Toshiba RAS-22N3AV2-A Service Manual Download Page 106

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13-2.

Indoor Unit (Part-E)

FILE NO. SVM-13003

Location

Part

Location

Part

No.

401

43T50308

SENSOR HEAT EXCHANGER

405

43T6V316

PC BOARD ASSY;WRS-LED

402

43T60331

TERMINAL; 3P

407

43T69966

PC BOARD ASSY

403

43T69320

TEMPERATURE SENSOR

412

43T21397

STEPPING-MOTOR

404

43T62003

CORD CLAMP

413

43T60386

MOTOR CORD

Description

Summary of Contents for RAS-22N3AV2-A

Page 1: ...R410A SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit High Wall Heat PumpType Heat PumpType RAS 22N3KV2 A RAS 22N3AV2 A January 2013 FILE NO SVM 13003 ...

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 48 11 HOW TO DIAGNOSE THE TROUBLE 64 12 HOW TO REPLACE THE MAIN PARTS 88 13 EXPLODED VIEWS AND PARTS LIST 104 FILE NO SVM 13003 ...

Page 3: ...nor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation Before installation please read these precautions for safety carefully Be sure to follow the precautions provided here to avoid safety risks The symbols and their meanings are shown below WARNING It indicates that incorrect use of this unit ma...

Page 4: ...cordance with the code governing such installation work internal wiring regulations and the manual A dedicated circuit and the rated voltage must be used Insufficient power supply or improper installation may cause electrical shock or fire Use a cabtyre cable to connect wires in the indoor outdoor units Midway connection is not allowed Improper connection or fixing may cause a fire Wiring between ...

Page 5: ...per drainage from the unit Ensure that drained water is discharged Improper drainage can result is water leakage causing water damage to furniture Tighten the flare nut with a torque wrench using the prescribed method Do not apply excess torque Otherwise the nut may crack after a long period of usage and it may cause the leakage of refrigerant Wear gloves heavy gloves such as cotton gloves for ins...

Page 6: ...ht kg Wiring connection Power supply Interconnection Usable temperature range Indoor C Outdoor C Installation plate Wireless remote controller Batteries Remote controller holder Toshiba New IAQ filter long Indoor unit Accessory Remote controller holder Pan head wood screw Plasma air purifier Installation manual Owner s manual Outdoor unit Drain nipple RAS 22N3KV2 A RAS 22N3AV2 A 6 0 1 2 6 7 7 0 1 ...

Page 7: ...or DB 35oC Air Flow High Pipe Length 7 5m Voltage 240V Conditions Indoor DB 20oC Outdoor DB 7oC WB 6oC Air Flow High Pipe Length 7 5m Voltage 240V 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 Capacity ratio Outdoor temp oC 0 20 40 60 80 100 120 15 10 5 0 5 10 Capacity ratio Outdoor temp oC Conditions Indoor DB 27oC WB 19oC Outdoor DB 35oC Air Flow High Pipe Le...

Page 8: ... in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused 5 After completion of installation work check to make sure that there is no refrigeration gas leakage If the refrigerant gas leaks into the room coming into contact with fire in the fan driven heater space heater etc a poisonous gas may occur 6 When an air conditioning system charged with a la...

Page 9: ...nly for thick pipings whose diameter is larger than 20 mm Thicknesses of socket joints are as shown in Table 3 2 2 Table 3 2 2 Minimum thicknesses of socket joints 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 ai...

Page 10: ... nut dimensions for R410A Nominal Outer Thickness diameter diameter in mm mm 1 4 6 35 0 8 3 8 9 52 0 8 1 2 12 70 0 8 A mm Flare tool for R22 clutch type 0 to 0 5 0 to 0 5 0 to 0 5 Conventional flare tool Clutch type Wing nut type 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 0 to 1 5 0 5 to 1 0 1 5 to 2 0 Nominal Outer diameter Thickness diameter in mm mm 1 4 6 35 0 8 3 8 9 52 0 8 1 2 12 70 0 8 Dimension mm ...

Page 11: ...orque for R410A is the same as that for conventional R22 Incidentally when the torque is weak the gas leakage may occur When it is strong the flare nut may crack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 3 2 7 shows reference values NOTE When applying oil to the flare surface be sure to use oil designated by the manufactu...

