Toshiba RAS-077SAV-E6 Service Manual Download Page 104

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TOSHIBA CARRIER (THAILAND) CO.,LTD.

Summary of Contents for RAS-077SAV-E6

Page 1: ...A SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit High Wall Heat PumpType Heat PumpType FILE NO SVM 15004 January 2015 RAS 077SKV E7 RAS 107SKV E7 RAS 137SKV E7 RAS 077SAV E6 RAS 107SAV E6 RAS 137SAV E6 ...

Page 2: ...5 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 46 11 HOW TO DIAGNOSE THE TROUBLE 59 12 HOW TO REPLACE THE MAIN PARTS 84 13 EXPLODED VIEWS AND PARTS LIST 98 FILE NO SVM 15004 ...

Page 3: ...nd 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 fit...

Page 4: ...ed 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...

Page 5: ... 205 205 Net weight kg 9 9 Fan motor output W 20 20 Air flow rate Cooling Heating m3 min 8 3 8 8 8 8 9 5 Outdoor unit Unit model RAS 077SAV E6 RAS 107SAV E6 Dimension Height mm 530 530 Width mm 660 660 Depth mm 240 240 Net weight kg 28 28 Compressor Motor output W 750 750 Type Model ASM89D16UEZ Fan motor output W 43 Air flow rate Cooling Heating m3 min 27 27 29 29 Piping Type Flare connection conn...

Page 6: ... 20 Air flow rate Cooling Heating m3 min 9 5 9 8 Outdoor unit Unit model RAS 137SAV E6 Dimension Height mm 530 Width mm 660 Depth mm 240 Net weight kg 28 Compressor Motor output W 750 Type Model ASM89D16UEZ Fan motor output W 43 Air flow rate Cooling Heating m3 min 31 31 Piping Type Flare connection connection Indoor unit Liquid side mm 6 35 Gas side mm 9 52 Outdoor unit Liquid side mm 6 35 Gas si...

Page 7: ...ge 230V RAS 077SKV E7 RAS 137SKV E7 RAS 107SKV E7 0 0 20 0 40 0 60 0 80 0 100 0 120 0 15 10 5 0 5 10 Heating Capacity ratio Outside Temperature ºC RAS 077SKV E7 RAS 107SKV E7 RAS 137SKV E7 RAS 077SKV E7 RAS 107SKV E7 RAS 137SKV E7 50 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 0 100 0 105 0 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Cooling Capacity ratio Outside Temperature oC Conditions Indoo...

Page 8: ... in the refrig eration 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 6 When an air conditioning system charged with a l...

Page 9: ...et joints Nominal diameter 1 4 3 8 1 2 5 8 Reference outer diameter of copper pipe jointed mm 6 35 9 52 12 70 15 88 Minimum joint thickness mm 0 50 0 60 0 70 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...

Page 10: ... to 0 5 0 to 0 5 0 to 0 5 0 to 0 5 Conventional flare tool Clutch type Wing nut type 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 2 0 to 2 5 1 0 to 1 5 2 0 to 2 5 Table 3 2 4 Dimensions related to flare processing for R22 Nominal diameter 1 4 3 8 1 2 5 8 Outer diameter mm 6 35 9 52 12 70 15 88 Thickness mm 0 8 0 8 0 8 1 0 A mm Flare tool for R22 clutch type 0 to 0 5 0 to 0 5 0 to 0 5 0 t...

Page 11: ...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 tighten ing 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 manufac...

Page 12: ...ant charging Refrigerant cylinder Leakage detector Charging cylinder Usage Pipe flaring Flaring by conventional flare tool Connection of flare nut Evacuating refrigerant charge run check etc Vacuum evacuating Refrigerant charge Refrigerant charge Gas leakage check Refrigerant charge R410A air water heat pump installation Existence of new equipment for R410A Yes Yes Yes Yes Yes Yes Yes Yes Note 2 W...

Page 13: ...d the connecting port of the electronic balance and charge liquid refrigerant Indoor unit Outdoor unit Opened Opened Refrigerant cylinder with siphon Check valve Open close valve for charging Electronic balance for refrigerant charging Opened Closed Service port 3 4 Recharging of Refrigerant When it is necessary to recharge refrigerant charge the specified amount of new refrigerant according to th...

Page 14: ... 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 fo...

Page 15: ... 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 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 pip...

