixing positions to fix the cord heater surely. * The end part from the marked part of the cord heater heats up. When there is the heating part near the electric parts box, a fire may generate. Be sure to set the heating part on the outdoor unit base plate at the fan room side or near it. (within 20cm from the outdoor unit base plate) Enlarged marked part Heating part * Be careful that the cord heater does not hit the fan. Fix the cord heater without any loosening or sag. Drill a hole on the side cabinet (R) for fixing the thermostat fixing plate. Added hole 2-φ5 Ø5 hole at two positions 5 When drilling a hole on the side cabinet (R), be sure not to damage the cabinet. 46 7 2-3 Side cabinet (R) Appendix-6 Appendix No. Photo / Explanatory diagram Procedure Rework the side cabinet (L) to remove part of it. Side cabinet (L) The area to be removed is indicated by the shaded lines in the left figure. After removing part of the side cabinet (L), deburr the edges of the side cabinet (L). 2-4 Delete Perform end process and bundling of each cable. Close-end connector insulation tape Using fixing screws (Self-tapping screw type-B Ø3.5 × 6mm), fix the thermostat to the thermostat fixing plate. Thermostat Power cord Perform end process for various lead cables and connect them according to the wiring diagram. Attach #250 Faston and UL-approved sleeves each to the end of lead cables which are connected to the thermostat. 2-5 Thermostat fixing plate Cord heater * Transparent L side P-shape clamp Fuse Fuse holder Using insulation tape, apply protective measures to the connected parts by the close-end connectors. Using P-shape clamp and the screws (Self-tapping screw type-B Ø4 × 8mm), fix the power cord to the thermostat fixing plate. When the power cord size does not match with Pshape clamp, procure the most appropriate one at the local site. Appendix-7 Appendix No. Photo / Explanatory diagram Procedure Assembly 3 Return a set of the refrigeration cycle assembly into the outdoor unit base plate and reassemble sound insulation board, partition plate assembly, fan motor assembly, and side cabinet (R/L) as original. Fix the thermostat fixing plate to the side cabinet (R), built in the inverter assembly, and then connect various cables. After then, incorporate front cabinet, upper cabinet, wiring cover, and valve cover as before. Return a set of the refrigeration cycle assembly into the outdoor unit base plate, and assemble sound insulation board, partition plate assembly, fan motor assembly, and side cabinet (R/L) as original. 3-1 Thermostat fixing plate Using screws (Self-tapping screw type-B Ø4 × 8mm, stainless), fix the thermostat fixing plate to the side cabinet (R). Side cabinet (R) 3-2 Do not make cord heater loose. Do not put the heating part near the electric parts box. For the cord heater, perform cable process so that there is no looseness or sag at the fan side. Perform cable process for collected cord heater and fan motor lead cables. 3-3 Perform cable process for the cord heater together with the fan motor lead cable, and collect the remained part of cables at cable process part of the inverter. Secure the power cord for the cord heater to the terminal block mounting plate using the P-shape clamp, and pull it out from the wiring area of the side cabinet (R). P-shape clamp * Check that there is the marked part of the cord heater on the outdoor unit base plate or near it. When there is the heating part near the electric parts box, a fire may generate. Power cord for cord heater To keep the lead wires from coming into contact with the edges of the sheet metal or tips of the screws, wrap the shield tubes around the leads to protect them and use the bundling ties to secure them. 3-4 4 After incorporating the inverter assembly as before, furthermore perform cable process for cord heater and power cord. Since the lead wires connected to the cord heater and thermostat may come into contact with the edges of the sheet metal or tips of the screws, wrap the shield tubes around the leads to protect them and use the bundling ties to secure them. Incorporate front cabinet, upper cabinet, wiring cover, water-proof cover and valve cover as before. In installation work, connect power cord for the cord heater to another breaker separated from one for power cord of the air conditioner. Appendix-8 Appendix 5.8 8 5. Drawing of thermostat fixing plate 37 2-Ø3.4 burring hole (Upward) 18 11 11 28 36 46 56 11 55 24 11 18 3-Ø3.4 burring hole (Downward) 45 Material: SGCC-Z08, Thickness: 0.8t Appendix-9 Appendix 6. Diagram showing positions φ3.2 mm holes to be additionally drilled in base plate Appendix-10 This product is compliant with Directive 2002/95/EC, and cannot be disposed as unsorted municipal waste. TOSHIBA CARRIER CORPORATION 2 CHOME 12-32, KONAN, MINATOKU, TOKYO, 108-0075, JAPAN Copyright © 1999 to 2005 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.
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