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Toshiba RAS-107SKV-E6 - User Manual

Toshiba RAS-107SKV-E6
104 pages
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R410A
SERVICE MANUAL
SPLIT TYPE
Indoor Unit Outdoor Unit
<High Wall, Heat Pump Type> <Heat Pump Type>
RAS-077SKV-E6 RAS-077SAV-E6
Revised on Apr, 2014
FILE NO. SVM-13092-2
RAS-107SKV-E6 RAS-107SAV-E6
RAS-137SKV-E6 RAS-137SAV-E6

Table of Contents

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Toshiba RAS-107SKV-E6 Specifications

General IconGeneral
TypeSplit System
Cooling Capacity2.5 kW
Heating Capacity3.2 kW
Power Supply220-240V, 50Hz
Indoor Unit Weight9 kg
Noise Level (Indoor)24 dB

Summary

General Safety Precautions

Installation and Refrigerant Safety

Safety precautions for R410A installation/servicing, including pressure, tools, and leak checks.

Electrical and High Voltage Safety

Prioritize electrical safety, disconnect power, handle high voltage circuits with extreme care.

General Safety Precautions

Operational and Handling Safety

Ensure unit stability, check for refrigerant leaks, handle parts carefully, secure against seismic activity.

Heating Operation Advisory

Low-temperature heating may require an antifreeze heater for drainage.

Product Specifications

Electrical Characteristics and Performance Data

Details electrical properties, operating currents, power consumption, COP, and noise levels for indoor/outdoor units.

Physical Dimensions and Piping Information

Provides dimensions for indoor/outdoor units, compressor details, and refrigerant piping specifications.

Refrigerant R410 A Handling and Safety

Safety During R410 A Installation and Servicing

Safety precautions for R410A installation/servicing, including pressure, tools, and leak checks.

R410 A Piping Material and Joint Specifications

Specifies copper pipe types, flare/socket joints, and processing procedures for R410A piping.

Required Tools for R410 A Installation

Exclusive Tools for R410 A System

Tools exclusively for R410A, detailing their specifications and interchangeability with R22.

General and Conventional Tools

General tools that can be used for R410A and R22 systems, including installation and measurement tools.

Refrigerant Recharging Procedure

Refrigerant Charging Steps

Detailed steps for recovering refrigerant, evacuating, and charging liquid refrigerant into the system.

Refrigerant Charging Configuration Diagram

Diagram showing the configuration of refrigerant cylinder, gauge manifold, and vacuum pump for charging.

Pipe Brazing Procedures and Materials

Brazing Filler Materials and Flux Usage

Describes silver, phosphor bronze, and low-temperature brazing fillers, and the importance of flux.

Flux Characteristics and Types

Explains flux characteristics like activation temperature and types: noncorrosive and activated flux.

Pipe Brazing Procedures and Materials

Piping Material Compatibility for Brazing

Specifies compatible piping materials, brazing fillers, and flux types for different joint types.

Brazing Process to Prevent Oxidation

Describes using dry nitrogen gas flow during brazing to prevent oxidation in the pipe interior.

Indoor Unit Construction Details

Indoor Unit Physical Layout and Dimensions

Exploded view and dimensions of the indoor unit, including air filter, heat exchanger, and mounting points.

Indoor Unit Mounting and Piping Connections

Details mounting plate, drain hose, and refrigerant pipe connection points for indoor unit installation.

Indoor Unit Construction Details

Outdoor Unit Physical Layout and Dimensions

Exploded view and dimensions of the outdoor unit, including fan, compressor, and air inlets/outlets.

Air Conditioner Wiring Diagram

Indoor Unit Wiring Schematic

Detailed wiring diagram for the indoor unit, including sensors, motors, and control board connections.

Outdoor Unit Wiring Schematic

Wiring diagram for the outdoor unit, illustrating connections for compressor, fan, and valves.

Electrical Component Specifications

Indoor Unit Electrical Parts

Specifications for indoor unit electrical components like fan motor, sensors, and louver motor.

Outdoor Unit Electrical Parts

Specifications for outdoor unit electrical parts including reactor, fan motor, sensors, and compressor.

Refrigerant Cycle and Operation Diagrams

Refrigerant Cycle Diagram (Cooling;Heating)

Diagram showing refrigerant flow for cooling and heating operations for specific indoor/outdoor models.

Key Operational Parameters and Notes

Notes on allowable pipe length, height difference, and refrigerant amount for system operation.

Refrigerant Cycle Operation Data

Cooling Operation Data

Operating data for cooling mode, including pressures, temperatures, and compressor speeds by model.

