Toshiba RAS-25G3AVSG-ND Service Manual

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SERVICE MANUAL

Indoor Unit

RAS-B25G3KVSG-ND

RAS-B35G3KVSG-ND

R32

FILE NO. SVM-24013

SPLIT TYPE

Outdoor Unit

RAS-25G3AVSG-ND

RAS-35G3AVSG-ND

June, 2024

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Summary of Contents for Toshiba RAS-25G3AVSG-ND

Page 1 FILE NO. SVM-24013 SERVICE MANUAL SPLIT TYPE Outdoor Unit Indoor Unit RAS-25G3AVSG-ND RAS-B25G3KVSG-ND RAS-35G3AVSG-ND RAS-B35G3KVSG-ND June, 2024...
Page 2 CONTENTS 1. SAFETY PRECAUTIONS ................3 2. SPECIFICATIONS ..................7 3. REFRIGERANT R32 .................. 9 4. CONSTRUCTION VIEWS ................ 17 5. WIRING DIAGRAM .................. 19 6. SPECIFICATIONS OF ELECTRICAL PARTS ......... 20 7. REFRIGERANT CYCLE DIAGRAM ............21 8. CONTROL BLOCK DIAGRAM ..............23 9.
Page 3 1. SAFETY PRECAUTIONS Read the precautions in this manual This appliance is ﬁ lled with R32. carefully before operating the unit. (Flammable Material) Information included in the Operation Service personnel should be handing this equipment Manual and/or Installation Manual. with reference to the Installation Manual. Warning Indications on the Air Conditioner Unit Warning indication Description...
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 WARNING • Never modify this unit by removing any of the safety guards or bypassing any of the safety interlock switches. • Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls.
Page 6 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 7 (Cooling / Heating) -15,46/-25,24 Installation plate Accessory Indoor unit Wireless remote controller Batteries Remote controller holder Toshiba IAQ filter Mounting screw 6(  4x25L) Remote controller holder 2(  3.1x16L) Flat head wood screw Installation manual Owner's manual * The specification may be subject to change without notice for purpose of improvement.
Page 8 2-2. Operation Characteristic Curve. <Cooling> <Heating> RAS-B35G3KVSG-ND RAS-B25G3KVSG-ND RAS-B25G3KVSG-ND RAS-B35G3KVSG-ND Conditions Conditions Indoor : DB 20 C/WB 15 Indoor : DB 27 C/WB 19 Outdoor : DB 7 C/WB 6 Outdoor : DB 35 C/WB 24 Indoor Air Flow : High Indoor Air Flow : High Pipe Length : 5m Pipe Length : 5m...
Page 9 3. REFRIGERANT R32 3. If a refrigeration gas leakage occurs during This air conditioner adopts the new refrigerant HFC (R32) which does not damage the ozone layer. installation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire, a The next section describes the precautions for air conditioner using the new refrigerant.
Page 10 Table 3-2-1 Thicknesses of annealed copper pipes Thickness (mm) Nominal diameter Outer diameter (mm) R32(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 11 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 conven- tional flare tool. Flare processing dimensions differ according to the type of flare tool.
Page 12 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 13 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 14 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 15 3-5. Brazing of Pipes 3. Types of flux 3-5-1. Materials for Brazing • Noncorrosive flux 1. Silver brazing filler Generally, it is a compound of borax and boric Silver brazing filler is an alloy mainly composed acid. of silver and copper. It is used to join iron, copper It is effective in case where the brazing tem- or copper alloy, and is relatively expensive though perature is higher than 800°C.
Page 16 3-5-3. Brazing As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified. Flow meter 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 17 4. CONSTRUCTION VIEWS 4-1. Indoor Unit Air filter Air filter Front panel Grille inlet Air outlet Heat exchanger Knock out system 66.5 50 55 66.5 Installation plate hanger Wireless remote controller 24 97 17.5 Remote controller holder Drain hose (0.6m) Connecting pipe (0.63m) (Flare 6.35mm)
Page 18 4-2. Outdoor Unit (Unit : mm) Ø6 hole Ø6 hole A detail Drawing (Back leg) Ø11x14 hole (For Ø8-Ø10 anchor bolt) Drain outlet B Detail Drawing (Front leg) FAN-GUARD P-FAN Ø 436 COVER-PV Front Side Liquid side (Flare Ø 6.35) Gas side (Flare ∅...
