Toshiba MAR-F105HTM8-PE DATA BOOK

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Page 1

A90-0233

Super Multi System

Service Manual

Air Conditioner - Multi Split Type System

HFC R407C

Page 2

Contents

Introduction

Precautions .......................................................................................................................................... 4

Components ......................................................................................................................................... 6

Outline of control system ...................................................................................................................... 9

Parts specification

Outdoor unit - general ......................................................................................................................... 12

Outdoor unit - refrigeration parts ......................................................................................................... 13

Outdoor unit - inverter assembly......................................................................................................... 14

Multi Controller - general .................................................................................................................... 15

Construction views

Outdoor unit........................................................................................................................................ 16

Multi Controller ................................................................................................................................... 17

Wiring diagram

Outdoor unit........................................................................................................................................ 18

Multi Controller ................................................................................................................................... 20

Refrigeration schematic

Outdoor unit........................................................................................................................................ 21

Normal operation - heat mode ............................................................................................................ 22

Normal operation - cool mode ............................................................................................................ 23

Simultaneous operation - mainly heat ................................................................................................. 24

Simultaneous operation - mainly cool ................................................................................................. 25

Diagnostic procedure

Diagnostic - outdoor unit ..................................................................................................................... 26

Diagnostic - Multi Controller unit ......................................................................................................... 32

Fault code display

Self-diagnostic function ...................................................................................................................... 34

Troubleshooting

Fault code table .................................................................................................................................. 36

Diagnostic procedure for check code ................................................................................................. 37

Control features ..................................................................................................................................... 63

Valve and sensor function and operation

Multi Controller valve function and operation ...................................................................................... 65

Outdoor unit valve functions ............................................................................................................... 66

Manual operation of valves ................................................................................................................. 67

Sensor and switch operation .............................................................................................................. 68

Refrigeration pipe installation

Leak test ............................................................................................................................................. 69

Vacuuming ......................................................................................................................................... 70

Charging ............................................................................................................................................. 71

Piping ................................................................................................................................................. 72

Additional refrigerant .......................................................................................................................... 73

Service parts list

Outdoor unit exploded views .............................................................................................................. 74

Inverter exploded view........................................................................................................................ 77

Multi Controller exploded view ............................................................................................................ 78

Multi Controller electrical parts ........................................................................................................... 79

Page 3

Introduction

Precautions

Please read these instructions carefully before starting the installation.

This equipment should only be installed by suitably trained operatives.

In all cases ensure safe working practice: Observe precautions for persons in the vicinity of the works.

Ensure that all local, national and international regulations are satisfied.

Check that the electrical specifications of the unit meet the requirements of the site.

Carefully unpack the equipment, check for damage or shortages. Please report any damage immediately.

Model MAR-F105HTM8-PE complies with the following EU Directives:

73/23/EEC (Low Voltage Directive), 89/336/EEC (Electromagnetic Compatibility) and 97/23/EC (Pressure Equipment Directive). Accordingly, they are designated for use in commercial and industrial environments.

97/23/EC Pressure Equipment Directive information

Conformity assessment procedure: Module D1 Pressure equipment:

Compressor, category II, Module A1 Liquid receiver, category II

Accumulator, category I High pressure switch, category II, Module A1 Notified body for inspection and quality assurance systems: BSI, Maylands Avenue, Hemel Hempstead, WP2 4SQ, UK.

Avoid installation in the following locations:

Where there is danger of flammable gas leakages.

Where there are high concentrations of oil.

Where the atmosphere contains an excess of salt (as in coastal areas). The air conditioner is prone to failure when used under this condition unless special maintenance is provided.

Where the airflow from the outdoor unit may cause annoyance.

Where the operating noise of the outdoor unit may cause annoyance.

Where the foundation is not strong enough to fully withstand the weight of the outdoor unit.

Where the water drainage may cause a nuisance or a hazard when frozen.

Where strong winds may blow against the air outlet of the outdoor unit.

Precautions for R407C outdoor units

R407C outdoor units use synthetic oils which are extremely hygroscopic. Therefore ensure that the refrigerant system is NEVER exposed to air or any form of moisture.

Mineral oils are unsuitable for use in these units and may lead to premature system failure.

Use only equipment which is suitable for use with R407C. Never use equipment which has been used with R22.

R407C should only be charged from the service cylinder in the liquid phase. It is advisable to use a gauge manifold set equipped with a liquid sight glass fitted in the centre (entry) port.

Page 4

Introduction

Precautions

Precautions for R-407C outdoor units

Liquid receiver fusible plug

In the event of the system being subjected to abnormal conditions it is protected by a fusible plug, positioned on the liquid receiver, within the outdoor unit. It is rated to fail at 70°C.

Position of fusible plug

System pressure measurement

To measure the system’s high and low pressures, connect a gauge manifold to the corresponding access port as indicated below.

Low pressure access port

High pressure access port

Explanation of Toshiba serial number

A serial label is attached to all Toshiba air conditioning units. Located on the label is an 8-digit number, which represents the month, year and batch number of the manufactured unit. A breakdown of the 8-digit number is defined below.

24480001

}

j jj

Year of

manufacture

2001 = 1 2002 = 2 2003 = 3

Month of

manufacture

41 = Jan. 42 = Feb. 43 = Mar. 44 = Apr. 45 = May 46 = Jun. 47 = Jul. 48 = Aug. 49 = Sep. 50 = Oct. 51 = Nov. 52 = Dec.

Site of

manufacture

8 = Plymouth

Model batch serial number

Page 5

Introduction

Components

Components - 3 pipe system

1. Outdoor unit

Model name Inverter unit MAR-F105HTM8-PE 10 HP

2. Multi Controllers

Model name No. of indoor units connectable RBM-Y1034F-PE 3 RBM-Y1044F-PE 4

3. Interface control kit

Model name Requirement RBC-16DIF1-PE 3 or 4 Multi Controllers used on a system

Combination of Multi Controllers, indoor units and interface kits

No. of No. of 3-way No. of 4-way No. of indoor units Multi Controllers Multi Controllers interface kits

1-8 1-2 Multi Controllers 0 930 1 10 2 1 1 11 1 2 1 12 0 3 1 13 3 1 2 14 2 2 2 15 1 3 2 16 0 4 2

Page 6

Introduction

Operating conditions

• Operating conditions of the unit are as follows:

Outdoor temperature -5 ~ 43°C Cooling

-15 ~ 21°C Heating

Room temperature 18 ~ 32°C Cooling

15 ~ 29°C Heating

Room humidity <80% Cooling

Note 1: Cooling capacity is rated at the following temperature conditions:

Indoor air inlet temperature 27°C DB, 19°C WB. Outdoor air inlet temperature 35°C DB.

Note 2: Heating capacity is rated at the following temperature conditions:

Indoor air inlet temperature 20°C DB. Outdoor air inlet temperature 7°C DB, 6°C WB.

Note 3: For details about the outdoor unit, indoor units or remote controller installation refer to the relevant

literature, i.e. Installation Instructions supplied with the units.

Note 4: Operatives handling refrigerants must be suitably qualified in accordance with local and national

codes of practice and statutory requirements.

Note 5: Legislation may regulate the removal of waste refrigerant from the systems. We advise

awareness of any regulations and duty of care. Waste refrigerant must NEVER be discharged to atmosphere.

Note 6: Electrical work should be in accordance with all relevant codes of practice and should be carried

out by suitably qualified personnel.

Note 7: Metric/Imperial pipe conversion.

Diameter (mm) 6.4 9.5 12.7 15.9 19.0 22.0 28.6 Nominal diameter (inch) 1/4 3/8 1/2 5/8 3/4 7/8 1-1/8

Note 8: Within this manual:

ODU = Outdoor Unit IDU = Indoor Unit R/C = Remote Controller D.O.L. = Direct On-Line compressor INV = Inverter ODU WB = Wet Bulb DB = Dry Bulb IOL = Inner Overload Relay Mg-Sw = Magnetic Contactor IGBT = Inverter Gate Bi-Polar Transistor OCR = Over Current Relay IPDU = Intelligent Power Drive Unit M/C = Multi Controller

Note 9: MPaG ⇒ kgf/cm2G conversion multiplier

1.0 MPaG = 10.2 kgf/cm2G

Page 7

Introduction

Super multi system basic components

3-pipe heat pump with simultaneous heating and cooling

This system allows separate operation of each indoor unit in either heating or cooling simultaneously.

3 pipes

3-pipe outdoor unit

T-pieces

Multi Controller

Indoor unit remote controller requesting cooling

Cooling operation

Indoor unit remote controller requesting heating

Heating operation

Indoor units

Remote controller

2 pipes

Page 8

Introduction

Outline of control system

The refrigerant and electrical systems of the Super Multi air conditioner are controlled by the Multi Controller and the outdoor unit microprocessors.

All RAV heat pump, R-407C, 4/5 series indoor units are compatible with the Super Multi system, i.e. 1~5 HP.

For system operation, initially the microprocessor in each indoor unit calculates the difference between the current room temperature (TA) and the requested temperature which has been set on the remote controller. A demand signal is determined and transmitted to the Multi Controller microprocessor in the form of operation commands (i.e. ON/OFF, cooling or heating operation mode, operation demand frequency).

The Multi Controller microprocessor receives operation commands from all indoor units connected, calculates the accumulative operation command and transmits this information to the outdoor unit interface microprocessor.

The interface microprocessor calculates the capacity required for heating or cooling and determines the operation mode of the outdoor unit and the actual frequency of the compressor.

Control system diagram

Indoor unit 1-A

Fan

Temp. sensor (TA)

Drain pump

Indoor unit microprocessor

Remote controller

1 - B

1 - C

1 - D

Multi Controller 1

Capacity rank setting switch

Pulse modulating

valve

Display LED

2-way valve

Outdoor unit

Protection unit

Comp. sensor

Temp. sensorTemp. sensor

Pulse modulating

valve

Interface microprocessorMulti Controller microprocessor

D.O.L. compressor

Display LED

2-way valve

Fan

2 - A

2 - B

2 - C

2 - D

Multi Controller 2

Multi Controller microprocessor

4-way valve

Communication

PCB

IPDU

Protection

unit

Inverter

compressor

Inverter

Power supply

Page 9

Introduction

Components

Setting of indoor unit capacity codes

• The setting of the indoor unit capacities is important. Set the correct indoor unit code numbers

according to the indoor unit capacity. The capacities are set by the rotary switches on the printed circuit board switch A (unit A), switch B (unit B), switch C (unit C) and switch D (unit D).

• During manufacture, the indoor capacity selection switches are set at ‘0’.

• Record the indoor capacity codes, indoor unit model names and locations in the installation manual,

and on the wiring diagram on the electrical panel cover.

Example: Room A Room B Room C

Capacity 16 Capacity 16 Capacity 26

Indoor unit Capacity No connection 10 13 16 20 26 36 46

Code number 0 2 3 4 5 6 8 10

(Example: Model RAV-364UH-PE, capacity = 36)

Multi Controller PCB

MCC-1210

Capacity select switches

• Multiple indoor units may be connected to each outdoor unit, providing the total indoor code does not

exceed the limits shown below.

