Page 1: Service Manual
FILE NO. SVM-13024-2 SERVICE MANUAL AIR-CONDITIONER (MULTI TYPE) <SUPER MODULAR MULTI SYSTEM - i> Outdoor Unit Model name: <Heat Pump Model> MMY-MAP0804HT8(J)P MMY-MAP0804HT8(J)P-E MMY-MAP0804HT8(J)P-TR MMY-MAP1004HT8(J)P MMY-MAP1004HT8(J)P-E MMY-MAP1004HT8(J)P-TR MMY-MAP1204HT8(J)P MMY-MAP1204HT8(J)P-E MMY-MAP1204HT8(J)P-TR MMY-MAP1404HT8(J)P MMY-MAP1404HT8(J)P-E MMY-MAP1404HT8(J)P-TR MMY-MAP1604HT8(J)P MMY-MAP1604HT8(J)P-E MMY-MAP1604HT8(J)P-TR MMY-MAP0804HT7(J)P MMY-MAP1004HT7(J)P MMY-MAP1204HT7(J)P MMY-MAP1404HT7(J)P MMY-MAP1604HT7(J)P <Cooling Only Model>...
Page 2: Table Of Contents
Contents SAFETY CAUTION ........... . 5 New Refrigerant (R410A) .
Page 3 Control Outline ............68 Applied Control and Functions (including Circuit Conﬁguration) .
Page 4 7-7. Service Support Function ............146 7-7-1.
Page 5 12 OUTDOOR UNIT PARTS REPLACEMENT METHODS ..... . 261 13 P.C. BOARD EXCHANGE PROCEDURES ....... . 274 13-1.
Page 6: Safety Caution
• The qualified service person is a person who installs, repairs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Corporation. He or she has been trained to install, repair, maintain, relocate and remove the air conditioners made by Toshiba Carrier Corporation...
Page 7 Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’ work clothing. In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below.
Page 8: Warning Indications On The Air Conditioner Unit
Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positions If removing the label during parts replace, stick it as the original. WARNING WARNING ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies Disconnect all remote electric...
Page 9: Precautions For Safety
PRECAUTIONS FOR SAFETY The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker for both the indoor and outdoor units to the OFF position. Otherwise, electric shocks may result.
Page 10 WARNING Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions. Only qualified service person (*1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and / or other problems.
Page 11 If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, put a sign in place so that no- Do not bring one will approach the work location before proceeding with the work.
Page 12 When the refrigerant gas leaks during work, execute ventilation. If the refrigerant gas touches to a fire, poisonous gas generates. A case of leakage of the refrigerant and the closed room full with gas is dangerous because a shortage of oxygen occurs. Be sure to execute ventilation.
Page 13 Only a qualified installer (*1) or qualified service person (*1) is allowed to install the air conditioner. If the air conditioner is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result. Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner.
Page 14: Declaration Of Conformity
Declaration of Conformity Manufacturer: TOSHIBA CARRIER (THAILAND) CO., LTD. 144 / 9 Moo 5, Bangkadi Industrial Park, Tivanon Road, Amphur Muang, Pathumthani 12000, Thailand Authorized Representative / Nick Ball TCF holder: Toshiba EMEA Engineering Director Toshiba Carrier UK Ltd. Porsham Close, Belliver Industrial Estate, PLYMOUTH, Devon, PL6 7DB.
Page 15 Speciﬁcations Sound power level (dBA) Model Weight (kg) Cooling Heating MMY-MAP0804HT8(J)P MMY-MAP0804HT7(J)P MMY-MAP0804HT8(J)P-E MMY-MAP0804HT8(J)P-TR MMY-MAP1004HT8(J)P MMY-MAP1004HT7(J)P MMY-MAP1004HT8(J)P-E MMY-MAP1004HT8(J)P-TR MMY-MAP1204HT8(J)P MMY-MAP1204HT7(J)P MMY-MAP1204HT8(J)P-E MMY-MAP1204HT8(J)P-TR MMY-MAP1404HT8(J)P MMY-MAP1404HT7(J)P MMY-MAP1404HT8(J)P-E MMY-MAP1404HT8(J)P-TR MMY-MAP1604HT8(J)P MMY-MAP1604HT7(J)P MMY-MAP1604HT8(J)P-E MMY-MAP1604HT8(J)P-TR MMY-MAP0804T8(J)P MMY-MAP0804T8(J)P-E − MMY-MAP0804T8(J)P-T MMY-MAP0804T8(J)P-ID MMY-MAP0804T8(J)P-SG MMY-MAP1004T8(J)P MMY-MAP1004T8(J)P-E − MMY-MAP1004T8(J)P-T MMY-MAP1004T8(J)P-ID MMY-MAP1004T8(J)P-SG MMY-MAP1204T8(J)P...
Page 16: Carrying In The Outdoor Unit
CARRYING IN THE OUTDOOR UNIT CAUTION Handle the outdoor unit carefully, observing the following items. • When using a forklift or other machinery for loading/unloading in transportation, insert the prongs of the forklift into the rectangular holes for handling as shown below. •...
Page 17 Weight centre and weight Weight centre of an outdoor unit Anchor bolt position Anchor bolt position Model type X (mm) Y (mm) Z (mm) Mass (kg) MAP080 MAP100 MAP120 MAP140 MAP160 – 16 –...
Page 18 SELECTION OF PIPE SIZE Coupling size of brazed pipe Connected section External size Internal size (Unit: mm) Connected section External size Internal size Standard outer dia. Min. depth of Min. thickness of connected Standard outer dia. insertion of coupling Oval value copper pipe (Allowable difference) +0.04...
Page 19: Adding Refrigerant
Adding refrigerant After finishing vacuuming, exchange the vacuum pump with a refrigerant canister and start additional charging of refrigerant. Calculation of additional refrigerant charge amount Refrigerant charge amount at shipment from the factory does not include the refrigerant for pipes at the local site. For refrigerant to be charged in pipes at the local site, calculate the amount and charge it additionally.
Page 20 Table 2 C (Corrective amount Combined HP (HP) Combined outdoor units (HP) of refrigerant) (kg) – – – 10HP – – – 12HP – – – 14HP – – – 16HP – – – 10.5 10HP – – 10HP 10HP –...
Page 21: New Refrigerant (R410A)
New Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer. 1. Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of refrigerant, the refrigerating oil has been also changed.
Page 22 4. Tools (1) Required Tools for R410A Mixing of different types of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types. 1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) 2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22) 3) Tools commonly used for R410A and for conventional refrigerant (R22) The table below shows the tools exclusive for R410A and their interchangeability.
Page 23: Wiring Diagrams
Wiring Diagrams 1-1. Outdoor Unit Models: MMY-MAP0804 * , MAP1004 * , and MAP1204 * – 22 –...
Page 24 Models: MMY-MAP1404 * and MAP1604 * – 23 –...
Page 25: Indoor Unit
1-2. Indoor Unit 1-2-1. 4-way Cassette Type Models: MMU-AP0094HP*, AP0124HP*, AP0154HP*, AP0184HP*, AP0244HP*, AP0274HP*, AP0304HP*, AP0364HP*, AP0484HP*, and AP0564HP* – 24 –...
Page 26: Compact 4-Way Cassette Type
1-2-2. Compact 4-way Cassette Type ∗ ∗ ∗ ∗ ∗ Models: MMU-AP0074MH , AP0094MH , AP0124MH , AP0154MH , and AP0184MH 6 4 3 1 2 5 6 4 3 1 2 5 CN309 (YEL) 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 1 2 3...
Page 27: 1-Way Cassette Type (Compact Type)
1-2-3. 1-way Cassette Type (Compact type) ∗ ∗ ∗ Models: MMU-AP0074YH , AP0094YH , and AP0124YH – 26 –...
Page 28: 1-Way Cassette Type Sh Series
1-2-4. 1-way Cassette Type SH series ∗ ∗ ∗ Models: MMU-AP0154SH , AP0184SH , and AP0244SH – 27 –...
Page 29: 2-Way Cassette Type 2 Series
1-2-5. 2-way Cassette Type 2 series Models: MMU-AP0072WH, AP0092WH, AP0122WH, AP0152WH, AP0182WH, AP0242WH, AP0272WH, AP0302WH, AP0482WH – 28 –...
Page 30: Concealed Duct Standard Type
1-2-6. Concealed Duct Standard Type ∗ ∗ ∗ ∗ ∗ ∗ Models: MMD-AP0074BH , AP0094BH , AP0124BH , AP0154BH , AP0184BH , AP0244BH ∗ ∗ ∗ ∗ ∗ AP0274BH , AP0304BH , AP0364BH , AP0484BH , and AP0564BH – 29 –...
Page 31: Concealed Duct Standard Type 6 Series
1-2-7. Concealed Duct Standard Type 6 series ∗ ∗ ∗ ∗ ∗ ∗ Models : MMD-AP0076BH , AP0096BH , AP0126BH , AP0156BH , AP0186BH , AP0246BH ∗ ∗ ∗ ∗ ∗ AP0276BH , AP0306BH , AP0366BH , AP0486BH , AP0566BH –...
Page 32: Concealed Duct High Static Pressure Type
1-2-8. Concealed Duct High Static Pressure Type ∗ ∗ ∗ ∗ ∗ Models: MMD-AP0184H , AP0244H , AP0274H , AP0364H , and AP0484H – 31 –...
Page 33 ∗ ∗ Models: MMD-AP0724H and AP0964H – 32 –...
Page 34: Slim Duct Type
1-2-9. Slim Duct Type ∗ ∗ ∗ ∗ ∗ Models: MMD-AP0074SPH , AP0094SPH , AP0124SPH , AP0154SPH , and AP0184SPH – 33 –...
Page 35: Slim Duct Type (Ap024, Ap027)
1-2-10. Slim Duct Type (AP024, AP027) ∗ ∗ Models: MMD-AP0244SPH , MMD-AP0274SPH – 34 –...
Page 36: Ceiling Type
1-2-11. Ceiling Type ∗ ∗ ∗ ∗ ∗ ∗ Models: MMC-AP0154H , AP0184H , AP0244H , AP0274H , AP0364H , and AP0484H – 35 –...
Page 37: High Wall Type 4Mh Series
1-2-12. High Wall Type 4MH series ∗ ∗ ∗ Models: MMK-AP0074MH , AP0094MH , and AP0124MH – 36 –...
Page 38: High Wall Type 3 Series
1-2-13. High Wall Type 3 series Models: MMK-AP0073H, AP0093H, AP0123H, AP0153H, AP0183H, AP0243H – 37 –...
Page 39: Floor Standing Cabinet Type
1-2-14. Floor Standing Cabinet Type ∗ ∗ ∗ ∗ ∗ ∗ Models: MML-AP0074H , AP0094H , AP0124H , AP0154H , AP0184H , and AP0244H – 38 –...
Page 40: Floor Standing Concealed Type
1-2-15. Floor Standing Concealed Type ∗ ∗ ∗ ∗ ∗ ∗ Models: MML-AP0074BH , AP0094BH , AP0124BH , AP0154BH , AP0184BH , and AP0244BH – 39 –...
Page 41: Floor Standing Type
1-2-16. Floor Standing Type ∗ ∗ ∗ ∗ ∗ ∗ ∗ Models: MMF-AP0154H , AP0184H , AP0244H , AP0274H , AP0364H , AP0484H , and AP0564H – 40 –...
Page 42: Air To Air Heat Exchanger With Dx Coil Unit
1-2-17. Air to Air Heat Exchanger with DX Coil Unit ∗ ∗ ∗ ∗ MMD-VNK502HEXE , MMD-VNK802HEXE , MMD-VNK1002HEXE , MMD-VNK1002HEXE2 – 41 –...
Page 43 c i t Fuse (printed circuit board) TCJ, TC1, TC2 c t i 43F11, 43F12 Relay for air supplying motor 43F21, 43F22 Relay for air exhausting motor RY701, RY702 Relay for air supplying motor c i t RY704, RY705 Relay for air exhausting motor c t i c i t (1) The dotted line represents a wire procured locally, and the dashed line represents an option sold...
Page 44 ∗ ∗ ∗ MMD-VN502HEXE , MMD-VN802HEXE , MMD-VN1002HEXE , MMD-VN1002HEXE2 – 43 –...
Page 45 c t i Fuse (printed circuit board) TFA sensor 43F11, 43F12 Relay for air supplying motor Fuse (motor) TCJ, TC1, TC2 Indoor coil sensor 43F21, 43F22 Relay for air exhausting motor RY701, RY702 Relay for air supplying motor RY704, RY705 Relay for air exhausting motor c t i (1) The dotted line represents a wire procured locally, and the dashed line represents an option sold separately.
Page 46: Fresh Air Intake Indoor Unit
1-2-18. Fresh Air Intake Indoor Unit Model: MMD-AP0481HFE (Option) 43F1 Surge absorber CN033 CN083 CN068 (GRN) (WHI) (BLU) CN030 CN104 CN102 CN101 CN100 CN103 (RED) (YEL) (RED) (BLK) (BRW) (GRN) RY007 CN080 P301 (GRN) CN073 RY004 EXCT Control P.C. Board (RED) RY006 for Indoor Unit...
Page 47 Models: MMD-AP0721HFE and MMD-AP0961HFE 43F1 Surge absorber (Option) 43F2 Surge absorber CN033 CN083 CN068 (GRN) (WHI) (BLU) CN030 CN104 CN102 CN101 CN100 CN103 (RED) (YEL) (RED) (BLK) (BRW) (GRN) RY007 CN080 P301 (GRN) CN073 RY004 EXCT (RED) Control P.C. Board RY006 CN304 (GRY) RY002...
Page 48: Parts Rating
Parts Rating 2-1. Outdoor Unit (50Hz model: MMY-MAP *** 4 * T8 * P * ) × × × × × l i o l i o 2TCTH-1 2-way valve coil AC220-240V 50Hz SV3B AC220-240V 50Hz SV3B,SV3E,SV3F 2-way valve coil FQ-G593 AC220-240V 50Hz SV2,SV3A,SV3C,SV3D,SV3E,SV41,SV42,SV5...
Page 49: Outdoor Unit (60Hz Model: Mmy-Map *** 4Ht7 * P)