Page 19 5. WIRING DIAGRAM WP-528 t° Outdoor Control P.C. Board 250V P200 T3.15A P201 250V 3 P202 F100 T3.15A 250V CN30 (WHI) Switching Serial Power Communication 3 Supply Circuit CN51 CN72 CN62 CN60 CN61 CN63 CN70 CN73 CN90 (GRN) (YEL) (YEL) (WHI) (WHI) (WHI) (WHI) (WHI) (WHI)
Page 20 6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit Parts name Type name Specifications Fan Motor (for indoor) WDP-340-30CA DC340V, 42W Room temp. sensor (TA-sensor) 10kΩ at 25°C Heat exchanger temp. sensor (TC-sensor) 10kΩ at 25°C Heat exchanger temp. sensor (TCJ-sensor) 10kΩ...
Page 21 7. REFRIGERANT CYCLE DIAGRAM 7-1. Refrigerant Cycle Diagram Temp. measurement INDOOR UNIT Indoor heat exchanger Cross flow fan Max. : 20m Min. : 2m Pressure measurement Chargeless : 15m Deoxidized copper pipe Gauge attaching port Charge : 20g/m Outer dia. : 6.35mm Vacuum pump connecting port Thickness : 0.8mm Sectional shape...
Page 22 7-2. Operation Data <Cooling> Temperature Heat exchanger Model name Standard Indoor Outdoor Compressor Connecting condition(°C) pipe temp. pressure fan mode fan mode revolution piping Indoor Outdoor P (MPa) T1 (°C) T2 (°C) (rps) 27/19 35/- RAS-B25G3KVSG-ND High 1.0 to 1.1 14 to 15 41 to 42 High RAS-B35G3KVSG-ND...
Page 23 8. CONTROL BLOCK DIAGRAM 8-1. Indoor Unit Indoor Unit Control Panel M.C.U Heat Exchanger Sensor (TC) Functions Operation • Louver Control Display Heat Exchanger Sensor (TCJ) Timer • 3-minute Delay at Restart for Compressor Display Temperature Sensor • Motor Revolution Control Hi-POWER Infrared Rays Signal Receiver Display...
Page 24 8-2. Outdoor Unit (Inverter Assembly) - 24 -...
Page 25 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 to conditioner. Its system can control the speed of compressor motor according to load.
Page 26 9-2. Operation Description 1. Basic operation ......................1. Operation control ..................... 2. Cooling/Heating operation ..................3. AUTO operation ....................... 4. DRY operation ......................2. Indoor fan motor control ....................3. Outdoor fan motor control ..................... 4. Capacity control ......................5. Current release control ....................6.
Page 27 Item Operation flow and applicable data, etc. Description 1. Basic 1. Operation control 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 28 Item Operation flow and applicable data, etc. Description 1. Basic 2. Cooling/Heating operation operation The operations are performed in the following parts by controls according to cooling/heating conditions. 1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal starts being transferred form the indoor controller to the outdoor unit.
Page 29 Item Operation flow and applicable data, etc. Description 2. Indoor fan <In cooling operation> motor control (This operation controls the fan speed at indoor unit side.) * Symbols The indoor fan (cross flow fan) is operated by the phase- : Ultra High control induction motor.
Page 30 Item Operation flow and applicable data, etc. Description 2. Indoor fan <In heating operation> 1) When setting the fan speed to L, motor control L+, M, M+ or H on the remote controller, the operation is per- formed with the constant speed HEAT ON shown in Fig.
Page 31 Alarm 3) Fan lock display 4) Motor operates as shown in the table below. In cooling operation In heating operation RAS-25G3AVSG-ND Hz < 13.8 13.8 ≤ Hz < 30.6 RAS-25G3AVSG-ND Hz < 21.0 21.0 ≤ Hz < 39.0 30.6 ≤ Hz 39.0 ≤...
Page 32 Current decrease which does not exceed the Capacity control continues. specified value. Mode Outdoor temperature: To (°C) Current Release Value (A) RAS-25G3AVSG-ND RAS-35G3AVSG-ND To  45 Cooling 45 > To  40 To < 40 To  16 11.5 11.5...
Page 33 Item Operation flow and applicable data, etc. Description 6. Release protective <In cooling/dry operation> 1) When temperature of the indoor control by tempera- heat exchanger drops below 5°C, (Prevent-freezing control for indoor heat exchanger) ture of indoor heat the compressor speed is In cooling/dry operation, the sensor of indoor heat exchanger reduced.
