Toshiba RAS-4M27S3AV-E Service Manual
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Toshiba RAS-4M27S3AV-E Service Manual

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FILE NO. SVM-15073

SERVICE MANUAL

AIR-CONDITIONER
SPLIT TYPE
RAS-4M27S3AV-E
RAS-4M27S3AV-A
RAS-4M27S3AV-TR
R410A
July , 201 5

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Summary of Contents for Toshiba RAS-4M27S3AV-E

  • Page 1: Service Manual

    FILE NO. SVM-15073 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE RAS-4M27S3AV-E RAS-4M27S3AV-A RAS-4M27S3AV-TR R410A July , 201 5...

  • Page 2: Table Of Contents

    FILE NO. SVM-15073 CONTENTS 1. SAFETY PRECAUTIONS ............3 2. SPECIFICATIONS ................ 5 3. REFRIGERANT R410A ............. 26 4. CONSTRUCTION VIEWS ............34 5. WIRING DIAGRAM ..............36 6. SPECIFICATIONS OF ELECTRICAL PARTS ......38 7. REFRIGERANT CYCLE DIAGRAM........... 39 8.

  • Page 3: Safety Precautions

    FILE NO. SVM-15073 1. SAFETY PRECAUTIONS The important contents concerned to the safety are described on the product itself and on this Service Manual. Please read this Service Manual after understanding the described items thoroughly in the following contents (Indications/Illustrated marks), and keep them. [Explanation of indications] Indication Explanation...
  • Page 4 FILE NO. SVM-15073 CAUTION TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY A switch or circuit breaker that can disconnect all poles must be included in the fixed wiring. Be sure to use an approved circuit breaker or switch. DANGER •...