Page 12: ...s the tools exclusive for R410A and their interchangeability Tools exclusive for R410A The following tools for R410A are required Tools whose specifications are changed for R410A and their interchangeability Note 1 When flaring is carried out for R410A using the conventional flare tools adjustment of projection margin is necessary For this adjustment a copper pipe gauge etc are necessary Note 2 Ch...

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

Page 14: ... 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 15: ...a flux which does not contain chlorine 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 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 pi...

Page 16: ...Grille Inlet 132 150 200 222 200 278 525 Drain hose 0 5m Hanger Hanger Connecting pipe 0 39m Flare 6 35 Flare 12 70 Connecting pipe 0 49m 786 262 5 262 5 235 215 215 235 320 6 5 40 47 85 6 5 40 23 109 215 5 153 5 Hanger Installation plate outline Hanger Hanger Outline of indoor unit For stud bold 6 For stud bold 8 10 Center line 63 Remote controller holder 17 5 149 57 Wireless remote controller 17...

Page 17: ...37 92 5 4 Service port Gas side Flare 12 70 Liquid side Flare 6 35 Electrical part 36 50 R15 6 hole 11x14 hole 330 316 B detail drawing Front leg 316 330 R15 50 36 R5 5 6 hole 600 A detail drawing Back leg 2 R5 5 x 17L Ushape 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 600 320 For 8 10 anchor bolt ...

Page 18: ...r Line Filter Surge Absorber F01 Fuse 250V T25A Power Relay Relay DB01 DB02 C12 C14 C13 YEL P21 BRW P20 R220 R219 PMV Discharge pipe Temp Sensor TD 3 2 1 3 2 1 Condenser pipe Temp Sensor TE 2 1 2 1 Thermo Sensor TA 1 2 1 2 CN62 BLU Heat Exchanger Sensor TC 1 2 1 2 CN01 CN02 CN51 Outdoor Temp Sensor TO 2 1 2 1 R321 R320 R319 P19 P18 Reactor Reactor Coil for 4 way Valve Indoor Terminal Block Wireles...

Page 19: ...sor TS sensor Discharge temp sensor TD sensor Outside air temp sensor TO sensor Heat exchanger temp sensor TE sensor Terminal block 5P Model name CH 57 FC ICF 140 43 4R Inverter attached Inverter attached Inverter attached Inverter attached DA150A1F 20F Compressor CAM MD12TCTH 6 Rating L 10mH 16A DC140V 43W 10kΩ 25 C 62kΩ 20 C 10kΩ 25 C 10kΩ 25 C 20A AC250V 3phases 4poles 1100W DC12V AC220 240V FI...

Page 20: ... Pulse Modulating valve at liquid side NOTE Gas leak check position Refrigerant flow Cooling Refrigerant flow Heating OUTDOOR UNIT INDOOR UNIT T1 Temp measurement Indoor heat exchanger Cross flow fan TC TA Deoxidized copper pipe Outer dia 12 7mm Thickness 0 8mm Sectional shape of heat insulator P Pressure measurement Gauge attaching port Vacuum pump connecting port Deoxidized copper pipe Outer dia...

Page 21: ...ture Standard Heat exchanger Indoor Outdoor Compressor condition C pressure pipe temp fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps NOTES 1 Measure surface temperature of heat exchanger pipe around center of heat exchaner path U bent Thermistor themometer 2 Connecting piping condition 7 5 m High 41 to 43 35 24 27 19 7 6 20 15 0 to 2 High High 81 11 to 13 0 9 to 1 1 2 6 to 2 8 42 ...

Page 22: ...Processing Temperature Processing Timer Serial Signal Communication Clean Function Heat Exchanger Sensor Tc Room Temperature Sensor Ta Infrared Rays Signal Receiver and Indication Initializing Circuit Power Supply Circuit Converter D C circuit Noise Filter Clock Frequency Oscillator Circuit MCU From Outdoor Unit Serial Signal Transmitter Receiver Serial Signal Communication Operation Command and I...

Page 23: ...ve circuit Noise Filter MCC5009 PCB 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 PMV control Discharge temp control 4 way valve control Signal communication to indoor unit PMV Pulse Motor Valve MCU Micro Controller Unit Outdoor Fan motor Compres...