Combination of Multi Controllers and indoor units

Number of Maximum No. of Indoor unit diversity Maximum system code Maximum code per Multi Controllers indoor units Multi Controller

1 4 135% 27 27 2 8 160% 32 27 3 12 27 (13*) 416 13

Example of systems with maximum possible code:

Outdoor unit

Interface kit

Multi Controller [code] (Max. system code)

OD OD

27 266668888

(27) (32)(32)

OD OD

27 13

27 2713 13 13 13 13

DIF

DIF DIF DIF

(32)

DIFDIF

Page 10

Introduction

Components

Indoor units

Type Appearance Model name Capacity code on

Multi Controller

Cassette (4-way) RAV-164UH-PE 4

RAV-264UH-PE 6 RAV-364UH-PE 8 RAV-464UH-PE 10

Cassette (2-way) RAV-104TUH-1-PE 2

RAV-134TUH-1-PE 3 RAV-164TUH-1-PE 4

RAV-104SBH-PE 2

Built-In Horizontal

RAV-164BH-PE 4 RAV-264BH-PE 6 RAV-364BH-PE 8 RAV-464BH-PE 10

Ceiling Suspended RAV-134CH/CHR-PE 3

RAV-164CH/CHR-PE 4 RAV-264CH/CHR-PE 6 RAV-364CH/CHR-PE 8 RAV-464CH/CHR-PE 10

High Wall RAV-105KH-E 2

RAV-135KH-E 3 RAV-165KH-E 4 RAV-265KH-E 5

High Wall RAV-264KH-PE 6

Built-In Vertical RAV-104NH-PE 2

RAV-134NH-PE 3 RAV-164NH-PE 4 RAV-264NH-PE 6

Floor Mounted RAV-164SH/SHR-PE 4

RAV-264SH/SHR-PE 6

Page 11

Parts specification

Outdoor unit

Specification of 3-pipe, heat recovery outdoor unit

Model name MAR-F105HTM8-PE

Cooling capacity kW 25.0 (28.0) Heating capacity kW 28.0 (31.5) Power supply 380-415 V, 3 phase, 50 Hz

Cooling

Operating current A 17.4 (19.1) Power consumption kW 11.8 (12.8) EER 2.11 (2.19) Power factor % 98 (97)

Heating

Operating current A 17.7 (15.5) Power consumption kW 11.8 (10.5) COP 2.37 (3.0) Power factor % 96 (98)

Starting current A 60 Starting method Direct Sound level Sound pressure dB 58

Sound power dB(A) 70 Dimensions (H x W x D) mm 1700 x 990 x 790 Net weight kg 285 Colour Silky Shade (Munsell 1-Y8.5/0.5)/RAL 1013 (DE ~9) Compressor Type Hermetically sealed (twin scroll)

Oil (volume) ml Polyolester NISSEKI RB74AF 74VG (7000)

Crankcase heater Internal type

Motor output kW 7.5 Fan assembly Fan Propeller fan

Motor output kW 0.4

Air flow volume m3/h 10,000 Refrigeration (charged weight) kg R-407C (19) Piping connection Liquid mm 15.9 (flare connection)

Discharge gas mm 19.0 (flare connection)

Suction gas mm 28.6 (brazing connection) Max. equivalent piping length m 120 Max. actual piping length m 100 Max. piping head m 50: when the outdoor unit is installed above

Suction accumulator case heater W 29 (240 V AC)

m 20: when the outdoor unit is installed below

Notes:

1. Specifications are subject to change without notice.

2. The specification shown in ( ) denotes operation with an indoor unit load diversity of 135%.

3. Operating conditions:

Outdoor temperature °C Cooling -5 to 43

Heating -15 to 21

Room temperature °C Cooling 18 to 32

Heating 15 to 29

4. Sound level: 1 m horizontal from centre.

1.5 m vertical from base.

Page 12

Parts specification

Outdoor unit

Specification of outdoor unit refrigeration cycle parts

Parts description MAR-F105HTM8-PE

Compressor model Model name MG1300CW-20

Motor type 3-phase induction motor

Power supply 380-415 V, 3 phase, 50 Hz

Output kW 7.5

Pole 2/2 (inverter side/non-inverter side)

Coil resistance Ω 1.49/2.51 (inverter side/non-inverter side)

Compressor oil name Polyolester NISSEKI RB68AF VG 74

Amount of oil ml 7,000

Fan motor Model name STF-200-350A

Motor type 1-phase, induction type

Power supply 220-240 V, 1 phase, 50 Hz

Output kW 0.4

Supply current A 3.2 ~ 3.5

Pole 6

Protective device Operation °C 145 ± 5

(Relay) Reset °C 86 ± 15

High pressure switch Model name ACB-JB128 Inverter side Operating pressure Operation MPa 3.2

Reset MPa 2.55 High pressure switch Model name ACB-JA64 Fixed side Operating pressure Operation MPa 3.2

Reset MPa 2.55 Low pressure switch Model name 20PS-1

Operating pressure Operation MPa 0.025

Reset MPa 0.15 4-way valve CHV-0712, coil AC240 V Liquid tank l (RSH 12) 12 Accumulator l (BT9-1 1/8) Check valve Model name YCV5-3SPTF-1

Maximum pressure MPa 3.3

Check joint Model name R-407C type

Maximum pressure MPa 3.53 Expansion valve EXV-V-E80HTF-9WS Compressor heater (Internal within the compressor) Accumulator heater W 29 (240 V AC) Pressure sensor Model name: NTP-Q250TF-2

Input voltage: DC12 V Output voltage: DC 0.5 - 4.5 V

Discharge temperature sensor 25°C = 50 kΩ

50°C = 18.1 kΩ

100°C = 3.35 kΩ Suction temperature sensor/ 0°C = 34.6 kΩ outdoor air temperature sensor 25°C = 10 kΩ

50°C = 3.4 kΩ Pulse modulating valve (Cooling bypass PMV1) EV18RC1, coil DC 12 V Pulse modulating valve (PMV2) EV23RC2, coil DC 12 V 2-way valve (SV1, SV2, SV4, SV5, SV16, SV17) NEV202DXF, coil AC 240 V 2-way valve (SV13, SV14, SV15) RP100-03, coil AC 240 V

Note:

Specifications are subject to change without notice.

Page 13

Parts specification

Outdoor unit

Specification of outdoor unit inverter assembly parts

Model name MAR-F105HTM8-PE

Power supply 380-415 V, 3 phase, 50 Hz PC board assembly PCB (IPDU) MCC-1342 PC board assembly PCB (noise filter) MCC-1366 PC board assembly PCB (interface) MCC-1223 PC board assembly PCB (communication) MCC-1387 Fan motor capacitor 8 µF/450 V AC Electrolytic capacitor 2200 µF/400 V Power supply terminal plate L1, L2, L3 600 V AC, 60 A, 3 pole Transformer Interface TT01 Magnetic contactor Inverter side FMCa - 1S Magnetic contactor Fixed side FC - 3 Reactor CH - 25 - 2FK Fuse 6 A 500 V AC Fuse 20 A 600 V AC Fuse 3.15 A 250 V AC Fuse 6.3 A 250 V AC Fuse 20 A 250 V AC Fuse 10 A 250 V AC Thermistor (PTC) Relay 15 A, 240 V AC

Note:

Specifications are subject to change without notice.

Page 14

Parts specification

Multi Controller unit

Specification of 3-pipe Multi Controller parts

Model name RBM-Y1034F-PE RBM-Y1044F-PE

Pulse modulating valve EV23RC7, coil DC 12 V Temperature sensor At 0°C = 32.8 kΩ, 25°C = 10 kΩ, 50°C = 3.6 kΩ Float switch FS-085-0031 PC board assembly PCB MCC-1222 Power supply transformer Model name FT69

Specification Primary side: AC 240 V, secondary side: AC 12 V Relay (PC board) G2R-117P, coil DC 12 V Heater 10.4 W/m

50 W 65 W Thermal fuse for heater Cut out at 119°C Heater fuse T1A Discharge gas side 2-way valve RP100-03, coil AC 240 V Suction gas side 2-way valve REV-1506DXFQ6, coil AC 240 V 2-way valve NEV202DXF-AC 240 V 2-way valve NEV603DXF-AC 240 V

Note:

Specifications are subject to change without notice.

Page 15

MAR-F105HTM8-PE Dimensional drawings

Construction view

Outdoor unit

4-15 x 20 (Slot)

790755

630

Grounding part of bottom plate

4 - ø 25 drain holes

1700

1582

110

700

Fixing bolt positions

Fixing bolt pitch

700

990

Pipe outlet (bottom)

601

Grounding part of bottom plate

Foundation dimensions

750

4-60 x 150 slot (for transport)

All dimensions in mm

568

500

Slot pitch

Details of piping connections

Knock outs on both sides of unit

Refrigerant pipe connecting port (Gas suction side) braze connection (ø 28.6)

Refrigerant pipe connecting port (Liquid side) flare connection (ø 15.9)

315

275

1146068

Refrigerant pipe connecting port (gas discharge side) flare connection (ø 19.0)

3-ø 20 cable gland knock outs ø 32 cable gland knock outs ø 25 cable gland knock outs

Page 16

Construction view

Multi Controller

Model A B C D E F RBM-Y1034F-PE 460 300 - 90 - 90 RBM-Y1044F-PE 530 370 90 90 90 90 All dimensions are in mm

2 notches for hanging bolts (12 x 21)

Electric parts box

Refrigerant pipe connection (brazing)

Liquid side ø 12.7

50 80

300

90 90

2 slots for hanging bolts (12 x 52)

3-pipe: RBM-Y1034F/Y1044F-PE

Connection (brazing) Liquid side ø 15.9

Wiring knockouts 6 x ø 20

110

Refrigerant pipe connection (brazing) Gas side ø 19

Refrigerant pipe connection (brazing) Delivery gas side ø 19

Refrigerant pipe connection (brazing) Suction gas side ø 28.6

Page 17

MAR-F105HTM8-PE

Wiring diagrams

Outdoor unit

Page 18

Wiring diagrams

Outdoor unit

Page 19

Wiring diagram

Multi Controllers

3-pipe Multi Controller (RBM-Y1034F-PE, RBM-Y1044F-PE)

Spark

killer

Capacity rank

setting

ABCD

7-segment LED

Display selector switch

Indoor

unit A

Indoor

unit B

Indoor

unit C

Symbol Part Name

PMVA, B, C, D Pulse modulating valve Th A, B, C, D, X Temperature sensor Tr Power transformer CS Float switch H Heater MS Reset switch F Fuse (T1A) SVD (A), (B), (C), (D) Electrically operated valve for discharge gas side SVD (A), (B), (C), (D) Electrically operated valve for suction gas side SVDD Electrically operated valve for increasing pressure SVSS Electrically operated valve for decreasing pressure SVH Electrically operated valve for superheat control LD 101, 102, 103, 104 Fault indicator LED

Parts layout

Control PC board

Terminal plate

Trans

• The dashed lines indicate wiring on site.

• and indicate terminal blocks, and numbers within them are terminal numbers.

• indicates a printed circuit board.

• The frame indicates the product body.

• RBM-Y1034F-PE does not have PMVD, SVD(D), SVS(D), ThD or the

Reset switch

connection block for indoor unit D. The capacity rank code setting for unit D is to be set to “0”.

Indoor

unit D

Outdoor

unit

Page 20

Refrigeration piping schematic diagram

Outdoor unit

Page 21

Refrigeration piping schematic diagram

Normal operation - heat mode

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Page 22

Refrigeration piping schematic diagram

Normal operation - cool mode

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Page 23

Refrigeration piping schematic diagram

Simultaneous operation - mainly heat

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Page 24

Refrigeration piping schematic diagram

Simultaneous operation - mainly cool

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Page 25

Diagnostic procedure

Outdoor unit

MAR-F104HTM8-PE, 3-pipe outdoor unit

Malfunction judgement is performed using the self-diagnostic function of the outdoor unit. The combination of the display switches (SW1, SW2) and the LEDs (LD 71~LD 74) indicates the diagnostic details.

Located on the electrical inverter cover is a transparent window, which allows the 7-segment LED to be viewed while the unit is in operation.

The transparent window has access holes to allow the adjuster pen, which is attached to the window, access to alter the setting of the display switch SW1 and SW2 while the unit is running.

A slit is positioned at one end of the pen to locate onto the rotary switch.

The adjuster pen can also be used to push switches SW3 and SW4 during the diagnostic procedure check.

