RAV-M241A-E
Contents
1. 34 86 34 28 knockout hole Fig 2 1 3 WIRING DIAGRAM Indoor Unit Unit A Unit B o supply mn Po dics O l Earth screw il C 3 4 y 6 Electrical Parts Box 52C1 52 2 e L RCol RCo1 52 2 RED WHI RED CM1 V o BLK A EN gt AN 51C1 Parts Position Fan Motor Compressor Coil met 20SRB 20SRA Fig 3 1 Symbol Name Symbol Name CM1 2 Compressor 51C1 2 Overload relay FMo Fan motor 52C1 2 Magnetic contactor RCc1 2 Running capacitor Compressor 20SRA B Solenoid coil RCo Running capacitor Fan motor 23H1 2 Thermostat Shows terminal block and figures show terminal numbers Broken lines show wiring at site Don t operate the units with the magnetic contactor pushed 6 4 SPECIFICATIONS OF ELECTRICAL PARTS Parts name Type Specifications Compressor 1 2 PH160X2 4L Output 1 1 kW 2 pole 10 220 240V 50 Hz Winding resistance Main coil 2 20 Aux coil 3 80 Fan motor STF 200 63B Output 63W 6 pole 19 220 240V 50 Hz Magne2. S H B A FILE NO A10 9507 SERVICE MANUAL AIR CONDITIONER SPLIT WALL TYPE RAV Co RAV M241A E GIA OM D CONTENTS SPECIFICATIONS EE TEE E 3 CONSTRUC HON VIEWS dem 5 2e Outdoor ER 5 WIRING DIAGRAM mr T 6 SPECIFICATIONS OF ELECTRICAL PARTS 7 REFRIGERANT PIPING DIAGRAM dca 8 s Muere EIE 9 UNIT INSTALLATION cR 10 Gals SENICE SPACE c aaa teder EAEan a aaa T aiaa m 10 TROUBLESHOOTING CHART FOR RAS 13EK RAV M241A E 11 fle De Prechecked iret dane dane 11 7 2 Primary Judgement of Trouble Sources 12 7 8 Iroubleshootirig FloWCliatts ir tt ente dee tuere det ERE De Du eR Ec dera Ende 16 7 4 Test Points on the PC Board and List of Voltage Values sss 19 7 5 to Check the Remote Control Including the Indoor PC Board 20 7 67 Board Layout c aak Eau 23 EXPLODED VIEWS AND PARTS LIST 24 1 SPECIFICATIONS RAV M241A E Operation Unit 2 indoor unit BTU h 12000 Cooling capacity kcal h 6000 BTU h 24000 kW 7 0 Power source Phase 1 V 220 240 Hz 50 Power consumption Cooling
3. Thermal fuse Wrong wiring or disconnection of connective cable All off Indicated when detected abnor mal Check flat cable correct if wiring is wrong If it is OK check PC board Thermal fuse cut off Indoor fan lock abnormality of indoor fan All off Indicated when detected abnor mal Check thermal fuse If it is OK check motor If motor is OK check PC board Refrigerant system Gas shortage gas leak Other refriger ant cycle trouble Heat exchanger sensor off break short Overload relay break All off Indicated when detected abnor mal Check gas quantity Check gas leakage If itis OK check heat exchanger sensor If heat exchanger sensor is OK check overload relay If overload relay is OK check refrigerant cycle If refrigerant cycle is OK check PC board Compressor break down All off 15 Indicated when detected abnor mal Check compressor If itis OK check PC board 7 3 Troubleshooting Flowcharts 7 3 1 Power cannot be Turned on No Operation at All lt Preliminary checks gt 1 Is the supply voltage normal 2 Is the connection to the AC output O K 3 the connection of the primary side and the secondary side of the power transformer inserted into the PC board 4 Is the FUSE F01 blown Operations Check items Probable main causes Turn t
4. LOZ LUT d Operate the TEMP O key and make sure the remote control display shows and blink ing of the OPERATION lamp If the operation lamp is blinking it shows the protection cir cuits for connecting cable is working or ther mal fuse is blown In the same way operate the TEMP key so that the display is increased one by one to continue checks by the self diagnosis as shown is the next table From 00 up to 03 check operations of protection circuits for each block and 04 to if check operations of the typical protection circuits fd Block level Table 7 5 Diagnosis function Block Symptom Air conditioner status Condition Judgement and action Indoor PC board Thermo sensor short break Continued operation Indicated when detected abnor mal Check thermo sensor If it is OK check PC board Around sensor circuit Heat exchanger sensor short break Continued operation Indicated when detected abnor mal Check heat exchanger sensor If itis OK check PC board Around sensor circuit Indoor fan lock abnormality of indoor fan All off Indicated when detected abnor mal Check motor Replace PC board if the same failure occurs after the motor check Abnormality of other indoor unit PC board Continued operation Indicated when detected abnor mal Replace PC board Cable connection