Page 34 *** If TO sensor is abnormal, TO value is fixed at -10°C. Table 2 Heating operation Model (time) RAS-25G3AVSG-ND RAS-35G3AVSG-ND <Defrost operation> <Returning from defrost operation> • Defrost operation in A to C zones 1) Stop operation of the compressor for approx.
Page 35 Item Operation flow and applicable data, etc. Description 7. Defrost control <No revert cycle defrost> (Only in heating (This function detect condition is same as normal operation) reverse defrost and it operate at TO above 2°C ). During defrosting operation is detected. 4-way valve keep heating position (No reverse) and PMV opening follow software fixed full open.
Page 36 Item Operation flow and applicable data, etc. Description 7. Defrost control • Strong defrost <Finish of defrost operation for strong (Only in heating Upgrade defrost ability when normal defrost ability defrost> operation) is not enough by increase defrosting finished • Returning conditions from defrost operation.
Page 37 Item Operation flow and applicable data, etc. Description 8. Louver control This function controls the air direction of the indoor unit. 1) Louver • The position is automatically controlled according to the operation position mode (COOL/HEAT). • The set louver position is stored in memory by the microcomputer, and the louver returns to the stored position when the next operation is performed.
Page 38 Item Operation flow and applicable data, etc. Description 8. Louver control 3) Swing • Swing operation is perfor in range 35° with the Fixed position as • Swing the center. When pressing [SWING] button during • If the swing range exceeded either upper or lower limit position, operation, the louver swing operation is perfomed in range 35°...
Page 39 Item Operation flow and applicable data, etc. Description 9. ECO When pressing [ECO] button on the remote controller, a <Cooling operation> operation Economic operation is performed. 1) The control target temperature <Cooling operation> increase 0.5ºC per hour up to 2ºC This function operates the air conditioner with the difference starting from the set temperature between the set and the room temperature as shown in the...
Page 40 Item Operation flow and applicable data, etc. Description 10. Temporary Pressing [RESET] button starts the temporary 1) When pressing [RESET] button, the operation of [AUTO] operation. When keeping temporary [AUTO] operation starts. operation [RESET] button pressed for 10 seconds or more, the 2) When keeping [RESET] button pressed temporary [COOL] operation is performed.
Page 41 Item Operation flow and applicable data, etc. Description 13. Pulse This function controls throttle amount of the 1) When starting the operation, move the Modulating refrigerant in the refrigerating cycle. valve once until it fits to the stopper. valve (P.M.V.) (Initialize) According to operating status of the air conditioner, control...
Page 42 Item Operation flow and applicable data, etc. Description 14. Self-Cleaning 1. Purpose function The Self-Cleaning operation is to minimize the growth of mold, bacteria etc. by running the fan and drying so as to keep the inside of the air conditioner clean. Unit now performing cooling or dry operation Self-Cleaning operation When the cooling or dry operation shuts...
Page 43 Item Operation flow and applicable data, etc. Description 14. Self-Cleaning function 14-1-1. Self-Cleaning diagram Operation display FCU fan rpm is depend on presetting. (500RPM) FCU louver OPEN OPEN (12.7º) CLOSE ON or OFF ON or OFF Timer display depend on presetting of timer function. depend on presetting of timer function.
Page 44 Item Operation flow and applicable data, etc. Description 15. Remote-A or B Setting the remote controller 1. Purpose selection This operation is to operate only one To separate using of remote control for each indoor indoor unit using one remote controller. unit in case of 2 air conditioner are installed nearly.
Page 45 Compressor Compressor Model Operation frequncy Fan Speed frequncy Fan Speed (rps) (rpm) (rps) (rpm) Silent1 Max 800 Max 860 RAS-25G3AVSG-ND Silent2 Silent1 Max 860 Max 860 RAS-35G3AVSG-ND Silent2 POWER-SELECTION AND SILENT OPERATION [100%] [75%] [50%] SILENT#2 SILENT#1 - 45 -...
Page 46 Item Operation flow and applicable data,etc Description <With Quiet control/Non-select method> 19. Outdoor 1. Purpose Quiet For the users who concern about noise control of the outdoor unit, this control controls Select "Conrol" or "No conrol" by keeping the max. revolutions of the compressor [RESET] button pushed for 20 seconds.
Page 47 Item Operation flow and applicable data,etc Description 20. Fireplace Fireplace button on remote controller is Keep air circulation during other heat Operation pressed. source applied. Fireplace 1: Note: Cancel cold draft prevention control and fan With Fireplace operation on heating speed depend on user require base on basic mode indoor unit always runs and cold control.
