Professional Documents
Culture Documents
HFC R407C
Contents
Introduction Precautions .......................................................................................................................................... 4 Components ......................................................................................................................................... 6 Outline of control system ...................................................................................................................... 9 Parts specification Outdoor unit - general ......................................................................................................................... Outdoor unit - refrigeration parts ......................................................................................................... Outdoor unit - inverter assembly ......................................................................................................... Multi Controller - general ....................................................................................................................
12 13 14 15
Construction views Outdoor unit ........................................................................................................................................ 16 Multi Controller ................................................................................................................................... 17 Wiring diagram Outdoor unit ........................................................................................................................................ 18 Multi Controller ................................................................................................................................... 20 Refrigeration schematic Outdoor unit ........................................................................................................................................ Normal operation - heat mode ............................................................................................................ Normal operation - cool mode ............................................................................................................ Simultaneous operation - mainly heat ................................................................................................. Simultaneous operation - mainly cool .................................................................................................
21 22 23 24 25
Diagnostic procedure Diagnostic - outdoor unit ..................................................................................................................... 26 Diagnostic - Multi Controller unit ......................................................................................................... 32 Fault code display Self-diagnostic function ...................................................................................................................... 34 Troubleshooting Fault code table .................................................................................................................................. 36 Diagnostic procedure for check code ................................................................................................. 37 Control features ..................................................................................................................................... 63 Valve and sensor function and operation Multi Controller valve function and operation ...................................................................................... Outdoor unit valve functions ............................................................................................................... Manual operation of valves ................................................................................................................. Sensor and switch operation .............................................................................................................. Refrigeration pipe installation Leak test ............................................................................................................................................. Vacuuming ......................................................................................................................................... Charging ............................................................................................................................................. Piping ................................................................................................................................................. Additional refrigerant .......................................................................................................................... Service parts list Outdoor unit exploded views .............................................................................................................. Inverter exploded view ........................................................................................................................ Multi Controller exploded view ............................................................................................................ Multi Controller electrical parts ...........................................................................................................
65 66 67 68
69 70 71 72 73
74 77 78 79 3
Introduction Precautions
Please read these instructions carefully before starting the installation. This equipment should only be installed by suitably trained operatives. In all cases ensure safe working practice: Observe precautions for persons in the vicinity of the works. Ensure that all local, national and international regulations are satisfied. Check that the electrical specifications of the unit meet the requirements of the site. Carefully unpack the equipment, check for damage or shortages. Please report any damage immediately. Model MAR-F105HTM8-PE complies with the following EU Directives: 73/23/EEC (Low Voltage Directive), 89/336/EEC (Electromagnetic Compatibility) and 97/23/EC (Pressure Equipment Directive). Accordingly, they are designated for use in commercial and industrial environments. 97/23/EC Pressure Equipment Directive information Conformity assessment procedure: Module D1 Pressure equipment: Compressor, category II, Module A1 Liquid receiver, category II Accumulator, category I High pressure switch, category II, Module A1 Notified body for inspection and quality assurance systems: BSI, Maylands Avenue, Hemel Hempstead, WP2 4SQ, UK. Avoid installation in the following locations: Where there is danger of flammable gas leakages. Where there are high concentrations of oil. Where the atmosphere contains an excess of salt (as in coastal areas). The air conditioner is prone to failure when used under this condition unless special maintenance is provided. Where the airflow from the outdoor unit may cause annoyance. Where the operating noise of the outdoor unit may cause annoyance. Where the foundation is not strong enough to fully withstand the weight of the outdoor unit. Where the water drainage may cause a nuisance or a hazard when frozen. Where strong winds may blow against the air outlet of the outdoor unit. Precautions for R407C outdoor units R407C outdoor units use synthetic oils which are extremely hygroscopic. Therefore ensure that the refrigerant system is NEVER exposed to air or any form of moisture. Mineral oils are unsuitable for use in these units and may lead to premature system failure. Use only equipment which is suitable for use with R407C. Never use equipment which has been used with R22. R407C should only be charged from the service cylinder in the liquid phase. It is advisable to use a gauge manifold set equipped with a liquid sight glass fitted in the centre (entry) port.
Introduction Precautions
Precautions for R-407C outdoor units
Liquid receiver fusible plug
In the event of the system being subjected to abnormal conditions it is protected by a fusible plug, positioned on the liquid receiver, within the outdoor unit. It is rated to fail at 70C.
}
Model batch serial number
Month of manufacture 41 = Jan. 42 = Feb. 43 = Mar. 44 = Apr. 45 = May 46 = Jun. 47 = Jul. 48 = Aug. 49 = Sep. 50 = Oct. 51 = Nov. 52 = Dec.
