FILE NO. SVM SERVICE MANUAL AIR CONDITIONER SPLIT WALL TYPE RAS-07SKSX-1 / RAS-07S2AX-1 RAS-09SKSX-1 / RAS-09SASX-1

Transcription

1 FILE. SVM SERVICE MANUAL AIR CONDITIONER SPLIT WALL TYPE RAS-07SKSX-1 / RAS-07S2AX-1 RAS-09SKSX-1 / RAS-09SASX-1 April, 2008

2 CONTENTS FILE. SVM SPECIFICATIONS 2. CONSTRUCTION VIEWS 2-1 Indoor Unit 2-2 Outdoor Unit (RAS-07S2AX-1) 2-3 Outdoor Unit (RAS-09SASX-1) 3. WIRING DIAGRAM 4. SPECIFICATION OF ELECTRICAL PARTS 4-1 Indoor Unit 4-2 Outdoor Unit (RAS-07S2AX-1) 4-3 Outdoor Unit (RAS-09SASX-1) 5. REFRIGERATION CYCLE DIAGRAM 5-1 RAS-07SKSX-1 / RAS-07S2AX RAS-09SKSX-1 / RAS-09SASX-1 6. CONTROL BLOCK DIAGRAM 7. OPERATION DESCRIPTION 7-1 Outline of Air Conditioner Control 7-2 Description of Operation Circuit 7-3 Low-Temperature Limit Control 7-4 Auto Restart Function 8. INSTALLATION PROCEDURE 8-1 Safety Cautions 8-2 Installation Diagram of Indoor and Outdoor Units 8-3 Installation 8-4 Indoor Unit 8-5 Outdoor Unit 8-6 How to Set Remote Control Selector Switch 8-7 Others 9. TROUBLESHOOTING CHART 9-1 Troubleshooting Procedure 9-2 Basic Check Items 9-3 Primary Judgement 9-4 Self-Diagnosis by Remote Control (Check Code) 9-5 Troubleshooting Flowcharts 9-6 Troubleshooting for Remote Control (Including The Indoor P.C. Board) 1

3 FILE. SVM PARTS REPLACEMENT 10-1 Indoor Unit 10-2 Outdoor Unit (RAS-07S2SX-1) 10-3 Outdoor Unit (RAS-09SASX-1) 11. EXPLODED VIEWS AND PARTS LIST 11-1 Indoor Unit (E-Parts Assy) 11-2 Indoor Unit 11-3 Outdoor Unit (RAS-07S2SX-1) 11-4 Outdoor Unit (RAS-09SASX-1) 2

4 MODE L 1. SPECIFICATIONS RAS-07SKSX-1 / RAS-07S2AX-1 FILE. SVM RAS-09SKSX-1 / RAS-09SASX-1 ITE M Capacity 3 Cooling 220V 240V 220V 240V kw Phase Power source V Hz 50 Power consumption kw Power factor % Running Indoor A 0.15 current Outdoor A Starting current A Moisture removal lit/h Noise Refrigerant Refrigerant control Indoor (H/M/L) db 40/35/30 43/38/33 Outdoor db Name of refrigerant R22 Rated amount kg 0.58 Capillary tube Gas side size mm 9.52 Connection type Flare connection Liquid side size mm 6.35 Interconnection Connection type pipe Maximum length (One way) Maximum height difference Flare connection m 10 *1 m 5 INDOOR UNIT RAS-07SKSX-1 RAS-09SKSX-1 Height mm 250 Dimensions Width mm 740 Net weight Evaporator type Indoor fan type Air volume Depth mm 185 kg High fan m 3 /h Finned tube Cross flow fan Fan motor output W 20 Air filter Honeycomb woven filter with PP frame OUTDOOR UNIT RAS-07S2AX-1 RAS-09SASX-1 Height mm 530 Dimensions Width mm 660 Depth mm 240 Net weight kg 25 Condenser type Outdoor fan type Finned tube Propeller fan Airflow volume m 3 /h Fan motor output W Compressor Safety device Louver type Medium fan m 3 /h Low fan Model m 3 /h PH108X1C-4DZDN2 Output W Fuse, Overload relay Automatic louver Usable outdoor temperature range C 21 ~ QK164PBA

5 Note : 1 Capacity is based on the following temperature conditions. FILE. SVM Temperature Indoor unit inlet air temperature Outdoor unit inlet air temperature Condition JIS C9612 Cooling (DB) 27 C (WB) 19 C (DB) 35 C (WB) 24 C Note : 2 *1 No need to charge extra refrigerant. 4

6 2. CONSTRUCTION VIEWS FILE. SVM Indoor Unit Wireless remote control 5

7 2-2. Outdoor Unit FILE. SVM C L C L

8 3. WIRING DIAGRAM FILE. SVM SINGLE PHASE TERMINAL BLOCK INDOOR OUTDOOR OUTDOOR TERMINAL BLOCK 1(L) 2(N) CHASSIS BLK BLK RED FAN MOTOR RED CAPACITOR CAPACITOR Type "A" FAN MOTOR Type "B" RED WHI OVERLOAD RELAY BLK COMPRESSOR PNK WHI 7

9 4. SPECIFICATION OF ELECTRICAL PARTS FILE. SVM Indoor Unit No. Parts name Type Specifications 1 Fan motor (for indoor) AFS AR AC Motor with 145 C thermo fuse 2 Thermo sensor (TA-sensor) 10k Ω at 25 C 3 Switching power supply (T01) ST Microcontroller unit (IC30) TMP87CM40ANG-6P68 5 Heat exchanger sensor (TC-sensor) 10k Ω at 25 C 6 Line filter (L01) LC*SS11V mH, 600mA 7 Bridge rectifier (DB01) DB105G 1A, 600 V 8 Capacitor (C27) EKMH401VSN470MP20S 47µF, 400 V 9 Fuse (F01) BET6.3A 6.3A, 250VAC 10 Varistor (R62, R63) SR561K14DL 560 V 11 Resistor (R64) RF-2TK5R6 5.6 Ω, 2 W 12 Louver motor MP24ZCT 12VDC 13 Relay (Comp., RY01) G4A-1A-E-CA Rating 20A/AC250 V, 12VDC 4-2. Outdoor Unit (RAS-07S2AX-1) Specifications Output (Rated) 605W, 2 poles, 1 phase, V~, 50Hz 1 Compressor PH108X1C-4DZDN2 Winding resistance (Ω) C-R C-S (at 20ºC) Output (Rated) 20 W, 6 poles, 1 phase, V~, 50Hz WLF A (Type "A") Winding resistance (Ω) Red-Black White-Black 2 Fan motor (for outdoor) (at 20ºC) Output (Rated) 20 W, 6 poles, 1 phase, V, 50Hz SKF B (Type "B") Winding resistance (Ω) Red-Black White-Black (at 20ºC) Running capacitor (for fan motor) Running capacitor (for compressor) DS451155NPQB RS44B256U0213S AC 450 V~, 1.5µF AC 440 V~, 25µF 5 Overload relay JMRA U/T : 4.2A (80ºC), Open : 135±5ºC, Close : 69±11ºC 8

10 FILE. SVM Outdoor Unit (RAS-09SASX-1) No. Parts name Type Compressor Fan motor (for outdoor) Running capacitor (for fan motor) QK164PBA WLF A (Type "A") SKF B (Type "B") DS451155NPQB AC 450 V~, 1.5µF Running capacitor 4 RS44B356U0215S AC 440 V~, 35µF (for compressor) Specifications Output (Rated) 780W, 2 poles, 1 phase, V~, 50Hz Winding resistance (Ω) C-R C-S (at 20ºC) Output (Rated) 20 W, 6 poles, 1 phase, V~, 50Hz Winding resistance (Ω) Red-Black White-Black (at 20ºC) Output (Rated) 20 W, 6 poles, 1 phase, V, 50Hz Winding resistance (Ω) Red-Black White-Black (at 20ºC) Overload relay LPAP960B U/T : 6.1A (80ºC), Open : 135±5ºC, Close : 75±11ºC 9