Page 48 Item Operation flow and applicable data, etc. Description 23. Display lamp To decrease the display lamp brightness or turn it off. brightness Press and hold for 3 seconds until brightness level ( adjustment ) is shown on remote control LCD then release the button. 2.
Page 49 Item Operation flow and applicable data, etc. Description Operating system setting 25. Operation 1. Purpose mode Choosing the operating system as select table appropriate in real condition 2. Operation Factory default setting prefer "Heat pump" system. Through it is able to cooling only system heating only system or return to factory default.
Page 50 9-3. Auto Restart Function This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored. This function is set to work when shipped from the factory.
Page 51 9-3-2. How to Set the Auto Restart Function To set the auto restart function, proceed as follows: The power supply to the unit must be on ; the function will not set if the power is off. Press the [RESET] button located in the center of the front panel continuously for three seconds. The unit receives the signal and beeps three times.
Page 52 9-4. Remote Controller and Its Functions 9-4-1. Parts Name of Remote Controller Infrared signal emitter Memory and Preset button Start/Stop button ( Mode select button ( AIR FLOW and HADA CARE FLOW button ( Fireplace/8°C button ( ECO button ( Comfort sleep button ( Weekly timer ( Temp for Weekly timer (...
Page 53 How to set WEEKLY TIMER 1. Press to enter WEEKLY TIMER setting. Blink 2. Press to select desired day in sequence. The sequence of day symbol appears on the LCD. WEEKLY SUMO TUWETHFRSA (All day) 3. Press to select the program number. ●...
Page 54 5. Press to select desired operation. 6. Press to select desired temperature. ● The temperature can be set between 17°C and 30°C. 7. Press to select the desired fan speed. 8. Add operations, if required. ● Press to use 8°C operation. (Notes: Fireplace cannot select and memorize in weekly function) ●...
Page 55 Edit Weekly timer program To edit the program after confirming the weekly timer setting, follow steps 1 - 3 below. 1. Press ● The day of the week and the program number of the current day will be displayed. 2. Press to select the day of the week and press to select program number to be...
Page 56 To delete programs The individual program 1. Press ● The day of the week and the program number is displayed. ● Select the day to delete the program. 2. Press to select the program number to be deleted. 3. Press ●...
Page 57 2. AUTOMATIC OPERATION To automatically select cooling, heating, or fan only operation. Press Press : Select Auto A. : Select the desired temperature. Min 17°C, Max 30°C Press Press 3. Press Press : Select AUTO, LOW , LOW+ , MED , MED+ , HIGH or Quiet...
Page 58 6. Hi-POWER OPERATION To automatically control room temperature and airflow for faster cooling or heating operation (except in DRY and FAN ONLY mode) Press Press : Start and stop the operation 7. ECO OPERATION To automatically control room temperature to save energy (except in DRY and FAN ONLY mode) Press : Start and stop the operation.
Page 59 10. POWER-SELECTION OPERATION / SILENT OPERATION (OUTDOOR UNIT) Power-Selection ( This function is used when the circuit breaker is shared with other electrical appliances. It limits the maximum current and power consumption to 100%, 75%, or 50% and can be implemented by POWER-SELECTION.
Page 60 11. TIMER OPERATION Set the timer when the air conditioner is operating. Setting the ON Timer Setting the OFF Timer Press : Set the desired Press : Set the desired ON timer. OFF timer. Press : Set the timer. Press : Set the timer.
Page 61 9-4-3. Name and Functions of Indications on Remote Controller [Display] All indications, except for the clock time indicator, are displayed by pressing the button. Transmission mark TIMER and weekly timer indicator This transmission mark indicates when the The time setting for timer operation and weekly remote controller transmits signals to the indoor timer function is indicated.
Page 62 10. INSTALLATION PROCEDURE 10-1. Installation Diagram of Indoor and Outdoor Units For the rear left, bottom left and left piping Wall Hook Installation Cut out a piece of SPACER from indoor plate unit packaging box, roll it and insert Flat head between the indoor unit and wall to tilt wood screw the indoor unit for better operation.
Page 63 10-2. Installation 10-2-1. Optional installation parts Part Parts name Q’ty code Refrigerant piping Liquid side : Ø6.35 mm each Gas side : Ø9.52 mm Pipe insulating material (polyethylene foam, 6 mm thick) Putty, PVC tapes each <Fixing bolt arrangement of outdoor unit> 108 mm Air inlet * Drain nipple and cap water proof...