  • Page 5: Specifications

    Outdoor unit Combinations of indoor unit models that can be connected Heat pump RAS-4M27S3AV-E, -A, -TR Refer to page 8 to 25 NOTES A 1-room connection is not an option for the indoor units (you cannot connect only one indoor unit).
  • Page 6 FILE NO. SVM-15073 2-2-1. SUMMARIES OF PRODUCT CHARACTERISTICS RAS-4M27S3AV-A AS/NZS 4755.3.1. These models supports DRM1 DRM2 DRM3. AS/NZS 4755 DRM1 DRM2 DRM3 Demand response mode Description DRM1 Compressor off E30m ≤ R × 0.50 × 0.5 DRM2 E30m ≤ R × 0.75 × 0.5 DRM3 *1: E30m = total electrical energy (kWh) used by the air conditioner for all purposes (including compressors, controls and fans) over a 30 min period.
  • Page 7 FILE NO. SVM-15073 2-2-2. SPECIFICATIONS OF ELECTRICAL PARTS 1. Parts for demand response (Common usage) Parts name Type Specifications Demand response P.C. board MCC-1653 AC230-240V,50Hz Transformer TT-02 AC230V,50/60Hz,150mA 2. Demand response P.C. board DRC signal reception connector CN01 Transformer output DRC signal connector CN102 transmission...
  • Page 8 FILE NO. SVM-15073 Outdoor Unit : RAS-4M27S3AV-E,-A,-TR <Cooling / 220V> Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 1 unit 2.00 2.0 ( 1.4 - 2.5 )
  • Page 9 FILE NO. SVM-15073 <Cooling / 220V> (Continued) Outdoor noise (dB) Total Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) A A A 3 units 07 07 07 2.00 2.00 2.00 6.0 ( 3.8 - 7.5 ) 2400 ( 950 - 2720 ) 11.48 ( 4.80 - 12.62 ) 10 07 07 2.70 2.00 2.00...
  • Page 10 FILE NO. SVM-15073 <Cooling / 220V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 4 units 07 07 07 07 1.78 1.78 1.78 1.78 7.1 ( 4.0 - 8.6 ) 2029 ( 850 - 2620 ) 9.71 ( 4.29 - 12.15 ) 10 07 07 07 2.33 1.72 1.72 1.72 7.5 ( 4.0 - 8.7 ) 2143 ( 890 - 2640 ) 10.25 ( 4.49 - 12.24 ) 13 07 07 07 2.90 1.57 1.57 1.57 7.6 ( 4.1 - 8.9 ) 2171 ( 900 - 2700 ) 10.39 ( 4.55 - 12.52 )
  • Page 11 FILE NO. SVM-15073 <Cooling / 230V> Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Power consumption Heating capacity Operating current Sound Sound status Pressure Power (kW) A A A 1 unit 2.00 2.0 ( 1.4 - 2.5 ) 650 ( 640 - 700 ) 3.67 ( 3.66 - 3.58 ) 2.70...
  • Page 12 FILE NO. SVM-15073 <Cooling / 230V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 3 units 07 07 07 2.00 2.00 2.00 6.0 ( 3.8 - 7.5 ) 2400 ( 950 - 2720 ) 10.98 ( 4.59 - 12.07 ) 10 07 07 2.70 2.00 2.00 6.7 ( 3.8 - 8.2 ) 2400 ( 950 - 2720 ) 10.98 ( 4.59 - 12.07 )
  • Page 13 FILE NO. SVM-15073 <Cooling / 230V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 4 units 07 07 07 07 1.78 1.78 1.78 1.78 7.1 ( 4.0 - 8.6 ) 2029 ( 850 - 2620 ) 9.29 ( 4.11 - 11.62 ) 10 07 07 07 2.33 1.72 1.72 1.72 7.5 ( 4.0 - 8.7 ) 2143 ( 890 - 2640 ) 9.81 ( 4.30 - 11.71 )
  • Page 14 FILE NO. SVM-15073 <Cooling / 240V> Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) A A A 1 unit 2.00 2.0 ( 1.4 - 2.5 ) 650 ( 640 - 700 ) 3.52 ( 3.51 - 3.43 ) 2.70...
