Toshiba RAS-25J2AVSG-ND Service Manual Download Page 123

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144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI,

AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

Summary of Contents for RAS-25J2AVSG-ND

Page 1: ...SERVICE MANUAL R32 Indoor Unit RAS 25J2KVSG ND RAS 35J2KVSG ND SPLIT TYPE Outdoor Unit RAS 25J2AVSG ND RAS 35J2AVSG ND Revised on July 2020 FILE NO SVM 20065 3 ...

Page 2: ...EWS 16 5 WIRING DIAGRAM 18 6 SPECIFICATIONS OF ELECTRICAL PARTS 19 7 REFRIGERANT CYCLE DIAGRAM 20 8 CONTROL BLOCK DIAGRAM 23 9 OPERATION DESCRIPTION 25 10 INSTALLATION PROCEDURE 61 11 HOW TO DIAGNOSE THE TROUBLE 78 12 HOW TO REPLACE THE MAIN PARTS 105 13 EXPLODED VIEWS AND PARTS LIST 119 2 ...

Page 3: ...prevent mixing of refrigerant or refrigerating machine oil the sizes of connecting sections of charging port on main unit and installation tools are different from those used for the conventional refrigerant units Accordingly special tools are required for the new refrigerant R32 units For connecting pipes use new and clean piping materials with high pressure fittings made for R32 only so that wat...

Page 4: ...IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE WORK AND THE INSTALLATION WORK IMMEDIATELY LET FRESH AIR INTO THE ROOM IF THE REFRIGERANT GAS IS HEATED SUCH AS BY FIRE GENERATION OF POISONOUS GAS MAY RESULT WARNING Never modify this unit by removing any of the safety guards or bypassing any of the saf...

Page 5: ... occur In case gas leaks and accumulates at surrounding of the unit it may cause of ﬁre Do not install in a place that can increase the vibration of the unit Do not install in a place that can amplify the noise level of the unit or where noise and discharged air might disturb neighbors To avoid personal injury be careful when handling parts with sharp edges Please read this installation manual car...

Page 6: ...13 8 12 3 14 0 Outdoor unit Unit model RAS 25J2AVSG ND RAS 35J2AVSG ND Dimension Height mm 550 550 Width mm 780 780 Depth mm 290 290 Net weight kg 38 38 Compressor Motor output W 1100 1100 Type Model DX136A1T 40N Fan motor output W 43 Air flow rate Cooling Heating m3 min 32 0 32 0 33 0 33 0 Piping Type Flare connection connection Indoor unit Liquid side mm 6 35 Gas side mm 9 52 Outdoor unit Liquid...

Page 7: ... DB 20oC WB 15oC Outdoor DB 7oC WB 6oC Indoor Air Flow High Pipe Length 5m Voltage 230V 0 0 20 0 40 0 60 0 80 0 100 0 120 0 25 20 15 10 5 0 5 10 Heating Capacity ratio Outside Temperature ºC RAS 25J2KVSG ND RAS 35J2KVSG ND 50 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 0 100 0 105 0 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Cooling Capacity ratio Outside Temperature oC Conditions Indoor DB 27o...

Page 8: ...ers in places where installation repairs or similar work on air conditioning equipment is performed 3 If a refrigeration gas leakage occurs during installation servicing be sure to ventilate fully If the refrigerant gas comes into contact with fire a poisonous gas may occur 4 When installing or removing an air conditioner do not allow air moisture dust or oil to remain in the refrigeration cycle O...

Page 9: ...s of socket 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 inst...

Page 10: ...pe 0 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...

Page 11: ...ning torque for R32 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 manu...

Page 12: ...ifold Charge hose Vacuum pump adapter Electronic balance for refrigerant charging Leakage detector Usage Pipe flaring Flaring by conventional flare tool Connection of flare nut Evacuating refrigerant charge run check etc Vacuum evacuating Refrigerant charge Gas leakage check R32 R410A air water heat pump installation Existence of new equipment for R32 Yes Yes Yes Yes Yes Yes Yes Whether conven tio...

Page 13: ...er and 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 ...

Page 14: ...ler 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 for refrigerant pipes 1 Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution which may cau...

Page 15: ... use 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 t...

Page 16: ...er holder 149 63 17 5 57 Wireless remote controller 18 193 800 Knock out system 50 7 55 226 Air filter Air filter Air outlet 293 Heat exchanger Front panel Grille inlet 50 7 55 66 5 50 50 55 66 5 50 114 340 Installation plate hanger 131 131 140 131 120 24 Installation plate hanger Drain hose 0 5m Installation plate hanger Flare 6 35mm Connecting pipe 0 58m Flare 9 52mm Connecting pipe 0 63m 24 97 ...

Page 17: ... Ø38 Drain outlet FAN GUARD COVER PV Liquid side Flare 6 35 Ø Gas side Flare 9 52 Service port 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 69 Unit mm 340 17 ...