5. When connecting or disconnecting the con nectors on the PC board hold the whole hous ing Do not pull at the lead wire 2 The PC board consists of the following 4 parts a Main PC board part Power relay indoor fan motor drive circuit and control circuit C P U and peripheral circuits buzzer drive circuit and buzzer b Infrared rays receive parts Infrared rays receiving circuit c Display LED d Switch PC board Wireless control TEMPORARY switch 2 Inspection procedures 1 When a PC board is judged to be failure check for disconnection burning or discoloration of the copper foil pattern or this PC board 3 Checking procedure Procedure e Buzzer PC board list below Table 7 7 Check point Symptom f Transformer PC board Check the defects of the PC board following the Buzzer Transformer Trouble cause Disconnect the power plug from the AC outlet and remove the PC board assembly from the electronic parts base Remove the flat cable from the terminal plate Is the fuse blown Application of shock voltage Short circuit of the indoor fan motor Turn the power ON If the OPERATION lamp flash 0 5 sec ON 0 5 sec OFF steps 1 3 in the right column are not neces sary Check power supply voltage 1 Between pins 1 and 3 of 5 220 240V AC Defective power cord power switch fuse or line filter or wrong wiring 2 Between pins 1 and 3 of C
6. by the check code turn off the power once and then turn on the power to reset memorized contents of the microcomputer to the initial status All clear button Switch for selecting service mode off e Rear bottom cover lt Self diagnosis by check codes gt 1 The self diagnosis by the check codes is con ducted under the block displays of item B E 2 Remote control key operation under the ser vice mode is conducted by ON OFF or TEMP The remote control display by each key op eration is varied as shown below Two digit number is displayed in a hexadecimal num ber Table 7 4 Operating key Indication after operation ON OFF rm LI n 1 1 is added to data before operation Example er H 1 LU 1 is subtracted from data before operation Example mU LUC LOUVER 10 is subtracted from data before operation Example SET LOUVER 3 The self diagnosis by the check codes is con ducted with procedures shown below a Enter the service mode and make sure the off timer display of the remote control shows b Operate the ON OFF key and make sure the timer lamp on the display section is blinking 5 Hz c At the same time also make sure the OP ERATION lamp is also blinking This shows that the protection circuit on the indoor PC board is working Data before operation is directly transferred Example n 1 n lt
7. part is defective outdoor fan motor The compressor does not operate The inside part is defective cuoc 2 Self diagnosis with remote controller With the indoor unit controller self diagnosis of protective circuit action can be done by turning the remote controller operation into service mode operating the remote controller observing the re mote controller indicators and checking whether OPERATION lamp flashes 5 Hz Note To perform this self diagnosis the remote con troller with the service code of 43069666 is re guired lt How to select remote controller operation mode gt 1 Selecting service mode Push the switch button provided on rear bot tom of the wireless remote controller with a tip of pencil for more than 3 seconds Make sure the setting temperature is displayed on the display and other display is turned off Rear bottom of remote controller Fig 7 1 e 2 Selecting ordinary mode Push the all clear button ACL on the rear bottom of the wireless remote controller by a tip of pencil for more than 3 seconds Make sure the operation mode display wind volume display clock display and setting temperature display are turned on and of the clock display is blinking Cautions when doing service 1 After completion of servicing always push the all clear ACL button to return the operation mode to the normal mode 2 After completion of servicing