  • Page 15 FILE NO. SVM-15073 <Cooling / 240V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power A A A (kW) 3 units 07 07 07 2.00 2.00 2.00 6.0 ( 3.8 - 7.5 ) 2400 ( 950 - 2720 ) 10.53 ( 4.40 - 11.56 ) 10 07 07 2.70 2.00 2.00...
  • Page 16 FILE NO. SVM-15073 <Cooling / 240V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 4 units 07 07 07 07 1.78 1.78 1.78 1.78 7.1 ( 4.0 - 8.6 ) 2029 ( 850 - 2620 ) 8.90 ( 3.94 - 11.14 ) 10 07 07 07 2.33 1.72 1.72 1.72 7.5 ( 4.0 - 8.7 ) 2143 ( 890 - 2640 ) 9.40 ( 4.12 - 11.22 )
  • Page 17 FILE NO. SVM-15073 Outdoor Unit : RAS-4M27S3AV-E,-A,-TR <Heating / 220V> Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) A A A 1 unit 2.70 2.7 ( 0.8 - 4.8 ) 900 ( 300 - 1980 )
  • Page 18 FILE NO. SVM-15073 <Heating / 220V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) A A A 3 units 07 07 07 2.70 2.70 2.70 8.1 ( 2.0 - 10.4 ) 2290 ( 380 - 2750 ) 10.96 ( 2.16 - 12.76 ) 10 07 07 3.53 2.38 2.38...
  • Page 19 FILE NO. SVM-15073 <Heating / 220V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 4 units 07 07 07 07 2.09 2.09 2.09 2.09 8.4 ( 2.9 - 11.5 ) 1792 ( 501 - 2560 ) 8.57 ( 2.53 - 11.87 ) 10 07 07 07 2.80 1.89 1.89 1.89 8.5 ( 2.9 - 11.5 ) 1812 ( 501 - 2560 ) 8.67 ( 2.53 - 11.87 )
  • Page 20 FILE NO. SVM-15073 <Heating / 230V> Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 1 unit 2.70 2.7 ( 0.8 - 4.8 ) 900 ( 300 - 1980 ) 4.50 ( 1.79 - 8.78 ) 4.00...
  • Page 21 FILE NO. SVM-15073 <Heating / 230V> (Continued) Total Outdoor noise (dB) Power Operating Indoor unit Unit capacity supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 3 units 07 07 07 2.70 2.70 2.70 8.1 ( 2.0 - 10.4 ) 2290 ( 380 - 2750 ) 10.48 ( 2.07 - 12.20 ) 10 07 07 3.53 2.38 2.38 8.3 ( 2.0 - 10.4 ) 2300 ( 380 - 2750 ) 10.53 ( 2.07 - 12.20 )
  • Page 22 FILE NO. SVM-15073 <Heating / 230V> (Continued) Total Outdoor noise (dB) Power Operating Indoor unit Unit capacity supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 4 units 07 07 07 07 2.09 2.09 2.09 2.09 8.4 ( 2.9 - 11.5 ) 1792 ( 501 - 2560 ) 8.20 ( 2.42 - 11.36 ) 10 07 07 07 2.80 1.89 1.89 1.89 8.5 ( 2.9 - 11.5 ) 1812 ( 501 - 2560 ) 8.29 ( 2.42 - 11.36 )
  • Page 23 FILE NO. SVM-15073 <Heating / 240V> Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) A A A 1 unit 2.70 2.7 ( 0.8 - 4.8 ) 900 ( 300 - 1980 ) 4.31 ( 1.71 - 8.42 )
  • Page 24 FILE NO. SVM-15073 <Heating / 240V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 3 units 07 07 07 2.70 2.70 2.70 8.1 ( 2.0 - 10.4 ) 2290 ( 380 - 2750 ) 10.04 ( 1.98 - 11.69 ) 10 07 07 3.53 2.38 2.38 8.3 ( 2.0 - 10.4 ) 2300 ( 380 - 2750 ) 10.09 ( 1.98 - 11.69 )
  • Page 25 FILE NO. SVM-15073 <Heating / 240V> (Continued) Total Outdoor noise (dB) Power Indoor unit Unit capacity Operating supply Heating capacity Power consumption Operating current Sound Sound status Pressure Power (kW) 4 units 07 07 07 07 2.09 2.09 2.09 2.09 8.4 ( 2.9 - 11.5 ) 1792 ( 501 - 2560 ) 7.86 ( 2.32 - 10.88 ) 10 07 07 07 2.80 1.89 1.89 1.89 8.5 ( 2.9 - 11.5 ) 1812 ( 501 - 2560 ) 7.95 ( 2.32 - 10.88 )