Page 64 10-2-2. Accessory and installation parts Indoor Unit Part name Part name Installation plate × 1 Wireless remote controller × 1 Battery × 2 Remote controller holder × 1 Mounting screw × 6 Flat head wood screw × 2 Flat head wood screw × 1 Battery cover Owner’s Manual ×...
Page 65 10-2-3. Installation/Servicing Tools Changes in the product and components 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 (3 way valve) has been changed. (1/2 UNF 20 threads per inch) •...
Page 66 10-3. Indoor Unit 10-3-2. Cutting a hole and mounting installation Plate 10-3-1. Installation place <Cutting a hole> • A place which provides the spaces around the indoor When installing the refrigerant pipes from the rear. unit as shown in the diagram. •...
Page 67 CAUTION 10-3-3. How to Connect Remote Controller for • If have curtain rails, window cornice or other Wire Operation objects, allow space from the indoor unit should be 65 mm or more. Indoor unit • If allow space is less than 65 mm, this can affect the opening and closing of the air inlet grille and Control wire the horizontal louver.
Page 68 10-3-4. Piping and drain hose installation Fix control wire which arrange as shown on ﬁgure 6 and 7 to terminal by provided screws (tighten ﬁrmly but not over 0.25 N·m <Piping and Drain Hose Forming> (0.03 kgf·m)). Set control wire through gutter way at rear side of remote controller * Since dewing results in a machine trouble, make as shown on f gure 8.
Page 69 <Left-hand connection with piping> <How to fix the Drain Cap> 1) Insert hexagon wrench (4 mm) in a center head. Bend the connecting pipe so that it is laid within 43 mm above the wall surface. If the connecting pipe is laid exceeding 43 mm above the wall surface, the indoor unit may unstably be set on the wall.
Page 70 10-3-5. Indoor unit fixing 10-3-6. Drainage 1. Pass the pipe through the hole in the wall, and hook 1. Run the drain hose sloped downwards. the indoor unit on the installation plate at the upper hooks. NOTE 2. Swing the indoor unit to right and left to confirm that •...
Page 71 At least • The allowable length of the connecting pipe. 50 cm Snow accumulation line Anchor bolts Model RAS-25G3AVSG-ND RAS-35G3AVSG-ND Holding frame Chargeless Up to 15 m Up to 15 m Maximum length 20 m...
Page 72 Draining the Water 10-4-3. Refrigerant piping connection <Flaring> • Holes are provided on the base plate of the outdoor unit to ensure that the defrost water produced during heating 1. Cut the pipe with a pipe cutter. operations is drained off eff ciently. If a centralized drain is required when installing the unit on a balcony or wall, follow the steps below to drain off the water.
Page 73 <Tightening connection> Evacuating Align the centers of the connecting pipes and tighten After the piping has been connected to the indoor unit, the flare nut as far as possible with your fingers . Then you can perform the air purge together at once. tighten the nut with a spanner and torque wrench as shown in the figure.
Page 74 CAUTION • Securely tighten the valve cap with torque in the following table • KEEP IMPORTANT 7 POINTS FOR PIPING WORK Cap Size (H) Torque Take away dust and moisture (inside of the 14~18 N.m connecting pipes). H17 - H19 Valve Rod (1.4 to 1.8 kgf·m) Tighten the connections (between pipes and unit).
Page 75 10-5. Electrical works The power supply can be selected to connect to indoor unit or outdoor unit. Choose proper way and connect the power supply and connecting cable by follow the instruction as following. Model RAS-B25G3KVSG-ND RAS-B35G3KVSG-ND Power source 50 Hz, 220 – 240 V Single phase Maximum running current 11.80A 11.85A...
Page 76 10-5-2. Power Supply and Connecting Cable Connection The power supply can be selected to connect to indoor unit or outdoor unit. Choose proper way and connect the power supply and connecting cable by follow the instruction as following. Power Supply Input at Outdoor Unit Terminal Block (Recommend) Indoor Unit Outdoor Unit Connecting cable...
Page 77 10-5-3. Power supply input Wiring Diagram for 1:1 Outdoor Unit Power supply input at Outdoor Terminal Block (Recommend) Indoor Terminal Block Outdoor Terminal Block Power supply input Power supply input at Indoor Terminal Block (Optional) Indoor Terminal Block Power supply input Outdoor Terminal Block...
