Toshiba MCY-MAP0401HT, MCY-MAP0601HT, MCY-MAP0501HT SERVICE MANUAL

FILE NO : A06-007

Quick reference

R410A

01 Refrigerant Piping

Allowable length/height difference of refrigerant piping

Outdoor unit

Height difference between indoor and outdoor units

H1

Main pipe

L1

Branching pipe L2

Branch header

1st branching

a

b

c

d

section

Branching pipe

L3

Indoor unit

Equivalent length corresponded to farthest piping L

Equivalent length corresponded to farthest piping after 1st branching Li

Height difference

between indoor units

L4

H2

g

e

f

Y-shape

branch joint

A 1

			Allowable value	Piping section
	Total extension of pipe (Liquid pipe, real length)		180 m	L1 + L2 + L3 + L4 + a + b + c + d + e + f + g
	Furthest piping length	Real length	100 m	L1 + L3 + L4 + g
	L (*1)	Equivalent length	125 m
Piping
Length	Max. equivalent length of main pipe		65 m	L1
	Equivalent length of furthest piping from		35 m	L3 + L4 + g
	1st branching Li (*1)
	Max. real length of indoor unit connecting pipe		15 m	a, b, c, d, e, f. g
	Height between indoor	Upper outdoor unit	30 m	———
Height	and outdoor units H1	Lower outdoor unit	20 m	———
Difference
	Height between indoor units H2		15 m	———

*1 : Furthest indoor unit from 1st branch to be named “A”.

02

Allowable length/height difference of refrigerant piping for quiet places (with PMV Kit)

Outdoor unit

Main pipe
L1
Branching pipe L2	Branch header

a

b

c

d

PMV Kit

1st branching

section

Height difference

Height difference

h

i

j

k

between indoor unit

between indoor

Branching pipe

and PMV Kit

and outdoor units

H2

H1

L3

Indoor unit

* Between highest unit

and lower units.

Example)

Equivalent length corresponded to farthest piping L

H2

Equivalent length corresponded to farthest piping after 1st branching Li

L4

Y-shape

e

f

g

H2

n

branch joint

l

m

A 1

H2

				Allowable	Piping section
				value
		Total extension of pipe		150 m	L1 + L2 + L3 + L4
		(Liquid pipe, real length)			+ a + b + c + d + e + f + g + h + I + j + k+ l + m + n
		Furthest piping length	Real length	65 m	L1 + L3 + L4 + g + n
		L (*1)	Equivalent length	80 m
	Piping	Max. equivalent length of main pipe		50 m	L1
	Length	Equivalent length of furthest piping from		15 m	L3 + L4 + g + n
		1st branching Li (*1)
		Max. real length of indoor unit connecting pipe		15 m	a + h, b + i, c + j, d + k, e + l, f + m. g + n
		Real length between PMV KIT and indoor unit		2 m or more	h, i, j, k, l, m, n
				below 10 m
	Height	Height between indoor	Upper outdoor unit	30 m	———
		and outdoor units H1	Lower outdoor unit	20 m	———
	Difference
		Height between indoor unit and PMV kit H2		15 m	———

*1 : Furthest indoor unit from 1st branch to be named “A”.

Note)

Do not connect two or more indoor units to one PMV Kit. Arrange one indoor unit and one PMV Kit set to 1 by 1.

NO GOOD OK

PMV Kit

PMV Kit

Indoor unit

Indoor unit

03 Continued

Addition of refrigerant

After vacuuming work, exchange the vacuum pump with the refrigerant bomb and then start the additional charging work of refrigerant.

Calculating the amount of additional refrigerant required

When the system is charged with refrigerant at the factory, the amount of refrigerant needed for the pipes on site is not included. Calculate the additional amount required, and add that amount to the system.

Additional refrigerant charge amount is calculated from size of liquid pipe at site and its real length.