2-2. Outdoor Unit (60Hz model: MMY-MAP *** 4HT7 * P) × × × × × l i o l i o 2TCTH-1 2-way valve coil AC208-230V 60Hz SV3B AC208-230V 60Hz SV3B,SV3E,SV3F 2-way valve coil FQ-D640 AC208-230V 60Hz SV2,SV3A,SV3C,SV3D,SV3E,SV41,SV42,SV5 AC208-230V 60Hz SV2,SV3A,SV3C,SV3D,SV6,SV41,SV42,SV43 AAG-M35FLTCTH-1 AAG-C25FLTCTH-1...
Page 50: Outdoor Inverter (50Hz Model: Mmy-Map *** 4 * T8 * P * )
2-3. Outdoor Inverter (50Hz model: MMY-MAP *** 4 * T8 * P * ) 3 Communication terminal block JXO-B2H AC30V (or no more than DC42V) / 1A, 6P l i f — t l i f — — — 10 Fuse (MCC-1596) GAC1 31.5A 31.5A/AC500V (P.C.
Page 51: Outdoor Inverter (60Hz Model: Mmy-Map *** 4Ht7 * P)
2-4. Outdoor Inverter (60Hz model: MMY-MAP *** 4HT7 * P) 3 Communication terminal block JXO-B2H AC30V (or no more than DC42V) / 1A, 6P l i f — t l i f — — — 10 Fuse (MCC-1596) GAC1 31.5A 31.5A/AC500V (P.C.
Page 52: Parts Layout In Outdoor Unit
2-5. Parts Layout in Outdoor Unit 8, 10, 12HP ∗ ∗ ∗ Model: MMY-MAP0804 , MAP1004 , MAP1204 – 51 –...
Page 53 14, 16HP ∗ ∗ Model: MMY-MAP1404 , MAP1604 – 52 –...
Page 54: Parts Layout In Inverter Assembly
2-6. Parts Layout in Inverter Assembly Outdoor Unit (8, 10, 12HP) ∗ ∗ ∗ Model: MMY-MAP0804 , MAP1004 , MAP1204 Inverter P.C. board for fan Interface P.C. board [Fan IPDU] [Outdoor control P.C. board] (MCC-1610) (MCC-1606) Noise Filter P.C. board (MCC-1608) Power supply terminal block...
Page 55 Outdoor Unit (14, 16HP) ∗ ∗ Model: MMY-MAP1404 , MAP1604 Inverter P.C. board for fan Interface P.C. board [Outdoor control P.C. board] [Fan IPDU] (MCC-1606) (MCC-1610) Noise Filter P.C. board (MCC-1608) Power supply terminal block Relay connector for central control Communication terminal block Magnet switch...
Page 56: Outdoor (Inverter) Print Circuit Board
2-7. Outdoor (Inverter) Print Circuit Board 2-7-1. Interface P.C. board (MCC-1606) Sensor input PMV4 output PMV2 output PMV1 output CN504 CN533 CN507 CN503 CN532 CN535 CN521 Option input/output CN502 CN531 CN534 CN520 CN505 CN511 CN508 CN510 CN513 CN523 CN514 CN509 CN512 High pressure SW CN305, 306, 307 UART communication...
Page 57: Inverter P.c. Board For Compressor (Mcc-1596) A3-Ipdu
2-7-2. Inverter P.C. board for compressor (MCC-1596) A3-IPDU – 56 –...
Page 58: Inverter P.c. Board For Fan (Mcc-1610)
2-7-3. Inverter P.C. board for fan (MCC-1610) CN602 CN702 UART CN504 communication between interfaces CN504 UART CN505 communication between CN705 Fan motor output U-phase A3-IPDU CN505 CN705 CN704 Fan motor output V-phase CN704 CN703 Fan motor output W-phase CN703 CN511 CN500 Reactor connecting terminal Power supply input...
Page 59: Refrigerant Piping Systematic Drawing
Refrigerant Piping Systematic Drawing Outdoor Unit (8, 10, 12HP) Model: MMY-MAP0804 , MMY-MAP1004 , MMY-MAP1204 Fan motor Right side (TO) Heat exchanger Left side Heat exchanger (TE1) (SV5) Reducer PMV1 4-way valve PMV2 (TS1) Check valve High-pressure sensor Low-pressure sensor (TL) (SV2) Fusible...
Page 60 Outdoor Unit (14, 16HP) Model: MMY-MAP1404 , MMY-MAP1604 Fan motor Right side (TO) Main heat exchanger PMV1 Sub heat exchanger at right side PMV2 Left side (TE1) Main heat exchanger Check valve PMV4 (TE2) Sub heat exchanger at left side Check valve 4-way valve High-pressure sensor...
Page 61 Explanation of Functional Parts (Connector CN321: White) SV3A 1) Supplies oil reserved in the oil header during ON time. (Connector CN321: White) SV3B 1) Returns oil supplied in the balance pipe to the compressor. (Connector CN321: White) SV3C 1) Pressurizes oil reserved in the oil header during ON time. (Connector CN322: White) SV3D 1) Reserves oil in the oil separator during OFF time.
Page 62: Indoor Unit
Indoor Unit Liquid Gas side side Strainer Capillary tube Heat exchanger at indoor side Pulse Motor Valve (PMV) Sensor (TCJ) Sensor (TC2) Sensor (TC1) Sensor Fan motor (TA) CAUTION MMU-AP007YH, AP012YH type air conditioners have no TC2 sensor. Explanation of functional parts in indoor unit Pulse Motor Valve (Connector CN082 (6P): Blue) 1) Controls super heat in cooling operation...
Page 63: Combined Refrigerant Piping System Schematic Diagrams
Combined Refrigerant Piping System Schematic Diagrams 4-1. Normal Operation (COOL Mode / DEFROST Mode) - High Outside Air Temperature (Roughly 20°C or Above) PMV1 PMV2 PMV4 PMV1 4-Way valve PMV2 4-Way valve Pressure sensor (high pressure) Pressure sensor Pressure sensor (low pressure) (high pressure) Pressure sensor...
Page 64: Normal Operation (Cool Mode) - Low Outside Air Temperature (Roughly Below 20°C)
4-2. Normal Operation (COOL Mode) - Low Outside Air Temperature (Roughly Below 20°C) PMV1 PMV2 PMV4 PMV1 4-Way valve PMV2 4-Way valve Pressure sensor (high pressure) Pressure sensor Pressure sensor (low pressure) (high pressure) Pressure sensor SV3D (low pressure) O.S. SV3D O.S.
Page 65: Normal Operation (Heat Mode)
4-3. Normal Operation (HEAT Mode) PMV1 PMV4 PMV1 4-Way valve PMV2 4-Way valve Pressure sensor (high pressure) Pressure sensor Pressure sensor (low pressure) (high pressure) Pressure sensor SV3D (low pressure) O.S. SV3D O.S. SV41 Accumulator SV42 Liquid tank Accumulator SV3C Liquid tank SV43 SV3C...
Page 66: Emergency Operation (Cooling Operation Under Header Outdoor Unit Backup Scenario)
4-4. Emergency Operation (Cooling Operation under Header Outdoor Unit Backup Scenario) Set Up as Temporary Header Unit during Emergency Operation Leakage from PMV: Liquid-side service valve Failure = Full closure PMV1 PMV1 PMV2 PMV2 PMV4 PMV4 4-Way valve 4-Way valve Pressure sensor Pressure sensor (high pressure)
Page 67: Emergency Operation (Heating Operation Under Header Outdoor Unit Backup Scenario)
4-5. Emergency Operation (Heating Operation under Header Outdoor Unit Backup Scenario) Set Up as Temporary Header Unit during Leakage from PMV: Emergency Operation Liquid-side service valve Failure = Full closure PMV1 PMV1 PMV2 PMV4 4-Way valve 4-Way valve Pressure sensor Pressure sensor (high pressure) (high pressure)
Page 68: Refrigerant Recovery From Failed Outdoor Unit (Pump-Down Operation Under Follower Outdoor Unit Backup Scenario)
4-6. Refrigerant Recovery from Failed Outdoor Unit (Pump-Down Operation under Follower Outdoor Unit Backup Scenario) Failure PMV1 PMV2 PMV4 PMV1 4-Way valve PMV2 4-Way valve Pressure sensor (high pressure) Liquid line bypass Pressure sensor Pressure sensor (low pressure) (high pressure) Pressure sensor SV3D (low pressure)
Page 69: Control Outline
Control Outline Indoor Unit Control Specifications Upon power 1. Identification of outdoor unit supply reset When the power supply is reset, the outdoor unit is identified, and control is redirected according to the identification result. 2. Indoor fan speed and air flow direction control availability settings Settings such as indoor fan speed and air flow direction control availability are replaced on the basis of EEPROM data.
Page 70 Fan speed 1. The fan operates in one of the four speed modes of “HIGH (HH)”, “MED (H)”, HH > H+ > H > control “LOW (L)” and “AUTO” on the basis of a command issued via the remote L+ > L > UL controller.
Page 71 Cold air 1. In heating operation, the upper limit of the fan tap is set according to the lower of TCJ: Indoor heat discharge whichever is the higher between TC2 sensor and TCJ sensor temperatures, on exchanger sensor prevention the one hand, and TC1 sensor temperature, on the other. temperature control •...
Page 72 Cooling oil While the outdoor unit is recovering cooling oil (refrigerant), the indoor units perform • Recovery operation normally takes place (refrigerant) the following control tasks: roughly every 2 hours. recovery control [common for operational (cooling thermo ON / thermo OFF / FAN), as well as non- •...
Page 73 Filter sign 1. The indoor fan’s cumulative hours of operation are counted, and when these “FILTER ” displayed display exceed the prescribed value (150H/2500H), a filter replacement signal is sent to (not applicable the remote controller to display a filter sign on it. to wireless type) 2.
Page 74 Selection of 1. The range of operations that can be performed via an indoor unit remote controller • In the case of a wired remote controller, central control can be determined through the setting of the central controller. “CENTRAL mode 2.
Page 75 Outdoor Unit Item Description of operation, numerical data, and other information Remarks 1. Pulse 1. PMV1, 2 control (PMV1 and 2) • During heating, PMV control may be provided with PMV1 motor valve 1) During air conditioner operation, the pulse count of a PMV (pulse motor valve) is alone, operated at 45 pulses (PMV) controlled between 90 and 1000.
Page 76 Item Description of operation, numerical data, and other information Remarks 2. Outdoor 1. Cooling fan control fan control 1) Outdoor fan speed (mode) is controlled on the basis of measurements provided by the Pd pressure sensor. 2) For a specified period after the start of cooling operation, the header outdoor unit controls outdoor fan speed (mode) on the basis of measurements provided by the Pd pressure sensor.
Page 77 Item Description of operation, numerical data, and other information Remarks 4. Oil level 1) Judgment as to whether an optimum amount of oil is present in the compressor • Oil level detection takes place regardless of the detection cases is made on the basis of the temperature readings of sensors TK1 to TK5. number of compressors, control This control function is performed by the header unit and each follower unit...
Page 78 Item Description of operation, numerical data, and other information Remarks 5. Oil This control function is aimed at preventing compressors from running out of oil by equation evening out the oil supply to outdoor units, and is basically performed by opening/ control closing solenoid valves SV3A, SV3B, SV3C, SV3D, and SV3F.
Page 79 Item Description of operation, numerical data, and other information Remarks 7. Defrosting 1. Defrosting commencement conditions • Frost formation temperature is -1.5 °C. control • During heating operation, the cumulative duration of operation in which TE1 sensor • If the outdoor units are a (reverse temperature falls below frost formation temperature is measured, and when this combination of different...
Page 80 Item Description of operation, numerical data, and other information Remarks 8. Release 1. SV2 gas balance control valve control This control function is aimed at achieving gas balance by opening SV2 while compressors are turned off so as to reduce their startup load the next time they are turned on.
Page 81 Item Description of operation, numerical data, and other information Remarks 8. Release 4. SV41, 42, 43 low pressure release control valve control This control function is aimed at providing low pressure protection, and is individually (cont’d) performed by the header unit and each follower unit. The control takes place during defrost operation, heating startup pattern control operation, and cooling operation.