Page 16: ...nger Flare 6 35mm Flare 9 52mm 116 Installation plate outline Center line Hanger Hanger Hanger 621 170 or more 170 or more 65 or more Minimum distance to wall Minimum distance to wall Minimum distance to ceiling 15 62 69 49 Knock out system Front panel 48 7 63 790 Knock out system 63 48 7 205 Air inlet Air filter Heat exchanger 275 FILE NO SVM 15004 64 5 73 5 110 58 17 5 25 Wireless remote control...

Page 17: ...FILE NO SVM 15004 4 2 Outdoor Unit C L C L 280 400 16 ...

Page 18: ...A P03 C07 ABSORBER SURGE 3 2 5 4 1 CM COMPRESSOR 3 3 BLK WHI RED 2 1 2 1 P09 P10 P11 6 2 2 TD TEMP SENSOR DISCHARGE PIPE TEMP SENSOR OUTDOOR TO 1 3 1 1 3 2 1 TEMP SENSOR SUCTION PIPE TS 3 1 2 1 3 PMV 3 2 5 4 1 IPM module VARISTOR COIL FOR 4WAY VALVE F02 FUSE 3 15A From Main Line C08 ...

Page 19: ...Parts name Type Specifications L 19mH 10A 2 Outdoor fan motor ICF 140 43 4R DC140V 43W 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 Reactor 1 20A AC250V ASM89D16UEZ PQ M01012 000082 SQ A2522G ...

Page 20: ...ickness 0 8mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attaching port Vacuum pump connecting port Pulse Modulating valve at liquid side TD 4 way valve Compressor ASM89D16UEZ TS T2 Outdoor heat exchanger Temp measurement Propeller fan Refrigerant amount 0 63kg OUTDOOR UNIT Muffler Muffler Min 2m Chargeless 15m Strainer Max ...

Page 21: ...ickness 0 8mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attaching port Vacuum pump connecting port Pulse Modulating valve at liquid side TD 4 way valve Compressor ASM89D16UEZ TS T2 Outdoor heat exchanger Temp measurement Propeller fan Refrigerant amount 0 63kg OUTDOOR UNIT Muffler Muffler TE TC TA Min 2m Chargeless 15m FILE...

Page 22: ...27 19 35 077SKV E7 0 9 to 1 1 13 to 14 45 to 46 High High 40 107SKV E7 0 9 to 1 0 11 to 12 48 to 49 High High 53 137SKV E7 0 8 to 1 0 10 to 11 48 to 49 High High 75 condition C Tempeature Heat exchanger pipe temp Model name Standard Indoor Outdoor Compressor RAS pressure fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 7 6 077SKV E7 2 4 to 2 5 36 to 37 0 to 1 High High 51 107SKV ...

Page 23: ...pressor Motor Revolution Control Timer Serial Signal Communication Processing Temperature Processing Functions M C U Indoor Unit Control Panel Power Supply Remote Control Heat Exchanger Sensor Temperature Sensor Infrared Rays Signal Receiver Infrared Rays Initiallizing Circuit Clock Frequency Oscillator Circuit Louver Motor 36 7KHz Power Supply Circuit Noise Filter Indoor Fan Motor Timer Display O...

Page 24: ...synthesis function Input current release control IPM 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 P M V Pulse Motor Valve M C U Micro Control Unit M C U For INDOOR UNIT 4 way valve P M V Inverter DC AC Gate dri...

Page 25: ...ion control 2 Role of outdoor unit controller 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 P M V control 4 way valve control Operations followed to judgment of serial signal from indoor side Detection of inverter input current and current release operation ...

Page 26: ... 2 Air direction adjustment 34 3 Swing 34 9 ECO operation 35 10 Temporary operation 36 11 12 Discharge temperature control 36 13 Pulse Modulating valve P M V control 37 Self Cleaning function 38 14 Remote A or B selection 39 9 3 Auto Restart Function 9 3 1 How to Set the Auto Restart Function 41 9 3 2 How to Cancel the Auto Restart Function 42 9 3 3 Power Failure During Timer Operation 42 9 4 Remo...

Page 27: ...emote 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 Hi POWER Indoor unit control Command signal generating function of indoor unit operation Calculation function temperature calculation Activation compensation function of indoor fan Cold draft pr...