Page 24: ... 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 PMV control 4 way valve control Detection of inverter input current and current release operation Over current detection and prevention operation to IGBT module Compressor stop functio...

Page 25: ... ECO operation 34 10 Temporary operation 35 11 Discharge temperature control 35 FILE NO SVM 13003 12 Pulse motor valve PMV control 36 13 Self Cleaning function 37 14 Remote Controller A or B selection 39 15 QUIET mode 40 16 COMFORT SLEEP 40 17 One Touch Comfort 40 18 Hi POWER Mode 41 19 FILTER Indicator 41 20 Short Timer 41 9 3 Auto Restart Function 9 3 1 How to Set the Auto Restart Function 42 9 ...

Page 26: ...peration select COOL HEAT AUTO DRY Temperature setup Air direction Swing Air volume select AUTO LOW LOW MED MED HIGH ECO COMFORT SLEEP ON timer setup QUIET OFF timer setup PRESET Hi POWER ONE TOUCH 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 27: ...operation stopped and if the room temperature is 20 C or more the fan operation is performed with Super Ultra LOW mode for 3 minutes Then select an operation mode Setup of remote controller Indoor fan motor control Louver control Operation Hz Control Requierment Compressor revolution control Outdoor fan motor control Operation Hz control Include limit control 4 way valve control In cooling operati...

Page 28: ... SUL Super Ultra Low L Low WF UH 1250 1156 WE H 1250 1156 WD M 1250 1156 WC H 1200 1101 WB M M 1050 938 WA 1020 902 W9 M L 980 858 W8 L 850 702 W7 L L L 810 659 W6 L L 800 648 W5 L UL L 760 605 W4 UL UL 700 540 W3 SUL SUL 650 485 W2 SUL 500 324 W1 500 324 Fan speed rpm Air flow rate m3 h Fan speed level COOL HEAT DRY Table 1 Indoor fan air flow rate broadly very with position of louver The values ...

Page 29: ...art and room temp is 3 C or lower than set temp Room temp Set temp 4 C In stability When 12 to 25 minutes passed after operation start and room temp is higher than set temp 3 C When 25 minutes or more passed after operation start Room temp Set temp 3 5 C FILE NO SVM 13003 1 Fan speed M L x 1 4 L 2 Fan speed M L x 2 4 L 3 Fan speed M L x 3 4 L 1 When setting the fan speed to L L M M or H on the rem...

Page 30: ...hen To is abnormal 22 1 50 3 50 3 MIN MAX MIN MAX MIN MAX f 6 f 9 f 8 f B f A f E f 5 f 9 f 7 f B f 9 f E f 3 f 7 f 5 f 9 f 7 f B f 1 f 3 f 1 f 7 f 3 f 9 f 1 f 3 f 1 f 5 f 3 f 7 f 0 f 1 f 0 f 3 f 1 f 4 f 6 f 9 f 8 f B f A f B f 5 f 9 f 7 f B f 9 f B f 3 f 7 f 5 f 9 f 7 f B f 1 f 3 f 1 f 7 f 3 f 9 f 1 f 3 f 1 f 5 f 3 f 7 f 0 f 1 f 0 f 3 f 1 f 4 f 1 f F f 1 f F f 1 f F In Heating operation Compresso...

Page 31: ...ompressor 4 According to the difference resulted from comparison of the correction value of Hz signal with the present operation Hz the inverter output and the commuta tion timing are varied 5 Change the compressor motor speed by outputting power to the compressor The contents of control opera tion are same in cooling operation and heating operation 1 The input current of the outdoor unit is detec...

Page 32: ...on temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value Description 1 When temperature of the indoor heat exchanger drops below 5 C the compressor speed is re duced P zone 2 When temperature of the indoor heat exchanger rises in the range from 6 C to under 7 C the compressor speed is kept Q zone 3 When temperature of the indoor...

Page 33: ...ones 1 Stop operation of the compressor for 20 seconds 2 Invert ON 4 way valve 10 seconds after stop of the compressor 3 The outdoor fan stops at the same time when the compressor stops 4 When temperature of the indoor heat exchanger becomes 38 C or lower stop the indoor fan Finish of defrost operation Returning conditions from defrost operation to heating operation 1 Temperature of outdoor heat e...

