Toshiba RAS-3M26G3AVG-TR Service Manual
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Toshiba RAS-3M26G3AVG-TR Service Manual

Toshiba RAS-3M26G3AVG-TR Service Manual

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FILE NO. SVM-23010-2
SERVICE MANUAL
AIR-CONDITIONER
SPLIT TYPE
RAS-3M26G3AVG-E
RAS-3M26G3AVG-TR
R32
Revised on Oct, 2023

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Summary of Contents for Toshiba RAS-3M26G3AVG-TR

  • Page 1 FILE NO. SVM-23010-2 SERVICE MANUAL AIR-CONDITIONER SPLIT TYPE RAS-3M26G3AVG-E RAS-3M26G3AVG-TR Revised on Oct, 2023...
  • Page 2 CONTENTS . .. - 2 -...

  • Page 3: Safety Precautions

    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. 7 Warning indications on the air conditioner unit This mark is for R32 refrigerant only.
  • Page 4 CAUTION New Refrigerant Air Conditioner Installation • THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R32 WHICH DOES NOT DESTROY OZONE LAYER. R32 refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working pressure of R32 refrigerant is approx.

  • Page 5: About The Refrigerant

    WARNING About the refrigerant • This product contains uorinated greenhouse gases. • Do not vent gases to the atmosphere. • The appliance shall be stored in a room without continuously operating ignition sources (for example: open ames, an operating gas appliance or an operating electric heater).
  • Page 6 WARNING • Be sure to use only approved accessories or the speci ed parts. Failure to do so may cause the unit to fall, water leakage, re or electrical shock. • After the installation work, ensure that there is no leakage of refrigerant gas. If the refrigerant gas leaks out of the pipe into the room and is heated by re or something else from a fan heater, stove or gas range, it causes generation of poisonous gas.
  • Page 7 WARNING • In accordance with IEC60335-2-40 2018 a minimum oor area MUST be observed when installing the Multi System air conditioner. Follow the table below to calculate the minimum oor area for installed product. Minimum oor area, When combined with indoor product. (m Refrigerant BI-FLOW CONSOLE amount...
  • Page 8 CAUTION • Exposure of unit to water or other moisture before installation may result in an electrical short. Do not store in a wet basement or expose to rain or water. • 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 or discharged air might disturb neighbors.
  • Page 9 CAUTION • Please read this installation manual carefully before installing the unit. It contains further important instructions for proper installation. • 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. •...

  • Page 10: Specifications

    2. SPECIFICATIONS The indoor and outdoor units that can be used in combination are shown in the tables below. Table of models that can be used in combination Type Outdoor unit Combinations of indoor unit models that can be connected Heat pump RAS-3M26G3AVG-E, -TR Refer to page 11 to 22...