Page 28: ...he operation mode the fan speed is controlled by the previous operation mode 4 DRY operation DRY operation is performed according to the difference between room temperature and the setup temperature as shown below In DRY operation fan speed is controlled in order to prevent lowering of the room temperature and to avoid air flow from blowing directly to persons 1 Detects the room temperature Ta whe...

Page 29: ...5 Fan speed M L x 1 4 L Linear approximation from M and L FILE NO SVM 15004 RAS 077SKV E7 RAS 107SKV E7 Cooling Heating Cooling Heating Fan speed Air flow rate rpm m3 h Fan speed Air flow rate rpm m3 h Fan speed Air flow rate rpm m3 h Fan speed Air flow rate rpm m3 h WF UH 1100 502 1150 534 1200 565 1200 565 WE UH H 1100 502 1150 534 1200 565 1200 565 WD H M UH 1050 471 1050 471 1150 534 1100 502 ...

Page 30: ... c 1 0 d 1 5 e 2 0 f 2 5 g 5 0 5 5 L W9 M WD 1 2 3 H WE H WE Line approximate H and SUL with Tc SUL W2 Stop 46 46 Tc 34 45 45 33 33 33 21 32 32 20 A 4 A 4 A 4 A 4 A 4 A 4 Fan speed MANUAL in starting Fan speed AUTO in stability Fan speed AUTO in starting L L M M H W8 L M 2 WA M H 2 WE Indication Fan speed Fan speed setup HEAT ON AUTO YES NO MANUAL TC 42 C Min air flow rate control Tc 52 51 42 41 L...

Page 31: ...ontroller YES YES NO NO Indoor unit controller Fan motor ON 3 Fan lock OFF status of fan motor continues 4 Motor operates as shown in the table below 1 Outdoor unit operation command Outdoor fan control Air conditioner OFF Alarm display Outdoor fan speed rpm Tap f 1 f 2 f 3 f 4 f 5 f 6 f 7 f 8 RAS 077SAV E6 300 300 350 350 400 400 450 450 500 500 550 550 600 600 700 700 Tap f 9 f A f B f C f D f E...

Page 32: ... compressor speed so that electric power of the compressor drive circuit does not exceed the specified value 5 Current release control Set temp Ts Room temp Ta Correction of Hz signal Outdoor temp To Setup of current release point Capacity control continues Detection of electromotive force of compressor motor winding Detection of motor speed and rotor position Inverter output change Commutation ti...

Page 33: ...pressor speed is kept Q zone When temperature of the indoor heat exchanger drops in the range from 48 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 52 C or when it drops below to 48 C the capacity control operation ret...

Page 34: ... TE0 TE TO0 TO 3 C SH SH0 2 TE 25 C SH SH0 2 More than 90 minutes accumulated heating operation time condition TE 2 C Table 1 In normal To In abnormal To TE0 TE 2 C SH SH0 2 TE0 TE TO0 TO 2 C SH SH0 2 Returning from defrost operation 1 Stop operation of the compressor for approx 40 seconds 2 Invert ON 4 way valve approx 30 seconds after stop of the compressor 3 The outdoor fan starts rotating at t...

Page 35: ...computer The angle of the louver is indicated as the louver closes fully is 0 1 Louver position in cooling operation mode COOL HEAT and the louver returns to the stored position when the next operation is performed Cooling Heating memory position The louver position can be arbitrarily set up by pressing FIX button FILE NO SVM 15004 Swing operation is perfor in range 35 with the Fixed position as t...

Page 36: ... A B C Time Compressor speed 0Hz A zone aHz B zone a to cHz C zone cHz 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 Room temp Set temp 3 5 3 0 2 5 1 5 1 0 TSC 1 0 2 0 5 5 1H 2H 11 10 7 6 5 4 3 2 1 OFF Dry Max 12 11 9 8 10 TA 6 0 6 5 3H 4H 5 0 4 5 4 0 2 0 0 5 0 5 12 9 8 Time Zone Frequency FAN Min Hz Fan speed depend on presetting and can change every speed 1 The control target tempe...

Page 37: ...for 3 seconds or more Did you press RESET button for 10 seconds or more Switch to AUTO RESTART control YES NO NO YES Temporary AUTO operation Temporary COOL Operation FILE NO SVM 15004 11 Discharge temperature control 1 Purpose This function detects error on the refrigerating cycle or error on the com pressor and performs protective control 2 Operation Control of the compressor speed The speed con...