Page 82 Item Description of operation, numerical data, and other information Remarks 11. A3-IPDU IPDU controls inverter compressors by issuing commands relating to compressor control speeds, speed increases/decreases, and current release control values via the interface P.C. board. The main control functions of the IPDU P.C. board are described below. 1.
Page 83 <Other points to note> Cooling operation under low outside temperature conditions 1) If pressure falls to extremely low levels, indoor units may be shut down via freeze prevention control based on the indoor TC sensor. 2) If pressure falls to extremely low levels, frequency may be reduced via cooling capacity control. 3) When the discharge temperature sensor reading falls below 60°C, the frequency may be increased above the level called for by the command received from the indoor unit.
Page 84: Applied Control And Functions (Including Circuit Conﬁguration)
Applied Control and Functions (including Circuit Conﬁguration) 6-1. Indoor Controller Block Diagram 6-1-1. When Wired (Simple) Remote Controller Connected <New 4-way Cassette Type> (MMU-AP 4HP*) – 83 –...
Page 85 <Compact 4-way Cassette Type, 1-way Cassette (SH) Type, 2-way Cassette Type, Ceiling Type, Concealed Duct Standard Type, Slim Duct Type, High Wall Type> – 84 –...
Page 86 <1-way Cassette (YH) Type, Floor Standing Type, Concealed Duct High Static Pressure Type, Floor Standing Concealed Type, Floor Standing Cabinet Type, Fresh Air Intake Type> – 85 –...
Page 87: When Wireless Remote Controller Kit Connected
6-1-2. When Wireless Remote Controller Kit Connected <New 4-way Cassette Type> (MMU-AP 4HP*) – 86 –...
Page 88 <Compact 4-way Cassette Type, 1-way Cassette (SH) Type, 2-way Cassette Type, Ceiling Type, Concealed Duct Standard Type, Slim Duct Type, High Wall Type> – 87 –...
Page 89 <1-way Cassette (YH) Type, Floor Standing Type, Concealed Duct High Static Pressure Type, Floor Standing Concealed Type, Floor Standing Cabinet Type, Fresh Air Intake Type> – 88 –...
Page 90: When Both Main (Sub) Remote Controller And Wireless Remote Controller
6-1-3. When Both Main (Sub) Remote Controller and Wireless Remote Controller Kit Connected <New 4-way Cassette Type> (MMU-AP – 89 –...
Page 91 <Compact 4-way Cassette Type, 1-way Cassette (SH) Type, 2-way Cassette Type, Ceiling Type, Concealed Duct Standard Type, Slim Duct Type, High Wall Type> – 90 –...
Page 92 <1-way Cassette (YH) Type, Floor Standing Type, Concealed Duct High Static Pressure Type, Floor Standing Concealed Type, Floor Standing Cabinet Type, Fresh Air Intake Type> – 91 –...
Page 93: Indoor Printed Circuit Board
6-2. Indoor Printed Circuit Board MCC-1570 <4-way Cassette Type> (MMU-AP 4HP*) – 92 –...
Page 94 MCC-1402 <Compact 4-way Cassette Type, 1-way Cassette (SH) Type, 2-way Cassette Type, Ceiling Type, Concealed Duct Standard Type, Slim Duct Type, High Wall Type> – 93 –...
Page 95 MCC-1403 <1-way Cassette (YH) Type, Floor Standing Type, Concealed Duct High Static Pressure Type, Floor Standing Concealed Type, Floor Standing Cabinet Type, Fresh Air Intake Type> – 94 –...
Page 96: Optional Connector Speciﬁcations Of Indoor P.c. Board
6-3. Optional Connector Speciﬁcations of Indoor P.C. Board – 95 –...
Page 97: Test Operation Of Indoor Unit
6-4. Test Operation of Indoor Unit Check function for operation of indoor unit (Functions at indoor unit side) This function is provided to check the operation of the indoor unit singly without communication with the remote controller or the outdoor unit. This function can be used regardless of operation or stop of the system. However, if using this function for a long time, a trouble of the equipment may be caused.
Page 98: Method To Set Indoor Unit Function Dn Code
6-5. Method to Set Indoor Unit Function DN Code (When performing this task, be sure to use a wired remote controller.) <Procedure> To be performed only when system at rest Push the buttons simultaneously and hold for at least 4 seconds. The unit No.
Page 99 Function CODE No. (DN Code) Table (Includes All Functions Needed to Perform Applied Control on Site) Filter display delay timer 0000: None 0001: 150H According to type 0002: 2500H 0003: 5000H 0004: 10000H Dirty state of filter 0000: Standard 0000: Standard 0001: High degree of dirt (Half of standard time) Central control address 0001: No.1 unit...
Page 100 High-ceiling adjustment 1-way cassette (SH) 0000: Standard (Air flow selection) Value Type AP015, AP018 AP024 0000 Standard (factory default) 3.5 m or less 3.8 m or less 0001 High-ceiling (1) 4.0 m or less 4.0 m or less 0003 High-ceiling (3) 4.2 m or less 4.2 m or less 2-way cassette...
Page 101 Type DN code “10” 0000 1-way Cassette MMU-AP 0001* 4-way Cassette MMU-AP 0002 2-way Cassette MMU-AP 0003 1-way Cassette (Compact) MMU-AP 0004 Concealed Duct Standard MMD-AP 0006 Concealed Duct High Static Pressure MMD-AP n i l l l a 0011 Floor Standing Concealed MML-AP Compact 4-way Cassette...
Page 102: Applied Control Of Indoor Unit
6-6. Applied Control of Indoor Unit Control system using remote control interface (TCB-IFCB-4E2) Wiring and setting • In the case of group control, the control system functions as long as it is connected to one of the indoor units (control P.C. board) in the group. If it is desired to access the operation and error statuses of other units, relevant signals must be brought to it from those units individually.
Page 103 Ventilating fan control from remote controller [Function] • The start/stop operation can be operated from the wired remote controller when air to air heat exchanger or ventilating fan is installed in the system. • The fan can be operated even if the indoor unit is not operating. •...
Page 104 Leaving-ON prevention control [Function] • This function controls the indoor units individually. It is connected with cable to the control P.C. board of the indoor unit. • In a group control, it is connected with cable to the indoor unit (Control P.C. board), and the CODE No. 2E is set to the connected indoor unit.
Page 105: Applied Control For Outdoor Unit
6-7. Applied control for Outdoor Unit The outdoor fan high static pressure support and priority operation mode setting (cooling / heating / number of units / or priority indoor unit) functions are made available by setting relevant switches provided on the interface P.C. board of the outdoor unit.
Page 106: Priority Operation Mode Setting
(2) High efficiency type Combination of outdoor units Maximum external Model Combined static pressure horsepower output MMY- Unit 1 Unit 2 Unit 3 (Pa) MAP1604 MAP1604 AP2424 MAP1204 MAP1204 AP2624 MAP1604 MAP1004 AP2824 MAP1604 MAP1204 AP3024 MAP1604 MAP1404 AP3224 MAP1604 MAP1604 AP3424 MAP1204...
Page 107 (2) Indoor unit setup method for priority indoor unit mode The setting can be changed only when the system is at rest. (Be sure to turn off the system prior to this operation.) Push the buttons simultaneously and hold for at least 4 seconds.
Page 108: Applied Control Of Outdoor Unit
6-8. Applied Control of Outdoor Unit Optional control P.C. boards provide access to a range of functions as listed below. Outdoor unit Control P.C. board to be used Outdoor unit interface P.C. board setting* for control Function Jumper to be P.C.
Page 109: Power Peak-Cut Control (Standard)
6-8-1. Power peak-cut Control (Standard) L1: Display lamp suring power peak cut control Header outdoor unit Locally procured Optional PCB Power supply Display Outdoor unit relay interface PCB [OPERATION] Shield wire PJ17 CN513 SW07 [ON] [OFF] 1 2 3 4 Bit 2 OFF Shield Connection cable...
Page 110: Power Peak-Cut Control (Extended)
<SW07 Bit 2 OFF (two-step control)> Power peak-cut control is enabled as long as SW1, as shown on the wiring diagram, is ON (continuously). Jumper wire Input 0% (forced stop) 60% capacity (upper limit regulated) 100% (normal operation) 100% (normal operation) Note 1: Specifications of display relay contact •...
Page 111: Snowfall Fan Control
6-8-3. Snowfall Fan Control Header outdoor unit Locally procured Connection Outdoor unit Optional PCB cable Snowfall sensor interface PCB COOL HEAT Shield wire SW1: Snowfall detection switch (snowfall sensor) Operation An external snowfall signal turns on the outdoor unit fan. Terminal Input signal Operation...
Page 112: Night Operation (Sound Reduction) Control
6-8-5. Night operation (sound reduction) Control Header outdoor unit Locally procured Connection Optional PCB Outdoor unit cable interface PCB COOL HEAT Shield wire SW1: Night time signal switch Operation This function decreases noise at night or other times as necessary. Terminal Input signal Operation...
Page 113: Operation Mode Selection Control
6-8-6. Operation Mode Selection Control Header outdoor unit Locally procured Connection Outdoor unit Optional PCB cable interface PCB COOL HEAT Shield wire SW1: Cooling mode specified input switch SW2: Heating mode specified input switch NOTE SW1: COOL mode selection switch SW2: HEAT mode selection switch Input signal Operation...
Page 114: Error/Operation Output
6-8-7. Error/Operation Output Locally procured Header outdoor unit (See “NOTE”) Optional PCB Outdoor unit interface PCB OUTPUT1 SW16 CN511 PJ20 OUTPUT2 1 2 3 4 OUTPUT3 Shield wire Operation In-operation output: An in-operation indication signal is output as long as at least one indoor unit is in operation in the line.
Page 115: Compressor Operation Output
6-8-8. Compressor Operation Output Locally procured Outdoor unit (See “NOTE”) Optional PCB Outdoor unit interface PCB CTR1 OUTPUT1 SW16 CTR2 PJ20 CN514 OUTPUT2 1 2 3 4 CTR3 OUTPUT3 Shield wire Operation When a compressor is in operation, a relay connected to the output terminal assigned to it is turned on (closed). When it is at rest, the relay is turned off (open).
Page 116: Operating Rate Output
6-8-9. Operating Rate Output Locally procured Header outdoor unit (See “NOTE”) Optional PCB Outdoor unit interface PCB OUTPUT1 SW16 PJ20 CN514 OUTPUT2 MONITOR 1 2 3 4 OUTPUT3 Shield wire Operation At the output terminals, a signal is present (relay closed) or absent (relay open) in various combinations according to the system operation factor, as shown in the diagram.
Page 117: Test Operation
TEST OPERATION 7-1. Procedure and Summary of Test Operation A test operation is executed with the following procedure. When problems or an error occurs at any step, remove the causes of the problem or error referring to “8 TROUBLESHOOTING.” Check basic items, mainly the installation work. Checks before test operation Be sure to enter the check results in checklist 1 and 2.
Page 118: Check Items Before Test Operation (Before Powering-On)
7-2. Check Items before Test Operation (before powering-on) Prior to the test operation, check the following items to verify there are no problems with the installation work. Main check items for electric wiring The communication system differs from that of R22 or R407 refrigerant “Modular Multi system” air conditioners. Check wiring points again carefully.
