Toshiba MMY-MAP0724HT6UL Service Manual Download

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9-5. Diagnosis procedure for each check code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

9-6. 7-segment display function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

9-7. Oil level judgment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

9-8. Leakage/clogging of refrigerating cycle circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

9-9. Sensor characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

9-10. Pressure sensor output check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

10 Backup Operation (Emergency Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

10-1. Note for backup operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

10-2. Compressor backup operation setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

10-3. Outdoor unit backup operation setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

10-3-1. Follower outdoor unit backup operation setting (failure of follower outdoor unit) . . . . . 181

10-3-2. Header outdoor unit backup operation setting (failure of header outdoor unit) . . . . . . 183

10-4. Cooling-season outdoor unit backup operation setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

11 Outdoor Unit Refrigerant Recovery Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

11-1. Refrigerant recovery from failed outdoor unit (pump-down) . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

11-1-1. Note for refrigerant recovery operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

11-1-2. Refrigerant recovery procedure A (case of no outdoor unit backup operation setting) 186

11-1-3. Refrigerant recovery procedure B (case of outdoor unit backup operation setting) . . . 189

11-2. How to operate system while failed outdoor unit being repaired . . . . . . . . . . . . . . . . . . . . . . . . 191

11-3. Work procedure after repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

12 Replacing Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

12-1. Compressor replacement procedure (outline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

12-2. Replacement of compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

12-3. Check procedure to search cause of compressor oil shortage . . . . . . . . . . . . . . . . . . . . . . . . . 198

13 Outdoor Unit Parts Replacement Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

14 P.C. Board Exchange Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

14-1. Replacement of outdoor P.C.board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

14-1-1. List of service P.C. boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

14-1-2. Configuration of inverter assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

14-1-3. Interface board replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

14-1-4. Inverter P.C. board for compressor replacement procedure . . . . . . . . . . . . . . . . . . . . 222

14-1-5. Fan IPDU P.C. board (MCC-1610) replacement procedure. . . . . . . . . . . . . . . . . . . . . 224

14-1-6. Noise filter P.C. board (MCC-1625 A, B, C) replacement procedure . . . . . . . . . . . . . . 225

15 Exploded Diagram / Parts Price List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Summary of Contents for MMY-MAP0724HT6UL

Page 1: ... CONDITIONER MULTI TYPE SERVICE MANUAL FILE No A11 019 Outdoor Unit SUPER MODULAR MULTI SYSTEM i Model name Heat Pump Model MMY MAP0724HT6UL MMY MAP0964HT6UL MMY MAP1144HT6UL PRINTED IN JAPAN Feb 2012 TDOC ...

Page 2: ...Normal operation COOL mode low outside air temperature roughly below 68 F 20 C 34 5 3 Normal operation HEAT mode 35 5 4 Emergency operation cooling operation under header outdoor unit backup scenario 36 5 5 Emergency operation heating operation under header outdoor unit backup scenario 37 5 6 Refrigerant recovery from failed outdoor unit pump down operation under follower outdoor unit backup scena...

Page 3: ...s setup a lower number of connected units is displayed There are outdoor indoor units that do not operate in a test operation 82 8 6 Test operation check 84 8 6 1 Fan check 84 8 6 2 Cooling heating test operation check 85 8 7 Service support function 89 8 7 1 Check function for connecting of refrigerant and control lines 89 8 7 2 Function to start stop ON OFF indoor unit from outdoor unit 91 8 7 3...

Page 4: ...t recovery operation 186 11 1 2 Refrigerant recovery procedure A case of no outdoor unit backup operation setting 186 11 1 3 Refrigerant recovery procedure B case of outdoor unit backup operation setting 189 11 2 How to operate system while failed outdoor unit being repaired 191 11 3 Work procedure after repair 192 12 Replacing Compressors 193 12 1 Compressor replacement procedure outline 193 12 2...

Page 5: ...ves Safety working clothing Electrical related work Gloves to provide protection for electricians and from heat Insulating shoes Clothing to provide protection from electric shock Work done at heights 50 cm or more Helmets for use in industry Transportation of heavy objects Shoes with additional protective toe cap Repair of outdoor unit Gloves to provide protection for electricians and from heat I...

Page 6: ...els are indicated on the specified positions If removing the label during parts replace stick it as the original Warning indication Description WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing CAUTION High temperature parts You might get burned when removing this panel ...

Page 7: ...Take steps to ensure that the power will not be turned on by marking out of service near the circuit breaker for instance until qualified service person arrives Continuing to use the air conditioner in the trouble status may cause mechanical problems to escalate or result in electric shocks or other failure Electric shock hazard When you access inside of the service panel to repair electric parts ...

Page 8: ...k When working at heights put a sign in place so that no one will approach the work location before proceeding with the work Parts and other objects may fall from above possibly injuring a person below When executing address setting test run or troubleshooting through the checking window on the electrical control box put on insulated gloves to provide protection from electric shock Otherwise you m...

Page 9: ...g cycle Failure to purge the air completely may cause the air conditioner to malfunction Do not charge refrigerant additionally If charging refrigerant additionally when refrigerant gas leaks the refrigerant composition in the refrigerating cycle changes resulted in change of air conditioner characteristics or refrigerant over the specified standard amount is charged and an abnormal high pressure ...

Page 10: ...here is leak of refrigerant at connecting section of pipes the air is sucked and causes further abnormal high pressure resulted in burst or injury Check after reinstallation Only a qualified installer 1 or qualified service person 1 is allowed to relocate the air conditioner It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire electric shocks injury wat...

Page 11: ...s instructions to install the air conditioner Be sure to use the company specified products for the separately purchased parts Use of non specified products may result in fire electric shock water leakage or other failure Have the installation performed by a qualified installer Do not supply power from the power terminal block equipped on the outdoor unit to another outdoor unit Capacity overflow ...

Page 12: ...bearing the weight of the unit into the rectangular holes shown below Tie the unit from 4 sides Apply padding in positions where the rope comes in contact with the outdoor unit so that no damage is caused to the outer surface of the outdoor unit There are reinforcing plates on the side surfaces so the rope cannot be passed through Front Back Correct Incorrect Incorrect Plaster Rope Plaster Rectang...

Page 13: ...8 400 24 4 620 621 281 B MAP0964HT6UL 25 8 655 15 4 390 25 6 650 817 370 MAP1144HT6UL Screw size Tightening torque ft lbs N m Power supply terminal M8 4 1 to 4 8 5 5 to 6 6 Ground screw M8 4 1 to 4 8 5 5 to 6 6 Control wire terminal M3 5 0 6 to 0 7 0 80 to 0 96 Anchor bolt position 27 6 700 Anchor bolt position 36 2 920 Anchor bolt position 29 7 755 Anchor bolt position 29 7 755 ...

Page 14: ...oor unit capacity type Adjustment amount of refrigerant lb Combined outdoor units 072 type 3 31 072 type 096 type 13 23 096 type 114 type 15 43 114 type 144 type 0 00 072 type 072 type 168 type 16 53 096 type 072 type 192 type 27 56 096 type 096 type 228 type 27 56 114 type 114 type L1 Ø1 2 30 ft L2 Ø1 2 15 ft L3 Ø3 8 10 ft a Ø1 4 10 ft b Ø3 8 15 ft c Ø1 4 10 ft d Ø1 4 10 ft Additional charge amou...

Page 15: ...others do not mix in because pipes are affected by impurities such as water oxide scales oil etc Use the clean pipes Be sure to brazing with flowing nitrogen gas Never use gas other than nitrogen gas 4 For the earth protection use a vacuum pump for air purge 5 R410A refrigerant is azeotropic mixture type refrigerant Therefore use liquid type to charge the refrigerant If using gas for charging comp...

Page 16: ...efrigerant Unusable Use the Refrigerant charging balance Gas leak detector Checking gas leak Exclusive to R410A Vacuum pump Vacuum drying Usable if a counter flow preventive adapter is attached Vacuum pump with counterflow Vacuum drying R22 Existing article Flare tool Flare processing of pipes Usable by adjusting size Bender Bending processing of pipes R22 Existing article Refrigerant recovery dev...

Page 17: ...igh pressure sensor Low pressure sensor Fusible plug PC board fuse Inverter overload protector Electrical specifications Unit MCA 4 A 18 23 24 MOCP 5 A 20 25 25 Refrigerant piping Connecting port dia Gas side main pipe In 7 8 7 8 1 1 8 Liquid side main pipe In 1 2 1 2 1 2 Balance pipe In 3 8 3 8 3 8 System interconnection wiring Up to 3280 ft Shielded wire AWG16 x 2 cores Up to 6560 ft Shielded wi...

Page 18: ...0A Charged refrigerant amount lb 3 25 4 25 4 25 4 25 4 25 4 25 4 25 4 25 4 High pressure switch psi OFF 420 ON 540 Protective devices High pressure switch High pressure sensor Low pressure sensor Fusible plug PC board fuse Inverter overload protector Electrical specifications Unit MCA 4 A 18 18 23 18 23 23 24 24 MOCP 5 A 20 20 25 20 25 25 25 25 Refrigerant piping Connecting port dia Gas side main ...

Page 19: ...ise filter T6 3A 250V MCC 1625C F70 F71 Fuse Transformer T8A 600V FM Fan motor HEATER1 HEATER2 Compressor case heater A HEATER Accumulator case heater L CM1 L CM2 Reactor for compressor L FM Reactor for fan Mg CTT Magnet contactor PD Pressure sensor High PS Pressure sensor Low PMV1 PMV2 Pulse motor valve main RB Rush current protect resistor SV2 SV3A SV3B SV3C SV3D SV3E SV41 SV42 SV51 2 way valve ...

Page 20: ... T6 3A 250V MCC 1625C F70 F71 Fuse Transformer T8A 600V FM Fan motor HEATER1 HEATER2 HEATER3 Compressor case heater A HEATER Accumulator case heater L CM1 L CM2 L CM3 Reactor for compressor L FM Reactor for fan Mg CTT Magnet contactor PD Pressure sensor High PS Pressure sensor Low PMV1 PMV2 Pulse motor valve main PMV4 Pulse motor valve sub RB Rush current protect resistor SV2 SV3A SV3B SV3C SV3D S...

Page 21: ...60 Hz SV2 SV3A SV3B SV3C SV3D SV3E O AC208 230 V 60 Hz SV2 SV3A SV3B SV3C SV3D SV3E SV3F SV6 O O 5 2 way valve coil FQ D640 AC208 230 V 60 Hz SV41 SV42 SV5 O AC208 230 V 60 Hz SV41 SV42 SV43 O O 6 High pressure SW ACB 4UB OFF 3 73 MPa ON 2 9 MPa O O O 7 Pressure sensor For high pressure NSK BC038F U220 0 5 4 3 V 0 3 73 MPa O O O 8 Pressure sensor For low pressure NSK BC010F U220 0 5 3 5 V 0 0 98 M...

Page 22: ...rter P C board for Compressor A3 IPDU MCC 1596 MCC 1596 O O O 12 Fuse MCC 1596 GAC1 31 5A 31 5 A AC500 V P C board O O O 13 Comp Motor drive IPM MCC 1596 PS22A76 25 A DC1200 V P C board O O O 14 Inverter P C board for fan FAN IPDU MCC 1610 MCC 1610 O O O 15 Fuse MCC 1610 CES15 15AF924 15 A AC250 V P C board O O O 16 Fan motor drive IPM MCC 1610 FSBB20CH60C 20 A DC600 V P C board O O O 17 Pipe temp...