Introduction Components
Components - 3 pipe system
1. Outdoor unit Inverter unit 10 HP
Combination of Multi Controllers, indoor units and interface kits No. of indoor units 1-8 9 10 11 12 13 14 15 16 No. of 3-way Multi Controllers 1-2 Multi Controllers 3 2 1 0 3 2 1 0 No. of 4-way Multi Controllers 0 1 2 3 1 2 3 4 No. of interface kits 0 1 1 1 1 2 2 2 2
Note 1: Cooling capacity is rated at the following temperature conditions: Indoor air inlet temperature 27C DB, 19C WB. Outdoor air inlet temperature 35C DB. Note 2: Heating capacity is rated at the following temperature conditions: Indoor air inlet temperature 20C DB. Outdoor air inlet temperature 7C DB, 6C WB. Note 3: For details about the outdoor unit, indoor units or remote controller installation refer to the relevant literature, i.e. Installation Instructions supplied with the units. Note 4: Operatives handling refrigerants must be suitably qualified in accordance with local and national codes of practice and statutory requirements. Note 5: Legislation may regulate the removal of waste refrigerant from the systems. We advise awareness of any regulations and duty of care. Waste refrigerant must NEVER be discharged to atmosphere. Note 6: Electrical work should be in accordance with all relevant codes of practice and should be carried out by suitably qualified personnel. Note 7: Metric/Imperial pipe conversion. Diameter (mm) Nominal diameter (inch) 6.4 1/4 9.5 3/8 12.7 1/2 15.9 5/8 19.0 3/4 22.0 7/8 28.6 1-1/8
Note 8: Within this manual: ODU = Outdoor Unit R/C = Remote Controller INV = Inverter ODU DB = Dry Bulb Mg-Sw = Magnetic Contactor OCR = Over Current Relay M/C = Multi Controller
= Indoor Unit = Direct On-Line compressor = Wet Bulb = Inner Overload Relay = Inverter Gate Bi-Polar Transistor = Intelligent Power Drive Unit
T-pieces
Multi Controller
3 pipes
Indoor units
Outdoor unit
Protection unit
Comp. sensor
Temp. sensor
2-way valve
Display LED
2-way valve
Fan
4-way valve
2-A
Multi Controller 2
Communication PCB
2-B
Multi Controller microprocessor
Inverter compressor
2-C
IPDU Inverter
2-D
Protection unit Power supply
Introduction Components
Setting of indoor unit capacity codes
The setting of the indoor unit capacities is important. Set the correct indoor unit code numbers according to the indoor unit capacity. The capacities are set by the rotary switches on the printed circuit board switch A (unit A), switch B (unit B), switch C (unit C) and switch D (unit D). During manufacture, the indoor capacity selection switches are set at 0. Record the indoor capacity codes, indoor unit model names and locations in the installation manual, and on the wiring diagram on the electrical panel cover.
Example: Room A Room B Room C
Capacity 16
Capacity 16
Capacity 26
Indoor unit Capacity No connection Code number 0 (Example: Model RAV-364UH-PE, capacity = 36)
10 2
13 3
16 4
20 5
26 6
36 8
46 10
Multiple indoor units may be connected to each outdoor unit, providing the total indoor code does not exceed the limits shown below.
Example of systems with maximum possible code: Outdoor unit Interface kit Multi Controller [code] (Max. system code)
OD
OD
OD OD
DIF DIF DIF DIF
OD OD
DIF DIF
27
(27)
6 27 (32)
26 27
6 13
6 13 (32)
27 20
8 13
8 13
8 13 (32)
8 13
10
Introduction Components
Indoor units
Type Appearance Model name Capacity code on Multi Controller 4 6 8 10
Cassette (4-way)
Cassette (2-way)
2 3 4
RAV-104SBH-PE
Built-In Horizontal RAV-164BH-PE RAV-264BH-PE RAV-364BH-PE RAV-464BH-PE Ceiling Suspended RAV-134CH/CHR-PE RAV-164CH/CHR-PE RAV-264CH/CHR-PE RAV-364CH/CHR-PE RAV-464CH/CHR-PE RAV-105KH-E RAV-135KH-E RAV-165KH-E RAV-265KH-E 4 6 8 10 3 4 6 8 10 2 3 4 5
High Wall
High Wall
RAV-264KH-PE
Built-In Vertical
2 3 4 6
Floor Mounted
RAV-164SH/SHR-PE RAV-264SH/SHR-PE
4 6
11