  • Page 11: Combination Of Indoor Units

    2-2. Combination of indoor units RAS‐3M26G3AVG-E, -TR Outdoor unit ： Power supply voltage： 220V Cooling Operation mode Unit capacity ： Operating Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) (kW) status C ΣkBTU Rate Rate Rate Rate －...
  • Page 12 Operation mode ： Cooling Power supply voltage： 220V Unit capacity Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) Operating (kW) status C ΣkBTU Rate Rate Rate Rate 3 units 3.50 2.45 1.05 2.00 7.00 9.00 1750 2300 2.05 8.33 10.88...
  • Page 13 Operation mode ： Cooling Power supply voltage： 230V Energy Operating Indoor unit Unit capacity (kW) Cooling capacity (kW) Power consumption (W) Operating current (A) EER SEER Grade status ΣkBTU Rate Rate Rate Rate － － － － － － 1 unit 1.50 1.30 1.50...
  • Page 14 Operation mode ：Cooling Power supply voltage： 230V Energy Operating Indoor unit Unit capacity (kW) Cooling capacity (kW) Power consumption (W) Operating current (A) EER SEER Grade status ΣkBTU Rate Rate Rate Rate 3 units 2.00 2.00 2.00 1.88 6.00 8.70 1500 2220 1.96...
  • Page 15 Cooling Operation mode ： Power supply voltage： 240V Unit capacity Operating Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) (kW) status C ΣkBTU Rate Rate Rate Rate － － － － 1 unit 1.50 1.30 1.50 2.00 1.88 1.88 1.93...
  • Page 16 Cooling Operation mode ： Power supply voltage： 240V Unit capacity Operating Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) (kW) status C ΣkBTU Rate Rate Rate Rate 3 units 3.50 2.45 1.05 2.00 7.00 9.00 1750 2300 1.88 7.64 9.97...
  • Page 17 Operation mode ： Heating Power supply voltage： 220V Unit capacity Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) Operating (kW) status C ΣkBTU Rate Rate Rate Rate － － － － 1 unit 2.00 1.20 2.00 2.50 1.77 3.16 3.66...
  • Page 18 Operation mode ： Heating Power supply voltage： 220V Unit capacity Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) Operating (kW) status C ΣkBTU Rate Rate Rate Rate 3 units 4.28 3.00 1.43 2.00 8.70 11.50 2000 2900 2.10 9.49 13.71...
  • Page 19 Operation mode ： Heating Power supply voltage： 230V Indoor unit Unit capacity (kW) Cooling capacity (kW) Power consumption (W) Operating current (A) SCOP Energy Grade Operating status D ΣkBTU Rate Rate Rate Rate Average Warmer Average Warmer － － － －...
  • Page 20 Operation mode ： Heating Power supply voltage： 230V Indoor unit Unit capacity (kW) Cooling capacity (kW) Power consumption (W) Operating current (A) SCOP Energy Grade Operating status D ΣkBTU Rate Rate Rate Rate Average Warmer Average Warmer － － 3 units 3.92 3.00 1.78 2.00 8.70...
  • Page 21 Operation mode ： Heating Power supply voltage： 240V Unit capacity Operating Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) (kW) status C ΣkBTU Rate Rate Rate Rate － － － － 1 unit 2.00 1.20 2.00 2.50 1.62 2.90 3.36...
  • Page 22 Operation mode ： Heating Power supply voltage： 240V Unit capacity Indoor unit Cooling capacity (kW) Power consumption (W) Operating current (A) Operating (kW) status C ΣkBTU Rate Rate Rate Rate 3 units 4.28 3.00 1.43 2.00 8.70 11.50 2000 2900 1.93 8.70 12.57...

  • Page 23: Operation Characteristic Curve

    Operation Characteristic Curve <Heating> <Cooling> 12.0 14.0 Conditions Indoor : DB 27 C/WB 19 Conditions Outdoor : DB 35 C/WB 24 Indoor : DB 20 C/WB 15 Indoor Air Flow : High 12.0 Outdoor : DB 7 C/WB 6 10.0 Pipe Length : 5m x 3 Indoor Air Flow : High Voltage : 220V/230V/240V...

  • Page 24: Safety During Installation/Servicing

    3. REFRIGERANT R32 3. If a refrigeration gas leakage occurs during This air conditioner adopts the new refrigerant HFC installation/servicing, be sure to ventilate fully. (R32) which does not damage the ozone layer. If the refrigerant gas comes into contact with fire, a The next section describes the precautions for air poisonous gas may occur.

  • Page 25: Processing Of Piping Materials

    Table 3-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) 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 26 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 R32 or conventional flare tool. Flare processing dimensions differ according to the type of flare tool.
  • Page 27 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 16.2 16.0 12.9 15.88 19.7 19.0 16.0 19.05 23.3 24.0 19.2 Fig. 3-2-2 Relations between flare nut and flare seal surface 2.
  • Page 28 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 R32 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 29: Recharging Of Refrigerant

    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 power switch.

  • Page 30: Brazing Of Pipes

    3-5. Brazing of Pipes 3. Types of flux • Noncorrosive flux 3-5-1. Materials for Brazing Generally, it is a compound of borax and boric 1. Silver brazing filler acid. It is effective in case where the brazing tem- Silver brazing filler is an alloy mainly composed perature is higher than 800°C.
  • Page 31 3-5-3. Brazing As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it Flow meter must be performed by a person qualified. In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to Stop valve proceed with brazing while letting dry Nitrogen gas (N2) flow.