Heating Operation Data

Operating data for heating mode, including pressures, temperatures, and compressor speeds by model.

Indoor Unit Control System Block Diagram

Indoor Unit Control Logic

Block diagram illustrating indoor unit control logic, including sensor inputs, MCU functions, and outputs.

Remote Control Interface and Functions

Shows remote control functions like mode selection, temperature setting, and fan speed control.

Indoor Unit Control System Block Diagram

Outdoor Unit Control Logic

Block diagram detailing outdoor unit control, including sensors, inverter, and valve control logic.

Air Conditioner Operation Description

Control System Overview and Roles

Overview of control system, indoor/outdoor unit roles, and their primary functions.

Signal Communication and Commands

Describes serial signal communication for operation commands and status information between units.

Detailed Operation Modes and Functions

Basic Operation Modes

Explains basic operation, cooling, heating, auto, and dry modes, including fan speed control.

Motor Control and Capacity Adjustment

Explains control of indoor/outdoor fan motors and capacity adjustment methods.

Protective, Special, and Remote Functions

Details various controls like protective, defrost, louver, ECO, PMV, auto restart, and remote operations.

Installation Procedures and Diagrams

Indoor and Outdoor Unit Installation Diagram

Diagram showing placement and connection points for indoor and outdoor units, including piping and drainage.

Wireless Remote Controller Setup

Steps for loading batteries into the wireless remote controller before initial setup.

Installation Procedures and Diagrams

Optional Installation Parts

Details optional parts required for installation, such as refrigerant piping and insulating material.

Outdoor Unit Fixing and Drainage Nipple

Guidance on securing the outdoor unit against wind and attaching the drain nipple for defrost water.

Installation Procedures and Diagrams

Accessory and Installation Parts List

Lists included accessories like installation plate, remote control, batteries, and manuals.

Installation Procedures and Diagrams

Installation and Servicing Tools for R410 A

Details changes in tools for R410A, emphasizing differences from R22 and new requirements for installation.

Indoor Unit Installation Guidelines

Indoor Unit Installation Location Requirements

Requirements for indoor unit placement, ensuring space, access, and avoiding sunlight/noise sources.

Remote Control Installation Location

Guidelines for remote control placement, avoiding obstacles and interference for optimal signal reception.

Indoor Unit Installation Guidelines

Cutting Holes and Mounting Installation Plate

Procedures for cutting holes for pipes and securely mounting the indoor unit's installation plate.

Electrical Wiring and Safety Precautions

Instructions for electrical work, ensuring correct voltage, dedicated power source, and safe wiring practices.

Indoor Unit Installation Guidelines

Connecting Cable Wiring

Step-by-step guide for connecting the electrical cable to the indoor unit's terminal block and securing it.

Piping and Drain Hose Installation

Instructions for shaping refrigerant pipes and installing the drain hose, ensuring proper insulation and slope.

Indoor Unit Installation Guidelines

Drain Cap and Piping Variations

Instructions for fixing the drain cap and connecting pipes for left-hand and bottom-left piping configurations.

Indoor Unit Installation Guidelines

Securing the Indoor Unit

Procedures for securely attaching the indoor unit to the installation plate, including checking for firmness.

Drainage System Setup

Guidelines for setting up the drainage system, ensuring proper slope and preventing dew-dropping.

Outdoor Unit Installation Guidelines

Outdoor Unit Installation Location Requirements

Requirements for outdoor unit placement, considering space, noise, wind, and gas exposure.

Cold Climate Installation Precautions

Precautions for installing in snowy or cold regions, including snow protection and drain management.

Refrigerant Piping Flaring Procedure

Instructions for cutting and flaring copper pipes for refrigerant connections, including dimensions and tools.

Outdoor Unit Installation Guidelines

Flare Connection and Tightening

Steps for connecting flare nuts, including tightening torque specifications and precautions.

Vacuum Pump Operation for Evacuation

Procedure for using a vacuum pump to evacuate refrigerant lines, ensuring proper pressure and time.

Outdoor Unit Installation Guidelines

Packed Valve Handling Precautions

Precautions for opening and tightening packed valve stems, and handling valve caps with specified torque.

Outdoor Unit Wiring Connection

Steps for connecting the power cord and connecting cable to the outdoor unit terminals, preventing water ingress.

Final Installation Checks and Settings

Gas Leak Test Procedure

Method for performing a gas leak test using a leak detector or soap water on flare nut connections.

Remote Control A-B Selection

Procedure for setting remote control to A or B to manage multiple indoor units in proximity.