Page 34: ...eturns to the stored position when the next operation is performed Cooling heating memory position The angle of the louver is indicated as the louver closes fully is 0 1 Louver position in cooling operation 2 Louver position in heating operation Description The louver position can be arbitrarily set up by pushing FIX button FILE NO SVM 13003 3 Swing Swing When pressing SWING b u Swing oper tton du...

Page 35: ...ot conrolled and can be selected during the ECO operation 6 5 6 0 5 5 5 0 4 5 4 0 3 5 3 0 2 5 2 0 1 5 1 0 0 5 TSC 0 5 1 0 2 0 Hz Cool min DRY max 10 50 FILE NO SVM 13003 12 DRY max COOL min 6 5 COOL min 11 DRY max COOL min 6 4 COOL min 10 DRY max COOL min 6 3 COOL min 9 DRY max COOL min 6 2 COOL min 8 DRY max COOL min 6 1 COOL min Hz a c 10 72 Heating operation 1 The difference of room temperature...

Page 36: ...or more Pi sound is heard and the temporary COOL operation starts 4 If the filter lamp goes on press RESET button to go off the filter lamp and then press RESET button again 5 To stop the temporary operation press the button again FILE NO SVM 13003 11 Discharge temperature control Td value 117 C 112 C 108 C 105 C 98 C Control operation Judges as an error and stops the compressor Reduce the compres...

Page 37: ... Discharge temp control SH Super Heat amount Ts Temperature of suction pipe of the compressor Tc or Te Heat exchanger temperature at evaporation side PMV Pulse Modulating Valve Starting up Initialize Move to initial position PMV open degree control SH control Td release control Turn OFF by remote controller Move to Stop Compressor Stop by Room Temperature Compressor ON Defrosting operation Control...

Page 38: ... the specified period based on duration of the operation which was performed prior to the shutdown after which the Self Cleaning operation stops The Self Cleaning operation is not performed after a heating operation 2 Operation 1 When the stop signal from the remote controller or timer off function is received only the timer indicator light 2 The period of the Self Cleaning operation is determined...

Page 39: ...embly 2 To cancel Self Cleaning operation 3 To set Self Cleaning operation Turn the power supply ON Press the RESET button located on the front panel of the indoor unit for more than 3 seconds After 3 seconds the unit beeps three times The Self Cleaning is cancelled Turn the power supply ON Press the RESET button located on the front panel of the indoor unit for more than 3 seconds After 3 seconds...

Page 40: ...e remote controller selection is set to A on all the indoor units There 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 b...

Page 41: ... The air condition can shut down by itself Remarks Comfort sleep mode will not operate in dry automatically mode and fan only mode automatically room temperature reach setting temperature The preset temperature will increase as show on ECO operation Item No 9 Press the COMFORT SLEEP button to choose the operating hours Repeat pressing to select the hours If the COMFORT SLEEP button is pressed agai...

Page 42: ...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 The Hi POWER operation will be cancelled when press Hi POWER button again 20 ShortTimer In the normal condition after switching one circuit breaker 3 minute dela...

Page 43: ... Less than 10 seconds Motions The unit is in operation The green indicator is on The unit stops operating The green indicator is turned off After approx three seconds The unit beeps three times If the unit is required to operate at this time press RESET button once more or use the remote controller to turn it on 1 The power supply to the unit must be ON The function will not set or reset if the po...

Page 44: ...rating The green indicator is turned off After approx three seconds The unit beeps three times The green indicator flashes for 5 seconds If the unit is required to operate at this time press RESET button once more or use the remote controller to turn it on 9 3 2 How to Set the Auto Restart Function To set Auto Restart Function proceed as follows 1 The power supply to the unit must be ON The functi...

Page 45: ...perature 9 4 Remote control 9 4 1 Remote Controller and Its Functions Note The provided Remote Controller is a wireless type which also can be used as a wire Please see How to Connect The Remote Controller for Wired Operation located in installation instruction in case of wired control is required In wire operation remote controller will return to initial condition PRESET TIMER and CLOCK will retu...

Page 46: ...esired ON timer Press Set the desired OFF timer Press Set the timer Press Set the timer Press Cancel the timer Press Press Set the ON timer Press Press Set the OFF timer Press button during the or mark flashing 1 1 2 3 2 3 3 4 Daily timer allows the user to set both the ON OFF timers and will be activated on a daily basis Setting Daily Timer During the daily timer is activation both arrows are ind...