A crimp connector is located on the other end of the adjuster pen. This connector can be used to ‘short’ TP1 or TP2 connectors when performing manual operation of the outdoor valves.

No other component other than that supplied must be used to adjust the rotary switches. Failure to do so may result in damage to the unit, malfunction or risk of electric shock.

Page 26

Diagnostic procedure

Outdoor unit

1. Communication serial signals and the system operating status are displayed by changing display switch SW2.

Display Display Indication 7-segment LED display switch switch LD 71 LD 72 LD73 LD74 SW1 SW2 position position

0 0 Sending/receiving status of Between Between Between Non-inverter

interface control board serial M/C (1) M/C (2) inverter compressor signal Sending Not sending Abnormal [E]

only [S] or receiving

[ ] Receiving Sending and Normal [0] only [J] receiving [0]

1 Operating instruction Operating Heating [H], Simultaneous ---------- ----------

from M/C (1) mode cooling/heating [HC],

Cooling [C], Stop [ ]

2 Instruction Heating frequency [00-1F] Cooling frequency [00-1F]

frequency (Refer to conversion table 2) (Refer to conversion table 2)

3 Outdoor unit Operating Heating [H], Cooling [0C], ---------- ----------

operating condition mode Simultaneous heating [Hc]

Defrost [J0], Simultaneous cooling [hC]

4 M/C Frequency ---------- ----------

operation release Off: [0] No: [0] 1 unit: [1] Yes: [1] 2 unit: [2]

5 Operating instruction Operating Heating [H], Simultaneous ---------- ----------

from M/C (2) mode cooling/heating [HC],

Cooling [C], Stop [-]

6 Instruction Heating frequency [00-1F] Cooling frequency [00-1F]

frequency (Refer to conversion table 2) (Refer to conversion table 2)

9 Inverter operation status Normal Operating ---------- ----------

[C] frequency

[0-F], Abnormal (Refer to [E] table 3)

10 Operating instruction to Normal Operating ---------- ----------

inverter from interface [C] frequency control board [0-F],

Abnormal (Refer to ---------- ---------[E] table 3)

11 Power supply frequency 50 Hz [5] [0] ---------- ----------

60 Hz [6]

Page 27

Diagnostic procedure

Outdoor unit

2. Display code conversion table - instruction frequency from Multi Controller.

Display 00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F code

Frequency 0 0 0 3.9 6.9 10.0 13.0 16.2 19.3 22.4 25.5 28.6 31.7 34.8 37.9 41.0 conversion value (Hz)

Display 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F code

Frequency 44.1 47.2 50.3 53.4 56.5 59.6 62.7 65.8 68.9 72.0 75.1 78.2 81.3 84.4 87.5 90.0 conversion value (Hz)

3. Display code conversion table - operating frequency of inverter compressor

Display 03456789ABCDEF code

Frequency 0 30.5 38.3 41.9 45.5 53.3 61.0 68.8 76.0 83.8 91.6 102.9 110.7 121.5 conversion value (Hz)

4. PMV opening information is displayed

Display Display Indication 7-segment LED display switch switch LD 71 LD 72 LD 73 LD 74 SW1 SW2 position position

1 2 PMV1 opening [P] [1] Displays the degree of PMV

opening (0 - 240) as a hexadecimal code:

3 PMV2 opening [P] [2] [00] : Closed, [F0] : Fully open

5. Malfunction information is displayed, refer to fault code section for details

Display Display Indication 7-segment LED display switch switch LD 71 LD 72 LD 73 LD 74 SW1 SW2 position position

2 0 Check code [E] Outdoor unit: [r] Refer to fault code section for

display for the M/C (1): [1] details (page 36) outdoor unit, M/C (2): [2] M/C (1), M/C (2)

Page 28

Diagnostic procedure

Outdoor unit

6. The indoor unit capacity rank setting is displayed.

Display Display Indication 7-segment LED display switch switch LD 71 LD 72 LD 73 LD 74 SW1 SW2 position position

3 0 Outdoor unit HP [9] 8 HP [8], 10 HP [A] [H] [P]

1 Capacity rank of Unit A [A] Displays the code number of the 2 indoor unit Unit B [b] indoor unit registered to each M/C. 3 connected to Unit C [C] 4 M/C (1) Unit D [d] Refer to the table below (7) for 5 Capacity rank of Unit A [A] indoor unit model capacity rank. 6 indoor unit Unit B [b] 7 connected to Unit C [C] 8 M/C (2) Unit D [d]

7. Indoor unit code No. conversion table

Code No. 0 23456810 Capacity rank No correction 10 13 16 20 26 36 46 (Indoor unit model example: Model RAV-364UH-PE, capacity rank = 36)

8. Sensor temperature display

Display Display Indication 7-segment LED display switch switch LD 71 LD 72 LD 73 LD 74 SW1 SW2 position position

4 0 Pressure sensor data [P] [d] Refer to table 9 conversion chart

1 ThD1 sensor data [d] [1] Refer to table 10 conversion chart 2 ThD2 sensor data [d] [2] 3 ThS sensor data [S] [1] Refer to table 11 conversion chart 4 TE sensor data [h] [E] 5 TO sensor data [h] [0]

Page 29

Diagnostic procedure

Outdoor unit

9. Outdoor unit - pressure sensor data

Display Pressure Display Pressure Display Pressure Display Pressure

(kgf/cm2G) (kgf/cm2G) (kgf/cm2G) (kgf/cm2G)

17 0.0 67 11.0 96 17.5 C6 24.0 1E 1.0 6B 11.5 9A 18.0 C9 24.5 25 2.0 6E 12.0 9E 18.5 CD 25.0 2D 3.0 72 12.5 A1 19.0 D1 25.5 34 4.0 76 13.0 A5 19.5 D4 26.0 3B 5.0 79 13.5 A9 20.0 D8 26.5 43 6.0 7D 14.0 AC 20.5 DC 27.0 4A 7.0 81 14.5 BD 21.0 DF 27.5 51 8.0 84 15.0 B4 21.5 E3 28.0 58 9.0 88 15.5 B7 22.0 E7 28.5 5C 9.5 8B 16.0 BB 22.5 EA 29.0 60 10.0 8F 16.5 BE 23.0 EE 29.5 63 10.5 93 17.0 C2 23.5 F2 30.0

These are sample displays. intermediate displays to those above are possible.

10. Outdoor unit - ThD1 and ThD2 sensor data

Display Temp. °C Display Temp. °C Display Temp. °C Display Temp. °C

05 -5.0 28 40.0 7C 85.0 C6 130.0 07 0.0 30 45.0 87 90.0 CB 135.0 09 5.0 38 50.0 90 95.0 D0 140.0 0C 10.0 41 55.0 9A 100.0 0F 15.0 4A 60.0 A2 105.0 12 20.0 54 65.0 AB 110.0 17 25.0 5E 70.0 B2 115.0 1C 30.0 68 75.0 B9 120.0 22 35.0 72 80.0 C0 125.0

These are sample displays. Intermediate displays to those above are possible. Display [00] signifies sensor open circuit.

11. Outdoor unit - ThS, TE, TO sensor data

Display Temp. °C Display Temp. °C Display Temp. °C Display Temp. °C

2A -20.0 7C 9.0 A2 22.0 C0 35.0 36 -15.0 7F 10.0 A5 23.0 C2 36.0 42 -10.0 82 11.0 A7 24.0 C4 37.0 51 -5.0 85 12.0 AA 25.0 C6 38.0 60 0.0 88 13.0 AC 26.0 C8 39.0 63 1.0 8B 14.0 AF 27.0 C9 40.0 66 2.0 8E 15.0 B1 28.0 D1 45.0 69 3.0 91 16.0 B3 29.0 D8 50.0 6C 4.0 94 17.0 B6 30.0 DE 55.0 6F 5.0 97 18.0 B8 31.0 E3 60.0 73 6.0 9A 19.0 BA 32.0 E7 65.0 76 7.0 9C 20.0 BC 33.0 EA 70.0 79 8.0 9F 21.0 BE 34.0

These are sample displays. Intermediate displays to those above are possible. Display [00] signifies sensor open circuit.

Page 30

Diagnostic procedure

Outdoor unit circuit test procedure

12. Outdoor unit circuit test procedure

• These systems have a feature which enables them to check that the wiring and piping connections are aligned with each other. This is carried out by allowing refrigerant to flow to one indoor unit at a time and monitoring that indoor unit’s coil sensor for a corresponding drop in temperature. Each indoor unit is tested in turn and where two Multi Controllers are installed each Multi Controller is tested in turn.

• This test would normally be used at the commissioning stage.

• Procedure for initialising the circuit test.

1. Turn the power off.

2. Ensure the capacity codes are set correctly, capacity switches set to ‘0’ are not tested.

3. Put the outdoor display switches SW1 and SW2 to 9 and Multi Controller(s) display switch to 6.

4. Turn the power back on.

5. Set all the remote controllers to cool mode and 29°C.

6. Press the on/off button to start all the indoor units (the outdoor LEDs show ‘1020’).

7. Press the outdoor unit switch SW3, and hold for 3 seconds.

8. The system is now in self-testing (all 8 LEDs will be flashing rapidly).

9. The system will stop at the end of the test.

• In the event of cross wiring/piping the system will indicate which units are faulty, see table below:

Outdoor display switch SW1 and SW2 set to position 9.

One and two Multi Controllers

Display Multi Controller Fault

1020 All None 1A20 1 Unit A 1B20 Unit B Units that are indicated 1C20 Unit C failed the test 1D20 Unit D 102A 2 Unit A 102B Unit B 102C Unit C 102D Unit D

Three or more Multi Controllers

Display Multi Controller Fault

1020 All None 1A20 1 Unit A or B 1B20 Unit C or D Units that are indicated 1C20 2 Unit A or B failed the test 1D20 Unit C or D 102A 3 Unit A or B 102B Unit C or D 102C 4 Unit A or B 102D Unit C or D

Page 31

Diagnostic procedure

Multi Controller

The combination of the display switch and the four 7-segment LEDs (LD 101-LD 104) indicates the diagnostic details.

MCC - 1223

7-segment LED

LD 101

LD 102

LD 103

LD 104

Unit B

Unit A

Capacity rank switches

Unit D

Unit C

Display switch

Multi Controller control board

7 segment LED display Switch Indication LD 101LD 102 LD 103 LD 104 position

0 Serial - - - Receiving Sending - Sending Receiving Receiving - Receiving Sending - Sending Receiving Sending

signal from to to from from from to to from to

1 Fault [E] - Fault code display (normal [00]). Refer to fault code section for details.

codes

2 Frequency Instructed demand frequency of cooling or heating [00 - 1F].

instructions Refer to the Multi Controller display conversion table (1) for display switch position “2” to the outdoor unit

3 Oil - - - Oil Superheat - Superheat Oil - - Oil Superheat - Superheat Oil -

retrieval, retrieval control control retrieval retrieval control control retrieval superheat unit B unit B unit A unit A unit D unit D unit C unit C control

Defrost Displays [dF] during defrost operation

4 Operation M/C operating Outdoor unit operating mode: Heating [H-], Cooling [-C], Simultaneous Heating [Hc],

mode mode: Simultaneous Cooling [hC], Stop [--], Defrost [J-]

5 Restart - - - Normal display [0], Restart timer counting [1]

timer 6 Circuit test [c] [k] Displays unit being tested [A b C d] Indicates faulty unit connection [A b C d] 7 PMV A [P] [A] Displays the degree of PMV opening (0-240) as a hexadecimal code: 8 PMV B [P] [b] [00]: Closed, [FO]: Fully open 9 PMV C [P] [c] 10 PMV D [P] [d] 11 ThA [h] [A] Displays sensor temperature 12 ThB [h] [b] Refer to the Multi Controller sensor temperature conversion table (1). 13 ThC [h] [c] 14 ThD [h] [d] 15 ThX [h] [H]

Heating [H-], Cooling [C-]*

unit B unit B unit A unit A oudoor unit D unit D unit C unit C outdoor

unit unit

* and Simultaneous Cooling/Heating [HC], Defrost [J-]

Page 32

Diagnostic procedure

Multi Controller

1. Display switch set to position “11”, “12”, “13” and “14”

Multi Controller - ThA, B, C, D and X sensor conversion table

Display Temp. °C Display Temp. °C Display Temp. °C Display Temp. °C

18 -10.0 44 1.0 70 12.0 9C 23.0 1C -9.0 48 2.0 74 13.0 A0 24.0 20 -8.0 4C 3.0 78 14.0 A4 25.0 24 -7.0 50 4.0 7C 15.0 A8 26.0 28 -6.0 54 5.0 80 16.0 AC 27.0 2C -5.0 58 6.0 84 17.0 B0 28.0 30 -4.0 5C 7.0 88 18.0 B4 29.0 34 -3.0 60 8.0 8C 19.0 B8 30.0 38 -2.0 64 9.0 90 20.0 3C -1.0 68 10.0 94 21.0 40 0.0 6C 11.0 98 22.0

Display [00] signifies sensor open circuit.