Page 23: ...SW1 Check joint Liqid pipe TL sensor Check joint High pressure High pressure sensor 4 way valve PMV Pulse Motor Valve Check joint Low pressure TS sensor Low pressure sensor TE1 sensor TO sensor SV3D valve SV2 valve SV3E valve SV3C valve SV5 valve SV3B valve TK5 sensor TK4 sensor SV3A valve TK1 sensor TK2 sensor Liqid tank Fusible plug Fusible plug Accumulator TD1 sensor Transfomer ...

Page 24: ...Check joint High pressure High pressure sensor 4 way valve PMV Pulse Motor Valve Check joint Low pressure TS sensor Low pressure sensor TE1 sensor TO sensor SV3D valve SV2 valve SV3E valve SV3C valve SV6 valve SV3B valve TK5 sensor TK4 sensor SV3A valve TK1 sensor TK2 sensor Liqid tank Fusible plug Fusible plug Accumulator SV3F valve TK3 sensor TE2 sensor High pressure SW3 SV43 valve Compressor3 T...

Page 25: ...face P C board Outdoor control P C board MCC 1606 Inverter P C board for fan FAN IPDU MCC 1610 Power supply terminal block Relay connector for central control Communication terminal block Magnet Contactor Inverter P C board for Compressor 2 A3 IPDU MCC 1596 Inverter P C board for Compressor 1 A3 IPDU MCC 1596 Thermistor ...

Page 26: ...n FAN IPDU MCC 1610 Noise Filter P C board MCC 1625 Power supply terminal block Relay connector for central control Communication terminal block Inverter P C board for Compressor 3 A3 IPDU MCC 1596 Inverter P C board for Compressor 2 A3 IPDU MCC 1596 Inverter P C board for Compressor 1 A3 IPDU MCC 1596 Relay terminal block for reactor Magnet Contactor ...

Page 27: ...tput PMV4 output UART communication Jumper select For inter unit cable between indoor and outdoor units For inter unit cable between outdoor units B Heater High pressure SW 7 segment LED PD sensor PS sensor Dyna doctor connecting terminal 4 way valve output Accumulator heater Comp case heater 3 Comp case heater 2 Comp case heater 1 ...

Page 28: ...g Compressor output W phase CN203 Compressor output V phase CN202 Compressor output U phase CN201 Reactor connecting terminal CN10 Reactor connecting terminal CN09 Power supply input L1 CN01 Power supply input L2 CN02 Power supply input L3 CN03 CN851 UART communication CN852 UART communication ...

Page 29: ...fan MCC 1610 UART communication between interface Fan motor output U phase Fan motor output V phase Fan motor output W phase UART communication between A3 IPDU Reactor connecting terminal Reactor connecting terminal Power supply input ...

Page 30: ... to FAN CN23 Power supply input L3 CN33 Power supply input L2 CN32 CN51 To Noise Filter C MCC 1625 A Power supply input L1 CN31 MCC 1625 B MCC 1625 C 220 V output to N F B CN72 460 V input from N F A CN73 220 V input from Transformer CN70 220 V input from Transformer CN71 460 V output to Transformer CN74 Power supply output L1 CN41 Power supply output L2 CN42 Power supply output L3 CN43 CN52 To No...

Page 31: ...ervice valve Balance pipe packed valve Liquid tank Reducer Low pressure sensor Fusible plug Accumulator Check valve High pressure switch Check valve Oil header Check valve High pressure switch Oil separator Compressor 2 Inverter Compressor 1 Inverter Solenoid valve Capillary tube Check valve Check joint Strainer Temperature sensor Distributor Symbol High pressure sensor Check valve Fan motor Check...

Page 32: ... Liquid tank Low pressure sensor Fusible plug Accumulator High pressure switch Oil header High pressure switch Oil separator Solenoid valve Capillary tube Check valve Check joint Strainer Temperature sensor Distributor Symbol High pressure sensor Fan motor Sub heat exchanger at right side Sub heat exchanger at left side Check valve Check valve High pressure switch Compressor 2 Inverter Compressor ...

Page 33: ...nector CN303 Red 1 Exchange function between main and sub exchangers in cooling operation 2 Preventive function for high pressure rising in heating operation Oil separator 1 Prevention for rapid decreasing of oil Decreases oil flowing to the cycle 2 Reserve function of surplus oil Temp Sensor TD1 TD2 TD3 TD1 Connector CN502 White TD2 Connector CN503 Pink TD3 Connector CN504 Blue 1 Protection of co...

Page 34: ...e Gas pipe Liquid pipe Liquid tank Pressure sensor high pressure Pressure sensor low pressure Accumulator 4 Way valve Indoor unit Note In DEFROST mode PMV4 also opens Pressure sensor low pressure High pressure gas or condensate liquid refrigerant Evaporative gas refrigerant low pressure gas Normal refrigerant line Note The header unit is the outdoor unit to which the indoor outdoor communication l...

Page 35: ...4 Way valve Indoor unit Note With a 096 type or 114 type outdoor unit the main heat exchanger and subheat exchanger may be switched over depending on the outside temperature and air conditioning loads Pressure sensor low pressure High pressure gas or condensate liquid refrigerant Evaporative gas refrigerant low pressure gas Normal refrigerant line Note The header unit is the outdoor unit to which ...

Page 36: ...sensor high pressure Pressure sensor low pressure Accumulator 4 Way valve Indoor unit Pressure sensor low pressure High pressure gas or condensate liquid refrigerant Evaporative gas refrigerant low pressure gas Normal refrigerant line Note The header unit is the outdoor unit to which the indoor outdoor communication line is connected All other outdoor units are called follower units The diagram sh...

Page 37: ... pressure gas or condensate liquid refrigerant Evaporative gas refrigerant low pressure gas Normal refrigerant line Note The header unit is the outdoor unit to which the indoor outdoor communication line is connected All other outdoor units are called follower units Leakage from PMV Liquid side service valve Full closure Set Up as Temporary Header Unit during Emergency Operation Failure Pressure s...

Page 38: ...quid refrigerant Evaporative gas refrigerant low pressure gas Normal refrigerant line Note The header unit is the outdoor unit to which the indoor outdoor communication line is connected All other outdoor units are called follower units Failure Pressure sensor low pressure Gas side service valve Full closure Balance pipe packed valve Full opening Refrigerant recovery line The diagram shows a 192 t...

Page 39: ... gas or condensate liquid refrigerant Evaporative gas refrigerant low pressure gas Normal refrigerant line Note The header unit is the outdoor unit to which the indoor outdoor communication line is connected All other outdoor units are called follower units Failure Pressure sensor low pressure Gas side service valve Full opening Full closure 10 minutes after system startup Balance pipe packed valv...

Page 40: ...y closed when the air conditioner is in thermo OFF state or upon being turned off normally or shut down due to an abnormality 2 PMV4 control applicable only to MMY MAP0964HT6UL MMY MAP1144HT6UL 1 When using a small capacity split type heat exchanger mainly a sub heat exchanger to a combination of a sub heat exchanger and main heat exchanger during cooling the pulse count of the PMV pulse motor val...

Page 41: ... 3 Control while follower unit at rest The fan is operated at mode 1 to prevent the accumulation of refrigerant inside the outdoor heat exchanger 3 Capacity control 1 The compressors of the header and follower units are controlled on the basis of capacity demand issued by indoor controllers 2 The two or three compressors featured in an outdoor unit operate on a rotational basis so that every time ...

Page 42: ...there is depletion oil equalization control takes over 3 This control function is performed whenever at least one compressor is in operation Oil level detection takes place regardless of the number of compressors whether it be one two or three Rough guide for oil level judgment 1 If TK1 TK4 57 2 F 14 C oil level of compressor 1 is optimum 2 If TK2 TK4 57 2 F 14 C oil level of compressor 2 is optim...

Page 43: ...naged by the header outdoor unit 1 Control commencement conditions When cooling operation has continued for at least 2 hours When cooling operation has started compressors have just been turned on though this does not always happen depending on outside air temperature conditions 2 Control details All compressors currently in operation are operated at the minimum speed with those currently not in o...

Page 44: ...he target rotational speed for defrosting control To protect the refrigerating cycle circuit the fan mode may be controlled during defrosting 3 Defrosting termination conditions Defrosting termination conditions are met when the TE1 temperature sensor measurement reaches a specified value roughly 53 6 F 12 C a certain period of time after the commencement of defrosting control In that event defros...

Page 45: ...trol details When Pd pressure becomes 493 psi 3 4 MPa SV2 is opened When Pd pressure becomes 406 psi 2 8 MPa SV2 is closed 3 Termination conditions Shutdown thermo OFF defrosting operation or cooling operation The number of header unit compressors in operation increases to two or more At least one follower unit compressor is turned on The speed of the compressor rises to 40 rps or more 3 SV2 low p...

Page 46: ...ower unit 1 Control details Compressors are shut down when Pd pressure reaches or exceeds P0 The compressor restart prevention timer 2 minutes 30 seconds is set and the control terminated When Pd P0 500 3 psi 3 45 MPa compressor No 2 or No 3 the last one of three compressors in terms of startup order in a three compressor configuration is shut down When Pd P0 507 5 psi 3 5 MPa compressor No 1 the ...

Page 47: ...buildup in the outdoor unit fan abnormality blockage of the cooling duct and IPDU P C board fault The TH temperature used in this control function is the highest registered by A3 IPDU1 A3 IPDU2 and A3 IPDU3 3 Overcurrent protection control 1 When the overcurrent protection circuit on an IPDU P C board detects an abnormal current the compressor is shut down 2 The compressor is restarted 2 minutes a...

Page 48: ...V operation However in a noisy environment it may simply be drowned out by ambient noise 2 Do not separate the actuator head section from any PMV during operation It may result in an inaccurate opening 3 When transporting relocating the set do not under any circumstances keep the actuator separated It may damage the valve by causing it to close and exposing it to pressure from sealed liquid 4 When...

Page 49: ... be used enable this function The maximum external static pressures of base units are shown below Table 1 Table 1 Maximum External Static Pressures of Base Outdoor Units Calculate duct resistance from outdoor unit air flow 7 1 2 Priority operation mode setting Purpose characteristics This function allows switching between priority cooling and priority heating Four patterns of priority operation mo...

Page 50: ...ome on so that the position of this unit can be confirmed 3 Use the button to select the CODE No 04 4 Use the button to select the SET DATA 0001 Priority set 0001 No priority set 0000 5 Push the button The setup is finished when the display changes from flashing to steady 6 Upon finishing the setup push the button This finalizes the setting When the button is pushed the display goes blank and the ...

Page 51: ... 1 Power peak cut Control For one input function Header unit CN513 blue SW07 1 J16 2 Power peak cut Control Enhanced Functions Header unit CN513 blue SW07 1 2 3 Snowfall Fan Control Header unit CN509 black 4 External master ON OFF Control Header unit CN512 blue 5 Night operation sound reduction Control Header unit CN508 red 6 Operation Mode Selection Control Header unit CN510 white Operation Mode ...

Page 52: ... provided that the J16 jumper wire on the interface P C board of the header outdoor unit has been removed Power peak cut control P C board SW1 SW2 L1 Interface P C board of header outdoor unit SW07 Bit 1 OFF SW07 Bit 1 ON Power peak cut control ON signal received ON OFF ON 0 forced stop 60 capacity upper limit regulated Power peak cut control OFF signal received OFF ON OFF 100 normal operation 100...

Page 53: ...utput Operation terminal must satisfy the following electrical rating When connecting a conductive load e g relay coil to the display relay load insert a surge killer CR for an AC power supply or a diode for preventing back electromotive force for a DC power supply on the bypass circuit The optional P C board should be connected to the header outdoor unit U1 Jumper wire J16 Input SW1 SW07 Bit 1 In...