8. 5 43066988 Valve 6 35 Hanger Solenoid Coil Capillary Tube 1 7 Dia Capillary Tube 1 5 Dia Cushion Rubber Holder OL Relay 06 47 Part No Description Part No Description 43154139 43160479 43160480 43055354 Switch Magnet Terminal Block 2P Terminal Block 6P Capacitor Plastic Film 35MFD 400V 25 43054380 43155146 43146443 43150220 Relay Overload Capacitor Electrolytic Solenoid Coil Bimetal Thermostat 26 p TOSHIBA CORPORATION 1 1 SHIBAURA 1 CHOME MINATO KU TOKYO 105 01 JAPAN
9. CN32 CN33 CNO6 CNO5 Transformer PC board MCC 629 Main PC board MCC 639 Fig 7 2 7 3 2 Power Relay RY01 does not Operate Louver is not controlled automatically Turn the power ON NO Does the operation lamp flash See power cannot be turned on YES YES Is the thermal fuse set on Thermal fuse is failure NO Does 12V DC supplied between TP7 GND Relay driver ICO1 02 is failure Replace PC board Replace PC board and NO 12V power circuit failure 003 003 Note When wiring to the thermal fuse has been broken the TIMER lamp and OPERATION lamp will flash with 5 Hz Eds 7 3 3 Only the Indoor Fan does not Operate lt Preliminary checks gt Does it neither work in COOL or FAN ONLY operation lt Check procedure gt Turn OFF the power REMOTE CONTROL position Turn ON the power REMOTE CONTROL position Does the fan stop at the operation stop condition Start operation at HIGH cooling Does the fan rotate Ne Control PC board failure Replace the PC board Does 120V AC or higher Motor control circuit failure ICO1 voltage apply to between red 03 D15 or 12V power circuit 003 and black lead of the motor D03 or thermal fuse failure Turn OFF the power Is it possible to rotate the cross flow fan by hand Turn ON the power
10. N06 12V AC Defective power transformer 3 Between TP6 5V and GND 5V AC Defective power circuit or short circuited load 4 Between TP7 12V and GND 12V DC Same as above 5 Between TP8 12V and GND 12V DC Thermal fuse operation Push the START STOP button once to set in operation mode Do not set to the fan only or on timer mode Check power supply voltage 1 Power relay coil voltage 12V DC 1 02 9 pin and ICO2 14 pin Relay coil cable is broken relay driver 181 is defective 2 Between terminals 1 and 2 Relay contact is defective SL connector is defective Start operation by using the anti restart timer 1 LEDs of the OPERATION lamp the TIMER lamp FAN ONLY lamp ECONO and AUTO lamp light up 2 3 seconds normal display does not appear 21 Display is failure or defect in the housing assembly Check point Symptom Trouble cause Push the START STOP button once to set in operation mode 1 Setting the anti restart timer 2 Cooling operation 3 Fan speed AUTO 4 Set the temperature sufficiently lower than the room temperature 5 Continuous operation 1 The compressor does not operate The temperature of the indoor heat exchange unit is extremely low 2 The OPERATION lamp flashes Defective control PC board Connect the motor connector to MOTOR and turn the
11. Repair the cross flow fan Change the setting to LOW cooling Does the rotating speed of the fan lower Stop the operation YES When rotating the cross flow fan by hand at the operation stop condition is the rotation signal 12VDC lt gt 0V detected between 2 gray lead and 9 brown lead of the motor connector PJ13 or CN13 1pulse 1 revolution Replace the fan motor Y Normal Motor circuit D06 ICO1 or 12V power circuit 003 D03 failure Replace the control PC board 18 7 3 4 Compressor does not lt Preliminary checks gt 1 Is the temperature set on the remote control higher than the room temperature in cool operation 2 Is contact of the crossing wiring O K lt Check procedure gt Turn the power ON l No Refer to t be turned on Does the operation lamp flash efer to Power cannot be turned YES Does power relay RY01 switch due to temperature adjustment Point for placing the tester bar Normal voltage value Is the resistance value of the thermo sensor TA and heat exchanger sensor TC normal NO Polarity Polarity Condition ICO2 9 pin C02 Apin RY01 ON DC 12V Approximate resistance value of the sensor 10 20 30 Normal voltage value under 20 7k O 12 6k 797kQ power relay ON condit