Page 38: ...alve so that it is in the range of set tempera ture Discharge temp control 4 When defrost operation is performed the open degree of valve is adjusted accord ing 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 ...

Page 39: ... operation performed prior to the reception of the stop code 3 After the Self Cleaning operation has been performed for the specified period the unit stops operating Unit now performing cooling or dry operation Press STOP button Only timer indicator lights and Self Cleaning operation starts Time set now elapses Operation stops function During Self Cleaning operations The louver opens slightly The ...

Page 40: ...earby 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 control ler also set to B At the factory the remote controller selection is set to A on all the indoor units There is no A ...

Page 41: ... 1 Automatic operation The indoor unit operates in according to the current operation 2 Cooling operation remote controller does not change The indoor unit s fan speed level increase 1 tap The preset temperature drops 1ºC The value of the preset temperature on the 3 Heating operation remote controller does not change The indoor unit s fan speed level increase 1 tap The preset temperature increases...

Page 42: ...ion 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...

Page 43: ...o operate at this time press RESET button once more or use the remote controller to turn it on 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 i...

Page 44: ... start or stop without using the remote control Operation mode is set on AUTOMATIC operation preset temperature is 25 C and fan operation is automatic speed FILE NO SVM 15004 7 AUTO RESTART OPERATION To automatically restart the conditioner after the power failure Power of the unit must be on 1 Press and hold the RESET button on the indoor unit for 3 seconds to set the operation 3 beep sound and O...

Page 45: ...ess Select A 2 COOLING HEATING FAN ONLY OPERATION To automatically select cooling or fan only operation 1 Press Select Cool Heat or Fan only 2 Press Set the desired temperature Cooling Heating Min 17 C Max 30 C Fan Only No temperature indication 3 Press Select AUTO LOW LOW MED MED or HIGH MODE MODE FAN 2 Press Set the desired temperature 3 DRY OPERATION COOLING ONLY For dehumidification a moderate...

Page 46: ...ither AUTO or Dry 6 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 7 ECO indicator Indicates when the ECO is in activated Press the ECO button to start and press it again to stop operation 8 A B change indicator remote controller When the remote controller switching function is set B appears in the remote ...

Page 47: ...t rear left rear right right bottom right Right Rear right Bottom right Rear left Bottom left Left 6 mm thick heat resisting polyethylene foam 1 Vinyl tape Apply after carrying out a drainage test Saddle Extension drain hose Not available provided by installer Shield pipe Air filter Hook Installation plate Hook 65 mm or more 170 mm or more 170 mm or more 600 mm or more 100 mm or more 45 mm or more...

Page 48: ...r attach drain nipple 7 to the bottom plate of the outdoor unit before installing it 10 2 1 Optional installation parts 10 2 Installation Fixing bolt arrangement of outdoor unit Drain outlet Air inlet Air outlet 280 mm 500 mm 53 mm 97 mm Ø25 mm Part Code A B C Parts name Refrigerant piping Liquid side 6 35 mm Gas side 9 52 mm Pipe insulating material polyethylene foam 6 mm thick Putty PVC tapes Q ...

Page 49: ...emote control holder x 1 Part No 4 5 6 Part No 7 Others Name Owner s manual Installation manual Part name Q ty 10 2 2 Accessory and installation parts The part marked with asterisk is packaged with the outdoor unit FILE NO SVM 15004 Mounting screw 4 x 25 s x 6 Flat head wood screw 3 1 x 16 s x 2 Drain nipple x 1 ...

Page 50: ... size have been changed to 1 2 UNF 20 threads per inch When purchasing a charge hose be sure to confirm the port size As pressure is high and gasification speed is fast it is difficult to read the indicated value by means of charging cylinder as air bubbles occur The size of opposite sides of flare nuts have been increased Incidentally a common wrench is used for nominal diameters 1 4 and 3 8 By i...

Page 51: ...ose to a heating source such as a stove Keep the remote control at least 1 m apart from the nearest TV set or stereo equipment This is necessary to prevent image disturbances or noise interference The location of the remote control should be determined as shown below Fig 10 3 1 Top view Indoor unit Reception range Reception range Remote control control Side view Indoor unit 45 45 75 FILE NO SVM 15...