Page 54: ...ms CAUTION 1 Do not turn on the COOL SW1 and HEAT SW2 terminals simultaneously 2 Be sure to provide a contact for each terminal External signal No voltage pulse contact The optional P C board should be connected to the header outdoor unit U1 Terminal Input signal Operation COOL SW1 Snowfall fan control Turns on outdoor unit fan Normal operation Cancels control Terminal Input signal Operation COOL ...

Page 55: ...ation The table below provides a rough guide to this capacity reduction Position of noise measuring device 3 3 ft 1 m from the front face of the set and 4 9 ft 1 5 m above ground anechoic sound Terminal Input signal Operation COOL SW1 Night time control Normal operation Outdoor unit base unit During low noise mode dB A Capacity Relative to maximum capacity Cooling Heating Model 072 type 50 approx ...

Page 56: ...indoor units operating in a mode different from the selected operation mode prohibited mode indoor units become non priority units thermostat OFF Prohibited mode indoor units J01 cut The selected operation mode is imposed on all indoor units operating in a different mode Header outdoor unit Locally procured Outdoor unit interface PCB Shield wire Optional PCB Connection cable SW1 Cooling mode speci...

Page 57: ...ay coil to loads K1 K2 and K3 insert a surge killer CR for an AC power supply or a diode for preventing back electromotive force for a DC power supply on the bypass circuit The optional P C board should be connected to the header outdoor unit U1 Electrical Rating 24 V or less AC DC 10 mA or more 1 A or less non conductive load C1 Connector cable 1 CN511 Connector on Interface side green K1 K2 Rela...

Page 58: ...ower supply or a diode for preventing back electromotive force for a DC power supply on the bypass circuit Electrical Rating 24 V or less AC DC 10 mA or more 1 A or less non conductive load C2 Connection cable 2 CN514 Interface side connector green CTR1 Elapsed operation counter 1 CTR2 Elapsed operation counter 2 CTR3 Elapsed operation counter 3 K1 K2 K3 Relay L1 L2 L3 Operation indication lamp OU...

Page 59: ... for an AC power supply or a diode for preventing back electromotive force for a DC power supply on the bypass circuit Function SW16 OUTPUT1 OUTPUT2 OUTPUT3 Operation factor FA System operation rate output Bit 1 ON Bit 2 OFF off off off FA 0 on off off 0 FA 20 off on off 20 FA 35 on on off 35 FA 50 off off on 50 FA 65 on off on 65 FA 80 off on on 80 FA 95 on on on 95 FA C2 Connection cable 2 CN514...

Page 60: ...in power supply is turned on Set up the addresses Test operation END Check basic items mainly the installation work Be sure to enter the check results in checklist 1 and 2 This check is done after the power has been turned on Check that the refrigerant circuit system is turned on normally Start the address setup in the outdoor indoor units Note Operation does not start simply by powering on Carry ...

Page 61: ...ck 1 Are the indoor and outdoor communication lines of the header unit connected to the U1 U2 terminals 2 Is the relay connector between the U1 U2 terminal and the U3 U4 terminal removed Set up factory default 3 Is the communication line between outdoor units connected to the U5 U6 terminal 4 Is the terminal resistance SW30 bit 2 on the interface PC board of the header unit turned on Set up factor...

Page 62: ...onnected to the communication lines of the indoor outdoor communication lines 5 Is the terminal resistance SW30 bit 2 on the interface PC board of the header unit turned on Set up factory default After address setup and test operation check turn on the SW30 bit 2 of the header unit for the smallest line address and turn off SW30 bit 2 of the header unit for other refrigerant lines See 8 4 3 Addres...

Page 63: ...nals U3 U4 Is the power of indoor units supplied collectively Is it grounded to earth Is the resistance sufficient 10 MΩ or higher MΩ or higher Is the main power voltage sufficient within 460 V 10 V Is the diameter of connecting pipe correct Is the branch kit correct Is the water drain of the indoor unit arranged so that it flows without accumulation Is the heat insulation of pipes sufficient conn...

Page 64: ...ional amount of refrigerant Additional amount of refrigerant Pipe diameter on the liquid side Additional refrigerant amount 1ft lb Total pipe length on each liquid side ft Additional amount of refrigerant pipe diameter on each liquid side lb Ø1 4 0 017 Ø3 8 0 037 Ø1 2 0 071 Ø5 8 0 108 Ø3 4 0 168 Additional amount of refrigerant by pipe length total Outdoor unit capacity type Adjustment amount of r...

Page 65: ...code is not displayed and only U1 is displayed on the 7 segment display A Check on the indoor unit 1 Display check on the remote control in the case of a wired remote control Check that a frame as shown in the following figure at left is displayed on the LC display section of the remote control If no frame is displayed as shown in the above figure at right the remote control does not have a normal...

Page 66: ... unit in the system where the address is to be set up 4 Address setup start Confirm the items in 8 4 3 Address setup procedure and then set up the address according to the operation procedure Be careful to note that the setup operation may differ in group control and central control systems Note The address cannot be set up if switches are not operated 5 Display check after setup After address set...

Page 67: ... the unit addresses of each line separately each line s header indoor unit is set separately In that case the CODE No L03 Indoor header unit overlap is indicated as running starts Change the group address to make one unit the header unit using wired remote control Without central control or with central control of 1 refrigerant lines Example 1 use Address setting procedure 1 With central control o...

Page 68: ... Do not use a same address as another system refrigerant line or a custom side Interface P C board on the header outdoor unit Line address switches on the outdoor interface PC board switch on switch off Example Controlling 2 or more refrigerant lines as a group System wiring diagram Outdoor Indoor Indoor Indoor Indoor Outdoor Remote control Group control Not used for setup of line address do not c...

Page 69: ...ndication starts flashing on the display When the flashing stops and remains lit on the display the setting is complete 7 Repeat steps 4 to 6 for other refrigerant lines 8 After completing address setting of all systems turn off dip switch 2 of SW30 on the interface P C boards of all the header outdoor units connected to the same central control except the unit that has the lowest address For unif...

Page 70: ...e central control address refer to the installation manuals of the central control devices 7 segment display Header unit interface P C board SW30 Header units are connected to the same central control except the header unit with the smallest line address number ...

Page 71: ...dress 1 No setting required 2 No setting required 3 1 Dip switch 2 of SW30 Terminator of indoor outdoor communication line and central control line ON No setting required Set to OFF after setting addresses No setting required Set to OFF after setting addresses ON Relay connector Connect after setting addresses Open Connect after setting addresses Open Connect after setting addresses Open Line syst...

Page 72: ...Follower unit 0002 12 Push the button OK when the display goes on Central control address 13 Using the buttons set DN code to 03 14 Using the buttons set up the central control address 0001 0064 15 Push button OK when display goes on 16 Push the button Setup is finished Setting up blinks when Setting up goes off operation is possible 17 Return to the original wiring over remote controls Wiring exa...

Page 73: ...n U1 U2 and U3 U4 of the header unit for each refrigerant line After that set up the central control address For central control address setup refer to the installation manual of the central control devices Confirming the indoor unit addresses and the position of an indoor unit using the remote control Confirming the numbers and positions of indoor units To see the indoor unit address of an indoor...

Page 74: ...ted one after another The first indicated unit number is the address of the header unit Only the fan and louvers of the indicated indoor unit are activated 3 Push the button to finish the procedure All the indoor units in the group stop To check all the indoor unit addresses using an arbitrary wired remote control When communication wirings of 2 or more refrigerant lines are interconnected for cen...

Page 75: ...ect another system address and check the indoor unit addresses of the line 6 Push the button to finish the procedure Changing the indoor unit address using a remote control To change an indoor unit address using a wired remote control The method to change the address of an individual indoor unit the indoor unit is paired with a wired remote control one to one or an indoor unit in a group The metho...

Page 76: ...is available when the addresses have already been set automatically When communication wirings of 2 or more refrigerant lines are interconnected for central control NOTE You can change the addresses of indoor units in each refrigerant line using an arbitrary wired remote control Enter the address check change mode and change the addresses If no number appears on UNIT No no outdoor unit exists on t...

Page 77: ...tivated Repeat steps 4 to 6 to change the indoor unit addresses so as to make each of them unique 7 Push the button All the segments on the LCD display light up 8 Push the button to finish the procedure Resetting the address Resetting to the factory default address undecided Method 1 Clearing each address separately using a wired remote control Set the system address indoor unit address and group ...

Page 78: ... completed successfully If the 7 segment display indicates A d n G the outdoor unit may still connected with other refrigerant lines Check the connection of the relay connectors between U1 U2 and U3 U4 NOTE Take care to carry out the procedure above correctly otherwise addresses in other refrigerate lines may also be cleared 5 Set the addresses again after finishing the clearance SW01 SW02 SW03 SW...

Page 79: ...follows 1 Remove the relay connector between U1 U2 and U3 U4 2 If it is off turn on SW30 bit 2 on the interface PC board at outdoor header unit side Turn off the power and then execute the operation 3 Turn on the indoor outdoor power for the refrigerant line for which an address is to be set up After approximately 1 minute check that U 1 is displayed on the 7 segment display 4 Execute the followin...

Page 80: ...wer unit removed Terminal resistance 3 Is the end resistance SW30 bit 2 of the header unit with the smallest line address number in the central control turned on Setup is unnecessary for follower units 4 Is the terminal resistance SW30 bit 2 of the header units except for the line with the smallest central control line address turned off Setup is unnecessary for follower units Line address 5 Are a...

Page 81: ...C board failure Replace the interface PC board E06 After address setup communication from all the indoor units is interrupted under the condition that a normal operation can be performed Check and correct disconnection of the indoor outdoor communication line the communication line between the header unit and the leading indoor unit Check for the influence of communication noise E16 E16 XX Alterna...

Page 82: ...formed with connecting an indoor outdoor communication line between outdoor units Fig 3 Correct wiring Address setup is performed under the condition of connecting multiple refrigerant lines Fig 3 Correct wiring Indoorremote control status Headerunit 7 segment display Cause Countermeasures No response None The communication line is not connected between indoor and outdoor the unit that does not re...

Page 83: ...nit After modification of wiring set up the addresses again and check the number of connected indoor units The number of outdoor units connected to a group is too few in group operation from an indoor remote control The indoor remote control is not connected with wire Miswiring of the indoor remote control Using the main indoor remote control connected to a group start a test operation specify the...

Page 84: ...iswiring example Fig 4 The number of connected outdoor units is too few Fig 5 The number of connected indoor units is too few Header unit Header unit Header unit Follower unit Header unit Follower unit Header unit Follower unit Header unit Line 1 Follower unit Line 2 Header unit Follower unit Header unit Follower unit Header unit Follower unit Header unit Follower unit Wiring forgotten ...

Page 85: ... of the indoor unit Is the sound normal Normal Check every indoor unit in turn Check code appears Check code appears When a check code has been displayed on the remote control remove the cause of the error referring to Check code and check position displayed on remote control and outdoor unit Check the indoor fan fan motor and fan circuit Check positions around the fan ...

Page 86: ...isplay as in procedure 1 appears in the display section 5 Push the Test button to clear the test operating mode TEST disappears from the display section and the status returns to the normal stopped status Procedure Operation content 1 Remove the nameplate of the receiver section by inserting a screwdriver or similar tool into the notch at the bottom of the plate and set the DIP switch to TEST RUN ...

Page 87: ...on to stop the operation 5 Turn off the air conditioner s power Change Bit 1 of switch S003 on the sensor PC board from on to off Attach the adjustment corner cap with the sensors to the ceiling panel Sensor cover Adjustment corner cap Sensor PC board Bit 1 Procedure Operation content 1 Turn on the air conditioner s power 2 Push the button and change the operating mode to COOL or HEAT with the Mod...