Control board communication diagram

Multi Controller

M/C (1)

Interface

control board

I/F

Multi Controller

M/C (2)

Remote

controller

Indoor unit

A few seconds 1 minute 1 minute1 minute

Remote controller fault code display time lapse for system malfunctions

Serial signal abnormalities: Between the I/F and the INV More than 3 minutes

Between the M/C and the I/F More than 2 minutes Between the indoor unit and the M/C More than 1 minute

Between the remote controller and indoor unit A few seconds INV abnormality: More than 3 minutes I/F abnormality: More than 2 minutes M/C and indoor unit abnormality: More than 1 minute

Inverter

control board

INV

Page 33

Fault code display

Self-diagnostic function

The remote controller, Multi Controller and outdoor unit have the facility to display fault codes which are used to determine any malfunction of the system.

• The remote controller is provided with a “check” button and a check display.

• The Multi Controllers and outdoor units are provided with display switches and LED displays.

Initially malfunctions can be identified from the remote controller check display.

Details of the Multi Controller and outdoor unit malfunctions can be determined from their control boards. (Multi Controller malfunctions are also displayed on the outdoor unit interface control board).

Fault code identification

When a malfunction has been identified, do not reset the system. Press the “CHECK” button on the remote controller and observe the display.

The location and cause of the malfunction can be determined from the fault code.

“CHECK” Flashes when phases are rotated.

FAN

MODE

FAN ONLY

AUTO

OPERATION

HIGH

COOL

MED

HEAT

LOW

AUTO

CHECK

TEMP

UNIT MANUAL

OFF ON

TIMER

CONT.

88 : 88

“STANDBY” displayed

• The total capacity rank settings of indoor units connected exceeds the allowable level, or an indoor capacity rank is set at “0” (Multi Controller).

NETWORK

CENTRAL

STANDBY

PREHEAT

DEFROST

LOUVER

ADDRESS

FILTER

REMOTE CONTROLLER

MODE

TIMER ADJUST

CHECK

FILTER

ON/OFF

Reset button

• Pressing the reset button with a pin will clear the memory.

Check button

• Pressing for 1 second will display fault codes.

• Pressing for 5 seconds will reset the indoor unit microprocessor.

• Pressing for 10 seconds will clear only the fault codes.

Page 34

Fault code display

Self-diagnostic function

Details of the malfunction check display

The following fault code display occurs when the check button is pressed for 1 second.

(Note: Up to 16 indoor units can be connected to one remote controller using group control.)

2 fault codes for each of the 16 indoor units can be displayed at 2 second intervals.

Example: Display for fault codes:

TEMP LOUVER

CHECK

UNIT

MANUAL

°c

Indoor unit number

The 1st fault detected

TIMER

ADDRESSCONT. OFF ON

The 2nd fault detected

Page 35

Fault code display

Self-diagnostic function

Remote controller fault code Multi Controller fault code Outdoor fault code

No communication signal between Interface PCB and IPDU

04 No communication signal between M/C and O/D

No communication signal between I/D and M/C 0b Drain pump fault - I/D unit 0C TA sensor fault 0d TC sensor fault 08 Reverse TC temperature change 09 No TC temperature change 11 Motor short circuit 12 Indoor PC board short circuit b5 External input display fault

(Low level refrigerant leak if RBC-RD1-PE fitted) b6 External interlock display fault

(High level refrigerant leak if RBC-RD1-PE fitted) 97 Central management communication short circuit 98 Central management address set-up fault 99 No communication I/D to R/C

15 Refer to M/C

1C Refer to O/D 1C Refer to O/D 08 Four-way valve alarm.

14 Refer to O/D 14 Refer to O/D 14 G-Tr short-circuit protective operation 17 Refer to O/D 17 Refer to O/D 17 Current detection circuit 21 Refer to O/D 21 Refer to O/D 21 High pressure SW circuit 1d Refer to O/D 1d Refer to O/D 1d Compressor error 1F Refer to O/D 1F Refer to O/D 1F Inverter malfunction d3 Refer to O/D d3 Refer to O/D d3 TH sensor circuit - Inverter microprocessor (IPDU) dA Refer to O/D dA Refer to O/D dA Heat sink overheat protective operation (IPDU)

NOTE:

• To retrieve fault codes from the outdoor unit ensure rotary switch SW1 is set to position ‘2’ and SW2 is set to position ‘0’.

• To retrieve fault codes from the Multi Controller ensure the display switch is set to position ‘1’.

04 No communication signal between Interface PCB and IPDU

No communication signal between M/C and O/D.

8A Multi Controller PCB error 88 Communication error between outdoor unit and Multi

Controller 80 ThA sensor fault 80 ThA sensor fault 81 ThB sensor fault 81 ThB sensor fault

82 ThC sensor fault 82 ThC sensor fault 83 ThD sensor fault 83 ThD sensor fault 84 ThX sensor fault 84 ThX sensor fault 0b Drain pump fault - M/C unit 0b Drain pump fault - M/C unit 89 Indoor units capacity codes too high or set to 0 89 Over capacity

tt tt

04 No communication signal between Interface PCB and

IPDU

tt tt

Er [E][r] fault code refers to Outdoor unit

A0 Discharge temp. sensor (TD1) short circuit A1 Discharge temp. sensor (TD2) short circuit A2 Suction temp. sensor (TS) short circuit A4 External air sensor (THo) short circuit A5 Outdoor heat exchanger sensor (TE) short circuit A6 Discharge temp. (TD1 and TD2) protective operation A7 Suction temp. (TS) protective operation AA High pressure sensor (Pd) short circuit Ad DOL compressor fault AE Low pressure fault (Ps) AF Outdoor Unit power source phase order miswiring 1C Extension IC, EEPROM short circuit

tt tt

Page 36

Troubleshooting

Diagnostic procedure for check code

Check code Status of air conditioner Operation cause [04] Outdoor unit stops 1. Wiring fault between indoor and Multi

Inverter serial signal Indoor unit fan continues Controller or Multi Controller and outdoor short circuit interface PC board. Inter-unit communication 2. Defective communication PC board.

3. Defective IPDU PC board.

4. Noise from outside.

5. High level refrigeration leak (RBC-RD2-PE).

Is there continuity of the

communication cable between

the indoor unit and Multi

Controller?

Ye s

Is there continuity of the

communication cable between

the Multi Controller the outdoor

Is there continuity of the

communication cable between

the outdoor interface PC board

and outdoor IPDU PC board?

Is there voltage present

between pins 4 and 5 of CN1

on communication PC board?

(DC 0 to 5 V, pin 5-GND)

between pins 3 and 5 of CN1

(DC 0 to 5 V, pin 5-GND)

Check noise interference from

unit

Ye s

Is there voltage present

on interface PC board?

Ye s

outside, etc.

Ye s

Is refrigerant detector

RBC-RD2-PE fitted?

Ye s

Replace communication cable

Communication PC board is defective - replace

IPDU PC board is defective - replace

Complete checks detailed above

Are the high level alarm and

the shutdown LEDs on the

RBC-RD2-PE (RED) on?

Ye s

Refrigerant leak. Leak-check unit.

Complete checks detailed above

Page 37

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [08] 1. 4-way valve operation error.

4-way valve reversal alarm 2. TS sensor/TE sensor error.

3. Pd sensor error.

4. Fixed-speed compressor Mg-SW operation error.

Is 4-way valve coil connector

connected?

Ye s

Is 4-way valve cool normal?

Ye s

Are connectors of TS, TE, Pd

sensors connected?

Ye s

Are resistance value

characteristics of TS and TE

sensors normal?

Ye s

Are the output voltage

characteristics of Pd sensor

normal?

Ye s

Is there a problem on wiring of

fixed-speed compressor?

Reset power supply and perform

trial heating operation.

Ye s

Modify connector connection

(4-way valve coil: CN 317)

4-way valve cool error

Modify connection of connectors. TS sensor: PJ3 TE sensor: PJ4 Pd sensor: PJ7

Sensor error

Correct wiring

Does 4-way valve operate?

Is fixed-speed compressor

activated?

Ye s

4-way valve error

Ye s

Does refrigerant bypass

from discharge to suction

on 4-way valve?

Does OL of Mg-SW

Does IOL of fixed-speed

compressor operate?

Ye s

operate?

Ye s

Restart the operation if a trouble has not

occurred in trial operation.

Check 4-way valve

Restart the operation after manual reset

Restart the operation after compressor

IOL reset (automatic reset)

Mg-SW error

Page 38

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [09] 1. Compressor running but not pumping.

No temperature change in TC temperature 2. Bi-Metal thermostat protection device.

3. Compressor wiring.

4. Faulty TC temperature sensor.

Is the power supply

voltage to the outdoor

unit normal?

Ye s

Is the compressor

running but not

pumping?

Ye s

Are the gas suction,

gas discharge and

liquid packed valves

fully open?

Ye s

Is the wiring of the

compressor normal?

Ye s

See judgement flow [1d] compressor fault

Modify power supply

Open packed valves

Modify connection of

wiring

Is the indoor unit in

Is the indoor TC sensor

normal and connected

Confirm: Lack of gas charge Pipe blockage

frost conditions?

Ye s

correctly?

Ye s

See judgement flow

[1d] compressor fault

Replace TC sensor

Page 39

Troubleshooting

Diagnostic procedure for check code

Check code Status of air conditioner Operation cause [0b] Operation stops for Multi 1. Float switch disconnection.

Drain pump fault Controller fault. 2. Drain pump operation error. Indoor unit or Multi Indoor unit fan continues for 3. Drain hose blockage. Controller unit fault.

Check connection of connector CN10

(Drain pump: Indoor main, PC board

(MCC-1292), CN10)

(Drain pump: Multi Controller, PC board

(MCC-1210) PJ10)

Check and modify wiring circuit.

(MCC-1292), (MCC-1210)

Is drain pump connected?

Ye s

Does float switch operate?

Ye s

Is circuit wiring

normal?(*1)

Indoor PC board error

(MCC-1292), (MCC-1210)

Float switch error

Check and modify wiring

circuit.

1 and 2/1 to 3 of the indoor main PC board, is 230V or not (MCC-1292), (MCC-1210).

Does drainage water collect?

Ye s

Does drain pump operate?

Ye s

Check for blockage of

drainage hose.

(*1) For confirmation, check voltage under condition that

connector is connected to CN10, pins 5 and 7, PJ10, pins 1 and 2

Is power to drain

pump turned on?(*2)

Ye s

Drain pump error

(*2) Check whether voltage of CN10/PJ10, pins

Check code Operation cause [0C]

Indoor sensor (TA) short or open circuit alarm TA sensor open/short

TA sensor open/short has been detected. Check disconnection of connector connection (TA sensor: CN04) circuit and resistance value characteristics of sensor.