  • Page 32: Construction Views

    4. CONSTRUCTION VIEWS 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 Liquid valve Connecting pipe port： Service part Connecting pipe dia.6.35 C unit Gas valve Connecting pipe dia.9.52...

  • Page 33: Wiring Diagram

    5. WIRING DIAGRAM - 33 -...

  • Page 34: Specifications Of Electrical Parts

    6. SPECIFICATIONS OF ELECTRICAL PARTS Parts name Model name Rating 3 Phases (6-Poles) ; 1500 W NA220A1F-20N Compressor SDM-340-60 Output 60 W Outdoor fan motor CH-56-3Z-T Reactor 5.8 mH, 18.5 A CH-76-2VK Reactor 9.9 mH, 1 A SHF(L)-7H-34U 4-way valve coil AC 200–240 V PMV coil DC 12 V...

  • Page 35: Refrigerant Cycle Diagram

    7. REFRIGERANT CYCLE DIAGRAM 7.1 Refrigerant cycle diagram High Pressure switch tank 1500cc NA220A2T-20N ∅2 -∅3 , 450Lx2 ∅2 -∅3 , 550Lx1 ∅2 -∅3 , 600Lx1 1.90kg (R32) Outdoor unit NOTE : • You need not add refrigerant if the piping length is 40m or less. •...
  • Page 36 7-2.　Operation　Data : RAS‐3M26G3AVG-E, -TR Outdoor　Unit <Cooling> Temperature No.of Standard Heat exchanger Compressor Indoor unit Indoor condition operating pressure pipe temperature revolution （rps） Indoor Outdoor units P（MP） T1(℃) T2(℃) － － － － 27/19 35/- 1 FCU 1.2 to 1.4 18 to 20 37 to 39 High －...
  • Page 37 <Cooling> Temperature No.of Standard Heat exchanger Compressor Indoor unit Indoor condition operating pressure pipe temperature revolution （rps） Indoor Outdoor units P（MP） T1(℃) T2(℃) － － 27/19 35/- 3 FCUs 1.3 to 1.5 22 to 24 42 to 44 High － －...
  • Page 38 <Heating> Temperature No.of Standard Heat exchanger Compressor Indoor unit Indoor condition operating pressure pipe temperature revolution （rps） Indoor Outdoor units P（MP） T1(℃) T2(℃) － － － － 20/15 1 FCU 1.4 to 1.6 24 to 26 4 to 6 High －...
  • Page 39 <Heating> Temperature No.of Standard Heat exchanger Compressor Indoor unit Indoor condition operating pressure pipe temperature revolution （rps） Indoor Outdoor units P（MP） T1(℃) T2(℃) － － 20/15 3 FCUs 1.6 to 1.8 26 to 28 1 to 3 High － － 1.6 to 1.8 27 to 29 1 to 3 High...

  • Page 40: Control Block Diagram

    8. CONTROL BLOCK DIAGRAM 8-1. Outdoor Unit (Inverter Assembly) Outdoor air temp. sensor Gas side pipe temp. sensor Suction temp. sensor Evaporator temp. sensor Discharge temp. sensor WP-524 (CONTROL P.C. B) A unit P.M.V. M.C.U A unit serial signal • Inverter outdoor frequency control communication circuit •...

  • Page 41: Operation Description

    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 42: Table Of Contents

    9-2. Operation Description 1. Basic operation ........................43 1. Operation control ....................... 43 2. Operating mode selection when performing 2-room operation ......... 44 3. Cooling/Heating operation ....................44 2. Outdoor fan motor control ....................... 45 3. Capacity control ........................46 Current release control ......................

  • Page 43: Basic Operation

    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 44: Operating Mode Selection When Performing 2-Room Operation

    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 45: Outdoor Fan Motor Control

    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 46: Capacity Control

    Item Operation flow and applicable data, etc. Description 3. Capacity 1) The indoor units from A to C determine the respective instruction revolutions from the difference between the remote controller setting temperature (Ts) and the indoor temperature (Ta), and control transmit this to the outdoor unit.