11 FILE. SVM RAS-07SKSX-1 / RAS-07S2AX-1 5. REFRIGERATION CYCLE DIAGRAM Cooling Indoor unit Heat exchanger T1 0.39m (Connecting pipe) 9.52 Cross flow fan 0.49m (Connecting pipe) 6.35 O.D.:9.52mm P O.D.:6.35mm Packed valve ( 9.52) Packed valve ( 6.35) Cooling Cooling Compressor PH108X1C-4DZDN2 Capillary tube 1.2x500s Heat exchanger Refrigerant Cooling Propeller fan Outdoor unit Mark ( R22 : 0.58 kg. ) means check points of Gas Leak. 50Hz Standard pressure P (MPaG) Surface temp. of heat exchanger interchanging pipe T1 ( C) Fan speed (indoor) Ambient temp. conditions DB/WB ( C) Indoor Outdoor Standard High 27/19 35/24 Cooling Overload High 32/23 43/26 Low temperature Low 21/15 21/15 Note Measure the heat exchanger temperature at the center of U-bend. (By means of TC sensor) 10

12 FILE. SVM RAS-09SKSX-1 / RAS-09SASX-1 Cooling Indoor unit Heat exchanger T1 0.39m (Connecting pipe) 9.52 Cross flow fan 0.49m (Connecting pipe) 6.35 O.D.:9.52mm P O.D.:6.35mm Packed valve ( 9.52) Packed valve ( 6.35) Cooling Cooling Compressor QK164PBA Capillary tube 1.5x700s Heat exchanger Refrigerant Cooling Propeller fan Outdoor unit Mark ( R22 : 0.58 kg. ) means check points of Gas Leak. 50Hz Standard pressure P (MPaG) Surface temp. of heat exchanger interchanging pipe T1 ( C) Fan speed (indoor) Ambient temp. conditions DB/WB ( C) Indoor Outdoor Standard High 27/ /24 Cooling Overload High 32/23 43/26 Low temperature Low 21/15 21/15 Note Measure the heat exchanger temperature at the center of U-bend. (By means of TC sensor) 11

13 6. CONTROL BLOCK DIAGRAM FILE. SVM Heat Exchange sensor Main Unit Control Panel Functions M.C.U. Operation Display Thermo. Sensor Infrared Rays Signal Reciver Initiallizing Circuit Clock Frequency Oscillator Circuit Louver Control 3-minutes Delay at Restart for Compressor Motor Revolution Control Processing (Temperature Processing) Timer Timer Display Fan Only Sign Display Indoor Fan Motor Power Supply Circuit Compressor ON/OFF Signal Louver ON/OFF Signal Noise Filter Relay Driver, Louver Driver Louver Motor Relay RY V~, 50Hz Compressor, Outdoor Fan Motor REMOTE CONTROL Remote Control Infrared Rays Operation (START/STOP) Operation Mode Selection AUTO, COOL, DRY, AUTO FAN Temperature Setting Fan Speed Selection ON TIMER Setting OFF TIMER Setting Louver Auto Swing Louver Direction Setting ECO 12

14 FILE. SVM OPERATION DESCRIPTION 7-1. Remote control Function of Push Putton Infrared signal emitter Set louver button (FIX) Auto Louver button (SWING) Mode select button (MODE) Reset button (RST) On timer button (ON) Off timer button (OFF) Reserve button (SET) Cancel button (CLR) Check button (CHK) ECO button (ECO) Fan speed button (FAN) Start/Stop button (START/STOP) Temperature button ( ) MODE AUTO COOL DRY AUTO FAN SWING MODE TEMP. Hr.ON TEMP. START/STOP FIX RST CHK OFF TIMER FAN AUTO QUIET FAN ECO ON OFF SET CLR 7 8 B

15 FILE. SVM Display of Remote Control All indications, except for the clock time indicator, are displayed by pressing the button. 1. Transmission mark This transmission mark indicates when the remote controller transmits signals to the indoor unit. 2. Mode indicator Indicates the current operation mode. (AUTO, COOL, DRY and AUTO FAN) 3. Temperature indicator Indicates the temperature setting. (17 C to 30 C) 4. ECO indicator Indicates when the ECO is in activated. Press the ECO button to start and press it again to stop operate. 5. A, B change indicator remote controller When the remote controller switching function is set, "B" appears in the remote controller display (When the remote controller seting is "A", there is no indication at this position.) 6. Swing Indicate when louver is swing. Press swing button to start the swing operation and press it again to stop the swing operation. 7. FAN speed indicator Indicates the selected fan speed. AUTO, QUIET or three fan speed levels ( LOW, MED, HIGH can be shown. Indicate Auto will be appear with Dry operation only. 8. ON/OFF TIMER indicator Indicates when the ON/OFF TIMER operation. (ON TIMER [Hr. ON], OFF TIMER [OFF]) B Hr.ON OFF

16 FILE. SVM Outline of Air Conditioner Control This is a fixed capacity type air conditioner, which uses a AC motor for an indoor fan. The AC motor drive circuit is mounted in the indoor unit. And electrical parts which operate the compressor and the outdoor fan motor, are mounted in the outdoor unit. The air conditioner is mainly controlled by the indoor unit controller. The controller operates the indoor fan motor based upon commands transmitted by the remote control and transfers the operation commands to the outdoor unit controller. The outdoor unit receives operation commands from the indoor unit, and operates the outdoor fan motor and the compressor. (1) Role of indoor unit controller The indoor unit controller receives the operation commands from the remote control and executes them. Temperature measurement at the air inlet of the indoor heat exchanger by the indoor temperature sensor Temperature measurement of the indoor heat exchanger by the heat exchanger sensor Louver motor control Indoor fan motor operation control LED display control Transferring of operation commands to the outdoor unit Receiving of information of the operation status and judging of the information or indication of error (2) Role of outdoor unit controller The outdoor unit controller receives the operation commands from the indoor controller and executes them. Compressor operation control Operation control of outdoor fan motor Operations according to the commands from the indoor unit Turning off the compressor and outdoor fan when the outdoor unit receives the shutdown command Louver control (1) Vertical air flow louver Position of veritcal air flow louver is automatically controlled according to the operation mode. Besides, position of vertical air flow louver can be arbitrarily set by pressing [FIX] button. The louver position which is set by [FIX] button is stored in the microcomputer, and the louver is automatically set at the stored position for the next operation. (2) Swing If [SWING] button is pressed when the indoor unit is in operation, the vertical air flow louver starts swinging. When [FIX] button is pressed, it stops swinging Indoor Fan Control The operation controls the fan speed at indoor unit side. The indoor fan (cross flow fan) is operated by the phase control induction motor. The fan rotates in 3 stages in MANUAL model, and in 5 stages in AUTO mode, respectively. (Table 7-2-1) 1) When setting the fan speed to L, M or H on the remote controller, the operation is performed with the constant speed shown in Fig Fig (7-2-1) Indication Fan speed L M H Low Med High 2) When setting the fan speed to AUTO on the remote controller, revolution of the fan motor is controlled to the fan speed level shown in Table 1 according to the setup temperature, room temperature, and heat exchanger temperature. 3) When setting the fan speed to QUIET on the remote controller, revolution of the fan motor is controlled to the fan speed level is L-. Table Indoor fan and air flow rate Model OPERATION MODE RAS-07SKSX-1 RAS-09SKSX-1 Cool Dry fan speed (rpm) Air flow (m 3 /h) fan speed (rpm) Air flow (m 3 /h) Fan speed level UH H M+ M L+ L L- UL SUL UH H M+ M L+ L L- UL SUL

17 7-3. Description of Operation Mode (1) When turning on the breaker, the operation lamp blinks. This means that the power is on (or the power supply is cut off.) (2) When pressing [ ] button on the remote control, receiving beep sounds from the indoor unit, and the next operation is performed together with opening the vertical air flow louver. (3) Once the operation mode is set, it is memorized in the microcomputer so that the previous operation can be effected thereafter simply by pressing [ ] button Fan only operation ([MODE] button on the remote control is set to the fan only operation.) (1) When [FAN] button is set to AUTO, the indoor fan motor operates as shown in Fig When [FAN] button is set to LOW, MED, or HIGH the motor operates with a constant air flow Cooling operation ([MODE] button on the remote control is set to the cooling operation.) (1) The compressor, outdoor fan and operation display lamp are controlled as shown in Fig (Room temp.) (Preset temp.) Preset temp. C FILE. SVM ON ON OFF OFF ON Compressor Outdoor fan OPERATION display (Room temp.) (Preset temp.) Preset temp. C (Preset temp.: 24 C) TE1 : *1 : Fan speed = (M + - L) x 3/4 + L *2 : Fan speed = (M + - L) x 2/4 + L *3 : Fan speed = (M + - L) x 1/4 + L M+ *1 *2 *3 Fig (2) When [FAN] button is set to AUTO, the indoor fan motor operates as shown in Fig When [FAN] button is set to LOW, MED or HIGH the motor operates with a constant air flow. (Room temp.) (Preset temp.) Preset temp. C M+ *1 *2 *3 (Linear approximation from M+ and L) TE2 : ECO operation can not be set. Fig Setting of air flow [FAN:AUTO] TE1 : *1 : Fan speed = (M + - L) x 3/4 + L *2 : Fan speed = (M + - L) x 2/4 + L *3 : Fan speed = (M + - L) x 1/4 + L (Linear approximation from M+ and L) Fig Setting of air flow [FAN:AUTO] 16