Page 78 10-5-4. In Case of Indoor Unit Connect With Inverter Multi System (IMS) Indoor Unit Stripping length of the Connecting cable Connecting cable connect to 1 2 3 connecting cable Terminal block Earth line 50 mm 10 mm 10 mm 70 mm Earth line Connecting cable...
Page 79 10-6. Others Note : 1. Repeat previous step to reset Remote Control to be A. 10-6-1 . Gas leak test 2. Remote Control A have not “A” display. 3. Default setting of Remote Control from factory is A. Check places for the indoor unit .
Page 80 10-6-4. Auto restart Function setting This product is designed so that, after a power failure, it can restart automatically in the same operating mode as before the power failure. INFORMATION The product was shipped with Auto Restart function in the ON position. Turn it OFF as required. <How to turn OFF the Auto Restart Function>...
Page 81 11. HOW TO DIAGNOSE THE TROUBLE The pulse motor 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 82 CAUTION A high voltage (equivalent to the supply voltage) is also energized to ground through the sensors, PMV and other low-voltage circuits. The sensor leads and other wires are covered with insulated tubes for protection. Nevertheless, care must be taken to ensure that these wires are not pinched.
Page 83 K Precautions when inspecting the control section of the outdoor unit NOTE : A large-capacity electrolytic capacitor is used in the outdoor unit controller (inverter). Therefore, if the power supply is turned off, charge (charging voltage DC280 to 380V) remains and discharging takes a lot of time. After turning off the power source, if touching the charging section before discharging, an electrical shock may be caused.
Page 84 11-1. First Confirmation 11-1-1. Confirmation of Power Supply Confirm that the power breaker operates (ON) normally. 11-1-2. Confirmation of Power Voltage Confirm that power voltage is AC 220–230–240 ± 10%. If power voltage is not in this range, the unit may not operate normally. 11-1-3.
Page 85 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. 11-3.
Page 86 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 in formation of the self-diagnosis on the display of the remote controller with the check codes.
Page 87 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 88 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 89 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 90 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 Outdoor P.C. (Relation of voltage, current error is detected packed valve opening, refrigerant board...
Page 91 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 The others (including Because of missed wiring, error is detected compressor, and operate again.
Page 92 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 93 11-5. Judgment of Trouble by Every Symptom 11-5-1. Indoor Unit (Including Remote Controller) (1) Power is not turned on (Does not operate entirely) <Primary check> 1. Is the supply voltage normal? 2. Is the normal voltage provided to the outdoor unit? 3.
Page 94 (2) Power is not turned on though Indoor P.C. board is replaced <Confirmation procedure> Turn on power supply. Return the wiring of the power relay is returned to Is it wired as shown in Figure below? Does operation lamp flash? the normal procedure.
Page 95 (3) Only the indoor motor fan does not operate <Primary check> 1. Is it possible to detect the power supply voltage (AC220–240V) between on the terminal block? 2. Does the indoor fan motor operate in cooling operation? (In heating operation, the indoor fan motor does not operate for approximately 10 minutes after it is turned on, to prevent a cold air from blowing in.) Turn off power supply once, and...
Page 96 Is it possible to Does check display Replace change airflow level remote on remote show high? to “HIGH”? Change the new PC Replace board. Does fan speed motor change? Fan motor operates normally. Is it possible to Does check cross-flow Replace bearing rotate cross-flow fan by fan bearing normal...
Page 97 (4) Indoor fan motor automatically starts to rotate by turning on power supply [For DC fan motor] <Cause> The IC is built in the indoor fan motor. Therefore the P.C. board is also mounted to inside of the motor. If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turning on power supply.
Page 98 (5) Troubleshooting for remote controller <Primary check> Check that A or B selected on the main unit is matched with A or B selected on the remote controller. There is no beep from the indoor unit Push the [ ] button. The OPERATION lamp of the air conditioner main unit does not light Does the transmission...
Page 99 11-5-2. Wiring Failure (Interconnecting and Serial Signal Wire) (1) Outdoor unit does not operate 1) Is the voltage between of the indoor terminal block varied? Confirm that transmission from indoor unit to outdoor unit is correctly performed based upon the follow- ing diagram.
Page 100 11-6. How to Check Simple the Main Parts <Check procedure> Gas leakage, Discharge temp. error, disconnection of TS/TC gas leakage sensors (Check code 02, 1C) (Check code 03, 1E) Valve drive check Is coil of the pulse motor valve Set it correctly. (P.M.V.) correctly set? Set it correctly.