  • Page 47: Winding/Coil Heating Control

    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 When the discharge sensor temperature...

  • Page 48: Discharge Temperature Control

    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. 120°C •...

  • Page 49: Service Switch (Sw81, Sw82) Operations

    9-3. Service switch (SW81, SW82) operations Various displays and various operations are enabled by push buttons (service) switches and LED on the outdoor control P.C. board. 9-3-1. LED display 5 patterns are provided for LED display. ○:ON (○*:3 sec ON/0.5 sec OFF), ●:OFF, ◎:Rapid Flashing(5 times/sec), ◇:Slow Flashing(1 time/sec) D800 D801 D802...
  • Page 50 9-3-2. Service switch setting and service support function You can choose service switch setting and service support function. Operating method is as below. Turn on the circuit breaker Push SW81 & SW82 at the same time for 5 sec or more Initial status D800 D801...
  • Page 51 [Confirmation method of various settings] You can confirm that various settings are validated. 1) Check LED displays are in the initial status. If it are not so, return them to the initial status. 2) Push and hold SW81 for 5 seconds or more. D804 changes to slow flashing. 3) Push SW81 several times and then stop it at the point where LED display (D800 to D804) to be checked.
  • Page 52 9-3-4. Service support function Various displays are available by setting service switches. [Operating method] 1) Check LED display is the initial status. If it is not so, set the initial status. 2) Push SW81 several times and stop it at the item that you want to check. ○:ON (○*:3 sec ON/0.5 sec OFF)●:OFF Display ◎:Rapid Flashing(5 times/sec) ◇:Slow Flashing(1 time /sec)
  • Page 53 3) Pushing SW82, the display changes to next item. To see other display contents, repeat that. 4) To finish LED display, be sure to execute item 1) to return LED to the initial status (error display of current occurrence) and then finish LED display. [Error display] The error which is occurring at present and the latest error (including error that is occurring now) can be confirmed by checking display on the outdoor control P.C.
  • Page 54 C. Sensor, current, compressor operation frequency, PMV opening, Miswiring (mispiping) check display Using the service display function, you can check a variety of information. ○:ON (○*:3 sec ON/0.5 sec OFF)●:OFF ◎:Rapid Flashing(5 times/sec) ◇:Slow Flashing(1 time /sec) display Contents D800 D801 D802 D803 D804 D805 Temp.
  • Page 55 9-3-5. How to set the SERVICE SWITCH SETTING. If you want to set the "COOLING ONLY SETTING OFF ⇒ ON" . ○:ON, ●:OFF, ◎:Rapid Flashing(5 times/sec), ◇:Slow Flashing(1 time/sec) Turn on the circuit breaker Initial status D800 D801 D802 D803 D804 D805 (Yellow)
  • Page 56 9-3-6. How to set the SERVICE SUPPORT FUNCTION. If you want to check the "COMPRESSOR FREQUENCY" . ○:ON, ●:OFF, ◎:Rapid Flashing(5 times/sec), ◇:Slow Flashing(1 time/sec) Turn on the circuit breaker Initial status D800 D801 D802 D803 D804 D805 (Yellow) (Yellow) (Yellow) (Yellow) (Yellow)

  • Page 57: Intermittent Operation Control For Indoor Fans Of The Indoor Unit At Thermo-Off Side In Heating Operation

    9-4. Intermittent Operation Control for Indoor Fans of the Indoor Unit at Thermo-off Side in Heating Operation While heating operation is executed in two rooms, if room temperature reached the setup temperature in one room and thermo-off occurred, the following operations start. (Refer to the figure below.) 1.
  • Page 58 In the case of an air conditioner using R32, in order to prevent any other refrigerant from being charged accidentally, the service port diameter of the outdoor unit control valve has been changed.(1/2 UNF 20 threads per inch) • In order to increase the pressure resisting strength of the refrigerant piping flare processing diameter and size of opposite side of flare nuts has been changed.

  • Page 59: Outdoor Unit

    Product F-GAS label Drain nipple specifi cation ∗1 Part that do not exist in RAS-3M26G3AVG-TR 10-2-2. Refrigerant Piping • Piping kit used for the conventional refrigerant cannot be used. • Use copper pipe with 0.8 mm or more thickness. • Flare nut and flare works are also different from those of the conventional refrigerant.