Page 119 (2) In the case that a central control system is connected (before address setup) (1) (4) Central remote controller To other refrigerant line Other refrigerant line o l l o l l Outdoor unit To indoor unit Indoor unit Remote Remote Remote controller...
Page 120 Checklist 1 • Using Checklist 1, check that there are no problems with the installation work. Is the capacity of the Outdoor total capacity Header unit (A) Indoor unit circuit breaker (Earth Follower unit (B) leakage breaker) Follower unit (C) appropriate? Follower unit (D) Is the gauge of the...
Page 121 • Check the additional amount of refrigerant. Checklist 2 Calculate the additional amount of refrigerant from the additional amount of refrigerant (A) by the pipe diameter on the liquid side, the pipe length to be connected, and the corrective amount of refrigerant (C) according to system horsepower.
Page 122: Check At Main Power-On
7-3. Check at Main Power-on After turning on the main power of the indoor units and outdoor unit in the refrigerant line to conduct a test operation, check the following items in each outdoor and indoor unit. (After turning on the main power, be sure to check in order: indoor unit outdoor unit.) <Check on the outdoor unit>...
Page 123: Address Setup
7-4. Address Setup This product requires address setup before operation. Follow this procedure for address setup. 7-4-1. Precautions (1) Address setup is not performed simply by turning on the power supply. (2) For indoor units, address setup can be done either by manual address setup or by automatic address setup: Automatic address setup: Setup from SW15 on the interface PC board of the header unit Manual address setup: Setup from the wired remote controller.
Page 124: Address Setup Procedure
7-4-3. Address Setup Procedure Central control of 2 or more refrigerant lines: go to Address setting procedure 2 When controlling a single refrigerant line When controlling 2 or more refrigerant lines (Example) centrally centrally Address setting procedure Central Outdoor Outdoor Outdoor Outdoor Central...
Page 125 (Example) Controlling 2 or more refrigerant lines as a group Outdoor Outdoor System wiring Indoor Indoor Indoor Indoor diagram (Group control) Remote controller Address setting procedure 2 Set a system address for each system using SW 13 and 14 on the interface P.C. board on the header outdoor unit of each system.
Page 126 Be sure to disconnect the relay connectors between the [U1U2] and [U3U4] terminals on all the header outdoor units that will be connected to the central control. (Factory default: disconnected) CENTRAL INDOOR OUTDOOR CONTROL UNIT UNIT Turn on indoor units first, and then turn on outdoor units. About 1 minute after turning the power on, confirm that the 7-segment display on the interface U.
Page 127 Set the central control address. (For the setting of the central control address, refer to the installation manuals of the central control devices.) Header unit interface P.C. board SW15 SW04 SW05 7-segment D600 D601 D602 D603 D604 display SW13 SW14 SW01 SW02 SW03 SW30 * Header units are connected to the same...
Page 128 Switch setting (setting example when controlling 2 or more refrigerant lines centrally) Outdoor units (setting manually) *The items in bold font must be set manually. Outdoor unit’s interface Header unit Follower unit Header unit Follower unit Header unit Factory default P.C.
Page 129 Manual address setup from the remote controller With indoor wiring work completed and outdoor wiring work not done—in cases where indoor unit addresses are decided in advance from the wired remote controller, or in cases where addresses are change after address setup. (Wiring example for 2 refrigerant lines) Arrange one indoor unit and one remote controller Line 1...
Page 130 NOTE (1) When setting the line address from the remote controller, do not use addresses 29 and 30. Addresses 29 and 30 cannot be set up on the outdoor unit. If they are incorrectly used, the code “E04” (indoor/outdoor communication circuit error) is output. (2) When manual address setup has been done from a remote controller, and central control over refrigerant lines is to be done, setup the header unit of each line as follows: •...
Page 131 To find an indoor unit’s position from its address When checking unit numbers controlled as a group CODE No. DATA SETTING UNIT No. R.C. TEMP. ON / OFF TIMER SET TIME FILTER Stop RESET TEST SET CL (Execute it while the units are stopped.) The indoor unit numbers in a group are indicated one after another.
Page 132 Push and hold the TIME buttons at the same time for more than 4 seconds. At first, the line 1 and CODE No. (Address Change) are indicated on the LCD display. (Select an outdoor unit.) UNIT LOUVER SWING/FIX Push the (left side of the button) and buttons repeatedly to select a system address.
Page 133 Push the TIME buttons repeatedly to change the value indicated in the SET DATA section to that you want. Push the button. UNIT LOUVER Push the button (left side of the button) repeatedly to select another indoor UNIT No. to change.
Page 134 Push the button. • The address of one of the indoor units connected to the selected refrigerant line is indicated on the LCD display and the fan and louvers of the unit are activated. At first, the current indoor unit address is displayed in SET DATA (No system address is indicated.) CODE No.
Page 135 2) Turn on dip switch 2 of SW30 on the interface P.C. board of the header outdoor unit if the switch is OFF. (Leave it as it is if it has already been set to ON.) Central remote controller Header Header Header Follower unit...
Page 136 In the case of an increase in address-undefined indoor units (extension, etc.) To set up the indoor address of a unit with an address that is undefined due to the extension of indoor units or replacement of PC board, etc., follow the methods below. Method 1 Set up an address individually from a wired remote controller.
Page 137: Check After Address Setup When Central Control System Is Connected
7-4-4. Check after Address Setup when Central Control System Is Connected When the central control system is connected, check that the following setup has finished after address setup. Central remote controller To other refrigerant line Line address = 2 Line address = 1 Other refrigerant line Follower unit (B) Follower unit (C)
Page 138: Troubleshooting In Test Operation
7-5. Troubleshooting in Test Operation If there are phenomena such as the output of a check code or the remote controller is not accepted when powered- on after wiring work or during address setup operation, the following causes are considered. 7-5-1.
Page 139: Operation From The Indoor Remote Controller Is Not Accepted, And A Check Code Is Displayed On The 7-Segment Display Of The Interface Pc Board Of The Header Unit
7-5-2. Operation from the indoor remote controller is not accepted, and a check code is displayed on the 7-segment display of the interface PC board of the header unit. Indoor remote Header unit controller 7-segment status display Line addresses and indoor addresses of all the connected Set up addresses.
Page 140: In Checking The Number Of Connected Outdoor Units And Connected Indoor Units
7-5-4. In checking the number of connected outdoor units and connected indoor units after address setup, a lower number of connected units is displayed. (There are outdoor/indoor units that do not operate in a test operation.) Miswiring of communication lines between outdoor units After modification of wiring, set up the addresses again and The number of or an unconnected wire ( Fig.
Page 141 Miswiring example Remote Header unit Figure controller 7-segment Miswiring example status display Header unit Header unit U3 U4 U5 U6 Fig. 1 E19-00 response U1 U2 U1 U2 U1 U2 U1 U2 Header unit Follower unit U1 U2 U5 U6 U1 U2 U5 U6 Fig.
Page 142: Test Operation Check
7-6. Test Operation Check 7-6-1. Fan Check START Check code appears When a check code has been Push the Start/Stop button on the remote controller. displayed on the remote controller, remove the cause of the error, referring to "Check code and check Check code position displayed on remote appears...
Page 143: Single Cooling/Single Heating Test Operation Check
7-6-2. Single cooling/Single heating Test Operation Check The Single cooling/Single heating test operation check can be performed on both the indoor remote controller and the outdoor header unit interface PC board. (1) Test operation start/stop operation Test operation from the indoor remote controller •...
Page 144 Wireless remote controller Wireless remote controller (4-way Cassette type) (Ceiling type) Test run (Forced cooling operation) Test run (Forced cooling operation) Requirement: Requirement: • Finish the forced cooling operation in a short • Finish the forced cooling operation in a short time because it applies excessive strength to the time because it applies excessive strength to the air conditioner.
Page 145 (2) Test operation START Refer to "Test operation procedure" Test operation for one indoor unit of the indoor remote controller. The operation does not start for approximately 3 minutes after Operation starts powering-on or stopping operation. Note: After powering-on, it may require up to 10 minutes to start the operation due to the initial communications of the system.
Page 146 Note 1: Criteria for the difference between suction and discharge temperatures (1) Cooling operation After operating for a minimum of 30 minutes in “COOL” mode, if the T dry bulb temperature difference between suction and discharge air of the indoor unit is 8°C or more, it is normal. (2) Heating operation After operating for a minimum of 30 minutes in “HEAT”...
Page 147: Service Support Function
7-7. Service Support Function 7-7-1. Check Function for Connecting of Refrigerant and Control Lines This function is provided to check misconnection of the refrigerant pipes and the control transmission line (Wiring over lines) between indoor unit and outdoor unit by using the switch on the interface P.C. board of the header unit. However, be sure to check the following items prior to executing this check function.
Page 148 Operation start (7-segment display) Press the push-switch SW04 on the interface P.C. board of the header unit for 2 seconds or more. The Cooling [ CC ] Operation operation starts. Heating [ HH ] Check that 7-segment display [B] shows [ CC] for cooling and [ HH] for heating.
Page 149: Function To Start/Stop (On/Off) Indoor Unit From Outdoor Unit
7-7-2. Function to Start/Stop (ON/OFF) Indoor Unit from Outdoor Unit The following functions of the indoor unit can start or stop by the switches on the interface P.C. board of the header unit. p/Release 7-segment display Cooling test Changes the mode of all the [Setup] Section A Section B...
Page 150 (1) Cooling test operation function This function is provided to change collectively the mode of all the indoor units connected to the same system for the cooling test operation mode, by using switches on the interface board of the header unit. <Operation procedure>...
