Toshiba RAS-137SAV-E Service Manual Download Page 1

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R410A

SERVICE MANUAL

SPLIT TYPE

Indoor Unit Outdoor Unit

<High Wall, Heat Pump Type> <Heat Pump Type>

RAS-137SKV-E RAS-137SAV-E
RAS-167SKV-E RAS-167SAV-E

Feb

, 2008

FILE NO. SVM-08011

Summary of Contents for RAS-137SAV-E

Page 1: ...R410A SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit High Wall Heat PumpType Heat PumpType RAS 137SKV E RAS 137SAV E RAS 167SKV E RAS 167SAV E Feb 2008 FILE NO SVM 08011 ...

Page 2: ...5 5 WIRING DIAGRAM 17 6 SPECIFICATIONS OF ELECTRICAL PARTS 19 7 REFRIGERANT CYCLE DIAGRAM 20 8 CONTROL BLOCK DIAGRAM 23 9 OPERATION DESCRIPTION 26 10 INSTALLATION PROCEDURE 49 11 HOW TO DIAGNOSE THE TROUBLE 62 12 HOW TO REPLACE THE MAIN PARTS 87 13 EXPLODED VIEWS AND PARTS LIST 105 FILE NO SVM 08011 ...

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: ...utput W Air flow rate Cooling Heating m3 min Piping Type connection Indoor unit Liquid side mm Gas side mm Outdoor unit Liquid side mm Gas side mm Maximum length m Maximum chargeless length m Maximum height difference m Refrigerant Name of refrigerant Weight kg Wiring Power supply connection Interconnection Usable temperature range Indoor Cooling Heating C Outdoor Cooling Heating C Accessory Indoo...

Page 6: ... speed rps Current A RAS 137SKV E RAS 167SKV E Cooling 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Outdoor temp Capacity ratio RAS 137SKV E RAS 167SKV E Conditions Indoor DB27 WB19 Indoor air flow High Pipe length 5m Capacity ratio 100 3 5kW RAS 137SKV E 4 5KW RAS 167SKV E Heating 0 20 40 60 80 100 120 15 10 5 0 5 10 Outdoor temp Heating Capacity ratio RAS 13...

Page 7: ... 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 8: ...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 9: ... 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 10: ...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 11: ...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 12: ...onnecting port of the electronic balance and charge liquid refrigerant Water heat exchanger 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 accordin...

Page 13: ... 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 stre...

Page 14: ... 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 15: ...For 13 series Flare 9 52mm For 16 series Flare 12 7mm 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 FILE NO SVM 08011 55 Wireless remote controller Remote controller holder 23 113 60 136 17 62 69 49 Knock out system Front panel 48 7 63 790 Knock out system 63 48...

Page 16: ...de Flare 6 35 Ø Flare 9 52 Gas side 13 Service port 2 11 x 14 Long holes For 8 10 anchor bolt Installation dimension Air outlel 100 or more 100 or more 600 or more 600 or more Air intlel Ø Ø Ø Ø6 hole 86 Ø6 hole Ø11x14 hole R15 28 A 320 R5 5 36 108 125 50 137 92 5 4 600 320 90 600 90 275 290 550 Ø 436 Z R15 50 36 2 320 342 69 Flare 12 7 16 2 R5 5 x 17L Ushape For 8 10 anchor bolt FILE NO SVM 08011...

Page 17: ... 17 5 WIRING DIAGRAM 5 1 RAS 137SKV E RAS 137SAV E FILE NO SVM 08011 ...

Page 18: ...5 2 RAS 167SKV E RAS 167SAV E 18 FILE NO SVM 08011 ...

Page 19: ...12V 10 Coil for 4 way valve AC220 240V C12A 01 R VHV Compressor 3 phases 4 poles 750W Inverter attached Inverter attached Inverter attached 8 Inverter attached DA89X1C 23FZ DA111A1F 20F1 Parts name Model name Rating CH 57 ICF 140 43 4R 11 Compressor thermo PW 2AL OFF 125 4 C ON 90 5 C 2 Room temp sensor TA sensor 10kΩ at 25 C 3 Heat exchanger temp sensor TC sensor 10kΩ at 25 C 4 Louver motor Outpu...