Page 101 11-7. How to Diagnose Trouble in Outdoor Unit 11-7-1. Summarized Inner Diagnosis of Inverter Assembly Diagnosis/Process flowchart Item Contents Summary Preparation Turn “OFF” the power supply breaker, and remove 3P Remove connector connector which connects of compressor. inverter and compressor. Check •...
Page 102 Diagnosis/Process flowchart Item Contents Summary Check Check winding resistance between phases of compres- sor, and resistance between outdoor frames by using a tester. → OK if 20MΩ or more • Is it grounded? Replace control board assembly. • Is it short-circuit ...
Page 103 (3) Check procedures Table 11-8-1 Procedure Check points Causes Turn off the power supply breaker Check whether or not the fuse (F01) Impulse voltage was applied or the and remove the P.C. board is blown. indoor fan motor short-circuited. assembly from electronic parts base.
Page 104 11-8-2. P .C . Board Layout CN21 CN36 CN32 Main Electrolyte Fan Motor Stepping motor HA1 Connector Fuse Capacitor (Wireless Adapter) Connector DB01 Diode Bridge Rectifier CN30 Power supply Input terminal (Line) Fuse CN10 Display R-03 Connector Resistor L-01 Line Filter CN31 CN63(Red) Power supply...
Page 105 11-8-3. Indoor Unit (Other Parts) Part name Checking procedure Room temp. (TA) sensor Disconnect the connector and measure the resistance value with tester. Heat exchanger (TC), (TCJ) (Normal temp.) sensor Temperature 10°C 20°C 25°C 30°C 40°C Sensor TA, TC, TCJ (kΩ) 20.7 12.6 10.0...
Page 106 11-8-5. Checking Method for Each Part Part name Checking procedure Electrolytic capacitor 1. Turn OFF the power supply breaker. 2. Discharge all three capacitors completely. 3. Check that safety valve at the bottom of capacitor is not broken. 4. Check that vessel is not swollen or exploded. 5.
Page 107 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 108 12. HOW TO REPLACE THE MAIN PARTS WARNING • Since high voltages pass through the electrical parts, turn off the power without fail before proceeding with the repairs. Electric shocks may occur if the power plug is not disconnected. • After the repairs have been completed (after the front panel and cabinet have been installed), perform a test run, and check for smoking, unusual sounds and other abnormalities.
Page 109 Part name Procedures Remarks Front panel 1) Stop operation of the air conditioner and turn Front panel Air inlet grille off its main power supply. 2) Open two screw caps and securely remove screws (2 pcs.) at the front panel. Screw Screw Screw cap...
Page 110 Part name Procedures Remarks Fan motor 1) Follow the procedure item 3 and 4 . Cross flow fan 2) Loosen the set screw of the cross flow fan. Cross flow fan Body back 3.5 mm Vertical louver Set screw Fan motor Hexagon screw driver 3) Remove 2 fixing screws of the motor band.
Page 111 Part name Procedures Remarks Drain pan 1) Follow the procedure item 3 . assembly 2) Remove screw holding the electric part cover. Connectors P.C.board Louver motor Screw connector Electric part cover 3) Disconnect the louver motor connector (5P) from P.C. board assembly. 4) Remove fixing screws of the unit display and remove unit display.
Page 112 Part name Procedures Remarks Vertical louver 1) Follow the procedure item 3 and 7 . Vertical assembly 2) Remove 2 fixing screws from the base vertical louver louver then remove the vertical louver Screw assembly from the body back. Screw Cross flow fan 1) Follow the procedure item 3 and 4 .
Page 113 Part name Remarks Procedures Heat exchanger 1) Follow the procedure in item 3 and 4 . (Evaporator) 2) Remove 2 fixing screws at the left side of the heat exchanger. Screws 3) Remove fixing screw at the upper right side of the heat exchanger.
Page 114 Microcomputer Part name Procedure Remarks Common procedure 1) Turn the power supply off to stop the Replace terminal block, operation of air-conditioner. microcomputer ass’y and the P .C. board ass’y. 2) Remove the front panel. • Remove the 2 fixing screws. 3) Remove the electrical part base.
Page 115 12-2. Outdoor unit Remarks Part name Procedures 1. Detachment Common procedure NOTE Upper cabinet Wear gloves for this job. Otherwise, you may injure your hands on the parts, etc. 1) Stop operation of the air conditioner, and turn off the main switch of the breaker for air conditioner.
