Toshiba RAS-137SAV-E3 Service Manual Download Page 18

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5-2. RAS-167SKV-E3 / RAS-167SAV-E3

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FILE NO. SVM-10015

Summary of Contents for RAS-137SAV-E3

Page 1: ...R410A SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit High Wall Heat PumpType Heat PumpType RAS 137SKV E3 RAS 137SAV E3 RAS 167SKV E3 RAS 167SAV E3 Revised on Mar 2010 FILE NO SVM 10015 1 ...

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 25 10 INSTALLATION PROCEDURE 49 11 HOW TO DIAGNOSE THE TROUBLE 63 12 HOW TO REPLACE THE MAIN PARTS 87 13 EXPLODED VIEWS AND PARTS LIST 102 FILE NO SVM 10015 ...

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: ...48 50 49 50 Indoor unit Unit model RAS 137SKV E3 RAS 167SKV E3 Dimention Height mm 275 275 Width mm 790 790 Depth mm 205 205 Net weight kg 9 9 Fan motor output W 20 30 Air flow rate Cooling Heating m3 min 9 5 10 4 11 5 12 4 Outdoor unit Unit model RAS 137SAV E3 RAS 167SAV E3 Dimention Height mm 550 550 Width mm 780 780 Depth mm 290 290 Net weigh kg 33 40 Compressor Motor output W 750 750 Type Sing...

Page 6: ...ting Capacity ratio RAS 137SAV E3 RAS 167SAV E3 Condition Indoor DB20 Indoor air flow High Pipe length 5m Voltage 230V Voltage 230V 7 FILE NO SVM 10015 Capacity ratio 100 4 2kW RAS 137SKV E3 5 2kW RAS 167SKV E3 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 100 110 120 Compressor Speed rps Current A 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 100 110 120 Compressor Speed rps Current A Condi...

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: ...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 13: ... 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 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 10015 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 26 Remote controller hold...

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 10015...

Page 17: ... 17 5 WIRING DIAGRAM 5 1 RAS 137SKV E3 RAS 137SAV E3 FILE NO SVM 10015 ...

Page 18: ...5 2 RAS 167SKV E3 RAS 167SAV E3 18 FILE NO SVM 10015 ...

Page 19: ... Coil for 4 way valve AC220 240V CAM MD12TCTH 2 STF 01AJ646A1 Compressor 3 phases 4 poles 750W Inverter attached Inverter attached Inverter attached 8 Inverter attached DA89X1C 23FZ2 DA108X1C 23FZ Parts name Model name Rating CH 57 x 2 PCS ICF 140 43 4R 137SAV E3 167SAV E3 CH 69 L 19mH 10A 2 Room temp sensor TA sensor 10kΩ at 25 C 3 Heat exchanger temp sensor TC sensor 10kΩ at 25 C 4 Louver motor ...

Page 20: ...uter 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 TD 4 way valve Compressor DA89X1C 23FZ2 TS T2 Outdoor heat exchanger Temp measurement Propeller fan Refrigerant amount 0 80kg OUTDOOR UNIT Muffler Muffler TE Min...

Page 21: ...tional 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 Ø1 2 x 80 Ø1 2 x 80 TD 4 way valve Compressor DA108X1C 23FZ TS T2 Outdoor heat exchanger Split capillary Temp measurement Propeller fan Refrigerant amount 1 05kg OUTDOOR UNIT Muffler Muffler TE TC...

Page 22: ... E3 0 7 to 0 9 10 to 12 40 to 42 High High 89 Heating Tempeature Model name Standard Heat exchanger Indoor Outdoor Compressor condition C RAS pressure pipe temp fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 7 6 137SKV E3 2 6 to 2 8 41 to 43 0 to 2 High High 83 167SKV E3 2 5 to 2 7 44 to 46 0 to 3 High High 86 NOTES 1 Measure surface temperature of heat exchanger pipe around ce...

Page 23: ...Controller Thermo Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver AUTO Swing Louver Direction Setting QUIET Operation Mode Selection AUTO COOL DRY HEAT REMOTE CONTROLLER ECO Hi POWER Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Functions Cold draft preventing Function 3 minute Delay at Restart for Compressor Fan Motor Starti...