Notes: 1. Specifications are subject to change without notice. 2. The specification shown in ( ) denotes operation with an indoor unit load diversity of 135%. 3. Operating conditions: Outdoor temperature C Room temperature C Cooling Heating Cooling Heating 4. Sound level: 1 m horizontal from centre. 1.5 m vertical from base. -5 to 43 -15 to 21 18 to 32 15 to 29
12
0C = 34.6 k 25C = 10 k 50C = 3.4 k EV18RC1, coil DC 12 V EV23RC2, coil DC 12 V NEV202DXF, coil AC 240 V RP100-03, coil AC 240 V
13
MAR-F105HTM8-PE 380-415 V, 3 phase, 50 Hz PCB (IPDU) PCB (noise filter) PCB (interface) PCB (communication) MCC-1342 MCC-1366 MCC-1223 MCC-1387 8 F/450 V AC 2200 F/400 V L1, L2, L3 Interface Inverter side Fixed side CH - 25 - 2FK 6A 20 A 3.15 A 6.3 A 20 A 10 A 500 V AC 600 V AC 250 V AC 250 V AC 250 V AC 250 V AC 15 A, 240 V AC 600 V AC, 60 A, 3 pole TT01 FMCa - 1S FC - 3
14
RBM-Y1034F-PE
RBM-Y1044F-PE
EV23RC7, coil DC 12 V At 0C = 32.8 k, 25C = 10 k, 50C = 3.6 k FS-085-0031 PCB MCC-1222 Model name Specification FT69 Primary side: AC 240 V, secondary side: AC 12 V G2R-117P, coil DC 12 V 10.4 W/m 65 W Cut out at 119C T1A RP100-03, coil AC 240 V REV-1506DXFQ6, coil AC 240 V NEV202DXF-AC 240 V NEV603DXF-AC 240 V
15
80
700 990
750
110 90
1700 1582
700 601
88 568 4-60 x 150 slot (for transport) 500 Slot pitch Details of piping connections Refrigerant pipe connecting port (Gas suction side) braze connection ( 28.6) Knock outs on both sides of unit 3- 20 cable gland knock outs 32 cable gland knock outs 25 cable gland knock outs
Refrigerant pipe connecting port (Liquid side) flare connection ( 15.9) 315 275 Refrigerant pipe connecting port (gas discharge side) flare connection ( 19.0) 68 60 114
All dimensions in mm
16
Model A B RBM-Y1034F-PE 460 300 RBM-Y1044F-PE 530 370 All dimensions are in mm
C 90
D 90 90
E 90
F 90 90
300
300
Wiring knockouts 6 x 20
110
Refrigerant pipe connection (brazing) Gas side 19 Refrigerant pipe connection (brazing) Suction gas side 28.6
17
18
19
Indoor unit A
Indoor unit B
Indoor unit C
Indoor unit D
Outdoor unit
Symbol PMVA, B, C, D Th A, B, C, D, X Tr CS H MS F SVD (A), (B), (C), (D) SVD (A), (B), (C), (D) SVDD SVSS SVH LD 101, 102, 103, 104
Part Name Pulse modulating valve Temperature sensor Power transformer Float switch Heater Reset switch Fuse (T1A) Electrically operated valve for discharge gas side Electrically operated valve for suction gas side Electrically operated valve for increasing pressure Electrically operated valve for decreasing pressure Electrically operated valve for superheat control Fault indicator LED
Parts layout
Trans
The dashed lines indicate wiring on site. and indicate terminal blocks, and numbers within them are terminal numbers. indicates a printed circuit board. The frame indicates the product body. RBM-Y1034F-PE does not have PMVD, SVD(D), SVS(D), ThD or the connection block for indoor unit D. The capacity rank code setting for unit D is to be set to 0.
Terminal plate
20
4321 4321
21
22
Key: High pressure gas Low pressure gas High pressure liquid Low pressure liquid
Key: High pressure gas Low pressure gas High pressure liquid Low pressure liquid
23
24
Key:
Key:
25
Located on the electrical inverter cover is a transparent window, which allows the 7-segment LED to be viewed while the unit is in operation. The transparent window has access holes to allow the adjuster pen, which is attached to the window, access to alter the setting of the display switch SW1 and SW2 while the unit is running. A slit is positioned at one end of the pen to locate onto the rotary switch. The adjuster pen can also be used to push switches SW3 and SW4 during the diagnostic procedure check. A crimp connector is located on the other end of the adjuster pen. This connector can be used to short TP1 or TP2 connectors when performing manual operation of the outdoor valves. No other component other than that supplied must be used to adjust the rotary switches. Failure to do so may result in damage to the unit, malfunction or risk of electric shock.