Page 116 Remarks Part name Procedures 1. Detachment Front cabinet 1) Perform step 1 in 1. 2) Remove the fixing screws (ST2TØ4 × 10L 2 pcs.) used to secure the front cabinet and inverter cover, the screws (ST2TØ4 × 10L 4 pcs.) used to secure the front cabinet at the bottom, and the fixing screws (ST2TØ4 ×...
Page 117 Part name Procedures Remarks Inverter assembly 1) Perform work of item 1 in 1. 2) Remove screw (ST2TØ4 × 10L 2 pcs.) of the upper part of the front cabinet. • If removing the inverter cover in this condition, P.C. board can be checked. •...
Page 118 Part name Procedures Remarks 1. Disconnect the leads and connectors connected to the other Control board CN63 CN60 CN71 CN72 CN73 assembly parts from the control board assembly. 1) Leads CN62 CN61 • 3 leads (black, white, orange) connected to terminal block.
Page 119 Part name Procedures Remarks Side cabinet 1. Side cabinet (right) 1) Perform step 1 in 2 and all the steps in 3. 2) Remove the fixing screw (ST2TØ4 × 10L 4 pcs.) used for securing the side cabinet to the bottom plate and valve fixing panel 2.
Page 120 Part name Procedures Remarks Compressor 1) Perform work of item 1 of 1 and 2, 3, 4, 5. 2) Extract refrigerant gas. 3) Remove the partition board. (ST2TØ4 × 10L 3 pcs.) 4) Remove the sound-insulation material. 5) Remove terminal cover of the compressor, and disconnect lead wire of the compressor from the terminal.
Page 121 Part name Procedures Remarks ‰ 1. Detachment Fan Guard 1) Perform work of item 1 of 2 . 2) Remove the front cabinet, and put it down Minus screwdriver so that fan guard side directs downward. Hooking claw Perform work on a corrugated cardboard, cloth, etc.
Page 122 13. EXPLODED VIEWS AND PARTS LIST 13-1. Indoor Unit ELECTRICAL PARTS ASSEMBLY Location Part Location Part Description Description 43T00795 FRONT PANEL ASSY 43T39364 MOTOR COVER 43T09585 GRILLE OF AIR INLET ASSY 43T39441 MOTOR BAND BACK ASSY 43T80357 AIR FILTER 43T39369 MOTOR BAND FRONT 43T03417 BACK BODY ASSY...
Page 123 13-2. Indoor Unit (Part-E) Location Part Location Part Description Description 43T50393 TEMPERATURE SENSOR 43TNV461 PC BOARD (WP-048) 43T6V673 TERMINAL(5P-TF) (FOR RAS-B35G3KVSG-ND) 43T50413 TA-SENSOR 43T60502 HOUSING-WiFi 43T62340 CORD-CLAMP 43T60605 TEMPERATURE SENSOR 43TN9904 PC BOARD ASSY : WRS-LED 43TNV460 PC BOARD (WP-048) (FOR RAS-B25G3KVSG-ND) - 123 -...
Page 124 13-3. Outdoor Unit 37,41 36,40 Location Part Location Part Description Description 43T42380 ASM-BASE(WITH HEATER) 43T46585 VALVE; PACKED 6.35DIA 43T00459 LEFT CABINET 43T46574 VALVE; PACKED 9.52 DIA 43T00690 RIGHT CABINET ASSEMBLY 43T46347 BODY PMV 43T00735 UPPER CABINET ASSEMBLY 43T63329 COIL PMV 43T00688 FRONT CABINET ASSEMBLY 43T46375...
Page 125 Location Part Location Part Description Description 43T67310 HEATSINK 43T60465 TEMPERATURE SENSOR 43TNV469 PC BOARD (WP-528) 43T50352 TEMPERATURE SENSOR (FOR RAS-25G3AVSG-ND) 43T50458 SENSOR-TA(TO) 43TNV470 PC BOARD (WP-528) 43T62313 PC PLATE BASE (FOR RAS-35G3AVSG-ND) 43T63318 HOLDER SENSOR 43T60553 TERMINAL(5P-W) 43T63316 HOLDER,SENSOR 43T50336...
Page 126 CARRIER AIR CONDITIONING (THAILAND) CO., LTD. 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANGPATHUMTHANI, PATHUMTHANI 12000, THAILAND...

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