Page 88: ...ping operation Note After powering on it may require up to 10 minutes to start the operation due to the initial communications of the system Check the operating status of the compressor Check the direction of the louver Execute a test operation using Start Stop Function of the Indoor Unit from Outdoor Unit in the Service Support Function section Check power voltage of the main power supply Check t...

Page 89: ...emperature conditions refer to 2 This compressor is driven with a 4 pole motor The value of the compressor frequency rps measured with a clamp meter at the compressor lead line is two times the rotation count rps of the compressor Each compressor may have a different frequency as a measure against resonance The temperature of the indoor heat exchanger TC indicates TCJ sensor temperature when cooli...

Page 90: ...of outdoor units connected to the system is displayed on 7 segment display A Check that this display surely matches with the expected No of outdoor units Check No of indoor units No of units with cooling thermo ON Set the rotary switches SW01 SW02 SW03 on the interface P C board of the header unit to 1 4 3 Then No of indoor units connected to the system is displayed on 7 segment display A Check th...

Page 91: ... 1 Check that No of misconnected indoor units is displayed on 7 segment display B after 15 minutes If there is no misconnection 00P is displayed Confirmation of check results 2 Press the push switch SW05 on the interface P C board of the header unit for 2 seconds or more The indoor address in which error is being detected is displayed on 7 segment display B If there are multiple indoor address in ...

Page 92: ...urn SW01 SW02 SW03 to 1 Section A C H Section B 11 00 is displayed on Section B for 5 seconds Batch stop Stops all the connected indoor units collectively Setup Set SW01 SW02 SW03 to 2 7 1 and press SW05 for 2 seconds or more Release Return SW01 SW02 SW03 to 1 Section A C H Section B 00 00 is displayed on Section B for 5 seconds 4 Individual start Starts the specified indoor unit Notes The content...

Page 93: ... the header unit to 2 5 1 C is displayed on 7 segment display A Press SW04 on the same board for 2 seconds or more Test run is displayed on the remote control of the indoor unit to be operated Check that C is displayed on 7 segment display B on the interface P C board of the header unit Return SW01 SW02 SW03 on the interface P C board of the header unit to 1 1 1 or press the push switch SW05 for 2...

Page 94: ...board of the header unit to 2 6 1 H is displayed on 7 segment display A Press SW04 on the same board for 2 seconds or more Test run is displayed on the remote control of the indoor unit to be operated Check that C is displayed on 7 segment display B on the interface P C board of the header unit Return SW01 SW02 SW03 on the interface P C board of the header unit to 1 1 1 or press the push switch SW...

Page 95: ...1 1 The indoor unit to be started operates Press the push switch SW05 on the interface P C board of the header unit for 2 seconds or more If the discharge temperature does not change though COOL or HEAT has been set up from the remote control misconnection is considered Be sure to turn on power at the indoor side before power ON of outdoor unit If an error is already displayed with SW01 SW02 SW03 ...

Page 96: ...y by heating priority control cooling priority control and selection of cooling or heating mode is not operated In this case operation ready or operation mode controlled is displayed on the remote control 7 segment display A 7 segment display B Rotary switches 7 segment display Address display of corresponding indoor unit 00 is displayed for 5 seconds after operation ON Press the push switch SW04 ...

Page 97: ...Change the mode to service monitor mode by pushing buttons simultaneously for 4 seconds or more 2 Using buttons set CODE No to FF 3 The display in Section A in the following figure is counted with interval of 5 seconds as 0005 0004 0003 0002 0001 0000 When the count arrives 0000 the error is cleared However counting from 0005 is repeated on the display 4 When button is pushed the status returns to...

Page 98: ...cleared and error detection is performed again Method 1 Be sure to reset power of both the outdoor and the indoor units 2 Turn on the power of the indoor unit prior to the power of the outdoor unit If the power is turned on in reverse order a check code E19 No of header unit error is output NOTE After power reset it requires usually 3 minutes to power on due to the initial communication of the sys...

Page 99: ...he power of the outdoor unit Set the display select switches on the interface P C board of the header unit as follows Set SW01 SW02 SW03 to 2 4 1 Press the push switch SW04 on the same board for 2 seconds or more Checking display of the connected remote control flashes Press the push switch SW05 on the interface P C board of the header unit for 2 seconds or more Check the connected remote control ...

Page 100: ...ng automatically returns to the normal opening 8 7 6 Pulse motor valve PMV forced open fully close fully function in outdoor unit This function is provided to forcedly open or close fully P M V PMV1 PMV2 PMV4 used in the outdoor unit for 2 minutes PMV1 PMV2 Open fully On the interface board of the outdoor unit set the dip switch SW12 bit1 to OFF SW12 bit2 to OFF and short circuit CN30 PMV1 PMV2 Cl...

Page 101: ...id valve output is exchanged when SW02 has been kept with the same number for 5 seconds or more NOTE 2 The mark O in the table indicates that the corresponding solenoid valve is forcedly turned on NOTE 3 The mark in the table indicates that ON OFF of the solenoid valve is controlled based upon the specifications of the air conditioner NOTE 4 The mark in the table indicates that the corresponding s...

Page 102: ...de operation 4 After that by changing the setup number of the switches SW02 and SW03 7 segment display B and the fan mode are changed Mode output pattern of the fan is as follows Clear This function is cleared by one of the following operations 1 When SW01 setting number was changed to other number 2 Press switch SW05 was pressed for 2 seconds or more SW02 SW03 7 segment display B Fan mode 1 4 63 ...

Page 103: ...conds or more 3 E 1 is displayed on 7 segment display A 4 The fan of the outdoor unit in which error occurred starts operation within approx 10 seconds after E 1 was displayed In case to operate the fans in all the normal outdoor units 1 Check that the switches SW01 SW02 SW03 on the interface P C board in the header unit are set to 1 1 1 2 Press the push switches SW04 and SW05 at the same time for...

Page 104: ... the interface P C board for 1 second or more The mode changes to the TO sensor value fix manual mode 3 As shown in the following table TO sensor value can be fixed by setting the rotary switch SW02 on the interface P C board Clear Return SW01 SW02 SW03 on the interface P C board in the outdoor unit to 1 1 1 NOTE If operated with TO sensor fixed by this function the system control operation of the...

Page 105: ...t operation function 7 C H Indoor collective start stop ON OFF function 11 r d Outdoor refrigerant recovery operation function Pump down function 16 E r Error clear function 2 1 16 3 H r Solenoid valve forced open close function 2 4 7 F d Fan forced operation function 2 15 t o Outside temperature sensor manual adjustment function 16 1 16 1 0 1 1 6 Indoor No 1 to 16 unit Indoor individual start sto...

Page 106: ...e control Procedure 1 Push buttons simultaneously for 4 seconds or more to call up the service monitor mode The service monitor goes on and temperature of the CODE No 00 is firstly displayed 2 Push the temperature setup buttons to select the CODE No to be monitored For displayed codes refer to the table next page 3 Push button to determine the item to be monitored Then monitor the sensor temperatu...

Page 107: ...psi 12 22 Compressor 1 discharge temperature Td1 1 F 0080 80 F 13 23 Compressor 2 discharge temperature Td2 1 F 14 24 Compressor 3 discharge temperature Td3 1 F 15 25 Suction temperature TS 1 F 16 26 Outdoor coil temperature 1 TE1 1 F 17 27 Outdoor coil temperature 2 TE2 1 F 18 28 Temperature at liquid side TL 1 F 19 29 Outside ambient temperature TO 1 F 1A 2A PMV1 2 opening 1 pls 0500 500 pulse 1...

Page 108: ...ld it just be the 3 minute delay period 3 minutes after compressor shutdown Could it just be the air conditioner having gone thermo OFF Could it just be the air conditioner operating in fan mode or put on the timer Could it just be the system going through initial communication 2 An indoor fan would not start Could it just be cold air discharge prevention control which is part of heating 3 An outd...

Page 109: ...or header and follower unit Periodic communication between indoor header and follower units cannot be maintained F01 ALT Indoor heat exchanger temperature sensor TCJ error Heat exchanger temperature sensor TCJ has been open short circuited F02 ALT Indoor heat exchanger temperature sensor TC2 error Heat exchanger temperature sensor TC2 has been open short circuited F03 ALT Indoor heat exchanger tem...

Page 110: ...e been set as master remote control in two remote control control alarm and shutdown for header unit and continued operation for follower unit Check code Display of receiving unit Typical fault site Description of error TCC LINK central control Outdoor 7 segment display Indicator light block Sub code Flash C05 No indication when wired remote control also in use Faulty central control communication...

Page 111: ...rom other refrigerant line 02 Connection of indoor unit from other refrigerant line E20 Connection to other refrigerant line found during automatic address setting Indoor unit from other refrigerant line is detected while indoor automatic address setting is in progress E23 E23 Outdoor outdoor communication transmission error Signal cannot be transmitted to other outdoor units E25 E25 Duplicated fo...

Page 112: ...ge temperature sensor TD2 has been detected H16 01 TK1 oil circuit error 02 TK2 oil circuit error 03 TK3 oil circuit error 04 TK4 oil circuit error 05 TK5 oil circuit error H16 Oil level detection circuit error No temperature change is detected by temperature sensor for oil level detection TK1 5 despite compressor having been started H25 H25 Outdoor discharge temperature sensor TD3 wiring error Wi...

Page 113: ...been shutdown in one refrigerant line due to detection of overflow detected by indoor unit P13 P13 ALT Outdoor liquid backflow detection error State of refrigerant cycle circuit indicates liquid backflow operation P15 01 TS condition 02 TD condition P15 ALT Gas leak detection Outdoor suction temperature sensor TS1 detects sustained and repeated high temperatures that exceed standard value P17 P17 ...

Page 114: ...pressor 2 03 Compressor 3 H03 Current detection circuit error Abnormal current is detected while inverter compressor is turned off P04 01 Compressor 1 02 Compressor 2 03 Compressor 3 P04 ALT Activation of high pressure SW High pressure SW is activated P07 01 Compressor 1 02 Compressor 2 03 Compressor 3 P07 ALT Heat sink overheating error Temperature sensor built into IGBT TH detects overheating P2...

Page 115: ...tion or shut down Procedure To be performed when system at rest 1 Invoke the SERVICE CHECK mode by pressing the buttons simultaneously and holding for at least 4 seconds The letters SERVICE CHECK light up and the check code 01 is displayed indicating the error history This is accompanied by the indoor unit No to which the error history is related and a check code 2 To check other error history ite...

Page 116: ...loading E19 Error in number of outdoor header units E20 Detection of refrigerant piping communication error during automatic address setting E23 Faulty transmission in outdoor outdoor communication E25 Duplicated follower outdoor address E26 Faulty reception in outdoor outdoor communication dropping out of outdoor unit E28 Outdoor follower unit error E31 IPDU communication error P01 Indoor AC fan ...

Page 117: ...tdoor discharge temperature sensor TD1 H06 Abnormal drop in low pressure sensor Ps reading Protective shutdown of outdoor unit H07 Abnormal drop in oil level H08 Error in temperature sensor for oil level detection circuit TK1 TK2 TK3 TK4 or TK5 H15 Wiring installation error or detachment of outdoor discharge temperature sensor TD2 H16 Oil level detection circuit error Error in outdoor unit TK1 TK2...

Page 118: ...est run in progress Setting incompatibility automatic cooling heating setting for model incapable of it and heating setting for cooling only model Light block Check code Cause of fault Operation Timer Synchronized blinking Ready Operation Timer Synchronized blinking Ready Operation Timer Alternate blinking Ready ...