26
position position
Heating [H], Simultaneous cooling/heating [HC], Cooling [C], Stop [ ] Heating frequency [00-1F] (Refer to conversion table 2) Heating [H], Cooling [0C], Simultaneous heating [Hc] Defrost [J0], Simultaneous cooling [hC]
----------
----------
Heating [H], Simultaneous cooling/heating [HC], Cooling [C], Stop [-] Heating frequency [00-1F] (Refer to conversion table 2) Normal [C] Abnormal [E] Operating frequency [0-F], (Refer to table 3) Operating frequency [0-F], Abnormal [E] (Refer to table 3) [0]
----------
----------
10
Normal [C]
----------
----------
-------------------
-------------------
11
50 Hz [5] 60 Hz [6]
27
Display code Frequency conversion value (Hz) Display code Frequency conversion value (Hz) 3.
10.0 13.0 16.2 19.3 22.4 25.5 28.6 31.7 34.8 37.9 41.0
10
11
12
13
14
15
16
17
18
19
1A
1B
1C
1D
1E
1F
44.1 47.2 50.3 53.4 56.5 59.6 62.7 65.8 68.9 72.0 75.1 78.2 81.3 84.4 87.5 90.0
30.5 38.3 41.9 45.5 53.3 61.0 68.8 76.0 83.8 91.6 102.9 110.7 121.5
PMV opening information is displayed Display switch SW2 position 2 Indication 7-segment LED display LD 71 LD 72
LD 73
LD 74
PMV1 opening
[P]
[1]
3 5.
PMV2 opening
[P]
[2]
Displays the degree of PMV opening (0 - 240) as a hexadecimal code: [00] : Closed, [F0] : Fully open
Malfunction information is displayed, refer to fault code section for details Display switch SW2 position 0 Indication 7-segment LED display LD 71 LD 72
LD 73
LD 74
Check code [E] display for the outdoor unit, M/C (1), M/C (2)
Outdoor unit: [r] Refer to fault code section for M/C (1): [1] details (page 36) M/C (2): [2]
28
LD 73
LD 74
Outdoor unit HP Capacity rank of indoor unit connected to M/C (1) Capacity rank of indoor unit connected to M/C (2)
8 HP [8], 10 HP [A] [H] Displays the code number of the indoor unit registered to each M/C. Refer to the table below (7) for indoor unit model capacity rank.
[P]
7.
Code No. 0 2 3 4 5 6 8 10 Capacity rank No correction 10 13 16 20 26 36 46 (Indoor unit model example: Model RAV-364UH-PE, capacity rank = 36) 8. Sensor temperature display Display switch SW2 position 0 1 2 3 4 5 Indication 7-segment LED display LD 71 LD 72 LD 73
LD 74
Pressure sensor data ThD1 sensor data ThD2 sensor data ThS sensor data TE sensor data TO sensor data
Refer to table 9 conversion chart Refer to table 10 conversion chart Refer to table 11 conversion chart
29
These are sample displays. intermediate displays to those above are possible. 10. Outdoor unit - ThD1 and ThD2 sensor data Display 05 07 09 0C 0F 12 17 1C 22 Temp. C -5.0 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 Display 28 30 38 41 4A 54 5E 68 72 Temp. C 40.0 45.0 50.0 55.0 60.0 65.0 70.0 75.0 80.0 Display 7C 87 90 9A A2 AB B2 B9 C0 Temp. C 85.0 90.0 95.0 100.0 105.0 110.0 115.0 120.0 125.0 Display C6 CB D0 Temp. C 130.0 135.0 140.0
These are sample displays. Intermediate displays to those above are possible. Display [00] signifies sensor open circuit. 11. Outdoor unit - ThS, TE, TO sensor data Display 2A 36 42 51 60 63 66 69 6C 6F 73 76 79 Temp. C -20.0 -15.0 -10.0 -5.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Display 7C 7F 82 85 88 8B 8E 91 94 97 9A 9C 9F Temp. C 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 Display A2 A5 A7 AA AC AF B1 B3 B6 B8 BA BC BE Temp. C 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 Display C0 C2 C4 C6 C8 C9 D1 D8 DE E3 E7 EA Temp. C 35.0 36.0 37.0 38.0 39.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0
These are sample displays. Intermediate displays to those above are possible. Display [00] signifies sensor open circuit.
30
31
7 segment LED display Switch Indication position LD 101LD 102 LD 103 LD 104
Serial signal
Sending to unit A
Sending to unit C
1 2
Fault codes
[E]
Fault code display (normal [00]). Refer to fault code section for details.