	Additional		Real length		Additional refrigerant charge		Compensation
	refrigerant charge R (kg)	=		×	amount per liquid pipe 1m	+	by outdoor HP
			of liquid pipe
	amount at site				(Table 1)		(Table 2)

Table 1

Pipe dia. at liquid side	Ø6.4	Ø9.5
Additional refrigerant amount/1m (kg)	0.025	0.055

Example : (0501 type)

L1

Table 2

Outdoor unit capacity type

0401 type

0501 type

0601 type

Compensation by outdoor HP (kg)

–0.8

–0.4

0

L2

L3

a

b

c

d

L1	Ø9.5 : 10m	L2	Ø9.5 : 10m	L3	Ø9.5 : 5m	a	Ø9.5 : 3m
b	Ø6.4 : 3m	c	Ø6.4 : 4m	d	Ø6.4 : 5m

Additional charge amount R (kg)

=(Lx × 0.025kg/m) + (Ly × 0.055kg/m) + (–0.4kg)

=(12 × 0.025kg) + (28 × 0.055kg) + (–0.4kg)

=1.44kg

Lx : Real total length of liquid pipe Ø6.4 (m) Ly : Real total length of liquid pipe Ø9.5 (m)

Note)

If the additional refrigerant amount indicates a negative result from the calculation, use air conditioner without the adding of any additional refrigerant.

Charging of refrigerant

•Keeping valve of the outdoor unit closed, be sure to charge the liquid refrigerant into service port at liquid side.

•If the specified amount of refrigerant cannot be charged, open fully valves of outdoor unit at liquid and discharge/suction gas sides, operate the air conditioner in COOL mode under condition that valve at suction gas side is a little returned to close side, and then charge refrigerant into service port at suction gas side. In this time, choke the refrigerant slightly by operating valve of the bomb to charge liquid refrigerant.The liquid refrigerant may be charged suddenly, therefore be sure to charge refrigerant gradually.

•When refrigerant leaks and refrigerant shortage occurs in the system, recover the refrigerant in the system and recharge refrigerant newly up to the correct level.

REQUIREMENT

Entry of refrigerant charge amount

•Complete the refrigerant record column found on the wiring diagram, with detail of the additional refrigerant amount and name of service engineer at the time of installation.

•The total amount of refrigerant refers to the shipment charge plus any additional refrigerant at the time of installation. The refrigerant amount at shipment is indicated on the unit name plate.

Refrigerant Cycle Diagram

04

Model : MCY-MAP0401/0501/0601HT, MCY-MAP0401/0501/0601HT2D

Outdoor unit

Heat exchanger

Sensor (TE)

Strainer
Capillary	Solenoid valve	4-way valve
tube 2	(SV5)
PMV
	Check valve
Strainer
		Solenoid valve
	Check joint	(SV2)
Sensor (TL)
High-pressure
sensor
		Solenoid valve
High-pressure		(SV4)
switch
	Muffler

Sensor (TD)

Liquid tank

Strainer

Check joint

Compressor (Inverter)

Sensor (TO)

Sensor (TS)

Capillary

tube 1

Low-pressure sensor

Check joint

Accumulator

Liquid side	Gas side
packed valve	ball valve

05 Continued

Explanation of Functional Parts

Functional part name			Functional outline	Connector
Solenoid valve	SV2	1)	Low-pressure release function	CN312 (White)
		2)	High-pressure release function
		3)	Gas balance function during off time
		4)	Hot gas bypass into accumulator
	SV4	1)	High-pressure release function	CN311 (Blue)
		2)	Low-pressure release function
	SV5	1)	Preventive function for high-pressure rising in heating operation	CN310 (White)
Capillary tube	1	ID : Ø1.5, Length : 200 mm
	2	ID : Ø2.2, Length : 100 mm
4-way valve		1)	Cooling/heating exchange	CN317 (Blue)
		2)	Reverse defrost
PMV (Pulse motor valve)		1)	Super heat control function	CN300 (White)
		2)	Sub-cool adjustment function in cooling operation
Temp. sensor	TD	1)	Protection of compressor discharge temp. Used for release	CN502 (White)
	TS	1)	Controls super heat in heating operation	CN504 (White)
	TE	1)	Controls defrost in heating operation	CN505 (Green)
		2)	Controls outdoor fan in heating operation
	TL	1)	Detects under cool in cooling operation	CN521 (White)
	TO	1)	Detects outside temperature	CN507 (Yellow)
High-pressure sensor		1)	Detects high-pressure and controls compressor capacity	CN501 (Red)
		2)	Detects high-pressure in cooling operation and controls the fan in low
			ambient cooling operation
Low-pressure sensor		1)	Detects low-pressure in cooling operation and controls compressor capacity	CN500 (White)
		2)	Detects low-pressure in heating operation and controls the super heat
Compressor case heater		1)	Prevents liquid accumulation to compressor	CN316 (White)
Accumulator case heater		1)	Prevents liquid accumulation to accumulator	CN321 (Red)