Page 47: ...mp blink 5 time sec for 5 seconds Do not operate ON timer and OFF timer 2 Press and hold the RESET button on the 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 Start and stop the operation Note Under certain conditions QUIET operation may not p...

Page 48: ... set B appears in the remote controller display When the remote controller setting is A there is no indication at this position 10 Comfort sleep Indicates when comfort sleep is activaled Push comfort sleep button to select 11 Quiet Indicates when quiet is activated Push quiet button to start and push it again to stop operation 12 One Touch Indicates when one touch comfort is activated Push one tou...

Page 49: ...tom right Rear left Bottom left Insulate the refrigerant pipes separately with insulation not together 8 mm thick heat resisting polyethylene foam 8 Flat head wood screw 3 Batteries 2 Wireless remote control 4 Remote control holder 8 Flat head wood screw 12 Flat head wood screw 13 Battery cover 6 Filter 5 Filter A B C D Vinyl tape Apply after carrying out a drainage test Saddle Extension drain hos...

Page 50: ... polyethylene foam 8 mm thick Putty PVC tapes Drain outlet Air inlet Air outlet 125 mm 108 mm Ø25 mm 28 mm 320 mm 106 mm 121 mm 99 mm 600 mm Fig 10 2 1 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 9 and cap water proof 10 to the bottom...

Page 51: ...ontrol holder x 1 Filter x 1 Part No 4 5 6 Part No Others Name Owner s manual Installation manual Part name Q ty 11 Filter x 1 Battery cover x 1 7 10 Mounting screw 4 x 25 s x 6 Flat head wood screw 3 1 x 16 s x 2 Flat head wood screw 3 1 x 25 s x 1 Screw 4 x 10 s x 2 8 9 12 13 The part marked with asterisk is packaged with the outdoor unit Drain nipple x 1 Cap water proof x 2 ...

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: ...pipe hole brim ring sold separately Mounting the installation plate Fig 10 3 2 m from the right side edge is e center of pipe hole 35 120 180 240 23 mm 65 mm The center of the pipe hole is above the arrow Pipe hole Fig 10 3 1 Fig 10 3 3 FILE NO SVM 13003 5 4 45 5 7 Top view Reception range Remote control Remote control Side view Indoor unit I ndoor unit R e c e p t i o n r a n g e To unit out line...

Page 54: ...rection FILE NO SVM 13003 l 10 3 3 Wiring Connection How to connect the connecting cable Wiring the connecting cable can be carried out without removing the front panel 1 Remove the air inlet grille Open the air inlet grille upward and pull it toward you 2 Remove the terminal cover and cord clamp 3 Insert the connecting cable according to the local rule into the pipe hole on the wall 4 Take out th...

Page 55: ...mote controller by sliding down and take it out 2 If batteries are exist please take them out The combination of using wire controller and batteries may cause of batteries explosion 3 Make hole for insert control wire by use screwdriver break the polyester sheet as shown on figure 7 4 Insert control wire from rear side of remote controller as shown on figure 8 5 Fix control wire which arrange as s...

Page 56: ...hanging drain hose For leftward connection bottom leftward connection and rear leftward connection s piping it is necessary to change the drain hose and drain cap How to remove the drain cap Clip the drain cap by needle nose pliers and pull out Fig 10 3 13 C Die cutting front panel slit Changing drain hose Piping preparation Rear right Rear left Bottom left Left Bottom right Right 1 Die cutting fr...

Page 57: ...pipe so that it is laid within 43 mm above the wall surface If the connecting pipe is laid exceeding 43 mm above the wall surface the indoor unit may unstably be set on the wall When bending the connecting pipe make sure to use a spring bender so as not to crush the pipe Refer to the table below for the bending radius of each connection pipe Fig 10 3 19 NOTE If the pipe is bent incorrectly the ind...

Page 58: ...ing the indoor unit onto the wall hook it at the lower part on the installation plate Pull the indoor unit toward you to confirm that it is firmly hooked on the installation plate For detaching the indoor unit from the installation plate pull the indoor unit toward you while pushing its bottom up at the specified parts Push Push Push unhook 1 Installation plate Hook here 2 Hook 1 Fig 10 3 22 Fig 1...

