CS-VA70KE CU-VA70KE CS-VA90KE CU-VA90KE CS-VA120KE CU-VA120KE

Order number RAC9911056C2 Room Air Conditioners CS-VA70KE CU-VA70KE CS-VA90KE CU-VA90KE CS-VA120KE CU-VA120KE © 1999 Matsushita Electric Industrial...
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Order number RAC9911056C2

Room Air Conditioners

CS-VA70KE CU-VA70KE CS-VA90KE CU-VA90KE CS-VA120KE CU-VA120KE

© 1999 Matsushita Electric Industrial Co., Ltd. All rights reserved. Unauthorized copying and distribution is a violation of law.

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

CONTENTS Page

Page 11 2-WAY / 3-WAY VALES

1 Features

3

2 Functions

4

11.1. EVACUATION OF INSTALLATION

44

2.1. REMOTE CONTROL

4

11.2. PUMPING DOWN

45

2.2. INDOOR UNIT

5

11.3. EVACUATION OF RE-INSTALLATION

46

2.3. OUTDOOR UNIT

6

11.4. BALANCE REFRIGERANT OF THE 2-WAY, 3-WAY

3 Product Specifications

7

3.1. CS-VA70KE / CU-VA70KE 3.2. CS-VA90KE / CU-VA90KE 3.3. CS-VA120KE / CU-VA120KE 4 Dimensions

VALVE 11.5. EVACUATION

7

12 Servicing Information

9

43

47 48 49

12.1. INSPECTION POINTS FOR THE INDOOR ELECTRONIC

11 13

CONTROLLER

49

12.2. INDOOR FAN MOTOR REMOVAL PROCEDURE

49

13

12.3. CROSS FLOW FAN REMOVAL PROCEDURE

51

4.2. CU-VA70KE / CU-VA90KE (OUTDOOR UNIT)

14

12.4. OUTDOOR UNIT SERVICING

52

4.3. CU-VA120KE(OUTDOOR UNIT)

14

12.5. REMOTE CONTROL RESET

52

15

12.6. CHANGING THE WIRELESS REMOTE CONTROL

4.1. CS-VA70KE / CS-VA90KE / CS-VA120KE (INDOOR UNIT)

5 Refrigeration Cycle Diagram

5.1. CS-VA70KE / CU-VA70KE, CS-VA90KE / CU-VA90KE 15 5.2. CS-VA120KE / CU-VA120KE

TRANSMISSION CODE 13 Troubleshooting Guide

16

6 Block Diagram

17

13.1. RELATIONSHIP BETWEEN THE CONDITION OF THE

7 Wiring Diagram

18

AIR CONDITIONER AND GAS PRESSURE AND

8 Operation Details

19

ELECTRIC CURRENT

53 54

55

13.2. DIAGNOSIS METHODS OF A MALFUNNCTION OF A

8.1. COOLING MODE OPERATION

19

8.2. SOFT DRY MODE OPERATION

21

8.3. HEATING MODE OPERATION

23

8.4. AUTOMATIC MODE OPARATION

27

8.5. SLEEP MODE AUTO OPERATION

27

8.6. AUTO RESTART CONTROL

28

8.7. INDOOR FAN MOTOR CONTROL

28

15.1. HOW TO USE ELECTRONIC CIRCUIT DIAGRAM

60

8.8. AIRFLOW DIRECTION CONTROL

29

15.2. ELECTRONIC CIRCUIT DIAGRAM

61

8.9. DELAY ON TIMER CONTROL

29

15.3. CHARACTERISTICS CHART

63

30

15.4. REMOTE CONTROLLER

64

30

15.5. TIMER TABLE

65

9 Installation And Servicing Air Conditioner Using R410A 9.1. OUTLINE

COMPRESSOR AND A 4-WAY VALVE 14 Technical Data

PIPING

56

14.2. OPERATION CHARACTERISTICS

57

16 Printed Circuit Board 16.1. INDOOR UNIT (MAIN)

31

56

14.1. THERMOSTAT CHARACTERISTICS

15 Electronic Circuit Diagram

9.2. TOOLS FOR INSTALLING/SERVICING REFRIGERANT

55

17 Exploded View & Replacement Parts List

60

66 66 67

9.3. REFRIGERANT PIPING WORK

35

9.4. INSTALLATION, TRANSFERRING SERVICING

37

17.1. CS-VA70KE / CS-VA90KE

67

41

17.2. CS-VA120KE

69

10.1. ATTACHED ACCESSORIES

41

17.3. CU-VA70KE / CU-VA90KE

71

10.2. SELECT THE BEST LOCATION

41

17.4. CU-VA120KE

73

10 Installation Information

18 Electronic Parts List

10.3. INDOOR/OUTDOOR UNIT INSTALLATION DIAGRAM 42

2

75

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

1 Features · R410A No Ozone Layer Damage Our new models use R410A as its refrigerant. This Refrigerant does not contain chlorine, so there´s no danger of damage to the ozone layer. · Compact Design · Comfort Improvement − Wider range of horizontal discharge air − Longer hours of sleep mode operation · Auto Restart − Auto restart operation after power failure · Removable and Washable Front Panel · Deodorizing Air Purifying Filter − Air Purifying Filter features a deodorizing function that removes unpleasant odors from the air. · Installation Work Improvement − Long piping up to 10 m (CS-VA70KE / CS-VA90KE) − Long piping up to 15 m (CS-VA120KE) · Quality Improvement − Low voltage protection − Gas leakage protection − Prevent compressor reverse cycle − 2-stage OLP to protect compressor (CS-VA90KE / CS-VA120KE) · Service Improvement − Easy fan motor replacement procedure − Front side servicing for outdoor unit

3

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

2 Functions 2.1.

REMOTE CONTROL

4

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

2.2.

INDOOR UNIT

5

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

2.3.

OUTDOOR UNIT

6

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

3 Product Specifications 3.1.

CS-VA70KE / CU-VA70KE

Cooling Capacity Heating Capacity Moisture Removal Power Source

Unit kW Btu/h kW Btu/h /h Pint/h Phase V Cycle

CS-VA70KE

CU-VA70KE 2.20 7,500 2.35 8,000 1.3 2.7 Single 230 50

Airflow Method

Air Volume

Indoor Air(Lo)

m / min(cfm)

Indoor Air(Me)

m / min(cfm)

Indoor Air(Hi)

m / min(cfm)

Outdoor Air

m / min(cfm) dB(A)

Noise Level Electrical Data

Input Running Current

Cooling Heating Cooling Heating Cooling Heating

; 5.5(190) ; 5.5(190) ; 6.0(210) ; 6.0(210) ; 6.7(240) ; 6.7(240) 22.4(790) Cooling ; High 34,Low 30 Cooling ; 46 heating ; High 33,Low 29 Heating ; 48 Cooling ; 0.64 Heating ; 0.60 Cooling ; 3.2 Heating ; 3.0 Cooling ; 3.44 Heating ; 3.92 13 G ; Half Union 3/8” G ; 3-Way valve 3/8” L ; Half Union 1/4” L ; 2-Way valve 1/4” G(gas side) ; 3/8” G(gas side) ; 3/8” L(liquid side) ; 1/4” L(liquid side) ; 1/4” 12 0.7 2.1 m 3 (1.0 mm ) 11 - 7/16(290) 18 - 29/32(480) 31 - 15/32(799) 30 - 23/32(780) 6 - 29/32(175) 9 - 21/32(245) 18(8.0) 64(29.0) Rotary(1 cylinder rolling piston type Induction(2-poles) 550 Cross-flow Fan Propeller Fan AS+Glass Fiber 30 AES+Glass Fiber 12 Transiator(4-poles) Induction(6-poles) 58.6 20 20 950 1,030 1,550 730 Evaporator Condenser Copper Copper Aluminium Aluminium Slit Fin Corrugated Fin (Plate fin configuration, forced draft) 1 x 18 2 x 12 18 18 600 x 252 x 25.4 856 x 457.2 x 22 Capillary Tube RB68A(300) 860(30.4)

kW A

COP Starting Current Piping Connection Port (Flare piping) Pipe Size (Flare piping) Drain Inner diameter Hose Length Power Cord length Number of core-wire Dimensions Height Width Depth Net Weight Compressor Type Motor Type Rated Output Air Circularizing Type Material Motor Type Input rated Output Fan Low Speed Medium High(heating) Heat description Exchange Tube material Fine material Fine type Row/Stage FPI Size(W x H x L) Refrigerant Control Device refrigeration Oil Refrigerant(R410A)

A inch inch inch inch mm m

inch(mm) inch(mm) inch(mm) lb(kg)

W

W W rpm rpm rpm

mm (c.c) g(oz)

7

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

Unit Thermostat Protection Device Capillary Tube Length flow Rate Inner Diameter Air Filter Material style Capacity Control Compressor Capacitor Fan motor Capacitor

CS-VA70KE Electronic Control -

mm /min mm

P.P Honeycomb

C ,C 970 5.0 1.2

CU-VA70KE Overload Protector C 310 11.3 1.3 -

Capillary Tube µF,VAC µF,VAC

-

· Specifications are subject to change without notice for further improvement.

8

25µF,370VAC 1.2µF,400VAC

C 610 6.5 1.2

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

3.2.

CS-VA90KE / CU-VA90KE

Cooling Capacity Heating Capacity Moisture Removal Power Source

Unit kW Btu/h kW Btu/h /h Pint/h Phase V Cycle

CS-VA90KE

CU-VA90KE 2.85 9,700 3.30 11,300 1.6 3.4 Single 230 50

Airflow Method

Air Volume

Indoor Air(Lo)

m / min(cfm)

Indoor Air(Me)

m / min(cfm)

Indoor Air(Hi)

m / min(cfm)

Outdoor Air

m / min(cfm) dB(A)

Noise Level Electrical Data

Input Running Current

Cooling Heating Cooling Heating Cooling Heating

; 6.3(220) ; 6.4(230) ; 7.4(260) ; 7.5(260) ; 8.5(300) ; 8.6(300) 22.4(790) Cooling ; High 38,Low 30 Cooling ; 48 heating ; High 38,Low 30 Heating ; 48 Cooling ; 0.94 Heating ; 0.86 Cooling ; 4.3 Heating ; 4.0 Cooling ; 3.03 Heating ; 3.84 20 G ; Half Union 3/8” G ; 3-Way valve 3/8” L ; Half Union 1/4” L ; 2-Way valve 1/4” G(gas side) ; 3/8” G(gas side) ; 3/8” L(liquid side) ; 1/4” L(liquid side) ; 1/4” 12 0.7 2.1 m 3 (1.0 mm ) 11 - 7/16(290) 18 - 29/32(480) 31 - 15/32(799) 30 - 23/32(780) 6 - 29/32(175) 9 - 21/32(245) 18(8.0) 71(32.0) Rotary(1 cylinder rolling piston type Induction(2-poles) 750 Cross-flow Fan Propeller Fan AS+Glass Fiber 30 AES+Glass Fiber 12 Transiator(4-poles) Induction(6-poles) 58.6 20 20 980 1,150 1,310 730 Evaporator Condenser Copper Copper Aluminium Aluminium Slit Fin Corrugated Fin (Plate fin configuration, forced draft) 2 x 12 1 x 18 18 19 600 x 252 x 25.4 856 x 457.2 x 22 Capillary Tube RB68A(350) 880(31.1) Electronic Control Overload Protector

kW A

COP Starting Current Piping Connection Port (Flare piping) Pipe Size (Flare piping) Drain Inner diameter Hose Length Power Cord length Number of core-wire Dimensions Height Width Depth Net Weight Compressor Type Motor Type Rated Output Air Circularizing Type Material Motor Type Input rated Output Fan Low Speed Medium High(heating) Heat description Exchange Tube material Fine material Fine type Row/Stage FPI Size(W x H x L) Refrigerant Control Device refrigeration Oil Refrigerant(R410A) Thermostat Protection Device

A inch inch inch inch mm m

inch(mm) inch(mm) inch(mm) lb(kg)

W

W W rpm rpm rpm

mm (c.c) g(oz)

9

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

Unit

CS-VA90KE

Capillary Tube

Air Filter

Length flow Rate Inner Diameter Material style

Capacity Control Compressor Capacitor Fan motor Capacitor

mm /min mm

P.P Honeycomb

C ,C 970 5.0 1.2

CU-VA90KE C 750 15.4 1.7 -

Capillary Tube µF,VAC µF,VAC

-

· Specifications are subject to change without notice for further improvement.

10

25µF,370VAC 1.2µF,400VAC

C 590 8.2 1.3

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

3.3.