12. e also causes the same lamp to flash Room temperature is in the range under which the The compressor will not start while the compressor compressor is turned on but the compressor will not start restart prevention timer three minute timer is actuated This applies also when power is turned on Fan speed remains unchanged when the fan speed button Fan speed is fixed at Low in the dry operation is operated in the dry operation Room temperature is in the range under which the The compressor will not stop while the compressor on compressor is turned off but the compressor will not stop hold timer two minute timer is actuated The compressor will not switch on or off even when the In the dry operation the compressor goes on and off at thermostat control is operated in the dry operation regular intervals independent of the thermostat control esi 7 2 Primary Judgement of Trouble Sources 7 2 1 Role of Indoor Unit Controller 7 2 2 Display of Abnormalities and Judgement The indoor unit controller receives the operation com of the Abnormal Spots mands from the remote control and assumes the fol The indoor unit of this machine observes the opera lowing functions tion condition of the air conditioner and displays the Measurement of the draft air temperature of the contents of the self diagnosis as block displays on indoor heat exchanger by using the temperature the display panel of the indoor unit s
13. ensor e Louver motor control e Control of the indoor fan motor operation e Control of the LED display Control of the outdoor unit compressor and the outdoor fan motor Table 7 2 Block display Self diagnosis OPERATION display flashing 1 Hz 1 Hz OPERATION display flashing 5 Hz 5 Hz 5 Hz Power failure When power is on Temperature sensor Ta short break OPERATION display flashing 5 Hz OPERATION display flashing 5 Hz Heat exchanger sensor Tc short break Indoor fan lock abnormality of indoor fan 1C03 D15 short break OPERATION display flashing 5 Hz Indoor PC board failure OPERATION and TIMER display flashing Thermal fuse is blown 5 Hz Indoor fan motor is overheat OPERATION TIMER and FAN ONLY display Gas shortage other refrigerant cycle flashing 5 Hz trouble Heat exchanger sensor open short break Overload relay trouble OPERATION TIMER and FAN ONLY display Compressor trouble flashing 5 Hz 1 Judgement from defective operation or abnormal operation Table 7 3 System Check Primary judgement No reaction on remote control Turn off the power Remote control is not The indoor part including the operation once turn it on again possible remote control is defective and try to operate the remote control again Remote controlis O K possible The outdoor fan does not rotate The compressor operates The outdoor
14. ese mean equivalent length Note 3 Operating range of the units Evaporator air inlet temperature 35 C DB 95 F DB Condenser air inlet temperature Maximum 32 DB 22 5 C WB 95 F DB 73 F WB 43 C DB 109 F DB Minimum Remark 21 C DB 15 5 C WB 70 F DB 60 F WB 21 C DB 70 F DB sure to refer to the service manual file No A00 9502 for the indoor unit RAS 13EK to be connected 2 1 Outdoor Unit RAV M241A E 45 2 CONSTRUCTION VIEWS 790 45 m b JL Air inlet Space required for service Anchor bolt hole 4 12 X 18 long hole g 1100 N 160 Space for service en ed As et JE 300 Space for wiring and piping S When installing the inlet is 4 to be faced to the wall side N 4 Y gt x Air outlet 36 ai 31 Electric parts box 880 m Both side Air outlet Electric parts cover C 7 P N g Refrigerant piping joint J Gas side 2 amp 12 7 70 57 Refrigerant piping joint Liquid side 2 p 6 4 bN FD o N 8 8 5 de ax s UUU U c 257 Power supply cord hole 419 knockout hole Inter unit wiring cord hole
15. he power off for about 5 seconds and then turn it on again Does the operation lamp flash YES Remedies em Dy symptons Does the transmission indicator of the remote control blink normally and is the transmission really performed Does operation start when you press the ON OFF button of the remote control Remote control is failure Replace Normal Connect the wire properly Is the lead wire disconnected from the infrared rays receive parts Is 50Hz 220 230 240V AC supplied to the primary side of the power source transformer Infrared rays receive parts or PC board failure Or there is a defect before the power transformer Refer to above Preliminary checks YES Refer to the figure below Replace Replace transformer Replace the PC board Replace the gt PC board NO Power transformer is failure 15 12V AC supplied to the secondary side of the power transformer YES Refer to the figure below Is the voltage display on the rear panel of the PC board normal 12V DC or 5V DC YES Microcomputer is failure 12V DC 5V DC power supply circuit failure DB01 C02 003 003 Q01 Q02 ICO6 346 Primary side Secondary side