Frequency Instructed demand frequency of cooling or heating [00 - 1F]. instructions Refer to the Multi Controller display conversion table (1) for display switch position 2 to the outdoor unit Oil retrieval, superheat control Defrost Operation mode Oil retrieval unit B Superheat control unit B Superheat Oil control retrieval unit A unit A Oil retrieval unit D Superheat control unit D Superheat Oil control retrieval unit C unit C -
Displays [dF] during defrost operation M/C operating Outdoor unit operating mode: Heating [H-], Cooling [-C], Simultaneous Heating [Hc], mode: Simultaneous Cooling [hC], Stop [--], Defrost [J-] Heating [H-], Cooling [C-]* [k] [A] [b] [c] [d] [A] [b] [c] [d] [H] Displays sensor temperature Refer to the Multi Controller sensor temperature conversion table (1). Displays unit being tested [A b C d] Displays the degree of PMV opening (0-240) as a hexadecimal code: [00]: Closed, [FO]: Fully open Normal display [0], Restart timer counting [1] Indicates faulty unit connection [A b C d]
5 6 7 8 9 10 11 12 13 14 15
Restart timer PMV A PMV B PMV C PMV D ThA ThB ThC ThD ThX
Circuit test [c] [P] [P] [P] [P] [h] [h] [h] [h] [h]
32
Indoor unit
A few seconds
1 minute
1 minute
1 minute
Remote controller fault code display time lapse for system malfunctions
Between the I/F and the INV Between the M/C and the I/F Between the indoor unit and the M/C Between the remote controller and indoor unit
More than 3 minutes More than 2 minutes More than 1 minute A few seconds More than 3 minutes More than 2 minutes More than 1 minute
33
Initially malfunctions can be identified from the remote controller check display. Details of the Multi Controller and outdoor unit malfunctions can be determined from their control boards. (Multi Controller malfunctions are also displayed on the outdoor unit interface control board).
STANDBY displayed The total capacity rank settings of indoor units connected exceeds the allowable level, or an indoor capacity rank is set at 0 (Multi Controller).
NETWORK
MODE FAN ONLY COOL FAN AUTO HIGH MED HEAT AUTO TEMP UNIT CHECK LOW CENTRAL OPERATION ST ANDBY PREHEAT DEFROST FILTER LOUVER MANUAL MODE
REMOTE CONTROLLER
TIMER CONT .
88 C 88: 88
OFF ON H M
TIMER ADJUS T
ON/OFF
Reset button Pressing the reset button with a pin will clear the memory. Check button Pressing for 1 second will display fault codes. Pressing for 5 seconds will reset the indoor unit microprocessor. Pressing for 10 seconds will clear only the fault codes.
34
TEMP
LOUVER MANUAL
CHECK
UNIT
c
TIMER CONT. OFF ON Indoor unit number ADDRESS
35
NOTE: To retrieve fault codes from the outdoor unit ensure rotary switch SW1 is set to position 2 and SW2 is set to position 0. To retrieve fault codes from the Multi Controller ensure the display switch is set to position 1.
36
Is there continuity of the communication cable between the indoor unit and Multi Controller? Yes
No
Is there continuity of the communication cable between the Multi Controller the outdoor unit Yes
No
Is there continuity of the communication cable between the outdoor interface PC board and outdoor IPDU PC board? Yes
No
Is there voltage present between pins 4 and 5 of CN1 on communication PC board? (DC 0 to 5 V, pin 5-GND) Yes
No
Is there voltage present between pins 3 and 5 of CN1 on interface PC board? (DC 0 to 5 V, pin 5-GND) Yes
No
No
Are the high level alarm and the shutdown LEDs on the RBC-RD2-PE (RED) on? Yes
No
37
Is 4-way valve cool normal? Yes Are connectors of TS, TE, Pd sensors connected? Yes Are resistance value characteristics of TS and TE sensors normal? Yes
No
No
No
Sensor error
No Sensor error
Is there a problem on wiring of fixed-speed compressor? No Reset power supply and perform trial heating operation.
No
No
Yes
Yes
Mg-SW error
38
No
No
No
Are the gas suction, gas discharge and liquid packed valves fully open? Yes
No
No
Replace TC sensor
No
39
Check connection of connector CN10 (Drain pump: Indoor main, PC board (MCC-1292), CN10) (Drain pump: Multi Controller, PC board (MCC-1210) PJ10)
No
No
(*1) For confirmation, check voltage under condition that connector is connected to CN10, pins 5 and 7, PJ10, pins 1 and 2 Does drainage water collect? Yes No
No
No
Check and modify wiring circuit. (*2) Check whether voltage of CN10/PJ10, pins 1 and 2/1 to 3 of the indoor main PC board, is 230V or not (MCC-1292), (MCC-1210).
Check code [0C] Indoor sensor (TA) short or open circuit alarm
TA sensor open/short has been detected. Check disconnection of connector connection (TA sensor: CN04) circuit and resistance value characteristics of sensor. When the sensors are normal, replace indoor PC board (MCC-1292). Check code [0D] Indoor sensor (TC) short or open circuit alarm Status of air conditioner Indoor unit fan stops. Preheat defrost is displayed on R/C. Operation cause TC sensor open/short
TC sensor open/short has been detected. Check disconnection of connection (TC sensor: CN05) circuit and resistance value characteristics of sensor. When the sensors are normal, replace indoor PC board (MCC-1292).