  • Page 26: Operation Characteristic Curve

    FILE NO. SVM-15036-2 2-3-1. Operation Characteristic Curve <Cooling> <Heating> • Conditions 220V • Conditions 220V Indoor : DB27˚C/WB19˚C Indoor : DB20˚C Outdoor : DB35˚C Outdoor : DB7˚C / WB6˚C Air flow : High Air flow : High Pipe length : 5m × 5 Pipe length : 5m ×...

  • Page 27: Refrigerant R410A

    FILE NO. SVM-15073 3. REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC 6. When an air conditioning system charged with a (R410A) which does not damage the ozone layer. large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, The working pressure of the new refrigerant R410A even when refrigerant leaks, its concentration...
  • Page 28 FILE NO. SVM-15073 Table 3-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R410A 6.35 0.80 0.80 9.52 0.80 0.80 12.70 0.80 0.80 15.88 1.00 1.00 2. Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare Joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm.
  • Page 29 FILE NO. SVM-15073 d) Flare Processing Make certain that a clamp bar and copper pipe have been cleaned. ØD By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conven- tional flare tool. Flare processing dimensions differ according to the type of flare tool.
  • Page 30 FILE NO. SVM-15073 Table 3-2-6 Flare and flare nut dimensions for R22 Dimension (mm) Nominal Outer diameter Thickness Flare nut width diameter (mm) (mm) (mm) 6.35 9.52 13.0 13.5 12.70 16.0 16.2 12.9 15.88 19.0 19.7 16.0 19.05 23.3 24.0 19.2 Fig.
  • Page 31 FILE NO. SVM-15073 3-3. Tools 3-3-1. Required Tools The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

  • Page 32: Recharging Of Refrigerant

    FILE NO. SVM-15073 3-4. Recharging of Refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment. When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s Connect the charge hose to packed valve service port...

  • Page 33: Brazing Of Pipes

    FILE NO. SVM-15073 1. Be sure to make setting so that liquid can be charged. 2. When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.
  • Page 34 FILE NO. SVM-15073 3-5-3. Brazing 2. Characteristics required for flux • Activated temperature of flux coincides with As brazing work requires sophisticated techniques, the brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. •...

  • Page 35: Construction Views

    FILE NO. SVM-15073 4. CONSTRUCTION VIEWS 4-1. Outdoor Unit RAS-4M27S3AV-E, -A, -TR 2-dia.12 × 17 U-sharp hole (for dia.8-10 anchor bolt) A leg part B leg part 2-dia.12 × 17 long hole (for dia.8-10 anchor bolt) Fan guard Hanger Connecting pipe port：...

  • Page 36: Wiring Diagram

    FILE NO. SVM-15073 5. WIRING DIAGRAM 5-1. Outdoor Unit RAS-4M27S3AV-A - 36 -...
  • Page 37 FILE NO. SVM-15073 5-2. Outdoor Unit RAS-4M27S3AV-E, -TR COLOR IDENTIFICATION BLK:BLACK GRN:GREEN BLU:BLUE WHI:WHITE RED:RED YEL:YELLOW Symbol Part name PULSE MOTOR VALVE DISCHARGE PIPE TEMP. SENSOR CONDENSER PIPE TEMP. SENSOR OUTDOOR TEMP. SENSOR SUCTION PIPE TEMP. SENSOR GAS SIDE PIPE TEMP. SENSOR A...
  • Page 38 FILE NO. SVM-15073 5-3. Outdoor Unit RAS-4M27S3AV-A Wiring between DRED (Demand response enabling device) and Outdoor Unit This model supports DRM1 DRM2 DRM3. AS/NZS 4755 DRM1 DRM2 DRM3 Important notice ■ • Install in accordance with the wiring rules (AS/NZS 3000). •...

  • Page 39: Wiring Procedure

    FILE NO. SVM-15073 Air conditioner demand response Demand response mode Description DRM1 Compressor off DRM2 E30m ≤ R × 0.50 × 0.5 DRM3 E30m ≤ R × 0.75 × 0.5 *1: E30m = total electrical energy (kWh) used by the air conditioner for all purposes (including compressors, controls and fans) over a 30 min period. = rated input electrical power of the air conditioner (kW) at rated capacity in the mode in which it is operating during the demand response event (i.e.cooling or heating).