CS-VA120KE / CU-VA120KE

Cooling Capacity Heating Capacity Moisture Removal Power Source

Unit kW Btu/h kW Btu/h /h Pint/h Phase V Cycle

CS-VA120KE

CU-VA120KE 3.55 12,000 4.00 13,600 2.0 4.2 Single 230 50

Airflow Method

Air Volume

Indoor Air(Lo)

m / min(cfm)

Indoor Air(Me)

m / min(cfm)

Indoor Air(Hi)

m / min(cfm)

Outdoor Air

m / min(cfm) dB(A)

Noise Level Electrical Data

Input Running Current

Cooling Heating Cooling Heating Cooling Heating

; 7.5(260) ; 7.8(280) ; 8.4(300) ; 8.7(310) ; 9.3(330) ; 9.7(340) 22.0(780) Cooling ; High 42,Low 38 Cooling ; 49 heating ; High 42,Low 38 Heating ; 49 Cooling ; 1.24 Heating ; 1.18 Cooling ; 5.6 Heating ; 5.4 Cooling ; 2.86 Heating ; 3.39 25 G ; Half Union 1/2” G ; 3-Way valve 1/2” L ; Half Union 1/4” L ; 2-Way valve 1/4” G(gas side) ; 1/2” G(gas side) ; 1/2” L(liquid side) ; 1/4” L(liquid side) ; 1/4” 12 0.7 2.1 m 3 (1.0 mm ) 11 - 7/16(290) 19 - 29/32(505) 31 - 15/32(799) 30 - 23/32(780) 6 - 29/32(175) 9 - 21/32(245) 18(8.0) 83(38.0) Rotary(1 cylinder rolling piston type Induction(2-poles) 1100 Cross-flow Fan Propeller Fan AS+Glass Fiber 30 AES+Glass Fiber 12 Transiator(4-poles) Induction(6-poles) 60.2 20 25 1200 1,330 1,500 730 Evaporator Condenser Copper Copper Aluminium Aluminium Slit Fin Corrugated Fin (Plate fin configuration, forced draft) 2 x 12 2 x 19 21 16 600 x 252 x 25.4 706 x 457.2 x 44 670 x 457.2 x 44 Capillary Tube RB68A(430) 1150(40.6) Electronic Control Overload Protector

kW A

COP Starting Current Piping Connection Port (Flare piping) Pipe Size (Flare piping) Drain Inner diameter Hose Length Power Cord length Number of core-wire Dimensions Height Width Depth Net Weight Compressor Type Motor Type Rated Output Air Circularizing Type Material Motor Type Input rated Output Fan Low Speed Medium High(heating) Heat description Exchange Tube material Fine material Fine type Row/Stage FPI Size(W x H x L) Refrigerant Control Device refrigeration Oil Refrigerant(R410A) Thermostat Protection Device

A inch inch inch inch mm m

inch(mm) inch(mm) inch(mm) lb(kg)

W

W W rpm rpm rpm

mm

(c.c) g(oz)

11

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

Unit

CS-VA120KE

Capillary Tube

Air Filter

Length flow Rate Inner Diameter Material style

Capacity Control Compressor Capacitor Fan motor Capacitor

mm /min mm

P.P Honeycomb

CU-VA120KE C 600 12.2 1.5

C 540 10.4 1.4 -

Capillary Tube µF,VAC µF,VAC

-

· Specifications are subject to change without notice for further improvement.

12

30µF,370VAC 1.2µF,400VAC

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

4 Dimensions CS-VA70KE / CS-VA90KE / CS-VA120KE (INDOOR UNIT) 175

799

61

290

290

Air intake direction

2100

48.5 55

34.5

52 Air outlet direction Left piping hole

Right piping hole

60

60

115

Installation plate hooks

Drain ports

Remote control transmitter

Gas Liquid side side

(410)

142



(45) 57

16

Relative position between the indoor unit and the installation plate

Slot (2 places) Slot (2 places)

Centre notch (40)

(40)

710

13.5

7

457 Installation plate 350

276

100

100

Arrow

Indoor unit external dimensions line

Arrow

Centre

Right piping hole

7

4.1.

(60)

(110)

Left piping hole Installation plate positioning gauge

13

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

CU-VA70KE / CU-VA90KE (OUTDOOR UNIT) 57

93

780

27.5

4.2.

245

480 467

Panasonic

77 67

2-way valve at Liquid side

105

280 312

57

112

780

27.5

CU-VA120KE(OUTDOOR UNIT)

245

2-way valve at Liquid side

93 67

505 494 105

570

105

11

4.3.

570

13

105

3-way valve at Gas side

14

3-way valve at Gas side

280 312

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

5 Refrigeration Cycle Diagram 5.1.

CS-VA70KE / CU-VA70KE, CS-VA90KE / CU-VA90KE INDOOR

OUTDOOR

C1 DRYER

CHECK VALVE C3

2-WAY VALVE

C2

C4

INTAKE TEMP. SENSOR

PIPE TEMP. SENSOR (T.R.S)

PIPE TEMP. SENSOR

HEAT EXCHANGER (EVAPORATOR)

HEAT EXCHANGER (CONDENSER) STRAINER

3-WAY VALVE

4-WAY VALVE

COMP.

COOLING

C1,C2,C3,C4; CAPILLARY TUBE

HEATING

15

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

5.2.

CS-VA120KE / CU-VA120KE INDOOR

OUTDOOR

DRYER

CHECK VALVE C1

2-WAY VALVE C2

INTAKE TEMP. SENSOR

PIPE TEMP. SENSOR (T.R.S)

PIPE TEMP. SENSOR

HEAT EXCHANGER (EVAPORATOR)

HEAT EXCHANGER (CONDENSER) STRAINER

3-WAY VALVE

4-WAY VALVE

COMP.

COOLING

C1,C2 ; CAPILLARY TUBE

HEATING

16

6 Block Diagram CS-VA70KE / CU-VA70KE CS-VA90KE / CU-VA90KE CS-VA120KE / CU-VA120KE

INDOOR UNIT MAIN POWER SWITCH

OUTDOOR UNIT FOR CU-VA70KE

P.C.B. 1 3C

ZNR2

1

FOR CU-VA120KE

TRS

RECEIVER P.C.B.

O.L.P. O.L.P.

O.L.P. CT1

TRANSFORMER

17

AC 230V 50Hz SINGLE PHASE

RY-PWR FUSE (3.15A)

THERMAL FUSE (99°C)

FOR CU-VA90KE

ZNR1

SSR1

4

4

3

3

WIRELESS REMOTE CONTROL TRANSMITTER

RY-HOT

4C

RELAY B

INDICATOR P.C.B.

FM

THERMAL FUSE (102°C)

5C

4-WAY VALVE

COMP

COMP

FM

STEPPING MOTOR 2

2

RELAY A

CS/CU-VA70KE/VA90KE/VA120KE A-008.DWG

* *

Indicates the electronic control unit. "C" Indicates the number of core wires. (Example:5C=5 core wires).

COMP

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

3C INDOOR FAN MOTOR

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

7 Wiring Diagram

POWER SUPPLY CORD

DISPLAY LAMP CN-DISP (W) 1 2 3 4

BR WWWW 4 3 2 1

Y/G

CN-DISP (W)

BL

R

CN-T (W)

THERMAL FUSE (102°C)

3 2 1

TRANSFORMER BL

R

T(BL) T(BL)

CN-RCV(W)

3

ELECTRONIC CONTROLLER (RECEIVER) CN-RCV (W)

1 2 3

B B B

CN-STM (G)

1

REMOTE CONTROL NO. A B

1 2 3 4 5

BR R O Y P

CN-TH (Y)

4

ELECTRONIC CONTROLLER

WIRELESS REMOTE CONTROL

4 3 2 1

CORE

R

CN FUSE (B)

2

BR

MAIN SW.

B

PUMP AUTO DOWN SW SW. (TEST RUN)

1 3 AC (BR)

W

L

COMP (BL)

THERMAL FUSE (99°C)

FUSE ZNR1 (Y2A L250W) AC(W) CR1

W

W

HD1(R) R B FM (B)

Y/G INDOOR UNIT TERMINAL

NV-HD1 ZNR2 CT1 SSR1 CN-MTR (G) 3 2 1

1 2 3 4

R BY 1 3 5 MOTOR

1 2 3 MOTOR 4 (FLAP) 5

SENSOR (PIPE TEMP.)

P BL

SENSOR (INTAKE TEMP.)

R

CU-VA120KE

CU-VA90KE TO I ND OOR UNI T

TO I ND OOR UNI T

CU-VA70KE OUTDOOR UNIT TERMINAL

CU-VA70KE

7

2

4 6

BLUE

YELL OW

8 7

RED

BLACK

BLUE

CAPACI TOR

CU-VA120KE CWA95230(Ω) 312.9 419.5

CU-VA70KE

CU-VA90KE

CU-VA120KE

18

5PS112DAA(Ω)

5KS150DAA(Ω)

3.12

2.21

4.57

3.53

CO I L REVERSING VAL VE

BLACK GRAY

B LUE

4

YELL OW

BLACK

BLACK

8

MAGNETIC RELAY B

RED

GRAY

BL ACK

6

1

CAPACI TOR

CU-VA90KE

BL ACK 2

GRAY

B LUE

CAPACI TOR

BLACK

BL UE

BLACK BLACK

CO I L REVERSING VAL VE

BLACK G R AY

BL ACK

F AN MOTOR

7

4 WHITE

WHI TE

8

3

TRS

BLUE

6

BLU E R ED

CAPACI TOR

2

4

OVER L OAD EL ECT R OLYT I C PROTECTOR C APACI TO R

YELLOW

YEL L OW

F AN MOTOR

2

BL ACK

BLUE

1

COMPRESSO R

BROWN

7

2

4

R ED

6

MAGNETIC RELAY B

GRAY

8

MAGNETIC RELAY A EL ECT ROL YT I C CAPACITOR

RED

G RAY

BL ACK

BLAC K 2

BLUE

WH I TE

BLAC K EL ECT R OLYT I C C APACI TO R

COIL REVERSING VALVE

BLA CK BLACK

1

MAGNETICR ELAY A EL ECT ROL YTI C CAPACI T OR

TERMINAL BLACK

4

TRS

WHI TE

BLUE

3

4

BLUE

CAPACITOR

2

BLUE

RED CAPACITOR

7

OVER LO AD PROT ECTOR

2 8 6

BLUE

YELLOW

4

BLUE

YELLOW

FAN MOTOR

1

BLACK

COMPRESSO R

BROWN

7

ELECTROLYTIC CAPACITOR

6

BLUE

GRAY 3 2

8

MAGNETIC RELAY A

2

MAGNETIC RELAY B

GRAY

RED

BLACK

ELECTROLYTIC CAPACITOR

BLACK

4

RED

OVER LOAD PROTECTOR

BLACK

1

W H ITE

BLACK GRAY

TRS

BLACK

COMPRESSOR

TERMINAL

WHITE

R ED

BLACK

1 2 3 4

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

8 Operation Details 8.1.

COOLING MODE OPERATION

Cooling in operation according to the remote control setting.

8.1.1.

Time Delay Safety Control (3 minutes)

· When the compressor is stopped by Power Switch, Remote Control or when there is a power failure, it restarts after 3 minutes when the Power Switch, Remote Control is turned ON or when the power supply is resumed. · When the setting temperature is reached during cooling operation, the compressor stops and it will not start for 3 minutes.

8.1.2.

7 Minutes Time Save Control

· The compressor will start automatically if it has stopped for 7 minutes even if the room temperature is below the compressor ON temperature.

8.1.3.

Anti-Freezing Control

· If the temperature of the indoor heat exchanger falls continously below 2°C for 4 minutes, the compressor turns off to protect the indoor heat exchanger from freezing.The fan speed setting remains the same.

· Compressor recommences when the indoor heat exchanger temperature rises to 10 °C (Recovery). *3 minutes waiting of Time Delay Safety Control is valid for Cooling Operation.

8.1.4.

Compressor Protection Control

· After the compressor operates for 50 seconds but the outdoor fan motor is still OFF, the compressor will stop and restart automatically.(Time Delay Safety Control is valid).

· If the above phenomenon is repeated 3 times, the compressor will stop. · The above phenomenon is reset when there is a change to heating mode or stopped by Remote Control Switch.

8.1.5.

Compressor Reverse Rotation Protection Control

· If the compressor is operating continually for 5 minutes or longer and the temperature difference between intake air and indoor heat exchanger is 2.5 °C or less for 2 minutes, the compressor will stop and restart automatically. (Time Delay Safety Control is valid).

T =Intake air temperature - Indoor heat exchanger temperature This is to protect the compressor against reverse rotation when there is an instantaneous power failure.

19

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

8.1.6.

Automatic Fan Speed Mode

When Automatic Fan Speed is selected on the remote control during cooling operation. · Fan speed rotates in the range of Hi to Me. · Deodorizing Control.

*1 Fan Speed is Hi until the compressor stops (when the set temperature is reached). *2 Fan Speed is Me after the compressor restarts.

8.1.7.

Cooling Operation Time Diagram

20

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

8.2.

SOFT DRY MODE OPERATION

· The unit performs cooling operation until the room temperature reaches the setting temperature set on the Remote Control, and then Soft Dry operation will start. (During Soft Dry operation, the indoor fan operates with SLo speed.) · Once room temperature reaches below Soft Dry OFF temperature, Indoor Fan, Compressor and Outdoor Fan stop for 6 minutes.

8.2.1.

Time Delay Safety Control

· Once the compressor stops, it will not restart for 3 minutes during Cooling operation.

8.2.2.

Anti-Freezing Control

· Same as Anti-Freezing Control for Cooling Mode operation.(For Soft Dry operation,6 minutes waiting is valid during compressor stops.)

8.2.3.

Compressor Protection Control

· Same as Compressor Protection Control for Cooling Mode Operation.

8.2.4.

Compressor Reverse Rotation Protection

· Same as Compressor Reverse Rotation Protection Control for Cooling Mode Operation.

8.2.5.

Automatic Fan Speed Mode

When Automatic Fan Speed is selected on the remote control during Soft Dry Operation. · Fan speed rotates at SLo. · Deodorizing Control.

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8.2.6.

Soft Dry Operation Time Diagram

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8.3.

HEATING MODE OPERATION

Heating in operation according to the remote control setting.

8.3.1.