40
Does indoor fan operate for a short period after resetting and resuming? Yes
No
Yes
Yes
No
No
Replace capacitor.
Yes
Is revolution pulse input from hole IC to CN18 connector 2-3 pins during fan operation? (Measurement by tester: Approx. DC2 to 2.5V) Yes
No
Operation cause 1. Irregularity of power source. 2. Noise of peripheral equipment. 3. Defective indoor PC board.
Yes Check power source voltage, modify lines, remove noise, etc.
41
Is the connection of the wiring connector on the IPDU PC board normal? Yes
No
No
No
42
No
No
Compressor error
Check code [1C] Extension IC, EEPROM short circuit alarm (Outdoor unit error)
Is there an irregularity of outdoor unit power source? No Yes
Operation cause 1. Outdoor unit power source error. 2. Interface PC board error.
Check power source voltage. Modify power source line. Check noise interference from outside, etc.
43
Does voltage reduction occur when the fixed-speed compressor has been activated? No
Yes
Yes
No
Compressor error
Yes
Yes
Modify refrigerant stagnation in the compressor case, and start the operation.
44
No
Does the voltage reduction occur when the fixed-speed compressor has been activated? No
Yes
No
Yes
45
No
No
No
No
No
No
Is there a problem with the outdoor unit heat exchanger? (1) Blockage of heat exchanger (2) Short circuit No
Yes
No
Remove cause.
Il circuito di bypass della SV2 normale?
No Check outdoor IPDU PC board. If defective, replace board. (Coil error, disconnection of wiring, etc.)
46
No
No
No
No
Is there any element to block heat exchange in the room? (1) Filter blockage (2) Heat exchanger blockage (3) Short circuit No
Yes
Check Multi Controller PC board. If defective, replace Is communication line between indoor and outdoor units correct? Yes Check and modify wiring No
Yes
No
Replace TC sensor
47
No
Are gas pipe, liquid pipe and service valve of the outdoor unit fully open? Yes
No
Is outdoor PMV 1 normal? 1. Connector connection 2. Wiring 3. Coil 4. Valve unit 5. Outdoor PC board Yes
No
No
48
Open/short of Tha sensor was detected. Check connector (Tha sensor: PJ1) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the Multi Controller.
Open/short of Thb sensor was detected. Check connector (Thb sensor: PJ2) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the Multi Controller.
Open/short of Thc sensor was detected. Check connector (Thc sensor: PJ3) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the Multi Controller.
Open/short of Thd sensor was detected. Check connector (Thd sensor: PJ4) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the Multi Controller.
Open/short of Thx sensor was detected. Check connector (Thx sensor: PJ5) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the Multi Controller.
49
Check lead connection between indoor unit and Multi Controller. If no error is detected, replace Multi Controller board (MCC-1210) or outdoor PC board (MCC-1223).
Operation cause 1. No. of connected indoor units/connected over capacity. 2. Incorrect set-up of indoor unit horse power or set to 0.
No Indoor units from another system have been incorrectly connected. Modify miswiring/installation.
No
Is total capacity of connected indoor units within indoor unit diversity? 1. M/C = 135% 2. 4 M/C = 160% Yes
No
Maximum No. of Indoor unit diversity Maximum system code indoor units 4 135% 27 8 160% 32 12 16
10 2
13 3
16 4
20 5
26 6
36 8
46 10
50
Check lead connection between indoor unit and Multi Controller and outdoor unit. If no error is detected, replace Multi Controller board (MCC-1210).
Operation cause 1. Connection error of (XY) for outdoor units. 2. Power source system error of the central controller and indoor unit. 3. Noise of peripheral devices. 4. Power failure. 5. Indoor PC board error, central controller error.
Check communication cable.
No
Yes
Is the power source of either central controller or indoor/ outdoor turned on? Yes
No
Clear the alarm after turning on the power source, and start the operation.
Yes
No
Is the operation status of the indoor unit reflected on the central controller? Yes
No Indoor PC board error No Is there noise interference, etc.? Yes Yes Eliminate noise interference.
Is the network address different from main or sub remote controller? Yes Clear the alarm after turning on the power source, and start the operation.
No
51
No
No
Yes
Yes
52
No
No Set SW01 to 1.
No
No
Yes
Yes
53
Open/short of TD1 sensor was detected. Check connector (TD1 sensor: PJ1) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the outdoor unit.