Page 24: ...rent sensor 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 Motor Valve M C U Micro Control Unit M C U For INDOOR UNIT 4 way valve P M V Invert...

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: ...ECO operation 36 10 Temporary operation 37 11 12 Discharge temperature control 37 13 Pulse Modulating valve P M V control 38 Self Cleaning function 39 14 15 Remote A or B selection 40 9 3 Auto Restart Function 9 3 1 How to Set the Auto Restart Function 43 9 3 2 How to Cancel the Auto Restart Function 44 9 3 3 Power Failure During Timer Operation 44 19 FILTER Indicator 42 9 4 Remote Controller and ...

Page 27: ...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 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: ...tion 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 L L M M H W6 L M 2 W9 M H 2 WC Indication Fan speed Fan speed setup COOL ON AUTO MANUAL 3 Fan speed M L x 3 4 L 4 ...

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: ...er 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 Compressor speed rps To 38 C To 28 C To To 15 C To 5 5 C To 0 C During To 38 C ECO mode To 38 C When To is abnormal 13 8 31 7 3...

Page 32: ...lectric 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 Change of compr...

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: ...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 35: ...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 36: ...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 FAN Min Hz Fan speed depend on presetting and can change every speed Hz a 20 30...

Page 37: ...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 10015 11 Discharge temperature control 1 Purpose This function detects error on the refrigerating cycle or error on the com pressor and performs protective ...

Page 38: ... 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 degree of valve to...

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: ... 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 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 ...

Page 41: ...e COMFORT SLEEP button is pressed again means cancel comfort sleep mode Heating mode The preset temperature will drop down as show on ECO operation Item No 9 choose the operating hours Repeat Press the COMFORT SLEEP button to pressing to setect thehours If the COMFORT SLEEP button is pressed again means cancel comfort sleep mode 1hr 3hr 5hr or 9hr 1hr 3hr 5hr or 9 hr 41 capacity SLEEP mode FILE NO...

Page 42: ...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 2ºC The value of the preset temperature on the 4 The Hi POWER mode can not be set in Dry operation 19 FILTER When the elapsed time reaches 1000 hours after Indicator air conditioner op...

Page 43: ...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 ...

Page 44: ...is required to 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...

Page 45: ...the typical consumer preferences in your region of the world The coutomised settings control temperature air flow strength air flow direction and other settings to provide you alternate contact with ONE TOUCH OF THE BUTTON If you prefer other settings you can select from the many other operation functions of your Toshiba unit Press ONE TOUCH Start the operaton 2 AUTOMATIC OPERATION To automaticall...

Page 46: ...remote control Pressing the RESET button the unit can start or stop without using the remote control Operation mode is set on AUTOMATIC operation preset temperature is 24 C and fan operation is automatic speed 8 TIMER OPERATION Setting the ON Timer Setting the OFF Timer Press ON Set the desired ON timer Press OFF Set the desired OFF timer Press SET Set the timer Press SET Set the timer Press CLR C...

Page 47: ...e indoor unit for 3 seconds to cancel the Setting operation 3 beep sound but OPERATION lamp does not blink 11 QUIET OPERATION To operate at super low fan speed for quiet operation except in DRY mode Press QUIET Start and stop the operation Note Under certain conditions QUIET operation may not provide adequate cooling or heating due to low sound features 12 COMFORT SLEEP OPERATION To save energy wh...

Page 48: ... shown when holding down the button for more than 3 seconds while the mark is flashing Press another button to turn off the mark 8 ECO indicator Indicates when the ECO is in activated Press the ECO button to start and press it again to stop operation 9 A B change indicator remote controller When the remote controller switching function is set B appears in the remote controller display When the rem...

Page 49: ...iary 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 Hook Installation plate Hook 65 mm ...

Page 50: ...of 10 to the bottom plate of the outdoor unit before installing it A Air inlet Air outlet Drain outlet 600 mm 90 mm 125 mm 108 mm 28 mm 86 mm 102 mm 320 mm 2 5 m m Æ 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 Part Code Q ty One each 1 One each 10 2 1 Optional installation parts 12 70 mm 137SKV E3 167SKV E...