  • Page 40: Specifications Of Electrical Parts

    FILE NO. SVM-15073 6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Outdoor Unit RAS-4M27S3AV-E, -A, -TR Parts name Model name Rating Compressor — DA220A2T-20LD Outdoor fan motor ICF-280-A60-1 Output 60 W Reactor CH-56-3Z-T 5.8 mH, 18.5 A CH-76-TM1 Reactor 9.9 mH, 1 A...

  • Page 41: Refrigerant Cycle Diagram

    FILE NO. SVM-15073 7. REFRIGERANT CYCLE DIAGRAM High Pressure switch tank 1500cc DA220A2T-20LD ∅2 -∅3 , 450Lx2 ∅2 -∅3 , 550Lx1 ∅2 -∅3 , 600Lx1 2.40kg (R410A) Outdoor unit NOTE : • You need not add refrigerant if the piping length is 40m or less. •...

  • Page 42: Operation Data

    FILE NO. SVM-15073 7-2. Operation Data Outdoor Unit: RAS-4M27S3AV-E, -A, -TR <Cooling> Standard Heat exchanger No. of Compressor Temperature condition Indoor unit pressure pipe temperature operating Indoor fan Outdoor fan revolution Indoor Outdoor units (rps) P (MP) T1 (ºC) T2 (ºC) 1 unit 0.9 to 1.1...
  • Page 43 FILE NO. SVM-15073 <Cooling> (Continued) Standard Heat exchanger No. of Compressor Temperature condition Indoor unit pressure pipe temperature operating Indoor fan Outdoor fan revolution units (rps) Indoor Outdoor P (MP) T1 (ºC) T2 (ºC) 3 units 0.8 to 1.0 11 to 13 51 to 53 High High...
  • Page 44 FILE NO. SVM-15073 <Cooling> (Continued) Standard Heat exchanger No. of Compressor Temperature condition Indoor unit pressure pipe temperature operating Indoor fan Outdoor fan revolution Indoor Outdoor units (rps) P (MP) T1 (ºC) T2 (ºC) 4 units 1.0 to 1.2 15 to 17 51 to 53 High High...
  • Page 45 FILE NO. SVM-15073 Outdoor Unit : RAS-4M27S3AV-E, -A, -TR <Heating> Standard Heat exchanger No. of Compressor Temperature condition Indoor unit pressure pipe temperature operating Indoor fan Outdoor fan revolution units (rps) Indoor Outdoor P (MP) T1 (ºC) T2 (ºC) 1 unit 2.1 to 2.3...
  • Page 46 FILE NO. SVM-15073 <Heating> (Continued) Standard Heat exchanger No. of Compressor Temperature condition Indoor unit pressure pipe temperature operating Indoor fan Outdoor fan revolution Indoor Outdoor units (rps) P (MP) T1 (ºC) T2 (ºC) 3 units 2.5 to 2.7 37 to 39 -2 to 0 High High...
  • Page 47 FILE NO. SVM-15073 <Heating> (Continued) Standard Heat exchanger No. of Compressor Temperature condition Indoor unit pressure pipe temperature operating Indoor fan Outdoor fan revolution units (rps) Indoor Outdoor P (MP) T1 (ºC) T2 (ºC) 4 units 2.2 to 2.4 33 to 35 -2 to 0 High High...

  • Page 48: Control Block Diagram

    FILE NO. SVM-15073 8. CONTROL BLOCK DIAGRAM 8-1. Outdoor Unit (Inverter Assembly) RAS-4M27S3AV-A Outdoor air temp. sensor Gas side pipe temp. sensor Suction temp. sensor Evaporator temp. sensor Discharge temp. sensor MCC-5071 (CONTROL P.C. B) A unit P.M.V. M.C.U A unit serial signal •...
  • Page 49 FILE NO. SVM-15073 8-2. Outdoor Unit (Inverter Assembly) RAS-4M27S3AV-E, -TR Outdoor air temp. sensor Gas side pipe temp. sensor Suction temp. sensor Evaporator temp. sensor Discharge temp. sensor MCC-5071 (CONTROL P.C. B) A unit P.M.V. M.C.U A unit serial signal •...