Time Delay Safety Control

· When the compressor is stopped by Power Switch, Remote Control or when there is a power failure, it restarts after 3 minutes when the Power Switch, Remote Control is turned ON or the power supply is resumed. · When the setting temperature is reached during heating operation, the compressor stops and it will not restart for 4 minutes. · Indoor Fan stops for 1 minute 3 minutes after the compressor stopped.Then,it will operate with SLo fan speed.

8.3.2.

Overload Protection Control

· If the temperature of the indoor heat exchanger rises to 51 °C, Outdoor Fan stops. The Outdoor Fan restarts when the indoor heat exchanger temperature falls to 49 °C. · If the indoor heat exchanger becomes 65 °C or more, the compressor will stop and restart automatically. (Time Delay Safety Control -4 minutes waiting)

8.3.3.

Compressor Reverse Rotation Protection Control

· If the compressor is operating continually for 5 minutes or longer and temperature difference between intake air and indoor heat exchanger is 5 C or less for 2 minutes, the compressor will stop and restart automatically. (Time Delay Safety Control is valid).

T =Indoor heat exchanger temperature - intake air temperature This is to protect the compressor against reverse rotation when there is a instantaneous power failure.

8.3.4.

4-way Valve Control

· 4way valve always ON during Heating operation. · When the unit is switched to "OFF" during Heating operation,4-way valve stays at Heating position for 5 minutes.

8.3.5.

Hot Start Control

When Heating operation starts, Indoor Fan will not start until the indoor heat exchanger reaches 30 °C as shown in the diagram below.

Hot Start is completed when indoor heat exchanger reaches 41 °C.

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8.3.6.

Automatic Fan Speed Mode

When Automatic Fan Speed is selected on the remote control during heating operation. · Fan speed rotates in the range of Me → SLo according to the heat exchanger temperature.

8.3.7.

Heating Operating Time Diagram

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

8.3.8.

Deicing Control

Deice operates to prevent frosting at outdoor heat exchanger. · Normal Deicing Deice operation detection commences after 30 minutes of Heating operation or 60 minutes after previous deice operation.If the TRS (Thermal Reed Switch) senses the outdoor piping temperature drops to -3 °C (TRS CLOSE) or less for 50 sec.continuosly during compressor is in operation, deice will start. (There is no detection during Outdoor Fan stops.) · Overload Deicing During heating operation, if the outdoor Fan OFF duration (due to overload control) is accumulated up to 60 minutes and 1 minute after the compressor starts, deicing starts. · Deicing ends when 1. 12 minutes after deicing operation starts; 2. TRS senses the outdoor piping temperature rises to 4 °C (TRS OPEN). 3. Deicing will not end immediately as time delay (Td) is valid as shown below. Time taken from deicing start to TRS OPEN (T) T 3 minutes 3 minutes T 6 minutes 6 minutes T 9 minutes T 9 minutes

Td (seconds) 0 60 120 180

· Once deicing operation starts, it will not end for 60 seconds. · After deicing operation, compressor stops for 30 seconds and 4-way valve stays at cooling position for 10 seconds.

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8.3.9.

Normal Deicing Time Diagram

8.3.10. Overload Deicing Time Diagram

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8.4.

AUTOMATIC MODE OPARATION

8.4.1.

Standard for Determining Operation Mode

1. Indoor fan operates at SLo fan speed for 20 seconds. 2. After judging indoor air temperature, the operation mode is determined and operation continued at the mode determined. 3. If indoor intake air is less than 16 °C, Heating mode will operate immediately. 4. After the operation mode has been determined, the mode does not change.However,Soft Dry mode operation includes Cooling mode operation. 5. If Automatic Mode operation is started while the air conditioner is operating, operation will continue.If current operation is in Cooling mode (including the operation which is a part of Soft Dry mode operation), it will be maintained, for 20 seconds at SLo fan speed.Then,the selected operation mode will continue. 6. Room temperature adjustment The following are added to the setting temperature specified as above. Higher → +2°C Standard → ±0°C Lower → -2°C

8.5.

SLEEP MODE AUTO OPERATION

8.5.1.

Cooling or Soft Dry operation

When you press the SLEEP Mode, the following movement will start to avoid overcooling. · The fan speed is automatically set to Low. · The setting temperature will be increased by 0.5 °C at the start of operation and by 0.5 °C one hour later. · The operation will stop after 8 hours.

8.5.2.

Heating operation

When you press the SLEEP Mode, the following movement will start to avoid overheating. · The fan speed is automatically set to Low or Super Low. · The setting temperature will be decreased by 2°C atthe start of operation and by 3°C one hour later. · The operation will stop after 8 hours.

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8.6.

AUTO RESTART CONTROL

· If there is a power failure, operation will be restarted automatically when the power is resumed. It will start with the previous operation mode and airflow direction. (Time Delay Safety Control is valid) · Auto Restart Control is not available when Timer or Sleep Mode is set. · This control can be omitted by cutting the jumper wire J2.(Refer Circuit Diagram)

8.7.

INDOOR FAN MOTOR CONTROL

· Auto Fan Speed Control When set to Auto Fan Speed, the fan speed is adjusted between maximum and minimum setting as shown in the table. · Manual Fan Speed Control Basic fan speed adjustment (3 settings, from Lo to Hi) can be carried out by using the Fan Speed selection button.

Cooling

Fan Speed No. Manual Auto Sleep

8

7

6

21.0 26.7 32.0 SHi

21.0 25.9 31.0 Hi

18.6 21.5 26.0 Me

High Speed ←→ Low Speed 5 4 3

2

1

0

11.0 11.0 11.0 MID START

7.2 7.2 7.2 START

0 0 0 STOP

Soft Dry Heating Voltage to Fan Motor Drive Transistor (V)

Manual Auto Sleep CS-VA70KE CS-VA90KE CS-VA120KE

17.0 18.1 22.5 Lo

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15.8 15.8 21.5 Lo-

11.0 11.0 16.5 SLo

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

8.8.

AIRFLOW DIRECTION CONTROL

8.8.1.

Airflow Direction Auto-Control

· When set to Airflow Direction Auto-Control on the remote control, the louver swings up and down as shown in the diagram. · The louver does not swing when the Indoor Fan stops during operation. · When stopped on the remote control, the discharge vent is closed with the louver.

*The left and right airflow direction louvers can be adjusted manually. *1 There is no swinging while indoor fan is stopped during Cooling and Soft Dry operation. *2 In Heating operation, when the indoor heat exchanger temperature rises to 38 °C, the airflow direction is changed from upper limit to lower limit.When the indoor heat exchanger temperature falls to 35 °C, the airflow direction is changed from lower limit to upper limit.

8.8.2.

Airflow Direction Manual Control

· When the Airflow Direction Setting button is pressed, the automatic airflow is released and the airflow direction louver moves up and down in the range shown in the diagram. The louver can be stopped by releasing the button at the desired louver position. · When the remote control is used to stop the operation, the discharge vent is closed with airflow direction louver.

*The left and right airflow direction louvers can be adjusted manually.

8.9.

DELAY ON TIMER CONTROL

· When the Delay ON Timer is set by using the remote control, the unit will start to operate slightly before the set time so that the room will reach nearly to the set temperature by the desired time. · For Cooling and Soft Dry mode, the operation will start 15 minutes before the set time. · For Heating mode, the operation will start 30 minutes before the set time. · For Automatic mode, the indoor fan will operate at SLo speed for 20 seconds 30 minutes before the set time to detect the intake air temperature to determine the operation mode.The operation indication lamp will blink at this time.

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9 Installation And Servicing Air Conditioner Using R410A 9.1.

OUTLINE

9.1.1.

About R410A Refrigerant

1. Converting air conditioners to R410A Since it was declared in 1974 that chlorofluorocarbons (CFC), hydro chlorofluorocarbons (HCFC) and other substances pose a destructive danger to the ozone layer in the earth´s upper stratosphere (20 to 40 km above the earth), measures have been taken around the world to prevent this destruction. The R22 refrigerant which has conventionally been used in ACs is an HCFC refrigerant and, therefore, possesses this ozonedestroying potential. International regulations (the Montreal Protocol on Ozone-Damaging Substances) and the domestic laws of various countries call for the early substitution of R22 by a refrigerant which will not harm the ozone layer. · In ACs, the HFC refrigerant which has become the mainstream alternative is called R410A. Compared with R22, the pressure of R410A is approximately 1.6 times as high at the same refrigerant temperature, but the energy efficiency is about the same. Consisting of hydrogen (H), fluorine (F) and carbon (C), R410A is an HFC refrigerant. Another typical HFC refrigerant is R407C. While the energy efficiency of R407C is somewhat inferior to that of R410A, it offers the advantage of having pressure characteristics which are about the same as those of R22, and is used mainly in packaged ACs. 2. The characteristics of HFC (R410A) refrigerants a. Chemical characteristics The chemical characteristics of R410A are similar to those of R22 in that both are chemically stable, non-flammable refrigerants with low toxicity. However, just like R22, the specific gravity of R410A gas is heavier than that of air. Because of this, it can cause an oxygen deficiency if it leaks into a closed room since it collects in the lower area of the room. It also generates toxic gas when it is directly exposed to a flame, so it must be used in a well ventilated environment where it will not collect.

Composition (wt%) Boiling point (°C) Vaporizing pressure (25°C) Saturated vapor density Flammability Ozone-destroying point (ODP) Global-warming point (GWP)

Table 1 Physical comparison of R410A and R22 R410A R32/R125 (50/50) -51.4 1.56 Mpa (15.9 kgf/cm ) 64.0 kg/m Non-flammable 0 1730

R22 R22 (100) -40.8 0.94 Mpa (9.6 kgf/cm ) 44.4 kg/m Non-flammable 0.055 1700

b. Compositional change (pseudo-azeotropic characteristics) R410A is a pseudo-azeotropic mixture comprising the two components R32 and R125. Multi-component refrigerants with these chemical characteristics exhibit little compositional change even from phase changes due to vaporization (or condensation), which means that there is little change in the circulating refrigerant composition even when the refrigerant leaks from the gaseous section of the piping. Accordingly, R410A can be handled in almost the same manner as the single-component refrigerant R22. However, when charging, because there is a slight change in composition between the gas phase and the liquid phase inside a cylinder or other container, charging should basically begin with the liquid side. c. Pressure characteristics As seen in Table 2, the gas pressure of R410A is approximately 1.6 times as high as that of R22 at the same refrigerant temperature, which means that special R410A tools and materials with high-pressure specifications must be used for all refrigerant piping work and servicing. Table2 Comparison of R410A and R22 saturated vapor density Unit:MPa Refrigerant Temperature(°C) R410A R22 -20 0.30 0.14 0 0.70 0.40 20 1.35 0.81 40 2.32 1.43 60 3.73 2.33 65 4.15 2.60

d. R410A refrigerating machine oil Conventionally, mineral oil or a synthetic oil such as alkylbenzene has been used for R22 refrigerating machine oil. Because of the poor compatibility between R410A and conventional oils like mineral oil, however, there is a tendency for the refrigerating machine oil to collect in the refrigerating cycle. For this reason, polyester and other synthetic oils which have a high compatibility with R410A are used as refrigerating machine oil. Because of the high hygroscopic property of synthetic oil, more care must be taken in its handling than was necessary with

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conventional refrigerating machine oils. Also, these synthetic oils will degrade if mixed with mineral oil or alkylbenzene, causing clogging in capillary tubes or compressor malfunction. Do not mix them under any circumstances.

9.1.2.

Safety Measures When Installing/Servicing Refrigerant Piping

Cause the gas pressure of R410A is approximately 1.6 times as high as that of R22, a mistake in installation or servicing could result in a major accident. It is essential that you use R410A tools and materials, and that you observe the following precautions to ensure safety. 1. Do not use any refrigerant other than R410A in ACs that have been used with R410A. 2. If any refrigerant gas leaks while you are working, ventilate the room. Toxic gas may be generated if refrigerant gas is exposed to a direct flame. 3. When installing or transferring an AC, do not allow any air or substance other than R410A to mix into the refrigeration cycle. If it does, the pressure in the refrigeration cycle can become abnormally high, possibly causing an explosion and/or injury 4. After finishing the installation, check to make sure there is no refrigerant gas leaking. 5. When installing or transferring an AC, follow the instructions in the installation instructions carefully. Incorrect installation can result in an abnormal refrigeration cycle or water leakage, electric shock, fire, etc. 6. Do not perform any alterations on the AC unit under any circumstances. Have all repair work done by a specialist. Incorrect repairs can result in an water leakage, electric shock, fire, etc.

9.2.

TOOLS FOR INSTALLING/SERVICING REFRIGERANT PIPING

9.2.1.