Page 18: ...HI MS Communication BLK 3 Circuit 3 Switching FM BLK Power WHI Supply CN501 CN600 CN601 CN602 CN603 CN700 CN703 CN705 GRN WHI WHI WHI WHI WHI YEL WHI 1 2 3 L N 1 3 1 2 1 2 3 1 2 1 2 3 1 2 3 4 5 6 1 3 1 3 Fuse Fuse T1A T1A 20SF 250V 250V Color Indication 1 2 P t t t t BLK BLACK WHI WHITE 63H TE TD TO TS PMV GRN GREEN YEL YELLOW ORN ORANGE Power Supply RED RED From Main Line HT 3 P21 WHI WHI P22 18 ...

Page 19: ... 7 Discharge temp sensor TD sensor Inverter attached 62kΩ at 20 C 8 Outside air temp sensor TO sensor Inverter attached 9 Heat Exchanger temp sensor TE sensor Inverter attached 10kΩ at 25 C 10 Terminal block 6 poles JX0 6B AC 250V 30A Parts name 10kΩ at 25 C STF H01AJ1872A1 AC 220 240V No Type name Specifications 1 Fan Motor for indoor 2 Room temp sensor TA sensor 10kΩ at 25 C 3 Heat exchanger tem...

Page 20: ... 35mm Thickness 0 8mm Sectional shape of heat insulator Allowable height difference 12m Allowable pipe length Strainer Pulse Modulating valve at liquid side Ø1 2 x 80 Ø1 2 x 80 TD 4 way valve Compressor DX136A1T 40N TS T2 Outdoor heat exchanger Split capillary Temp measurement Refrigerant amount 0 76kg Propeller fan OUTDOOR UNIT Muffler Muffler TE TC TA The maximum pipe length of this air conditio...

Page 21: ...al shape of heat insulator Allowable height difference 12m Allowable pipe length Strainer Pulse Modulating valve at liquid side Ø1 2 x 80 Ø1 2 x 80 TD 4 way valve Compressor DX151A1T 30N TS T2 Outdoor heat exchanger Split capillary Temp measurement Refrigerant amount 0 76kg Propeller fan OUTDOOR UNIT Muffler Muffler TE TC TA The maximum pipe length of this air conditioner is 15 m When the pipe len...

Page 22: ... ND 1 0 to 1 1 12 to 13 43 to 44 High High 35 Tempeature condition C Heat exchanger pipe temp Connecting piping m 5 Model name Standard Indoor Outdoor Compressor pressure fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 7 6 RAS 25J2KVSG ND 2 1 to 2 2 34 to 35 2 to 3 High High 40 Tempeature condition C Heat exchanger pipe temp Connecting piping m Heating RAS 25J2KVSG ND 14 to 15 4...

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

Page 24: ...nt Detector P M V Pulse Modulating Valve M C U Micro Control Unit For INDOOR UNIT 4 way valve P M V Inverter DC AC Inverter DC AC Outdoor Fan motor Compressor WP 044 P C B OUTDOOR UNIT Current detect Current detect M C U PWM synthesis function Input current release control IPM over current detect control Outdoor fan control High power factor correction control Inverter output frequency control A D...

Page 25: ... of operation command signal Serial signal from outdoor unit controller to indoor unit controller The following signals are sent from the outdoor unit controller The current operation mode The current compressor revolution Outdoor temperature Existence of protective circuit operation For transferring of these signals the indoor unit controller monitors the contents of signals and judges existence ...

Page 26: ...f Cleaning function 41 17 Remote A or B selection 43 9 3 Auto Restart Function 9 3 1 How to Set the Auto Restart Function 49 9 3 2 How to Cancel the Auto Restart Function 50 9 3 3 Power Failure During Timer Operation 50 9 4 Remote Controller and Its Fuctions 9 4 1 Parts Name of Remote Controller 51 9 4 2 Operation of remote control 51 18 Hi POWER Mode 43 9 4 3 Name and Functions of Indications on ...

Page 27: ...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 Timer function Indoor heat exchanger release control Indoor fan motor Louver motor Outdoor unit Outdoor unit control Frequency control of inverter output Wavefo...

Page 28: ...ting the 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 ...

Page 29: ...rature and heat exchanger temperature Fig 1 Fig 2 2 5 Ta C 2 0 1 5 1 0 0 5 Tsc a b c d e M WC 3 4 5 L W7 Air volume AUTO L L M M H W7 L M 2 WA M H 2 WD Indication Fan speed Fan speed setup COOL ON AUTO MANUAL 3 Fan speed M L x 3 4 L 4 Fan speed M L x 2 4 L 5 Fan speed M L x 1 4 L Linear approximation from M and L Table 1 Indoor fan air flow rate Fan speed Mode RAS 25J2KVSG ND level Cooling Heating...

Page 30: ...b 0 5 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...

Page 31: ...the motor stopped Air conditioner ON Remote controller YES YES NO NO Indoor unit controller Fan motor ON 3 Fan lock OFF status of fan motor continues 4 Motor operates as shown in the table below 1 Outdoor unit operation command Outdoor fan control Air conditioner OFF Alarm display Outdoor fan speed rpm In cooling operation In heating operation RAS 25J2AVSG ND Hz 13 8 13 8 Hz 32 4 32 4 Hz RAS 25J2A...