Page 119: ...ndoor and outdoor units Check indoor address setting Check indoor outdoor tie cable Check outdoor termination resistance setting SW30 Bit 2 E06 E06 No of indoor units from which signal is received normally I F Dropping out of indoor unit All stop Indoor unit initially communicating normally fails to return signal for specified length of time Check power supply to indoor unit Is power turned on Che...

Page 120: ...o of indoor units connected Check for defect in outdoor P C board I F E18 Indoor unit Error in communication between indoor header and follower units Stop of corresponding unit Periodic communication between indoor header and follower units cannot be maintained Check remote control wiring Check indoor power supply wiring Check P C boards of indoor units E19 E19 00 No header unit 02 Two or more hea...

Page 121: ...ss SW05 on its own E31 E31 Symbol O signifies site of IPDU error I F IPDU communication error All stop Communication is disrupted between IPDUs P C boards in inverter box Check wiring and connectors involved in communication between IPDU I F P C board for bad contact or broken wire Check for defect in outdoor P C board I F A3 IPDU or Fan IPDU Check for external noise F01 Indoor unit Indoor TCJ sen...

Page 122: ...esistance is infinity or zero open short circuit Check connection of TF sensor connector and wiring Check resistance characteristics of TF sensor Check for defect in indoor P C board F12 F12 I F TS1 sensor error All stop Sensor resistance is infinity or zero open short circuit Check connection of TS1 sensor connector Check resistance characteristics of TS1 sensor Check for defect in outdoor P C bo...

Page 123: ... 02 Compressor 2 side 03 Compressor 3 side IPDU Compressor breakdown All stop Inverter current detection circuit detects overcurrent and shuts system down Check power supply voltage AC 460 V 10 Check for defect in compressor Check for possible cause of abnormal overloading Check for defect in outdoor P C board A3 IPDU H02 H02 01 Compressor 1 side 02 Compressor 2 side 03 Compressor 3 side IPDU Comp...

Page 124: ... equalizing circuit for clogging H08 H08 01 TK1 sensor error 02 TK2 sensor error 03 TK3 sensor error 04 TK4 sensor error 05 TK5 sensor error I F Error in temperature sensor for oil level detection All stop Sensor resistance is infinity or zero open short circuit Check connection of TK1 sensor connector Check resistance characteristics of TK1 sensor Check for defect in outdoor P C board I F All sto...

Page 125: ...isconnection of TK3 sensor Check resistance characteristics of TK3 sensor Check for connection error involving TK1 TK2 TK3 TK4 and TK5 sensors Check for faulty operation in SV3E or SV3F valve Check for clogging in oil equalizing circuit capillary and faulty operation in check valve Check for refrigerant entrapment inside compressor No temperature change is detected by TK4 despite compressor having...

Page 126: ...oor addresses L08 L08 Indoor unit Indoor group addresses not set Stop of corresponding unit Address setting has not been performed for indoor units Check indoor addresses This code is displayed when power is turned on for the first time after installation L09 Indoor unit Indoor capacity not set Stop of corresponding unit Capacity setting has not been performed for indoor unit Set indoor capacity D...

Page 127: ...for leakage of SV4 circuit Check SV4 circuit wiring or installation error in SV41 SV42 or SV43 P04 P04 01 Compressor 1 side 02 Compressor 2 side 03 Compressor 3 side IPDU Activation of high pressure SW All stop High pressure SW is activated Check connection of high pressure SW connector Check for defect in Pd pressure sensor Check outdoor service valves gas side liquid side to confirm full opening...

Page 128: ...SH control Check full close operation of outdoor PMV 1 2 4 Check for defect in Pd or Ps sensor Check gas balancing circuit SV2 for clogging Check balance pipe Check SV3B circuit for clogging Check defect in outdoor P C board I F Check capillary of oil separator oil return circuit for clogging Check for leakage of check valve in discharge pipe convergent section P15 P15 01 TS condition I F Gas leak...

Page 129: ... Check resistance characteristics of TS1 and TE1 sensors Check output voltage characteristics of Pd and Ps pressure sensors Check for wiring error involving TE1 and TL sensors P20 P20 I F Activation of high pressure protection All stop Pd sensor detects pressure equal to or greater than 522 psi 3 6 MPa Check for defect in Pd pressure sensor Check service valves gas side liquid side to confirm full...

Page 130: ...connection of fan motor connector Check for defect in fan IPDU P C board All stop Sub code C Higher temperature than the specified value is detected during operation of the fan Check fan motor Check for defect in fan IPDU P C board All stop Sub code D The resistance value of the sensor is infinite or zero open or short circuit Check for defect in fan IPDU P C board All stop Sub code E Fan IPDU DC ...

Page 131: ...or defect in central control communication line Check termination resistance setting Check power supply for devices at other end of central control communication line Check defect in P C boards of devices at other end of central control communication line C12 General purpose device I F Blanket alarm for general purpose device control interface Continued operation Error signal is input to control i...

Page 132: ... If there is any loose connector tighten it with a pair of pliers etc before connecting the lead How to Check Resistance of Compressor Winding 1 Turn off the power supply 2 Remove compressor leads from the compressors 3 With each compressor check the phase to phase winding resistances and winding to outdoor cabinet resistance using a multimeter Earth fault It is normal if the winding to outdoor ca...

Page 133: ...ted on the remote control as its communication is down However the code is indicated on the compliant manager of TCC LINK Check code Check code name Cause Is the inter unit wire of remote controls A B normal Correct inter unit cable of remote control Correct connector connection and check circuit wiring Is there no disconnection or connector contact error on harness out of terminal block of indoor...

Page 134: ...ain period from the indoor unit which has used to send signals normally E06 is displayed Was power turned on in order of indoor unit outdoor unit Check code Check code name Indoor Outdoor communication circuit error Detected at indoor side Cause 1 Power of outdoor unit was firstly turned on 2 Connection error of communication line between indoor and outdoor 3 End terminal resistance setup error on...

Page 135: ...ct communication line Check code Check code name Cause Indoor Outdoor communication circuit error Detected at outdoor side 1 Indoor outdoor communication end terminal resistance setup error 2 Indoor outdoor communication connection error Is inter unit wire U1 U2 between indoor and outdoor short circuited Is connection of inter unit wire between indoor and outdoor correct Is there no error on power...

Page 136: ...door P C board error Is there any trouble on power line Check indoor control P C board Failure Replace Check power voltage Improve the line condition Eliminate noise etc Check code Check code name Cause Automatic address start error 1 Starting automatic addressing of indoor units during automatic addressing in another refrigerant line Sub code 01 2 Starting automatic addressing of outdoor units du...

Page 137: ...its beyond the limit Check code Check code name Cause 1 There are 48 or more connected indoor units 2 Capacity over of total connected indoor units 3 Incorrect setup of indoor units power Sub code 00 Capacity over 01 number of connected units Is backup operation of our outdoor unit being set up Is No of connected indoor units correct Is setup of indoor units HP correct Is total capacity of connect...

Page 138: ...tc Check code Check code name Cause Header outdoor unit quantity error 1 Misconnection of inter unit wire between indoor and outdoor 2 Outdoor I F P C board error Sub code 00 No header unit 02 Two or more header units Are not communication lines U1 U2 between indoor and outdoor connected to multiple outdoor units Is communication line between indoor and outdoor connected to one unit per 1 system C...

Page 139: ...display of the header unit The fan of the outdoor unit which stopped due to occurrence of error starts rotating Push SW05 to stop the fan Check code Check code name Cause Check code Check code name Cause Check code Check code name Cause Duplicated follower outdoor address setup Addresses are duplicated by manual setup of outdoor address Do not set up outdoor addresses manually Decrease of connecte...

Page 140: ...stance value See Outdoor unit temperature sensor characteristics on 9 9 Sensor characteristics If sensor is normal replace outdoor I F P C board Check code Check code name Cause Is TC1 sensor connector CN100 Brown on indoor P C board normally connected Indoor TC1 sensor error TC1 sensor Open Short Are characteristics of TC1 sensor resistance value normal Check indoor main P C board Defect Replace ...

Page 141: ...acteristics on 9 9 Sensor characteristics If sensor is normal replace outdoor I F P C board Cause Check code name Check code TL sensor error TL sensor Open Short Cause Check code name Check code TO sensor error TO sensor Open Short Cause Check code name Check code Indoor TA sensor error TA sensor Open Short Cause Check code name Check code TS1 sensor error TS1 sensor Open Short Cause Check code na...

Page 142: ...ssure Check joint by pressure gauge 2 Pressure display on 7 segment display 3 Output voltage of I F P C board If 1 and 2 3 are different an error of pressure sensor itself is considered If 2 and 3 are different check interface P C board Value can be confirmed by 7 segment display function on outdoor I F P C board Pd SW01 02 03 1 1 2 Ps SW01 02 03 1 2 2 1 Pressure Check joint by pressure gauge 2 Pr...

Page 143: ...irmly Details of compressor power connecting section Correct connector connection or wiring Compressor error Motor burning etc Correct cause of overload Correct power line Check power voltage and line Correct power line Check external noise etc Check I F P C board Is there any trouble of outdoor unit power supply This error is detected during operation of air conditioner of IC10 non volatile memor...

Page 144: ...tor connection or wiring Is wiring or connector connection on A3 IPDU P C board normal Does voltage drop occur when other compressor starts Is MG CTT normal 2 Abnormal overload Is there no refrigerant stagnation in compressor shell Check A3 IPDU P C board Is compressor normal 3 Compressor error Is case heater output normal Check case heater Correct refrigerant stagnation in compressor shell Correc...

Page 145: ... Repair faulty parts Repair faulty parts Replace PMV body Replace PMV body A Cooling Does indoor fan normally operate in cooling season Is there clogging of indoor air filter or heat exchanger Is indoor PMV normal Refrigerant shortage or clogging or pipe deformed Are following items concerned to indoor fan motor normal 1 Connector connection 2 Condenser 3 Motor 4 Fan Is connector connection or coi...

Page 146: ...es or not If it is equivalent to outside temperature clogging of SV3E is considered 5 in the figure Reference If SV3E valve is clogged temperature does not change at all sensors TK1 TK2 TK3 TK4 and TK5 f Clogging check for SV3F valve While outdoor unit is operated set up SW01 02 03 2 1 3 7 segment display Hr and push SW04 for 2 seconds or more Set up SW02 8 and turn on SV3C SV3E SV3F valves 7 segm...

Page 147: ...nt display Hr 3 A If temperature is low at secondary side of the valve or it does not change clogging of valve or check valve is considered 1 in the figure b Leakage check for SV3C valve While outdoor unit is operating set up SW01 02 03 2 1 3 7 segment display Hr and push SW04 for 2 seconds or more Set up SW02 8 and turn on SV3C valve 7 segment display Hr 3 C If temperature does not change up clog...

Page 148: ...nce value 2 Oil equalization circuit error Check valve capillary clogging strainer clogging 3 Refrigerant stagnation in the compressor shell Compressor 1 Correct installation of sensor Correct miswiring misinstallation TK1 CN531 black TK2 CN532 green TK3 CN533 pink TK4 CN534 yellow TK5 CN535 red Sensor error Replace clogging part Is not TK1 sensor detached Is there no miswiring or misinstallation ...

Page 149: ...uit error Check valve capillary clogging strainer clogging 3 Refrigerant stagnation in the compressor shell Is not TK2 sensor detached Is there no miswiring or misinstallation on TK1 TK2 TK3 TK4 TK5 sensors Are characteristics of TK2 sensor resistance value normal After resetting the power Start a test operation in COOL or HEAT mode Display TK2 sensor temperature on 7 segment display with SW01 02 ...