18 FILE. SVM Dry operation ([MODE] button on the remote control is set to the dry operation.) (1) The compressor, outdoor fan and operation display on the remote control are controlled as shown in Fig (Room temp.) (Preset temp.) Preset temp. C Fig (2) The microcontroller turns the compressor on and off at the regular intervals (4 to 6 minutes). While the compressor is turning off, the indoor fan motor operates in the SUPER LOW position. The pattern of operation depending on the relation between room temperature and preset temperatures is shown in Fig Room temp. Preset temp.+1 Preset temp. ON:6min. OFF:4min. ON:6min. OFF:4min. ON:5min. OFF:5min. ON:5min. OFF:5min. OFF OFF Compressor Outdoor fan ON OPERATION display (1) One of 2 operations (Cooling or Fan only) is selected according to difference between the preset temperature and the room temperature at which the automatic operation has started, as shown in Fig The Fan only operation continues until the room temperature reaches a level at which another mode is selected. (2) Temporary Auto When the [RESET] button on the indoor unit is pushed, the preset temperature is fixed at 24 C and the indoor unit is controlled as shown in Fig (Room temp.) (Preset temp.) C 0 Cooling operation Fan only operation Fig Low-Temperature Limit Control The microcontroller detects the indoor heat exchanger temperature to prevent the indoor heat exchanger from freezing. The compressor and outdoor fan motor are controlled as shown in Fig Compressor Outdoor fan ON ON ON ON OFF OFF OFF Indoor fan L *SL L SL L SL L *Super Low Fig (3) [FAN] button on the remote control is set to AUTO only. (4) The ECO operation cannot be set Automatic operation ([MODE] button on the remote control is set to the automatic operation.) Heat exchanger temperature ( C) 5 2 Fig Compressor Outdoor fan ON Less than 2 C continues for 5 minutes OFF 17

19 7-5. Auto Restart Function This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored. This function is not set to work when shipped from the factory. Therefore it is necessary to set it to work How to Set the Auto Restart Function To set the auto restart function, proceed as follows: The power supply to the unit must be on ; the function will not set if the power is off. Press the [RESET] button located in the center of the front panel continuously for three seconds. The unit receives the signal and beeps three times. The unit then restarts operating automatically in the event of power supply being accidentally shut down. When the unit is standby (Not operating) FILE. SVM Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) RESET button The unit is on standby. The unit starts to operate. The unit beeps three times and continues to operate. Motions After approx. three seconds, The green indicator is on. The green indicator flashes for 5 seconds. If the unit is not required to operate at this time, press [RESET] button once more or use the remote controller to turn it off. When the unit is in operation Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) RESET button The unit is in operation. The unit stops operating. The unit beeps three times. Motions After approx. three seconds, The green indicator is on. The green indicator is turned off. 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. While the filter check indicator is on, the RESET button has the function of filter reset betton. 18

20 FILE. SVM How to Cancel the Auto Restart Function To cancel auto restart function, proceed as follows : Repeat the setting procedure : the unit receives the signal and beeps three times. The unit will be required to be turned on with the remote controller after the main power supply is turned off. When the system is on stand-by (not operating) Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) The unit is on standby. The unit starts to operate. Motions After approx. three seconds, The green indicator is on. The unit beeps three times and continues to operate. If the unit is not required to operate at this time, press [RESET] button once more or use the remote controller to turn it off. RESET button When the system is operating Operation Press [RESET] button for more than three seconds. (Less than 10 seconds) The unit is in operation. The unit stops operating. Motions After approx. three seconds, The green indicator is on. The green indicator is turned off. 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. RESET button Power Failure During Timer Operation When the unit is turned off because of power failure during timer operation, the timer operation is cancelled. In that case, set the timer operation again. TE : The Everyday Timer is reset while a command signal can be received from the remote controller even if it stopped due to a power failure. 19

21 8. INSTALLATION PROCEDURE FILE. SVM Safety Cautions For general public use Power supply cord of parts of appliance for Outdoor use shall be at least polychloroprene sheathed flexible cord (design H07 RN-F), or cord designation 245 IEC66.(Shall be installed in accordance with national wiring regulations.) CAUTION DANGER FOR USE BY QUALIFIED PERSONS ONLY. TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK. CONNECT THE CONNECTING CABLE CORRECTLY. IF THE CONNECTING CABLE IS CONNECTED WRONGLY, ELECTRIC PARTS MAY BE DAMAGED. CHECK THE EARTH WIRE THAT IT IS T BROKEN OR DISCONNECTED BEFORE INSTALLATION. DO T INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION. TO PREVENT OVERHEATING THE INDOOR UNIT AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEATORS, FURNACE, STOVES, ETC. WHEN MOVING THE AIR-CONDITIONER FOR INSTALLING IT IN ATHER PLACE AGAIN, BE VERY CAREFUL T TO GET THE SPECIFIED REFRIGERANT (R410A) WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CYCLE. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CYCLE BECOMES ABRMALLY HIGH AND IT RESULTINGLY CAUSES BURST OF THE PIPE AND INJURIES ON PERSONS. IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE, IT CAUSES GENERATION OF POISOUS GAS. WARNING Never modify this unit by removing any of the safety guards or bypassing any of the safety interlock switches. Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls. Before doing the electrical work, attach an approved plug to the power supply cord. Also, make sure the equipment is properly earthed. Appliance shall be installed in accordance with national wiring regulations. If you detect any damage, do not install the unit. Contact your TOSHIBA dealer immediately. CAUTION To Disconnect the Appliance from the Main Power Supply This appliance must be connected to the main power supply by means of a circuit breaker or a switch with a contact separation of at least 3 mm in all poles. If this is not possible, a power supply plug with earth must be used. This plug must be easily accessible after installation. The plug must be disconnected from the power supply socket in order to disconnect the appliance completely from the mains. Exposure of unit to water or other moisture before installation could result in electric shock. Do not store it in a wet basement or expose to rain or water. After unpacking the unit, examine it carefully for possible damage. 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 carefully before installing the unit. It contains further important instructions for proper installation. 20

22 FILE. SVM REQUIREMENT OF REPORT TO THE LOCAL POWER SUPPLIER Please make absolutely sure that the installation of this appliance is reported to the local power supplier before installation. If you experience any problems, or if the installation is not accepted by the supplier, the service agency will take adequate countermeasures. Remark per EMC Directive 89/336/EEC To prevent flicker impressions during the start of the compressor (technical process) following installation conditions do apply. 1. The power connection for the air conditioner has to be done at the main power distribution. This distribution has to be of an impedance. Normally the required impedance is reached at a 32A fusing point. Air conditioner fuse has to be 16A max.! 2. No other equipment should be connected to this power line. 3. For detailed installation acceptance, please contact your power supplier whether its restriction does apply for products like washing machines, air conditioners or electrical ovens. 4. For power details of the air conditioner, refer to the rating plate of the product. 21

23 8-2. Installation Diagram of Indoor and Outdoor Units FILE. SVM mm or more 47 mm or more Hook 1 Installation plate For the rear left and left piping Wall Hook 120 mm or more Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better operation. Air filter Do not allow the drain hose to get slack. (Attach to the front panel.) Shield pipe Cut the piping hole sloped slightly. Active Carbon-Catechin filter 5 Pan head wood screw 7 Make sure to run the drain hose sloped downward. Before installing the wireless remote control With the remote control cover open, load the batteries supplied correctly, observing their polarity. 2 Wireless remote control 4 Remote control holder 2 Wireless remote control The auxiliary piping can be connected to the left, rear left, rear right, right, bottom right or bottom left. Right Rear right Bottom right Rear left Left Bottom left 3 Batteries Insulate the refrigerant pipes separately with insulation, not together. Vinyl tape Apply after carrying out a drainage test. 6 mm thick heat resisting polyethylene foam 600 mm or more 45 mm or more Saddle 100 mm or more 400 mm or more Extension drain hose (Not available, provided by installer) 100 mm or more 22