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

Page 33: ...he compressor 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 operati...

Page 34: ...considered Defrost zone In normal TO In abnormal TO A zone TO 10 C TE0 TE TO0 TO 3 C SH SH0 2 TE0 TE 3 C SH SH0 2 B zone TO 10 C TE0 TE TO0 TO 2 C SH SH0 2 TE0 TE 2 C SH SH0 2 C zone To 10 C TE 25 C SH SH0 2 D zone TO 10 C Accumulate heating operation time e minute TE 0 C E zone TO 10 C accumulate heating operation time e min No E zone If TO sensor is abnormal TO value is fixed at 10 C Returning f...

Page 35: ...ontrol Only in heating operation Strong defrost Upgrade defrost ability when normal defrost ability is not enough by increase defrosting finished operation Finish of defrost operation for strong defrost Do cut the jumper J803 on CDU PCB Returning conditions from defrost operation to heating operation 1 Temperature of outdoor heat exchanger rises to 13 C or higher 2 Temperature of outdoor heat exch...

Page 36: ...e air direction of the indoor unit Description 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 0 1 Louver position in cooling operation mode COOL HEAT and the louver returns to the s...

Page 37: ...wer Limit Position 30 o 5 o Swing range 35o SWING button during operation the louver starts swinging Upper Limit Position Lower Limit Position Fixed Position before start swing 17 5 o 17 5 o Swing range 35o 4 HADA CARE Position Air flow upward to the ceiling provide indirect air flow to body and homogenize room temperature HADA care Louver position Initial setting of Cooling storage position Louve...

Page 38: ...me Compressor speed 0Hz A zone aHz B zone a to cHz C zone cHz 0 0 5 1 0 1 5 2 0 2 5 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 Room temp Set temp 3 5 3 0 2 5 1 5 1 0 TSC 1 0 2 0 5 5 1H 2H 11 10 7 6 5 4 3 2 1 OFF Dry Max 12 11 9 8 10 TA 6 0 6 5 3H 4H 5 0 4 5 4 0 2 0 0 5 0 5 12 9 8 Time Zone Frequency FAN Min Hz Fan speed depend on presetting and can change every speed 1 The control target temperature in...

Page 39: ... control 1 Purpose This function detects error on the refrigerating cycle or error on the com pressor and performs protective control 2 Operation Control of the compressor speed The speed control is performed as described in the left table based upon the discharge temperature Td value 117 C 115 C 106 C 103 C 96 C Control operation Judges as an error and stops the compressor Reduce the compressor s...

Page 40: ... it is in the range of set tempera ture Discharge temp control 4 When defrost operation is performed the open degree of valve is adjusted accord ing to each setup conditions during preparation for defrost and during defrost operation 4 way valve is inversed 5 To turn off the compressor while the air conditioner stops by control of the thermostat or by remote controller adjust the open degree of va...

Page 41: ...of the 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 slightl...

Page 42: ...oller to confirm setting Note Table above will show current status of Self Cleaning function Set or Cancel Self Cleaning function by push the RESET button on air conditioner When setting is changed the sound warning will alarm Beep The setting is changed following below 14 1 2 Self Cleaning function release How to set cancel Self Cleaning function To set cancel the Self Cleaning function proceed a...

Page 43: ... the Remote Control by the tip of the pencil 00 will be shown the air conditioner ON shown on the display Picture 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 is memorized Picture 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 C...

Page 44: ...ER SELECTION AND SILENT OPERATION Silent button on remote controller is pressed Silent 1 Cooling heating capacity is limited maximum for 70 of rated Only compressor speed is limited Silent 2 CDU sound level is limited for lowest CDU sound level Compressor and CDU fan speed are limited This function is used when the user need to keep silent at outdoor side It is limit maximum compressor speed and C...

Page 45: ...r can be reduced As the maximum number of revolution of the compressor is restricted the rise up performance at the start time is weakened Select Conrol or No conrol by keeping RESET button pushed for 20 seconds No control at shipment from the factory Exchanging from No control to Control Beep sound is heard Pi Pi Pi Pi Pi and the operation LED 5Hz flashes for 5 seconds Exchanging from Control to ...

Page 46: ...jective heating operation 8 C heating operation 8 C Normal operation 8 C Normal operation Fireplace 1 Fireplace 2 Fireplace 1 Fireplace 2 22 QUIET mode Quiet mode is the system which control the revolving speed of indoor fan to work constantly at lower than speed L In addition noise level of indoor unit is less than usual Remarks 1 2 Quiet mode is unable to work in dry mode Quiet mode is appropria...

Page 47: ...de Heating mode The preset temperature will drop down as show on ECO operation Item No 9 Press the COMFORT SLEEP button to choose the operating hours Repeat pressing to setect thehours 1hr 3hr 5hr or 9 hr If the COMFORT SLEEP button is pressed again means cancel comfort sleep mode SLEEP mode To decrease the display lamp brightness or turn it off Press and hold 1 FAN for 3 seconds until brightness ...

