Toshiba RAS-167SAV-E5 Service Manual Download Page 22

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– 22 –

8-2. Outdoor Unit (Inverter Assembly)

FILE NO. SVM-13027

220

–

240 V

50Hz

MICR

O-COMPUTER BLOCK DIA

GRAM

Driver circuit

of P.M.V.

Heat exchanger

temp.sensor

Suction temp.

sensor

Outdoor air

temp. sensor

Discharge

temp. sensor

Indoor unit

send/receive

circuit

Relay

circuit

Noise

Filter

Converter

(AC

→

DC)

Clock

frequency

4MHz

High Power

factor Correction

circuit

Input current

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.

Inverter

(DC

→

AC)

Gate drive

circuit

Gate drive

circuit

Inverter

(DC

→

AC)

Outdoor

Fan motor

Compressor

MCC5009 (P

.C.B)

OUTDOOR UNIT

Current

detect

Current

detect

220

–

0 V

0Hz

Summary of Contents for RAS-167SAV-E5

Page 1: ...R410A SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit High Wall Heat PumpType Heat PumpType RAS 167SKV E5 RAS 167SAV E5 March 2013 FILE NO SVM 13027 RAS 16EKV EE RAS 16EAV EE ...

Page 2: ...5 5 WIRING DIAGRAM 17 6 SPECIFICATIONS OF ELECTRICAL PARTS 18 7 REFRIGERANT CYCLE DIAGRAM 19 8 CONTROL BLOCK DIAGRAM 21 9 OPERATION DESCRIPTION 23 10 INSTALLATION PROCEDURE 24 11 HOW TO DIAGNOSE THE TROUBLE 58 12 HOW TO REPLACE THE MAIN PARTS 78 13 EXPLODED VIEWS AND PARTS LIST 94 FILE NO SVM 13027 ...

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: ...ut W Type Model Fan motor output W Air flow rate Cooling Heating m 3 min Piping Type connection Indoor unit Liquid side mm Gas side mm Outdoor unit Liquid side mm Gas side mm Maximum length m Maximun chargeless length m Maximum height difference m Refrigerant Name of refrigerant Weight kg Wiring connection Power supply Interconnection Usable temperature range Indoor Cooling Heating o C Outdoor Coo...

Page 6: ...ating Capacity ratio RAS 167SKV E5 RAS 16EKV EE Condition Indoor DB20 Indoor air flow High Pipe length 5m Voltage 230V Voltage 230V 6 FILE NO SVM 13027 Capacity ratio 100 5 2kW RAS 167SKV E5 5 2kW RAS 16EKV EE 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 Condit...

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: ...nger Flare 6 35mm Flare 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 13027 64 5 73 5 110 58 17 5 25 Wireless remote controller Rem...

Page 16: ...quid side Flare 6 35 Ø Gas side 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 2 R5 5 x 17L Ushape For 8 10 anchor bolt FILE NO SVM 13027 102 Flare 12 7 Ø ...

Page 17: ... CM FM PMV BLK BLACK BLU BLUE RED RED GRY GRAY PNK PINK WHI WHITE BRW BROWN ORN ORANGE YEL YELLOW PUR PURPLE COLOR IDENTIFICATION F01 FUSE 25A AC250V COIL FOR 4WAY VALVE TERMINAL COVER TERMINAL COVER TYPE A TERMINAL COVER TYPE B 1 1 2 2 3 3 4 4 5 5 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 1 1 2 2 3 3 4 1 2 3 4 4 5 5 1 1 3 3 4 4 5 5 6 6 1 2 3 3...

Page 18: ...lock 5P 30A AC600V 9 COIL FOR P M V DC12V 10 Coil for 4 way valve AC220 240V CAM MD12TCTH 5 SQ Compressor 3 phases 4 poles 750W Inverter attached Inverter attached Inverter attached 8 Inverter attached DA108X1C 23FZ Parts name Model name Rating CH 57 x 2 PCS ICF 140 43 4R FILE NO SVM 13027 No Parts name Type Specifications ICE 340 30 4 DC 340V 30W 2 Room temp sensor TA sensor 10kΩ at 25 C 3 Heat e...

Page 19: ...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 20: ...EE 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 167SKV E5 2 5 to 2 7 44 to 46 0 to 3 High High 86 16EKV EE 2 5 to 2 7 44 to 46 0 to 3 High High 86 NOTES 1 Measure surface temperature of heat exchanger pipe around cent...

Page 21: ... 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 Starting Control Processing Temperature Processing Timer Serial Signal Communication Clean Function FILE NO SVM 13027 8 CONTROL BLOCK DIAGRAM 8 1 Indoor Unit REMOTE CONTROL Remote Control Operation Operation Mode Se...

Page 22: ...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 23: ...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 24: ... 2 Air direction adjustment 33 3 Swing 33 9 ECO operation 34 10 Temporary operation 35 11 12 Discharge temperature control 35 13 Pulse Modulating valve P M V control 36 Self Cleaning function 37 14 Remote A or B selection 38 9 3 Auto Restart Function 9 3 1 How to Set the Auto Restart Function 40 9 3 2 How to Cancel the Auto Restart Function 41 9 3 3 Power Failure During Timer Operation 41 9 4 Remo...