  • Page 60: Installation

    10-2-5. Installation Upper side view (Unit: mm) ■ Installation Location • A place which can bear the weight of the outdoor unit and does not cause an increase in noise level and vibration. • A place where the operation noise and air discharge do not disturb neighbours.

  • Page 61: Refrigerant Piping

    Fixing the Outdoor Unit ■ Refrigerant Piping Connection Fix the outdoor unit using attachment bolts. Flaring • Use 8 mm or 10 mm anchor bolts and nuts. • Do not allow the attachment bolts to protrude by more than 15 mm. 1.
  • Page 62 Pipe connection (Unit : N•m) 1. Piping connections to the outdoor unit should be arranged in the sequence A, B, C starting from Outer dia. of copper pipe Tightening torque the bottom. Ø6.35 mm 14 to 18 (1.4 to 1.8 kgf•m) (For each piping connection, the gas pipe is on the bottom and the liquid pipe is on the top.) Ø9.52 mm...
  • Page 63 CAUTION CAUTION • KEEP IMPORTANT 7 POINTS FOR Use a torque wrench and tighten the nut at PIPING WORK. the specifi ed torque value. (1) Take away dust and moisture (inside of the connecting pipes). 6. Tighten all the caps on the valves securely, then perform a gas leak inspection.

  • Page 64: Electrical Work

    Wiring connection ■ Performing Additional Installation of an Indoor Unit 1. Collect refrigerant from the outdoor unit. • The dash lines show on-site wiring. 2. Turn off the circuit breaker. For indoor unit RAS-M series. 3. Perform additional installation referring to the procedure from “Refrigerant Piping Connection”...
  • Page 65 <Pump down process> Terminal block (Connecting cable) 1. Turn off the Air Conditioner system. 2. Connect the charge hose from the manifold valve to the service port of the packed valve at gas side. 1(L) 1(L) 1(L) 3. Turn on the Air Conditioner system in cooling operation more POWER SUPPLY than 10 minutes.

  • Page 66: Miswiring (Mispiping) Check

    10-2-8. Miswiring (Mispiping) Check 7. The below is displayed when the error is detected. (* Repetition of 3 sec ON / 0.5 sec OFF) Make sure that the wiring and piping for each room D800 D801 D802 D803 D804 D805 have the same alphabetical codes (A, B, C).

  • Page 67: Test Operation

    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

    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

    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. described in the following table. If a claim is made for running operation, check 11-1-2.

  • Page 70: Primary Judgment

    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: Self-Diagnosis By Remote Controller (Check Code)

    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 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 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 Block distinction Operation of diagnosis function Action and Judgment Check Check Display flashing Block Cause of operation conditioner code code error status Outdoor Current on inverter circuit All OFF Flashes after 1. Remove connecting lead wire of the is over limit in short time. error is detected compressor, and operate again.
  • Page 75 Block distinction Operation of diagnosis function Action and Judgment Check Check Display flashing Block Cause of operation conditioner code code error status 1. Check installation conditions such as Compressor drive output error. All OFF Flashes after Outdoor (Relation of voltage, current error is detected packed valve opening, refrigerant 8 times*.
  • Page 76 Block distinction Operation of diagnosis function Action and Judgment Check Check Display Block Cause of operation conditioner code code flashing error status The others Compressor does not rotate. All OFF Flashes after 1. Remove connecting lead wire of the (including Because of missed wiring, error is detected compressor, and operate again.
  • Page 77 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%) The others operates error is detected unit has been sent when...
  • Page 78 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: Service Support Function (Led Display, Switch Operation)