Page 48: ...SET button to make 00 disappear j Press button to turn the unit OFF k Set the operation mode or plasma air sending the signal to the unit l Use the tip of the pencil to push the m Press button to turn the unit ON n When short timer is activated all setting on the remote operates immediately besides all indicatiors on front panel turns ON continuously for 3 seconds 3 4 27 Cord Heater Control 2 1 Pu...

Page 49: ...reset if the power supply is OFF 2 Press the RESET button located on the front panel of the indoor unit for more than 3 seconds 3 After 3 seconds the unit beeps three times When the system is on stand by not operating When the system is operating 9 3 Auto Restart Function This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set oper...

Page 50: ...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 function will not set or reset if the power supply is OFF 2 Press the RESET button located on the front panel of the indoor unit for more than 3 seconds 3 After 3 seco...

Page 51: ...d 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 return to initial condition when user shutdown power supply of Air conditioner 1 Infrared ...

Page 52: ... PG 1 appears on the LCD Press to change the program number in the sequence program 1 to program 4 PG 1 PG 2 PG 3 4 PG 4 Press or to select the desired time The time can be set between 0 00 and 23 50 in 10 minute intervals Press and hold the button to change setting time for 1 hr Only one of ON or OFF timer can be set on each program ON timer display OFF timer display OFF timer is used to stop the...

Page 53: ...desired fan speed 8 Add operations if required 6 Press 7 Press Press to use 8 C operation Notes Fireplace cannot select and memorize in weekly function Press Press Press to use ECO operation to use Hi POWER operation to use SILENT operation 9 Adding or editing the program The program can be set to perform on all the required days until is pressed to confirm the setting 10 If adding or editing a pr...

Page 54: ...r to be Resetting the operation 1 Press 2 Press press conf rmed 3 Press to exit confirming mode Deactivating WEEKLY TIMER operation Press while WEEKLY is displayed on the LCD The WEEKLY indicator will disappear from the LCD However the program will remain in the remote control The TIMER lamp goes off To reactivate the WEEKLY TIMER operation again press again LCD shows the next program The program ...

Page 55: ...ll blink to delete the program 2 Press deleted 3 Press 4 Press Press while the LCD is blinking The program has now been deleted All programs The day of the week and the program number will be displayed 1 Press 2 Press and hold for 3 seconds All programs will be deleted and LCD displays current operation Notes Make sure the remote control receiving module on the air conditioner receives the signal ...

Page 56: ...r low speed programmed from factory 8 C Heating Operation 8 C Heat mode operation for keep room temperature 5 13 C with less of energy usage Fireplace and 8 C Heating Operation 8 C FIREPLACE 1 FIREPLACE 2 Normal operation Note While Fireplace operation on heating mode indoor unit fan always runs and cold air breezing might be occurred Fireplace and 8 C will operate in Heating mode only 4 COOLING H...

Page 57: ...FORT SLEEP OPERATION For comfortable sleep automatically control air flow and automatically turn OFF Except in DRY mode 1 Press Select 1 3 5 or 9 hrs for OFF timer operation Note The cooling operation the set temperature will increase automatically 1 degree hour for 2 hours maximum 2 degrees increase For heating operation the set temperature will decrease 2 Press to cancel the comfort sleep operat...

Page 58: ...will have a tight sleep in nighttime By this feature the heating capacity will be optimized to deliver such silent experience The silent operation can be selected from one of two purposes Silent 1 and Silent 2 There are three setting parameters Standard level Silent 1 Silent 2 Silent 1 Though operating silently the Heating or Cooling capacity is still prioritized to ensure having suff cientcomfort...

Page 59: ...r the next same operation 12 PRESET OPERATION Set your preferred operation for future use The setting will be memorized by the unit for future operation except air flow direction 1 Select your preferred operation for 3 seconds to memorize the setting The P mark 2 Press and hold displays 3 Press Operate the preset operation 13 AIR FLOW DIRECTION 1 Press FIX Move the louver in the desired vertical d...

Page 60: ...tart and press it again to stop the operation 8 PRESET indicator Flashes for 3 seconds when the PRESET button is pressed during operation The mark is shown when holding down the button for more than 3 seconds while the mark is flashing Press another button to turn off the mark 9 POWER SEL 10 A B change indicator remote controller When the remote controller switching function is set B appears in th...

Page 61: ...by installer Shield pipe Air filter Hook Installation plate Hook 65 mm or more 300 mm or more 300 mm or more 600 mm or more 100 mm or more 100 mm or more 600 mm or more 600 mm or more Make sure to run the drain hose sloped downward Do not allow the drain hose to get slack Cut the piping hole sloped slightly Refrigerant piping must be protected from physical damage Install a plastic cover or equiva...