Page 25: ...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 26: ...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 27: ...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 28: ... 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 29: ...ner 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 ...

Page 30: ...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 Change of comp...

Page 31: ...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 32: ...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 33: ...e 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 33 FILE NO SVM 13027 Swing operation is perfor in range 35 with the Fixed position as the center If t...

Page 34: ... 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 30 3...

Page 35: ...ess 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 13027 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 Oper...

Page 36: ... 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 37: ... 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 38: ...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 39: ... 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 40: ...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 41: ...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 42: ... 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 cooling perfo...

Page 43: ... 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 13027 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 44: ...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 45: ...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 100 mm or mor...

Page 46: ...thick Putty PVC tapes Part Code Q ty One each 1 One each 10 1 2 Optional installation parts 10 2 Installation B C Fixing bolt arrangement of outdoor unit Secure the outdoor unit with fixing bolts and nuts if the unit is likely to be exposed to a strong wind Use 8 mm or 10 mm anchor bolts and nuts If it is necessary to drain the defrost water attach drain nipple 7 and cap water proof 8 to the botto...

Page 47: ...ote control x 1 Battery x 2 Part name Q ty Remote control holder x 1 Part No 4 5 6 Part No 7 8 Others Name Owner s manual Installation manual Part name Q ty The part marked with asterisk is packaged with the outdoor unit Mounting screw 4 x 25 s x 6 Flat head wood screw 3 1 x 16 s x 2 Drain nipple x 1 Cap water proof x 2 47 ...

Page 48: ... 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 49: ...ect sunlight or close 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...

Page 50: ...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 51: ...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 52: ...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 53: ...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 54: ... Clutch type Imper Outer dia R410A Conventional of copper pipe tool used tool used 10 4 2 Precautions about Installation in Regions with Snowfall and 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 a...

Page 55: ... 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 56: ...respective matched numbers on the terminal block of indoor and outdoor 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 o...

Page 57: ...wn on the display 4 Press 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 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 pres...

Page 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...te 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 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...

Page 66: ...ible to detect DC 1V or more between 5 and 3 of motor connector CN31 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 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 betwee...

Page 67: ... 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 connector while the fa...

Page 68: ...ble when setting the temporary switch of the air conditioner main unit to TEST RUN or TEMPORARY AUTO Can any signal 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 t...

Page 69: ...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 70: ...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 71: ...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 72: ...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 73: ...ors OPERATION TIMER FILTER PRE DEP HI POWER are lit for 3 seconds and they return to normal 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 OPERATION indicator flashes 1 Check it is impossible to detect the voltage AC120V or higher voltage between red and black 2 The m...

Page 74: ...ance 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 13027 ...

Page 75: ... 3 2 1 Refer to 11 5 1 5 Measure 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 outd...

Page 76: ...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 77: ...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 78: ...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 79: ... 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 80: ... 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 81: ... 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 exchanger fixing holder S...

Page 82: ... 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 13027 ...

Page 83: ...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 13027 ...

Page 84: ...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 assembling the two hooking claws of the motor band ...

Page 85: ...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 86: ...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 87: ... 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 88: ...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 89: ...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 90: ... burner Take care to keep the 4 way valve away from naked flames Otherwise it may malfunction 7 Remove the fixing screw of the bottom plate and heat exchanger ST1TØ4 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 ...

Page 91: ...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 13027 1 Detachment 1 Perform step 1 in all the steps in and 1 in 2...

Page 92: ...structed The product will not be controlled properly and trouble will result if the sensors have not been installed in their proper 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 insta...

Page 93: ... 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 94: ...ts FILE NO SVM 13027 Location Part Location Part No No No No 401 43T69319 TEMPERATURE SENSOR 404 43T62003 CORD CLAMP 402 43T60365 TERMINAL BLOCK 3P 405 43T6V376 PC BOARD ASSY WRS LED 403 43T69320 TEMPERATURE SENSOR 406 43T6V387 PC BOARD Description Description ...

Page 95: ...3T20328 CROSS FLOW FAN ASSEMBLY 218 43T79313 CAP DRAIN 206 43T49359 PIPE SHIELD 219 43T44507 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 TER...

Page 96: ...25 ELECTRIC PART COVER 25 43T49335 RUBBER CUSHION 8 43T41438 COMPRESSOR 26 43T46367 4 WAY VALVE 9 43T43412 CONDENSER ASSEMBLY 27 43T63327 COIL 4WAY 10 43T46358 VALVE PACKED 6 35 DIA 28 43T63319 HOLDER SENSOR 11 43T46368 VALVE PACKED 12 7 DIA 29 43T79305 DRAIN NIPPLE 12 43T47331 BONNET 6 35 DIA 30 43T39333 MOTOR BASE CONNECTION PLATE 13 43T47333 BONNET 12 70 DIA 31 43T63318 HOLDER SENSOR 14 43T0044...

Page 97: ... Location Part Location Part No No No No 701 43T62320 HEATSINK 705 43T60377 TEMPERATURE SENSOR 702 43T69872 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60392 TERMINAL 5P 707 43T62313 BASE PLATE PC 704 43T60326 FUSE Description Description ...

Page 98: ...TOSHIBA CARRIER THAILAND CO LTD ...

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Toshiba RAS-167SAV-E5, Service Manual

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