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Toshiba RAS-25J2KVSG-ND Service Manual
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Toshiba RAS-25J2KVSG-ND Service Manual

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SERVICE MANUAL
Indoor Unit
RAS-25J2KVSG-ND
RAS-35J2KVSG-ND
R32
FILE NO. SVM-20065-3
SPLIT TYPE
Outdoor Unit
RAS-25J2AVSG-ND
RAS-35J2AVSG-ND
Revised on July, 2020

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Summary of Contents for Toshiba RAS-25J2KVSG-ND

  • Page 1 FILE NO. SVM-20065-3 SERVICE MANUAL SPLIT TYPE Indoor Unit Outdoor Unit RAS-25J2KVSG-ND RAS-25J2AVSG-ND RAS-35J2KVSG-ND RAS-35J2AVSG-ND Revised on July, 2020...

  • Page 2: Table Of Contents

    CONTENTS 1. SAFETY PRECAUTIONS ................3 2. SPECIFICATIONS ..................6 3. REFRIGERANT R32 ...................8 4. CONSTRUCTION VIEWS ................ 16 5. WIRING DIAGRAM .................. 18 6. SPECIFICATIONS OF ELECTRICAL PARTS ......... 19 7. REFRIGERANT CYCLE DIAGRAM ............20 8. CONTROL BLOCK DIAGRAM ..............23 9.

  • Page 3: Safety Precautions

    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. For general public use Power supply cord of outdoor unit shall be more than 1.5 mm (H07RN-F or 60245IEC66) polychloroprene...
  • Page 4 DANGER • ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO IN- STALL/MAINTAIN THE AIR CONDITIONER. INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE. • TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF.
  • Page 5 • For R32 model, use pipes, flare nut and tools which is specified for R32 refrigerant. Using of existing (R22) piping, flare nut and tools may cause abnormally high pressure in the refrigerant cycle (piping), and possibly result in explosion and injury. •...

  • Page 6: Specifications

    Outdoor (Cooling / Heating) 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 7 2-2. Operation Characteristic Curve. <Cooling> <Heating> RAS-35J2KVSG-ND RAS-35J2KVSG-ND RAS-25J2KVSG-ND RAS-25J2KVSG-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...

  • Page 8: Refrigerant R32

    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 9 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 10 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 11 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 12 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 13 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 14 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. 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 15 2. Characteristics required for flux 3-5-3. Brazing • Activated temperature of flux coincides with the As brazing work requires sophisticated techniques, brazing temperature. experiences based upon a theoretical knowledge, it must be performed by a person qualified. • Due to a wide effective temperature range, flux is hard to carbonize.

  • Page 16: Construction Views

    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 (0.5m) Connecting pipe (0.63m) (Flare 6.35mm)
  • Page 17 4-2. Outdoor Unit (Unit : mm) Ø6 hole R5.5 Ø6 hole Ø11x14 hole A detail Drawing (Back leg) Ø 11 x 14 Hole 38 Drain outlet Ø B Detail Drawing (Front leg) (For 8 - 10 anchor bolt) Ø Ø FAN-GUARD Ø...

  • Page 18: Wiring Diagram

    5. WIRING DIAGRAM WP-044 t° Outdoor Control P.C. Board 250V T3.15A 250V M M S S T3.15A 250V CN300 (WHI) Serial Communication Circuit Switching Power Supply CN501 CN600 CN601 CN602 CN603 CN700 CN703 CN705 (GRN) (WHI) (WHI) (WHI) (WHI) (WHI) (YEL) (WHI) 1 2 3 L N...

  • Page 19: Specifications Of Electrical Parts

    6. SPECIFICATIONS OF ELECTRICAL PARTS 6-1. Indoor Unit Parts name Type name Specifications Fan Motor (for indoor) ICF-340-30-6 DC340V, 42W Room temp. sensor (TA-sensor) 10kΩ at 25°C Heat exchanger temp. sensor (TC-sensor) 10kΩ at 25°C Louver motor 24BYJ48-ST Output (Rated) 4 phase, DC12V 6-2.

  • Page 20: Refrigerant Cycle Diagram

    7. REFRIGERANT CYCLE DIAGRAM 7-1. Refrigerant Cycle Diagram RAS-25J2KVSG-ND / RAS-25J2AVSG-ND 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.
  • Page 21 RAS-35J2KVSG-ND / RAS-35J2AVSG-ND 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 Deoxidized copper pipe...
  • Page 22 Indoor Outdoor P (MPa) T1 (°C) T2 (°C) (rps) 27/19 35/- RAS-25J2KVSG-ND High 1.0 to 1.1 14 to 15 41 to 42 High High High 0.9 to 1.0 12 to 13 43 to 44 RAS-35J2KVSG-ND <Heating>...