When the sensors are normal, replace indoor PC board (MCC-1292).

Check code Status of air conditioner Operation cause [0D] Indoor unit fan stops. TC sensor open/short

Indoor sensor (TC) short ‘Preheat defrost’ is or open circuit alarm displayed on R/C.

TC sensor open/short has been detected. Check disconnection of connection (TC sensor: CN05) circuit and resistance value characteristics of sensor.

When the sensors are normal, replace indoor PC board (MCC-1292).

Page 40

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [11] 1. Fan motor circuit connection error.

Indoor fan motor short circuit alarm 2. Capacitor error.

3. Fan motor error.

4. Defective indoor PC board.

Does indoor fan operate for a

short period after resetting and

resuming?

Ye s

Is there a connection error of

CN07 connector?

Is approx. DC12V to 13V output

to CN07 connector 1-3 pins?

Ye s

Is there a connection error

of CN07 connector?

Is capacitor normal?

Ye s

Confirm there is no

mechanical lock on the fan

motor?

Ye s

Modify connection and wiring.

Replace capacitor.

Is revolution pulse input from

hole IC to CN18 connector 2-3

pins during fan operation?

(Measurement by tester:

Approx. DC2 to 2.5V)

Ye s

Check code Operation cause [12] 1. Irregularity of power source.

Indoor PC board short circuit alarm 2. Noise of peripheral equipment.

3. Defective indoor PC board.

Is there an irregularity of

power source?

Indoor PC board check

Defective t Replacement

Ye s

Check power source voltage, modify

Replace fan motor.

Replace MCC-1292

PC board

lines, remove noise, etc.

Page 41

Troubleshooting

Diagnostic procedure for check code

Check code Status of air conditioner Operation cause [14] Operation stops 1. Outdoor unit power supply error.

IPDU short circuit 2. Wiring error on IPDU PC board. protective operation 3. AC fuse disconnection. alarm (Power Transistor) 4. Inverter compressor error.

5. Defective IPDU PC board.

Is the power supply voltage

of the outdoor unit normal?

Ye s

Is the connection of the wiring

connector on the IPDU PC board

normal?

Ye s

Is AC 20A fuse working?

Ye s

Is inverter compressor normal?

Ye s

Is smoothing capacitor normal?

(2200µ F,400V x 2)

Ye s

Confirm the power supply line.

Modify connector of wiring.

Replace IPDU PC board and fuse.

Replace IPDU PC board and inverter

compressor.

Confirm capacitance and appearance -

Replace if faulty.

Replace IPDU PC board.

Check IPDU PC board.

Page 42

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [17] 1. Defective wiring of IPDU PC board.

Current detection circuit alarm 2. Defective IPDU PC board. Refer to outdoor unit

Is wiring connector on IPDU PC

board normal?

Ye s

Is compressor operation normal?

Ye s

Check IPDU PC board.

Modify connection of wiring

Compressor error

Check code Operation cause [1C] 1. Outdoor unit power source error.

Extension IC, EEPROM short circuit alarm 2. Interface PC board error.

(Outdoor unit error)

Is there an irregularity of outdoor

unit power source?

Ye s

Check power source voltage.

Modify power source line.

Check noise interference from outside, etc.

Check interface PC board fault code.

Page 43

Troubleshooting

Diagnostic procedure for check code

Check code Status of air conditioner Operation cause [1d] Operation stops 1. Outdoor unit power source error.

Compressor error alarm 2. Inverter compressor circuit system error. Refer to outdoor unit 3. Inverter compressor error.

4. Inverter compressor refrigerant stagnation.

5. Defective IPDU PC board.

Is the power source voltage of the

outdoor unit normal?

Ye s

Does voltage reduction occur

when the fixed-speed compressor

has been activated?

Is the connection of wiring on

the IPDU PC board normal?

Ye s

Is there an abnormal overload?

Is the inverter compressor normal?

Ye s

Confirm the power source supply.

Modify connector wiring.

Modify cause of overload.

Compressor error

Is there refrigerant stagnation

in the compressor case?

Check IPDU PC board.

Ye s

Is the inverter winding

output normal?

Check IPDU PC board.

Ye s

Modify refrigerant stagnation in the compressor case, and start

the operation.

Page 44

Troubleshooting

Diagnostic procedure for check code

Check code Status of air conditioner Operation cause [1F] Operation stops 1. Outdoor unit power source error.

Compressor break down 2. Inverter compressor circuit system error. Refer to outdoor unit 3. IPDU PC board error.

Is the power source voltage of the

outdoor unit normal?

Ye s

Does the voltage reduction occur

when the fixed-speed compressor

has been activated?

Is the wiring connection on the

IPDU PC board correct?

Ye s

Is there an abnormal overload?

Check IPDU PC board.

Ye s

Confirm the power source supply.

Modify wiring connector.

Remove cause of overload.

Page 45

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [21] 1. Inverter high pressure SW error.

Inverter high pressure SW system alarm 2. Inverter IOL operation.

3. Service valve closed.

4. Outdoor fan, capacitor error.

5. Indoor/Outdoor PMV blockage.

6. Outdoor heat exchanger blockage.

7. SV2 circuit blockage.

8. Indoor – Outdoor communication error.

9. Pd sensor error.

10.Refrigerant overcharge.

Does the inverter high pressure

switch operate?

Ye s

Are the inverter high pressure

switch parts normal?

Ye s

Is service valve fully open?

Ye s

Does the cooling outdoor fan

Is there a problem with the

outdoor unit heat exchanger?

(1) Blockage of heat exchanger

Il circuito di bypass della SV2 è normale?

Is SV2 bypass circuit normal?

normally operate?

Ye s

(2) Short circuit

Ye s

Check parts. If defective, replace.

Open service valve fully.

Ye s

Remove cause.

Repair SV2 bypass circuit.

See judgment flow of IPDU IOL

Check and modify wiring

Are the connection, capacitor

and fan motor normal?

Ye s

Repair defective position.

Are the high pressure sensor

characteristics normal?

Ye s

Replace high pressure sensor.

Check outdoor IPDU PC board. If defective, replace board.

(Coil error, disconnection of wiring, etc.)

operation circuit “E5”.

Is the inverter IOL

circuit normal?

Ye s

Is circuit wiring normal?

Ye s

Page 46

Troubleshooting

Diagnostic procedure for check code

Does heating indoor fan

operate normally?

Ye s

Are the Multi Controller PMV/

solenoid valves normal?

Ye s

Is there any element to block

heat exchange in the room?

(1) Filter blockage

(2) Heat exchanger blockage

(3) Short circuit

Is communication line

between indoor and outdoor

units correct?

Ye s

Eliminate blocking

element

Check Multi Controller

Check and modify

wiring

Are the connector

connection and coil

normal?

Ye s

Is there a blockage on

whole valve?

PC board.

If defective, replace

Repair defective

position

Ye s

Replace PMV unit

Are the

connection and fan

motor normal?

Ye s

Is the sensor resistance

value characteristic TC

normal?

Repair defective

position

NoYe s

Refrigerant overcharge

Blockage Pipe breakage Abnormal overload

Check indoor PC board.

If defective, replace

Replace TC sensor

Page 47

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [E5] 1. Inverter IOL operation.

Inverter IOL operation 2. Service valve closed.

3. Outdoor PMV 1 error.

4. Miswiring of communication between indoor and outdoor unit.

Is IOL circuit normal?

1. Connector

2. Wiring

3. Outdoor PC board Ye s

Are gas pipe, liquid pipe and

service valve of the outdoor

unit fully open?

Ye s

Is outdoor PMV 1

normal?

1. Connector connection

2. Wiring

3. Coil

4. Valve unit

5. Outdoor PC board Ye s

Is wiring correct?

Ye s

Insufficient refrigerant,

blockage, pipe breakage

(Check miswiring of the outdoor unit according to miswiring check function.)

(Check there is no blockage or pipe breakage.)

Repair IOL circuit

Open service valve fully

Repair outdoor PMV

Set normal wiring

Page 48

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [80]

Gas temp. sensor (Tha) short circuit Tha sensor open/short

Open/short of Tha sensor was detected. Check connector (Tha sensor: PJ1) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the Multi Controller.

Check code Operation cause [81]

Gas temp. sensor (Thb) short circuit Thb sensor open/short

Open/short of Thb sensor was detected. Check connector (Thb sensor: PJ2) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the Multi Controller.

Check code Operation cause [82]

Gas temp. sensor (Thc) short circuit Thc sensor open/short

Open/short of Thc sensor was detected. Check connector (Thc sensor: PJ3) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the Multi Controller.

Check code Operation cause [83]

Gas temp. sensor (Thd) short circuit Thd sensor open/short

Open/short of Thd sensor was detected. Check connector (Thd sensor: PJ4) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the Multi Controller.

Check code Operation cause [84]

Gas temp. sensor (Thx) short circuit Thx sensor open/short

Open/short of Thx sensor was detected. Check connector (Thx sensor: PJ5) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the Multi Controller.

Page 49

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [88] 1. Error connection between Multi Controller

Communication alarm between Multi Controller and outdoor unit.

and outdoor unit 2. Outdoor PC board error (MCC-1223).

3. Multi Controller PC board error (MCC-1210).

4. Multi Controller does not recognise outdoor capacity.

Check lead connection between indoor unit and Multi Controller.

If no error is detected, replace Multi Controller board (MCC-1210) or outdoor PC board (MCC-1223).

Check code Operation cause [89] 1. No. of connected indoor units/connected over

Indoor over capacity capacity.

2. Incorrect set-up of indoor unit horse power or set to 0.

Is No. of connected indoor

units acceptable? (*1)

Ye s

Is set-up of indoor unit

horse power correct? (*2)

Ye s

Is total capacity of

connected indoor units

within indoor unit diversity?

1. M/C = 135%

2. 4 M/C = 160% Ye s

Check IPDU PC board

Indoor units from another system have been

incorrectly connected.

Modify miswiring/installation.

Modify set-up of horse power.

Keep capacity of connected indoor units

within unit diversity.

(*1)

Number of Maximum No. of Indoor unit diversity Maximum system code Maximum code per Multi Controllers indoor units Multi Controller

1 4 135% 27 27 2 8 160% 32 27 3 12 27 (13*) 416 13

(*2) Indoor unit Capacity No connection 10 13 16 20 26 36 46

Code number 0 2 3 4 5 6 8 10

(Example: Model RAV-364UH-PE, capacity = 36)

Page 50

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [8A] 1. Multi Controller PC board error.

Multi Controller PC board malfunction

Check lead connection between indoor unit and Multi Controller and outdoor unit.

If no error is detected, replace Multi Controller board (MCC-1210).

Check code Operation cause [97] 1. Connection error of (XY) for outdoor units.

Central management communication 2. Power source system error of the central short circuit controller and indoor unit.

3. Noise of peripheral devices.

4. Power failure.

5. Indoor PC board error, central controller error.

Are X,Y communication cables

normal?

Ye s

Is there a connection error of

power source wiring?

Is the power source of either

central controller or indoor/

outdoor turned on?

Ye s

Did power failure occur?

Is [97] displayed only on

the central controller?

Ye s

Is the network address

different from main or sub

remote controller?

Ye s

Clear the alarm after turning on the power source, and start the

operation.

Ye s

Is the operation status of

the indoor unit reflected on

the central controller?

Is there noise

interference, etc.?

Central controller error

Ye s

Check communication cable.

Check power source wiring.

Clear the alarm after turning on the

power source, and start the operation.

Indoor PC board error

Is there noise

interference, etc.?

Ye s

Eliminate noise interference.

Page 51

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [98] 1. Miswiring of XY communication cables.

Central management address set-up fault 2. Duplicated network addresses.

3. Indoor PC board error, central controller error.

Is the wiring connection of

communication cables to X,Y normal?