Page 20: ...n Deoxidized copper pipe Outer dia 6 35mm Thickness 0 8mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attaching port Vacuum pump connecting port Strainer Pulse Modulating valve at liquid side SEV16RC9 TD 4 way valve STF 0108Z Compressor DA89X1C 23FZ TS T2 Outdoor heat exchanger Temp measurement Propeller fan Refrigerant amoun...

Page 21: ... 0 8mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attaching port Vacuum pump connecting port Strainer Pulse Modulating valve at liquid side SEV16RC9 Ø1 2 x 80 Ø1 2 x 80 TD 4 way valve STF 0108Z Compressor DA111A1F 20F1 TS T2 Outdoor heat exchanger Split capillary Temp measurement Propeller fan Refrigerant amount 0 85kg OUTDO...

Page 22: ...oor Outdoor P MPa T1 C T2 C rps 27 19 35 24 137SKV E 0 8 to 1 0 11 to 13 39 to 41 High High 77 167SKV E 0 7 to 0 9 10 to 12 47 to 49 High High 89 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 15 7 6 137SKV E 2 7 to 2 9 43 to 45 0 to 2 High High 80 167SKV E 2 5 to 2 7 39 t...

Page 23: ... Circuit Power Supply Circuit Infrared Rays 36 7kHz Remote Controller Thermo Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver AUTO Swing Louver Direction Setting Operation Mode Selection AUTO COOL DRY HEAT REMOTE CONTROLLER ECO Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Functions Cold draft preventing Function 3 minute Dela...

Page 24: ...ial Signal Transmitter Receiver Converter D C circuit Noise Filter Indoor Fan Motor Louver Motor Louver Motor Drive Control Indoor Fan Motor Control Initializing Circuit Clock Frequency Oscillator Circuit Power Supply Circuit Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Functions Cold draft preventing Function 3 minute Delay at Restart for Compressor Fan Motor Starting C...

Page 25: ... Rotor position detect circuit Rotor position detect circuit 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 P M V Pulse Modulating Valve M C U Micro Contr...

Page 26: ...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 27: ...6 3 Swing 36 9 ECO operation 37 10 Temporary operation 38 11 38 12 Discharge temperature control 39 13 Pulse Modulating valve P M V control 14 Self Cleaning function 40 15 Selt Cleaning function release 41 16 Remote A or B selection 42 9 3 Auto Restart Function 44 9 3 1 How to Set the Auto Restart Function 44 9 3 2 How to Cancel the Auto Restart Function 45 9 3 3 Power Failure During Timer Operati...

Page 28: ...N 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 preventive function ...

Page 29: ...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 30: ...r revolution of the fan motor is controlled to the fan speed level shown in Fig 2 and Table 1 according to the setup tempera ture room temperature and heat exchanger temperature Fig 1 Fig 2 Table 1 Indoor fan air flow rate 2 5 Ta C 2 0 1 5 1 0 0 5 Tsc a b c d e M WB 3 4 5 L W6 Air volume AUTO Fan speed setup COOL ON AUTO MANUAL 3 Fan speed M L x 3 4 L 4 Fan speed M L x 2 4 L 5 Fan speed M L x 1 4 ...

Page 31: ... 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 Fan speed setup HEAT ON AUTO YES NO MANUAL TC 42 C Min air flow rate control Tc 52 51 42 41 Limited to Min WD tap Fan speed ÐW8 W8 TC 42 a 10 x WD W8 W8 a In up operatio...

Page 32: ... 400 when the motor stopped Air conditioner ON Remote controller 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 137SAV E 200 300 370 440 440 500 550 600 Tap f 9 f...

Page 33: ... 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 timing change Chang...

Page 34: ...pressor 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 ret...

Page 35: ...lower stop the indoor fan Finish of defrost operation 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 Returning from defrost operation 1 Stop operation of the compressor for approx 50 seconds 2 I...

Page 36: ...either upper or lower limit position swing operation is performed in width 35 from the limit which the stop position exceeded 3 Swing 2 Louver position in heating operation 2 Air direction adjustment The position is automatically controlled according to the operation The set louver position is stored in memory by the microcomputer The angle of the louver is indicated as the louver closes fully is ...

Page 37: ... x 2 COOL min 8 DRY max COOL min 6 x 1 COOL min 30 minutes A B C 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 Min Hz Hz 137SKV E 167SKV E Coo...