Page 151 (2) Heating test operation function This function is provided to change collectively the mode of all the indoor units connected to the same system for the heating test operation mode, by using switches on the interface board of the header unit. <Operation procedure>...
Page 152 (3) Batch start/stop (ON/OFF) function This function is provided to start/stop collectively all the indoor units connected to the same system by using switches on the interface board of the header unit. <Operation procedure> Be sure to turn on power at the indoor side Power ON before power-ON of outdoor unit.
Page 153 (4) Individual start/stop (ON/OFF) individual test operation function This function is provided to start/stop (ON/OFF) individually each indoor unit connected to the same system by using switches on the interface board of the header unit. Set SW01 [16] and set SW02, SW03 to indoor address No. (1 to 64) to be started (Refer to the following table*) - only the setup indoor unit starts operation.
Page 154: Error Clearing Function
7-7-3. Error Clearing Function (1)Clearing from the main remote controller Error clearing in outdoor unit Error of the outdoor unit currently detected is cleared by the unit of one refrigerant circuit system to which the indoor units operated by the remote controller is connected. (Error of the indoor unit is not cleared.) For clearing errors, the service monitor function of the remote controller is used.
Page 155 (2)Clearing error by using switches on the interface board of the header unit Using the switches on the interface P.C. board of the header unit, this function is to clear the currently detected error for each refrigerant circuit system without resetting the power supply. Errors in both outdoor and indoor units are once cleared, and error detection is performed again.
Page 156: Remote Controller Distinction Function
7-7-4. Remote Controller Distinction Function This function is provided to distinguish the remote controller connected to the indoor unit from the outdoor unit for a refrigerant circuit system by using switches on the interface P.C. board of the header unit. <Distinction procedure>...
Page 157: Pulse Motor Valve (Pmv) Forced Open/Close Function In Indoor Unit
7-7-5. Pulse Motor Valve (PMV) Forced Open/Close Function in Indoor Unit This function is provided to open or close forcedly PMV for 2 minutes in all the indoor units by the switch operation on the interface P.C. board of the header unit. This function is also used to open PMV fully when turning off the power and executing an operation.
Page 158: Solenoid Valve Forced Open/Close Function In Outdoor Unit
7-7-7. Solenoid Valve Forced Open/Close Function in Outdoor Unit This function is provided to forcedly open each solenoid valve mounted in the outdoor unit by the switch operation on the interface P.C. board in the outdoor unit. Use this function to check there is no refrigerant clogging with ON/ OFF operation of the solenoid valve.
Page 159: Fan Operation Check In Outdoor Unit
7-7-8. Fan Operation Check in Outdoor Unit This function is provided to check the fan operation of the outdoor unit by using switches on the interface P.C. board in the outdoor unit. The frequency of the fan speed can be controlled by setting of the switches. Use this function to check the operation or abnormal sound in the fan system.
Page 160: Abnormal Outdoor Unit Discrimination Method By Fan Operating Function
7-7-9. Abnormal Outdoor Unit Discrimination Method By Fan Operating Function This function is provided to forcedly operate the fan of the outdoor unit in which an error occurred or the fan of the normal outdoor unit by the switch operation on the interface P.C. board in the header unit. To specify which one of the follower units connected to the system was faulty, use this function for the system stop due to a follower unit fault (Check code [E28]).
Page 161: Manual Adjustment Function Of Outside Temperature (To) Sensor
7-7-10. Manual Adjustment Function of Outside Temperature (TO) Sensor This function is provided to fix TO sensor value manually by the switch operation on the interface P.C. board in the outdoor unit. When the unit stops abnormally due to TO sensor failure, etc, an emergent operation is available by setting up the value manually to position near the current outside temperature.
Page 162 <Service support function list> Refrigerant circuit and control communication line check function (Cooling [J . C] operation) Refrigerant circuit and control communication line check function (Heating operation) l l u l l o n i l e l l v i t [H .
Page 163: Monitor Function Of Remote Controller Switch
7-7-11. Monitor Function of Remote Controller Switch When using a remote controller with the model name RBC-AMT32E, the following monitor functions can be used. Calling of display screen <Content> The sensor temperature or operation status of the remote controller, indoor unit, or the outdoor unit can be known by calling up the service monitor mode from the remote controller.
Page 164 Unit Remote controller display example Room temperature (During control) ×1 °C Room temperature (Remote controller) ×1 °C × ° l i o × ° [0024]=24°C l i o × ° l i o × ° Indoor discharge temperature (TF) ×1 °C ×...
Page 165: Troubleshooting
TROUBLESHOOTING 8-1. Overview (1) Before engaging in troubleshooting (a) Applicable models All Super Module Multi (SMMS-i) models. (Indoor units: MMO-APOOO, Outdoor units: MMY-MAPOOO4 ) (b) Tools and measuring devices required • Screwdrivers (Philips, flat head), spanners, long-nose pliers, nipper, pin to push reset switch, etc. •...
Page 166: Troubleshooting Method
8-2. Troubleshooting Method The remote controllers (main remote controller and central control remote controller) and the interface P.C. board of an outdoor unit are provided with an LCD display (remote controller) or a 7-segment display (outdoor interface P.C. board) to display operational status. Using this self-diagnosis feature, the fault site/faulty part may be identified in the event of a fault by following the method described below.
Page 167 (Error detected by main remote controller) Check code Display of receiving unit Outdoor 7-segment display Indicator light block Typical fault site Description of error Main remote Operation Timer Ready controller Sub-code Flash No master remote controller, Signals cannot be received from indoor unit; –...
Page 168 List of Check Codes (Outdoor Unit) IPDU: Intelligent Power Drive Unit (Inverter P.C. board) : Lighting, : Flashing, : Goes off (Errors detected by SMMS-i outdoor interface - typical examples) ALT.: Flashing is alternately when there are two flashing LED SIM: Simultaneous flashing when there are two flashing LED Check code Display of receiving unit...
Page 169 Check code Display of receiving unit Outdoor 7-segment display TCC-LINK Indicator light block central control Typical fault site Description of error or main remote Operation Timer Ready Sub-code Flash controller display Outdoor suction Outdoor suction temperature sensor (TS1) has – temperature sensor (TS1) been open/short-circuited.
Page 170 Check code Display of receiving unit Outdoor 7-segment display TCC-LINK Indicator light block central control Typical fault site Description of error or main remote Operation Timer Ready Sub-code Flash controller display A3-IPDU Fan A3-IPDU IPDU IPDU There are insufficient number of IPDUs (P.C. boards) in inverter box.
Page 171 (Errors detected by IPDU featuring in SMMS-i standard outdoor unit - typical examples) Check code Display of receiving unit Outdoor 7-segment display TCC-LINK Indicator light block central control Typical fault site Description of error or main remote Operation Timer Ready Sub-code Flash controller...
Page 172: Troubleshooting Based On Information Displayed On Remote Controller
8-3. Troubleshooting Based on Information Displayed on Remote Controller Using main remote controller (RBC-AMT32E) (1) Checking and testing When a fault occurs to an air conditioner, a check code and indoor unit No. are displayed on the display window of the remote controller. Check codes are only displayed while the air conditioner is in operation.
Page 173 Using TCC-LINK central control remote controller (TCB-SC642TLE2) (1) Checking and testing When a fault occurs to an air conditioner, a Display of Unit No. Display of check code check code and indoor unit No. are displayed UNIT No. on the display window of the remote controller. TEST Check codes are only displayed while the air Alternate blinking...
Page 174 Using indoor unit indicators (receiving unit light block) (wireless type) To identify the check code, check the 7-segment display on the header unit. To check for check codes not displayed on the 7-segment display, consult the “List of Check Codes (Indoor Unit)” in “8-2. Troubleshooting Method”.
Page 175 Heat exchanger temperature sensor (TCJ) error Operation Timer Ready Heat exchanger temperature sensor (TC2) error Indoor unit temperature sensor Heat exchanger temperature sensor (TC1) error errors Ambient temperature sensor (TA) error Alternate blinking Discharge temperature sensor (TF) error Discharge temperature sensor (TD1) error Operation Timer Ready Discharge temperature sensor (TD2) error...
Page 176 Operation Timer Ready Outdoor EEPROM error Synchronized blinking Other (indications not involving check code) Operation Timer Ready – Test run in progress Synchronized blinking Operation Timer Ready Setting incompatibility – (automatic cooling/heating setting for model incapable of it and heating setting for cooling-only model) Alternate blinking –...
Page 177: Check Codes Displayed On Remote Controller And Smms-I Outdoor Unit (7-Segment Display On I/F Board) And Locations To Be Checked
8-4. Check Codes Displayed on Remote Controller and SMMS-i Outdoor Unit (7-Segment Display on I/F Board) and Locations to Be Checked For other types of outdoor units, refer to their own service manuals. Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations)
Page 178 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Duplicated indoor address Indoor Duplicated All stop More than one indoor unit is • Check indoor addresses. unit indoor address assigned same address.
Page 179 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Indoor Error in Stop of Periodic communication • Check remote controller unit communication corresponding between indoor header and wiring.
Page 180 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code IPDU All stop Communication is disrupted • Check wiring and A3-IPDU Fan communication between IPDUs (P.C. connectors involved in IPDU error boards) in inverter box.
Page 181 Check code Location System Error detection Outdoor 7-segment display Description Check items (locations) Main status condition(s) remote detection Check Sub-code controller code TO sensor All stop Sensor resistance is infinity • Check connection of TO error or zero (open/short circuit). sensor connector.