  • Page 23: Control Block Diagram

    8. CONTROL BLOCK DIAGRAM 8-1. Indoor Unit Indoor Unit Control Panel M.C.U Functions Operation Heat Exchanger Sensor • Louver Control Display Timer • 3-minute Delay at Restart for Compressor Temperature Sensor Display • Motor Revolution Control PURE Infrared Rays Signal Receiver Display •...
  • Page 24 8-2. Outdoor Unit (Inverter Assembly) - 24 -...

  • Page 25: 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 to conditioner. Its system can control the speed of compressor motor according to load.
  • Page 26 9-2. Operation Description 1. Basic operation ......................27 1. Operation control ....................27 2. Cooling/Heating operation ..................28 3. AUTO operation ..................... 28 4. DRY operation ......................28 2. Indoor fan motor control ..................... 29 3. Outdoor fan motor control ................... 31 4.

  • Page 27: Operation Control

    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: Basic Operation

    Operation flow and applicable data, etc. Description Item 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: Indoor Fan Motor Control

    +1.0 *5 : Fan speed = (M + –L) x 1/4 + L +0.5 (Linear approximation L(W7) from M+ and L) (Table 1) Indoor fan air flow rate Fan speed Mode RAS-25J2KVSG-ND RAS-35J2KVSG-ND Cooling Heating level Cooling Heating Cool Heat...
  • Page 30 Item Operation flow and applicable data, etc. Description 1) When setting the fan speed to L, 2. Indoor fan <In heating operation> 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: Outdoor Fan Motor Control

    Item Operation flow and applicable data, etc. Description The blowing air volume at the outdoor unit side is controlled. 1) The operation command sent 3. Outdoor fan motor control from the remote controller is Receiving the operation command from the controller of processed by the indoor unit indoor unit, the controller of outdoor unit controls fan speed.

  • Page 32: Capacity Control

    Item Operation flow and applicable data, etc. Description The cooling or heating capacity depending on the load is 1) The difference between set 4. Capacity control adjusted. temperature on remote controller (Ts) and room temperature (Ta) According to difference between the setup value of tempera- is calculated.

  • Page 33: Release Protective Control By Temperature Of Indoor Heat Exchanger

    Item Operation flow and applicable data, etc. Description 1) When temperature of the indoor 6. Release protective <In cooling/dry operation> control by tempera- heat exchanger drops below 5°C, (Prevent-freezing control for indoor heat exchanger) the compressor speed is ture of indoor heat In cooling/dry operation, the sensor of indoor heat exchanger reduced.

  • Page 34: Defrost Control (Only In Heating Operation)

    Item Operation flow and applicable data, etc. Description 7. Defrost control (This function removes frost adhered to the outdoor The necessity of defrost operation is heat exchanger.) detected by the outdoor heat exchanger (Only in heating operation) The temperature sensor of the outdoor heat temperature (TE) and outdoor air ex-changer (TE sensor) judges the frosting status of temperature (TO).
  • Page 35 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 36: Louver Control

    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 37: Swing

    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 38: Eco Operation

    * 10 (DRY max - COOL min) /6 x 3 + COOL min * 9 (DRY max - COOL min) /6 x 2 + COOL min * 8 (DRY max - COOL min) /6 x 1 + COOL min RAS-25J2KVSG-ND RAS-35J2KVSG-ND Cool min (Hz) DRY max (Hz) <Heating operation>...

  • Page 39: Temporary Operation

    Item Operation flow and applicable data, etc. Description 10. Temporary Pressing [RESET] button starts the temporary opera- 1) When pressing [RESET] button, the tion of [AUTO] operation. When keeping [RESET] temporary [AUTO] operation starts. operation button pressed for 10 seconds or more, the temporary 2) When keeping [RESET] button pressed [COOL] operation is performed.

  • Page 40: Pulse Modulating Valve (P .M.v.) Control

    Item Operation flow and applicable data, etc. Description This function controls throttle amount of the 1) When starting the operation, move the 13. Pulse Modulating refrigerant in the refrigerating cycle. valve once until it fits to the stopper. (Initialize) valve (P.M.V.) According to operating status of the air conditioner, control this function also controls the open degree of valve...

  • Page 41: Self-Cleaning Function

    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 42 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 43: Remote-A Or B Selection

    Item Operation flow and applicable data, etc. Description 1. Purpose 15. Remote-A or B Setting the remote controller This operation is to operate only one selection To separate using of remote control for each indoor unit in case of 2 air conditioner are installed nearly. indoor unit using one remote controller.