Page 38: ...ter lamp ON Press RESET button Did you press RESET button for 3 seconds or more Did you press RESET button for 10 seconds or more Switch to AUTO RESTART control YES YES NO NO NO YES Temporary AUTO operation Temporary COOL Operation FILE NO SVM 08011 11 Discharge temperature control 1 Purpose This function detects error on the refrigerating cycle or error on the com pressor and performs protective ...

Page 39: ...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 40: ... 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 41: ... holding it continue The will beep 3 times in the first 3 seconds but it is not related to Self Cleaning function After holding about 20 seconds the air conditioner will beep 5 times without any blinking of display The Self Cleaning Operation had been cancelled Remark Presetting of Self Cleaning function above AUTO How to set Self Cleaning function To set the Self Cleaning function proceed as foll...

Page 42: ...re is no A setting display Setting the remote controller To separate using of remote control for each indoor unit in case of 2 air conditioner are installed nearly Remote Control B Setup 1 Press RESET button on the indoor unit to turn 2 Point the remote control at the indoor unit 3 Push and hold CHK button on the Remote Control by the tip of the pencil 00 will be shown the air conditioner ON shown...

Page 43: ...tton to turn the unit OFF k Set the operation mode or plasma air sending the signal to the unit l Use the tip of the pencil to push the on display them press CLR button m Press button to turn the unit ON n When short timer is activated all immediately besides all indicatiors on 3 seconds 43 FILE NO SVM 08011 17 FILTER When the elapsed time reaches 1000 hours the Indicator FILTER indicator lights A...

Page 44: ...it 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 Au...

Page 45: ...ime 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 is on stand by not o...

Page 46: ...ss FAN Select AUTO QUIET LOW MED or HIGH FILE NO SVM 08011 MODE AUTO COOL FAN TEMP TEMP STAR T STOP SWING MODE TIMER ON OFF SET CLR ECO RST CHK FIX FAN AUTO QUIET HEAT DRY Hr ON OFF B 1 Infrared signal emitter 2 Set louver button FIX 3 Auto louver button SWING 4 Mode select button MODE 5 6 On timer button ON 7 8 9 10 11 12 13 14 Reset button RST Off timer button OFF Reserve button SET Cancel butto...

Page 47: ... and fan operation is automatic speed 6 TIMER OPERATION FILE NO SVM 08011 Setting the ON Timer Setting the OFF Timer Press TIMER ON Set the desired ON timer 1 2 3 Press TIMER OFF Set the desired ON timer Press TIMER SET Set the timer Press TIMER CLR Cancel the timer Press TIMER SET Set the timer Press TIMER CLR Cancel the timer Note Keep the remote control in accessible transmission to the indoor ...

Page 48: ...es when the ECO is in activated Press the ECO button to start and press it again 6 Operation Indicate when press the operation ON OFF button to stop operate 5 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 seting is A there is no indication at this position 7 FAN speed indicator Indic...

Page 49: ...g hole sloped slightly The auxiliary piping can be connected to the left 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 Pan head wood screw Remote control holder Vinyl tape Apply after carrying out a drainage test Saddle Extension drain hose Not available provided by installer Shield pipe Air filter Hoo...

Page 50: ...e outdoor unit before installing it 10 2 2 Accessory and Installation Parts Suction side Diffuser Elongated drain hole Drain hole Part name Q ty Installation plate 1 Wireless remote control 1 Battery 2 Remote control holder 1 Part No Part name Q ty Mounting screw Ø4 25L 6 Remote control holder mounting screw Ø3 1 16L 2 Part No Part name Q ty Drain nipple x 1 Water proof rubber cap x 2 Others Name ...

Page 51: ... 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 52: ...ght 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 Fig 10 3 1 10 3 2 Drilling a Hole and Mounting Instal lation Plate Drilling a hole When install the refrigerant pipes ...

Page 53: ...e air conditioner NOTE Wire type More than 1 5 mm2 H07RN F or 60245IEC66 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 discon nects all poles and has a contact separa tion of at least 3 mm must be incorporated in the fixed wiring An approved circuit breaker or switch must be used ...

Page 54: ...he 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 CAUTION Earth line Connecting cable about 15 cm Connecting cable Screw Screw Earth line Terminal block Screw Cord clamp Terminal cover 1 2 3...

Page 55: ...posi tioned 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 17 NOTE If the pipe is incorrectly bent the indoor unit may be unsta...

