Toshiba MAR-F105HTM8-PE DATA BOOK

A90-0233

Super Multi System

Service Manual

Air Conditioner - Multi Split Type System

HFC R407C

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

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.

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

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

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

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

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

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

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

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.

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.

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.

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.

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

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

MAR-F105HTM8-PE

Wiring diagrams

Outdoor unit

Wiring diagrams

Outdoor unit

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

Refrigeration piping schematic diagram

Outdoor unit

Refrigeration piping schematic diagram

Normal operation - heat mode

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Refrigeration piping schematic diagram

Normal operation - cool mode

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Refrigeration piping schematic diagram

Simultaneous operation - mainly heat

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

Refrigeration piping schematic diagram

Simultaneous operation - mainly cool

High pressure gas

Low pressure gas

Key:

High pressure liquid

Low pressure liquid

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