  • Page 44: Power Selection Mode

    Item Operation flow and applicable data,etc Description ] button on the remote controller is 1. Purpose 17. POWER pressed) Selection The function is used when its circuit Mode − Power Selection 75% is 75% of maximum breaker is shared with other electrical current.

  • Page 45: Outdoor Quiet Control

    As the maximum number of revolution of the compressor is restricted, the rise- up performance at the start time is weakened. <Maximum number of revolution of compressor at normal time and Quiet control time> RAS-25J2KVSG-ND RAS-35J2KVSG-ND Outside temp. Normal time Quiet controlled...

  • Page 46: Fireplace Operation

    L. In addition, - The compressor speed is controlled as show in noise level of indoor unit is less than usual. the figure. Remarks : RAS-25J2KVSG-ND RAS-35J2KVSG-ND Quiet mode is unable to work in dry mode. Model Cool min (Hz)

  • Page 47: Display Lamp Brightness Adjustment

    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 48: Operation Mode Select Table

    Item Operation flow and applicable data, etc. Description 25. Operation Operating system setting 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 49: Auto Restart Function

    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 from the factory.

  • Page 50: How To Cancel The Au To Restar T Function

    9-3-2. How to Set the Auto Restart Function To set Auto Restart Function, proceed as follows: 1. The power supply to the unit must be ON ; The function will not set or reset if the power supply is OFF. 2.

  • Page 51: Parts Name Of Remote Contr Oller

    9-4. Remote control 9-4-1. Remote control and its functions 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 ( On timer button (...
  • Page 52 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 53 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 54 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 55 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 56 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 57 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 58 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 59 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 60: Name And Functions Of Indications On Remote Controller

    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 61: Installation Procedure

    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 between the indoor unit and wall to tilt Flat head the indoor unit for better operation.
  • Page 62 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 125 mm 28 mm...
  • Page 63 10-2-2. Accessory and installation parts Indoor Unit Part name Part name Installation plate × 1 Wireless remote control × 1 Battery × 2 Remote control holder × 1 Mounting screw × 6 Flat head wood screw × 2 Owner’s Manual × 1 Installation Manual ×...
  • Page 64 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 65 10-3. Indoor Unit 10-3-2. Cutting a hole and mounting installation 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 66 10-3-3. How to Connect Remote Controller for <When the installation plate is directly mounted on Wire Operation the wall> 1. Securely fit the installation plate onto the wall by screwing it in the upper and lower parts to hook up Indoor unit the indoor unit.
  • Page 67 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 68 <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 69 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 70 10-4-2. Precautions about installation in Regions 10-4. Outdoor Unit with Snowfall and Cold Temperatures 10-4-1. Installation place • Do not use the supplied drain nipple for draining • A place which provides the spaces around the water. Drain the water from all the drain holes directly. outdoor unit as shown in the diagram •...
  • Page 71 Draining the Water 10-4-3. Refrigerant piping connection • Holes are provided on the base plate of the outdoor unit to ensure that the <Flaring> defrost water produced during heating operations is drained off eff ciently. If a centralized drain is required when installing the unit on a balcony or 1.
  • Page 72 <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 73 Cap Size (H) Torque CAUTION 14~18 N.m H17 - H19 KEEP IMPORTANT 6 POINTS FOR PIPING WORK. Valve Rod (1.4 to 1.8 kgf·m) • (1) Take away dust and moisture (inside of the connecting 33~42 N.m H22 - H30 pipes). (3.3 to 4.2 kgf·m) (2) Tighten the connections (between pipes and unit).
  • Page 74 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-25J2KVSG-ND RAS-35J2KVSG-ND Power source 50Hz, 220 – 240 V Single phase Maximum running current 11.80A...
  • Page 75 10-5-2. Power Supply and Connecting Cable Connection Power Supply Input at Outdoor Unit Terminal Block (Recommend) Indoor Unit Outdoor Unit Connecting cable Power supply Stripping length of the Connecting cable Connecting cable connect to terminal terminal block connect to connecting cable block (1, 2, 3, (L, N, Terminal block (L N 1 2 3)
  • Page 76 10-5-3. Power supply input Wiring Diagram Power supply input at Outdoor unit Terminal Block (Recommend) Indoor Terminal Block Chassis Chassis Outdoor Terminal Block Power supply input Power supply input at Indoor unit Terminal Block (Optional) Indoor Terminal Block Chassis Power supply input Chassis Outdoor Terminal...
  • Page 77 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 78: How To Diagnose The Trouble