Page 62: ...am 6 mm thick 1 C Putty PVC tapes One each Drain outlet Air inlet Air outlet 108 mm 28 mm 600 mm 320 mm 125 mm 86 mm 102 mm 90 mm Ø 3 8 m m 340 mm Secure the outdoor unit with fixing bolts and nuts if the unit is likely to be exposed to a strong wind Use Ø8 mm or Ø10 mm anchor bolts and nuts If it is necessary to drain the defrost water attach drain nipple and cap water proof to the bottom plate o...

Page 63: ...ounting screw 6 7 8 9 Owner s Manual 1 Outdoor Unit Part name No Part name No Cap water proof 2 Air filters Clean every 2 weeks 1 Open the air inlet grille 2 Remove the air filters 3 Vacuum or wash and then dry them 4 Reinstall the air filters and close the air inlet grille Flat head wood screw 2 Installation Manual 1 Flat head wood screw 1 Battery cover Drain nipple 1 63 ...

Page 64: ...ort 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 B...

Page 65: ...utting a hole and mounting installation Cutting a hole When installing the refrigerant pipes from the rear 1 After determining the pipe hole position on the mounting plate A drill the pipe hole 65 mm at a slight downward slant to the outdoor side NOTE When drilling a wall that contains a metal lath wire lath or metal plate be sure to use a pipe hole brim ring sold separately Mounting the installat...

Page 66: ...ward you to remove it as shown on ﬁgure 1 Arrange the control wire as detail and speciﬁcation as shown on ﬁgure 2 Securely connect the control wire to terminal of Display unit as shown on ﬁgure 3 tighten ﬁrmly but not over 0 12 N m 0 01 kgf m Set the control wire out from indoor unit same portion as power supply and connecting cable as shown on ﬁgure 3 Notch for wire out Reassembly the indoor unit...

Page 67: ...e Piping preparation 1 Die cutting back body slit Cut out the slit on the leftward or right side of the back body for the left or right connection and the slit on the bottom left or right side of the back body for the bottom left or right connection with a pair of nippers 2 Changing drain hose For leftward connection bottom leftward connection and rear leftward connection s piping it is necessary ...

Page 68: ...nect the auxiliary pipes and connecting pipes to each other and cut off the insulating tape wound on the connecting pipe to avoid double taping at the joint moreover seal the joint with the vinyl tape etc Since dewing results in a machine trouble make sure to insulate both the connecting pipes Use polyethylene foam as insulating material When bending a pipe carefully do it not to crush it Installa...

Page 69: ...ide Fig 10 3 16 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 17 CAUTION Arrange the drain pipe for proper drainage from the unit Improper drainage can result in dew dropping This air conditioner has the structure designed to drain water collecte...

Page 70: ... bear the weight of the outdoor unit and does not allow an increase in noise level and vibration A place where the operation noise and discharged air do not disturb your neighbors A place which is not exposed to a strong wind A place free of a leakage of combustible gases A place which does not block a passage When the outdoor unit is to be installed in an elevated position be sure to secure its f...

Page 71: ...r 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 Draining the Water 10 4 3 Refrigerant piping connection Flaring 1 Cut the pipe with a pipe cutter Fig 10 4 3 2 Insert...

Page 72: ...se 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 If oil inside of the vacuum pump enters into the air conditioner which use R32 refrigeration cycle trouble may result 1 ...

Page 73: ... kgf m 14 18 N m 1 4 to 1 8 kgf m A H Hexagon wrench is required Service Port Cap Valve Rod Cap CAUTION KEEP IMPORTANT 6 POINTS FOR PIPING WORK 1 Take away dust and moisture inside of the connecting pipes 2 Tighten the connections between pipes and unit 3 Evacuate the air in the connecting pipes using a VACUUM PUMP 4 Check gas leak connected points 5 Be sure to fully open the packed valves before ...

Page 74: ...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 insulate the cords which are not going to be used Locate them so that they do not touch any electrical or metal parts 5 Secure ...

Page 75: ... mm Connecting cable Earth line Earth line Power cord Power Supply Input at Indoor Unit Terminal Block Optional Indoor Unit Outdoor Unit Power supply cable connect to N t Terminal block L N 1 2 3 Earth line Power supply cable Power supply cable Stripping length of the power supply cable N L Earth line 50 mm 10 mm 70 mm 10 mm Connecting cable Earth line Connecting cable Connecting cable connect to ...

Page 76: ...7 Wrong wiring connection may cause some electrical part burn out 8 Incorrect or incomplete wiring is carried out it will cause an ignition or smoke 9 This product can be connected to main power supply Connection to fixed wiring A switch which disconnects all poles and has a contact separation at least 3mm must be incorporated in the fixed wiring CAUTION Power supply input Power supply input at Ou...

Page 77: ...tting 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 different There is no relation between A setting B setting and A room B room when connecting the piping and cables To separate using of remote control for each indoor unit in case of 2 air conditioner are installed near Remote Control B Setup 1 Press...

Page 78: ...eck service as the electric shock may be caused in case of touching parts on the P C board by hand The new inverter will be incorporated starting with this unit K The control circuitry has an uninsulated construction No 1 2 3 4 5 Troubleshooting Procedure First Confirmation Primary Judgment Judgment by Flashing LED of Indoor Unit Self Diagnosis by Remote Controller Judgment of Trouble by Every Sym...