16. ion Thermo sensor or heat exchanger sensor is failure Is 220 230 240V AC Replace thermo supplied between terminal blocks 1 and 2 YES sensor or heat Outdoor unit is failure exchanger sensor 7 4 Test Points on the PC Board and List of Voltage Values Microcomputer is failure Replace PC board Power relay RYO1 is failure Replace power relay The test points TP are indicated on the rear of the PC board The voltage values on the test points for defect diagnosis items are listed below Table 7 6 Point for placing the tester bar Defect diagnosis item Normal voltage value Polarity Polarity Condition Does the power relay RY01 switch ICO2 9 pin 1 02 14 pin Br ed is ON No load 14 2V Is the voltage of the secondary side of With load 12 2V the transformer O K Primary voltage is about 230V Is the voltage of the primary side of the transformer O K 1 220 240V 5V or less normal Are both PTH terminals 5V AC or less Either end of PTH AC or more abnormal 7 5 How to Check the Remote Control Including the Indoor Board There is no reception tone from the receptor The operation lamp of the air conditioner main unit does not light Push the START STOP button Does the transmission indicator flash NO Is operation possible when the trans
17. iping Permissible piping unit number length 21 22 head H Remarks RAS 13EK 2 5 1 2 Piping Material and Sizes Piping material Table 5 2 Phosphate deoxidized copper seamless pipes for air conditioners Model RAS 13EK Piping Larger Tof size mm Smaller 6 4 5 1 3 Air Purging Subject the refrigerant tube of outdoor and in door units to air purge with a vacuum pump Do not carry out this air purge by using the refrig erant filled in the outdoor unit To handle valves a 5 mm hexagon wrench is needed 15m 5m Fig 5 2 5 1 4 Refrigerant Pipe Connecting Position 5 1 5 Additional Refrigerant Quantities Table 5 2 Model RAV M241A E Addition per meter No need 6 UNIT INSTALLATION 6 1 Service Space Ensure that there is sufficient space around the outdoor unit for installation and servicing 100 or more 500 or more 300 or more 500 or more Ar 100 or more 100 or more 500 or more Fig 6 1 Do not install in a place that can increase the vibration and amplify the noise level of the units Be sure to fix the outdoor unit with four 4 M10 anchor bolts according to foundation drawings below 45 790 45 364 340 10 7 TROUBLESHOOTING CHART FOR RAS 13EK RAV M241A E Troubleshooting Procedures Following details of What to be prechecked first make
18. kW 24 Power factor Cooling 96 97 Running current Cooling A 10 8 Starting current Cooling A 68 Operating noise SPL dB A 53 Refrigerant Name of refrigerant R 22 Charge volume kg 0 85 0 85 Refrigerant control Capillary tube Interconnection pipe Gas side size 12 7 1 27 Coupler style Flare Liguid side size 6 4 1 4 Coupler style Flare Standard length 7 6 25 Maximum length of one way 15 48 Minimum length 2 7 Maximum height Indoor unit higher 5 16 Outdoor unit higher 5 16 INDOOR UNIT Model RAS 13EK SERVICE DATA FILE NO A00 9502 OUTDOOR UNIT Model RAV M241A E Dimensions Height ft in 790 2 7 7 64 880 34 64 mm Width mm ft in Depth mm ft in 310 12 27 Net weight kg Ibs 70 154 3 Condenser type Finned tube Condenser fan type Propeller fan Fan motor output 63 Compressor Model PH160X2 4L Output 1100 Protective device SPL Sound Pressure Level Specifications are subject to change without notice Fuse Inner overload relay 1 Cooling capacity is based on the following temperature conditions Evaporator air inlet temperature 27 DB 80 F DB 19 5 WB 67 F WB Condenser air inlet temperature Note 2 Th