24 FILE. SVM Installation Optional installation parts Part Code A B C Parts name Refrigerant piping Liquid side : 6.35 mm Gas side : 9.52 mm Pipe insulating material (polyethylene foam, 6 mm thick) Putty, PVC tapes Q'ty One each 1 One each <Fixing bolt arrangement of outdoor unit> 500 mm 97 mm Air inlet 280 mm 53 mm Air outlet Drain outlet Fig 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. 23

25 FILE. SVM Accessory and installation parts Part No. Part name (Q'ty) Part No. Part name (Q'ty) Part No. Part name (Q'ty) Installation plate x 1 Battery x 2 Active Carbon-Catechin filter x Wireless remote control x 1 Remote control holder x 1 Mounting screw 4 x 25 lx 6 Others Name Owner s manual Installation manual 7 Pan head wood screw 3.1 x 16 lx 2 24

26 FILE. SVM Indoor Unit Installation place A place which provides the spaces around the indoor unit as shown in the above diagram. A place where there is no obstacle near the air inlet and outlet. A place that allows easy installation of the piping to the outdoor unit. A place which allows the front panel to be opened Cutting a hole and mounting installation plate <Cutting a hole> When installing the refrigerant pipes from the rear. 90 mm 66 mm CAUTION Direct sunlight to the indoor unit's wireless receiver should be avoided. The microprocessor in the indoor unit should not be too close to RF noise sources. (For details, see the owner's manual.) 42 mm Pipe hole Fig mm <Remote control> A place where there are no obstacles such as a curtain that may block the signal from the indoor unit. Do not install the remote control in a place exposed to direct sunlight or close to a heating source, such as a stove. Keep the remote control at least 1 m apart from the nearest TV set or stereo equipment. (This is necessary to prevent image disturbances or noise interference.) The location of the remote control should be determined as shown below. Indoor unit 75 (Side view) Reception range Remote control (Top view) Indoor unit Reception range Remote control 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. TE 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 installation plate> Hook Hook Pipe hole Thread Indoor unit Weight Hook Pipe hole 6 35 Mounting screw Installation plate Fig Fig

27 FILE. SVM <When the installation plate is directly mounted on the wall> 1. Securely fit the installation plate onto the wall by screwing it in the upper and lower parts to hook up the indoor unit. 2. To mount the installation plate on a concrete wall with anchor bolts, utilize the anchor bolt holes as illustrated in the above figure. 3. Install the installation plate horizontally in the wall. CAUTION When installing the installation plate with a mounting screw, do not use the anchor bolt hole. Otherwise the unit may fall down and result in personal injury and property damage. Installation plate <Keep horizontal direction> 5 mm dia. hole Anchor bolt Projection 15 mm or less Electrical work 1. The supply voltage must be the same as the rated voltage of the air conditioner. 2. Prepare the power source for exclusive use with the air conditioner. CAUTION This appliance can be connected to the mains in either of the following two ways. (1) Connection to fixed wiring: A switch or circuit breaker which disconnects all poles and has a contact separation of at least 3 mm must be incorporate in the fixed wiring. An approved circuit breaker or switches must used. (2) Connection with power supply plug: Attach power supply plug with power cord and plug it into wall outlet. An approved power supply cord and plug must be used. TE Ensure all wiring is used within its electrical rating. Model RAS-07,09SKSX-1 Clip anchor (local parts) Fig Mounting screw 4 x 25s Power source Maximum running current Plug socket & fuse rating Power cord 50 Hz, V Single phase 7.5A 16A 1 mm 2 or more CAUTION Failure to firmly install the unit may result in personal injury and property damage if the unit falls. In case of block, brick, concrete or similar type walls, make 5 mm dia. holes in the wall. Insert clip anchors for appropriate 6 mounting screws. TE Secure four corners and lower parts of the installation plate with 4 to 6 mounting screws to install it. 26

28 <How to connect the connecting cable> Wiring of 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 cords) into the pipe hole on the wall. 4. Take out the connecting cable through the cable slot on the rear panel so that it protrudes about 15 cm from the front. 5. Insert the connecting cable fully into the terminal block and secure it tightly with screws. 6. Tightening torque : 1.2 N m (0.12 kgf m) 7. Secure the connecting cable with the cord clamp. 8. Fix the terminal cover, rear plate bushing and air inlet grille on the indoor unit. CAUTION Be sure to refer to the wiring system diagram labeled inside the front panel. Check local electrical cords and also any specific wiring instructions or limitations. FILE. SVM Cord clamp Terminal block Terminal cover Connecting cable Screw about 15 cm Screw Fig Earth line 65 mm 10 mm 10 mm 50 mm Earth line Connecting cable Stripping length of the connecting cable Fig TE Use stranded wire only. Wire type : H07 RN-F or more <How to install the air inlet grille on the indoor unit> When attaching the air inlet grille, the contrary of the removed operation is performed. Fig

29 FILE. SVM Piping and drain hose installation <Piping and drain hose forming> * Since dewing results in a machine trouble, make sure to insulate both the connecting pipes. (Use polyethylene foam as insulating material.) Rear right Rear left Bottom left Left Bottom right Right Die-cutting Front panel slit Changing drain hose 1. Die-cutting Front panel slit For leftward connection, cut out slit on the left side of the front panel. (A knife will produce splinters, so use nippers.) 2. Changing 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 drains cap Clip drain cap by needle-nose plier, and pull out. Piping preparation How to fix the drains cap 1) Insert hexagonal wrench (4 mm) in a center head. 4 mm Fig ) Firmly insert drains cap. No gap CAUTION Insert a hexagon wrench (4 mm) Fig Firmly insert the drain hose and drain cap; otherwise, water may leak. <In case of right or left piping> Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. Application causes deterioration and drain leakage of the plug. After scribing slits of the front panel with a knife or a making-off pin, cut them with a pair of nippers or an equivalent tool. Fig How to install the drain hose Firmly insert drain hose connecting part until hitting on a heat insulator. Slit Fig Heat insulator Drain hose <In case of bottom right or bottom left piping> After scribing slits of the front panel with a knife or a making-off pin, cut them with a pair of nippers or an equivalent tool. Fig Slit Fig

30 FILE. SVM <Left-hand connection with piping> Bend the connecting 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. Bend the connection pipe within a radius of 30 mm. To connect the pipe after installation of the unit (figure) Indoor unit fixing 1. Pass the pipe through the hole in the wall, and hook the indoor unit on the installation plate at the upper hooks. 2. Swing the indoor unit to right and left to confirm that it is firmly hooked up on the installation plate. 3. While pressing 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 up on the installation plate. 210 mm 165 mm (To the forefront of flare) Gas side Liquid side 1 Hook here 1 Installation plate 43 mm Outward form of indoor unit R 30 mm (Use polisin (polyethylene) core or the like for bending pipe.) 2 Hook Fig Press (unhook) 80 Use the handle of screwdriver, etc. Fig For detaching the indoor unit from the installation plate, pull the indoor unit toward you while pushing its bottom up at the specified parts. TE If the pipe is bent incorrectly, the indoor unit may unstably be set on the wall. After passing the connecting pipe through the pipe hole, connect the connecting pipe to the auxiliary pipes and wrap the facing tape around them. Push Push CAUTION Bind the auxiliary pipes (two) and connecting cable with facing tape tightly. In case of leftward piping and rear-leftward piping, bind the auxiliary pipes (two) only with facing tape. Fig Indoor unit Auxiliary pipes Connecting cable Installation plate Carefully arrange pipes so that any pipe does not stick out of the rear plate of the indoor unit. Carefully connect 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. 29

31 FILE. SVM Drainage 1. Run the drain hose sloped downwards. TE Hole should be made at a slight downward slant on the outdoor side. 50 mm or more Do not rise the drain hose. Fig 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. Drain hose CAUTION Do not put the drain hose end into water. Shield pipe Inside the room Fig Do not form the drain hose into a wavy shape. Do not put the drain hose end in the drainage ditch. Extension drain hose 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 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 Outdoor Unit Installation place A place which provides the spaces around the outdoor unit as shown in the left diagram. A place which can 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 feet. An allowable length of the connecting pipe is up to 10 m. An allowable height level is up to 5 m. A place where the drain water does not raise any problem. CAUTION 1. Install the outdoor unit without anything blocking the air discharging. 2. When the outdoor unit is installed in a place exposed always exposed to strong wind like a coast or on a high storey of a building, secure the normal fan operation using a duct or a wind shield. 3. In particularly windy areas, install the unit such as to avoid admission of wind. 4. Installation in the following places may result in trouble. Do not install the unit in such places. A place full of machine oil. A saline-place such as the coast. A place full of sulfide gas. A place where high-frequency waves are likely to be generated as from audio equipment, welders, and medical equipment. Wall Drain guide Strong wind Space for pipes Fig Fig