06

	Wired
	remote	Check code name
	controller
	display
	E01	Communication error between indoor and remote controller
		(Detected at remote controller side)
	E02	Remote controller sending error
	E03	Communication error between indoor and remote controller
		(Detected at indoor side)
	E04	Indoor/outdoor communication circuit error
		(Detected at indoor side)
	E06	Decreased number of indoor units
	—	Indoor/outdoor communication circuit error
		(Detected at outdoor side) [E07]
	E08	Duplicated indoor addresses
	E09	Duplicated master remote controllers
	E10	Communication error between indoor P.C. board assembly
	E12	Automatic address start error
	E15	No corresponding indoor unit during automatic address
	E16	No. of connected indoor units / Capacity over
	E18	Communication error between indoor header and follower units
	E19	Outdoor unit quantity error
	E20	Other line unit connected during automatic address
	E23	Communication sending error
	E25	Duplicated outdoor follower address setup
	E31	IPDU communication error
	F01	Indoor TCJ sensor error
	F02	Indoor TC2 sensor error
	F03	Indoor TC1 sensor error
	F04	TD1 sensor error
	F06	TE1 sensor error
	F07	TL sensor error
	F08	TO sensor error
	F10	Indoor TA sensor error
	F12	TS1 sensor error
	F13	TH sensor error
	F15	Outdoor temp sensor miscabling (TE1, TL)
	F16	Outdoor pressure sensor miscabling (Pd, Ps)
	F23	Ps sensor error
	F24	Pd sensor error
	F29	Indoor other error
	F31	Outdoor EEPROM error
	H01	Compressor breakdown
	H02	Compressor error (lock)

Wired

remote Check code name controller

display

	H03	Current detection circuit system error
	H04	Compressor 1 case thermo operation
	H06	Low-pressure protective operation
	L03	Duplicated indoor center units
	L04	Duplicated outdoor line address
	L05	Duplicated indoor units with priority
		(Displayed on indoor unit with priority)
	L06	Duplicated indoor units with priority
		(Displayed on the unit other than indoor unit with priority)
	L07	Group line in individual indoor unit.
	L08	Indoor group / address unset
	L09	Indoor capacity unset
	L10	Outdoor capacity unset
	L20	Duplicated central control addresses
	L29	IPDU quantity error
	L30	Interlock in indoor unit from outside
	—	Extended IC (Integrated Circuit) error
		(Detected at outdoor unit side) [L31]
	P01	Indoor fan motor error
	P03	Discharge temp TD1 error
	P04	Actuation of high-pressure SW
	P07	Heat sink overheat error
	P10	Indoor overflow error
	P12	Indoor fan motor error

The standard ducted unit air conditioner utilizes a direct current (DC) indoor fan motor that features current limiting protection.

In the event power is not isolated prior to service, the protective control circuit will activate and stop the unit operating.

The check code “P12”will be displayed on the remote controlleronce service work has been completed, this code can be cleared by switching off then on the electrical isolation device of the indoor unit and pressing the operation stop button on the remote controller to reset the system.

	P13	Outdoor liquid back detection error
	P15	Gas leak detection (TS1 condition)
		Gas leak detection (TD condition)
	P17	Discharge temp TD2 error
	P19	4-way valve operation error
	P20	High-pressure protective operation
	P22	Outdoor fan IPDU error
	P26	G-Tr short-circuit protection error
	P29	Compressor position detection circuit error
	P31	Other indoor error (Group follower unit error)

07 Switch (SW08) Set Up ofThe Outdoor Unit

When using the outdoor unit under the following conditions, it is necessary to set up DIP switch on the outdoor unit interface P.C. board.

Cautions

When anyone of the following condition is applied, set up DIP switch.

1.When using PMV Kit in the Mini-SMMS system

2.When using the indoor unit under high humidity condition

[Reference]

Indoor side : 27°C dry bulb temperature 24°C wet bulb temperature Operation time 4 hours or more.

1Setup method

• Turn on DIP switch [SW08] on the interface P.C. board of the outdoor unit.

Outdoor unit interface P.C. board

	SW11				SW12			SW13					SW14
ON		3	4	ON		3	4	ON	2	3	4	ON		2	3	4
1	2			1	2			1					1
	SW06				SW07			SW08		SW09					SW10
ON		3	4	ON		3	4	ON		ON	2	3	4		ON	2	3	4
1	2			1	2			1		1					1

Switch [SW08]

Check at Main Power-ON

08

After turning on the main power of the indoor units and outdoor unit in the refrigerant line to be executed with a test operation, check the following items in outdoor and each indoor unit.