Page 56: ...hooked on the installation plate Installation plate Indoor unit Connecting cable Auxiliary pipes 10 3 7 Drainage 1 Run the drain hose at a downward sloped angle NOTE Hole should be made at a slight downward slant on the outdoor side 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 e...

Page 57: ...ain water does not cause any problems Precautions for adding refrigerant 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 refri...

Page 58: ...d 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 Do not use ordinary garden hose but one can flatten and prevent water from draining Fig 10 4 3 Commercially available drai...

Page 59: ...ering 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 Use a vacuum pump 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 ...

Page 60: ...wer cord 30 30 10 L N 10 1 2 3 10 10 40 40 Earth line Earth line Connecting cable Power cord CAUTION Incorrect wiring connection may cause electri cal 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 If incorrect or incomplete wiring is carried out fire or...

Page 61: ...ay receive the remote control signal simultaneously and operate In this case the operationcan be preserved by setting either one indoor unit or remote control to B setting Both are set to A setting in setting of indoor unit and remote control are different room B room when connecting the piping and cables When two Indoor units are Installed in the separated rooms it is not necessary to change the ...

Page 62: ...rd 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 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 62 63 63 64 67 No 6 7 8 9 10 ...

Page 63: ...e components Sensor leads 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 touc...

Page 64: ...easing 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 flas...

Page 65: ...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 66: ...e display of the remote control The timer lamp on the indoor unit blinks continuously 5 times per 1 sec 2 Press 8TEMP button If there is no fault with a code the indoor unit will beep once Pi and the display of the remote control will change as follows Check the unit with all 35 check codes 00 to 22 Press 9TEMP button to change the check code backwards If there is a fault the indoor unit will beep...

Page 67: ...r 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 Operation of diagnosis function Block Indoor P C board etc Not d...

Page 68: ...tion Block Outdoor P C board Not displayed Outdoor P C board Others including compressor Operation of diagnosis function Cause of operation Inverter over current protective circuit operates Short time Position detect circuit error or short circuit between windings of compressor Current detect circuit error Being out of place disconnection or short circuit of the outdoor heat exchanger sensor TE or...

Page 69: ...upply by pushing START STOP button on remote controller Is voltage DC12V or 5V indicated on rear of indoor control board normal Does transmission mark on remote controller flash normally and is its signal transmitted properly Item by symptoms Operation Check Item Considerable principle cause Measures Parts R01 C01 C02 R02 C03 D01 D02 D03 D04 Remote controller is defective Refer to 5 Troubleshootin...

Page 70: ...properly Is DC310 340V supplied between CN31 1 3 Does fan motor connector between CN31 1 3 short circuit Item by symptoms Operation Check Item Considerable principle cause Measures Parts R01 R02 DB01 C01 C03 IC01 and T101 are defective Remote controller is defective Refer to 5 Troubleshooting for remote controller Parts of a power supply circuit defective Unit operates normally Replace main P C bo...

Page 71: ...flow fan by hand at the operation stop condition is the rotation signal DC 12V 0V detected between 2 Purple lead and 3 Blue lead of the motor connector CN33 1 pulse 1 revolutio Dose AC120V or ligher voltage apply to between red and black lead of the motor Is it possible to change airflow level to HIGH Stop the operation Does fan motor continue to operate Does indoor fan operate Fan motor operates ...

Page 72: ...ector CN31 Check this condition within 15 seconds after starting unit 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 CN31 Is it possible to detect DC 1V or more between 5 and 3 of motor connector CN31 Is it possible to detect DC 310 340V between 1 and 3 of motor connector CN31 Motor connection cond...

Page 73: ... in RAS 167SKV E Cause 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 Inspection procedure 1 Remove the front panel Remove 2 screws 2 Remove the cover of the fan motor lead wires 3 Check DC voltage with CN31 connec...

Page 74: ... of Trouble by Every Symptom AFS 220 20 4AR 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 oper 1 3 5 1 2 3 2 1 3 2 1 3 2 1 3 2 1 3 CN31 CN33 P C board WHI BLK RED BLK RED WHI BLU PUR GRY BLU PUR GRY Resistance value Position P C board Between 3 Black 1 Red Between 3 Black 5 White Between 1 Red 5 White 74 15 Ω 100 20 ...