Page 52: ...ck concrete or similar type walls make 5 mm dia holes in the wall Insert clip anchors for appropriate mounting screws NOTE Secure four corners and lower parts of the installation plate with 4 to 6 mounting screws to install it Installation plate Keep horizontal direction 10 3 3 Electrical work 1 The supply voltage must be the same as the rated voltage of the air conditioner 2 Prepare the power sou...

Page 53: ...eftward or right side of the front panel for the left or right connection and the slit on the bottom left or right side of the front panel for the bottom left or right connection with a pair of nippers 2 Changing drain hose For leftward connection bottom leftward connection and rearleftward connection s piping it is necessary to change the drain hose and drain cap How to remove the Drain Cap Clip ...

Page 54: ...end the connection pipe within a radius of 30 mm To connect the pipe after installation of the unit figure Fig 10 3 15 80 270 mm 230 mm 43 mm To the forefront of flare Gas side Outward form of indoor unit R 30 mm Use polisin polyethylene core or the like for bending pipe Use the handle of screwdriver etc Liquid side CAUTION Bind the auxiliary pipes two and connecting cable with facing tape tightly...

Page 55: ...se sloped downwards NOTE Hole should be made at a slight downward slant on the outdoor side Fig 10 3 18 2 Put water in the drain pan and make sure that the water is drained out of doors 3 When connecting extension drain hose insulate the connecting part of extension drain hose with shield pipe Fig 10 3 19 CAUTION Arrange the drain pipe for proper drainage from the unit Improper drainage can result...

Page 56: ...d Cold Temperatures Do not use the supplied drain nipple for draining water Drain the water from all the drain holes directly hood and plate Do not use a double stacked design To protect the outdoor unit from snow accumulation install a holding frame and attach a snow protection Snow protection plate Snow protection hood At least 50 cm Snow accumulation line Holding frame Front Anchor bolts Instal...

Page 57: ... threaded side old valv Internally threaded side e 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 start evacuating Perform evacuating for about 15 minutes if the piping length is 20 meters 15 minutes for 20 meters assuming a pump capacity of ...

Page 58: ...or unit 3 When connecting the connecting cable to the outdoor unit terminal make a loop as shown in the installation diagram of indoor and outdoor unit to prevent water coming in the outdoor unit 4 Insulate the unused cords conductors from any water coming in the outdoor unit Proceed them so that they do not touch any electrical or metal parts Fig 10 4 10 Stripping length of connection cable Packe...

Page 59: ... MODE during pushing CHECK B will show on the display and 00 will disappear and the air conditioner will turn OFF The Remote Control B FILE NO SVM 15004 NOTE 1 Repeat above step to reset Remote Control to be A 2 Remote Control A has not A display 3 Default setting of Remote Control from factory is A is memorized Picture Picture 1 2 10 5 3 Test operation To switch the TEST RUN COOL mode press RESET...

Page 60: ...ervice as the electric shock may be caused in case of touching parts on the P C board by hand The new inverter will be incorporated starting with this unit K The control circuitry has an uninsulated construction No 1 2 3 4 5 Troubleshooting Procedure First Confirmation Primary Judgment Judgment by Flashing LED of Indoor Unit Self Diagnosis by Remote Controller Judgment of Trouble by Every Symptom ...

Page 61: ...y circuit components and result in damage to the components 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 tu...

Page 62: ... Increasing of compressor motor speed stops approx 30 seconds after operation started and then compressor motor speed increases again approx 30 seconds after In AUTO mode the operation mode is changed In HEAT mode the compressor motor speed does not increase up to the maxi mum speed or decreases before the temperature arrives at the set temperature Description The OPERATION lamp of the indoor unit...

Page 63: ...onditioner 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 OPERATION Green Flashing display 1 Hz OPERATION Green TIMER Yellow FILTER Orange Flashing display 5 Hz OPERATION Green FILTER Orange Flashing display 5 Hz OPERATION Green TIMER Yellow Flashing d...

Page 64: ...Press TEMP or TEMP 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 The TIMER indicator of the indoor unit flashes continuously 5 times per 1 sec Check the unit with all 52 check codes to as shown in Table 11 4 1 Press TEMP or TEMP button to change the check code backward If there is a fault the indoor unit ...

Page 65: ...oom Operation Flashes when 1 Check the sensor TA and connection board temperature sensor is continues error is detected 2 In case of the sensor and its short Circuit or disconnection connection is normal check the P C board TC sensor The heat Operation Flashes when 1 Check the sensor TC and connection exchanger temperature continues error is detected 2 In case of the sensor and its sensor of the i...