Page 79: ...t parts without first turning off the power At times such as when the circuit board is to be replaced place the circuit board assembly in a vertical position Laying the board flat on an electrically conductive object such as the top panel of the air conditioner s outdoor unit while a charge is still retained by the electrolytic capacitors of the inverter s main circuit may cause short circuiting b...

Page 80: ...e charging section before discharging an electrical shock may be caused Discharge the electrolytic capacitor completely by using soldering iron etc Discharging method 1 Remove the inverter cover plating by opening four mounting claws 2 As shown below connect the discharge resistance approx 100Ω4 0W or plug of the soldering iron to voltage between terminals of the C09 C10 WARNING ELECTRIC SHOCK is ...

Page 81: ...erated 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 indoo...

Page 82: ...em 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 Flashing display 1 Hz OPERATION TIMER Flashing display 5 Hz OPERATION Flashing display 5 Hz OPERATION TIMER White Flashing display 5 Hz OPERATION Flashing display 5 Hz Protective circuit operation for indoor P C board Protective c...

Page 83: ...dicatesthe in formation of the self diagnosison the display of the remote controller with the check codes If a fault isdetected all lampson the indoor unit will flash at 5Hz and it will beep for 10seconds Beep Beep Beep The timer lamp usually flashes 5Hz during self diagnosis is indicated on the display of the remote controller Press ON OFF button to change the check code backward 2 digits alphanu...

Page 84: ...hort 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 indoor unit connection is normal check the is out of place disconnection P C board short circuit or migration Fan motor of the indoor unit All OFF Flashes...

Page 85: ...ard outdoor 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 pre...

Page 86: ... detect circuit of inverter P C board error error is detected 4 times Even if trying to operate again all operations stop replace inverter P C board All OFF Flashes after error is detected 4 times 1 Check sensors TE TS connection In case of sensors and it s connection is normal check the inverter P C board 2 Check 4way valve operation position In case TE TS detected temperature relationship are di...

Page 87: ...ut after continue Flashing stop and stop with interval of approx 10 that signal is stop some time Outdoor unit and outdoor unit to 40 minutes Instantaneous power stop start to operate Check protector hardware such failure when the return as Hi Pressure switch Some protector signal from the Thermal Relay etc hardware of the outdoor unit is Check refrigerant amount packed outdoor unit open normal va...

Page 88: ...n 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 8 times amount and power supply rate 10 Installation problem both of operation and non operation Instantaneous power conditi...

Page 89: ...ed error is count as 1 time then once operation is stop and re started After re starting operation within 6 minutes if same error is detected error count is add count become 2 times When error count comes 4 8 11 or 18 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 includi...

Page 90: ... controller Is voltage DC5V 12V and 15V indicated on rear of indoor control board nor mal Does transmission mark on remote controller flash normally and is its signal transmitted properly 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 fa...

Page 91: ...rd is replaced Confirmation procedure YES YES NO NO Turn on power supply Does operation lamp flash Is it wired as shown in Figure below Return the wiring of the power relay is returned to the normal procedure To the paragraph of No Power turns on 91 ...

Page 92: ...ck 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 CN36 Is it possible to detect DC 311 340V between 1 and 3 of motor connector CN36 Motor connection condition Is it possible to detect DC 15V between 4 and 3 of motor connector CN36 Is it possible ...

Page 93: ...nge airflow level 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 Replace 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 ...

Page 94: ...ove the cover of the fan motor lead wires 3 Check DC voltage with CN36 connector while the fan motor is rotating NOTE Do not disconnect the connector while the fan motor is rotating Use a thin test rod Indoor fan starts rotating when power supply is turned on Check output DC voltage of fan motor on P C board Measure voltage between 3 GND BLACK and 5 V line YELLOW of motor connector CN36 while indo...

Page 95: ...g within 5 cm distance from the radio P C board is failure Replace P C board Is operation possible when the transmitter is moved nearer to the infrared signal receiver of the air conditioner Battery life Replace the batteries Dose the transmission indicator light Is there any beep and operation Normal Remote control is failure Replace remote control Push the button YES There is no beep from the in...

Page 96: ...onds after starting of the operation Be sure to prepare a diode for judgment Normal time Voltage swings between DC15 and 60V Inverter Assembly check 11 7 1 Abnormal time Voltage does not vary 2 Outdoor unit stops in a little while after operation started Check procedure Select phenomena described below 1 The outdoor unit stops 10 to 20 minutes after operation started and 10 minutes or more are req...

Page 97: ...nd 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 control pulse motor valve inc...

Page 98: ...e connector CN31 of outdoor fan motor and using a tester check resistance value between every phases at motor side Check terminal voltage of electrolytic capacitor B A Operation Measure ment Stop Check Measure ment Turn on the power breaker and operate the air condi tioner in COOL mode by time shortening Measure terminal voltage of the electrolytic capacity After operation turn off the power break...