Necessary Tools

In order to prevent an R410A AC from mistakenly being charged with any other refrigerant, the diameter of the 3-way valve service port on the outdoor unit has been changed. Also, to increase its ability to withstand pressure, the opposing dimensions have been changed for the refrigerant pipe flaring size and flare nut. Accordingly, when installing or servicing refrigerant piping, you must have both the R410A and ordinary tools listed below. Type of work Flaring Bending, connecting pipes

Air purging

Gas leak inspection

Table 3 Tools for Installation, transferring or replacement Ordinary tools R410A tools Flaring tool (clutch type), pipe cutter, Copper pipe gauge for clearance Adjustment, reamer flaring tool (clutch type)*1) Torque wrench (nominal diameter 1/4,3/8,1/2) Fixed spanner (opposing sides 12 mm, 17 mm, 19mm) Adjustable wrench, Spring bender Vacuum pump Manifold gauge, charging hose, Hexagonal wrench vacuum pump adaptor (opposing sides 4 mm) Gas leak inspection fluid or soapy water Electric gas leak detector for HFC refrigerant*2)

*1). You can use the conventional (R22) flaring tool. If you need to buy a new tool, buy the R410A type. *2). Use when it is necessary to detect small gas leaks. For other installation work, you should have the usual tools, such as screwdrivers (+,-), a metal-cutting saw, an electric drill, a hole core drill (65 or 70 dia.), a tape measure, a level, a thermometer, a clamp meter, an insulation tester, a voltmeter, etc. Type of work Refrigerant charging

Brazing (Replacing refrigerating cycle parts*1)

Table 4 Tools for servicing Ordinary tools

R410A tools Electronic scale for refrigerant charging Refrigerant cylinder Charging orifice and packing for refrigerant cylinder

Nitrogen blow set (be sure to use nitrogen blowing for all brazing), and brazing machine

*1). Always replace the dryer of the outdoor unit at the same time. The replacement dryer is wrapped in a vacuum pack. Replace it last among the refrigerating cycle parts. Start brazing as soon as you have opened the vacuum pack, and begin the vacuuming operation within 2 hours.

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9.2.2.

R410A Tools

1. Copper tube gauge for clearance adjustment (used when flaring with the conventional flaring tool (clutch type)) · This gauge makes it easy to set the clearance for the copper tube to 1.0-1.5 mm from the clamp bar of the flaring tool.

Fig. 1 Copper tube gauge for clearance adjustment 2. Flaring tool (clutch type) · In the R410A flaring tool, the receiving hole for the clamp bar is enlarged so the clearance from the clamp bar can be set to 0-0.5 mm, and the spring inside the tool is strengthened to increase the strength of the pipe-expanding torque. This flaring tool can also be used with R22 piping, so we recommend that you select it if you are buying a new flaring tool.

Fig. 2 Flaring tool (clutch type) 3. Torque wrenches

Fig. 3 Torque wrenches

For 1/4 (opposite side x torque) For 3/8 (opposite side x torque) For 1/2 (opposite side x torque)

Table 5 Conventional wrenches 17mm X 18 N m (180 kgf cm) 22mm X 42 N m (420 kgf cm) 24mm X 55 N m (550 kgf cm)

R410A wrenches 17mm X 18 N m (180 kgf cm) 22mm X 42 N m (420 kgf cm) 26mm X 55 N m (550 kgf cm)

4. Manifold gauge · Because the pressure is higher for the R410A type, the conventional type cannot be used. Table 6 Difference between R410A and conventional high/low-pressure gauges Conventional gauges R410A gauges High-pressure gauge (red) -76 cmHg - 35 kgf/cm -0.1 - 5.3 Mpa -76 cmHg - 53 kgf/cm Low-pressure gauge (blue) -76 cmHg - 17 kgf/cm -0.1 - 3.8 Mpa -76 cmHg - 38 kgf/cm · The shape of the manifold ports has been changed to prevent the possibility of mistakenly charging with another type of refrigerant.

Port size

Table 7 Difference between R410A and conventional manifold port size Conventional gauges R410A gauges 7/16 UNF 20 threads 1/2 UNF 20 threads

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5. Charging hose · The pressure resistance of the charging hose has been raised to match the higher pressure of R410A. The hose material has also been changed to suit HFC use, and the size of the fitting has been changed to match the manifold ports.

Fig. 4 Manifold gauge charging hose

Pressure resistance Material

Table 8 Difference between R410A and conventional charging hoses Conventional hoses R410A hoses Working pressure 3.4 MPa (35 kgf/cm ) 5.1 MPa (52 kgf/cm ) Bursting pressure 17.2 MPa (175 kgf/cm ) 27.4 MPa (280 kgf/cm ) NBR rubber HNBR rubber Nylon coating inside

6. Vacuum pump adaptor · When using a vacuum pump for R410A, it is necessary to install an electromagnetic valve to prevent the vacuum pump oil from flowing back into the charging hose. The vacuum pump adaptor is installed for that purpose. If the vacuum pump oil (mineral oil) becomes mixed with R410A, it will damage the unit.

Fig. 5 Vacuum pump adaptor 7. Electric gas leak detector for HFC refrigerant · The leak detector and halide torch that were used with CFC and HCFC cannot be used with R410A (because there is no chlorine in the refrigerant).

· The present R134a leak detector can be used, but the detection sensitivity will be lower (setting the sensitivity for R134a at 1, the level for R410A will drop to 0.6).

· For detecting small amounts of gas leakage, use the electric gas leak detector for HFC refrigerant. (Detection sensitivity with R410A is about 23 g/year.)

Fig. 6 Electric gas leak detector for HFC refrigerant

8. Electronic scale for refrigerant charging · Because of the high pressure and fast vaporizing speed of R410A, the refrigerant cannot be held in a liquid phase inside the charging cylinder when charging is done using the charging cylinder method, causing bubbles to form in the measurement scale glass and making it difficult to see the reading. (Naturally, the conventional R22 charging cylinder cannot be used because of the differences in the pressure resistance, scale gradation, connecting port size, etc.) · The electronic scale has been strengthened by using a structure in which the weight detector for the refrigerant cylinder is held by four supports. It is also equipped with two connection ports, one for R22 (7/16 UNF, 20 threads) and one for R410A (1/2 UNF, 20 threads), so it can also be used for conventional refrigerant charging. · There are two types of electronic scales, one for 10-kg cylinders and one for 20-kg cylinders. (The 10-kg cylinder is recommended.) Refrigerant charging is done manually by opening and closing the valve.

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Fig. 7 Electronic scale for refrigerant charging

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

9. Refrigerant cylinders · The R410A cylinders are labeled with the refrigerant name, and the coating color of the cylinder protector is pink, which is the color stipulated by ARI of the U.S. · Cylinders equipped with a siphon tube are available to allow the cylinder to stand upright for liquid refrigerant charging.

Fig. 8 Refrigerant cylinders 10. Charging orifice and packing for refrigerant cylinders · The charging orifice must match the size of the charging hose fitting (1/2 UNF, 20 threads). · The packing must also be made of an HFC-resistant material.

Fig. 9 Charging orifice and packing

9.2.3.

R410A Tools Which Are Usable for R22 Models (1) (2) (3) (4) (5) (6) (7) (8) (9)

Table 9 R410A tools which are usable for R22 models R410A tools Copper tube gauge for clearance adjustment Flaring tool (clutch type) Manifold gauge Charging hose Vacuum pump adaptor Electric gas leak detector for HFC refrigerant Electronic scale for refrigerant charging Refrigerant cylinder Charging orifice and packing for refrigerant cylinder

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Usable for R22 models OK OK NG NG OK NG OK NG NG

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

9.3. 9.3.1.

REFRIGERANT PIPING WORK Piping Materials

It is recommended that you use copper and copper alloy jointless pipes with a maximum oil adherence of 40 mg/10 m. Do not use pipes that are crushed, deformed, or discolored (especially the inside surface). If these inferior pipes are used, impurities may clog the expansion valves or capillaries. Because the pressure of ACs using R410A is higher than those using R22, it is essential that you select materials that are appropriate for these standards. The thickness of the copper tubing used for R410A is shown in Table 10. Please be aware that tubing with a thickness of only 0.7 mm is also available on the market, but this should never be used.

Nominal diameter 1/4 3/8 1/2

9.3.2.

Table 10 Copper tube thickness (mm) Soft pipe Outside diameter (mm) R410A 6.35 0.80 9.52 0.80 12.7 0.80

Thickness (mm) (Reference)R22 0.80 0.80 0.80

Processing and Connecting Piping Materials

When working with refrigerant piping, the following points must be carefully observed: no moisture or dust must be allowed to enter the piping, and there must be no refrigerant leaks. 1. Procedure and precautions for flaring work a. Cut the pipe Use a pipe cutter, and cut slowly so the pipe will not be deformed. b. Remove burrs and clean shavings from the cut surface If the shape of the pipe end is poor after removing burrs, or if shavings adhere to the flared area, it may lead to refrigerant leaks. To prevent this, turn the cut surface downward and remove burrs, then clean the surface, carefully. c. Insert the flare nut (be sure to use the same nut that is used on the AC unit) d. Flaring Check the clamp bar and the cleanliness of the copper pipe. Be sure to use the clamp bar to do the flaring with accuracy. Use either an R410A flaring tool, or a conventional flaring tool. Flaring tools come in different sizes, so be sure to check the size before using. When using a conventional flaring tool, use the copper pipe gauge for clearance adjustment, etc., to ensure the correct A dimension (see Fig. 10)

Fig. 10 Flaring dimensions

Fig. 11 Relation between the flare nut structure and flaring tool end Nominal diameter

Outside diameter (mm)

1/4 3/8 1/2

6.35 9.52 12.70

Table 11 R410A flaring dimensions Wall thickness A(mm) (mm) R410A flaring Conventional flaring tool tool, clutch type Clutch type Wing-nut type 0.8 0 - 0.5 1.0 - 1.5 1.5 - 2.0 0.8 0 - 0.5 1.0 - 1.5 1.5 - 2.0 0.8 0 - 0.5 1.0 - 1.5 2.0 - 2.5

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Nominal diameter

Outside diameter (mm)

1/4 3/8 1/2

6.35 9.52 12.70

Nominal diameter 1/4 3/8 1/2 Nominal diameter 1/4 3/8 1/2

Outside diameter (mm) 6.35 9.52 12.70 Outside diameter (mm) 6.35 9.52 12.70

Table 12 R22 flaring dimensions Wall thickness A(mm) (mm) R410A flaring Conventional flaring tool tool, clutch type Clutch type Wing-nut type 0.8 0 - 0.5 0.5 - 1.0 1.0 - 1.5 0.8 0 - 0.5 0.5 - 1.0 1.0 - 1.5 0.8 0 - 0.5 0.5 - 1.0 1.5 - 2.0

Table 13 R410A flare and flare nut dimensions Unit:mm Wall thickness A +0, -0.4 B C (mm) dimension dimension 0.8 0.8 0.8

9.1 13.2 16.6

9.2 13.5 16.0

9.0 13.0 16.2

9.2 13.5 16.0

Flare nut width

13 20 23

17 22 26

D dimension

Flare nut width

13 20 20

17 22 24

6.5 9.7 12.9

Table 14 R22 flare and flare nut dimensions Unit:mm Wall thickness A +0, -0.4 B C (mm) dimension dimension 0.8 0.8 0.8

D dimension

6.5 9.7 12.9

2. Procedure and precautions for flare connection a. Check to make sure there are no scratches, dust, etc., on the flare and union. b. Align the flared surface with the axial center of the union. c. Use a torque wrench, and tighten to the specified torque. The tightening torque for R410A is the same as the conventional torque value for R22. Be careful, because if the torque is too weak, it may lead to a gas leak. If it is too strong, it may split the flare nut or make it impossible to remove the flare nut. Nominal diameter 1/4 3/8 1/2

9.3.3.

Table 15 R410A tightening torque Outside Tightening torque diameter (mm) N m (kgf cm) 6.35 14 - 18 (140 - 180) 9.52 33 - 42 (330 - 420) 12.70 55 (550)

Torque wrench tightening torque N m (kgf cm) 18 (180) 42 (420) 55 (550)

Storing and Managing Piping Materials

1. Types of piping and their storage The following is a general classification of the refrigerant pipe materials used for ACs.

Because the gas pressure of R410A is approximately 1.6 times as high as that of R22, copper pipes with the thickness shown in Table 10, and with minimal impurities must be used. Care must also be taken during storage to ensure that pipes are not crushed, deformed, or scratched, and that no dust, moisture or other substance enters the pipe interior. When storing sheathed copper pipes or plain copper pipes, seal the openings by pinching or taping them securely. 2. Markings and management a. Sheathed copper pipes and copper-element pipes When using these pipes, check to make sure that they are the stipulated thickness. For flare nuts, be sure to use the same nut that is used on the AC unit. b. Copper pipes Use only copper pipes with the thickness given in table 10, and with minimal impurities. Because the surface of the pipe is exposed, you should take special care, and also take measures such as marking the pipes to make sure they are easily distinguished from other piping materials, to prevent mistaken use. 3. Precautions during refrigerant piping work Take the following precautions on-site when connecting pipes.(Keep in mind that the need to control the entry of moisture and dust is even more important than in conventional piping.) a. Keep the open ends of all pipes sealed until connection with the AC equipment is complete.

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b. Take special care when doing piping work on rainy days. The entering of moisture will degrade the refrigerating machine oil, and lead to malfunctions in the equipment. c. Complete all pipe connections in as short a time as possible. If the pipe must be left standing for a long time after removing the seal, it must be thoroughly purged with nitrogen, or dried with a vacuum pump.

9.4.

INSTALLATION, TRANSFERRING SERVICING

9.4.1.