    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 79 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 80 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 81 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 82 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 83 11-4. Self-Diagnosis by Remote Controller (Check Code) 1. If the lamps are indicated as shown B to E in Table 11-4-1, 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 84 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 85 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 86 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 87 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 88 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 89 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 (including...
  • Page 90 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 91 (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 92 (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 93 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 94 (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 95 (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 96 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 97 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 98 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 99 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 not grounded. Replace control board assembly.  → OK if about •...
  • Page 100 (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 101 11-8-2. P .C . Board Layout +12V [1] Sensor characteristic table : Discharge temp. sensor : Room temp. sensor : Heat exchanger temp. sensor : Outdoor temp. sensor : Suction temp. sensor TA, TC, TO, TS, TE : Outdoor heat exchanger temp sensor Temperature (˚C) - 101 -...
  • Page 102 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) (Normal temp.) sensor Temperature 10°C 20°C 25°C 30°C 40°C Sensor 20.7 12.6 10.0 TA, TC (kΩ) Remote controller Refer to 11-5-1.
  • Page 103 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 104 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 105: How To Replace The Main Parts

    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 106 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 107 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 108 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 109 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 110 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 111 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 112 12-2. Outdoor unit Remarks Part name Procedures Common procedure 1. Detachment Upper cabinet NOTE 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 113 Part name Procedures Remarks Inverter assembly 1) Perform work of item 1 in 1. Inverter cover 2) Remove screw (ST2TØ4 × 10L 2 pcs.) of the upper part of the front cabinet. P.C. board • If removing the inverter cover in this (Soldered surface) condition, P.C.
  • Page 114 Part name Procedure Remarks Control board 1. Disconnect the leads and connectors connected to assembly the other parts from the control board assembly. CN601 CN703 CN602 CN600 CN603 1) Leads • 3 leads (black, white, orange) connected to terminal block. •...
  • Page 115 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 116 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 Compressor the terminal.
  • Page 117 Part name Procedures Remarks ‰ 1. Detachment Electronic expansion valve 1) Perform step 1 in ‚ , all the steps in ƒ coil and 1 in … 2) Remove the coil by pull it upward. 2. Attachment 1) Insert a valve coil to value body by push it downward.
  • Page 118 Remarks Part name Procedures TE sensor (outdoor heat exchanging temperature sensor) " • Attachment Install the sensor onto the straight pipe part of the condenser output pipe. TS sensor (Suction pipe temperature sensor) • Attachment Install the senser onto the straight pipe part of the suction pipe. Be careful for the lead direction of the sensor.

  • Page 119: Exploded Views And Parts List

    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 43T39368 MOTOR BAND BACK 43T80349 AIR FILTER 43T39369 MOTOR BAND FRONT 43T03417 BACK BODY ASSY 43T44691...
  • Page 120 13-2. Indoor Unit (Part-E) Location Part Location Part Description Description 43T50393 TEMPERATURE SENSOR 43T6W836 PC BOARD 43T6V673 TERMINAL(5P-TF) (FOR RAS-25J2KVSG-ND) 43T50392 SENSOR,THERMOSTAT 43T6W837 PC BOARD 43T62340 CORD-CLAMP (FOR RAS-35J2KVSG-ND) 43T6W727 PC BOARD ASSY : WRS-LED 43T60502 HOUSING-WiFi - 120 -...
  • Page 121 13-3. Outdoor Unit 37,41 36,40 Location Part Location Part Description Description 43T42380 ASM-BASE 43T47404 BONNET, 9.52 DIA 43T00459 LEFT CABINET 43T46504 VALVE;PACKED 6.35 DIA 43T00690 RIGHT CABINET ASSEMBLY 43T46503 VALVE ; PACKED 9.52 DIA 43T00735 UPPER CABINET ASSEMBLY 43T46347 BODY PMV 43T00688 FRONT CABINET ASSEMBLY 43T63329...
  • Page 122 13-4. Outdoor Unit (Part-E) TO-SENSOR TE-SENSOR TD-SENSOR TS-SENSOR 710 HOLDER-SENSOR (TE) 711 HOLDER-SENSOR (TS) 712 HOLDER-SENSOR (TD) Location Part Location Part Description Description 43T62351 HEATSINK 43T50334 TEMPERATURE SENSOR 43T6W834 PC BOARD 43T50352 TEMPERATURE SENSOR (FOR RAS-25J2AVSG-ND) 43T50360 TC-SENSOR(TO) 43T6W835 PC BOARD 43T62313 PC PLATE BASE (FOR RAS-35J2AVSG-ND)
  • Page 123 144/9 MOO 5, BANGKADI INDUSTRIAL PARK, TIVANON ROAD, TAMBOL BANGKADI, AMPHUR MUANG, PATHUMTHANI 12000, THAILAND.

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