Page 150: ...utes after compressor 1 has operated If low temperature continues approximately outside temp or temperature has little change a clogging of strainer of oil equalization circuit clogging of capillary tube or malfunction of check valve is considered Correct miswiring misinstallation TK1 CN531 black TK2 CN532 green TK3 CN533 pink TK4 CN534 yellow TK5 CN535 red Correct installation of sensor Is not TK...

Page 151: ...efer to the article of the check code H07 Is not TK5 sensor detached Is there no miswiring or misinstallation on TK1 TK2 TK3 TK4 TK5 sensors Are characteristics of TK5 sensor resistance value normal Replace SV3E valve Outdoor discharge temperature sensor TD3 misconnection 1 Coming off of TD3 sensor 2 Misinstallation of TD1 TD2 or TD3 sensor miswiring characteristics error of resistance value Corre...

Page 152: ...code name Cause Duplicated indoor units with priority Displayed on indoor unit with priority Two or more prior indoor units exist This check code is displayed on the indoor unit set as a prior one when two or more prior indoor units are detected Priority setup with two or more units is not available As only one indoor unit with priority is valid change the setup Check code Check code name Cause Du...

Page 153: ...n set up so as to match with the model I F P C board A ssy service for the outdoor unit is common to this series A setup for model selection different from that for P C board with trouble is necessary Set up a model based upon the P C board A ssy exchange procedure Incompatible combination of outdoor units An SMMS i outdoor unit SMMS4 series unit and an outdoor unit of other series are connected D...

Page 154: ...Replace communication line I F P C board error Correct connection of connector In the case that All IPDUs A3 IPDUs and fan IPDUs do not return response Two A3 IPDUs NO 1 and 2 exist in 072 type In 096 type 114 type three A3 IPDUs No 1 2 3 exist Interlock in indoor unit from outside Abnormal input from the outside Is outside device connected to connector CN80 Does outside device correctly operate C...

Page 155: ...anger clogging air short circuit 7 SV2 circuit error 8 SV4 circuit error 9 SV5 circuit error 10 Discharge line check valve malfunction 11 Refrigerant overcharge Note High pressure SW is normally closed B contact Does high pressure SW operate Are parts of high pressure SW normal Sub code 01 Compressor 1 02 Compressor 2 03 Compressor 3 Cooling To B Heating To C Replace the highpressure sensor Reset ...

Page 156: ...gging Tighten screws Check fan and fan motor Correct wiring to compressor or connector connection Correct power line Is SV2 circuit normal Is SV4 circuit normal Does heating indoor fan normally operate Heating operation Is indoor PMV normal Is there any interference of heatexchanging of indoor unit 1 Filter clogging 2 Heat exchanger clogging 3 Air short circuit Is SV5 circuit normal Are any indoor...

Page 157: ...tance value between each phase at motor side of fan motor connector CN333 on indoor P C board MCC 1402 correct 1 Is resistance value at motor side of fan motor connector CN334 on indoor P C board MCC 1402 correct 2 Is output of indoor fan motor position detective signal correct 3 1 Is not winding 1 Red lead to 3 White lead 3 White lead to 5 Black lead 5 Black lead to 1 Red lead opened shorted Resi...

Page 158: ...here no clogging of SV3B valve of any other unit than malfunctioning one Is there no leakage of check valve of main discharge pipe in follower units in which compressors are driven in cooling operation Check I F P C board Check code Check code name Cause Gas leak detection TS condition Sub code 01 1 Outdoor unit service valve closed 2 Outdoor PMV error 3 TS1 sensor error 4 Refrigerant shortage clo...

Page 159: ... circuit connected Refrigerant shortage clogging pipe breakage Check there is no clogging and pipe breakage and then recharge refrigerant Check code Check code name Cause Discharge temp TD2 error 1 Outdoor unit service valve closed 2 Outdoor PMV error 3 TD sensor error 4 Refrigerant shortage clogging of refrigerant circuit 5 4 way valve error 6 SV4 circuit leakage misinstallation Open service valv...

Page 160: ... 2 Wiring 3 Coil 4 Valve body 5 Outdoor I F P C board Are service valves of gas and liquid sides fully opened Check code Check code name Cause 4 way valve reverse error 1 4 way valve error 2 TS1 sensor TE1 sensor error 3 Pd sensor Ps sensor error 4 TE sensor TL sensor misconnection Sub code Detected outdoor unit No Is 4 way valve coil connector connected Are output voltage characteristics of Pd an...

Page 161: ...r PMV normal 1 Connector connection 2 Wiring 3 Coil 4 Valve body 5 Outdoor I F P C board Is there any interference of heat exchanging of outdoor unit 1 Heat exchanger clogging 2 Air short circuit Is SV2 bypass circuit normal Is SV4 circuit normal Is check valve of main discharge pipe normal Refrigerant overcharge clogging pipe breakage abnormal overload Check code Check code name Cause High pressu...

Page 162: ...nnection on fan IPDU P C board normal Is not outdoor fan motor locked Is the resistance of the motor s winding wire normal Is sub code of outdoor I F P C board 0 Is there no problem such as stuffing or blast blowing to discharge port of outdoor fan Check fan IPDU Correct wire connector connection Replace motor Replcae fan IPDU Clear the cause of overhead Check code Check code name Cause Check code...

Page 163: ...4Ω Is not winding opened Check A3 IPDU P C board Failure Replace Check and correct circuit and cables such as wiring to compressor etc Compressor error Replace Compressor error Replace Compressor error Replace Other indoor error Group follower unit error Another indoor unit in the group is abnormal When the header unit of the group detected error E03 L03 L07 or L08 the follower unit of the group d...

Page 164: ...k code is displayed in the right hand section of the 7 segment display B U1 OOO OOO Check code To check the check code set the rotary switches SW01 SW02 SW03 to 1 1 1 If there is a sub code the display alternates between the check code OOO 3 seconds and the sub code OOO 1 second 2 Check the check code and follow the applicable diagnostic procedure 3 If the 7 segment display shows U1 E28 there is a...

Page 165: ... B 10 Refrigerant oil recovery operation A Oil recovery in cooling C1 Normal C B Refrigerant recovery in heating H1 Normal H 11 Automatic addressing A Ad B During automatic addressing FF Normal 12 Power pick cut A dU B Normal During 50 90 capacity operation _50 _90 While control is based on BUS line input E50 E90 13 Optional control P C board input Displays optional control status A B Operation mo...

Page 166: ...3 7 Compressor backup A C b B Displays compressor backup setting status Normal Compressor No 1 backup 1 Compressor No 2 backup 1 Compressor No 3 backup 1 8 A B 9 Control valve output data Displays control output status of solenoid valve A B 4 way valve ON 4 way valve 2 OFF H 1 4 way valve OFF 4 way valve 2 ON H 0 10 SV2 ON SV5 OFF SV6 OFF 2 1 0 0 SV2 OFF SV5 ON SV6 ON 2 0 1 0 SV2 OFF SV5 OFF SV6 O...

Page 167: ... displayed alternately for 1 second and display for 3 seconds respectively Data with negative value is displayed as Letter symbol t d 1 Data 5 TD2 sensor data Letter symbol t d 2 Data 6 TD3 sensor data Letter symbol t d 3 Data 7 TS sensor data Letter symbol t S Data 8 TE1 sensor data Letter symbol t E Data 9 TE2 sensor data Letter symbol t E 2 Data 10 TL sensor data Letter symbol t L Data 11 TO se...

Page 168: ...ressor No 2 is ON 0 1 0 When compressor No 3 is ON 0 0 1 5 Fan operation mode A U SW03 setting No 1 Outdoor unit No U2 B At rest F 0 In mode 63 F 6 3 6 Release signal A U SW03 setting No 1 Outdoor unit No U2 B Normal r Upon receiving release signal r 1 7 Oil level judgment A U SW03 setting No 1 Outdoor unit No U2 B Normal Low level L 8 Compressor 1 operating current A U SW03 setting No 1 Outdoor u...

Page 169: ...2 is changed the latest error code of a follow unit U2 U4 will be displayed SW01 SW02 SW03 Display detail 4 1 16 1 3 Indoor BUS communication signal receiving status B Upon receiving signal 1 Other times 5 Indoor check code B No check code 6 Indoor capacity B 0 6 to 4 5 7 Indoor request command S code operation mode B represents mode COOL C HEAT H FAN F OFF S represents S code 0 to F 8 Indoor PMV ...

Page 170: ...lts 4 When checking is completed revert the SW01 SW02 SW03 setting to 1 1 1 2 Oil Level Judgment Results Display example Displayed digit Judgment result Description O Normal The amount of oil in the compressor is sufficient 1 2 Low level The amount of oil in the compressor is insufficient Both 1 and 2 stand for insufficiency If this result persists the system will turn itself off in a protective s...

Page 171: ...rcuit capillary Strainer H Corresponding unit Oil level low detection and protection H07 Oil level low SV3E valve I Corresponding unit Oil level detection circuit error Oil level low detection and protection H16 05 H07 Oil circuit error Oil level low Oil level low Oil return distributor J Corresponding unit Oil level low detection and protection H07 Oil level low SV3C bypass capillary K Correspond...

Page 172: ...lve High pressure sensor Low pressure sensor Oil separator Check valve Check valve High pressure SW High pressure SW Check valve Check valve Oil header Check valve Check valve Liquid tank Fusible plug Accumulator Liquid side packed valve Gas side service valve Balance pipe packed valve Fusible plug ...

Page 173: ...ection and protection H07 Oil level low SV3E valve I Corresponding unit Oil level detection circuit error Oil level low detection and protection H16 05 H07 Oil circuit error Oil level low Oil level low SV3F valve J Corresponding unit Oil level low detection and protection H07 Oil level low Oil return distributor K Corresponding unit Oil level low detection and protection H07 Oil level low SV3C byp...

Page 174: ...e High pressure sensor Low pressure sensor Oil separator High pressure SW High pressure SW Oil pipe Check valve Check valve Liquid tank Fusible plug Accumulator Liquid side service valve Gas side service valve Balance pipe packed valve Check valve Check valve High pressure SW Right side sub heat exchanger Fusible plug ...

Page 175: ...TE2 TL and TO sensors Resistance kΩ 50 F 10 C or below Temperature F C Resistance kΩ 50 F 10 C or above Resistance kΩ 50 F 10 C or below Temperature F C Resistance kΩ 50 F 10 C or above Outdoor TD1 TD2 TD3 TK1 TK2 TK3 TK4 and TK5 sensors Temperature F C Resistance kΩ Temperature F C Resistance kΩ ...

Page 176: ... name Lead wire color Input output name Lead wire color 1 OUTPUT White 2 OUTPUT White 3 GND Black GND Black 4 5V Red 5V Red High pressure side Pd Low pressure side Ps 0 5 4 3 V 0 540 9 psi 0 3 73 MPa 0 5 3 5 V 0 142 1 psi 0 0 98 MPa High pressure side output voltage V Low pressure side output voltage V Pressure psi MPa Pressure psi MPa Indoor TA sensor Resistance kΩ Temperature F C Temperature F C...

Page 177: ...w Resistance kΩ 55 F 10 C or above Temperature F C Indoor TC1 sensor Temperature F C Resistance kΩ Resistance kΩ 55 F 10 C or below Resistance kΩ 55 F 10 C or below Temperature F C Indoor TC2 and TCJ sensors Temperature F C Resistance kΩ ...

Page 178: ...k Outdoor Unit Pd sensor characteristics 0 to 639 psi 4 41 MPa 0 5 to 5 V output for 0 to 639 psi 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 ...

Page 179: ... sensor characteristics 0 to 215 psi 1 47 MPa 0 5 to 5 V output for 0 to 215 psi 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 ...