32 Refrigerant piping connection 1. Cut the pipe with a pipe cutter. Roughness 90 Obliquity Warp FILE. SVM (Unit : N m) Outer dia. of copper pipe Tightening torque to 18 (1.6 to 1.8 kgf m) to 42 (3.0 to 4.2 kgf m) Fig Insert a flare nut into the pipe, and flare the pipe. Projection margin in flaring : A (Unit : mm) Tightening torque of flare pipe connections Flare at indoor unit side A Die Pipe Fig Outer dia. of copper pipe Rigid A Imperial to to to to 1.5 Fig Flare at outdoor unit side <Tightening connection> Align the centers of the connecting pipes and tighten the flare nut as far as possible with your fingers. Then tighten the nut with a spanner and torque wrench as shown in the figure. Mark line CAUTION Do not apply excess torque. Otherwise, the nut may crack depending on the conditions. Half union Fig Flare nut Externally threaded side Internally threaded side Use a wrench to secure. Use a torque wrench to tighten. CAUTION Fig KEEP IMPORTANT 4 POINTS FOR PIPING WORK (1) Take away dust and moisture (Inside of the connecting pipes.) (2) Tight connection (between pipes and unit) (3) Evacuate the air in the connecting pipes using VACUUM PUMP. (4) Check gas leak (connected points) 31

33 Evacuating After the piping has been connected to the indoor unit, you can perform the air purge together at once. AIR PURGE Evacuate the air in the connecting pipes and in the indoor unit using a vacuum pump. Do not use 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 R410A, refrigeration cycle trouble may result.) 1. Connect the charge hose from the manifold valve to the service port of the gas side packed valve. 2. Connect the charge hose to the port of the vacuum pump. 3. Open fully the low pressure side handle of the gauge manifold valve. 4. Operate the vacuum pump to start evacuating. Perform evacuating for about 15 minutes if the piping length is 20 meters. (15 minutes for 20 meters) (assuming a pump capacity of 27 liters per minute.) Then confirm that the compound pressure gauge reading is 101 kpa (76 cmhg). 5. Close the low pressure side valve handle of gauge manifold. 6. Open fully the valve stem of the packed valves (both sides of Gas and Liquid). 7. Remove the charging hose from the service port. 8. Securely tighten the caps on the packed valves. <Packed valve handling precautions> Open the valve stem all the way out; but do not try to open it beyond the stopper. Securely tighten the valve stem cap with torque in the following table: Gas side ( 9.52 mm) Liquid side ( 6.35 mm) Service port FILE. SVM Fig to 42 N m (3.0 to 4.2 kgf m) 16 to 18 N m (1.6 to 1.8 kgf m) 9 to 10 N m (0.9 to 1.0 kgf m) Hexagonal wrench is required. 4 mm Compound pressure gauge -101 kpa (76 cmhg) Handle Lo Charge hose Connecting pipe Pressure gauge Manifold valve Handle Hi (Keep full closed) Charge hose Vacuum pump adapter for counter-flow prevention Vacuum pump Packed valve at gas side Service port (Valve core (Setting pin)) Packed valve at liquid side Fig

34 FILE. SVM Wiring connection 1. Remove the valve cover from the outdoor unit. 2. Connect the connecting cable to the terminal as identified with their respective matched numbers on the terminal block of indoor and outdoor unit. 3. When connecting the connecting cable to the outdoor unit terminal, make a loop as shown in the installation diagram of indoor and outdoor unit, to prevent water coming in the outdoor unit. 4. Insulate the unused cords (conductors) from any water coming in the outdoor unit. Proceed them so that they do not touch any electrical or metal parts. <Stripping length of connecting cable> 75 mm 10 mm Earth line 10 mm 65 mm Terminal block Terminal screw Connecting cable Screw Fig (L) 2(N) Cord clamp Earth line 8-6. How to Set Remote Control Selector Switch When two indoor units ae installed in seperated rooms, there is no need to change the selector switch. <Remote control selector switch> When two indoor units are installed in the same room or the adjacent two rooms, they may be controlled simultaneously with a single remote control. To prevent this, set either unit and its remote control to B setting. (Both units are set to A setting before shipment.) The remote control signal is not recived when the indoor unit setting is different from the remote control one. 1. Setting the remote control selector switch with the indoor unit. 1. Press RESET button on the indoor unit to turn the air conditioner ON. 2. Point the remote control at the indoor unit. Note: 1. Repeat above step to reset Remote Control to be A. 2. Remote Control A has not A display. 3. Default setting of Remote Control from factory is A. CAUTION Wrong wiring connection may cause some electrical parts burn out. Be sure to comply with local codes on running the wire from indoor unit to outdoor unit (size of wire and wiring method etc.) Every wire must be connected firmly. TE Wire type: H07 RN-F or 245 IEC66 (2.0 mm 2 or more) 33

35 FILE. SVM Set the remote control selector switch with the remote control 8-7. Others Gas leak test [B] is indicated on the liquid crystal display when setting remote control selector switch to B. [A] is not indicated on the display even if the selector switch is set to A. Valve cover 1) Load the remote control with the batteries. 2) Press the [CHECK] button using something with sharp point. (The preset temperature on the remote control changes to [00].) 3) Press the [MODE] button while pressing the [CHECK] button, [B] is indicted at the right of the present temperature display. To reset the switch to the [A] setting, press the [MODE] button again while pressing the [CHECK] button. Service cap connection Valve stem cap connection Fig Check the flare nut connections, valve stem cap connections and service port cap connections for gas leak with a leak detector or soap water Test operation To switch the TEST RUN (COOL) mode, press RESET button for 10 seconds. (The beeper will make a short beep.) MODE AUTO COOL DRY AUTO FAN TEMP. B FAN AUTO QUIET B TEMP. START/STOP SWING FIX FAN [MODE] button MODE RST CHK ECO TIMER ON OFF SET CLR [CHECK] button RESET button Fig Auto restart setting Fig This product is designed so that, after a power failure, it can restart automatically in the same operating mode as before the power failure. 3. Confirm that the indoor unit can operate with the new setting. Information The product was shipped with Auto Restart function in the off position. Turn it on as required. <How to set the auto restart> Press and hold the RESET button for about 3 seconds. the electronic beeper makes three short beeps to tell you the Auto Restart has been selected. To cancel the Auto Restart, follow the steps described in the section Auto Restart Function of the Owner s Manual. 34

36 9. TROUBLESHOOTING CHART FILE. SVM Troubleshooting Procedure Follow the details of 9-2. Basic Check Items. If there is no trouble corresponding to 9-2, check whether or not there are faulty parts following 9-4. Self-Diagnosis by Remote Control Basic Check Items Power supply voltage The line voltage must be AC V. If it is not within this range, the air conditioner may not operate normally Incorrect cable connection between Indoor and outdoor units The indoor unit is connected to the outdoor unit with 5 cables (Heat pump model) or 3 cables (Cooling Only model). Check that the indoor and outdoor units have been properly connected with terminals assigned the same numbers. If the connectors are not properly connected, the outdoor unit will not operate normally, or OPERATION lamp and TIMER lamp will blink (5Hz) Program control The microcontroller operates as shown in Table to control the air conditioner. If there are any operational problems, check whether or not the problems correspond to Table If they correspond to the Table, they are not problems with the air conditioner, but they are indispensable operations to control and maintain the air conditioner properly. Table No. Operation of air conditioner Descriptions 1 2 The indoor fan motor speed does not change in the Dry operation. 3 When the main power supply is turned on, the OPERATION lamp on the indoor unit blinks. The compressor is not turned off even though the room temperature is in the range that the compressor is turned off. 4 The compressor is not turned on and off even though the thermo control is operated in the Dry operation. The OPERATION lamp blinks to indicate that power is turned on. If the [START/STOP] button is pressed, the lamp stops blinking. The indoor fan motor speed is automatically controlled in the Dry operation. The compressor has a function that it is not turned off for 3 minutes after it is turned on even though the room temperature is in the range that the compressor is turned off. In the Dry operation, the compressor is turned on and off automatically at the regular intervals, independent of the thermo control. 5 The compressor is not turned on even though the room temperature is in the range that the compressor is turned on. 6 The operation mode changes in the Automatic operation. 7 The Auto Fan operation continues in the Automatic operation. 8 The ECO operation operation does not work. The compressor is not turned on in the restart delay timer (3-minutes timer) operation. It is also not turned on after the power supply is turned on because of this timer operation. In Automatic operation, the room temperature is detected all time for control fan speed and the operation mode is changed every 15 minutes according to difference between the room temperature and the preset temperature. When the room temperature is in the range (Preset temperature ± 1 C), the Auto Fan operation is selected. These operations do not work when the unit is in the Dry operation or Auto Fan operation. 35