Page 59: ...ge can result in dew dropping This air conditioner has the structure designed to drain water collected from dew which forms on the back of the indoor unit to the drain pan Therefore do not store the power cord and other parts at a height above the drain guide Space for pipes Wall Drain guide Fig 10 3 26 ...

Page 60: ...ot use a double stacked design To protect the outdoor unit from snow accumulation install a holding frame and attach a snow protection CAUTION 1 Insall the outdoor unit in a location where there are no obstructions near its air intake or air outlet 2 When the outdoor unit is installed in a place that is always exposed to strong wind like on the coast or on a high story of a building secure the nor...

Page 61: ...e the refrigerant in the outdoor unit For details see the manual of the vacuum pump Using a vacuum pump Be sure to use a vacuum pump with counter flow prevention function so that inside oil of the pump does not flow backward into pipes of the air conditioner when the pump stops 1 Connect the charge hose from the manifold valve to the service port of the packed valve at gas side 2 Connect the charg...

Page 62: ... CAUTION 10 4 5 Wiring connection 1 Remove the valve cover the electric parts cover and the cord clamp from the oudoor unit 2 Connect the connecting cable to the terminal as identified by the matching numbers on the terminal block of indoor and outdoor unit 3 Insert the power cord and the connecting cable carefully into the terminal block and secure it tightly with screws 4 Use vinyl tape etc to i...

Page 63: ... 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 remote control to B setting Both are set to A setting in factory shipment The remote control signal is not received when the settings of indoor unit and remote control are ...

Page 64: ...re Information The product was shipped with Auto Restart function in the off position Turn it on as required How to set the auto restart 1 Press and hold the RESET button on the indoor unit 3 seconds to set the operation 3 beep sound and OPERATION lamp blink 5 time sec for 5 seconds 2 Press and hold the RESET button on the indoor unit for 3 seconds to cancel the operation 3 beep sound but OPERATIO...

Page 65: ...ase of touching parts on the P C board by hand The new inverter 3DV inverter will be incorporated starting with this unit 3DV 3 shunt Discrete Vector control The control circuitry has an uninsulated construction Fig 11 1 IGBT 6 FET 6 MCU Compressor Fan motor Shared potential Driver Driver Amplifier Amplifier No 1 2 3 4 5 6 7 8 9 10 Troubleshooting Procedure First Confirmation Primary Judgment Judg...

Page 66: ... the components Do NOT lay the circuit board assembly flat Precautions when inspecting the control section of the outdoor unit NOTE A large capacity electrolytic capacitor is used in the outdoor unit controller inverter Therefore if the power supply is turned off charge charging voltage DC280 to 380V remains and discharging takes a lot of time After turning off the power source if touching the cha...

Page 67: ...rated Increasing of compressor motor speed stops approx 30 seconds after operation started and then compressor motor speed increases again approx 30 seconds after In AUTO mode the operation mode is changed In HEAT mode the compressor motor speed does not increase up to the maxi mum speed or decreases before the temperature arrives at the set temperature Description The OPERATION lamp of the indoor...

Page 68: ... operation of the air conditioner 3 When item B and C or item B and apart of item E occur concurrently priority is given to the block of item B 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 display 5 Hz OPERATION Green Flashing display 5 Hz Protective c...

Page 69: ...on 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 ON or OFF button to change the check code backward If there is a fault the indoor unit will beep for 10 seconds B...

Page 70: ...oom Operation Flashes when 1 Check the sensor TA and connection board temperature sensor is continues error is detected 2 In case of the sensor and its short Circuit or disconnection connection is normal check the P C board TC sensor The heat Operation Flashes when 1 Check the sensor TC and connection exchanger temperature continues error is detected 2 In case of the sensor and its sensor of the i...

Page 71: ...or unit open 4 The outdoor unit abnormal stop at circuit of signal some time Signal circuit of indoor If the other check codes are found P C board or outdoor concurrently check them together P C board is failure Check protector hardware such in some period as Hi Pressure switch Thermal Relay etc Check refrigerant amount or any possibility case which may caused high temperature or high pressure Che...