Page 180: ... the system single refrigerant line For a three compressor model the backing up of two faulty compressors is prohibited Note 3 It is prohibited to combine compressor backup operation and outdoor unit backup operation Note 4 With a two outdoor unit system containing an MMY MAP0964HT6UL and a MMY MAP0724HT6UL do not preform outdoor unit backup operation to back up the MMY MAP0964HT6UL It could lead ...

Page 181: ...compressor as shown in the table below 3 Turn on the power supply to all the units connected to the system This is the end of compressor backup operation setting Three compressor model SW06 Bit 1 Bit 2 Bit 3 Bit 4 Factory default setting OFF OFF OFF OFF When compressor No 1 front left is faulty ON OFF OFF OFF When compressor No 2 front center is faulty OFF ON OFF OFF When compressor No 3 front rig...

Page 182: ...outdoor unit 3 Leave the service valves of the liquid and balance pipe fully open to prevent refrigerant stagnation in the unit However if there is a leakage from an outdoor PMV unable to close fully close the liquid pipe service valve 4 In case of fault in compressor electrical part I F P C board or IPDU P C board From this point on keep the power supply to the failed unit off In case of fault in...

Page 183: ...settings needed to gain permission for backup operation from the header unit error clearance 1 Set SW01 02 03 on the interface P C board to 1 1 1 and confirm that U1 E26 dropping out of an outdoor unit is displayed on the 7 segment display 2 Set SW01 02 03 on the interface P C board to 2 16 1 Upon confirming that Er is displayed on the 7 segment display press SW04 and hold for 5 seconds or more 3 ...

Page 184: ... system part Disconnect the connector CN03 for outdoor outdoor communication BUS2 provided on the interface P C board Selection of new header unit 5 Select a new header unit from the follower units on the basis of the following criteria If only one follower unit is connected select it as the header unit If two or more follower units are connected select the follower unit that is nearest to the fai...

Page 185: ... pressure sensor temperature sensor refrigerating cycle part or fan system part Turn on the power supply to protect the compressor by turning on the case heater When the power supply to the unit is turned on E19 error in the number of outdoor header units will be displayed on the 7 segment display However this will not cause any problems This is the end of header outdoor unit backup operation sett...

Page 186: ...failure has been caused by a fault in the interface P C board or electric circuit this function is not available In that case follow the procedure specified in the Outdoor Unit Backup Operation Setting section Work procedure 1 Turn off the power supply to all the units connected to the system Setup of failed outdoor unit Regardless of whether the failed outdoor unit is the header unit or a followe...

Page 187: ...the heat exchangers or sub heat exchangers cannot be recovered In that case recover any residual gas in the heat exchangers or sub heat exchangers using a tube piercing valve or some other tool After a pump down operation do not perform any welding until the residual gas in the heat exchangers is recovered 11 1 2 Refrigerant recovery procedure A case of no outdoor unit backup operation setting Wor...

Page 188: ...ust the pressure to around 17 psi 0 12 MPa by slowly closing the gas pipe service valve with checking pressure data 11 Compare the low pressure sensor outputs of the failed unit with that of the unit for pressure adjustment and wait until the two pressure readings become almost the same After letting the system continue operating for a while longer fully close the gas pipe service valve of the uni...

Page 189: ...nit for pressure adjustment Approx 10 minutes after system startup fully close gas pipe service valve Set SW01 02 03 to 1 2 2 to have low pressure sensor output displayed Ps While monitoring low pressure sensor output adjust pressure to around 17 psi 0 12 MPa by slowly closing gas pipe service valve Wait until low pressure sensor outputs of failed outdoor unit and outdoor unit for pressure adjustm...

Page 190: ...ed outdoor unit 1 Connect the liquid pipe check joint and the low pressure side check joint using a gauge manifold and purge the manifold of air to recover refrigerant from the liquid tank and heat exchangers 2 Fully close the liquid pipe packed valve of the failed outdoor unit Leave the service valve of the gas pipe and the packed valve of the balance pipe fully open Setup of unit selected as hea...

Page 191: ...vered refrigerant This is necessary to determine how much additional refrigerant will be needed after the completion of the repair This is the end of the refrigerant recovery operation Set SW01 02 03 of the header unit back to 1 1 1 Approx 10 minutes after system startup fully close gas pipe service valve Select header unit as unit for pressure adjustment Header unit outdoor unit selected as such ...

Page 192: ...unt of refrigerant to be removed according to the capacity of the failed outdoor unit See the table below Example If a 114 type outdoor unit is under repair in a 228 type system Amount of refrigerant required by system as it was initially 228 type 78 3 lb 34 5 kg Amount of refrigerant required by system with available outdoor units only 114 type 40 8 lb 26 0 kg Amount of refrigerant to be removed ...

Page 193: ... sure to perform vacuuming in from the three check joints shown in the diagram below liquid pipe discharge pipe and suction pipe SW12 CN30 PMV operation Bit 1 Bit 2 Bit 3 Bit 4 OFF OFF OFF OFF Short circuit PMV1 and 2 fully open for 2 minutes OFF ON OFF OFF Short circuit PMV4 fully opens for 2 minutes Fan Fan motor Right side Main heat exchanger Main Heat exchanger Left side Left side sub heat exc...

Page 194: ...pressor only WARNING In situations such as indoor unit relocation and repairs it is not possible to recover all the refrigerant held by the system in the outdoor units It could cause a serious accident such as blow out or injury Be sure to perform refrigerant recovery using a refrigerant recovery device WARNING When detaching a pipe by heating with a burner a welded joint take care as any oil left...

Page 195: ...of oil in faulty compressor A gal cc 0 A 0 264 1000 1 Adjust the amount of oil in the new compressor to 0 264 gal 1000 cc Lay the new compressor down and draw 0 238 900 gal cc of oil via the oil equalization pipe Notes Do not draw more than 0 238 900 gal cc of oil as it may cause damage to the compressor If the faulty compressor contained 0 132 500 gal cc or less there may have been a problem with...

Page 196: ...ount of oil in faulty and normal compressors A B gal cc 0 A B 0 528 2000 1 Adjust the amount of oil in the two new compressors to 0 264 1000 each total 0 528 2000 Lay the compressors down and draw 0 238 900 gal cc of oil from each of them via their oil equalization pipes Notes Do not draw more than 0 238 900 gal cc of oil from a compressor as it may cause damage If the faulty compressor contained ...

Page 197: ...aulty compressor and two normal compressors A B C gal cc 0 A B C 0 8 3000 1 Adjust the amount of oil in the three new compressors to 0 3 1000 gal cc each total 0 8 3000 gal cc Lay the compressors down and draw 0 2 900 gal cc of oil from each of them via their oil equalization pipes Notes Do not draw more than 0 2 900 gal cc of oil from a compressor as it may cause damage If the faulty compressor c...

Page 198: ...ped Connect a vacuum pump consecutively to the check joints placed in the liquid and discharge pipes and on the high pressure side of the suction pipe and turn it on Operate the vacuum drying until the vacuum gauge indicates 1 mmHg Method to fully open PMV manually 1 Turn on the power switch of the outdoor unit 2 With the Bits 1 and 2 of SW12 set to off short circuit the pins of CN30 3 Disconnect ...

Page 199: ...tion of TK1 TK2 TK3 TK4 and TK5 sensor in the unit that has replaced compressor Are the characteristics of the TK1 TK2 TK3 TK4 or TK5 sensors of the unit that has replaced compressor correct With the compressor s disconnected check the oil circuit in accordance with the procedure described below Replace the faulty sensor Open the balance pipe valves fully Correct the miswiring or connection To nex...

Page 200: ...pipe check valve F Replace the part Leakage of SV3A valve G 5 With pressure applied to the check joint of discharge pipe with nitrogen manually open the SV3B valve If gas escapes from the suction pipe section of the disconnected compressor there is a leak from the SV3A valve Replace the part Leakage of SV3B valve H 6 Then manually open the SV3A valve If gas escapes from the suction pipe section of...

Page 201: ...essure applied to the check joint of discharge pipe with nitrogen manually open the SV3B valve If gas escapes from the suction pipe section of the disconnected compressor there is a leak from the SV3A valve Replace the part Leakage of SV3B valve H 6 Then manually open the SV3A valve If gas escapes from the suction pipe section of the disconnected compressor there is a leak from the SV3B valve Repl...

Page 202: ...ve the protective plate back Remove the upper hook from the middel partition plate and then remove the lower hook from the center hole of the bottom plate 7 Remove the screws for the discharge cabinet side cabinet Left and right M5 0 4 10 mm 6 pcs each For 096 type and 114 type remove the screws from the discharge cabinet M5 0 6 15 mm 4 pcs For 096 type and 114 type remove the screws from the left...

Page 203: ...ut installation by following the detachment procedure in reverse 10 1 Be careful of the hooks provided on the suction cabinet service panel and lower cabinet No Part to be replaced Work procedure Remarks 8 Remove the hook of the protective plate side from the hole of the middle partition plate 2 locations 8 Protective plate side Service panel Hook ...

Page 204: ...on plate upper M5 0 4 10 mm 2 pcs With a 096 type 114 type the fan motor can be replaced without removing the discharge cabinet side covers 4 Remove the flange nut securing the fan motor and propeller fan To loosen the nut turn it clockwise 5 Remove the square washer 6 Remove the propeller fan CAUTION Lift it straight up Do not forcibly pull it or it may get stuck No Part to be replaced Work proce...

Page 205: ...ecuring alignment between the D cut surface and the arrow mark it may cause the fan to melt and fall off due to friction heat 2 Be sure to put the square washer in place Otherwise unusual noises and vibrations may result 3 Tighten the flange nut at a torque of 11 1 ft lbs 15 N m To tighten the flange nut turn it counterclockwise No Part to be replaced Work procedure Remarks Disconnect faston conne...

Page 206: ... the clamp filter from the fan motor with trouble then attach the clamp filter to the substitution in the same way as before replacement Wind the fan motor lead once around the clamp filter No Part to be replaced Work procedure Remarks 4 Clamp filter ...

Page 207: ...for the waterproof board M4 0 1 10 mm 2 pcs 6 Remove the brazed joints of the piping connected 2 locations 7 Remove the screws for the heat exchanger end plate and pull the heat exchanger out M5 0 1 10 mm 2 pcs No Part to be replaced Work procedure Remarks With a 096 type 114 type remove the discharge cabinet anchor plates Left and right M5 0 1 2 mm 2 pcs 2 sets With a 096 type 114 type also remov...

Page 208: ...n the locking lever with your finger The lower part of the box moves forward 8 Hold the top board with both hands to disengage the top hook No Part to be replaced Work procedure Remarks 4 Steps only applicable to a 096 type 114 type Remove the reactor lead cover M4 0 1 10 mm 1 pc Remove the screws securing the box M4 0 1 10 mm 1 pc Detach the reactor leads 6 terminal block bolts and 2 faston conne...

Page 209: ...erse 8 1 Before pushing the lower part in pull the reactor leads out Take care so that the wiring does not get caught in the way Reconnect all the wiring No Part to be replaced Work procedure Remarks Before pushing lower part in pull leads out through hole When pushing lower part in be sure to keep wiring out of way ...

Page 210: ... board fixing heat sink screws Tightening torque of M4 screws 0 7 1 ft lbs 0 98 0 1 N m Tightening torque of M3 screws 0 4 1 ft lbs 0 55 0 1 N m 4 Fan IPDU board 1 Stop operation of the outdoor unit and turn off the breaker 2 Remove the screws that secure the heat sink heat sink M3 x 0 8 20 mm 5 pcs 3 Detach wires 4 Remove the board from the card edge spacer in the corner Tightening torque of boar...