Page 51: ... A614DE x 1 Part No 4 5 6 Part No 7 8 9 Others Name Owner s manual Installation manual Part name Q ty Mounting screw 4 x 25 s x 6 Flat head wood screw 3 1 x 16 s x 2 Drain nipple x 1 10 2 2 Accessory and installation parts The part marked with asterisk is packaged with the outdoor unit Cap water proof x 2 10 Filter RB A614DE x 1 FILE NO SVM 10015 ...

Page 52: ... 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 53: ...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 54: ...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 55: ...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 How to remove the drain cap Clip drain cap with needle nose pliers and pull out Fig 10 3 9 How to remove the drain hose The drain hose is secured in place by a screw Remove the screw securing the drain hose then pull out the dra...

Page 56: ...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 15 NOTE If the pipe is incorrectly bent the indoor unit may be unsta...

Page 57: ...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 19 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 58: ...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 59: ...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 60: ...e 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 press...

Page 61: ...orrect 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 smoke may result Prepare the power supply for the exclusive use of the air conditioner This product can...

Page 62: ...es Remote control A or B Selection When two indoor units are installed in the same room or adjacent two rooms if operating a unit two units may receive the remote control signal simultaneously and operate In this case the operation can be preserved by setting either one indoor unit or remote control to B setting Both are set to A setting in factory shipment The remote control signal is not receive...

Page 63: ...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 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 No 6 7 8 9 10 ...

Page 64: ...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 65: ...button is operated 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 ...

Page 66: ...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 67: ...p 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 ON or OFF button to change the check code backward If there is a fault the indoor unit will beep for 10 seconds Beep Beep Beep Note the check code on the display of the remo...

Page 68: ...rns 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 display...

Page 69: ...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 70: ... 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 defective Replace main P C board Refer to Primary check or this problem is one step short of power P C Is the voltage ...

Page 71: ...roperly 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 IC11 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 boa...

Page 72: ...low 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 n...

Page 73: ...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 74: ... in RAS 167SKV E3 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 conne...

Page 75: ... of Trouble by Every Symptom AFS 220 20 4D 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 Ω...

Page 76: ...thyristor fluorescent light NO NO NO NO NO NO NO NO Is operation possible when setting the temporary switch of the air conditioner main unit to TEST RUN or TEMPORARY AUTO Can any signal tone be heard 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 condi...

Page 77: ...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 78: ...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 79: ...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 80: ...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 81: ...r does not operate 2 OPERATION lamp blinks 1 Motor does not rotate The key operation is accepted 2 The Motor rotates but it vibrates too much Shut off the power supply and remove the P C board assembly from the electronic parts base Remove the connecting cable from the terminal block Remove the connector for the motor and turn the power on If the OPERATION lamp blinks 0 5 sec ON 0 5 sec OFF when t...

Page 82: ...l 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 and...

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 10015 ...

Page 84: ...istance 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 sensor TE...

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 Tester rod 2 3 2 3 4 1 1 2 3 DB01 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 Completely discharge the four el...

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: ...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 88: ... 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 89: ... 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 pushing at the t...

Page 90: ... 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 2 screws Heat exchanger fixing holder Screw l FILE NO SVM 10015 5 Remove right side of the end plate from two fixing rib while sliding slig...

Page 91: ...tion and then incorporate it in the main body Two screws Bearing Bearing base FILE NO SVM 10015 Procedures Remarks Bearing base Fan motor 1 Follow to the procedure till item 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 Set screw Two screw Motor c...

Page 92: ...t keeping 5 0 mm from closed wall of the main unit Holding the 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 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 assem...

Page 93: ...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 94: ...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 95: ... 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 96: ...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 97: ...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 98: ...y valve away from naked 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 NUT 3 pcs fixing the compres sor to the bottom plate Remarks Reactor 1 Perform work of item 1 of and 2 Remove screws fixing th...

Page 99: ...ng 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 Check that all the hooking claws are fixed to the specified positions FILE NO SVM 10015 1 Detachment 1 Perform step 1 in all the steps in and 1 in 2...

Page 100: ...er positions 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 Attachment With its leads pointed upward install the sensor onto the vertical straight pipe part of the discharge pipe TO sensor Outside air temperature sensor Attachment Inse...