  • Page 50: Operation Description

    FILE NO. SVM-15073 9. OPERATION DESCRIPTION 9-1. Outline of Air Conditioner Control • Detection of inverter input current and current release operation This air conditioner is a capacity-variable type air • Over-current detection and prevention operation conditioner, which uses DC motor for the indoor fan to IGBT module (Compressor stop function) motor and the outdoor fan motor.
  • Page 51 FILE NO. SVM-15073 9-2. Operation Description 1. Basic operation ........................52 1. Operation control ....................... 52 2. Operating mode selection when performing 2-room operation ......... 53 3. Cooling/Heating operation ....................53 2. Outdoor fan motor control ....................... 54 3. Capacity control ........................55 Current release control ......................
  • Page 52 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description 1. Operation control 1. Basic operation Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are controlled. 1) The operation conditions are selected by the remote controller as shown in the below. 2) A signal is sent by ON button of the remote controller.
  • Page 53 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description 2. Operating mode selection when performing 2-room operation 1. Basic operation 1) The outdoor unit operating mode conforms to the instructions of the indoor unit that was pushed first. 2) When combined operation consisting of cooling (dry) and heating, fan (air purification) and heating, or cleaning operation and heating is performed, operation conforms to the instructions of the indoor unit that was pushed first as shown in the following table.
  • Page 54 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description 2. Outdoor fan The blowing air volume at the outdoor unit side is controlled. 1) The operation command sent motor control from the remote controller is Receiving the operation command from the controller of indoor processed by the indoor unit unit, the controller of outdoor unit controls fan speed.
  • Page 55 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description 3. Capacity 1) Four indoor units from A to D determine the respective instruction revolutions from the difference control between the remote controller setting temperature (Ts) and the indoor temperature (Ta), and transmit this to the outdoor unit.
  • Page 56 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description 5. Winding/Coil When the outdoor temperature is low, the windings/ Winding/Coil heating is performed when heating control coils are heated to ensure compressor reliability. the following conditions are met. Condition 1 : Outdoor temperature To Winding/Coil...
  • Page 57 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description 1. Purpose 8. Discharge temperature This function detects error on the control refrigerating cycle or error on the compressor, and performs protective control. Td value Control operation 2. Operation Judges as an error and stops the compressor.
  • Page 58 FILE NO. SVM-15073 Item Operation flow and applicable data, etc. Description The following settings are availiable by DIP switch setup. 11. Various setting on outdoor unit (Power save, Function Setting position Control contents Cooling-only, etc.) Power save Turn the switch to ON, when using the power save function. SW802 setup SW802...

  • Page 59: Installation Procedure

    FILE NO. SVM-15073 10. INSTALLATION PROCEDURE 10-1. Installation/Servicing Tools Changes in the product and components In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valve (3-way valve) has been changed. (1/2 UNF 20 threads per inch) •...
  • Page 60 FILE NO. SVM-15073 10-2. Outdoor Unit 10-2-1. Accessory and Installation Parts CD-ROM Rubber cap Installation manual (Installation manual) (Water-proof) ∗1 F-GAS label Drain nipple ∗1 ∗1 Part that do not exist in RAS-4M27S3AV-A,-TR. 10-2-2. Refrigerant Piping • Piping kit used for the conventional refrigerant cannot be used. •...
  • Page 61 FILE NO. SVM-15073 10-2-5. Installation 1. Piping connections to the outdoor unit should be arranged in the sequence A, B, C, D starting NOTE from the bottom. (For each piping connection, the gas pipe is on For installation, at least 3 dimensions should be the bottom and the liquid pipe is on the top.) kept free from obstacles (walls).

  • Page 62: Tightening Connection

    FILE NO. SVM-15073 How to remove the front panel • Tightening torque of flare pipe The pressure of R410A is higher than R22. 1. Remove 5 screws of the front panel. (Approx. 1.6 times) 2. Pull the front panel downward. Therefore securely tighten the flare pipes which connect the outdoor unit and indoor unit with the specified tightening torque using a torque wrench.

  • Page 63: Refrigerant Piping Connection

    FILE NO. SVM-15073 10-2-7. Evacuating 10-2-6. Refrigerant Piping Connection After the piping has been connected to all indoor unit(s), CAUTION you can perform the air purge together at once. KEEP IMPORTANT 4 POINTS FOR PIPING WORK AIR PURGE 1. Keep dust and moisture from entering the pipes. Evacuate the air in the connecting pipes and in the 2.

  • Page 64: Wiring Connection

    FILE NO. SVM-15073 Packed valve handling precautions • Open the valve stem all the way out ; do not try to open it beyond the stopper. • Securely tighten the valve stem cap in torque is as follows : Gas side (Ø12.7 mm) 50 to 62 N•m (5.0 to 6.2 kgf•m) Gas side (Ø9.52 mm) 33 to 42 N•m (3.3 to 4.2 kgf•m)
  • Page 65 FILE NO. SVM-15073 10-2-8. Check and Test Operation 10-2-9. Miswiring (Mispiping) Check Make sure that the wiring and piping for each room have the same alphabetical codes (A, B, C, D). For R410A, use the leak detector exclusively manu- Connect and secure the power cord. factured for HFC refrigerant (R410A, R134a, etc.).
  • Page 66 FILE NO. SVM-15073 ¤ : LED ON, : LED OFF, : LED Flash Description D800 D801 D802 D803 D804 D805 ¤ Before check Normal operation (no error) Checking A unit Checking B unit During check Checking C unit Checking D unit ¤...