Page 211: ...4 6 4 pcs Remove the screws starting from the front 5 Remove the reactor and replace it M4 6 1 pc 1210W chassis 990W chassis No Part to be replaced Work procedure Remarks 3 For 096 and 114 only remove the separate reactor box Remove the upper and lower screws M5 x 10 slide the claw to the right and then remove the reactor box Swing the reactor box upwards slip it downwards and then pull it out For...

Page 212: ...replaced Work procedure Remarks Back Liquid tank Accumulator Oil separator PD sensor Compressor 1 Compressor 2 Inverter assembly Front PS sensor Transformer Back Liquid tank Oil separator PD sensor Accumulator Compressor 1 Compressor 2 Compressor 3 PS sensor Front Inverter assembly Transformer ...

Page 213: ...ew No Part to be replaced Work procedure Remarks TD1 sensor yellow TD2 sensor red Accumulator Compressor 1 Compressor 2 TS1 sensor gray TK4 sensor white TK1 sensor black One closer to you TK5 sensor green Oil separator TL sensor white TK2 sensor blue One farther from you Accumulator Liquid tank Transformer ...

Page 214: ...e replaced Work procedure Remarks TD1 sensor yellow TD2 sensor red TD3 sensor black Accumulator Compressor 1 Compressor 2 Compressor 3 TK4 sensor white TS1 sensor gray TK3 sensor yellow TK1 sensor black One closer to you Oil separator TK5 sensor green TK2 sensor blue One farther from you TL sensor white Liquid tank Accumulator Transformer ...

Page 215: ...teel fixing bands are used 11 No Part to be replaced Work procedure Remarks Suction pipe Distributor Ø19 05 Ø22 22 Oil header Liquid pipe Ø25 4 Ø12 7 SV2 valve Discharge pipe Ø6 35 Ø15 88 SV41 valve Suction pipe Ø8 0 Ø19 05 SV42 valve Suction pipe Ø8 0 Ø19 05 Suction pipe Distributor Ø22 2 Ø22 2 SV3C valve Discharge pipe Ø6 35 Ø15 9 Oil header Liquid pipe Ø25 4 Ø15 9 2 used Liquid pipe Balance pip...

Page 216: ...er The band can be placed the other way around but only at the expense of work efficiency 3 Place the SUS band tightly around the pipe fixing rubber so that there is no gap between them Take utmost care not to create a gap over the curved section of the rubber where the hairpin side of the band is located 4 While holding the rubber press down the base of the hook lightly against the rubber and eng...

Page 217: ...e 7 Remove the end sections of the pipes above the 4 way valve which were cut in step 5 8 Install a new 4 way valve Provide adequate cover for the 4 way valve to protect it from overheating During the installation insert pipes firmly into the 4 way valve or a blockage or leakage involving brazing filler metal may result 9 Reinstall the PMV assembly which was removed in step 4 Provide adequate cove...

Page 218: ... 4 way valve 7 Remove the end sections of the pipes above the 4 way valve which were cut in step 5 8 Install a new 4 way valve Provide adequate cover for the 4 way valve to protect it from overheating During the installation insert pipes firmly into the 4 way valve or a blockage or leakage involving brazing filler metal may result 9 Reinstall the PMV assembly which was removed in step 4 Provide ad...

Page 219: ...r housing and move it to a flat surface 6 Remove the housing front cover screws M4 x 0 2 6mm 6pcs 7 Detach both the Faston terminals and round terminals Caution When unplugging a Faston terminal grasp the wire at the base of the terminal 8 Remove the leads from the holder 9 Remove the shield screws and then remove the shield M4 x 0 3 8mm 3pcs No Part to be replaced Work procedure Remarks Screw tig...

Page 220: ...ransformer housing make sure that 4 7 inches 120 mm of the black tube covered part of the leads extend from the holder 2 When bundling the leads make sure that the distance between the band and the bend is 2 6 inches 65 mm as shown in the figure No Part to be replaced Work procedure Remarks Screw tightening locations for transformer housing back Right side Left side Transformer housing 10 Screws B...

Page 221: ...door control P C board MCC 1606 Inverter P C board for fan FAN IPDU MCC 1610 InterfaceP C board Outdoor control P C board MCC 1606 Noise Filter P C board MCC 1625 Inverter P C board for Compressor 3 A3 IPDU MCC 1596 Inverter P C board for Compressor 2 A3 IPDU MCC 1596 Inverter P C board for Compressor 1 A3 IPDU MCC 1596 Thermistor Magnet Contactor Inverter P C board for Compressor 1 A3 IPDU MCC 15...

Page 222: ...ed and the equipment will not operate 5 Set the dip switch settings of the service board to match the switch settings of the PCB being replaced 6 Install the service board to the outdoor control unit Confirm that it is securely fixed to the PCB Mounts 7 Connect the connectors and fast on terminals Confirm that they are correctly and securely inserted 8 If a component on the board is bent during bo...

Page 223: ... Applicable model P C board type code Product code 431 6V 489 Inverter P C board for Compressorr MMY MAP0724HT6UL MMY MAP0964HT6UL MMY MAP1144HT6UL MCC 1596 ASM PCB A3IPDU 4 1 3 4 1 4 1 2 1 1 1 2 3 4 4 1 1 4 Compressor IPDU Black wire White wire A DB01 White wire Pinch this part by round nose pliers for removing the PCB Ex MMY MAP0724HT6UL Compressor IPDU MCC 1596 Screw Spacer 4 Spacer are in pack...

Page 224: ...s it can cause component damage The torque of the screws for DB01 is 0 55N m 0 41ft lbs and it for Q201 is 1 2N m 0 89ft lbs 10 Re connect the connectors and fast on terminals 1 Be sure that all the connectors and the fast on terminals are connected correctly and securely inserted 11 If the components on the PCB were bent during this procedure straighten them so they do not touch other parts 12 In...

Page 225: ...PDU to the heat sink by the five screws that were removed in step 3 If the screws are loose the effected component will generate heat and cause in to breakdown Do not use an electric driver or an air driver as it can cause component damage The torque of 5 screws IC701 DB509 DB510 and Q590 is 0 41 ft lbs 0 55 N m 8 Re connect the connectors and fast on terminals 1 Be sure that all the connectors an...

Page 226: ... be reused during the installation of the service P C board so keep them in a safe place Parts code Description Applicable model P C board type code Product code 431 6V 497 Noise filter P C board MMY MAP0724HT6UL MMY MAP0964HT6UL MMY MAP1144HT6UL MCC 1625 A B C ASM PCB N F Ex MMY MAP0724HT6UL Noise Filter P C board MCC 1625 C Noise Filter P C board A MCC 1625 A Noise Filter P C board 431 6V 497 PC...

Page 227: ...s leads both connected to the screw on terminals 8 of the just removed noise filter P C board A and reinstall them on the service P C board A by firmly connecting them to the screw on terminals 8 in the same manner as before Line Filter installation Screw the line filter and the connecting wires together to the terminals as below The torque of 6 screws of the line filter is 1 84 ft lbs 2 5 N m Ple...

Page 228: ...iring using the connectors and fast on terminals removed in step 3 Make sure that the connectors and fast on terminals are connected correctly and securely 10 If any component on the P C board becomes crooked during replacement straighten it without touching any other component 11 Mount the terminal block sub assembly 1 and firmly secure it using the screws 3 12 Securely connect the red white and ...

Page 229: ...228 15Exploded Diagram Parts Price List SMMS i OUTDOOR UNIT MMY MAP0724HT6UL ...

Page 230: ...229 MMY MAP0724HT6UL ...

Page 231: ... MOTOR FAN CONDENSER RIGHT SIDE CONDENSER LEFT SIDE PULSE MOTOR VALVE 2 PULSE MOTOR VALVE 1 REDUCER OIL HEADER HIGH PRESSURE SENSOR LOW PRESSURE SENSOR ACCUMULATOR VALVE 4WAY SEPARATOR OIL PLUG FUSIBLE LIQUID LINE VALVE PACKED GAS LINE VALVE SERVICE OIL BALANCE LINE VALVE PACKED HIGH PRESSURE SWITCH TANK LIQUID A3 COMPRESSOR 1 COMPRESSOR 2 Symbol ...

Page 232: ...231 SMMS i OUTDOOR UNIT MMY MAP0964HT6UL MMY MAP1144HT6UL ...

Page 233: ...232 MMY MAP0964HT6UL MMY MAP1144HT6UL ...

Page 234: ...R FAN CONDENSER RIGHT SIDE CONDENSER LEFT SIDE PULSE MOTOR VALVE 2 PULSE MOTOR VALVE 1 PULSE MOTOR VALVE 4 OIL HEADER HIGH PRESSURE SENSOR LOW PRESSURE SENSOR ACCUMULATOR VALVE 4WAY SEPARATOR OIL PLUG FUSIBLE LIQUID LINE VALVE SERVICE GAS LINE VALVE SERVICE OIL BALANCE LINE VALVE PACKED HIGH PRESSURE SWITCH TANK LIQUID HIGH PRESSURE SWITCH HIGH PRESSURE SWITCH Symbol ...

Page 235: ... 43146742 VALVE CHECK 1 1 025 4314N050 VALVE PMV 2 3 3 026 4314N044 VALVE 2WAY 3 3 3 027 4314N048 COIL SOLENOID AC208 230 60HZ 3 3 3 028 43148241 SEPARATOR 1 029 43148249 SEPARATOR 1 1 030 43148247 TANK LIQUID 1 031 43148248 TANK LIQUID 1 1 032 43148245 ACCUMULATOR 1 1 033 43148246 ACCUMULATOR 1 035 43119513 GUARD FAN 1 1 1 036 4314G295 CONDENSER ASSY TWO ROW LEFT 1 037 4314G296 CONDENSER ASSY TWO...

Page 236: ...70 43F47401 BONNET 3 8 IN 1 1 1 072 43148220 PLUG FUSIBLE 2 2 2 074 44246236 TUBE CAPILLARY BYPASS 1 0X2 0X2000L 1 1 1 075 44246239 TUBE CAPILLARY ID 1 2 1 1 1 076 43F19904 HOLDER SENSOR TS 9 12 12 077 43197183 BOLT COMPRESSOR 6 9 9 078 43149325 BAND FIX 5 9 9 079 43149388 RUBBER SUPPORTER PIPE 1 1 080 431S8213 OWNER S MANUAL 1 1 1 081 4314Q093 STRAINER 1 082 4314Q094 STRAINER 2 2 083 4314Q054 STR...

Page 237: ...236 SMMS i INV SERVICE PARTS LIST MMY MAP0724HT6UL 4 pieces PC board ...

Page 238: ...237 SMMS i INV SERVICE PARTS LIST MMY MAP0964HT6UL MMY MAP1144HT6UL 4 pieces PC board ...

Page 239: ...1 1 1 711 43F69524 SUPPORT SPACER 2 2 2 712 43182011 SPACER EDGE 13 13 13 713 4316V497 PC BOARD ASSY NOISE FILTER MCC 1625 1 1 1 714 4316V450 PC BOARD ASSY INTERFACE MCC 1606 1 1 1 715 4316V452 PC BOARD ASSY FAN IPDU MCC 1610 1 1 1 716 4316V489 PC BOARD ASSY COMP IPDU MCC 1596 2 3 3 717 43158229 REACTOR CH 79 2 3 3 718 43282001 BUSHING 3 3 3 719 43183020 COLLAR 3 3 3 721 43155226 FILTER LINE 1 1 1...

Page 240: ...n combined with a gas leak detection device The concentration is as given below Concentration limit Compliance to the local applicable regulations and standards for the concentration limit is required NOTE 1 If there are 2 or more refrigerating systems in a single refrigerating device the amounts of refrigerant should be as charged in each independent device For the amount of charge in this exampl...

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