Page 101: ... 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 102: ...O SVM 10015 Location Part Location Part No No No No 401 43T69319 TEMPERATURE SENSOR 404 43T62003 CORD CLAMP Made in Thailand 402 43T60365 TERMINAL BLOCK 3P 405 43T69633 PC BOARD ASSY WRS LED 403 43T69320 TEMPERATURE SENSOR 406 43T69876 PC BOARD Made in Thailand Description Description ...

Page 103: ...tion Part Location Part No No No No 401 43T69319 TEMPERATURE SENSOR 404 43T62003 CORD CLAMP Made in Thailand 402 43T60365 TERMINAL BLOCK 3P 405 43T69633 PC BOARD ASSY WRS LED 403 43T69320 TEMPERATURE SENSOR 406 43T69876 PC BOARD Made in Thailand Description Description ...

Page 104: ... FAN ASSEMBLY 219 43T44449 REFRIGERANT CYCLE ASSEMBLY Made in Thailand 221 43T00488 PANEL SERVICE ASSEMBLY 206 43T11301 PIPE SHIELD Made in Thailand 207 43T83003 HOLDER REMOTE CONTROL 222 43T80318 AIR FILTER R Made in Thailand Made in Thailand 223 43T80319 AIR FILTER L Made in Thailand 208 43T60382 MOTOR CORD Made in Thailand 224 43T09438 GRILLE OF AIR INLET ORIGINAL WHITE 209 43T82310 INSTALLATIO...

Page 105: ...MBLY 219 43T44451 REFRIGERANT CYCLE ASSEMBLY Made in Thailand 221 43T00488 PANEL SERVICE ASSEMBLY 206 43T11320 PIPE SHIELD Made in Thailand 207 43T83003 HOLDER REMOTE CONTROL 222 43T80318 AIR FILTER R Made in Thailand Made in Thailand 223 43T80319 AIR FILTER L Made in Thailand 208 43T60382 MOTOR CORD Made in Thailand 224 43T09438 GRILLE OF AIR INLET ORIGINAL WHITE 209 43T82310 INSTALLATION PLATE M...

Page 106: ...BBER CUSHION Made in Malaysia 8 43T41420 COMPRESSOR Made in China 26 43T46343 4 WAY VALVE 9 43T43434 CONDENSER ASSEMBLY 27 43T63320 4 WAY VALVE COIL ASSEMBLY 10 43T46332 VALVE PACKED 6 35 DIA Made in Thailand 28 43T63319 HOLDER SENSOR Made in Thailand 11 43T46331 VALVE PACKED 9 52 DIA Made in Thailand 29 43T79305 DRAIN NIPPLE 12 43T47331 BONNET 6 35 DIA Made in Thailand 30 43T39333 MOTOR BASE CONN...

Page 107: ...BBER CUSHION Made in Malaysia 7 43T62325 ELECTRIC PART COVER 26 43T46367 4 WAY VALVE 8 43T41438 COMPRESSOR 27 43T63327 COIL 4WAY 9 43T43412 CONDENSER ASSEMBLY 28 43T63319 HOLDER SENSOR Made in Thailand 10 43T46358 VALVE PACKED 6 35 DIA 29 43T79305 DRAIN NIPPLE 11 43T46368 VALVE PACKED 12 7 DIA 30 43T39333 MOTOR BASE CONNECTION PLATE 12 43T47331 BONNET 6 35 DIA Made in Thailand 31 43T63318 HOLDER S...

Page 108: ...cation Part No No No No 701 43T62320 HEATSINK Made in Thailand 705 43T60377 TEMPERATURE SENSOR 702 43T69815 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60392 TERMINAL 5P Made in Thailand 704 43T60326 FUSE 707 43T62313 BASE PLATE PC Made in Thailand Description Description ...

Page 109: ...cation Part No No No No 701 43T62320 HEATSINK Made in Thailand 705 43T60377 TEMPERATURE SENSOR 702 43T69872 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60392 TERMINAL 5P Made in Thailand 704 43T60326 FUSE 707 43T62313 BASE PLATE PC Made in Thailand 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-E3, Service Manual

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