Inspecting Gas Leaks with a Vacuum Pump for New Installations (Using New Refrigerant Piping))

1. From the viewpoint of protecting the global environment, please do not release refrigerant into the atmosphere. a. Connect the projecting side (pin-pushing side) of the charging hose for the manifold gauge to the service port of the 3-way valve. (1) b. Fully open the handle Lo of the manifold gauge and run the vacuum pump. (2) (If the needle of the low-pressure gauge instantly reaches vacuum, re-check step a).) c. Continue the vacuum process for at least 15 minutes, then check to make sure the low-pressure gauge has reached -0.1 MPa (-76 cmHg). Once the vacuum process has finished, fully close the handle Lo of the manifold gauge and stop the vacuum pump operation, then remove the charging hose that is connected to the vacuum pump adaptor. (Leave the unit in that condition for 1-2 minutes, and make sure that the needle of the manifold gauge does not return.) (2) and (3) d. Turn the valve stem of the 2-way valve 90° counter-clockwise to open it, then, after 10 seconds, close it and inspect for a gas leak (4) e. Remove the charging hose from the 3-way valve service port, then open both the 2-way valve and 3-way valve. (1) (4) (Turn the valve stem in the counter-clockwise direction until it gently makes contact. Do not turn it forcefully.) f. Tighten the service port cap with a torque wrench (18 N m (1.8 kgf m)). (5) Then tighten the 2-way valve and 3-way valve caps with a torque wrench (42 N m (4.2 kgf m)) or (55 N m (5.5 kgf m)). (6) g. After attaching each of the caps, inspect for a gas leak around the cap area. (5) (6) Precautions · Be sure to read the instructions for the vacuum pump, vacuum pump adaptor and manifold gauge prior to use, and follow the instructions carefully. · Make sure that the vacuum pump is filled with oil up to the designated line on the oil gauge. · The gas pressure backflow prevention valve on the charging hose is generally open during use. When you are removing the charging hose from the service port, it will come off more easily if you close this valve.

Fig. 12 Vacuum pump air purging configuration

9.4.2.

Transferring (Using New Refrigerant Piping)

1. Removing the unit a. Collecting the refrigerant into the outdoor unit by pumping down The refrigerant can be collected into the outdoor unit (pumping down) by pressing the TEST RUN button, even when the temperature of the room is low. · Check to make sure that the valve stems of the 2-way valve and 3-way valve have been opened by turning them counterclockwise. (Remove the valve stem caps and check to see that the valve stems are fully opened position. Always use a hex wrench (with 4-mm opposing sides) to operate the valve stems.)

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

· Press the TEST RUN button on the indoor unit, and allow preliminary operation for 5-6 minutes. (TEST RUN mode) · After stopping the operation, let the unit sit for about 3 minutes, then close the 2-way valve by turning the valve stem in the clockwise direction. · Press the TEST RUN button on the indoor unit again, and after 2-3 minutes of operation, turn the valve stem of the 3way valve quickly in the clockwise direction to close it, then stop the operation. · Tighten the caps of the 2-way valve and 3-way valve to the stipulated torque. · Remove the connection pipes (liquid side and gas side). b. Removing the indoor and outdoor units · Disconnect the pipes and connecting electric cables from between the indoor and outdoor units · Put capped flare nuts onto all of the pipe connections of the indoor and outdoor units, to make sure no dust or other foreign matter enters. · Remove the indoor and outdoor units. 2. Installing the unit Install the unit using new refrigerant piping. Follow the instructions in section 4.1 to evacuate the pipes connecting the indoor and outdoor units, and the pipes of the indoor unit, and check for gas leaks.

9.4.3.

AC Units Replacement (Using Existing Refrigerant Piping)

When replacing and R410A AC unit with another R410A AC unit, you should re-flare the refrigerant piping. Even though the replacement AC unit uses the R410A, problems occur when, for example, either the AC unit maker or the refrigerating machine oil is different. When replacing an R22 AC unit with an R410A AC unit, the following checks and cleaning procedures are necessary but are difficult to do because of the chemical characteristics of the refrigerating machine oil (as described in items c) and d) of section About R410A Refrigerant(2)). In this case, you should use new refrigerant piping rather than the existing piping. 1. Piping check Because of the different pressure characteristics of R22 and R410A, the design pressure for the equipment is 1.6 times different. The wall thickness of the piping must comply with that shown in Table 10, but this is not easy to check. Also, even if the thickness is correct, there may be flattened or bent portions midway through the piping due to sharp curves. Buried sections of the piping also cannot be checked. 2. Pipe cleaning A large quantity of refrigerating machine oil (mineral oil) adheres to existing pipes due to the refrigeration cycle circulation. If the pipes are used just as they are for the R410A cycle, the capacity will be lowered due to the incompatibility of this oil with the R410A, or irregularities may occur in the refrigeration cycle. For this reason, the piping must be thoroughly cleaned, but this is difficult with the present technology.

9.4.4.

Refrigerant Compatibility (Using R410A Refrigerant in R22 ACs and Vice Versa)

Do not operate an existing R22 AC with the new R410A refrigerant. Doing so would result in improper functioning of the equipment or malfunction, and might lead to a major accident such as an explosion in the refrigeration cycle. Similarly, do not operate an R410A AC with R22 refrigerant. The chemical reaction between the refrigerating machine oil used in R410A ACs and the chlorine that is contained in R22 would cause the refrigerating machine oil to degrade and lead to malfunction.

9.4.5.

Recharging Refrigerant During Servicing

When recharging is necessary, insert the specified amount of new refrigerant in accordance with the following procedure. 1. Connect the charging hose to the service port of the outdoor unit. 2. Connect the charging hose to the vacuum pump adaptor. At this time, fully open the 2-way valve and 3-way valve. 3. Fully open the handle Lo of the manifold gauge, turn on the power of the vacuum pump and continue the vacuum process for at least one hour. 4. Confirm that the low pressure gauge shows a reading of -0.1 Mpa (-76 cmHg), then fully close the handle Lo, and turn off the vacuum pump. Wait for 1-2 minutes, then check to make sure that the needle of the Low pressure gauge has not returned. See Fig.13 for the remaining steps of this procedure. 5. Set the refrigerant cylinder onto the electronic scale, then connect the hose to the cylinder and to the connection port for the electronic scale. (1)(2) Precaution: Be sure to set up the cylinder for liquid charging. If you use a cylinder equipped with a siphon tube, you can charge the liquid without having to turn the cylinder around 6. Remove the charging hose of the manifold gauge from the vacuum pump adaptor, and connect it to the connection port of the electronic scale. (2)(3) 38

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

7. Open the valve of the refrigerant cylinder, then open the charging valve slightly and close it. Next, press the check valve of the manifold gauge and purge the air. (2)(4) (Watch the liquid refrigerant closely at this point.) 8. After adjusting the electronic scale to zero, open the charging valve, then open the valve Lo of the manifold gauge and charge with the liquid refrigerant. (2)(5) (Be sure to read the operating instructions for the electronic scale.) 9. If you cannot charge the stipulated amount, operate the unit in the cooling mode while charging a little of the liquid at a time (about 150 g/time as a guideline). If the charging amount is insufficient from one operation, wait about one minute, then use the same procedure to do the liquid charging again. Precaution: Never use the gas side to allow a larger amount of liquid refrigerant to be charged while operating the unit. 10. Close the charging valve, and after charging the liquid refrigerant inside the charging hose, fully close the valve Lo of the manifold gauge, and stop the operation of the unit. (2)(5) 11. Quickly remove the charging hose from the service port. (6) If you stop midway through, the refrigerant that is in the cycle will be discharged. 12. After putting on the caps for the service port and operating valve, inspect around the caps for a gas leak. (6)(7)

Fig. 13 Re-charging refrigerant

9.4.6.

Brazing

As brazing requires sophisticated techniques and experiences, it must be performed by a qualified person. In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry nitrogen gas (N ) flow. 1. Attach a reducing valve to the nitrogen gas cylinder. 2. Attach a reducing valve to the nitrogen gas cylinder. 3. Apply a seal onto the clearance between the piping and inserted pipe for the nitrogen gas in order to prevent the nitrogen gas from flowing backward. 4. When the nitrogen gas is flowing, be sure to keep the piping end open. 5. Adjust the flow rate of nitrogen gas so that it is lower than 0.05 m /h, or 0.02 MPa (0.2 kgf/cm ) by means of the reducing valve.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

6. After taking the steps above, keep the nitrogen gas flowing until the piping cools down to a certain extent (i.e. temperature at which pipes are touchable with finger). 7. Completely remove the flux after brazing.

Fig. 14 Prevention of Oxidation during Brazing

* Cautions during brazing 1. General Cautions a. The brazing strength should be high as required. b. After operation, airtightness should be kept under pressurized condition. c. During brazing do not allow component materials to become damaged due to overheating. d. The refrigerant pipe work should not become blocked with scale or flux. e. The brazed part should not restrict the flow in the refrigerant circuit. f. No corrosion should occur from the brazed part. 2. Prevention of Overheating Due to heating, the interior and exterior surfaces of treated metal may oxidize. Especially, when the interior of the refrigerant circuit oxidizes due to overheating, scale occurs and stays in the circuit as dust, thus exerting a fatally adverse effect. So, make brazing at adequate brazing temperature and with a minimum of heating area. 3. Overheating Protection In order to prevent components near the brazed part from overheating damage or quality deterioration due to flame or heat, take adequate steps for protection such as (1) by shielding with a metal plate, (2) by using a wet cloth, and (3) by means of heat absorbent. 4. Movement during Brazing Eliminate all vibration during brazing to protect brazed joints from cracking and breakage. 5. Oxidation Preventative In order to improve the brazing efficiency, various types of antioxidant are available on the market. However, the constituents of these are widely varied, and some are anticipated to corrode the piping materials, or adversely affect HFC refrigerant, lubricating oil, etc. Exercise care when using an oxidation preventive.

9.4.7.

Servicing Tips

The drier must also be replaced whenever replacing the refrigerant cycle parts. Replace the refrigerant cycle parts first before replacing the drier.The drier is supplied in a vacuum pack. Perform brazing immediately after opening the vacuum pack, and then start the vacuum within two hours.In addition, the drier also needs to be replaced when the refrigerant has leaked completely.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

10 Installation Information 10.1. ATTACHED ACCESSORIES

10.2. SELECT THE BEST LOCATION 10.2.1. INDOOR UNIT · There should not be any heat source or steam near the unit. · There should not be any obstacles blocking the air circulation. · A place where air circulation in the room is good. · A place where drainage can be easily done. · A place where noise prevention is taken into consideration. · Do not install the unit near the door way. · Ensure the spaces indicated by arrows from the wall, ceiling or other obstacles. · Indoor unit of this room air conditioner shall be installed on the wall in a height of at least 2.3m.

10.2.2. OUTDOOR UNIT · If an awning is built over the unit to prevent direct sunlight or rain, be careful that heat radiation from the condenser is not obstructed. · There should not be any animal or plant which could be affected by hot discharged air. · Keep the spaces indicated by arrows from wall, ceiling, fence or other obstacles. · Do not place any obstacles which may cause a short circuit of the discharged air.

10.2.3. PIPING LENGTH MODEL VA70KE VA90KE VA120KE

Piping size Gas Liquid 3/8” 1/4” 3/8” 1/4” 1/2” 1/4”

Rated Length (m)

Max. Elevation (m)

Max. Piping Length (m)

7 7 10

5 5 5

10 10 15

*1.The additional gas charge is unnecessary up to the Max. piping length. (CS-VA70KE, CS-VA90KE) *2. The above models (CS-VA120KE) will be installed at a 15 m (max) distance. The refrigerant should be added 150g. ( 15m - 10m ) x 30g = 150g

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

10.3. INDOOR/OUTDOOR UNIT INSTALLATION DIAGRAM

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

11 2-WAY / 3-WAY VALES 2-way Valve (Liquid Side)

Works Shipping

3-way Valve (Gas Side)

Shaft Position Close (With valve cap) Closed (Counter-clockwise)

Shaft Position Close (With valve cap) Closed (Clockwise)

Service Port Close (With cap) Open (Push-pin)

Open (With valve cap) Closed (Clockwise)

Open (With valve cap) Open (Counter-clockwise)

Evacuation (Servicing) Gas charging (Servicing) Pressure check (Servicing)

Open

Open

Open

Open

Open

Open

Gas releasing (Servicing)

Open

Open

Closed (With cap) Open (Connected manifold gauge) Open With vacuum pump Open (With charging cylinder) Open (Connected manifold gauge) Open (Connected manifold gauge)

Evacuation (Installation and Re-installation) Operation Pumping down (Transferring)

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

11.1. EVACUATION OF INSTALLATION WHEN INSTALLING AN AIR CONDITIONER, BE SURE TO EVACUATE THE AIR INSIDE THE INDOOR UNIT AND PIPES in the following procedure.

If air remains in the indoor unit and refrigeration pipes, it will affect the compressor, reduce the cooling capacity, and could lead to a malfunction.

Procedure: Caution

1. Connect a charging hose with a push pin to the Low side of a charging set and the service port of a 3-way valve.

If gauge needle does not move from 0 cmHg to -76 cmHg in step 3. above, take the following measures:

∙ Be sure to connect the end of the charging hose with the push pin to the service port.

If the leaks stop when the piping connections are tightened further, continue working from step 3.

2. Connect the centre hose of the charging set to a vacuum pump adapter and a vacuum pump.

If the leaks do not stop when the connections are retightened, repair the location of the leak.

3. Turn on the power switch of the vacuum pump and make sure that the needle in the gauge moves from 0 MPa (0 cmHg) to -0.1 MPa (-76 cmHg). Then evacuate the air for approximately ten minutes. 4. Close the Low side valve of the charging set and turn off the vacuum pump. Make sure that the needle in the gauge does not move for approximately five minutes. BE SURE TO TAKE THIS PROCEDURE IN ORDER TO AVOID GAS LEAKAGE. 5. Disconnect the charging hose from the vacuum pump and from the service port of the 3-way valve. 6. Tighten the service port cap at a torque of 18N m with a torque wrench. 7. Remove the valve caps of the 2-way valve and the 3way valve. Position both of the valves to with a torque wrench. "open" using a hexagonal wrench (4 mm). 8. Mount the valve caps onto the 2-way and 3-way valves. ∙ Be sure to check for gas leakage.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

11.2. PUMPING DOWN

Procedure:

9. Disconnect the charge set, and mount the 2-way and 3way valves stem caps and the service port caps.

1. Confirm that both the 2-way and 3-way valves are set to the opened position.

∙ Use a torque wrench to tighten the service port cap to a torque of 18 N m

∙ Remove the valve stem caps and confirm that the valve stems are in the opened position.