Troubleshooting and Fault Diagnosis

Troubleshooting Procedure Overview

Overview of troubleshooting steps, including confirmation, judgment, and symptom analysis.

Inverter and Control Circuitry Precautions

Safety warnings regarding high voltage, uninsulated circuitry, and handling the inverter assembly.

Troubleshooting and Fault Diagnosis

Outdoor Unit Control Section Precautions

Precautions for inspecting the outdoor unit controller, especially capacitor discharging to prevent electric shock.

Initial Troubleshooting Checks

Power Supply and Voltage Confirmation

Confirms normal operation of the power breaker, supply voltage, and proper cable connection.

Normal Operation vs. Trouble Identification

Identifies normal microcomputer operations that might appear as faults, such as compressor restart delay.

Indoor Unit Fault Indicators

Primary Fault Judgment Methods

Describes primary judgment methods: LED flashing, self-diagnosis via remote, and symptom analysis.

Indoor Unit LED Flashing Code Interpretation

Interprets flashing patterns of indoor unit LEDs (OPERATION, TIMER, FILTER) to identify specific faults.

Remote Controller Self-Diagnosis

Using Remote Controller in Service Mode

Instructions on entering service mode, navigating check codes, and interpreting diagnostic results.

Remote Controller Check Code Interpretation

Details alphanumeric check codes displayed on the remote controller for identifying specific faults.

Remote Controller Self-Diagnosis

Check Codes and Troubleshooting Actions

Table mapping check codes to causes, status, flashing errors, and recommended actions for diagnosis and repair.

Symptom-Based Troubleshooting for Indoor Unit

Troubleshooting Power-On Issues

Guides through checking power supply, voltage, cable connections, and fuses for power-on failures.

Troubleshooting Specific Indoor Unit Symptoms

Diagnoses issues like no operation, fan display errors, compressor speed anomalies, and AUTO mode changes.

Symptom-Based Troubleshooting for Indoor Unit

Indoor Fan Motor Operation Diagnosis

Checks power supply to fan motor, motor rotation, fan speed, and signal output for diagnosis.

Remote Controller Troubleshooting

Remote Controller Primary Checks

Checks for direct sunlight, fluorescent lights, transmission indicators, and battery life.

Remote Controller Operation Testing

Tests operation with temporary settings, signal tone on radio, and verifies transmission indicator light.

Wiring and Outdoor Unit Operation Issues

Outdoor Unit Operation Failure

Checks voltage between indoor/outdoor terminals and serial signal transmission for outdoor unit failure.

Outdoor Unit Stoppage After Startup

Analyzes phenomena like unit stopping after 10-20 mins, requiring power cycle, or stopping with alarms.

Simple Component Checks

Checking Pulse Motor Valve (PMV) and Sensors

Guides on checking PMV coil connection, positioning, inverter connection, and sensor seating.

Gas Amount and Valve Clogging Check

Steps to check gas amount, valve clogging, and condensation at PMV outlet for system health.

Outdoor Unit Inverter Assembly Diagnosis

Inverter Assembly Diagnosis Workflow

Flowchart for diagnosing inverter issues, including fuse check, capacitor voltage, fan rotation, and winding resistance.

Inverter Component Resistance Checks

Procedures for checking compressor winding resistance and grounding to diagnose motor or board issues.

Indoor Unit P.C. Board Checks

P.C. Board Handling Precautions

Precautions for safely removing and handling the indoor unit's P.C. board, including power disconnection and connector care.

P.C. Board Inspection Procedures

Procedures for inspecting the P.C. board for burning, discoloration, or component issues.

Indoor Unit P.C. Board Checks

Specific P.C. Board Troubleshooting Checks

Step-by-step checks for P.C. board faults, including fuse, voltage, indicators, compressor, and fan motor signals.

P.C. Board Layout and Sensor Characteristics

Indoor Unit P.C. Board Component Layout

Diagram showing the layout of the indoor unit's P.C. board, including connectors and voltage points.

Temperature Sensor Resistance Characteristics

Graph illustrating the resistance characteristics of temperature sensors (TA, TC, TO, TS, TE) versus temperature.

Component Resistance Checks (Indoor;Outdoor)

Indoor Unit Component Resistance

Resistance values for indoor unit sensors, remote, louvers, and fan motor for diagnostic testing.

Outdoor Unit Component Resistance

Resistance values for outdoor unit compressor, fan motor, valve coils, and reactor for diagnostic testing.

Component Checking Methods

Electrolytic Capacitor and Converter Module Checks

Methods for checking electrolytic capacitors and converter modules, including continuity and charging characteristics.