Ye s

Is [98] displayed only on the

central controller?

Ye s

Is [97] displayed only on the

central controller?

Ye s

Is there duplication of

network addresses?

Check indoor PC board. If defective, replace.

Ye s

Check connection of wiring.

Check duplication of network addresses.

Check No. of connected central

controllers to 1 unit.

Check the central controller. If defective, replace.

Page 52

Troubleshooting

Diagnostic procedure for check code

Check code Status of air conditioner Operation cause [99] Indoor unit stops 1. Remote controller circuit connection error.

Remote controller serial 2. Duplicated indoor No.1 units. signal circuit alarm 3. Remote controller error.

4. Indoor PC board error.

Are A, B, C internal wires normal? Check connection of wiring.

Ye s

Is there a connection error?

Is group operation performed?

Ye s

Is SW01 set to No. 1 on

the master unit?

Ye s

Is SW01 duplicated?

Ye s

Check indoor PC board.

If defective, replace.

Set SW01 to 1.

Correct switch SW01.

Is SW01 set to No. 1?

Ye s

Does the indoor unit operate?

Ye s

Does serial LED (Green)

D15 on the indoor PC board

flash?

Does serial LED (Orange)

D14 on the indoor PC

board flash?

Ye s

Check indoor PC board.

If defective, replace.

Check remote controller.

If defective, replace.

Make unit set-up No.1.

Page 53

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [A0]

Discharge temp. sensor (TD1) short circuit TD1 sensor open/short

Open/short of TD1 sensor was detected. Check connector (TD1 sensor: PJ1) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the outdoor unit.

Check code Operation cause [A1]

Discharge temp. sensor (TD2) short circuit TD2 sensor open/short

Open/short of TD2 sensor was detected. Check connector (TD2 sensor: PJ2) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the outdoor unit.

Check code Operation cause [A2]

Suction temp. sensor (TS) short circuit TS1 sensor open/short

Open/short of TS1 sensor was detected. Check connector (TS1 sensor: PJ3) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the outdoor unit.

Check code Operation cause [A4]

External air sensor (Tho) short circuit Tho sensor open/short

Open/short of Tho sensor was detected. Check connector (Tho sensor: PJ5) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the outdoor unit.

Check code Operation cause [A5]

Outdoor heat exchange sensor (TE) short circuit TE sensor open/short

Open/short of TE sensor was detected. Check connector (TE sensor: PJ4) and characteristics of sensor resistance value.

When sensor is normal, replace interface PC board of the outdoor unit.

Page 54

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [A6] 1. Outdoor unit service valve closed.

Discharge temperature TD1 and TD2 alarm 2. Cooling bypass PMV error. (>130°C) 3. TD sensor error.

4. Insufficient refrigerant, blockage in pipe.

5. Blockage of PMV assembly on the liquid line.

Are the gas pipe and liquid pipe

service valves of the outdoor unit

fully open ?

Ye s

Are PMV 2 and SV13

operating normally?

Ye s

Is the cooling bypass

PMV 1 normal ?

Ye s

Are the resistance characteristics

of TD sensor normal ?

Ye s

Is wiring correct ?

Ye s

(Check miswiring of the outdoor unit according to miswiring check function.)

Open valves fully.

Replace defective part.

Cooling bypass PMV 1 error.

Replace TD sensor.

Correct wiring.

Insufficient refrigerant, blockage,

Multi Controller blockage.

pipe breakage.

Page 55

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [A7] 1. Outdoor unit service valve closed.

Suction temperature (TS) alarm (>40°C) 2. Blockage PMV assembly on the liquid line.

3. TS pressure switch error.

4. Insufficient refrigerant, blockage in pipe.

Are the gas pipe and liquid pipe

service valves of the outdoor unit

fully open ?

Ye s

Is there a blockage in the

expansion valve on the liquid line?

Are the characteristics of TS

pressure switch normal?

(N/C type)

Ye s

Insufficient refrigerant, blockage,

pipe breakage.

Ye s

Open valves fully.

Replace expansion valve.

Replace TS pressure switch.

Check code Operation cause [AA]

High pressure sensor (Pd) short circuit Pd sensor output voltage alarm

If there is an abnormal output voltage of Pd sensor: Check connector circuit (Pd sensor: PJ7) and output voltage of the sensor.

If the sensor is normal, replace the outdoor interface PC board.

Sensor characteristics: Input 12 V DC (± 10%) across red and black leads of the pressure sensor. Output 0.5 to 4.5 V at 0 to 2.45 MPa across white and black leads of the pressure sensor.

Page 56

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [Ad] 1. Fixed-speed compressor high pressure SW error.

Fixed-speed compressor fault 2. Fixed-speed compressor IOL operation.

3. Service valve closed.

4. Outdoor fan, capacitor error.

5. Multi Controller/outdoor PMV blockage.

6. Outdoor heat exchanger blockage.

7. SV2 circuit blockage.

8. Miswiring of communicaiton between indoor and outdoor unit.

9. Pd sensor error.

10.Refrigerant overcharge.

OCR: Overload Current Relay

Does the fixed-speed high

pressure switch operate?

Ye s

Are the fixed-speed high

pressure switch parts normal?

Ye s

Is service valve fully open?

Ye s

Does the outdoor fan

normally operate?

Ye s

Is there a problem with the

outdoor unit heat exchanger?

(1) Blockage of heat exchanger

(2) Short circuit (air flow)

(3) Blockage of air flow

Check parts. If defective, replace.

Open service valve fully.

Repair failed position.

Replace high pressure sensor.

Ye s

Remove cause.

Are the connection, capacitor

See judgment flow of fixed-speed

Check compressor withstand

and fan motor normal?

Ye s

Are the high pressure sensor

characteristics normal?

Ye s

Check outdoor interface PC board. If defective replace board.

IOL, OL circuits “E6”.

Reset relay.

resistance.

Check and modify wiring

Is the fixed-speed

IOL circuit normal?

Ye s

Is the fixed-speed

OCR circuit normal?

Ye s

Is circuit wiring normal?

Ye s

Page 57

Troubleshooting

Diagnostic procedure for check code

Does heating indoor fan

operate normally?

Ye s

Is the Multi Controller PMV/

solenoid valve normal?

Ye s

Is there any element to block

heat exchange in the room?

(1) Filter blockage

(2) Heat exchanger blockage

(3) Short circuit (air flow)

Is communication line

between indoor and Multi

Controller units correct?

Ye s

Eliminate blocking

element.

Check Multi Controller

Check and modify

wiring.

Are the connector

connection and coil

normal?

Ye s

Is there a blockage on

whole valve?

PC board.

If defective, replace

and outdoor fan motor

Repair defective

position.

Ye s

Replace PMV unit.

Is the sensor resistance

value characteristic TC

Are the connection

normal?

Ye s

normal?

Repair defective

connection.

NoYe s

Refrigerant overcharge Blockage Pipe breakage Abnormal overload

Check indoor PC board.

Replace TC sensor.

If defective, replace

Page 58

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [E6] 1. Power supply error.

Fixed-speed IOL, OL alarm 2. Fixed-speed compressor IOL operation.

3. Service valve closed.

4. Blockage in Multi Controller PMV/outdoor PMV 1.

5. Miswiring of communication between indoor and outdoor units.

OCR: Overload Current Relay

Are the following items

related to power supply

normal?

400 V ± 10%

circuit of fixed-speed compressor power supply circuit system

Ye s

Is Mg-SW defective?

Is constant speed

compressor normal ?

1. Is compressor winding normal ?

2. Is compressor locked?

Overload operation,

liquid compression

Ye s

Does OCR operate ?

Check the OCR reset button.

(Manual reset)

Is OCR circuit normal ?

1. OCR unit

2. OCR wiring

Ye s

Are gas pipe, liquid pipe, and

service valve of the outdoor

unit fully open ?

Ye s

Is outdoor PMV 1

normal?

1. Connector connection

2. Wiring

3. Coil

4. Valve unit

5. Outdoor PC board Ye s

Ye s

Repair OCR circuit.

Open service valves fully.

Repair outdoor PMV.

1. Power supply voltage is

2. Phase missing, short-

Repair power supply system.

Ye s

Replace Mg-SW.

Replace fixed-speed

compressor.

Is IOL circuit normal ?

1. Connector

2. Wiring

3. Outdoor PC board

Ye s

Is wiring normal ?

Ye s

Insufficient refrigerant, blockage,

pipe breakage.

(Check miswiring of the outdoor unit according to miswiring check function.)

(Check there is no blockage or pipe breakage.)

Repair IOL circuit.

Set normal wiring.

Page 59

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [AE] 1. Ps pressure switch error.

Low pressure fault (Ps) 2. Ps switch connection error. Detected by low pressure switch <0.02 MPa 3. Compressor compressing error.

4. 4-way valve error.

5. Refrigeration undercharge.

6. Gas leak.

Is Ps switch connector

correctly connected?

Ye s

Is Ps switch normally closed (NC)?

Ye s

Is low pressure below

0.95 MPa during

operation of compressor?

Ye s

Check interface PC board.

Modify connector connection.

Does refrigerant bypass

from outlet to inlet on 4-way

valve?

Ye s

Check 4-way valve.

Confirm refrigeration charge correct.

PJ9 (MCC-1223)

Ps switch error. Replace switch.

Check compressor.

(No leaks from system.)

Check code Operation cause [AF] Abnormal power phase order or missing phase of

Outdoor unit power source phase power supply to the outdoor unit. order miswiring

There is an abnormal power phase order or missing phase of power supply to the outdoor unit. Check power supply wiring.

Page 60

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [b5] 1. External device error.

External input display fault 2. Indoor PC board error. [b6]

External interlock display fault Fault on CN17 - fault on external device (accessory)

Is the external device connected

to connector CN17 ?

Ye s

Is the external device

operating normally ?

Ye s

Check cause of the operation.

Check indoor PC board.

If defective, replace.

Check external device.

If defective, replace.

Check code Operation cause [d3] Error of temp. sensor incorporated in IGBT

TH sensor alarm (Inverter Gate Bi-Polar Transistor) Refer to outdoor unit

There is an error with the temp. sensor incorporated in IGBT. Check connectors CN07 on IPDU PC board and CN600 on interface PC board. If there is no problem, replace IPDU PC board.

Page 61

Troubleshooting

Diagnostic procedure for check code

Check code Operation cause [dA] 1. Power supply failure.

Abnormal overheat of heat sink 2. Outdoor fan error. Refer to outdoor unit 3. Heat sink installation failure.

4. Blockage of heat sink cooling duct.

5. Defective inverter PC board.

Is power supply voltage normal ?

Ye s

Is the wiring connector

connection normal on the

inverter PC board ?

Ye s

Is outdoor fan normal ?

Ye s

Is there a screw loose on the IGBT module or heat sink on

inverter PC board ?

Is there a blockage in the heat

sink cooling duct ?

Ye s

Check the circuit wiring, for example wiring to the

inverter compressor or connector connection.

Check power supply.

Check fan and fan motor.

Tighten screws.

Remove blockage.

Check inverter PC board.

Page 62

Control features

Outdoor unit

No. Control Description Diagram

1 Defrost • During heating operation, defrost is

(Heating mode) controlled by the outdoor unit heat

exchanger temperature sensor (TE).

• When the cumulative operating time with TE in zone [A] has amounted to 25 minutes, defrost operation starts. Subsequent defrosts occur after a cumulative time of 55 minutes. When heating operation resumes after defrost, the timer is reset.

• The maximum defrost period after TE returns to zone [B] is 1 minute.

• Heating operation resumes immediately after TE returns to zone [C].

2 Oil retrieval • During cooling operation, oil retrieval is

(Cooling mode) performed if one or more Indoor units are

OFF.

• If this condition is satisfied, when cooling operation commences, oil retrieval takes place for 1 minute. If cooling operation continues, oil retrieval is repeated for 1 minute every 60 minutes.