∙ Be sure to check for gas leakage.

∙ Be sure to use a hexagonal wrench to operate the valve stems.

10. Disconnect pipes from indoor unit and out-door unit.

2. Operate the unit for 10 to 15 minutes. 3. Stop operation and wait for 3 minutes, then connect the charge set to the service port of the 3-way valve. ∙ Connect the charge hose with the push pin to the Gas service port. 4. Air purging of the charge hose. ∙ Open the low-pressure valve on the charge set slightly to purge air from the charge hose. 5. Set the 2-way valve to the closed position. 6. Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 0 MPa (0 kg/cm G). If the unit cannot be operated at the cooling condition (weather is rather cool), press the TEST RUN button so that the unit can be operated. 7. Immediately set the 3-way valve to the closed position. ∙ Do this quickly so that the gauge ends up indicating 0.1 MPa (1 kg/cm G) to 0.3 MPa (3 kg/cm G) 8. Use refrigerant reclaiming equipment refrigerant from indoor unit and pipes.

to

collect

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

11.3. EVACUATION OF RE-INSTALLATION WHEN RE-INSTALLING AN AIR CONDITIONER, BE SURE TO EVACUATE THE AIR INSIDE THE INDOOR UNIT AND PIPES in the following procedure.

If air remains in the indoor unit and refrigeration pipes, it will affect the compressor, reduce the cooling capacity, and could lead to a malfunction.

9. Mount valve caps onto the 2-way and 3-way valves.

Procedure:

∙ BE SURE TO USE REFRIGERANT RECLAIMING EQUIPMENT WHILE DISCHARGING THE REFRIGERANT.

1. Connect a charging hose with a push pin to the Low side of a charging set and the service port of the 3-way valve.

∙ Purge the air from charge set’s centre hose.

∙ Be sure to connect the end of the charging hose with the push pin to the service port.

∙ Be sure to check for gas leakage.

2. Connect the center hose of the charging set to a vacuum pump adapter and a vacuum pump.

Caution If gauge needle does not move from 0 MPa (0 cmHg) to 0.1 MPa (-76 cmHg) in step 3. above, take the following measures:

3. Turn on the power switch of the vacuum pump and make sure that the needle in the gauge moves from 0 MPa (0 cmHg) to -0.1 MPa (-76 cmHg). Then evacuate the air for approximately ten minutes.

If the leaks stop when the piping connections are tightened further, continue working from step 3.

4. Close the Low side valve of the charging set and turn off the vacuum pump. Make sure that the needle in the gauge does not move for approximately five minutes.

If the leaks do not stop when the connections are retightened, repair the location of the leak.

BE SURE TO TAKE THIS PROCEDURE IN ORDERTO AVOID GAS LEAKAGE. 5. Disconnect the charging hose from the vacuum pump. 6. Charge the pipes and indoor unit with gas refrigerant from 3-way valve service port, and then discharge the refrigerant until low side (gas side) gauge needle indicates 0.3 MPa (3 kg/cm ). 7. Tighten the service port cap at a torque of 18 N m with a torque wrench. 8. Remove the valve caps of the 2-way valve and the 3way valve. Position both of the valves to "open" using a hexagonal wrench (4 mm).

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

11.4. BALANCE REFRIGERANT OF THE 2-WAY, 3-WAY VALVE (Lack of refrigerant in the refrigeration cycle)

Procedure: 1. Confirm that both the 2-way and 3-way valve are set to the open position. 2. Connect the charge set to the 3-way valve’s service port. · Leave the valve on the charge set closed. · Connect the charge hose with the push-pin to the service port. 3. Connect the charge set´s centre hose to refrigerant reclaiming equipment. · Purge the air from charge hose. 4. Open the valve (Low side) on the charge set and discharge the refrigerant until the gauge indicates 0.05 MPa (0.5 kg/cm G) to 0.1 MPa (1 kg/cm G). · If there is no air in the refrigeration cycle (the pressure when the air conditioner is not running is higher than 0.1 MPa (1 kg/cm G), discharge the refrigerant until the gauge indicates 0.05 MPa (0.5 kg/cm G) to 0.1 MPa (1 kg/cm G). If this is the case, it will not be necessary to apply an evacuation. · Discharge the refrigerant gradually; if it is discharged too suddenly, the refrigeration oil will also be discharged. 5. Turn on refrigerant reclaiming equipment.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

11.5. EVACUATION (No refrigerant in the refrigeration cycle)

Procedure: 1. Connect the vacuum pump adapter and vacuum pump to the charge sets centre hose. 2. Evacuation for approximately one hour. · Confirm that the gauge needle has moved toward -0.1 MPa (-76 cmHg) [vacuum of 4 mmHg or less.] 3. Close the valve (Low side) on the charge set, turn off the vacuum pump, and confirm that the gauge needle does not move (for approximately 5 minutes after turning off the vacuum pump). 4. Disconnect the charge hose from the vacuum pump. · Vacuum pump oil If the vacuum pump oil becomes dirty or depleted, replenish as needed.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

12 Servicing Information 12.1. INSPECTION POINTS FOR THE INDOOR ELECTRONIC CONTROLLER 1. The Electronic Controller, a Signal Receiver and an Indicator can be seen by removing the Front Grille and Control Board Cover, as shown in the Fig 1.

Fig. 1

12.2. INDOOR FAN MOTOR REMOVAL PROCEDURE 1. Remove the connector CN-MTR (GREEN) of Fan Motor and connector CN-STM (GREEN) of stepping motor from the electronic controller. Release the earth wire (YELLOW-GREEN) from the control board and sensors from its holders. (Refer Fig. 1) 2. Remove the Control Board The Control Board can be removed by releasing the top, left and right tabs shown in Fig. 2, 3, 4.

Fig. 2

Fig. 4

Fig. 3

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

3. Remove the Fan Motor Loosen the Fan Motor securing screw at the junction with Cross Flow Fan. (Fig. 5)

Fig. 5 Remove the particular piece and the Fan Motor can be taken off as shown in Fig. 6 and 7.

Fig. 6

Fig. 7

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

4. To fix the Indoor Fan Motor, ensure that the Fan Motor securing screw is positioned at the rear side and the Fan Motor lead wire is positioned parallelly with the Fan Motor. (Fig 8.)

Fig. 8

12.3. CROSS FLOW FAN REMOVAL PROCEDURE 1. Remove the Indoor Fan Motor. (Refer to the removal procedure of the Indoor Fan Motor.)

Fig. 9 2. Remove the Air Discharge Grille by taking off the screws that hold the Air Discharge Grille and then pull the Air Discharge Grille in a down and forward direction. 3. Pull off the Bearing at the left of the Cross Flow Fan. (Fig. 10)

Fig. 10

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

4. Take off the mounting tab at the left of the Heat Exchanger, pull the Heat Exchanger forward (left side) and remove the Cross Flow Fan. (Fig 11.)

Fig. 11

12.4. OUTDOOR UNIT SERVICING Outdoor Unit can be serviced by just removing the outdoor chassis front cover as shown in the Fig 12.

Fig. 12

12.5. REMOTE CONTROL RESET When the batteries are inserted for the first time, or the batteries are replaced, all the indications will blink and the remote control might not work. If this happens, remove the back cover of the remote control and you will find a resetting terminal, and by shorting it with a minus screwdriver, it will return to normal.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

12.6. CHANGING THE WIRELESS REMOTE CONTROL TRANSMISSION CODE When two indoor units are installed in the same room, in order to prevent operating errors caused by using two remote controls, set up the remote control [ B ←→ A ] switch (SW1). The unit is set to A when it is shipped.

· By adding a jumper wire to the remote control side and a carbon resistor ( 1/4 W, 10 kΩ Ω ) to the indoor printed circuit board, it is possible to select from 4 types of transmission codes including the condition at time of delivery (1) condition.

1 2 3 4

Remote control Switch SW B ←→ A J-B A B A Jumper wire B Jumper wire

Indoor printed circuit board Switch SW1 RX A B A 10k Ω B 10k Ω

53

Note At product delivery

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

13 Troubleshooting Guide

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

13.1. RELATIONSHIP BETWEEN THE CONDITION OF THE AIR CONDITIONER AND GAS PRESSURE AND ELECTRIC CURRENT Condition of the air conditioner Low Pressure

Cooling Mode High Pressure

Electric current during operation

Low Pressure

Heating Mode High Pressure

Electric current during operation

Insufficient refrigerant (gas leakage) Clogged capillary tube or Strainer Short circuit in the indoor unit Heat radiation deficiency of the outdoor unit Inefficient compression

· Carry out the measurements of gas pressure, electric current, and temperature fifteen minutes after an operationis started.

13.2. DIAGNOSIS METHODS OF A MALFUNNCTION OF A COMPRESSOR AND A 4-WAY VALVE Nature of fault Insuffic0ient compressing of a compressor

Symptom · Electric current during operation becomes approximately 20% lower than the normal value. · The discharge tube of the compressor becomes abnormally hot (normally 70 to 90 °C).

Locked compressor

Inefficient switches of the 4-way valve

· The difference between high pressure and low pressure becomes almost zero. · Electric current reaches a high level abnormally, and the value exceeds the limit of an ammeter. In some cases, a breaker turns off. · The compressor is a humming sound. · Electric current during operation becomes approximately 80% lower than the normal value. · The temperature difference between from the discharge tube to the 4-way valve and from suction tube to the 4-way valve becomes almost zero.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

14 Technical Data 14.1. THERMOSTAT CHARACTERISTICS

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

14.2. OPERATION CHARACTERISTICS

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

15 Electronic Circuit Diagram 15.1. HOW TO USE ELECTRONIC CIRCUIT DIAGRAM Before the circuit diagram, read the following carefully. Voltage measurement voltage has been measured with a digital tester when the indoor fan is set at high fan speed under the following conditions without setting the timer. Use them for servicing. Voltage indication is in Red at cooling and all operations. Voltage indication is in (Red) at heating.

Cooling Heating

Intake air temperature 27 20

Temperature Discharge air Pipe setting temperature temperature 16 17 15 30 40 50

Indications for resistance a. K .... k Ω W...watt b. type Not indicated

M....MΩ Not indicated.....1/4 W ........... ..........

carbon resister Tolerance ± 5 metal oxide resister Tolerance ± 1

Indications for capacitor a. Unit b. Type

µ .... µF P .... pF Not indicated .. ceramic capacitor (S) .......... S series aluminum electrolytic capacitor (Z) .......... Z series aluminium electrolytic capacitor (SU) ....... SU series aluminium electrolytic capacitor (P) .......... P series polyester system (SXE)...... SXE series aluminium electrolytic capacitor (SRA) .... SRA series aluminium electronic capacitor (KME) .... KME series aluminium electrolytic capacitor

Diode without indication ............ MA165 Circuit Diagram is subject to change without notice for further development.

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CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

15.2. ELECTRONIC CIRCUIT DIAGRAM CS-VA70KE / CU-VA70KE CS-VA90KE / CU-VA90KE CS-VA120KE / CU-VA120KE ELECTRONIC CIRCUIT

REMOCON NO. 0 1 2 3

SW1 OFF ON OFF ON

RX

R50 J1

+

L5 CWA 43036

CS-VA120KE CS-VA90KE CS-VA70KE 4.64k 7.68k 12.7k



SW1 A

R71 24k

5

5

B 0

RX

IC1 µPD78011CW

REMOTE CONTROL NO. RA1 10k X 3

5

AUTO RESTART

64 AVREF

1.4

DEICE BELOW 1.3V

2

62 P17

P22

3

61 P16

P23

4

P24

5

59 58 57

C26 16V 10µ

+

R23 20k

3



Fig.2 56

Fig.1

J5

2

INTAKE AIR TEMPERATURE SENSOR (15k,3950)

1

C25 16V 10µ

+

R22 15k

0



X1 8MHz (30pF X 2) R31 4.7k

ZD1 A54D8.2EL2TB

IC

PD PH302C 8

IN+

µPC2800GR Vcc1

1

c

7

IN-

OUT

2

6

CO

Vcc2

3

5

GND

F0

4

2

2

1

1

0.01µ

6.3V 47µ



C31 16V 10µ

R28 1k

R25 150k

R29 240

Q4 2SC1740S

C30 0.01µ



OUT 50 X1 IN 2.5 49 X2 VDO 5 48 R26 10k 47 46 45

5

NH-2 2 1 CN-TEST

44 43

+ 42



41 R32 2k

40 39

C32 0.01µ

38

RA2 10k X 4

INDICATOR

TIMER SLEEP

(RED) (ORANGE) (ORANGE)

36

1

1

2

2

3

3

0

R33 330 0

35 34

5

4

33

4

P26

8MHz OSC

BUZZER

RELAY DRIVE SIGNAL POWER CLOCK INPUT

P40

REMOTE- CONTROL COMMAND INPUT

P42 P43

RESET

P67

P65

FAN MOTOR DRIVE SIGNAL

P61 P60

P45

P50

TIMER SHORTEN

5

4.3k

RS

6

21.5k

2

SK

R/B

7

1

CS

V CC

8

FAN MOTOR CONTROL

P51 P52

39.2k

(1.9) 1.8

11

c

3k

0 (5)