Diode Check Procedure

Procedure for checking diodes using a tester, including resistance values for good products and troubleshooting.

Outdoor Fan Motor Diagnosis

Outdoor Fan Motor Symptoms and Causes

Lists symptoms of outdoor fan motor failure and potential causes like mechanical lock or circuit failure.

Simple Outdoor Fan Motor Good;Bad Test

Provides a simple test procedure to determine if the outdoor fan motor is functional by checking resistance and rotation.

Cancelling Clean Operation Setting

Procedure to Cancel Clean Operation

Steps involving modifying the indoor PC board and using the reset button to cancel Clean Operation.

Replacing Main Internal Parts

General Replacement Precautions

Emphasizes turning off power, test runs, avoiding flames, and handling live parts with care.

Indoor Unit Front Panel Replacement

Procedure for removing the indoor unit's front panel, including opening grilles and filters.

Replacing Main Internal Parts

Front Panel Removal and Reassembly

Steps for removing front panel screws and hooks, and instructions for reassembling the front panel.

Replacing Main Internal Parts

Electric Parts Box Assembly Replacement

Procedure for removing and replacing the electric parts box, including disconnecting sensors and motors.

Replacing Main Internal Parts

Horizontal Louver Removal

Procedure for removing the horizontal louver shafts and the louver assembly from the unit.

Evaporator (Heat Exchanger) Replacement

Instructions for removing the evaporator, including pipe holders, fixing screws, and separating the heat exchanger.

Replacing Main Internal Parts

Bearing Replacement

Procedure for removing the bearing base and its screws, and caution for reassembly.

Replacing Main Internal Parts

Fan Motor Replacement

Procedure for removing the fan motor, including loosening set screws, removing covers, and cutting motor leads.

Replacing Main Internal Parts

Cross Flow Fan Installation

Guidelines for installing the cross flow fan, including positioning and securing it with a set screw.

Microcomputer Replacement

Microcomputer Replacement Procedure

Procedure for replacing the microcomputer, involving power shutdown, panel removal, and base removal.

Outdoor Unit Part Replacement

Outdoor Unit Common Procedure

Steps for removing and reattaching the outdoor unit's upper cabinet and front cabinet.

Outdoor Unit Front Cabinet Replacement

Detailed procedure for removing and reattaching the outdoor unit's front cabinet panels and screws.

Outdoor Unit Part Replacement

Inverter Assembly Replacement

Procedure for replacing the inverter assembly, including safety precautions for high voltage and capacitor discharging.

Outdoor Unit Part Replacement

Outdoor Fan Motor Replacement

Procedure for removing the fan motor, propeller fan, and associated connectors.

Compressor Replacement

Detailed steps for compressor replacement, including refrigerant extraction, partition removal, and pipe disconnection.

Reactor Replacement

Procedure for removing and replacing the reactor, involving screw removal.

Outdoor Unit Part Replacement

Fan Guard Replacement

Procedure for removing and attaching the fan guard, including precautions to prevent scratches.

Pulse Modulating Valve (PMV) Coil Replacement

Procedure for replacing the PMV coil, including rotation and positioning instructions.

Outdoor Unit Part Replacement

Control Board Assembly Replacement

Procedure for disconnecting connectors and replacing the control board assembly, including heat sink and P.C. board base.

Temperature Sensor Replacement

Temperature Sensor Replacement Procedure

Step-by-step guide for cutting, stripping, soldering, and securing replacement temperature sensors.

Common Service Parts for Sensors

Lists common service parts for sensors, including springs, tubes, tape, and terminals.

Indoor Unit Parts List and Exploded Views

Indoor Unit Part Identification

Exploded view and list of parts for the indoor unit, identifying components by location and part number.

Indoor Unit Parts List and Exploded Views

Indoor Unit Component Breakdown

Comprehensive list of indoor unit components, including motors, fans, sensors, and panels with part numbers.

Outdoor Unit Parts List (RAS-077,107 SAV-E6)

Outdoor Unit Component Identification

Exploded view and list of parts for outdoor units, identifying components by location and part number.

Outdoor Unit Parts List (RAS-077,107 SAV-E6)

Outdoor Unit Component Breakdown

Comprehensive list of outdoor unit components for RAS-137SAV-E6, including fan, compressor, and valves with part numbers.

Outdoor Unit (Part-E) Parts List

Outdoor Unit (Part-E) Component Identification

Exploded view and list of parts for Outdoor Unit (Part-E), identifying components by location and part number.

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