Page 66: ...or unit open 4 The outdoor unit abnormal stop at circuit of signal some time Signal circuit of indoor If the other check codes are found P C board or outdoor concurrently check them together P C board is failure Check protector hardware such in some period as Hi Pressure switch Thermal Relay etc Check refrigerant amount or any possibility case which may caused high temperature or high pressure Che...

Page 67: ...resistance of compressor winding If circuit is shortage replace the compressor Current detect circuit of All OFF Flashes after Even if trying to operate again all inverter P C board error error is detected operations stop replace inverter 4 times P C board TE sensor The heat All OFF Flashes after 1 Check sensors TE TS and connection exchanger temperature error is detected 2 In case of the sensors ...

Page 68: ...rror count comes 4 or 8 times record error to check code But after re starting operation if no error is detected and air conditioner can operate more than 6 minutes error count is cleared The others Return signal of the outdoor Indoor unit Flashes when 1 Check power supply Rate 10 including unit has been sent when operates error is detected 2 If the air conditioner repeat operates compressor opera...

Page 69: ...tc 4 Observe any possibility cause which may affect high temperature of compressor Compressor is high current All OFF Flashes after 1 Check installation conditions such as though operation Hz is error is detected packed valve opening refrigerant decreased to minimum limit 8 times amount and power supply rate 10 Installation problem both of operation and non operation Instantaneous power condition ...

Page 70: ...ATION lamp blinking NO YES NO NO YES YES Is it possible to turn on power supply by pressing button on remote control Does transmission mark on remote control flash normally and is its signal transmitted properly Remote control is defective Refer to 4 Remote Control Is fuse F01 of indoor control board blown Is voltage DC 12V or 5V indicated on rear of indoor control board normal Microcomputer is de...

Page 71: ...on though Indoor P C board is replaced Confirmation procedure YES YES NO NO To item of Power is not turned on Turn on power supply Does operation lamp flash Is wired correctly to white and black lead wires of terminal board Correct wiring 70 ...

Page 72: ...or Does the fan rotate Change the setting of cooling to high fan Operation stops Shut off the power supply Motor control circuit failure IC03 Q39 and D01 or 12 V Switching power supply failure Does the cross flow fan rotate normally Is the rotation signal DC 5 V 0 V output between 2 gray lead wire and 3 brown lead wire of the motor connector CN11 when rotating the cross flow fan by hand in no oper...

Page 73: ...e a thin test rod of Judgment of Trouble by Every Symptom RPG 240 25A Do not disconnect the connector while the fan motor is rotating For P C board side proceed to the item Only indoor fan does not operate 1 3 5 1 2 3 2 1 3 2 1 3 2 1 3 2 1 3 CN10 CN11 P C board WHI BLK RED BRW GRY YEL Resistance value Position P C board Between 3 Black 1 Red Between 3 Black 5 White Between 1 Red 5 White 218 33 Ω 3...

Page 74: ...gnal tone be heard in a transistor radio when transmitting within 5 cm distance from the radio P C board is failure Replace P C board Is operation possible when the transmitter is moved nearer to the infrared signal receiver of the air conditioner Battery life Replace the batteries Dose the transmission indicator light Is there any beep and operation Normal Remote control is failure Replace remote...

Page 75: ...transmission from indoor unit to outdoor unit is correctly performed based upon the follow ing diagram NOTE Measurement should be performed 2 minutes and 30 seconds after starting of the operation Be sure to prepare a diode for judgment Normal time Voltage swings between DC15 and 60V Inverter Assembly check 11 7 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while after ope...

Page 76: ...d gas if pressure is low Is connecter of coil connected to inverter Is coil of the pulse motor valve P M V correctly set 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 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 ...

Page 77: ...s not frame grounded with Q R or S Summary 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 electro lytic capacitor 500µF or 760µF of C07 with printed WARNING ELECTRIC SHOCK on P C board OK if 500µF or 760µF DC280 to 380V Remove CN31 while pushing the part indicated by an ...

Page 78: ...e Main Parts 11 8 1 How to Check the P C Board Indoor Unit 1 Operating precautions 1 When removing the front panel or the P C board be sure to shut off the power 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 Inspe...