Page 182 Check code Location System Error detection Outdoor 7-segment display Description Check items (locations) Main status condition(s) remote detection Check Sub-code controller code Indoor Other indoor Stop of Indoor P.C. board does not • Check for defect in indoor P.C. – –...
Page 183 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Low oil level All stop Operating compressor <All outdoor units in protection detects continuous state of corresponding line to be low oil level for about 2 hours.
Page 184 Check code Location System Error detection Outdoor 7-segment display Description Check items (locations) Main status condition(s) remote detection Check Sub-code controller code 01: TK1 oil circuit error Oil level All stop No temperature • Check for disconnection of TK1 sensor. 02: TK2 oil circuit error detection change is detected...
Page 185 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Indoor Duplicated Stop of There is more than one • Check indoor addresses. unit indoor header corresponding header unit in group. •...
Page 186 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Error in No. of All stop Insufficient number of IPDUs • Check model setting of A3-IPDU Fan IPDUs are detected when power is P.C.
Page 187 Check code Location System Error detection Outdoor 7-segment display Description Check items (locations) Main status condition(s) remote detection Check Sub-code controller code 01: Compressor 1 side IPDU Activation of high- All stop High-pressure SW is • Check connection of high- 02: Compressor 2 side pressure SW activated.
Page 188 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Outdoor liquid All stop <During cooling operation> • Check full-close operation backflow When system is in cooling of outdoor PMV (1, 2, 4). detection error operation, high pressure is •...
Page 189 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Detected outdoor unit No. 4-way valve All stop Abnormal refrigerating cycle • Check for defect in main reversing error data is collected during body of 4-way valve.
Page 190 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code 0 * : IGBT circuit IPDU Outdoor fan All stop (Sub code: 0 ) • Check fan motor. 1 * : Position detection circuit IPDU error Fan IPDU over current...
Page 191: Errors Detected By Tcc-Link Central Control Device
Errors Detected by TCC-LINK Central Control Device Check code Location Error detection Outdoor 7-segment display Main Description System status Check items (locations) condition(s) remote detection Sub-code controller TCC-LINK TCC-LINK Continued Central control device is • Check for defect in central central control operation unable to transmit signal.
Page 192 Points to Note When Servicing Compressor (1) When checking the outputs of inverters, remove the wiring from all the compressors. How to Check Inverter Output (1) Turn off the power supply. (2) Remove compressor leads from the IPDU P.C. board (A3-IPDU). (Be sure to remove all the leads.) (3) Turn on the power supply and start cooling or heating operation.
Page 193: Diagnosis Procedure For Each Check Code
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Page 224: 7-Segment Display Function
8-6. 7-Segment Display Function 7-segment display on outdoor unit (interface P.C. board) The interface control P.C. board features a 7-segment LED display designed to check operational status. Display items can be changed by changing the combination of the number settings of rotary switches provided on the P.C. board (SW01, SW02 and SW03).
Page 225 (1)Display of System Information (Displayed on Header Outdoor Unit Only) Unused System capacity A […8]~[48]:8 to 48 HP B [HP] No. of outdoor units A […1]~[…4]:1 to 4 B […P] No. of indoor units connected / A […0.]~[48.]:0 to 48 (No. of units connected) No.
Page 226 (2)Display of Outdoor Unit Information (Displayed on Each Outdoor Unit) B Check code (only latest one displayed) If there is no check code, [– – –] is displayed. If there is sub-code, check code [ ] and sub-code [– ] are displayed alternately, for 3 seconds and 1 second, respectively.
Page 227 (3)Display of Outdoor Cycle Data (Displayed at Each Outdoor Unit) Pd pressure data Pd pressure (MPaG) is displayed in decimal format. (MPaG: Approx. 10 times magnitude of kg/cm P d. Ps pressure data Ps pressure (MPaG) is displayed in decimal format. P S.
Page 228 (4)Display of Outdoor Cycle Data (Displayed at Header Unit) * This method is used when displaying follower unit information on the 7-segment display of the header unit. ], : SW03 setting No. + 1 (Outdoor unit No. U2 to U4) B Check code is displayed (latest one only).
Page 229 (5)Display of Indoor Unit Information (Displayed on Header Unit Only) Indoor BUS communication signal B Upon receiving signal: [… … 1], Other times: [… … …] receiving status Indoor check code B No check code: [– – –] Indoor HP capacity 0.
Page 230: Oil Level Judgment Display
8-7. Oil Level Judgment Display The current compressor oil level judgment results can be accessed by setting the switches provided on the interface P.C. board of an outdoor unit. Perform the checks in accordance with the procedure described below. Operation Procedure (1) Start the operation.
Page 231: Leakage/Clogging Of Refrigerating Cycle Circuit
8-8. Leakage/Clogging of Refrigerating Cycle Circuit List of Check Codes Generated upon Occurrence of Leakage/Clogging in Outdoor Cycle or Oil Circuit Part (MMY-MAP0804 , 1004 , 1204 ) Clogging Site of fault Unit generating Part Detected fault and check code Symptom (see next page) check code...
Page 232 Fan motor Right-side (TO) Heat exchanger Left-side Heat exchanger (TE1) (SV5) Reducer PMV1 4-way valve PMV2 (TS1) Check valve High-pressure sensor Low-pressure sensor (TL) (SV2) Fusible (SV3D) Oil separator plug Check valve Check valve (SV42 ) (SV41) (TD1) High-pressure (TD2) High-pressure Liquid tank Accumulator...
Page 233 List of Check Codes Generated upon Occurrence of Leakage/Clogging in Outdoor Cycle or Oil Circuit Part (MMY-MAP1404 , 1604 ) Clogging Site of fault Unit generating Part Detected fault and check code Symptom (see next page) check code Outdoor PMV1, 2, 4 Corresponding unit Activation of high-pressure protection Rise of pressure...
Page 234 Fan motor Right-side (TO) Main heat exchanger PMV1 Right-side sub-heat exchanger PMV2 Left-side (TE1) Main heat exchanger Check valve PMV4 (TE2) Left-side sub-heat exchanger Check valve 4-way valve High-pressure sensor (TS1) (SV6) (SV2) Low-pressure sensor (TL) Oil separator (SV3D) Fusible plug (SV41) Accumulator...
Page 235: Sensor Characteristics
8-9. Sensor Characteristics Outdoor Unit Temperature sensor characteristics Outdoor TS1, TE1, TE2, TL and TO sensors Temperature [°C] Resistance [kΩ] 114.8 83.9 62.1 46.5 35.2 Resistance 26.9 [kΩ] 20.7 (10 °C or below) Resistance 16.1 [kΩ] (10 °C or above) 12.7 10.0kΩ...
Page 236 Outdoor Unit Pressure sensor characteristics • Input/output wiring summary High pressure side (Pd) Low pressure side (Ps) Pin No. Input/output name Lead wire color Input/output name Lead wire color OUTPUT White — — — — OUTPUT White Black Black • Output voltage vs. pressure 4.3V 3.5V 3.73MPa...
Page 237 Indoor TC1 sensor Temperature [°C] Resistance [kΩ] 99.9 74.1 55.6 42.2 32.8 Resistance Resistance [kΩ] 25.4 [kΩ] (10 °C or below) (10 °C or above) 19.8 15.6 12.4 10.0 Temperature [°C] Indoor TC2 and TCJ sensors Temperature [°C] Resistance [kΩ] 115.2 84.2 62.3...
Page 238: Pressure Sensor Output Check
8-10. Pressure Sensor Output Check Outdoor Unit Pd sensor characteristics 0 to 4.41 MPa (0.5 to 5V output for 0 to 4.41 MPa) Voltage readings across pins 2 and 3 of CN501 on indoor unit main P.C. board (with negative-side probe of multimeter placed on pin 3) VOLT VOLT...
Page 239 Outdoor Unit Ps sensor characteristics 0 to 1.47 MPa (0.5 to 5V output for 0 to 1.47 MPa) Voltage readings across pins 2 and 3 of CN500 on indoor unit main P.C. board (with negative-side probe of multimeter placed on pin 3) VOLT VOLT VOLT...
Page 240: Backup Operation
BACKUP OPERATION (EMERGENCY OPERATION) This product offers backup modes of operation to tide over certain emergency situations. If a fault occurs in one of the compressors, it is possible to operate the system on an emergency basis by operating only the remaining compressor(s), (compressor backup operation).
Page 241: Compressor Backup Operation Setting
9-2. Compressor Backup Operation Setting <Outline> If a fault occurs to one of the compressors installed in outdoor unit, follow the procedure described below to back up the faulty compressor by using the remaining, normal compressor(s). <Work Procedure> (1) Turn off the power supply to all the outdoor units connected to the system. (2) Set the DIP switches of SW06, provided on the interface P.C.
Page 242: Outdoor Unit Backup Operation Setting
9-3. Outdoor Unit Backup Operation Setting <Outline> This product allows outdoor unit backup operation setting to be performed either at the header unit or a follower unit. If any of the fault modes specified below occurs to one of the outdoor units in a multi-outdoor unit system, proceed with outdoor unit backup operation.
Page 243 (6) Turn on the power supply to all the units connected to the system other than the failed follower unit. Determine what to do with the power supply to the failed follower unit in the following manner. <In case of fault in compressor, electrical part, I/F P.C. board, or IPDU P.C. board> Leave the power supply off.
Page 244: Header Outdoor Unit Backup Operation Setting (Failure Of Header Outdoor Unit)
9-3-2. Header outdoor unit backup operation setting (failure of header outdoor unit) <Work procedure> (1) Turn off the power supply to all the units connected to the system at the source. [Setup of failed header outdoor unit] (2) Fully close the gas pipe service valve of the failed outdoor unit. (3) Leave the service valves of the liquid and balance pipes fully open (to prevent refrigerant stagnation in the failed outdoor unit).
Page 245 (8) Set Bits 1 and 2 of SW30 on the interface P.C. board same as that of the failed header unit (terminator resistance setting). Outdoor interface P.C. board of unit selected as new header unit Turn on Bit 2 of SW09. SW06 SW07 SW09...
Page 246: Cooling-Season Outdoor Unit Backup Operation Setting
9-4. Cooling-Season Outdoor Unit Backup Operation Setting <Outline> Limited to summer and other situations where there is no need for heating operation, this function makes it possible to get backup operation up and running quickly without going through the normal setup procedure, regardless of which type of outdoor unit has failed, the header unit or a follower unit.
Page 247: Outdoor Unit Refrigerant Recovery Method
OUTDOOR UNIT REFRIGERANT RECOVERY METHOD 10-1. Refrigerant Recovery from Failed Outdoor Unit (Pump-Down) This product supports refrigerant pump-down, a function which allows refrigerant to be recovered from an outdoor unit in need of repair using a normal outdoor unit in a system featuring multiple outdoor units. 10-1-1.