18

20 21 22 23 24

7

2

12

20k

VOLTAGE CORRECTION

35.7k

10k

13

14

8.06k 1000P

8

d 9

22

SSR1

5

0

5

0

10

3

RY-HOT

39.2k

R38

D17

A54MA165TA5

R39

D18

A54MA165TA5

R40

D19

A54MA165TA5

R41

D20

A54MA165TA5

R42

D21

A54MA165TA5

R43

D22

A54MA165TA5

R44

D23

A54MA165TA5

R45

Q6

2SC1741AS

0

0

RY POWER DRIVE R46 2.2k

8

25 26 27 28

TEST RUN

P53 29

AUTO OPERATION

P54 30

1

5 C21 + 1000P –

MODEL R38 R39 R40 R41 R42 R43 R44 R45

R48 91

C22 10V 100µ

RY-PWR

+ –

R19 2.49k

4 C20 10V 100µ

CS-VA120KE 10.2k 8.45k 6.04k 4.64k 4.42k 3.74k 3.16k 2.80k

R18 7.15k

VR1 500

CS-VA90KE 10.2k 8.45k 8.45k 6.34k 5.62k 4.64k 3.83k 3.57k

CS-VA70KE 10.2k 8.45k 8.45k 6.34k 5.90k 5.36k 4.75k 4.75k

BUZZER DRIVE b

R47 1k

c

10k BZ

b

R72 10k

e

D6 ERA15-01

+ –

R17 1.74k

Q18 UN4211 D24 MA723

c

10k

C34 470µ

CWA 48004 e

1.6

1.6

R52 2.4k 1W

c

1.6

3.3

23.2k

51.1k A54MA165TA5

0

5

51.1k

D16

0

5.23k

1

a

6

AMP. 6

10 12

3

OSC

C33 100µ

5

7

b 4

7

PULSE SIGNAL GENERATOR

13k

5

8.87k

b

10k

Q7 UN4211

R53 2.4k 1W

10k c

e

3.3

b

P47

R54 2.4k 1W

10k

3.3

Q8 UN4211

3.3

10k c

e 3.3

b

10k

Q9 UN4211

3.3

10k e 5

e

P55

P57 P56

P44

P46

STEPPING MOTOR DRIVE SIGNAL

P64 P63

7

P41 19

FAN MOTOR CURRENT DETECTION

GND

DI

IC4 µPA2003C 5

15 P36 SHi 0 (5) 16 P37

P00

P66

5

V SS 17

POWER

DO

3

2.94k

START 8 P27 MID.START 9 P30 SLo 10 P31 Lo11 P32 Lo 12 P33 Me 13 P34

P01

RESET

6

4

DISPLAY GND

V SS

31 32

5

0

Q10 UN411F

10k b

4.7k R55 750

c 1.6 e

IC4 µPA2003C

(GREEN) (KR-5) CN-STM 1 2 3 4 5

FAN MOTOR SPEED CONTROL

2

5

R34 330

CN-DISP (KR-4)

Q11 UN411F

R35 330

9

a

GND CHECK PIN b

R56 750 c

1

15

10k b

4.7k

STEPPING MOTOR DRIVE 16

2

L6 CWA 43036

1.6

R57 750

e

Q12 UN411F

10k b

4.7k 14

STEPPING MOTOR (HORIZONTAL VANE)

P02

P25

0

Hi 5 (0) 14 P35

37 P62 (PH-4) CN-DISP

ON/OFF

FAN SPEED CONTROL SIGNAL

52 XT2

2.7

C42 50V 1µ

R37 2k

PIPE TEMP. INTAKE AIR TEMP.

53 P04

C29 16V 10µ

R21 5.1k

R27 5.1k

(SHIELD CASE)

SW2 (AUTO SW)

RELAY DRIVE SIGNAL

55 P10

2.5

RESET SIGNAL GENERATION

CN-RCV (KR-3)

137k

P11

DEICE DETECTION

51 IC(VPP)

e

e

+ –

c

3

0.01µ +

b

10K

3



R30 100K

10K

(PH-3) CN-RCV

P12

SSR DRIVE SIGNAL

2.5

Q5 UN4211 b

+ +

R36 2k

RECEIVER

P13

REMOTE- CONTROL NO. DETECTION

54 AV SS C44 10V 100µ

SW3 (PUMP DOWN SW)

P14

J2

5

1

P21

Fig.2 4

PIPE TEMPERATURE SENSOR (20k,3950)

P20

63 AVDD

60 P15 0

(YELLOW) (XH-4) CN-TH1

IC7 A52BX7809

IC5 A54BR9011B

R70 10K

MICRO COMPUTER

R50

10k 10k

C24 10V 100µ

c

3

c 1.6

13

d

4

8

61

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

1 2 3 4

AC 14

TEMPERATURE FUSE 99 C 1

+ C14 35V – 3300µ

R12 51k

+

C19 1000P

C17 0.1µ

C2 250VAC 0.082µ ECQ-UV

R14 5.1k

ECQV

e

Q3 UN4211

T1 CWA40235

C8 630V 2200P

L3 CWA43036

ECQF 11

L4 CWA43036 C10 0.18µ

AC 15

L2 CWA43036

SXE



R7 32.4k

AMP 18

1

C11 0.01µ 19

e

Q16

(29) 28

2

c

e

+ –

C6 450V 100µ

4

6 2 8

7

FAN MOTOR

DB1 A54D3SBA60F1

BLUE

R2 560k 1/2W

RED

BLUE

CAPACITOR BLUE BLUE

4

A52STA302A

FAN MOTOR DRIVE 3

8 1 (28) 27

YELLOW

D3 1SS131

2 4 27 (28)

25 (28)

BLUE

6 b 3

c 5

(GREEN) (XH-3) CN-MTR

7 14 (15) 14 (15)



C35 50V 10µ

R49 620

Q13 UN4211 b

FAN MOTOR

3.0

FAN MOTOR COIL RESISTANCE (AT 20 C) CWA98244....CONNECTOR 1 AND 2 , 2 AND 3 , 1 AND 3 6.1

c

10k

3.3

R51 3.3k 1W

10k 3 a 0.5

5 b

7 e

c

b

10k 10k

3.0

6.0 7

0.5

4 6

R61 7.5k 8

5

4

6

D8

R62 5.1k

D9

R63 5.1k

D10

R64 5.1k

D11

R65 10k

D12

R66 10k

D13

R67 10k

+ – 8.5 (8.2)

R59 510k

c

3.3

0.5

C36 50V 10µ

3.0

Q14 UN4211

2

C39 1000P

C37 1000P

e

Q15 UN4211 8 1

b

Q17

A52STA303A

c

IC6 A52MPC393C

10k

3.3

FAN SPEED CONTROL

10k

FAN MOTOR DRIVE R58 5.1k

e

C40 1000P

COMPRESSOR TERMINAL

U 3 V 2 W 1

14 (15)

+

RED TRADE MARK

a

8.8 (8.5)

R60 3.32k

C38 1000P

D8-D13 A54MA165TA5 X 6

D7 A54MA164TA5

62

GRY

FOR CU-VA120KE

FOR CU-VA90KE

MAGNETIC RELAY A

4

YELLOW

C5 250VAC 0.047µ

L1 CWA 43101

R5 36

AC 0.01

RED

ECQ-UV

b

R4 24 1W

5

7

BROWN 2

GRAY

+

D.C A.C CONVERTER

T2 CWA40263

R9 1.5k

8

GRAY

6

LF1 CWA49148 C7 ?

D1 A54RB44-08V

b

200

ECQ-UV

AC 40

Q1 2SC4300M c

ECQ-UV

ELECTROLYTIC CAPACITOR

2

R8 0.47 1W

Q2 2SD2220

C3 250VAC 0.01µ

MAGNETIC RELAY B

D2 MA649

RED CAPACITOR

C3 250VAC 0.01µ

4

8 C18 25V 4.7µ

BLUE WHITE

R3 82k

C9 50V 680µ

R6 + 10k –

ECQV

+

R10 10k

C12 33µ



COMPRESSOR

C1 250VAC 0.082µ ECQ-UV

R1 7.5

b

10k

(28) 29

YELLOW YELLOW

BLACK BLACK

10k

YELLOW

BLACK

D4 A54MA723TA

c

C23 0.022µ

R15 24.9k

FUSE 3.15A ZNR1 CWA54C036 TRS

D15 A54MA165TA5 C13 10µ

REGULATOR

A56W2DEH1-5

WHITE

G

IC3 AN78N05

0.5 (0.6)

WHITE

COIL REVERSING VALVE

R13 + 10k –



CR1 CWA59015

19

I

12V

~

+

O C15 25V 100µ



G

12

+

C28 25V 100µ

RY-PWR CWA 00106

~



12

ZNR2 ERZ-TCEAK471

SSR1

~

+

I

5V

RY-HOT CWA00161



O

AC (WHT/GRY)

CT1 CWA40322

DB2 S1VB10

REGULATOR 5

T (BLK/ WHT)

AC (BRW)

BLACK

IC2 A52MPC78M12H

R20 10k

FM (BLU)

GRY

FOR CU-VA70KE

HOT (RED)

BLACK

2

~

3 2 1

GRY

BLACK

(VH-2) CN-T

T (BLK/ WHT)

(XH-3) BLUE CN-FUSE

C16 16V 100µ

BLACK

TRANSFORMER CWA40C246 TEMPERATURE FUSE 102 C

POWER SUPPLY SWITCH

OVER LOAD PROTECTOR

1 2 3 4

ELECTROLYTIC CAPACITOR

AC230V 50Hz SINGLE PHASE

YELLOW

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

15.3. CHARACTERISTICS CHART Fig.1

Fig.2

Sensor (Thermistor) Characteristics

70

Intake Air/ Pipe Temp. Data

1 Pipe Temp.Sensor 2 Intake Air Temp.Sensor

4 Voltage (V)

60

Resistance (k½)

50 1

40

2

30

3 2

Intake Air Temp.Data IC1 56 Pin

1

20

0

Pipe Temp. Data IC1 57 Pin

0

10 20 30 40 50 60 70 Temperature(°C)

10 0

0

-10

10

20

40

30

50

Temperature(°C)

Fig.3

Indoor Fan Speed Fan Speed

High Speed 8

No.

7

6

Low Speed

5

4

3

2

1

0

Manual Cooling

Auto Sleep

Soft Dry Manual Auto

Heating

Sleep Voltage to Fan Moter Drive Transister(V)

CS-VA70KE

21.0 21.0 18.6 17.0 15.8 11.0 11.0

7.2

0

CS-VA90KE

26.7 25.9 21.5 18.1 15.8 11.0 11.0

7.2

0

CS-VA120KE

32.0 31.0 26.0 22.5 21.5 16.5 11.0

7.2

0

Shi

Fig.4

Hi

Lo

Lo-

MID START STOP SLo START

TRS Characteristics 4 °C -3 °C

OPEN CLOSE

Fig.5

Me

OLP Characteristics (Compressor)

CS-VA70KE(CWA12304)

CS-VA90KE(CWA12298)

20

20

10

10

5 4 3

5 4 3 20

40

60

80

100

120

140

20

CS-VA120KE(CWA12364) 20 10 5 4 3 20

40

60

80

100

120

140

63

40

60

80

100

120

140

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

15.4. REMOTE CONTROLLER

64

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

15.5. TIMER TABLE Name

Time

Sleep Mode Waiting Sleep Mode Operation Real Timer Time Delay Safety Control Forced Operation Time Save Control Anti-freezing Control Soft Dry Off Indoor Fan Step Change Heating Operation Start Deicing Overload Deicing Outdoor Fan Forced Operation Outdoor Fan OFF Time Accumulation Ending of Deice Operation After Deice Ended 4-way Valve Control Mode judgement Deice End judgement

TRS Recovery Detection

Hot-start-Comp.Forced ON Time Cooling Deodorizing Control Soft Dry

Comp.Reverse Rotation Detection Comp./Fan Motor Delay Timer Intake Air Anti-Freezing Prevention Outdoor Fan Delay Timer

1 hr. 8 hrs. 1 h. 10 min. 1 min. 2 min. 58 sec. 60 sec. 7 min. 4 min. 6 min. 1 sec. 30 min. 60 min. 4 min. 50 sec. 1 min. 30 sec. 60 min. 12 min. 30 sec. 10 sec. 5 min. 20 sec. 60 sec. 120 sec. 180 sec. 12 min. 6 min. 3 min. 1 min. 30 sec. 40 sec. 70 sec. 20 sec. 180 sec. 180 sec. 40 sec. 360 sec. 5 min. 2 min. 1.6 sec. 16 min. 1.6 sec.

65

Test Mode (When test point Shortcirculated) 6 sec. 48 sec. 1 min. 10 sec. 1 sec. 0 sec. 0 sec. 42 sec. 0 sec. 36 sec. 0 sec. 3 sec. 6 sec. 24 sec. 0 sec. 6 sec. 3 sec. 360 sec. 72 sec. 3 sec. 1 sec. 30 sec. 0 sec. 0 sec. 0 sec. 0 sec. 72 sec. 36 sec. 18 sec. 6 sec. 0 sec. 4 sec. 7 sec. 2 sec. 18 sec. 18 sec. 4 sec. 36 sec. 30 sec. 0 sec. 0 sec. 96 sec. 0 sec.