Page 79: ...R FILTER PRE DEF Hi POWER are lit for 3 seconds and they return to normal 3 seconds later 1 Check whether or not the compressor operates 2 Check whether or not the OPERATION indicator flashes 1 Check whether or not the compressor operates 2 Check whether or not the OPERATION indicator flashes 1 Check it is impossible to detect the voltage AC120V or higher voltage between red and black 2 The motor ...

Page 80: ...ue k Temperature C TA TC TO TS TE TD 1 Sensor characteristic table 79 FILE NO SVM 15004 11 8 2 P C Board Layout TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TS Suction temp sensor TE Outdoor heat exchanger temp sensor ...

Page 81: ... 15004 1 Compressor Model ASM89D16UEZ No Part name Checking procedure White Red Back Position Resistance value Red White White Black 1 44Ω 20 C Black Red Measure the resistance value of each winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Red White Black Measure the resistance value of winding by using the tester Resistance value 2210 221Ω Under 2...

Page 82: ... Check that the normal rectification characteristics are shown in continuity test by the tester 11 8 5 Checking Method for Each Part Case that product is good Pointer swings once and returns slowly When performing test once again under another polarity the pointer should return No Part name Checking procedure 5 Outdoor temperature sensor TO discharge temperature sensor TD suction temperature senso...

Page 83: ...uit 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 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 If the resistance val...

Page 84: ...lease ON Operation LED Self cleaning flash 1 Hz function Timer LED Flash 1 Hz OFF flash 1 Hz not flash ON OFF ON OFF Setting diagnosis code 06 on remote controller See detail of setting diagnosis code in 11 4 1 Take the remote controller to direction of LED display on air conditioner press TEMP of the remote controller Fig 11 10 2 1 time to send the code 07 then air conditioner will shutdown autom...

Page 85: ...shed 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 inspectin...

Page 86: ... screws 2 pcs 6 Take off three hooks of panel from rear side How to assemble the front panel 1 Press three center positions and two lower center positions of the air outlet and then hang the hanging hooks 3 pcs at the top side of the front panel to the rear plate 2 Tighten two screws Incomplete hanging or incomplete pressing may cause a dewdrops or generation of a fluttering sound 2 Screws Three h...

Page 87: ... parts box assembly onto the claws on the back body 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 5 Disengage the display unit by simply pushing at the top of the display unit 6 Re...

Page 88: ... 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 FILE NO SVM 15004 Remarks 4 Remove one fixing screw on the heat exchage fixing holder to separate the heat exchage from the back body 5 Remove right side of the end plate from two fixing rib while sliding slightly the heat exchanger rightward 2 screws Heat exchang...

Page 89: ... Remove the two screws used to secure the bearing base 3 Remove the bearing base Caution at assembling If the bearing is out from the housing push it into the specified position and then incorporate it in the main body Remarks Two screws Bearing Bearing base FILE NO SVM 15004 ...

Page 90: ...e cross flow fan 3 Remove two fixing screws of the motor cover and them remove the motor cover 4 Remove two more fixing screws of the motor band and remove the motor band Remarks 5 Pull the fan motor outward Set screw Two screws Motor cover Two screws on motor band Part name FILE NO SVM 15004 ...

Page 91: ...he set screw install the cross flow fan so that flat area on shaft of the fan motor comes to the mounting hole of the set screw FILE NO SVM 15004 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 b...

Page 92: ... 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 Remarks Replace terminal block microcomputer ass y and the P C board ass y 12 2 Microcomputer FILE NO SVM 15004 ...

Page 93: ...net 2 After connecting the power cord and connecting cable attach the cord clamp and wiring cover Insert the upper part into the upper cabinet and insert the claw which has been hooked to the lower part into the square hole and then fix it with screw ST1T 4 x 10s 1 pc 3 Attach the valve cover ST1T 4 x 10s 1 pc Insert the upper part to the upper cabinet set the hook claw of the valve cover to squar...

Page 94: ...in some cases NOTE This capacitor is one with mass capacity Therefore it is dangerous that a large spark generates if short circuiting between Requirement As each connector has a lock mecha nism avoid to remove the connector by holding the lead wire but by holding the connector The connector is one with lock so remove it while pushing the part indicated by an arrow Be sure to remove the connector ...