  • Page 67: Test Operation

    FILE NO. SVM-15073 10-3. Test Operation 10-3-4. Remote Control A-B Selection 10-3-1. Gas Leak Test • When two indoor units are installed in the same room or adjacent two rooms, if operating a unit, two units may Check the flare nut connections for gas leaks with a receive the remote control signal simultaneously and gas leak detector and/or soapy water.

  • Page 68: How To Diagnose The Trouble

    FILE NO. SVM-15073 11. HOW TO DIAGNOSE THE TROUBLE The pulse modulating circuits are mounted to both indoor and outdoor units. Therefore, diagnose troubles according to the trouble diagnosis procedure as described below. (Refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.) Table 11-1 Troubleshooting Procedure Page...

  • Page 69: First Confirmation

    FILE NO. SVM-15073 11-1. First Confirmation 11-1-3. Operation Which is not a Trouble (Program Operation) 11-1-1. Confirmation of Power Supply For controlling the air conditioner, the program Confirm that the power breaker operates (ON) operations are built in the microcomputer as normally.

  • Page 70: Primary Judgment

    FILE NO. SVM-15073 11-2. Primary Judgment To diagnose the troubles, use the following methods. 1) Judgment by flashing LED of indoor unit 2) Self-diagnosis by service check remote controller 3) Judgment of trouble by every symptom Firstly use the method (1) for diagnosis. Then, use the method (2) or (3) to diagnose the details of troubles. For any trouble occurred at the outdoor unit side, detailed diagnosis is possible by 6-serial LED on the control P.C.
  • Page 71 FILE NO. SVM-15073 11-4. Self-Diagnosis by Remote Controller (Check Code) 1. If the lamps are indicated as shown B to E in Table 11-3-1, execute the self-diagnosis by the remote controller. 2. When the remote controller is set to the service mode, the indoor controller diagnoses the operation condition and indicates the information of the self-diagnosis on the display of the remote controller with the check codes.
  • Page 72 FILE NO. SVM-15073 11-4-2 Caution at Servicing 1. After using the service mode of remote controller finished, press the [ ] button to reset the remote controller to normal function. 2. After finished the diagnosis by the remote controller, turn OFF power supply and turn its ON again to reset the air conditioner to normal operation.
  • Page 73 FILE NO. SVM-15073 Block distinction Operation of diagnosis function Action and Judgment Check Check Display flashing Block Cause of operation conditioner code code error status Serial signal 1) Defective wiring of the Indoor unit Flashes when 1) to 3) The outdoor unit never and connecting connecting cable or operates...
  • Page 74 FILE NO. SVM-15073 Block distinction Operation of diagnosis function Action and Judgment Check Check Display flashing Block Cause of operation conditioner code code error status Outdoor P.C. Current on inverter circuit All OFF Flashes after 1. Remove connecting lead wire of the board is over limit in short time.
  • Page 75 FILE NO. SVM-15073 Block distinction Operation of diagnosis function Action and Judgment Check Check Display flashing Block Cause of operation conditioner code code error status Compressor drive output error. All OFF Flashes after 1. Check installation conditions such as (Relation of voltage, current error is detected packed valve opening, refrigerant 8 times*.
  • Page 76 FILE NO. SVM-15073 Block distinction Operation of diagnosis function Action and Judgment Check Check Display Block Cause of operation conditioner code code flashing error status Compressor does not rotate. All OFF Flashes after 1. Remove connecting lead wire of the Because of missed wiring, error is detected compressor, and operate again.
  • Page 77 FILE NO. SVM-15073 Block distinction Operation of diagnosis function Action and Judgment Check Check Display Block Cause of operation conditioner code code flashing error status Return signal of the outdoor Indoor unit Flashes when 1. . Check power supply (Rate +10%) operates error is detected unit has been sent when...
  • Page 78 FILE NO. SVM-15073 11-5. Judgment of Trouble by Symptom 11-5-1. Wiring Failure (Interconnecting and Serial Signal Wire)(1) Outdoor unit does not operate 1) Is the voltage between of the indoor terminal block varied? 2) Confirm that transmission from indoor unit to outdoor unit is correctly performed based upon the following diagram.
  • Page 79 FILE NO. SVM-15073 Service Support Function (LED Display, Switch Operation) 1. Outline A various setup and operation check can be performed by DIP switches at 2 positions (SW801, SW802) and the pushdown button switches (SW800) on the outdoor control P.C. board MCC-5071. Operation part Part No.
  • Page 80 FILE NO. SVM-15073 11-6. Trouble Diagnosis by Outdoor LED For the outdoor unit, the self-diagnosis is possible by LED (Green) and five LEDs (Red). ∗ LED (Green)(D800) and LEDs (Red)(D801 to D805) are provided on the control P.C. board MCC-5071. 1.
  • Page 81 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [07] [Case thermo operation, Power supply error ] Is AC mains voltage correct? Confirm power supply (198 to 264V) construction. etc. Are CN609 of P.C.
  • Page 82 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [18] ∗ There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C. board to judge which error it is. Heat exchanger temp.
  • Page 83 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [1C] ∗ There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C. board to judge which error it is. Compressor system error, Compressor lock, Gas side temp.
  • Page 84 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [1C] [A room gas side temp. sensor (TGa) error] (Continued) Is connection of CN604 Correct connector. on P.C.B MCC-5071 correct? →...
  • Page 85 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [1C] [Communication error between MCUs] (Continued) Are connections of CN802 on P.C.B MCC-5071 Correct connection. and CN802 on P.C.B MCC-1571 correct? Check outdoor P.C.
  • Page 86 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [1F] [Compressor break down] Is AC mains voltage correct? Check wiring construction. (198 to 264V) Ask repair of power supply. Is wire connection correct? Compressor lead Check wire connection...
  • Page 87 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [20] [PMV error for D room] (Continued) Repair defective position. Is PMV under correct conditions? Replace defective part. Error Check temp. sensor of D room indoor unit? Correct connector.
  • Page 88 FILE NO. SVM-15073 Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [21] (Continued) Heating operation Are connections of Does the heating indoor fan connectors,capacitors normally operate? and fan motor normal? Is there any element which blocks indoor heat exchanger? Elimination of Repair...
  • Page 89 FILE NO. SVM-15073 11-6. TROUBLESHOOTING RAS-4M27S3AV-A 1. Before Troubleshooting Each model corresponds to DRED (Demand response enabling device) by AS/NZS 4755.3.1. DRM1, DRM2 and DRM3 are executed as follows, upon directions from the power company, Be sure to confirm they are not operated before usually troubleshooting. Air conditioner demand response Demand response mode Description...
  • Page 90 FILE NO. SVM-15073 Troubleshooting for Demand Unit Demand P.C. board is failed. Exchange of transformer, Fuse exchange of Demand F100 is melted. P.C. board Take off wiring of Exchange of transformer, CN102. Short-circuit is exchange of Demand found between “~” and P.C.
  • Page 91 FILE NO. SVM-15073 11-7. Inspection of the Main Parts [1] Sensor characteristic table : Discharge temp. sensor : Outdoor temp. sensor : Outdoor heat exchanger temp. sensor : Suction temp. sensor TGa to TGd : Gas side temp. sensor TO, TE, TS, TGa to TGd Temperature (˚C) 11-8.
  • Page 92 FILE NO. SVM-15073 11-9. How to Simply Judge Whether Outdoor Fan Motor is Good or Bad 1. Symptom • Outdoor fan motor does not rotate. • Outdoor fan motor stops within several tens seconds though it started rotating. • Outdoor fan motor rotates or does not rotate according to the position where the fan stopped, etc. Remote controller check code “02 : Outdoor block, 1A : Outdoor fan drive system error”...
  • Page 93 FILE NO. SVM-15073 <MCC-1571> Electrolytic capacitors (760µF/400V) Lead wire for grounding P09 (Black) Fan motor output Fan motor output Fan motor output CN300 CN300 CN300 Compressor Compressor Compressor (Red, White, Black) (Red, White, Black) (Red, White, Black) output terminals output terminals output terminals CN200 CN200...
  • Page 94 FILE NO. SVM-15073 <MCC-5071> Indoor/Outdoor communication wire Power supply Protective fuse connecting connector F01 (250V, 3.15A ,plastic case) CN01 (Red) Lead wire for Indoor/ Indoor/Outdoor communication signal LED Outdoor communication D502, D511, D517, D524 P01 (Yellow) (Orange,Indoor → Outdoor) P02 (Red) D501, D508, D515, D520 P03 (Green) (Green,Outdoor →...