37 9-3. Primary Judgement Role of indoor unit controller The indoor unit controller receives the operation commands from the remote control and executes them. Temperature measurement at the air outlet of the indoor heat exchanger by the indoor temperature sensor Temperature setting of the indoor heat exchanger by the heat exchanger sensor Louver motor control Indoor fan motor operation control LED display control Transferring of operation commands to the outdoor unit Failure diagnosis FILE. SVM The indoor unit diagnoses the operation condition and indicates the information of the self-diagnosis with the lamps on the display panel of the indoor unit. Table A B C D E F G Lamps OPERATION lamp is blinking. (1Hz) OPERATION lamp is blinking. (5Hz) OPERATION lamp is blinking. (5Hz) OPERATION lamp is blinking. (5Hz) OPERATION lamp is blinking. (5Hz) OPERATION and TIMER lamps are blinking. (5Hz) OPERATION and TIMER lamps are blinking. Self-diagnosis Power failure (when the power supply is turning on) Thermo sensor (TA) short or break Heat exchanger sensor (TC) short or break Indoor fan motor lock or failure Indoor P.C. board failure Wrong wiring of connecting cable Cycle failure Gas shortage or other refrigerant cycle trouble Heat exchanger sensor open, break or short Overload relay or thermostat trouble of compressor The remote control does not work. The outdoor fan does not rotate. Table Diagnosis by detective operation Symptom Check Primary judgement Turn off the power supply once, then turn it on. Try to operate the remote control. The compressor operates. The compressor does not operate. The remote control still does not work. The remote control works. The indoor unit (and/or remote control) is/are defective. OK. The outdoor unit (Outdoor fan motor) is defective. An internal part of the compressor or PCB is defective. 36

38 9-4. Self-Diagnosis by Remote Control (Check Code) (1) If the lamps are indicated as shown B to G in Table 9-3-1, exchanger the self-diagnosis by the remote control. (2) When the remote control is set to the service mode, the indoor controller diagnoses the operation condition and indicate the information of the self-diagnosis on the display of the remote control with the check codes. If a fault is detected, all lamps on the indoor unit will blink at 5Hz and it will beep for 10 seconds (Pi, Pi, Pi...). The timer lamp usually blinks (5Hz) during the self-diagnosis. FILE. SVM How to use remote control in service mode (1) Press [CHK] button with a tip of pencil to set the remote control to the service mode. 00 is indicated on the display of the remote control. The timer lamp on the indoor unit blinks continuously. (5 times per 1 sec.) (2) Press [8TEMP.] button. If there is no fault with a code, the indoor unit will beep once (Pi) and the display of the remote control will change as follows: d 1E 22 TEMP. START/STOP SWING FIX FAN MODE RST CHK ECO TIMER ON OFF SET CLR WC-K10JE Check the unit with all 35 check codes (00 to 22). as shown in Table Press [9TEMP.] button to change the check code backwards. If there is a fault, the indoor unit will beep for 10 seconds (Pi, Pi, Pi...). Note the check code on the display of the remote control. 2-digits alphanumeric will be indicated on the display. All lamps on the indoor unit will blink. (5 times per 1 sec.) Alphanumeric characters are used for the check code. is 5. is 6. is A. is B. is C. is D. (4) Press [START/STOP] button to release the service mode. The display of the remote control returns to as it was before service mode was engaged. 37

39 Table FILE. SVM Check code Block level Diagnosis function Block Indoor P.C. board Check code Air Symptom Conditioner Condition status Thermo. sensor short/break. Continued operation. Indicated when detected abnormal Judgement and action 1. Check thermo sensor. 2.If it is OK, check P.C. board. Heat exchanger sensor short/break. Continued operation. Indicated when detected abnormal 1. Check heat exchanger sensor. 2.If it is OK, check P.C. board. Indoor fan lock, abnormality of indoor fan or thermal fuse break. All off Indicated when detected abnormal 1. Check heat thermal fuse is blow or not? (Terminal block part.) 2.If the thermal fuse is not blow, check indoor fan motor. (Refer to trouble shooting flow charts.) Abnormality of other indoor unit P.C. board. All off Indicated when detected abnormal Replace P.C. borad. Cable connection/ Thermal fuse Refrigerant system 1) Wrong wiring or disconnection of connective cable. 2) Terminal fuse cut off. All off Indicated when detected abnormal 1. Check connective cable correct if wiring is wrong. 2. Check thermal fuse and Terminal blocks. 3.If it is OK, check P.C. board. Other parts (including compressor) 1) Overload relay or thermostat for compressor break. All off Indicated when detected abnormal 1.If overload relay and themostat for compressor are OK, check refrigerant cycle. 2. If refrigerant cycle is OK, check P.C. board. 3. If heat exchanger sensor is OK, check overload relay and themostat for compressor. Content detected by the check codes " " t o " " are stored in memory of the microcomputer even if the power supply is turned off. Therefore, contents of operations in the past are all displayed. 38

40 FILE. SVM Troubleshootig Flowcharts Power can not be turned on (No operation at all) <Preliminary checks> (1) Is the supply voltage normal? (2) Is the connection to the AC output OK.? Shut off the power supply from AC outlet once and turn it on after 5 seconds. Operation Check Items Main cause Countermeasure Symptom Does the OPERATION lamp blink? Does the fuse (F01) blow? Does the power turn on by pushing the [START/STOP] button of the remote control? Does the transmission indicator of remote control flash normally and transmit certainly? Remote control is defective. (No problem) Parts (R62, R63, SG01, C25, C26, DB01, C27, T01) are defective. Replace the remote control. Does the thermal fuse blow? (Under PF. Terminal) Wrong wiring of AC cord or connecting cable is defective. Replace the thermal fuse set. Check connection. Is the indication voltage (DC12V or 5V) of main P.C. board correct? Does the CN12 connector the wrong connecting? P.C. board is defective. Replace the main P.C. board. Is the voltage across C27 measured DC310 ~ 340V? Refer to the paragraph "Pre-check", or defective circuit before power P.C. board block. Re-wiring the cable. Is the voltage across C32 measured DC12V? Shut off the power supply once, and turn it on again after disconnecting the motor connector CN10*. Is the voltage across C32 measured DC12V? Replace the main P.C. board. Motor is defective. * Be sure to disconnect the motor connector CN10 after shut off the power supply, or it will be a cause of damage of the motor. 39

41 Power can not be turned on after replacing indoor P.C. board <Checking Procedure> FILE. SVM Connect the AC Power supply Does the OPERATION lamp blink? 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". Black White 1 2 Indoor Terninal Block CN31 Blue 4 Brown Green/Yellow RY01 3 Supply AC 220~240V 50/60 Hz 40

42 FILE. SVM Outdoor unit does not operate Shut off the power supply from AC outlet once and turn it on after 5 seconds. Does the OPERATION lamp blink? See "Power can not be turned on". Does the power turn on by pushing the [START/STOP] button of the remote control? See "Power can not be turned on". Is AC V supplied between terminal block 1-2? Relays (RY01) Q02 or IC30 is failure. Replace the P.C. board. Is cable connection between indoor and outdoor units correct? Correct cabling between indoor and outdoor units. Check items as following procedure in 9-5-4, 9-5-5,