19. mitter is moved nearer to the infrared signal receiver of the air conditioner Push the all clear button ACL on the wireless remote control with a tip of pencil for more than 3 seconds 15 there direct sunlight on the receptor of the air conditioner Is there any thyristor fluorescent light near by Does the transmission indicator light Battery life Is operation possible when setting the control operation switch of the air conditioner main unit to COOL or AUTO Is there any reception tone and operation Can any signal tone be heard in a transistor radio when transmitting within 5cm distance from the radio YES NE Keep the air conditioner Avoid direct away from thyrstor sunlight fluorescent light PC board is failure Replace the Normal Remote control batteries is failure Note After battery replacement shortcircuit Y the metal terminal at the side of the battery compartment all clear terminal Replace with a pencil Replace remote control PC board 20 7 5 1 How to Check the PC Board 1 Operating precautions 1 When removing the front panel or the PC board be sure to disconnect the power plug from the AC outlet When removing the PC board hold the edge of the PC board and do not apply force to the parts
20. power ON Start operation as follows 1 Set the operation mode to ONLY 2 Set the fan speed to HIGH 3 Continuous operation 1 There is a voltage of 120V or more between the red and black motor connector leads Indoor fan motor is failure 2 The motor does not rotate But the key operation of the remote control is accepted Contact of the motor connector is defective 3 Motor rotates but vibrates hard Main PC board is failure Table 7 8 Approximate value of the sensor thermistor resistance Ta Tc Sensor Thermo Sensor 7 5 2 How to Reduce the Operation Time of the Anti restart Timer e Drill 2 holes on the rear of the wireless remote control unit Wireless remote controller Attach the diode 151555 or equivalent to the rivet inside the unit Push the START STOP button to start operation with the diode attached 22 Timer short diode Fig 7 3 7 6 PC Board Layout Top view Bottom view ux 8 EXPLODED VIEWS AND PARTSLIST Part No Description Part No Description 43120168 43143701 43041728 43121636 43191494 43046151 43046232 Fan Propeller Condenser Compressor AC 220 240V 50 Hz PH160X2 4L Motor Fan STF 200 63B Guard Fan Valve 2 Way Packed Valve 12 7 24 43046228 43145103 43119390 43146443 43047492 43047491 4304962
21. sure of the basic items When there is no trouble corresponding to above check in detail the faulty parts following How to judge faulty parts by symptoms later 7 1 What to be Prechecked First 7 1 3 Operations not Regarded as Failure program operation In terms of the control of air conditioner the opera tions shown in Table 7 1 are made as a program op eration incorporated in a microcomputer If a claim is made about the operation check it corresponds to the contents in the table If it does it is an indispens 7 1 2 Incorrect Cable Connection between able operation for the control and maintenance of the Indoor and Outdoor Units air conditioner but not a failure of the units 7 1 1 Power Supply Voltage The power supply voltage must be from AC 198V to 264V If the power voltage is not within this range the air conditioner may not work normally The indoor unit is connected to the outdoor unit with 3 cables Make certain that the terminals of indoor and outdoor connectors have been connected properly by the same numbers not connected as specified the outdoor unit won t operate normally Operations which are not Deemed Trouble Table 7 1 Operation of air conditioner Description When the POWER plug of the indoor unit is inserted the The OPERATION lamp flashes indicating that power is OPERATION lamp flashes turned on If this happens press the START STOP button once and flash will stop Power failur
22. tic contactor VC20FA AC 240V Capacitor MT 40MP356W For compressor 1 2 AC 400V 35 uF EAG45M355UF1 For fan motor AC 450V 3 5 uF Solenoid coil 2 way valve NEV AC240 AC 220 240V Bimetal thermostat CS 12 110 C ON 95 C OFF 5 REFRIGERANT PIPING DIAGRAM RAV M241A E ZJosseidwog Jesuopuog 105591909 Jesuopuog mime 009 x S O OOt X LL 009 x gL 00 X z o eqn 9 eqn Medeo soyejnwnooy Medeo 44502 VSO 6 319409 31949 OX OM OM d X pexoed payoed x x PIET PRET x mE Pee peop uc uu 98 uui z io uui g epis seo epis pinbr1 epis seo epis pinbr1 edid edid edid edid Jojeode 3 Jojeode 3 L NUN UE zi g Joopur v Joopuj Fig 5 1 5 1 Refrigerant Piping 5 1 1 Permissible Piping Length and Head The minimum inter unit refrigerant piping length shall be 2m Limit the number of bends in the refrigerant piping to 10 or less Model RAS 13EK 1 Unit A Unit B RAS 13EK ME Table 5 1 Connectable indoor Permissible p
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RAV M241A E