• During oil retrieval the following occurs: a. All Multi Controller PMVs are opened.

The degree of opening is dependant on the capacity of the Indoor unit .

b. If the D.O.L. compressor is OFF the

inverter compressor speed increases to SD.

• When cooling operation ends the timer is reset.

3 Superheat control • Superheat is controlled by the Multi

(Cooling mode) Controller for cooling operation.

The level of superheat is determined by the difference between the evaporator outlet temperature for each indoor unit (ThA, B, C, D) and the saturation temperature (ThX).

• If the superheat of an indoor unit enters zone [Y], the relevant M/C PMV opens further to compensate for this increase. The degree of additional opening is dependant on the capacity of the indoor unit.

• When zone [Z] is reached the PMV opening is held at the level set in zone [Y].

• When the level of superheat returns to zone [X] the control is cancelled.

Temp.

(°C)

-3

60 min.

1 min.

Oil

retrieval

Superheat

(°C)

Cooling mode

1 min.

Oil

retrieval

< 60 min.

Compr. off

Timer reset

Page 63

Control features

Outdoor unit/Multi Controller

No. Control Description

4 Simultaneous a. Changeover between cooling and heating operations for each indoor unit.

cooling/heating operation The solenoid valves inside the Multi Controller are energised when operation

commands are sent from the indoor units.

• SVS valve (suction side) opens for a cooling command.

• SVD valve (discharge side) opens for a heating command.

b. Determination of the outdoor unit operation mode and frequency of the

compressor.

These are determined by the difference between the total requested cooling command frequencies and the total requested heating command frequencies of all Indoor units.

c. Outdoor unit refrigerant control during cooling dominant mode.

• Refrigerant flow is controlled by PMV2. The degree of opening is

controlled by the difference of all requested cooling and heating command frequencies and the compressor operation frequency.

This flow control is required to divide cooling exhaust heat appropriately between indoor units in heating mode and the outdoor unit heat exchanger.

• High pressure control is performed to ensure that the capacity of the

indoor units in heating is maintained. This is controlled by the outdoor unit fan control and the changeover from the main heat exchanger to the sub heat exchanger.

d. Outdoor unit refrigerant control during heating dominant mode.

• Superheat control is performed by the outdoor unit expansion valve.

• Evaporating temperature control is performed by the outdoor unit fan

control to ensure that the capacity of the Indoor units in cooling mode is maintained.

• Changeover from expansion valve to capillary control is performed

when there is a minimal difference between the cooling and heating demands and the heat absorption of the outdoor unit heat exchanger is low.

Page 64

Valve and sensor function and operation

Multi Controller

Multi Controller - valve functions

Symbol Name of valve Description of function

PMV (A, B, C, D) Flow rate control valve This opens to the extent corresponding to the capacity

and performance required of each indoor unit.

SVS (A, B, C, D) Suction gas valve Opens when commands from the indoor units require

cooling operation.

SVD (A, B, C, D) Discharge gas valve Opens when commands from the indoor units require

heating operation.

SVSS Pressure reducing Opens when the number of units in heating operation

solenoid valve is reduced (heating to shutdown or cooling).

Opens when defrost operation starts. Opens during oil retrieval control in cooling operation.

SVDD Pressure increasing Opens when the number of units in heating operation

solenoid valve is increased (shutdown or cooling to heating).

Opens while control is performed to prevent liquid in discharge pipe from being blocked.

SVH Superheat solenoid valve Opens when unit in cooling operation is present.

Multi Controller - valve operation

Outdoor operation mode Indoor operation mode SVD SVS PMV

Shutdown Shutdown, fan OFF OFF Fully closed During operation Shutdown, fan OFF ON Fully closed

Cooling OFF ON Rated opening Cooling thermo-control (@ setpoint) OFF OFF ON Fully closed Heating ON OFF Rated opening Heating thermo-control (@ setpoint) OFF ON OFF Fully closed

Page 65

Valve and sensor function and operation

Outdoor unit

Outdoor unit - valve functions

Symbol Name of valve Description of function

20SF 4-way reversing valve OFF: Normal operation. (4-way valve) Cooling operation ON: Low load condition when sub heat exchanger is

required. Used in combination with SV15.

4-way reversing valve ON: Normal operation. Heating operation OFF: Defrost operation.

SV1 High-pressure release Heating operation.

solenoid valve Energised when TE >11°C

SV2 Hot gas bypass solenoid Opens when Pd < 13 kgf/cm2G (ccoling)

valve (For cooling-dominant mode and sub heat exchanger

operation Pd < 17 kgf/cm2G - 3-pipe only). Opens when outdoor ThO < 0°C

SV4 Solenoid valve for D.O.L. Opens when the D.O.L. compressor starts for

compressor start-up unloading. SV5 Gas balance Opens when compressor stops. SV13 Cooling solenoid valve Opens for cooling-only operations. SV14 Solenoid valve for SV14 opens for heating operation.

expansion valve. SV15 Sub heat exchanger Opens for sub heat exchanger requirement.

solenoid valve SV16 Solenoid valve for capillary SV16 opens for low load conditions during heating-

dominant operation.

SV17 Solenoid valve for compressor Open when compressor ON.

Closed when compressor OFF.

PMV1 Cooling bypass flow Opens when ThD1 or ThD2 > 110°C.

control valve Opens when ThS > 20°C. PMV2 Outdoor flow control valve Opens during cooling-dominant operation.

Degree of opening depending on cooling/heating demands.

Page 66

Valve and sensor function and operation

Valve operation

Outdoor unit - valve operation

Outdoor operation mode 20SF SV15 SV13 SV14 SV16 SV17 PMV2

Cooling operation Outdoor main heat OFF OFF ON OFF OFF ON -

exchanger

Sub heat exchanger ON ON ON OFF OFF ON Heating operation - ON OFF OFF ON OFF ON Simultaneous Outdoor main heat OFF OFF OFF OFF OFF ON Opening degree

cooling-dominant exchanger control operation Sub heat exchanger ON ON OFF OFF OFF ON Opening degree

control Simultaneous Expansion valve ON OFF OFF ON OFF ON heating-dominant Capillary ON OFF OFF OFF ON ON -

operation

Manual operation of valves

Note: 1. Ensure that the system is OFF before valves are manually operated.

2. Valves will reassume their required position unless electrically isolated.

a. Multi Controller

Display switch Valve Short point position

0 PMV A TP 1 TP 2 1 PMV B Selected valve is fully opened for 2 Selected valve is fully closed for 2 2 PMV C minutes. minutes 3 PMV D

b. Outdoor unit

SW1 SW2 Short point Operation Function

0 N/A TP1 Valves will automatically assume PMV 1 fully open for 2 minutes. 1 their required position after 2 PMV 2 fully open for 2 minutes. 0 TP2 minutes. PMV 1 fully closed for 2 minutes. 1 PMV 2 fully closed for 2 minutes. 2 0 TP3 Push SW04 Solenoid valves manually energised

in sequence when pressed.

Press SW03 Solenoid valves automatically

energised in sequence (1 second intervals)

Note:

During Manual/Automatic operation of outdoor valves, SV17 will not be energised. To confirm operation of SV17 operation is as follows: Energised valve when compressor ON.

Page 67

Valve and sensor function and operation

Sensor and switch operation

Multi Controller sensor operation

Temperature According to a difference between the evaporator outlet temperature and sensor (ThA, B, C, D) saturation temperature (ThX):

a. Performs superheat control.

(cooling operation)

b. Determines the degree of opening of PMV 2.

(cooling-dominant operation)

Outdoor unit sensor and switch operation

Discharge pressure Determines the frequency of the inverter compressor and the ON/OFF status of sensor D.O.L. compressor.

Controls the outdoor unit fan operation. Controls the hot gas bypass SV2. Controls the changeover from outdoor unit main heat exchanger to sub heat exchanger.

Suction temperature Controls the degree of opening of PMV 1. sensor (ThS) Stops operation when ThS > 40°C for 10 minutes (Fault code [A7]).

Discharge temperature Controls the degree of opening of PMV 1. sensor (ThD1, ThD2) Stops operation when the discharge temperature > 130°C (Fault code [A6]).

Outdoor unit heat Controls the defrost operation. exchanger sensor (TE) Controls the outdoor unit fan operation. Heating operation Controls the high pressure release valve SV1.

Outdoor temperature Controls the hot gas bypass SV2. sensor (ThO) Controls the outdoor unit fan operation.

Prevents heating operation when ThO > 25°C. High pressure switch Stops operation when Pd > 30 kgf/cm2G. Low pressure switch Stops operation when suction pressure < 0.25 kgf/cm2G:

• After 30 seconds for cooling operation.

• After 10 minutes for heating operaton.

The low pressure switch is ignored during defrost operation.

Page 68

Refrigerant pipe installation

Leak test

Airtight test

Carry out an airtight test after the refrigerant piping is complete. For an airtight test, connect a nitrogen gas bottle as shown, and apply pressure (use oxygen-free nitrogen, OFN).

The pressure test must be completed before supplying power to ensure that the Multi Controller PMVs (pulse modulating valves) are open.

The test must be completed with the indoor units, Multi Controllers and outdoor unit connected.

• Be sure to carry out the test from the service ports of the packed valves at the discharge gas, liquid and suction gas side.

• Keep all of the valves at discharge gas, liquid and suction gas sides fully closed. Nitrogen may enter the cycle of the outdoor unit. Therefore, retighten the valve rod before applying pressure. (For all valves.)

• For each refrigerant line, apply pressure gradually at the discharge gas, liquid and suction gas sides.

Never use oxygen, or a flammable noxious gas.

Detailed drawing of packed valve

Service port at gas discharge side

manifold

Service port at gas suction side

Service port at liquid side

Packed valve fully closed (gas suction side)

Brazed

Flare

connection

Flare

connection

Inverter outdoor unit

Service port

Packed valve fully closed (liquid side)

Packed valve fully closed (gas discharge side)

Copper pipe ø 6.4

Low pressure gauge

High pressure gauge

Gauge manifold

Regulator

Copper pipe ø 6.4

Nitrogen

gas

To detect a large leakage Step 1: 0.3 MPa (3 kg/cm2 G) Apply pressure for 3 minutes or more Step 2: 1.5 MPa (15 kg/cm2 G) Apply pressure for 3 minutes or more

To detect a fine leakage Step 3: 3.0 MPa (30 kg/cm2 G) Apply pressure for 24 hours

• Check for a reduction in pressure. If there is no reduction in pressure this is acceptable. If there is a reduction in pressure check for a leakage. (Note: If there is a difference of ambient temp. between when the pressure was applied and 24 hours later, then pressure could change by approx. 0.01 MPa (0.1 kg/cm2 G) - so correct the pressure change.

Page 69

Refrigerant pipe installation

Vacuuming

Leak position check

If a pressure drop is detected, check for leakage at connecting points. Locate the leakage by listening, feeling, using foaming agent, etc. - then rebraze or retighten.

Air purge

The air purge must be completed before supplying power to ensure the Multi Controller’s PMVs are open.

Using a vacuum pump, complete an air purge. Never use refrigerant gas.

• After the airtight test, discharge the nitrogen gas.

• Connect a gauge manifold to the service port at discharge gas, liquid and suction gas sides, and connect a vacuum pump as shown.

• Be sure to vacuum at discharge gas, liquid and suction gas sides.

Detailed drawing of packed valve

Packed valve fully closed (gas suction side)

Inverter outdoor unit

Low pressure gauge

High pressure gauge

Gauge manifold

Service port at gas discharge side

manifold

Service port at gas suction side

Service port at liquid side

Brazed

Flare

connection

Flare

connection

Service port

Packed valve fully closed (liquid side)

Packed valve fully closed (gas discharge side)

Vacuum pump

• Use a vacuum pump with high vacuum carry-over degree (-0.013 x 105 Pa; 0.750 mm Hg or less) and large displacement (40 l/min. or more).