Page 75: ...s are exhausted Does radio sound is affected by remote controller when a signal is transmitted at distance of 5 cm from radio Is transmission mark indicated P C board is defective Replace P C board Replace batteries Replace remote controller Normal operation Remote controller is defective NO YES NO YES NO YES NO YES NO YES NO YES NO YES Does indoor unit start to operate by automatic restart functi...

Page 76: ...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 8 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while after ope...

Page 77: ...ressure 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 indoor hea...

Page 78: ...mary 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 C14 with printed CAUTION HIGH VOLTAGE on P C board OK if 500µF or 760µF DC280 to 380V Remove CN300 while pushing the part indicated by an arrow because CN300 is a connector with...

Page 79: ...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...

Page 80: ...ll indicators OPERATION TIMER FILTER PURE are lit for 3 seconds and they return to normal 3 seconds later 1 Check whether or not the com pressor operates 2 Check whether or not the OP ERATION indicator flashes 1 Check whether or not the com pressor operates 2 Check whether or not the OP ERATION indicator flashes 1 Check it is impossible to detect the voltage AC120V or higher voltage between red an...

Page 81: ...ther or not all indicators OPERATION TIMER FILTER PURE are lit for 3 seconds and they return to normal 3 seconds later 1 Check whether or not the com pressor operates 2 Check whether or not the OP ERATION indicator flashes 1 Check whether or not the com pressor operates 2 Check whether or not the OP ERATION indicator flashes 1 Check it is impossible to detect the voltage DC 15V between 3 and 4 of ...

Page 82: ...0 Resistance value k Temperature C TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TE Outdoor heat exchanger temp sensor TS Suction temp sensor TA TC TO TE TS TD 1 Sensor characteristic table 5V RAS 137SKV E 82 FILE NO SVM 08011 ...

Page 83: ...Resistance value k Temperature C TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TE Outdoor heat exchanger temp sensor TS Suction temp sensor TA TC TO TE TS TD 1 Sensor characteristic table 12V GND 5V FILE NO SVM 08011 ...

Page 84: ...re the resistance value of each winding coil by using the tester Under normal temp 25 C Position 1 to 2 1 to 3 1 to 4 1 to 5 Resistance value 250 20Ω Refer to 11 5 1 3 and 4 Under 20 C Disconnect the connector and measure resistance value with the tester Normal temperature Outdoor temperature sensor TO discharge temperature sensor TD suction temperature sensor TS outdoor heat exchanger temperature...

Page 85: ...ered surface Heat sink IGBT side C12 C13 C14 Case that product is good Pointer swings once and returns slowly When performing test once again under another polarity the pointer should return C12 C13 C14 500µF or 760µF 400V Resistance value in good product Tester rod 2 3 2 3 4 1 1 2 3 DBO1 4 4 2 3 1 10 to 20 Ω when the multimeter probe is reversed 2 Diode block 1 Turn OFF the power supply breaker 2...

Page 86: ...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 value between 1 Red le...

Page 87: ...s 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...

Page 88: ...front panel fixing 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 soun...

Page 89: ...c 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 5 Disengage the display unit by simply pushi...

Page 90: ...re 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 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 ex...

Page 91: ...dure in the item 2 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 ...

Page 92: ... 2 Loosen the set screw of the 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 Motor cover Two Screws Two screws on motor band ...

Page 93: ...n 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 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 ...

Page 94: ...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 P C board layout CN33 CN31 R02 R01 C01 FUSE L01 C02 C03 CN51 T01 IC12 C121 C133 RAS 137SKV E FILE NO SVM 08011 ...

Page 95: ... 0 10 20 30 40 50 Resistance value k Temperature C TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TE Outdoor heat exchanger temp sensor TS Suction temp sensor TA TC TO TE TS TD 1 Sensor characteristic table 12V GND 5V ...

Page 96: ...e the indoor unit 2 Attach the upper cabinet ST1TØ4 10L 5 pcs 3 Perform cabling of connecting cable and attach the cord clamp Fix the cord clamp by tightening the screws ST2T 4 x 14L 3 pcs fitting 2 concave parts of the cord clamp to each connecting cables 4 Attach the valve cover ST1T 4 x 10L 2 pcs Insert the upper part into the square hole of the side cabinet set hook claws of the valve cover to...

Page 97: ...t 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 wer...

Page 98: ... 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 Discharging position Discharging period 10 seconds or more Plug of soldering iron The connector is one with lock so remove it while pushing...