Page 95: ...osed end splice 1 Perform work of item 1 of 1 1 of 2 2 Extract refrigerant gas 3 Remove the partition board ST1T 4 x 10s 3 pcs 4 Remove the sound insulation material 5 Remove the terminal cover of the compressor and disconnect the lead wire of the compressor thermo and the compressor from the terminal 6 Remove the pipe connected to the compressor with a burner Make sure the flame does not touch th...

Page 96: ...2 Attachment 1 Insert the claws of the fan guard in the hole of the front cabinet Push the hooking claws 8 positions by your hand and fix the claws Requirement This completes all the attaching work Check that all the hooking claws are fixed to the specified positions Fan guard Minus screwdriver Hooking claw 7 Pulse Modulating Valve coil 8 1 Detachment 1 Perform work of item 1 of 1 and 1 of 2 2 Tur...

Page 97: ...e 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 Moun...

Page 98: ... 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 Remarks 1 2 3 4 5 6 Parts name Sensor Sensor Spring A Sensor Spring B Thermal constringent tube Color tape Terminal Q ty 1 1 1 3 1 3 Cutting here Cutting here Cutting here Soldered part Dryer Winding the color tape 100 200 Connector Thermal sensor part Therma...

Page 99: ...No No 401 43T69319 TEMPERATURE SENSOR 405 43T6V376 402 43T60365 TERMINAL BLOCK 3P 406 43T6V542 403 43T69320 TEMPERATURE SENSOR 406 43T6V543 404 43T62003 CORD CLAMP 406 43T6V545 PC BOARD ASSY WRS LED PC BOARD RAS 077SKV E7 PC BOARD RAS 107SKV E7 PC BOARD RAS 137SKV E7 Description Description 401 403 405 402 404 406 ...

Page 100: ...AIN 206 43T49359 PIPE SHIELD 219 43T44505 REFRIGERANT CYCLE ASSEMBLY 207 43T83310 HOLDER REMOTE CONTROL 221 43T00627 PANEL SERVICE ASSEMBLY 208 43T60382 MOTOR CORD 222 43T80327 FILTER AIR R 209 43T82310 INSTALLATION PLATE 223 43T80328 FILTER AIR L 211 43T19333 HOLDER SENSOR 224 43T09438 GRILLE OF AIR INLET 212 43T09408 PIPE HOLDER 226 43T62328 TERMINAL COVER 213 43T03360 BACK BODY ASSEMBLY 227 43T...

Page 101: ... 43T62323 TERMINAL COVER 21 43T00448 FIXING PLATE VALVE 8 43T46422 VALVE PACKED 9 52 DIA 22 43T42335 BASE PLATE ASSEMBLY 9 43T47332 BONNET 9 52 DIA 23 43T79305 DRAIN NIPPLE 10 43T46421 VALVE PACKED 6 35 DIA 24 43T58309 REACTOR 11 43T47331 BONNET 6 35 DIA 25 43T46367 4 WAY VALVE 12 43T21375 FAN MOTOR 26 43T63327 COIL 4WAY 13 43T47001 NUT FLANGE 27 43T04305 PARTITION 15 43T49327 CUSHION RUBBER 28 43...

Page 102: ...3T62323 TERMINAL COVER 21 43T00448 FIXING PLATE VALVE 8 43T46422 VALVE PACKED 9 52 DIA 22 43T42335 BASE PLATE ASSEMBLY 9 43T47332 BONNET 9 52 DIA 23 43T79305 DRAIN NIPPLE 10 43T46421 VALVE PACKED 6 35 DIA 24 43T58309 REACTOR 11 43T47331 BONNET 6 35 DIA 25 43T46367 4 WAY VALVE 12 43T21375 FAN MOTOR 26 43T63327 COIL 4WAY 13 43T47001 NUT FLANGE 27 43T04305 PARTITION 15 43T49327 CUSHION RUBBER 28 43T3...

Page 103: ...rt No No No No 701 43T62351 HEATSINK 704 43T60326 FUSE 702 43T6V445 PC BOARD RAS 077SAV E6 705 43T50334 TEMPERATURE SENSOR 702 43T6V446 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 707 43T62313 BASE PLATE PC 703 43T60392 TERMINAL 5P Description Description RAS 107 137SAV E6 ...

Page 104: ...TOSHIBA CARRIER THAILAND CO LTD ...

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Toshiba RAS-077SAV-E6, Service Manual

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