Page 248 (5) [rd] [… FF] will be displayed on the 7-segment display, and pump-down operation will start. * To put the operation on hold midway, turn off the power supply to all the outdoor units, or press SW05 on the interface P.C. board. Header unit Failed outdoor unit Connect liquid pipe check joint and low...
Page 249 [Setup of failed outdoor unit] (13)When the low-pressure sensor output of the failed outdoor unit falls below 0.10MPa, fully close the balance pipe packed valve, and press SW05 on the interface P.C. board to finish the pump-down operation. (14)Turn off the power supply to all the outdoor units, and recover the residual refrigerant in the outdoor unit using a refrigerant recovery device.
Page 250: Refrigerant Recovery Procedure B (Case Of Outdoor Unit Backup Operation Setting)
10-1-3. Refrigerant recovery procedure B (Case of outdoor unit backup operation setting) <Outline> If outdoor unit backup operation setting is performed, use an alternative refrigerant recovery procedure as described below, provided that the power cannot be turned on for the failed outdoor unit. (Refrigerant will be recovered from the failed outdoor unit using the test cooling operation function.) Note 1: If cooling-season outdoor unit backup operation or outdoor unit backup operation is in progress with the power supply to the failed outdoor unit turned on, follow the procedure described in “10-1-2.
Page 251 [Setup of outdoor units other than header unit and failed unit] (8) Leaving the balance pipes of the unit for pressure adjustment and the failed unit fully open, fully close the balance pipe packed valves of all other outdoor units. [Setup of header unit] (9) While monitoring the low-pressure sensor output, adjust the pressure to around 0.12 MPa by slowly closing the gas pipe service valve.
Page 252: How To Operate System While Failed Outdoor Unit Being Repaired
10-2. How to Operate System While Failed Outdoor Unit Being Repaired <Outline> After refrigerant is recovered from the failed outdoor unit through a pump-down operation, the overall amount of refrigerant held by the system becomes excessive, and this makes it impossible to operate the remaining outdoor units even though they are not faulty.
Page 253: Work Procedure After Repair
10-3. Work procedure after Repair When vacuuming in the repaired outdoor unit, follow the procedure described below. <Work procedure> (1) Fully open PMV1 and 2 and PMV4 (MMY-MAP1404 and MAP1604 only) in accordance with the table below. Note: PMV full-opening operation via short-circuiting of the CN30 pins is automatically undone after 2 minutes, causing the valves to fully close.
Page 254: Replacing Compressors
REPLACING COMPRESSORS 11-1. Compressor Replacement Procedure (Outline) START WARNING In situations such as indoor unit relocation and repairs, Is the outdoor unit the only one in the system? it is not possible to recover all the refrigerant held by the system in the outdoor units.
Page 255: Replacement Of Compressors
11-2. Replacement of Compressors <Checking color of oil in faulty compressor> • Lay the faulty compressor down, draw a small amount of oil via the oil equalization pipe, and check its color against color samples. • Determine the number of compressors to be replaced according to the color checking result. Replace the faulty compressor only.
Page 256 [When replacing normal as well as faulty compressor] - applicable to MMY-MAP0804 , 1004 and 1204 <Dismantling normal compressor> • Dismantle the normal compressor in the same way as the faulty compressor. Note: • Be sure to insulate the removed compressor leads using insulation tape, etc. WARNING When detaching a pipe by heating with a burner a welded joint, take care as any oil left in the piping may burn in a momentary flash of fire when the weld filler metal melts.
Page 257 [When replacing normal as well as faulty compressors] - applicable to MMY-MAP1404 and 1604 <Dismantling normal compressors> • Dismantle the normal compressors in the same way as the faulty compressor. Note: • Be sure to insulate the removed compressor leads using insulation tape, etc. WARNING When detaching a pipe by heating with a burner a welded joint, take care as any oil left in the piping may burn in a momentary flash of fire when the weld filler metal melts.
Page 258 <Installing compressor> • Install a compressor by following the dismantling procedure in reverse. • The dismantling process may have loosened compressor leads and faston connectors. Prior to installation, therefore, tighten them a little with a pair of pliers, and verify that they are tight after reconnection. Notes: •...
Page 259: Check Procedure To Search Cause Of Compressor Oil Shortage
11-3. Check Procedure to Search Cause of Compressor Oil Shortage Are the balance pipes of all outdoor units connected to the Open the balance pipe valves fully. same refrigerant line fully open? Are there any miswiring or incorrect Correct the miswiring or connection. connection of TK1, TK2, TK3, TK4 and TK1: CN531 TK2: CN532 TK5 sensor in the unit that has...
Page 260 <MMY-MAP1404 and MAP1604 > Check items and procedures to follow when checking oil circuit with compressor(s) disconnected 1) With PMV1, 2 and 4 fully closed, apply pressure to the check joint of liquid pipe with nitrogen, and check the pressure at the check joint of discharge pipe. If the pressure at the check joint of discharge pipe increases, there is a leak from PMV1, 2 or 4 (A, B) and either Leakage of outdoor PMV discharge pipe check valve (C, D).
Page 261 <MMY-MAP0804 , MAP1004 and MAP1204 > Check items and procedures to follow when checking oil circuit with compressor(s) disconnected 1) With PMV1 and 2 fully closed, apply pressure to the check joint of liquid pipe with nitrogen, and check the pressure at the check joint of discharge pipe.
Page 262: Outdoor Unit Parts Replacement Methods
OUTDOOR UNIT PARTS REPLACEMENT METHODS Cabinet 2) Discharge cabinet Screws (4 corners) WARNING Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment 1) Stop the air conditioner operation, and turn off the circuit breaker.
Page 263 Propeller fan WARNING 2) Screws (4 corners) Fan motor Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment 1) Stop the air conditioner operation, and turn off the Discharge cabinet side cover circuit breaker.
Page 264 Propeller fan 2. CAUTION for replacement or attachment D-cut surface of fan Fan motor 1) Insert the propeller fan while aligning the D-cut motor shaft (continued) surface of the fan motor shaft with the arrow mark ) on the fan. (If the propeller fan is tightly mounted on the shaft without securing alignment between the D-cut surface and the arrow mark (...
Page 265 Heat exchanger 2) Motor base 3) Discharge cabinet anchor plate WARNING Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. Before the work, be sure to recover the refrigerant of outdoor unit into cylinders or another unit connected to the same system.
Page 266 Inverter assembly WARNING 4) Screw (with arrow mark) Wear a pair of gloves. Removable design Otherwise, you will risk an injury involving a replacement part or some other object. 4) Screw (with arrow mark) 1. Detachment 4) Connector for fan reactor 1) Stop the air conditioner operation, and turn off the circuit breaker.
Page 267 Reactor assembly • 14, 16HP case WARNING 3) Screw Fixing claw (slide stopper to right) Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment 1) Stop the operation, and turn off the circuit breaker. 2) Remove the inverter assembly.
Page 268 2-way valve coils Rear SV3B SV3A Pressure sensors locations MAP0804 SV3C MAP1004 MAP1204 Liquid tank SV3E SV3D Oil separator SV41 SV42 Accumulator PD sensor Compressor 1 Compressor 2 PS sensor Inverter assembly Front MAP1404 Rear MAP1604 SV3B SV3C SV3A Liquid tank SV3F SV3E SV3D...
Page 269 Temperature sensors Product Front View - locations and identification colors TD1 sensor (yellow) TD2 sensor (red) MAP0804 MAP1004 MAP1204 Accumulator Compressor 1 Compressor 2 Product Rear View TK1 sensor (black) TS1 sensor (gray) TK4 sensor (white) - One closer to you TK5 sensor (green) TK2 sensor (blue) Accumulator...
Page 270 Temperature sensors Product Front View - locations and TD1 sensor (yellow) TD2 sensor (red) TD3 sensor (black) identification colors (continued) MAP1404 MAP1604 Accumulator Compressor 1 Compressor 2 Compressor 3 Product Rear View TK4 sensor (white) TS1 sensor (gray) TK3 sensor (yellow) TK1 sensor (black) - One closer to you TK5 sensor (green)
Page 271 Pipe fixing rubber This product employs pipe fixing rubber (eyeglass type), combined with a SUS band, to restrain pipes - detachment/ subject to vibration to improve reliability. attachment <Use of SUS band - total 5 locations> MAP0804 Suction pipe <=> Distributor Oil header <=>...
Page 272 Pipe fixing rubber WARNING - detachment/ attachment Wear a pair of gloves. (common) Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment 1) Hold the pipe fixing rubber in such a manner that your fingers and thumb are in contact with the two Squeeze rubber to create small gap.
Page 273 4-way valve WARNING - detachment/ attachment Wear a pair of gloves. MAP0804 4) Brazed point Otherwise, you will risk an injury involving a MAP1004 replacement part or some other object. MAP1204 Before starting the work, be sure to recover the refrigerant of outdoor unit by removing it with a refrigerant recovery device.
Page 274 4-way valve WARNING - detachment/ attachment 4) Brazed point Wear a pair of gloves. (continued) Otherwise, you will risk an injury involving a MAP1404 replacement part or some other object. MAP1604 Before starting the work, be sure to recover the refrigerant of outdoor unit by removing it with a refrigerant recovery device.
Page 275: C. Board Exchange Procedures
P.C. BOARD EXCHANGE PROCEDURES Indoor Unit 13-1. Replacement of Indoor P.C. Boards P.C. board type 431-6V-379 MMU-AP MMU-AP 2WH series MMU-AP 1MH series 431-6V-437 MMU-AP 2SH series MCC-1402 MMC-AP 1H series MMD-AP 1SPH/SH series 431-6V-325 MMD-AP MMU-AP 1WH series MMU-AP 1YH series MMD-AP 1H series 431-6V-326 MCC-1403...
Page 276 Method 2 If it is not possible to turn on the indoor unit or read the setting data from the P.C. board to be replaced via a wired remote controller or operate the remote controller due to the failure of its power supply circuit - Replacing EEPROM (IC503, IC10) (For the location of this component and the method to replace it, see the “EEPROM Location Diagram”...
Page 277 Procedure 1: Reading Setting Data from EEPROM (Read the setting data from EEPROM, including both the factory settings and any modifications made to them on site.) Push the buttons simultaneously and hold for at least 4 seconds. (This number corresponds to the same number shown on the Remote Controller Operation Diagram.) * In the case of group control, the unit No.
Page 278: And The Remote Controller