Page 99: ...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 ...

Page 100: ...d heat exchanger Remarks Detail A Detail B Detail C 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 clock wise 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 4 pcs holding by hands so that the fan motor do...

Page 101: ...ed flames Otherwise it may malfunction 7 Remove the fixing screw of the bottom plate and heat exchanger ST1TØ4 10L 1 pc 8 Remove the fixing screw of the bottom plate and valve fixing plate ST1TØ4 10L 1 pc 9 Pull upward the refrigeration cycle 10 Remove BOLT 3 pcs fixing the compres sor to the bottom plate Precautions when assembling the com pressor Tighten the compressor bolts using a tightening t...

Page 102: ... Remove the front cabinet and put it down so that fan guard side directs downward Perform work on a corrugated cardboard cloth etc to prevent flaw to the product 3 Remove the hooking claws by pushing 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 posit...

Page 103: ...heir proper positions Shown in the above figure is the model 167SAV E The sensor mounting positions in the model 137SAV E are all Detail C for RAS 167SAV E Detail C for RAS 137SAV E TS sensor Suction pipe temperature sensor Attachment Install the senser onto the straight pipe part of the suction pipe Be careful for the lead direction of the sensor TD sensor Discharge pipe temperature sensor Attach...

Page 104: ... 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 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 T...

Page 105: ...V E 222 43T80318 AIR FILTER R 206 43T11301 PIPE SHIELD 223 43T80319 AIR FILTER L RAS 137SKV E 224 43T09410 GRILLE OF AIR INLET ORIGINAL WHITE 207 43T63003 REMOTE CONTROL HOLDER 208 43T60382 MOTOR CORD 209 43T82310 INSTALLATION PLATE 211 43T19333 SENSOR FIX PLATE 212 43T09408 PIPE HOLDER 213 43T03360 BACK BODY ASSEMBLY 226 43T62328 TERMINAL COVER 214 43T39327 BEARING BASE 227 43T69426 WIRELESS REMO...

Page 106: ...T69319 TEMPERATURE SENSOR 405 43T69633 PC BOARD ASSY WRS LED 402 43T60002 TERMINAL BLOCK 3P 406 43T69709 ASM PCB SERV FOR 167SKV E 403 43T69320 TEMPERATURE SENSOR 406 43T69710 ASM PCB SERV FOR 137SKV E 404 43T62003 CORD CLAMP Description Description FILE NO SVM 08011 ...

Page 107: ...8 18 15 7 6 8 8 26 27 11 13 10 12 14 24 25 16 17 3 For model RAS 167SAV E 31 HOLDER SENSOR TE FOR PIPE O D 6 35 19 BIMETAL THERMO 29 DRAIN NIPPLE 32 HOLDER SENSOR TD FOR PIPE O D 8 0 33 HOLDER SENSOR TS FOR PIPE O D 9 52 For model RAS 137SAV E RAS 137SAV E RAS 167SAV E ...

Page 108: ...ina 22 43T21375 FAN MOTOR FOR RAS 137SAV E 23 43T47001 NUT FLANGE 9 43T43411 CONDENSER ASSEMBLY 24 43T47354 BOLT COMPRESSOR M6 FOR RAS 167SAV E 25 43T49335 RUBBER CUSHION 9 43T43410 CONDENSER ASSEMBLY 26 43T46343 4 WAY VALVE FOR RAS 137SAV E 27 43T63315 4WAY VALVE COIL ASSEMBLY 28 43T63319 HOLDER SENSOR 29 43T79305 DRAIN NIPPLE 10 43T46332 VALVE PACKED 6 35 DIA 30 43T39317 MOTOR BASE CONNECTION PL...

Page 109: ...21 HEATSINK FOR 167SAV E 702 43T69656 PC BOARD FOR 137SAV E 703 43T60384 TERMINAL BLOCK 6P 701 43T62320 HEATSINKA FOR 137SAV E 704 43T60326 FUSE 705 43T60377 TEMPERATURE SENSOR 706 43T50304 SENSOR HEAT EXCHANGER 707 43T62313 BASE PLATE PC 702 43T69657 PC BOARD FOR 167SAV E Description Description ...

Page 110: ... 56 FILE NO SVM 03005 TOSHIBA CARRIER THAILAND CO LTD 144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND ...

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Toshiba RAS-137SAV-E, Service Manual

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