Open/short of TD2 sensor was detected. Check connector (TD2 sensor: PJ2) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the outdoor unit.
Open/short of TS1 sensor was detected. Check connector (TS1 sensor: PJ3) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the outdoor unit.
Open/short of Tho sensor was detected. Check connector (Tho sensor: PJ5) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the outdoor unit.
Check code Operation cause [A5] Outdoor heat exchange sensor (TE) short circuit TE sensor open/short
Open/short of TE sensor was detected. Check connector (TE sensor: PJ4) and characteristics of sensor resistance value. When sensor is normal, replace interface PC board of the outdoor unit.
54
Are the gas pipe and liquid pipe service valves of the outdoor unit fully open ? Yes
No
No
No
No
Replace TD sensor.
No
Correct wiring. (Check miswiring of the outdoor unit according to miswiring check function.)
55
Are the gas pipe and liquid pipe service valves of the outdoor unit fully open ? Yes
No
Yes
No
If there is an abnormal output voltage of Pd sensor: Check connector circuit (Pd sensor: PJ7) and output voltage of the sensor. If the sensor is normal, replace the outdoor interface PC board. Sensor characteristics: Input 12 V DC ( 10%) across red and black leads of the pressure sensor. Output 0.5 to 4.5 V at 0 to 2.45 MPa across white and black leads of the pressure sensor.
56
No
No
No
No
No
No
Is there a problem with the outdoor unit heat exchanger? (1) Blockage of heat exchanger (2) Short circuit (air flow) (3) Blockage of air flow No
Yes
Remove cause.
57
No
No
No
No
Is there any element to block heat exchange in the room? (1) Filter blockage (2) Heat exchanger blockage (3) Short circuit (air flow) No
Yes
Check Multi Controller PC board. If defective, replace Is communication line between indoor and Multi Controller units correct? Yes Check and modify wiring. No
Yes
No
Replace TC sensor.
58
Does OCR operate ? Check the OCR reset button. (Manual reset) No
Yes
Are the following items related to power supply normal? 1. Power supply voltage is 400 V 10% 2. Phase missing, shortcircuit of fixed-speed compressor power supply circuit system Yes Is Mg-SW defective? No
No
No
Repair OCR circuit. Is constant speed compressor normal ? 1. Is compressor winding normal ? 2. Is compressor locked?
Replace Mg-SW.
Are gas pipe, liquid pipe, and service valve of the outdoor unit fully open ? Yes
No
No
Yes Open service valves fully. Replace fixed-speed compressor. Overload operation, liquid compression No
Is outdoor PMV 1 normal? 1. Connector connection 2. Wiring 3. Coil 4. Valve unit 5. Outdoor PC board Yes
No
No
59
No
No
No
No
Check compressor. Confirm refrigeration charge correct. (No leaks from system.)
Check code [AF] Outdoor unit power source phase order miswiring
Operation cause Abnormal power phase order or missing phase of power supply to the outdoor unit.
There is an abnormal power phase order or missing phase of power supply to the outdoor unit. Check power supply wiring.
60
No
No
Operation cause Error of temp. sensor incorporated in IGBT (Inverter Gate Bi-Polar Transistor)
There is an error with the temp. sensor incorporated in IGBT. Check connectors CN07 on IPDU PC board and CN600 on interface PC board. If there is no problem, replace IPDU PC board.
61
No
No
Check the circuit wiring, for example wiring to the inverter compressor or connector connection.
No
Is there a screw loose on the IGBT module or heat sink on inverter PC board ? No
Yes
Remove blockage.
62
Compr. off
Timer reset
63
64
SVDD
SVH
65
SV1 SV2
Solenoid valve for D.O.L. compressor start-up Gas balance Cooling solenoid valve Solenoid valve for expansion valve. Sub heat exchanger solenoid valve Solenoid valve for capillary
SV16 opens for low load conditions during heatingdominant operation. Solenoid valve for compressor Open when compressor ON. Closed when compressor OFF. Cooling bypass flow Opens when ThD1 or ThD2 > 110C. control valve Opens when ThS > 20C. Outdoor flow control valve Opens during cooling-dominant operation. Degree of opening depending on cooling/heating demands.
66
a.
Multi Controller Valve PMV A PMV B PMV C PMV D Short point TP 1 Selected valve is fully opened for 2 minutes. TP 2 Selected valve is fully closed for 2 minutes
Operation Valves will automatically assume their required position after 2 minutes. Push SW04 Press SW03
Function PMV 1 fully open for 2 minutes. PMV 2 fully open for 2 minutes. PMV 1 fully closed for 2 minutes. PMV 2 fully closed for 2 minutes. Solenoid valves manually energised in sequence when pressed. Solenoid valves automatically energised in sequence (1 second intervals)
Note: During Manual/Automatic operation of outdoor valves, SV17 will not be energised. To confirm operation of SV17 operation is as follows: Energised valve when compressor ON.