    Service Support Function (LED Display, Switch Operation) 1. Outline A various setup and operation check can be performed by the push down button switches (SW81, SW82) on the outdoor control P.C. board WP-524. Operation part Part No. Specifications Operation contents SW81 Push down button switch Performs the specific operation to check maintenance and various initial settings.
  • Page 80 11-6. Trouble Diagnosis by Outdoor LED For the outdoor unit, the self-diagnosis is possible by LED (Green) and five LEDs (Yellow). Green LED (D805) and Yellow LEDs (D800 to D804) are provided on the display P.C. board WP-524. 1. In the initial LED display status, Green LED(D805) is lighted as below. Normal Error occurring D800...
  • Page 81 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [1C]  [Case thermo operation, Power supply error ] Is AC mains voltage correct? Confirm power supply (198 to 264V) construction.
  • Page 82 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) ∗ There is a possibility that it is one of the following errors. [18] Confirm LED on outdoor P.C.
  • Page 83 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) ∗ There is a possibility that it is one of the following errors. [1C] Confirm LED on display P.C.
  • Page 84 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF 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 CN64 Correct connector.
  • Page 85 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.)   [1D] [Compressor lock]  Is AC mains voltage correct? Check wiring construction. (198 to 264V) Ask repair of power supply.
  • Page 86 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [20] ∗ There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C.
  • Page 87 :ON ( *:3 sec ON / 0.5 sec OFF) :OFF Check Outdoor Check and troubleshooting code LED display (Item without special mention indicates part of outdoor unit.) [21] ∗ There is a possibility that it is one of the following errors. Confirm LED on outdoor P.C.
  • Page 88 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 TGc : Gas side temp. sensor TO, TE, TS, TGa to TGc Temperature (˚C) Outdoor Unit Part name...

  • Page 89: How To Simply Judge Whether Outdoor Fan Motor Is Good Or Bad

    11-8. 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 90 <WP-500-SK-01> - 90 -...
  • Page 91 <WP-524> - 91 -...