(After turning on the main power, be sure to check in order of indoor unit → outdoor unit.)

If the power supply of the outdoor unit has been firstly turned on, [E19] appears on the 7-segment display on the interface P.C. board until the power supply of the indoor unit is turned on. However it is not an error.

<Check on outdoor unit>

1.Check that all the rotary switches, SW01, SW02, and SW03 on the interface P.C. board of the outdoor unit are set up to “1”.

2.If other error code is displayed on 7-segment [B], remove the cause of trouble referring to “ Troubleshooting”.

3.Check that [L08] is displayed on 7-segment display [B] on the interface P.C. board of the outdoor unit. (L08: Indoor address unset up)

(If the address setup operation has already finished in service time, etc, the above check code is not displayed, and only [U1] is displayed on 7-segment display [A].)

Interface P.C. board

7-segment display [A]

7-segment display [B]

SW01 SW02 SW03

<Check on indoor unit>

1.Display check on remote controller (In case of wired remote controller)

Check that a frame as shown in the following left figure is displayed on LC display section of the remote controller.

GOOD			NO
			GOOD
TEMP.		ON / OFF	TEMP.		ON / OFF
TIMER SET	FAN	MODE	TIMER SET	FAN	MODE
TIME	SWING/FIX	VENT	TIME	SWING/FIX	VENT
FILTER			FILTER
RESET TEST SET CL	UNIT		RESET TEST SET CL	UNIT
Normal status			Abnormal status
(Power and operation stop)			(Power is not normally turned on.)

If a frame is not displayed as shown in the above right figure, the power of the remote controller is not normally turned on. Therefore check the following items.

•Check power supply of indoor unit.

•Check wiring between indoor unit and remote controller.

•Check whether there is cutoff of cable around the indoor control P.C. board or not, and check connection failure of connectors.

•Check failure of transformer for the indoor microcomputer.

•Check indoor control P.C. board failure.

09 Address Setup

After power-ON, set up the indoor address from the interface P.C. board of the outdoor unit. (The address setup operation cannot be performed by power-ON only. )

Cautions

1.It requires approx. 5 minutes usually for 1 line to automatically set up address. However in some cases, it may require maximum 10 minutes.

2.It is unnecessary to operate the air conditioner for address setup.

3.Manual address setup is also available besides automatic setup.

Automatic address: Setup from SW15 on the interface P.C. board of the outdoor unit

Manual address: Setup from the wired remote controller. (For details, refer to section “Address setup procedure”)

Address Setup and Check Procedure

	Procedure	Item			Operation and check contents
	1	Indoor unit power-ON	Turn on power of indoor unit in refrigerant line to which address is set up.
	2	Outdoor unit power-ON	Turn on power of all the outdoor units in refrigerant line to which address is set up.
	3	7-segment display check	Check that [L08] is displayed on 7-segment display [B] on the interface P.C. board of the outdoor
			unit in the system to which address is set up.
			Confirm the corresponding items in “Address setup procedure”, and then set up address
	4	Address setup start	according to the operation procedure.
			(Be sure that the setup operation may differ in group control or central control.)
			Note) Address cannot be set up if switches are not operated.
		Display check after	• After address setup, [U1] [		] are displayed in 7-segment display section.
	5		• If an error code is displayed in 7-segment display [B], remove the cause of trouble referring to
		setup
			“Troubleshooting”.
			Using 7-segment display function, check the system information of the scheduled system.
			(This check is executed on the interface P.C. board of the outdoor unit.)
						Rotary switch setup			7-segment display
		System information				SW01	SW02	SW03	[A]	[B]
	6
		check after setup		System capacity		1	2	3	[No. of HP]	[HP]
				No. of connected outdoor unit		1	3	3	[Connected No. of units]	[ P]
				No. of connected indoor units		1	4	3	[Connected No. of units]
			After the above checks, return rotary switches SW01, SW02, SW03 to 1/1/1.

		7-segment		Push-switch	Push-switch
Interface P.C. board		display [A]		SW04	SW05
								Push-switch
								SW15
								7-segment
								display [B]

SW01 SW02 SW03

Rotary switches