Procedure 2: Replacing P.C. Board Replace the faulty P.C. board with a service P.C. board. Be sure to replicate the old jumper setting (removal), switch setting (SW501), and connector short-circuit setting (e.g. CN34) on the service P.C. board. (See the diagram at below.) Connector for drain pump (CN504) (MCC-1570) The type and capacity of the indoor unit...
Page 279 Procedure 3: Writing Setting Data in EEPROM (The EEPROM of the service P.C. board has been set to the factory default values.) Push the buttons simultaneously and hold for at least 4 seconds. (This number corresponds to the same number shown on the Remote Controller Operation Diagram.) (Under UNIT No., ALL is displayed.) At the same time, the CODE No.
Page 280 EEPROM Location Diagram The EEPROM (IC503, IC10) is mounted on an IC socket. Use a pair of tweezers, etc. to remove it. When installing it, adjust its orientation as shown in the diagram below. During EEPROM removal/installation, take care not to bend IC leads. P.C.
Page 281 CODE No. list (Example) t l i g i l t l i l l o t f i ° 2 Existence of automatic COOL/HEAT mode 0001: No auto mode cooling/heating * Automatically selection by connected outdoor n i l unit y t i y t i...
Page 282: Replacement Of Outdoor P.c. Boards
Outdoor Unit 13-2. Replacement of Outdoor P.C. Boards 13-2-1. List of service P.C. boards Part code Description Applicable model P.C. board type code Product code 43T6V373 Interface P.C. board MMY-MAP0804 MCC-1606 ASM-PCB(I/F) MMY-MAP1004 43T6V374 MMY-MAP1204 43T6V371 MMY-MAP1404 MMY-MAP1604 43T6V372 t l i f 13-2-2.
Page 283: Interface Board (Mcc-1606) Replacement Method
13-2-3. Interface board (MCC-1606) replacement method This Interface board is commonly installed in different models before shipment. When the board assembly is to be replaced, check the displayed inspection contents below and replace the board in accordance with the model, following the below procedure.
Page 284: Comp-Ipdu P.c. Board (Mcc-1596) Replacement Procedure
13-2-4. Comp-IPDU P.C. Board (MCC-1596) Replacement Procedure This board is commonly installed in different models before shipment. Set the dip switch (SW800) setting of the service board to the switch setting before replacement. Replacement Steps: (1) Turn off the power supply of the outdoor unit and allow at least 3 minute for the capacitor to discharge. (2) Remove all the connectors and the fast-on terminals ( ) connected to the Compressor IPDU.
Page 285 (6) Set the dip switch (SW800) setting of the service board to match the switch setting from the original PCB. - Set the dip switch (SW800) depending on the position of the IPDU within the electrical box, as shown in the following diagram.
Page 286: Fan Ipdu P.c. Board (Mcc-1610) Replacement Procedure
13-2-5. Fan IPDU P.C. Board (MCC-1610) Replacement Procedure Replacement steps: (1) Turn off the power supply of the outdoor unit and allow at least one minute for the capacitor to discharge. Confirm that the light of the LED (D640) fades away. (2) Remove all the connectors and the fast-on terminals ( ) connected to the FAN IPDU.
Page 287: Noise Filter P.c. Board (Mcc-1608 A, B) Replacement Procedure
13-2-6. Noise Filter P.C. Board (MCC-1608 A, B) Replacement Procedure <1. Preparation (model selection)> All P.C. boards of this type leave the factory with default settings that are common to all applicable models. When replacing a P.C. board assembly on site, follow the procedure described below. <2.
Page 288 (3) Disconnect all the connectors and fastons used to connect wiring to the noise filter P.C. board. • The line filter ( ) and its leads, both connected to the screw-on terminals ( ) of the noise filter P.C. board (A) will be removed in step 6.
Page 289 (7) Install the service P.C. boards (A) and (B) in the outdoor unit controller. (Make sure that they are firmly secured to the card edge spacers ( (8) Securely connect the service P.C. boards to the chassis using the earthing screws ( ), ( ) removed in step 4.
Page 290: Exploded Diagram/Parts List
EXPLODED DIAGRAM/PARTS LIST SMMS-i OUTDOOR UNIT MMY-MAP0804HT8P, MMY-MAP1004HT8P, MMY-MAP1204HT8P 007 009 – 289 –...
Page 291 – 290 –...
Page 292 REFRIGERATION CIRCUIT DIAGRAM MOTOR FAN CONDENSER RIGHT SIDE (TO) CONDENSER LEFT SIDE (TE1) (SV5) REDUCER VALVE 4WAY PULSE MOTOR VALVE 2 (TS1) PULSE MOTOR VALVE 1 HIGH PRESSURE SENSOR LOW PRESSURE SENSOR (TL) (SV2) PLUG SEPARATOR (SV3D) FUSIBLE (SV42) (SV41) HIGH PRESSURE TANK LIQUID (TD1)
Page 293 SMMS-i OUTDOOR UNIT MMY-MAP1404HT8P, MMY-MAP1604HT8P 007 009 068 077 – 292 –...
Page 294 – 293 –...
Page 295 REFRIGERATION CIRCUIT DIAGRAM MOTOR FAN PULSE MOTOR CONDENSER VALVE 1 RIGHT SIDE (TO) PULSE MOTOR VALVE 2 CONDENSER LEFT SIDE (TE1) PULSE MOTOR (TE2) VALVE 4 VALVE 4WAY HIGH PRESSURE SENSOR (TS1) (SV6) LOW PRESSURE (SV2) SENSOR (SV3D) SEPARATOR (TL) HIGH PRESSURE SWITCH PLUG FUSIBLE...
Page 296 Q'ty/Set MMY- Ref. Part No. Description MAP0804 MAP1004 MAP1204 MAP1404 MAP1604 HT8P HT8P HT8P HT8P HT8P 43T20333 FAN, PROPELLER 43T19354 CABINET, AIR OUTLET 43T00624 CABINET ASSY, AIR INLET, FRONT 43T00620 CABINET, AIR INLET, BACK 43T00625 CABINET ASSY, AIR INLET, FRONT 43T00622 CABINET, AIR INLET, BACK 43T41453...
Page 297 HT8P 43T49352 RUBBER, SUPPORTER, PIPE 43T49353 RUBBER, SUPPORTER, PIPE 43T49354 RUBBER, SUPPORTER, PIPE 43T49355 RUBBER, SUPPORTER, PIPE 43T01309 MARK, TOSHIBA 43T63346 HOLDER, SENSOR, TO 43T19355 CABINET, SIDE, UP 43T00623 PANEL 43T50349 SENSOR ASSY, LOW PRESSURE 43T50350 SENSOR ASSY, HIGH PRESSURE...
Page 298 Inverter Assembly MMY-MAP0804HT8P, MMY-MAP1004HT8P, MMY-MAP1204HT8P 4.0mm CN705 CN704 CN703 CN510 CN511 – 297 –...
Page 299 Inverter Assembly MMY-MAP1404HT8P, MMY-MAP1604HT8P 4.0mm CN705 CN704 CN703 CN510 CN511 JXO-6B – 298 –...
Page 300 Q'ty/Set MMY- Ref. Part No. Description MAP0804 MAP1004 MAP1204 MAP1404 MAP1604 HT8P HT8P HT8P HT8P HT8P 43T50432 SENSOR ASSY, SERVICE 43T95303 SUPPORTER, ASSY 43T50348 SENSOR ASSY, SERVICE 43T60437 TERMINAL, 4P 43T58316 REACTOR, CH-55 43T58317 REACTOR, CH-79 43T60423 TERMINAL, 6P 43T52317 CONTACTOR, MAGNETIC 43T60436 TERMINAL, 6P...
Page 301 SMMS-i OUTDOOR UNIT MMY-MAP0804T8P, MMY-MAP1004T8P, MMY-MAP1204T8P 007 009 – 300 –...
Page 302 – 301 –...
Page 303 REFRIGERATION CIRCUIT DIAGRAM MOTOR FAN CONDENSER RIGHT SIDE (TO) CONDENSER LEFT SIDE (TE1) (SV5) REDUCER VALVE 4WAY PULSE MOTOR VALVE 2 (TS1) PULSE MOTOR VALVE 1 HIGH PRESSURE SENSOR LOW PRESSURE SENSOR (TL) (SV2) PLUG SEPARATOR (SV3D) FUSIBLE (SV41) (SV42) HIGH PRESSURE (TD1) (TD2)
Page 304 SMMS-i OUTDOOR UNIT MMY-MAP1404T8P, MMY-MAP1604T8P 007 009 068 077 – 303 –...
Page 305 – 304 –...
Page 306 REFRIGERATION CIRCUIT DIAGRAM MOTOR FAN PULSE MOTOR CONDENSER VALVE 1 RIGHT SIDE (TO) PULSE MOTOR VALVE 2 CONDENSER LEFT SIDE (TE1) PULSE MOTOR (TE2) VALVE 4 VALVE 4WAY HIGH PRESSURE SENSOR (TS1) (SV6) LOW PRESSURE (SV2) SENSOR (SV3D) SEPARATOR (TL) HIGH PRESSURE SWITCH PLUG FUSIBLE...
Page 307 Q'ty/Set MMY- Ref. Part No. Description MAP0804 MAP1004 MAP1204 MAP1404 MAP1604 43T20333 FAN, PROPELLER 43T19354 CABINET, AIR OUTLET 43T00624 CABINET ASSY, AIR INLET, FRONT 43T00619 CABINET, AIR INLET, BACK 43T00625 CABINET ASSY, AIR INLET, FRONT 43T00621 CABINET, AIR INLET, BACK 43T41453 COMPRESSOR, DA421A3FB-29M 43T63345...
Page 308 MAP1604 43T49352 RUBBER, SUPPORTER, PIPE 43T49353 RUBBER, SUPPORTER, PIPE 43T49354 RUBBER, SUPPORTER, PIPE 43T49355 RUBBER, SUPPORTER, PIPE 43T01309 MARK, TOSHIBA 43T63346 HOLDER, SENSOR, TO 43T19355 CABINET, SIDE, UP 43T00623 PANEL 43T50349 SENSOR ASSY, LOW PRESSURE 43T50350 SENSOR ASSY, HIGH PRESSURE...
Page 309 Inverter Assembly MMY-MAP0804T8P, MMY-MAP1004T8P, MMY-MAP1204T8P 4.0mm CN705 CN704 CN703 CN510 CN511 – 308 –...
Page 310 Inverter Assembly MMY-MAP1404T8P, MMY-MAP1604T8P 4.0mm CN705 CN704 CN703 CN510 CN511 JXO-6B – 309 –...
Page 311 Q'ty/Set MMY- Ref. Part No. Description MAP0804 MAP1004 MAP1204 MAP1404 MAP1604 43T50347 SENSOR ASSY, SERVICE 43T95303 SUPPORTER, ASSY 43T50348 SENSOR, TD (F6) 43T60437 TERMINAL, 4P 43T58316 REACTOR, CH-55 43T58317 REACTOR, CH-79 43T60423 TERMINAL, 6P 43T52317 CONTACTOR, MAGNETIC 43T60436 TERMINAL, 6P 43T95301 SUPORT, SPACER 43T95302...
Page 312 SMMS-i OUTDOOR UNIT MMY-MAP0804HT7P, MMY-MAP1004HT7P, MMY-MAP1204HT7P 007 009 – 311 –...
Page 313 – 312 –...
Page 314 REFRIGERATION CIRCUIT DIAGRAM MOTOR FAN CONDENSER RIGHT SIDE (TO) CONDENSER LEFT SIDE (TE1) (SV5) REDUCER VALVE 4WAY PULSE MOTOR VALVE 2 (TS1) PULSE MOTOR VALVE 1 HIGH PRESSURE SENSOR LOW PRESSURE SENSOR (TL) (SV2) PLUG SEPARATOR (SV3D) FUSIBLE (SV41) (SV42) HIGH PRESSURE (TD1) (TD2)
Page 315 SMMS-i OUTDOOR UNIT MMY-MAP1404HT7P, MMY-MAP1604HT7P 007 009 068 077 – 314 –...
Page 316 – 315 –...
Page 317 REFRIGERATION CIRCUIT DIAGRAM MOTOR FAN PULSE MOTOR CONDENSER VALVE 1 RIGHT SIDE (TO) PULSE MOTOR VALVE 2 CONDENSER LEFT SIDE (TE1) PULSE MOTOR (TE2) VALVE 4 VALVE 4WAY HIGH PRESSURE SENSOR (TS1) (SV6) LOW PRESSURE (SV2) SENSOR (SV3D) SEPARATOR (TL) HIGH PRESSURE SWITCH PLUG FUSIBLE...
Page 318 Q'ty/Set MMY- Ref. Part No. Description MAP0804 MAP1004 MAP1204 MAP1404 MAP1604 HT7P HT7P HT7P HT7P HT7P 43T20333 FAN, PROPELLER 43T19354 CABINET, AIR OUTLET 43T00624 CABINET ASSY, AIR INLET, FRONT 43T00619 CABINET, AIR INLET, BACK 43T00625 CABINET ASSY, AIR INLET, FRONT 43T00621 CABINET, AIR INLET, BACK 43T41453...
Page 319 HT7P 43T49352 RUBBER, SUPPORTER, PIPE 43T49353 RUBBER, SUPPORTER, PIPE 43T49354 RUBBER, SUPPORTER, PIPE 43T49355 RUBBER, SUPPORTER, PIPE 43T01309 MARK, TOSHIBA 43T63346 HOLDER, SENSOR, TO 43T19355 CABINET, SIDE, UP 43T00623 PANEL 43T50349 SENSOR ASSY, LOW PRESSURE 43T50350 SENSOR ASSY, HIGH PRESSURE...
Page 320 Inverter Assembly MMY-MAP0804HT7P, MMY-MAP1004HT7P, MMY-MAP1204HT7P 4.0mm CN705 CN704 CN703 CN510 CN511 – 319 –...
Page 321 Inverter Assembly MMY-MAP1404HT7P, MMY-MAP1604HT7P 4.0mm CN705 CN704 CN703 CN510 CN511 JXO-6B – 320 –...
Page 322 Q'ty/Set MMY- Ref. Part No. Description MAP0804 MAP1004 MAP1204 MAP1404 MAP1604 HT7P HT7P HT7P HT7P HT7P 43T50347 SENSOR ASSY, SERVICE 43T95303 SUPPORTER, ASSY 43T50348 SENSOR, TD (F6) 43T60437 TERMINAL, 4P 43T58316 REACTOR, CH-55 43T58317 REACTOR, CH-79 43T60423 TERMINAL, 6P 43T52317 CONTACTOR, MAGNETIC 43T60436 TERMINAL, 6P...

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Toshiba MMY-MAP0804HT8JP Service Manual

Safety Caution

New Refrigerant (R410A)

1 Wiring Diagrams

2 Parts Rating

3 Refrigerant Piping Systematic Drawing

4 Combined Refrigerant Piping System Schematic Diagrams

5 Control Outline

6 Applied Control and Functions (Including Circuit Conﬁguration)

7 Test Operation

8 Troubleshooting

9 Backup Operation

(Emergency Operation)

10 Outdoor Unit Refrigerant Recovery Method

11 Replacing Compressors

12 Outdoor Unit Parts Replacement Methods

13 C. Board Exchange Procedures

14 Exploded Diagram/Parts List

Quick Links

SERVICE MANUAL

Troubleshooting

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Summary of Contents for Toshiba MMY-MAP0804HT8JP

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Table of Contents