• Ensure to create a vacuum at -0.013 x 105 Pa (0.75 mm Hg) at the discharge gas, liquid and suction gas.

• After the procedure has been completed, replace the vacuum pump with a refrigerant bottle and add the refrigerant if required.

Page 70

Refrigerant pipe installation

Charging the system with additional refrigerant

Adding the refrigerant

After the airtight test, replace the vacuum pump with a refrigerant bottle to charge the system.

Calculating the additional refrigerant required

The Super Multi contains sufficient refrigerant to operate an installation having 5 metres of pipework (when delivered). The refrigerant amount at shipment does not include the refrigerant needed for the piping - so first calculate this amount, and then add it.

The total refrigerant charge must be calculated by the weight and within a tolerance of ± 50 g.

Refrigerant charge amount shipped from the factory:

Outdoor unit model name MAR-F105HTM8-PE Charging amount (kg) 19.0 Maximum gas charge (kg) 36.3

The amount of additional refrigerant is calculated from the actual length of the liquid pipe.

To calculate the additional refrigerant volume, refer to the diagram and follow the steps below:

(i) The main pipe length is taken as the addition of pipes X, Y and Z.

(ii) The sub pipe length is taken as the addition of the two longest of the four (if 4 Multi Controllers).

(iii) The branch pipe lengths must be individually calculated using the 8 longest pipes.

(iv) Do not attempt to add gas above the maximum shown in the table above.

(v) For systems with one Multi Controller ignore the sub-pipe section within the additional gas charge

calculation.

(vi) When using three Multi Controllers, it is important that a reducer is used on the pipework for the third

Multi Controller. Pipework before the reducer is classed as main piping and after as sub piping.

Charging the system

• Keeping the outdoor unit valve closed, charge the refrigerant from the service port on the liquid side.

• If the specified amount of refrigerant cannot be charged - fully open all the outdoor unit’s valves, then perform the cooling operation with the valve at the gas side slightly closed.

• If leaks cause a shortage of refrigerant - recover the refrigerant from the system, and recharge with new refrigerant to the total refrigerant charge.

• Prolonged operation with either an overcharge or deficiency in refrigerant will lead to a loss of performance, increased running costs and will cause damage to the machine. Warranty will be void.

Page 71

Additional refrigerant

One Multi Controller

Additional refrigerant

Piping

Outdoor

Two Multi Controllers

Outdoor

Three Multi Controllers

Outdoor

Indoor

M/C

Indoor

M/C

Table 1 - Branch pipes

RAV-10* : 0.030 kg/m RAV-13* : 0.030 kg/m

Indoor

RAV-16* : 0.030 kg/m RAV-26* : 0.045 kg/m

M/C

RAV-36* : 0.045 kg/m RAV-46* : 0.045 kg/m

Example: RAV-464CH-PE i RAV-46*

Four Multi Controllers

Indoor

Outdoor

Pipe Additional gas/metre Additional gas

MAR-F105 - main pipe L1 (X+Y+Z) (minus 2 m) x 0.19 kg/m = 1st longest sub pipe L2 (minus 1 m) x 0.125 kg/m = 2nd longest sub pipe L2 (minus 1 m) x 0.125 kg/m = 1st longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 2nd longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 3rd longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 4th longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 5th longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 6th longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 7th longest branch pipe L3 (minus 2 m) x Refer to Table 1 = 8th longest branch pipe L3 (minus 2 m) x Refer to Table 1 =

M/C

L1 = Main pipe (X + Y + Z) L2 = Sub pipe

Total additional gas charge = kg

L3 = Branch pipe

Page 72

Refrigerant pipe installation

Additional refrigerant charging method

(1) Loosely connect the refrigerant cylinder hose to the gauge manifold, then open the source valve VH on

the cylinder, purge the air in the hose, and then tighten the hose.

(2) As shown in the diagram below, turn the refrigerant cylinder upside down, open the valve VH on the

gauge manifold, and then charge the liquid side pipe with refrigerant in the liquid state. (Note that with some types of refrigerant cylinders, the liquid refrigerant will be output through siphoning action with the cylinder in the normal upright position.) If the proper charging amount cannot be reached, close the valve VH, turn the refrigerant cylinder upright, open the liquid-side and balance packed valves completely, and open the gas-side packed valve only half way. Begin the cooling operation, open valve VL, and then charge the gas-side pipe with refrigerant in the liquid state.

(3) While watching the scales display, quickly close the valve VL completely when the system has been

charged with the proper amount of additional refrigerant. Then close the source valve Va on the cylinder, and open the gas-side packed valve completely.

(4) Record the amount of additional refrigerant that was added to the system on the nameplate inside the

front panel (lower) of the outdoor unit.

Indoor unit

Liquid pipe

Gauge manifold

Gas pipe

Refrigerant bottle

Scales

Packed valve (liquid side)

Low

High

pressure

Gas

Liquid

Refrigerant gas

Packed valve (discharge gas side)

Outdoor unit

Page 73

Exploded view and service parts

Outdoor unit

Page 74

Exploded view and service parts

Outdoor unit

Page 75

Exploded view and service parts

Outdoor unit

Ref. Service Description

part No.

01 43A00020 Plate side (Right) 02 43A00021 Plate side (Left) 03 43A00022 Air-in cabinet (Front) 04 43A00023 Air-in cabinet (Back) 05 43A00024 Cabinet-down (Front) 06 43A00025 Cabinet-down (Back) 07 43A00026 Service panel 08 43A00027 Air-out cabinet 09 43A20004 Propeller fan - PY631 10 43A41504 Compressor - 10 HP (INV) 11 43A49011 Switch, high pressure 12 43A49006 Switch, high pressure 13 43151230 Switch, low pressure 14 43A49012 Pressure sensor service kit 15 43A46038 Solenoid coil assembly 16 43A46039 Solenoid coil assembly 17 43A6040 Solenoid coil assembly 18 43146252 Check valve 19 43A46032 Check valve - Dia. 15 mm 20 43146351 Service valve (1-1/8”) 21 43146503 Packed valve (5/8”) 22 43146504 Packed valve (3/4”) 23 43146398 Valve body 24 43046151 2-way valve 25 43A46041 Pulse modulating valve (PMV 1) 26 43A46042 Pulse modulating valve (PMV 2) 27 43A46010 Expansion valve 28 43A46007 4-way valve

Note:

Part 35 - Replace both dryers at the same time.

Ref. Service Description

part No.

29 43A48005 Accumulator 30 43A48006 Liquid tank 31 43A60013 Fusible plug 32 43A43018 Condenser assembly - right 33 43A43019 Condenser assembly - left 34 43A44089 Sub condenser 35 43A45003 Dryer-XH-10C 36 43A46036 Check joint 37 43147529 Strainer 38 43147537 Strainer 39 43A57002 Accumulator heater 40 43A51005 Isolator 41 43A21022 Fan motor 42 43107200 Spring 43 43195198 Spacer 44 43195186 Rubber cushion - under 45 43195185 Rubber cushion - upper 46 43A95001 Rubber support cushion 47 43A19011 Fan guard 48 43A16007 Wiring diagram 49 43A55008 Capi-form-SV15 50 43A55009 Capi-form-4WV 51 43A55010 Capi-form-SV1 52 43A55011 Capi-SV2 (straight) 53 43A55012 Capi-form-SV16 54 43A47034 Capi-form-compressor 55 43A86001 EP window 56 43A89002 Push fastener 57 43A89003 Adjuster pen

Page 76

Exploded view and service parts

Outdoor unit - inverter assembly

Ref. Service Description

part No.

101 43A52005 Magnetic contactor - FC - 3 102 43A58009 Transformer - TT01 103 43A55004 MF - capacitor - 8µF/450 V AC 104 43A55005 Capacitor - electrolytic -

2200µF/400 V 105 43A50030 Temperature sensor TS - blue 106 43A50031 Temperature sensor THO - green 107 43A50032 Temperature sensor TE - black 108 43A50015 Temperature sensor TD1 - white 109 43A50016 Temperature sensor TD2 - red 110 43A50033 Thermistor (PTC) 111 43A69016 Heatsink 112 43A69035 PC board (IPDU) MCC-1342 113 43A69018 PC board (noise filter) MCC-1366 144 43A69036 PC board (interface) MCC-1223 115 43A69037 PC board (communication)

MCC-1387 116 43A60034 Terminal-6P 117 43A60035 Terminal-9P

Ref. Service Description

part No.

118 43A34001 Relay 119 43A60016 Terminal block - 3P/60 A 120 43A55006 Reactor - CH - 25 - 2FK 121 43A60020 Fuse - 6 A 122 43A60021 Fuse - 20 A 123 43A52006 Magnetic contactor - FMCa -

1S - 02 124 43A60022 Fuse holder - 30 A 125 43A60023 Fuse - 3.15 A 126 43A60024 Fuse - 6.3 A 127 43A63002 Bushing 128 43A63003 Collar 129 43A63004 Supporter (PCB) 130 43A63005 Supporter assembly 131 43A63006 Supporter assembly 132 43A60036 Fuse - 20 A 133 43A60037 Fuse - 10 A 134 43A60038 Fuse-block

Note:

Part 104 - Replace both capacitors at the same time.

Page 77

Exploded view and service parts

3-pipe Multi Controller

3-pipe Multi Controller (RBM-Y1034F-PE, RBM-Y1044F-PE)

Ref. Service Description

part No.

1 43107215 Holder, sensor 2 43146443 Solenoid coil 3 43046151 2-way valve 4 43046156 Check valve 5 43046269 Pulse modulating valve 6 43046270 2-way valve 7 43847010 Capillary tube 2.0 diameter 8 43146283 Check valve 9 43146398 Valve body 10 43146506 Solenoid coil 11 43A46011 Expansion valve 12 43146505 2-way valve 13 43151231 Float switch 14 43157252 Panel heater (RBM-Y1044F-PE)

Ref. Service Description

part No.

15 43157253 Panel heater (RBM-Y1034F-PE) 16 43189026 Insulator, liquid A 17 43189027 Insulator, liquid B 18 43189028 Insulator, header A

(RBM-Y1044F-PE)

19 43189029 Insulator, header A

(RBM-Y1034F-PE)

20 43189031 Insulator, header B

(RBM-Y1044F-PE)

21 43189032 Insulator, header B

(RBM-Y1034F-PE) 22 43A47011 Capillary tube 0.8 diameter 23 43A47012 Capillary tube 1.0 diameter

Page 78

Exploded view and service parts

3-pipe Multi Controller

3-pipe Multi Controller electrical parts assembly (RBM-Y1034F-PE, RBM-Y1044F-PE)

102

107

106

105

104

103

PJ7

PJ5

PJ4

PJ3

PJ2

PJ9 PJ1

PJ8

PJ6

PJ16

PJ12

THX

THD

THC

THB

THA

PJ13

PJ14

7-segment LED

LD1 LD2 LD3 LD4

Capacity rank

107

Display selector

ABCD

setting

switches

108

Outdoor unit

Indoor units

109

112

111

Note: Terminal D is present on RBM-Y1044F-PE unit only.

Ref. Service Description

part No.

101 43158139 Transformer (FT69) 102 43169627 PC board assembly (MCC-1222) 103 43150162 Sensor (ThA) 104 43150163 Sensor (ThB) 105 43150164 Sensor (ThC) 106 43150165 Sensor (ThD) (RBM-Y1044F-PE)

107 43150166 Sensor (ThX) 108 43151242 Micro-switch 109 43A60001 Terminal block 4P 110 43060776 Terminal block 2P 111 43A60008 Fuse T1A 112 43A60007 Fuse holder

110

part No.

Page 79

www.toshiba-aircon.co.uk

MADE IN UK

A90-0233

Revised October 2002