Page 72: ...resistance of compressor winding If circuit is shortage replace the compressor Current detect circuit of All OFF Flashes after Even if trying to operate again all inverter P C board error error is detected operations stop replace inverter 4 times P C board TE sensor The heat All OFF Flashes after 1 Check sensors TE TS and connection exchanger temperature error is detected 2 In case of the sensors ...

Page 73: ...rror count comes 4 times record error to check code But after re starting operation if no error is detected and air conditioner can operate more than 6 minutes error count is cleared The others Return signal of the outdoor Indoor unit Flashes when 1 Check power supply Rate 10 including unit has been sent when operates error is detected 2 If the air conditioner repeat operates compressor operation ...

Page 74: ...sound of initial operation etc 4 Observe any possibility cause which may affect high temperature of compressor Compressor is high current All OFF Flashes after 1 Check installation conditions such as though operation Hz is error is detected packed valve opening refrigerant decreased to minimum limit 4 times amount and power supply rate 10 Installation problem both of operation and non operation In...

Page 75: ...N10 1 3 short circuit Item by symptoms Operation Check Item Considerable principle cause Measures Remote controller is defective Refer to 5 Troubleshooting for remote controller Unit operates normally Replace main P C board Replace fan motor Is fuse F01 of indoor control board blown Microcontroller is defective NO NO NO NO NO YES YES YES YES YES YES Point remote to digital camera Can see infrared ...

Page 76: ...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 between 5 and 3 of motor connector CN31 Is it possible to detect DC 294 325V between 1 and 3 of motor connector CN31 Motor connection condition Is it possible to detect DC 15V between 4 and 3 of motor connector CN...

Page 77: ...evel to HIGH Is it possible to rotate cross flow fan by hand properly Fan motor operates normally Replace bearing of cross flow fan YES YES YES NO NO NO Does check cross flow fan bearing normal condition Replace indoor fan motor Peplace main P C board Does check display on remote show high Change the new PC board Does fan speed change Replace remote Replace motor NO NO NO YES YES YES 76 A B FILE N...

Page 78: ...ore 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 3 2 1 Remove the grille 3 2 2 Remove the cover terminal by release one screw 3 2 3 Check DC voltage with CN31 connector while the fan motor is rotating 1 Turn on breaker 2 After Fan motor oper...

Page 79: ...tton Is transmission mark indicated Reciver P C board is defective Replace reciver 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 Push the button Does indoor unit beep and operate Reset by take off battery the push button till LCD 5 Troubleshooting for remote controller Primary check Check that ...

Page 80: ...rom 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 5 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while after operation started...

Page 81: ... pressure from service port and add gas if pressure is low Is connecter of coil connected to inverter Is coil of the pulse motor valve P M V correctly set Existence of condensation at outlet of P M V If there is condensation at outlet 1 4 inch Ø6 35mm valve side the valve is clogged Are temp sensors of indoor outdoor units correctly set to the holder NOTE The temperature sensors which are used to ...

Page 82: ... failure Remove connector of compressor Replace control board Check terminal Voltage of electrolytic capacitor are in Voltage Rate Turn ON power Supply NO 10 x 1 414 Replace control board NO Cooling 17 C Connect discharge resistance approx 100Ω 40W or soldering iron plug between terminals of the electro lytic capacitor 760µF of C14 with printed CAUTION HIGH VOLTAGE on P C board Discharging positio...

Page 83: ... CN300 of outdoor fan motor Check winding resistance by ohmmeter are correct Check rotor locking by rotate Turn OFF power supply Replace outdoor fan motor NO Replace compressor Replace control board Replace compressor YES Does compresser operate normally with hand Can it rotate Turn OFF power supply Check compressor winding resistance correct is in rate A NO NO YES NO FILE NO SVM 13003 ...

Page 84: ...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 connec tors on the P C board hold the whole housing Do not pull at the lead wire 11 8 2 How to shorten time for start the compressor 1 Turn on remote 2 Setting requirment o...

Page 85: ... 10 20 30 40 50 Resistance value kΩ 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 FILE NO SVM 13003 ...

Page 86: ...TE Checking procedure Measure the resistance value of each winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Under 20 C Measure the resistance value of winding by using the tester Under 20 C Disconnect the connector and measure resistance value with the tester Normal temperature ...