  • Page 95: How To Replace The Main Parts

    FILE NO. SVM-15073 12. HOW TO REPLACE THE MAIN PARTS 12-1. Outdoor Unit Part name Procedure Remarks CAUTION Common procedure Never forget to put on the gloves at working time; otherwise an injury will be caused by the parts etc. 1.
  • Page 96 FILE NO. SVM-15073 Part name Procedure Remarks 1. Detachment Discharge port cabinet 1) Perform work of Detachment 1 of 1 . 2) Take off screws for the discharge port cabinet and the partition plate. (ST1T Ø4 × 8, 3 pcs.) 3) Take off screws for the discharge port cabinet and the bottom plate.
  • Page 97 FILE NO. SVM-15073 Part name Procedure Remarks Inverter 1) Perform works Detachment 1 of 1 and 3 . assembly Inverter fixed board Fixing screw WARNING Never disassemble the inverter until 5 minutes after the power supply was turned off because there is a fear that an electric shock may occur.
  • Page 98 FILE NO. SVM-15073 Part name Procedure Remarks Inverter 8) Remove the soundproof plate (upper). Soundproof plate (upper) assembly 9) Remove the terminal cover of the compressor (Continued) and then remove the compressor lead of the compressor. 10) Pull up the inverter assembly and then remove it. Reactor cover side Compressor lead Case thermo...
  • Page 99 FILE NO. SVM-15073 Part name Procedure Remarks CDB P.C. 1) Perform works of Detachment 1 of 1 and 4) Power supply Terminal relay board connector connector CAUTION CDB P.C. board Never disassemble the inverter until 5 minutes after the power supply was turned off because there is a fear that an electric shock may occur.
  • Page 100 FILE NO. SVM-15073 Part name Procedure Remarks 7) Remove the earth wire of IPDU P.C. board. IPDU P.C. Fixing screws (Truss head B tight screw Ø4 × 6, 1 pc.). Earth screw board for element 8) Take off fixing screws for IPDU P.C. board. (Continued) (7 positions) (Flange nut to fix element Ø3 ×...
  • Page 101 FILE NO. SVM-15073 Part name Procedure Remarks 1. Reactor to be attached to the inverter Replacement of reactor assembly Reactor cover Reactor relay connector 1) Perform works of Detachment 1 of 1 and 2) Remove the relay connector of the reactor. 3) Remove the reactor cover.
  • Page 102 FILE NO. SVM-15073 Part name Procedure Remarks Fan motor 1) Perform works of Detachment 1 of 1 and 2 . Propeller fan 2) Take off flange nut which fixes the fan motor and the propeller fan. Loosened by Loosened by Loosened by ∗...
  • Page 103 FILE NO. SVM-15073 Part name Procedure Remarks 1. Removal of defective compressor Compressor assembly 1) Perform work of Detachment 1 of 1 . 2) Recover the refrigerant gas from the outdoor unit. 3) Perform works of 2 , 3 and 4 . 4) Remove the soundproof plate and TD sensor.
  • Page 104 FILE NO. SVM-15073 Part name Procedure Remarks 1. Detachment Fan guard 1) Perform works of Detachment 1 of 1 and 2 . Discharge CAUTION Bell mouth port cabinet Work on the cardboard, cloth, and etc. in order to prevent damage on the product. 2) Take off the discharge port cabinet and put it as the fan guard side directs downward.
  • Page 105 FILE NO. SVM-15073 Part name Procedure Remarks ∗ Attachment 4-way valve coil Mount 4-way valve coil so that the label side directs upper side of the cabinet. Detail A 4-way valve unit 4-way valve unit 4-way valve unit Label Label Label 4-way valve coil 4-way valve coil...
  • Page 106 FILE NO. SVM-15073 Part name Procedure Remarks ∗ Attachment TE sensor (Outdoor heat Mount TE sensor on the straight part of the exchange condenser discharge port pipe so that the lead temperature) wire directs upward and the sensor directs the liquid store tank.
  • Page 107 FILE NO. SVM-15073 Part name Procedure Remarks ∗ Attachment TG sensor TGd: Blue Mount these sensors on the directly arranged TGc: Green part of the header connecting pipe at gas side TGb: Red so that the cabinet turns toward the front side TGa: Yellow and the sensors turn toward upper cabinet.
  • Page 108 FILE NO. SVM-15073 Part name Procedure Remarks Sensor wiring ∗ Bind TS sensor, TE sensor and TO sensor with process the bundling band. Inverter fixing board (Continued) ∗ Pass TE sensor and TO sensor through upper part of the inverter fixing board and then bind them with the bundling band.
  • Page 109 FILE NO. SVM-15073 ∗ RAS-4M27S3AV-A only Part name Procedure Remarks Demand P.C. CUATION board Never forget to put on the gloves at working time; otherwise an injury will be caused by the parts etc. NOTE) When working, be sure to use the insulate tools and put on the insulated gloves.

  • Page 110: Exploded Views And Parts List

    AIR OUTLET CABINET 43T50307 BIMETAL THERMOSTAT ASSEMBLY FIN GUARD ASSEMBLY RUBBER CUSHION 43T19346 43T49346 FIN GUARD 43T19345 43T39342 MOTOR BASE 43T19343 FAN GUARD(TOSHIBA) 43T47001 NUT FLANGE 43T22313 BELLMOUTH 43T20329 PROPELLER FAN 43T42347 BASE PLATE ASSEMBLY FAN MOTOR 43T21429 COMPRESSOR 43T58307...

  • Page 111: Inverter Assembly

    FILE NO. SVM-15073 13-2. Inverter Assembly Location Part Location Part Description Description SERV-TERMINAL 43T61315 SPACER(BUSH) 43T60423 43T60452 SERV-TERMINAL 43T61316 SPACER(COLLAR) 43T50347 SENSOR ASSY, SERVICE 43T6V587 ASM-PCB(FAN-REL) 43T50356 SERVICE-SENSOR 43T61324 ASM-SPACER-SET 43T60433 SENSOR ASSY,SERVICE 43T6V586 PC-BOARD REACTOR PC-BOARD 43T60422 43T6V585 PC BOARD(DRC)(for RAS-4M27S3AV-A) 43T58307 REACTOR 43T6V475...

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