Remarks

60 min. after previous Deice Comp. ON continuously for 4 min. TRS ON continuously for 50 sec. Comp. ON 1 min. and above

Outdoor Fan ON, Compressor OFF 4-way Valve ON

Comp. Comp. Comp. Comp. Comp. Comp. Comp. Comp.

ON ON OFF OFF OFF ON OFF ON 5 min. and above

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

16 Printed Circuit Board 16.1. INDOOR UNIT (MAIN)

66

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17 Exploded View & Replacement Parts List 17.1. CS-VA70KE / CS-VA90KE 17.1.1. Exploded View

67

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.1.2. Replacement Parts List Ref.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

CS-VA70KE / CS-VA90KE CWD50C202 CWA98244 CWH02C053 CWH4580304 CWH64K007 CWB30C257 CWT01C605 CWH6002140 CWT25005 CWE20C480 CWA98245 CWH52C003 CWE24394 CWH10887 CWA28C469 CWA20C620 CWA04088 CWA40C246 CWA741450 (CS-VA70KE) CWA741451 (CS-VA90KE) CWA74321 CWE39C271 CWA50C521 CWH13396 CWH13C256 CWH13385 CWA75C556 CWE11C590 CWE22C287 CWD93C070 CWD00215 XTN4+16C CWH52230 CWH5880580 CWF561578 CWF61659 CWH36122 CWH82C144 CWD00C111 CWD00220

DESCRIPTION & NAME CHASSY COMPLETE FAN MOTOR CROSS FLOW FAN COMPLETE SCREW-CROSS FLOW FAN BEARING ASS’Y EVAPORATOR TUBE ASS’Y COMPLETE FLARE NUT (1/4”) FLARE NUT (3/8”) DISCHARGE GRILLE COMPLETE MOTOR-AIR SWING TAP-DRAIN TRAY VANE CONTROL BOARD TERMINAL BOARD COMPLETE POWER SUPPLY CORD SLIDE SWITCH TRANSFORMER COMPLETE ELECTRONIC CONTROLLER ELECTRONIC CONTROLLER RECEIVER INDICATOR COMPLETE SENSOR COMPLETE CONTROL BOARD TOP COVER CONTROL BOARD FRONT COVER CONTROL BOARD COVER PIECE REMOTE CONTROL COMPLETE FRONT GRILLE COMPLETE INTAKE GRILLE COMPLETE PARTICULAR PIECE AIR FILTER SCREW-FRONT GRILLE CAP-FRONT GRILLE DRAIN HOSE OPERATING INSTRUCTIONS INSTALLATION INSTRUCTIONS INSTALLATION PLATE BAG COMPLETE-INSTALLATION SCREW AIR PURIFYING FILTER COMPLETE AIR PURIFYING FILTER

(Note) ∙ Spare parts are supplied from ; "M" is from MACC, Malaysia (Vender code : 086). "J" is from Japan. ∙ "●"marked parts are recommended to be kept in stock.

68

Q’TY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 2

Remarks M M M M M J J M J M M M M M M M M M J J M M M J M M M M M M M M M M J J M M M M





● ● ● ● ● ● ● ●





CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.2. CS-VA120KE 17.2.1. Exploded View

69

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.2.2. Replacement Parts List Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

CS-VA120KE CWD50C202 CWA98244 CWH02C053 CWH4580304 CWH64K007 CWB30C211 CWT01C2037 CWH6002140 CWT25096 CWE20C481 CWA98245 CWH52C003 CWE24394 CWH10887 CWA28C470 CWA20C620 CWA04088 CWA40C246 CWA742124 CWA74321 CWE39C271 CWA50C521 CWH13396 CWH13C256 CWH13385 CWA75C556 CWE11C590 CWE22C287 CWD93C070 CWD00215 XTN4+16C CWH52230 CWH5880580 CWF563048 CWF612033 CWH36122 CWH82C144 CWD00C111 CWD00220 CWA16C126

DESCRIPTION & NAME CHASSY COMPLETE FAN MOTOR CROSS-FLOW FAN SCREW-CROSSFLOW FAN BEARING ASS’Y EVAPORATOR TUBE ASS’Y COMPLETE FLARE NUT (1/4”) FLARE NUT (1/2”) DISCHARGE GRILLE COMPLETE MOTOR-AIR SWING CAP-DRAIN TRAY VANE CONTROL BOARD TERMINAL BOARD COMPLETE POWER SUPPLY CORD SLIDE SWITCH TRANSFORMER COMPLETE PC BOARD WITH COMPONENT PC BOARD WITH COMPONENT INDICATOR COMPLETE SENSOR COMPLETE CONTROL BOARD COVER CONTROL BOARD COVER CONTROL BOARD COVER REMOTE CONTROL COMPLETE FRONT GRILLE COMPLETE INTAKE GRILLE COMPLETE PARTICULAR PIECE AIR FILTER SCREW-FRONT GRILLE CAP FRONT GRILLE DRAIN HOSE OPERATING INSTRUCTIONS INSTALLATION INSTRUCTIONS INSTLLATION PLATE BAG COMPLETE-INSTALLATION SCREW AIR PURIFYING FILTER COMPLETE AIR PURIFYING FILTER FUSE ASSY

(Note) ∙ Spare parts are supplied from ; "M" is from MACC, Malaysia (Vender code : 086). "J" is from Japan. ∙ "●"marked parts are recommended to be kept in stock.

70

Q’TY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 2 1

Remarks M M M M M J J M J M M M M M M M M M J M M M J M M M M M M M M M M J J M M M M M



● ● ●

● ● ● ● ● ● ●



● ●

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.3. CU-VA70KE / CU-VA90KE 17.3.1. Exploded View

71

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.3.2. Replacement Parts List Ref.No. 1 1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 16 17 18 18 19 20 21 22 22 23 23 24 24 25 26 27 28 29 29 30 31 32 33 34 35 36 37 38 39 40

CU-VA70KE / CU-VA90KE CWD50K438F (CU-VA70KE) CWD50K456D (CU-VA90KE) CWD54113 CW4580399 CWA95245 CWH55406 CWH00K037 CWH56032 CWB09722 (CU-VA70KE) CWB09729 (CU-VA90KE) CWH50077 CWH56000 CWB32C328 H35074C CWB01488 CWB02520 CWB00048 CWT01C609 (CU-VA70KE) CWT01C610 (CU-VA90KE) CWB14013 CWT01C613 (CU-VA70KE) CWT01C645 (CU-VA90KE) CWB10036 CWA43C677 CWH15C081 CWA12304 (CU-VA70KE) CWA12298 (CU-VA90KE) CWH17006 (CU-VA70KE) CWH17038 (CU-VA90KE) CWH7041200 (CU-VA70KE) CWH34033 (CU-VA90KE) CWH7080300 CWG30786 CWH10881 CWA28K216 CWA31653 (CU-VA70KE) CWA31646 (CU-VA90KE) CWH30057 CWA31342 CWA00059 CWA4711012 CWA32C045 CWA32C067 CWA14C000 CWE00K198B CWE06C046E CWH13302 CWE16037C

DESCRIPTION & NAME CHASSY ASS´Y CHASSY ASS´Y FAN MOTOR BRACKET SCREW-FAN MOTOR BRACKET FAN MOTOR SCREW-FAN MOTOR MOUNT PROPELLER FAN NUT-PROPELLER FAN COMPRESSOR COMPRESSOR ANTI-VIBRATION BUSHING NUT-COMPRESSOR MOUNT CONDENSER HOLDER COUPLING ASS´Y 3-WAY VALVE 2-WAY VALVE 4-WAY VALVE TUBE ASS´Y (RECEIVER) TUBE ASS´Y (RECEIVER) RECEIVER TUBE ASS´Y (CHECK VALVE, CAPILLARY) TUBE ASS´Y (CHECK VALVE, CAPILLARY) DRYER V-COIL COMPLETE SOUND PROOF BOARD OVERLOAD PROTECTOR OVERLOAD PROTECTOR TERMINAL COVER TERMINAL COVER HOLDER-O.L.P. HOLDER-O.L.P. NUT-TERMINAL COVER SOUND PROOF MATERIAL CONTROL BOARD TERMINAL BOARD ASS´Y CAPACITOR-COMPRESSOR CAPACITOR-COMPRESSOR HOLDER CAPACITOR CAPACITOR-FAN MOTOR (1.2 µF, 400 V) ELECTRO MAGNETIC SWITCH TERMINAL BOARD ASS´Y ELECTROLYTIC CAPACITOR ELECTROLYTIC CAPACITOR THERMO RELAY CABINET ASS´Y CABINET FRONT PLATE CONTROL BOARD COVER HANDLE

(Note) ∙ Spare parts are supplied from ; "M" is from MACC, Malaysia (Vender code : 086). "J" is from Japan. ∙ "●"marked parts are recommended to be kept in stock.

72

Q’TY 1 1 1 4 1 3 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

Remarks J J J M M M M M J J M M J J J J J J J J J J J M M M M M M M M M M M M M M M M M M M M M M M M M



● ●

● ● ●

● ● ● ●



● ●

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.4. CU-VA120KE 17.4.1. Exploded View

73

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

17.4.2. Replacement Parts List Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

CU-VA120KE CWD50K612B CWD54260 CWH4580399 CWA95230 CWH55406 CWH03K002 CWH56032 CWB092012 CWH50055 CWH56000 CWB32C1010 CWH35180A CWB011005 CWB021003 CWB00048 CWB14010 CWT01C2039 CWB10036 CWA43C691 CWH151004 CWA12364 CWH17006 CWH34033 CWH7080300 CWG30888 CWH10878 CWA28K216 CWA31647 CWH30057 CWA31342 CWA00059 CWA4711012 CWA32C067 CWA32C084 CWA14C000 CWE00K240A CWE06C125A CWH13C286 CWE16037C

DESCRIPTION & NAME CHASSY COMPLETE BRACKET FAN NOTOR SCREW-FAN MOTOR BRACKET FAN MOTOR SCREW-FAN MOTOR MOUNT PROPELLER FAN NUT-PROPELLER FAN COMPRESSOR ANTI-VIBRATION BUSHING NUT-COMPRESSOR MOUNT CONDENSER HOLDER-COUPLING 3-WAY VALVE 2-WAY VALVE 4-WAY VALVE RECEIVER TUBE ASSY (EXP.VALVE.CAPILLARY) DRYER 4-WAY VALVE COIL SOUND PROOF BOARD OVERLOAD PROTECTOR TERMINAL COVER HOLDER-OLP NUT SOUND PROOF MATERIAL CONTROL BOARD TERMINAL BOARD COMPLETE SH CAPACITOR HOLDER-CAPACITOR SH CAPACITOR ELECTRO MAGNETIC SWITCH TERMINAL BOARD COMPLETE CAPACITOR CAPACITOR THERMO RELAY CABINET COMPLETE CABINET FRONT COMPLETE CONTROL BOARD COVER HANDLE

(Note) ∙ Spare parts are supplied from ; "M" is from MACC, Malaysia (Vender code : 086). "J" is from Japan. ∙ "●"marked parts are recommended to be kept in stock.

74

Q’TY 1 1 4 1 3 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

Remarks J J M J M M M J J M J J J J J M J J J J J M M M J M M M M M M M M J M J J M M





● ● ● ● ● ● ●

● ● ●

CS-VA70KE / CU-VA70KE / CS-VA90KE / CU-VA90KE / CS-VA120KE / CU-VA120KE

18 Electronic Parts List ( Model:CWA741450 / CWA741451 / CWA742124 ) SYMBOL BZ CT D1 D2 D3 D6 D24 D7 D13,D15 D23 DB1 DB2 FUSE IC1 IC1 IC1 IC2 IC3 IC4 IC5 IC6 IC7 L1 L2 L6 LF1 Q1 Q10 Q12 Q16 Q17 Q2 Q3,Q5,Q7 Q9,Q13 Q15,Q18 Q4 Q6 RY-HOT RY-PWR SSR1 SW1 SW2,SW3 T1 T2 VR1 X1 ZD1 ZDR1

PART NO.

DESCRIPTION & NAME SOUND GENERATOR TRANSFORMER DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE FUSE INTEGRATED CIRCUIT (CWA741450) INTEGRATED CIRCUIT (CWA741541) INTEGRATED CIRCUIT (CWA742124) INTEGRATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT V-COIL V-COIL NOISE FILTER TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR ELECTRO MAGNETIC RELAY ELECTRO MAGNETIC RELAY TYRISTOR SLIDE SWITCH PUSH SWITCH TRANSFORMER TRANSFORMER VARIABLE RESISTOR RESONATOR DIODE DIODE

CWA48004 CWA40322 RB44-8V CWA54C197 1SS131T RA15-01KB MA723TA MA165TA5 D35BA60F1 1VB10E XBA2C31TRO UPD011W191 UPD011W231 UPD011W213 UPC78M12H CWA52C040 UPA2003C BR9011B UPC0393C BX7809 CWA43101T CWA43036 CWA49184 CWA55C081 DTA143XST STA302A STA303A 2SD2220QTA DTC114EST 2SC1740STPQ 2SC1741ASTR CWA00161 CWA00106 W2DEH1-5 CWA04042 CWA01059 CWA40235 CWA40263 VG67TP152 CST8.0MTWT RD8.2EL2TB CWA54C036

(Note) ∙ Spare parts are supplied from ; "M" is from MACC, Malaysia (Vender code : 086). "J" is from Japan.

75

REMARKS M M M M M M M M M M M J J J M M M M M M M M M M M M M M M M M M M M M M M M M M M M

MEMO :

MEMO :

Printed in Japan MS1299SO