Page 87: ...k that electrolytic liquid does not blow off 6 Check that the normal charging characteristics are shown in continuity test by the tester 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 760µF 400V 1 Turn OFF the power supply breaker 2 Completely discharge the four electrolytic capacitors 3 ...

Page 88: ...f 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 lea...

Page 89: ...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 90: ...pcs 6 Take off four 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 4 pcs at the top side of the front panel to the rear plate 2 Tighten four screws Incomplete hanging or incomplete pressing may cause a dewdrops or generation of a fluttering sound 2 Screws Three hooks 4 Scr...

Page 91: ...ly 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 top of t...

Page 92: ...zontal louver leftward Evaporator Heat exchanger 1 Follow to the procedure in the item 2 Remove the pipe holder from the rear side of the main unit 3 Remove two fixing screws at the left side of the end plate of the heat exchanger Remarks 4 Remove two fixing screw on the heat exchage fixing holder to separate the heat exchage from the back body Screw Screw 2 Screws FILE NO SVM 13003 ...

Page 93: ...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 Two screws Bearing Bearing base FILE NO SVM 13003 ...

Page 94: ...rew 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 Two screws on motor band Two screws on motor cover FILE NO SVM 13003 ...

Page 95: ... 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 assembling the two fixin...

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 3 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: ...nect them they must be pressed in the direction of the arrow while pulling them out P C board base P C board CN700 CN602 CN300 CN701 CN603 CN601 CN600 FILE NO SVM 13003 CN703 CN703 Heater 2P White NOTE These connectors have a disconnect prevention mechanism as such the lock on their housing must be released before they are disconnected 2 Remove the control board assembly from the P C board base Re...

Page 100: ...at 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 does n...

Page 101: ... 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 2 pcs 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 102: ...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 13003 1 Detachment 1 Perform step 1 in all the steps in and 1 in 2...

Page 103: ...structed The product will not be controlled properly and trouble will result if the sensors have not been installed in their proper positions Detail C 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 upw...

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: ...OR RIGHT DOWN 204 43T80331 FILTER AIR 215 43T44031 EVAPORATOR ASSY 205 43T09040 LOUVER HORIZONTAL 216 43T19333 HOLDER SENSOR 206 43T70313 HOSE DRAIN 217 43T49010 PIPE SHIELD 207 43T79313 CAP DRAIN 218 43T82008 PLATE INSTALLATION 208 43T21371 MOTOR FAN 219 43T49043 HOLDER PIPE 209 43T20016 FAN ASSY CROSS FLOW 220 43T62031 COVER TERMINAL 210 43T39021 BASE BEARING 221 43T66315 WIRELESS REMOTE CONTROL...

Page 106: ... Part No No No No 401 43T50308 SENSOR HEAT EXCHANGER 405 43T6V316 PC BOARD ASSY WRS LED 402 43T60331 TERMINAL 3P 407 43T69966 PC BOARD ASSY 403 43T69320 TEMPERATURE SENSOR 412 43T21397 STEPPING MOTOR 404 43T62003 CORD CLAMP 413 43T60386 MOTOR CORD Description Description ...

Page 107: ... ASSEMBLY 25 43T46343 4 WAY VALVE 10 43T46358 VALVE PACKED 6 35 DIA 26 43T63320 4 WAY VALVE COIL ASSEMBLY 11 43T46374 VALVE PACKED 12 7DIA H4 27 43T63319 HOLDER SENSOR 12 43T47331 BONNET 6 35 DIA 28 43T79305 DRAIN NIPPLE 13 43T47333 BONNET 12 70 DIA 29 43T39341 MOTOR BASE CONNECTION PLATE 14 43T00448 FIXING PLATE VALVE 30 43T63318 HOLDER SENSOR 15 43T00563 RIGHT SIDE CABINET ASSEMBLY 31 43T63317 H...

Page 108: ...03 Location Part Location Part No No No No 701 43T62331 HEATSINK 705 43T60377 TEMPERATURE SENSOR 702 43T69965 PC BOARD 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60392 TERMINAL 5P 707 43T62313 BASE PLATE PC 704 43T60326 FUSE Description Description ...

Page 109: ...TOSHIBA CARRIER THAILAND CO LTD ...

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Toshiba RAS-22N3AV2-A, Service Manual

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