43 Only compressor does not operate FILE. SVM Shut off the power supply from AC outlet once and turn it on after 5 seconds. Does the OPERATION lamp blink? See "Power can not be turned on". Does the power turn on by pushing the [START/STOP] button of the remote control? See "Power can not be turned on". Is the voltage across the indoor terminal ( 1-2 ) AC V? Relays (RY01) or Q02 or IC30 is failure. Replace the P.C. board. Is cable connection between indoor and outdoor units correct? Correct cabling between indoor and outdoor units. Is the voltage across the outdoor terminal ( 1-2 ) AC V? Cables between indoor and outdoor units are defective. Are all the cords for compressor normal? Re-wire or replace the defective cords. Is the compressor motor winding normal? (Check the winding resistor.) Compressor is defective. Is the capacitor for compressor normal. Capacitor is defective. Is the overload relay normal? Overload relay is defective. Does the compressor start? Compressor is defective. Compressor starts but it stops after a while? Is the gas quantity normal? (Check the pressure) Gas shortage (Gas leakage) Compressor is defective 42

44 Only outdoor fan does not operate FILE. SVM Shut off the power supply from AC outlet once and turn it on after 5 seconds. Does the OPERATION lamp blink? See "Power can not be turned on". Does the power turn on by pushing the [START/STOP] button of the remote control? See "Power can not be turned on". Is the voltage across the terminal : AC V? Relays (RY01) or Q02 or IC30 is failure. Replace the P.C. board. Is cable connection between indoor and outdoor units correct? Correct cabling between indoor and outdoor units. Is the voltage across the terminal : AC V? Cables between indoor and outdoor units are defective. Are all the cords for outdoor fan motor normal? Correct the wire or replace the defective cords. Is the outdoor fan motor winding normal? (Check the winding resistance) Outdoor fan motor is defective. Is the capacitor for compressor normal? Capacitor for outdoor fan motor is defective. Outdoor fan motor is defective. 43

45 FILE. SVM Shut off the power supply once. Turn the power supply. Does the fan stop in no operating status? Control P.C. board is defective. Replace the P.C. board. Start the operation with low fan setting in cool operation. Does the fan rotate? Does AC 120V or higher voltage apply to between red and black lead of fan motor? Shut off the power supply. Does connecting terminal, connecting cable or power supply cord completely? Does not found the short wire about connecting cable and power cord? Change the setting of cooling to hight fan. Does the cross flow fan rotate normally? Repair the bearing of the fan. Thermal fuse operated due to prevent temperature rising cause of incompleted connecting. Turn on the power supply. Does the fan speed become higher? Operation stops Motor control circuit failure (IC30, IC03, Q08) or 12V power circuit failire. Replace the P.C. board. Is the rotation signal (DC+12V-0V) output between 2 (gray lead wire) and 3 (brown lead wire) of the motor connector (CN11) when rotating the cross flow fan by hand in no operating status? (1 pulse/one turn) Replace the fan motor Normal Replace the control P.C. board. Replace connecting the cable (or power cord), thermal fuse and terminal block. 44

46 9-6. Troubleshooting for Remote Control (Including the Indoor P.C. Board) FILE. SVM Push the [START/STOP] button. There is no been from the indoor unit. The operation lamp of the air conditioner main unit does not light. Does the transmission indicator blink? Is there direct sunlight on the receptor of the air conditioner? Reset the remote control by use the tip pencil push in the RESET hole Is there any thyristor fluorescent light near by? Is operation possible when the transmitter is moved nearer to the infrared signal receiver of the air conditioner? Push the [START/STOP] button Battery life Is operation possible when setting the temporary switch of the air conditioner main unit to "TEST RUN" or "TEMPORARY AUTO"? Dose the transmission indicator light? Is there any beep and operation? Can any signal tone be heard when transmitting within 5 cm distance from the radio? P.C. board is failure. Remote control is failure. Avoid direct sunlight. Keep the air conditioner away from thyristor fluorescent light. Replace P.C. board Replace the batteries Normal Replace remote control. 45

47 9-6-1 How to check the P.C. board (1) Operating precautions 1) When removing the front panel or the P.C. board, be sure to shut off the power supply. 2) When removing the P.C. board, hold the edge of the P.C. board and do not apply force to the parts. 3) When connecting or disconnecting the connectors on the P.C. board, hold the Whole housing. Do not pull at the lead wire. FILE. SVM (2) Inspection procedres 1) When a P.C. board is judged to be defective, check for disconnection, burning, or discoloration of the copper foil pattern or this P.C. board. 2) The P.C. board consists of the following 2 parts a. Main P.C. board part: power relay, indoor fan motor drive circuit and control circuit, C.P.U. and peripheral circuits, buzzer drive circuit and buzzer. b. Infrared rays receive and indication parts: Infrared rays receiver unit and LED. 46

48 (3) Checking procedure FILE. SVM Table No. Procedure Check Point (Symptom) Causes 1 Shut off the power supply and remove the P.C. board assembly from the electronic parts base. Remove the connecting cable from the terminal block. 1. Is the fuse blown? 1. Application of shock voltage. Overload by short-circuit of the parts. 2 Remove the connector for the motor, and turn the power on. If the OPERATION lamp blinks (0.5 sec. : ON, 0.5 sec. : OFF) when the power turning on, the checking points described as 1-4 of right column are not necessary to perform. Voltage check 1. Between 4 of RY01 and CN31 (AC 220~240V) 2. Between + and of C27 (DC 310 ~ 340V) 3. Between 5V and GND 4. Between 12V and GND 1. A C power cord is defective. P oor contact of the terminal plate. Miss wiring of the power relay. 2. Capacitor (C25, C26) is defective. Line filter (L01) is defective. Diode (DB01) is defective. 3. IC02 is defective. 4. T01, DB01, R64, C27 are detective. 3 Make the operation status by pushing once the [START/STOP] button, except the status of [FAN ONLY], [ON TIMER]. Voltage check 1. Voltage of relay coil. (DC 12V) Between pin C of Q02 and GND 2.Between No. 1 and 2 of connecting cable terminal block. (AC 220~240V) 1. Breaking wire of the relay coil, defective relay driver. 2. Poor contact of relay. 4 Start the operation with the system which the time of the restart delay timer is shortened. 1. All indicators light for 3 sec.. 2. Indicators do not indicate normally after approximate 3 sec.. } Defective indicator, or poor housing assembly. (CN12) 5 Make the operation status by pressing once the [START/STOP] button. 1.The time of the restart delay timer is shortened. 2. Cool operation 3. Air volume [AUTO] 4. Make the setting temperature lower enough than room temperature. 5. Continuous operation. 1. Compressor does not operate. 2. OPERATION lamp blinks. 1. The temperature of the indoor heat exchanger is abnormally lower. 2. Poor contact of the heat exchanger sensor. (The connector is disconnected.) (CN01) 3. Heat exchanger sensor, main P.C. board are defective. (Refer to Table for the judgment of defective resistance values.) 4. Main P.C. board is defective. 6 Turn the power on after connecting the motor connector. Start the operation with the following condition. 1. Operation [Cooling] 2. Airflow [High fan] 3. Continuous operation 1.Motor does not rotate. (The key operation is accepted.) 2. The Motor rotates, but it vibrates too much. 1. Poor contact of the motor connector. 2. P.C. board is defective. 47

49 Table Approximate resistance value of thermo sensor FILE. SVM Temperature 0 C 10 C 20 C 25 C 30 C (kω) Resistance value How to shorten time of restart delay timer 1 2 Press [CLR] button while pressing [CHK] button with a tip of a pencil. Then press [START/STOP] signal to the indoor unit. MODE AUTO COOL DRY AUTO FAN TEMP. Hr.ON OFF FAN AUTO QUIET TEMP. 2 START/STOP SWING MODE FIX RST CHK FAN ECO TIMER 1 ON OFF SET CLR 48

50 10. PART REPLACEMENT FILE. SVM Indoor Unit No. Part name Procedures Remarks 1 Front panel How to remove the front panel 1) Stop the operation of the air conditioner and turn off its main power supply. 2) Pull the air inlet grille toward you to open it and remove the air inlet grille. Then remove the 2 screws fixing the front panel. 3) First open the horizontal louver, and then remove the front panel from the back body by pulling it toward you Screws 3 2 How to mount the front panel Push the front panel back in and make sure all hooks are locked. 2 Electrical part How to remove the electrical part. 1) Remove the front panel with procedure 1. 2) Remove the screw holding the electrical part cover. 3) Disconnect the 3 connectors 2-(3P) for the fan motor and the connector (5P) for the louver motor from the P.C. board assembly. 4) Pull out the TC sensor from the sensor holder. 5) Remove the screw for the ground connection, remove the screw for the electrical part box. Then remove the LED and the electrical part box from the main unit. 4 TC Sensor 2 Screws How to mount the electrical part. 1) To put back the electrical part box, lock it to the upper hook of the back body. 2) Tighten the screws on the electrical part box. 3) Connect the 3 connectors and arrange the wiring same as original condition and then tighten the screw from the LED unit to the back body. 4) Attach the TC sensor to the holder. 5) Tighten the screw for the ground connection. 6) Tighten the screw on the electrical part cover. 3 3-Connectors 5 Screws 3 Horizontal louver 1) Remove the front panel and the electrical part following procedure 2. 2) Remove the center shaft of the horizontal louver from the back body. 3) Remove the left shaft from the back body. 4) Remove the horizontal louver from the back body. 3 Left shaft 2 Center shaft 49