Page 99: ...k Simply the Main Parts 11 8 1 How to Check the P C Board Indoor Unit 1 Operating precautions 1 When removing the front panel or the P C board be sure to shut off the power supply breaker 2 When removing the P C board hold the edge of the P C board and do not apply force to the parts 3 When connecting or disconnecting the connectors on the P C board hold the whole housing Do not pull at the lead w...

Page 100: ...PERATION TIMER HI POWER 8 C Wi Fi are lit for 3 seconds and they return to normal 3 seconds later 1 Check whether or not the compressor operates 2 Check whether or not the OPERATION indicator flashes 1 Check whether or not the compressor operates 2 Check whether or not the OPERATION indicator flashes 1 Check it is impossible to detect the voltage AC120V or higher voltage between red and black 2 Th...

Page 101: ...value k Temperature C TA TC TO TS TE TD 1 Sensor characteristic table 11 8 2 P C Board Layout TD Discharge temp sensor TA Room temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TS Suction temp sensor TE Outdoor heat exchanger temp sensor 5V GND 12V 101 ...

Page 102: ... White White Black Black Red 3 4 Way valve coil at 20 C 4 Pulse Modulating Valve PMV coil Model CAM MD12TCTH 5 5 Outside air temp sensor TO Discharge temp sensor TD Suction temp sensor TS Exchanger temp sensor TE 1 10Ω 33 7 1 7Ω Resistance value Position 1 31Ω Position White Red Black Measure the resistance value of each winding by using the tester Red White Black Measure the resistance value of w...

Page 103: ...onverter module 1 Turn OFF the power supply breaker 2 Discharge all three capacitors completely 3 Check that the normal rectification characteristics are shown in continuity test by the tester 11 8 5 Checking Method for Each Part Case that product is good Pointer swings once and returns slowly When performing test once again under another polarity the pointer should return No Part name Checking pr...

Page 104: ...inside of the outdoor fan motor 4 Motor drive circuit failure of the outdoor P C board 3 How to simply judge whether outdoor fan motor is good or bad NOTE However GND circuit error inside of the motor may be accepted in some cases when the above check is performed When the fan motor does not become normal even if P C board is replaced replace the outdoor fan motor If the resistance value between 1...

Page 105: ... 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 inspecting the cir cuitry wear rubber gloves to avoid contact with the live parts Electric shocks may be received if the live parts are touched High voltage circuits are contained insi...

Page 106: ...the procedure item 3 2 Remove screw holding the electric part cover 3 Disconnect the connectors for the fan motor and louver motor from P C board assembly 4 Remove the earth screw and earth line from evaporator 5 Pull out TC sensor from sensor holder of the evaporator 6 Remove the 2 fixing screws that secures the electric parts box assembly unit display assembly and remove the electric parts box a...

Page 107: ...otor band 4 Pull the motor band and the fan motor outward 3 5 mm Cross flow fan Set screw Fan motor Body back Horizontal louver 6 1 Remove shaft of the horizontal louver from the back body First remove 2 the center shafts then remove the other shafts To re installation Check the type name of fan motor Keep connector position and arrange fan motor wires follow figure 4 5 Fan motor connector Fan mot...

Page 108: ...an from the back body Louver motor connector P C board To re installation Press the drain pan into the back body Please make sure ribs of drain pan in left and right side must be install to lock position Press the center arm of drain pan to back body Connectors Electric part cover Screw Unit display Screw Louver motor connector Center arm of drain pan Back body Drain pan Back body Drain pan Rib of...

Page 109: ... the Cross flow fan is keep 3 5mm 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 4 Lift up the heat exchanger follow the figure Pull out the left hand side until the cross flow fan is released from the shaft of the fan motor and then pull out the lower side of heat exchanger ...

Page 110: ...e of the main unit 5 Pull out the right hand side until the locking slot of heat exchanger is released from the hook of the motor cover then pull out the upper side of heat exchanger Please make sure that the hook of motor cover must be installed into the locking slot of heat exchanger Hook Heat exchanger Motor cover 10 To re installation Locking slot Heat exchanger Screws Pipe holder Heat exchang...

Page 111: ...urn the power supply off to stop the operation of air conditioner 2 Remove the front panel Remove the 2 fixing screws 3 Remove the electrical part base Remarks Replace terminal block microcomputer ass y and the P C board ass y Microcomputer 111 ...

Page 112: ... cabinet 1 Detachment 1 Perform step 1 in 1 2 Remove the fixing screws ST2TØ4 10L 2 pcs used to secure the front cabinet and inverter cover the screws ST2TØ4 10L 4 pcs used to secure the front cabinet at the bottom and the fixing screws ST2TØ4 10L 2 pcs used to secure the motor base The front cabinet is fitted into the side cabinet left at the front left side so pull up the top of the front cabine...

