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

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.

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.

of 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.

2	4	4	8	0	0	0	1
j		j	j		}
Year of	Month of		Site of	Model batch serial number
manufacture	manufacture		manufacture
2001 = 1	41 = Jan.		8 = Plymouth
2002 = 2	42 = Feb.
2003 = 3	43 = Mar.
	44	= Apr.
	45	= May
	46	= Jun.
	47	= Jul.
	48	= Aug.
	49	= Sep.
	50	= Oct.
	51 = Nov.
	52	= Dec.

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
9	3		0	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

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

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-pipe	Indoor unit remote controller requesting cooling
outdoor unit
	Cooling operation
T-pieces	Indoor unit remote controller requesting heating
	Multi Controller
	Heating operation

3 pipes

Indoor units

Remote controller

2 pipes

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

2 - A

2 - B

2 - C

2 - D

Multi Controller 1

Capacity rank setting switch

Temp. sensor

Pulse modulating valve

Multi Controller microprocessor

Display LED

2-way valve

Multi Controller 2

Multi Controller microprocessor

Outdoor unit

Protection unit

Comp. sensor

Temp. sensor

Pulse modulating valve

Interface microprocessor

D.O.L. compressor

Display LED

2-way valve

Fan

4-way valve

Communication

PCB

Inverter compressor

IPDU Inverter

Protection	Power
unit	supply

9

10

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*)
4	16			13

Example of systems with maximum possible code:

OD

OD

Outdoor unit

OD

OD

Interface kit

D

DIF

DIF

IF

Multi Controller [code]	27	276	276	136	136 207	138	138	138	138
(Max. system code)	(27)		(32)		(32)			(32)

			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

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
		m	20: when the outdoor unit is installed below
Suction accumulator case heater		W	29 (240 V AC)

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.

1.5m vertical from base.

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.

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 F/450 V AC
Electrolytic capacitor		2200 F/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.

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.

15

Construction view

Outdoor unit

MAR-F105HTM8-PE

Dimensional drawings

4-15 x 20 (Slot)

80	Grounding part of bottom plate

755 790 630

Fixing bolt positions

Fixing bolt pitch

700

990

80	Grounding part of bottom plate

Foundation dimensions

Pipe outlet (bottom)

750

110 90

1700

1582
700
		601
88
	568	Knock outs on	3-ø 20 cable gland knock outs
	500	both sides of unit
			ø 32 cable gland knock outs
4-60 x 150 slot
	Slot pitch
			ø 25 cable gland knock outs
(for transport)
	Details of piping connections
		Refrigerant pipe connecting port
		(Gas suction side) braze connection (ø 28.6)

		315
		275
68	60	114

All dimensions in mm

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

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

4 - ø 25 drain holes

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

		A		Refrigerant pipe
				connection (brazing)
	C	D	90 55
				Liquid side ø 12.7
	E	F	90 55
	300		80 50	300
	110

Refrigerant pipe connection (brazing) Gas side ø 19

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

Refrigerant pipe connection (brazing) Delivery gas side ø 19

Refrigerant pipe connection (brazing) Suction gas side ø 28.6

17

Wiring diagrams

Outdoor unit

MAR-F105HTM8-PE

18

Wiring diagrams

Outdoor unit

19

Wiring diagram

Multi Controllers

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

Spark

killer

7-segment LED

Capacity rank setting

A B C D Display selector switch

Indoor	Indoor	Indoor	Indoor	Outdoor
unit A	unit B	unit C	unit D	unit

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
			Trans
					Reset
		Terminal plate			switch

•The dashed lines indicate wiring on site.

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

•234234 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

connection block for indoor unit D.

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

20

Refrigeration piping schematic diagram

Outdoor unit

21

Refrigeration piping schematic diagram

Normal operation - heat mode

High pressure gas

Low pressure gas

High pressure liquid

Low pressure liquid

Key:

22

Refrigeration piping schematic diagram

Normal operation - cool mode

High pressure gas

Low pressure gas

High pressure liquid

Low pressure liquid

Key:

23

Refrigeration piping schematic diagram

Simultaneous operation - mainly heat

High pressure gas

Low pressure gas

High pressure liquid

Low pressure liquid

Key:

24

Refrigeration piping schematic diagram

Simultaneous operation - mainly cool

High pressure gas

Low pressure gas

High pressure liquid

Low pressure liquid

Key:

25