  • Page 92: How To Replace The Main Parts

    12. HOW TO REPLACE THE MAIN PARTS 12-1. Outdoor Unit Part name Procedure Remarks Common CAUTION procedure Front panel Never forget to put on the gloves at working time; otherwise an injury will be caused by the parts etc. 1.Detachment 1) Stop operation of the air conditioner, and turn off the switch of the breaker.
  • Page 93 Part name Procedure Remarks Discharge 1. Detachment Left side Perform work of Detachment 1 of 1 . port cabinet guard condenser Plate fixing Remove the two air outlet cabinet screws Motor base condenser which assemble to partition plate (Ø4 x 8). Remove the two air outlet cabinet screws which assemble to motor base (Ø4 x 8).
  • Page 94 Part name Procedure Remarks Back 1. . Detachment Rear cabinet cabinet 1) Perform work of Detachment 1 of 1 . 2) Remove the two back cabinet screws which assemble to plate fixing valve (Screw Ø4 x 8). 3) Remove four back cabinet screws (HEX-ST-SCREW Ø4x10).
  • Page 95 Part name Procedure Remarks Inverter Cable tie assembly fixing lead (Continue) Cable tie Cable tie fixing lead fixing lead 5) Remove a inverter cover screw (TT2T-4x8) and remove the inverter cover. Screw (TT2T-4x8) Remove 6) Remove the connectors that are connected from CDB P.C.board to the other parts.
  • Page 96 Part name Procedure Remarks 9) Remove a plate fixing CDB P.C. board screw Inverter assembly (TT2T-4x8) (Continue) CDB P.C. board Screw (TT2T-4x8) Remove 10) Remove the connectors that are connected IPDU P.C. board to IPDU P.C. board and the other parts. 11) Remove plate fixing from plate terminal and plate fixing condenser, then move the inverter box to up direction from partition.
  • Page 97 Part name Procedure Remarks Inverter CDB P.C.board UART assembly (Continue) High pressure switch 1) Perform works of Detachment 1 of 1 and 4) of 4 . 4-way valve coil CAUTION Compressor case thermo Never disassemble the inverter until 5 minutes after the power supply was turned off because Earth srew Compressor...
  • Page 98 Part name Procedure Remarks Reactor Reactor to be attached to the inverter assembly. Perform works of detachment 1 of 1 , 2 , 4 and 5 . Remove the six duct cover screws (TT2T-4x8). Remove the reactor cover screws (TT2T-4x8). Remove the two reactor screws (TT2T-4x8).
  • Page 99 Part name Procedure Remarks Fan motor 1) Perform works of Detachment 1 of 1 , 2 . 2) Remove a inverter cover screw (TT2T-4x8). 3) Remove a plate fixing CDB P.C. board screw (TT2T-4x8) 4) Remove the cushion at the top of inverter box. 5) Cut two cable ties that fasten with the fan motor lead.
  • Page 100 Part name Procedure Remarks Fan motor 6) Remove the plug of fan motor on the IPDU P.C. board. 7) Remove the lead of fan motor from rubber fixing lead at the partition plate. 8) Remove lead of fan motor from fan motor plate fixing. 9) Remove the four fan motor screws which assemble to motor base.
  • Page 101 Part name Procedure Remarks Compressor Perform works of Detachment 1 of 1 . Recover the refrigerant gas from the outdoor unit. Nut (Ø8 mm) Perform works of 2 , 3 , 4 and 5 . 1.47-1.96 N.m (15-20 kgf.cm) Remove the soundproof plate and TD sensor. Remove a cover terminal of compressor.
  • Page 102 Part name Procedure Remarks 1. Detachment Fan guard Perform works of detachment 1 of 1 and 2 . Fan guard hooking claw CAUTION 8 positions fixing Work on the cardboard, cloth, and etc. in order to prevent damage on the product. 2) Remove the four bell mouth screws which assemble to air outlet cabinet (Ø4x10).
  • Page 103 Part name Procedure Remarks 4-way valve Detachment coil 1) Perform works of Detachment 1 of 1 . 2) Remove a inverter cover screw (TT2T-4x8). 3) Remove a plate fixing CDB P.C. board screw (TT2T-4x8). 4) Cut a cable tie fixing lead at the inverter box then remove plug of 4-way coil.
  • Page 104 Part name Procedure Remarks ∗ Attachment TD sensor (Discharge Fix TD sensor on the straight part of the discharge sensor) pipe so that the lead wire directs upward and the sensor directs upward of the cabinet. Discharge tube TD sensor Compressor TS sensor ∗...
  • Page 105 Part name Procedure Remarks ∗ Attachment TE sensor ( Heat Fix TE sensor on the straight part of the exchanger condenser discharge port pipe so that the lead sensor) wire directs upward and the sensor directs the liquid store tank. Reference end of curve TE sensor Condenser...
  • Page 106 Part name Procedure Remarks ∗ Attachment TG sensor NOTE) TGa: Yellow Fix these sensors on the directly arranged TGb: Red part of the header connecting pipe at gas side At working time (finish time), be TGc: Green sure not to damage the cover of so that the cabinet turns toward the front side the sensor lead wire with edge of and the sensors turn toward upper cabinet.

  • Page 107: Exploded Views And Parts List

    UPPER CABINET ASSEMBLY 43T46564 SOCKET ASSEMBLY (12.7D) 43T39342 MOTOR BASE 43T58307 REACTOR 43T04505 PARTITION ASSEMBLY 43T21517 FAN-MOTOR (SDM-340-60) 43T19372 FAN GUARD(TOSHIBA) 43T50343 COMPRESSOR THERMOSTAT ASSEMBLY 43T20329 PROPELLER FAN 43T60620 LEAD ASSY, COMPRESSOR 43T79325 DRAIN NIPPLE 43T47354 BOLT COMPRESSOR (M6) 43T22313...

  • Page 108: Inverter Assembly

    13-2. Inverter Assembly REACTOR, CH-56-3Z-T TO-SENSOR REACTOR, CH-76 TS-SENSOR FUSE 3.15A 250VAC TE-SENSOR TERMINAL, 9P TD-SENSOR TGA-SENSOR TERMINAL BLOCK, 3P TGB-SENSOR TGC-SENSOR FUSE 10A 250VAC HOLDER SENSOR(TE, TGC) BOARD (IPDU) BOARD (CDB) HOLDER SENSOR(TGA, TGB) FUSE 10A 250VAC COV-E-PART HOLDER SENSOR(TD) TUBE Location Part...
  • Page 109 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

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