Page 113: ...ble type in some cases 4 Remove screw ST2TØ4 x 10L 4pcs fixing the terminal part of inverter box to the main body 5 Remove the front cabinet by performing step 1 in 2 and remove the fixing screws ST2TØ4 x 10L for securing the main body and inverter box 6 Remove various lead wires from the holder at upper part of the inverter box 7 Pull the inverter box upward 8 Disconnect connectors of various lea...

Page 114: ...sconnect prevention mechanism as such the lock on their housing must be released before they are disconnected 2 Remove the control board assembly from the spacer Remove the heat sink and control board assembly while keeping them screwed together 3 Remove the two fixing screws used to secure the heat sink and control board assembly 4 Mount the new control board assembly NOTE When mounting the new c...

Page 115: ...e bottom plate and heat exchanger 6 Fan motor 1 Perform work of item 1 of 1 and 2 2 Remove the flange nut fixing the fan motor a the propeller Flange nut is loosened by turning clockwise To tighten the flange nut tur counterclockwise 3 Remove the propeller fan 4 Disconnect the connector for fan motor from the inverter 5 Remove the fixing screws 3 pcs holding by hands so that the fan motor does not...

Page 116: ...e compressor from the terminal 6 Remove pipe connected to the compressor with a burner 7 Remove the ﬁxing screw of the bottom plate and heat exchanger ST2TØ4 10L 1 pc 8 Remove the ﬁxing screw of the bottom plate and valve ﬁxing plate ST2TØ4 10L 1 pc 9 Pull upward the refrigeration cycle 8 Reactor 1 Perform work of item 1 of 2 and 3 2 Remove screws fixing the reactors ST2TØ4 10L 2 pcs Compressor Re...

Page 117: ...rrow mark in the right figure and remove the fa 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 Minus screwdriver Hooking claw Check that all the hooking claws are fixed to the specified positions Electronic expansion valve coil 1 Detachment 1 Perform step 1 in all the steps in and 1 in 2 Remove the ...

Page 118: ...the heat exchanger CAUTION During the installation work and on its completion take care not to damage the coverings of the sensor leads on the edges of the metal plates or other parts It is dangerous for these coverings to be damaged since damage may cause electric shocks and or a fire CAUTION After replacing the parts check whether the positions where the sensors were installed are the proper pos...

Page 119: ... FRONT PANEL ASSY GRILLE OF AIR INLET ASSY AIR FILTER BACK BODY ASSY VERTICAL LOUVER ASSY DRAIN PAN ASSY HORIZONTAL LOUVER DRAIN HOSE DRAIN CAP MOTOR STEPPING FAN MOTOR CROSS FLOW FAN ASSY BASE BEARING BEARING ASSY MOLD 229 43T91396 MOTOR COVER MOTOR BAND BACK MOTOR BAND FRONT REFRIGERATION CYCLE ASSY HOLDER SENSOR PIPE SHIELD INSTALLATION PLATE PIPE HOLDER TERMINAL COVER ASSY WIRELESS REMOCO HOLD...

Page 120: ... 402 43T6V673 403 43T50392 406 43T6W837 404 43T62340 405 43T6W727 TEMPERATURE SENSOR TERMINAL 5P TF SENSOR THERMOSTAT CORD CLAMP PC BOARD ASSY WRS LED 407 43T60502 PC BOARD FOR RAS 25J2KVSG ND PC BOARD FOR RAS 35J2KVSG ND HOUSING WiFi Description Description 402 404 405 406 401 403 407 120 ...

Page 121: ...NET ASSEMBLY FRONT CABINET ASSEMBLY FIXING PLATE VALVE MOTOR BASE CONNECTION PLATE PARTITION ASSEMBLY MOTOR BASE FAN GUARD PROPELLER FAN DRAIN NIPPLE PACKED VALVE COVER ASSEMBLY HOLDER SENSOR CAP WATERPROOF CONDENSER ASSEMBLY COMPRESSOR FOR RAS 35J2AVSG ND COMPRESSOR FOR RAS 25J2AVSG ND BONNET 6 35 DIA 84 43T04416 BONNET 9 52 DIA VALVE PACKED 6 35 DIA VALVE PACKED 9 52 DIA BODY PMV COIL PMV 4 WAY ...

Page 122: ...326 712 43T63317 TEMPERATURE SENSOR TEMPERATURE SENSOR TC SENSOR TO PC PLATE BASE HOLDER SENSOR HOLDER SENSOR HOLDER SENSOR 705 43T50353 HEATSINK PC BOARD FOR RAS 25J2AVSG ND PC BOARD FOR RAS 35J2AVSG ND TERMINAL 6P FUSE TEMPERATURE SENSOR Description Description 701 702 709 704 705 TS SENSOR 706 TD SENSOR 707 TE SENSOR 708 TO SENSOR 703 710 HOLDER SENSOR TE 711 HOLDER SENSOR TS 712 HOLDER SENSOR ...

Page 123: ...144 9 MOO 5 BANGKADI INDUSTRIAL PARK TIVANON ROAD TAMBOL BANGKADI AMPHUR MUANG PATHUMTHANI 12000 THAILAND ...

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Toshiba RAS-25J2AVSG-ND, Service Manual

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