51 FILE. SVM No. Part name Procedures Remarks 4 Heat exchanger 1) Remove the front panel, electrical part and the horizontal louver following procedure 3. 2) Remove the pipe holder at the rear side of main unit. 3) Remove the 2 screws on the heat exchanger at the base bearing. 4) Remove the screw on the heat exchanger at the fixed plate from the back body and then pull out the right hand side until the socket of heat exchanger released from the hook of the band motor (L), and then pull out the upper side of heat exchanger slowly. 3 2-Screws 2 Pipe holder 4 Screws 5 Cross flow fan 1) Remove the front panel, electrical part, horizontal louver and the heat exchanger following procedure 4. 2) Remove the 2 screws on the band motor (L) and remove the 2 screws on the band motor (R) and then remove the cross flow fan. 3) Loosen the set screw of the cross flow fan then separate the fan and the fan motor. Notice To assemble cross flow fan and fan motor to the unit, please turn the fan motor unit the center of its terminal meets the top position of band motor (R). Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is 4.7 mm. 2 2-Screws (L) 4.7 mm 6 Set screw Middle of the fan motor terminal 2-Screws (R) 2 6 Base bearing 1) Remove the front panel, electrical part, horizontal louver, heat exchanger and the cross flow fan following procedure 5. 2) Remove the 2 screws fixing the base bearing. 3) Remove the bearing from the base bearing. If the housing protrudes from the base bearing, put the housing in position and attach the bearing to the base bearing. 2 2-Screws 50

52 10-2. Outdoor Unit FILE. SVM No. Part name Procedures Remarks 1 Common procedure 1. Detachment 1) Stop operation of the air conditioner, and turn off the main switch and breaker of the air conditioner. 2) Remove the valve cover. (ST1T 4 x 10s 1 pc) After removing screw, remove the valve cover pulling it downward. 3) Remove the wiring cover (ST1T 4 x 10s 2 pcs.), and then remove the power cord, connecting cable, and cord clamp (ST2T 4 x 16s 2 pcs.). 4) Remove the upper cabinet. (ST1T 4 x 10s 5 pcs.) After removing screws, remove the upper cabinet pulling it upward. 2. Attachment 1) Attach the upper cabinet. (ST1T 4 x 10s 5 pcs.) Hook the rear side of the upper cabinet to the claw of the rear cabinet, and then place it on the front cabinet. 2) After connecting the power cord and connecting cable, attach the cord clamp and wiring cover. Insert the upper part into the upper cabinet, and insert the claw which has been hooked to the lower part into the square hole, and then fix it with screw. (ST1T 4 x 10s 1 pc.) 3) Attach the valve cover. (ST1T 4 x 10s 1 pc.) Insert the upper part to the upper cabinet, set the hook claw of the valve cover to square holes (at three positions) of the main unit, and attach it pushing upward. Upper cabinet Wiring cover Valve cover Upper cabinet 2 Front cabinet 1. Detachment 1) Perform work of item 1 of 1. 2) Remove upper screw (ST1T 4 x 10s 3 pcs.) of the front cabinet, and lower screws (ST1T 4 x 10s 8 pcs.) of the front cabinet. Both side of front cabinet envelop the unit, so remove it by pulling sideward. 2. Attachment 1) Assemble front cabinet to the unit. 2) Attach the removed screws to the original positions. 51

53 No. Part name Procedures Remarks FILE. SVM Fan motor 1) Perform work of item 1 of 1 and 1 of 2. 2) Remove the flange nut fixing the fan motor and the propeller fan. Flange nut is loosened by turning clockwise. (To tighten the flange nut, turn counterclockwise.) 3) Remove the propeller fan. 4) Disconnect the connector for the fan motor from the ASM-E-PARTS. 5) Remove the fixing screws (4 pcs.) holding the fan motor by hand so that it does not fall. 6) Cut the motor lead at the point which is 100 mm apart from the connector toward the fan. 7) Use the connector used for the ASM-E-PARTS, and pinch the lead wires using the closed end splice. Fan motor Propeller fan Flange nut 100 Closed end splice 4 Compressor 1) Perform work of item 1 of 1, 1 of 2, 3 2) Extract refrigerant gas. 3) Remove the partition board. (ST1T 4 x 10s 3 pcs.) 4) Remove the sound-insulation material. 5) Remove the terminal cover of the compressor, and disconnect the lead wire of the compressor thermo and the compressor from the terminal. 6) Remove the pipe connected to the compressor with a burner. Make sure the flame does not touch the 4 way valve. 7) Remove the fixing screw of the base plate and heat exchanger. (ST1T 4 x 10s 2 pcs.) 8) Pull upward the refrigeration cycle. 9) Remove the nut fixing the compressor to the base plate. Compressor 52

54 No. Part name Procedures Remarks FILE. SVM Fan guard 1. Detachment 1) Perform work of item 1 of 1 and 1 of 2. Requirement: Perform the work on a corrugated cardboard, cloth, etc. to prevent scratches to the product. 2) Remove the front cabinet, and place it down so that the fan guard side faces downwards. 3) Remove the hooking claws by pushing a minus screwdriver according to the arrow mark in the right figure, and remove the fan guard. Minus screwdriver Hooking claw 2. Attachment 1) Insert the claws of the fan guard in the hole of the front cabinet. Push the hooking claws (8 positions) by your hand and fix the claws. Requirement: This completes all the attaching work. Check that all the hooking claws are fixed to the specified positions. 6 Capacitor for compressor 1) Perform the common procedure 1. 2) Remove the fixing screw and the capacitor band. ( 1-Screw 4 x 10s) 3) Disconnect the lead wires. Capacitor for compressor Capacitor band Screws 4 x 10s 7 Capacitor for fan motor 1) Perform the common procedure 1. 2) Remove the fixing screw and the capacitor band. ( 1-Screw 4 x 10s) 3) Disconnect the lead wires. Screws 4 x 10s Capacitor for fan motor 53

55 FILE. SVM EXPLODED VIEWS AND PARTS LIST Indoor Unit (E-Parts Assy) Location Part Location Part Description No. No. No. No. Description T60378 TERMINAL T62003 CORD CLAMP T69371 SENSOR;HEAT EXCHANGER T69745 PC BOARD (RAS-07SKSX-1) T69005 SENSOR;THERMOSTAT T69746 PC BOARD (RAS-09SKSX-1) T69612 DISPLAY UNIT T60343 POWER CORD T69364 FUSE,TEMPERATURE 54

56 FILE. SVM Indoor Unit Location Part Location Part Description No. No. No. No. Description T00462 FRONT PANEL ASSY T49006 HOLDER FOR PLATE T09393 GRILLE OF AIR INLET T22312 BEARING ASSY, MOLD T03358 BACK BODY ASSY T39319 BASE BEARING T80315 AIR FILTER T20323 ASSY CROSS FLOW FAN T09392 HORIZONTAL LOUVER T39320 MOTOR BAND(LEFT) T70313 HOSE, DRAIN T39321 MOTOR BAND(RIGHT) T79301 CAP-DRAIN T21393 FAN MOTOR T21363 MOTOR; STEPPING T82309 INSTALLATION PLATE T44424 REFRIGERATION CYCLE ASSY T69437 WIRELESS REMOTE CONTROL T47353 PIPE; SUCTION (RAS-13) T63002 REMOTE CONTROL HOLDER T47355 PIPE; SUCTION (U1U2_GD) T62326 TERMINAL COVER T11317 PIPE SHIELD T60317 CORD MOTOR LOUVER T19333 HOLDER, SENSOR T07311 PIPE HOLDER T49329 PLATE OF EVA SEAL 55