67
Valve and sensor function and operation Sensor and switch operation
Multi Controller sensor operation
Temperature sensor According to a difference between the evaporator outlet temperature and (ThA, B, C, D) saturation temperature (ThX): a. Performs superheat control. (cooling operation) b. Determines the degree of opening of PMV 2. (cooling-dominant operation)
68
Gauge manifold
Service port at liquid side Packed valve fully closed (gas discharge side)
To detect a large leakage Step 1: 0.3 MPa (3 kg/cm2 G) Apply pressure for 3 minutes or more Step 2: 1.5 MPa (15 kg/cm2 G) Apply pressure for 3 minutes or more To detect a fine leakage Step 3: 3.0 MPa (30 kg/cm2 G) Apply pressure for 24 hours Check for a reduction in pressure. If there is no reduction in pressure this is acceptable. If there is a reduction in pressure check for a leakage. (Note: If there is a difference of ambient temp. between when the pressure was applied and 24 hours later, then pressure could change by approx. 0.01 MPa (0.1 kg/cm2 G) - so correct the pressure change.
69
Air purge
The air purge must be completed before supplying power to ensure the Multi Controllers PMVs are open. Using a vacuum pump, complete an air purge. Never use refrigerant gas. After the airtight test, discharge the nitrogen gas. Connect a gauge manifold to the service port at discharge gas, liquid and suction gas sides, and connect a vacuum pump as shown. Be sure to vacuum at discharge gas, liquid and suction gas sides.
Detailed drawing of packed valve Packed valve fully closed (gas suction side) Inverter outdoor unit Low High pressure pressure gauge gauge
Gauge manifold
Brazed
Service port Service port at gas suction side Flare connection Packed valve fully closed (liquid side) Vacuum pump
Use a vacuum pump with high vacuum carry-over degree (-0.013 x 105 Pa; 0.750 mm Hg or less) and large displacement (40 l/min. or more). Ensure to create a vacuum at -0.013 x 105 Pa (0.75 mm Hg) at the discharge gas, liquid and suction gas. After the procedure has been completed, replace the vacuum pump with a refrigerant bottle and add the refrigerant if required.
70
The amount of additional refrigerant is calculated from the actual length of the liquid pipe. To calculate the additional refrigerant volume, refer to the diagram and follow the steps below: (i) The main pipe length is taken as the addition of pipes X, Y and Z.
(ii) The sub pipe length is taken as the addition of the two longest of the four (if 4 Multi Controllers). (iii) The branch pipe lengths must be individually calculated using the 8 longest pipes. (iv) Do not attempt to add gas above the maximum shown in the table above. (v) For systems with one Multi Controller ignore the sub-pipe section within the additional gas charge calculation. (vi) When using three Multi Controllers, it is important that a reducer is used on the pipework for the third Multi Controller. Pipework before the reducer is classed as main piping and after as sub piping.
71
L1
L3
L1
L2
L3
Table 1 - Branch pipes RAV-10* : 0.030 kg/m RAV-13* : 0.030 kg/m RAV-16* : 0.030 kg/m RAV-26* : 0.045 kg/m RAV-36* : 0.045 kg/m RAV-46* : 0.045 kg/m Example: RAV-464CH-PE
Indoor
L2
L3
RAV-46*
L2
L3
Pipe MAR-F105 - main pipe L1 (X+Y+Z) (minus 2 m) x 1st longest sub pipe L2 (minus 1 m) 2nd longest sub pipe L2 (minus 1 m) 1st longest branch pipe L3 (minus 2 m) 2nd longest branch pipe L3 (minus 2 m) 3rd longest branch pipe L3 (minus 2 m) 4th longest branch pipe L3 (minus 2 m) 5th longest branch pipe L3 (minus 2 m) 6th longest branch pipe L3 (minus 2 m) 7th longest branch pipe L3 (minus 2 m) 8th longest branch pipe L3 (minus 2 m) x x x x x x x x x x
Additional gas/metre 0.19 kg/m 0.125 kg/m 0.125 kg/m Refer to Table 1 Refer to Table 1 Refer to Table 1 Refer to Table 1 Refer to Table 1 Refer to Table 1 Refer to Table 1 Refer to Table 1 = = = = = = = = = = = =
Additional gas
kg
72
VH
73
74
14
75
76
Ref. Service part No. 101 43A52005 102 43A58009 103 43A55004 104 43A55005 105 106 107 108 109 110 111 112 113 144 115 116 117 43A50030 43A50031 43A50032 43A50015 43A50016 43A50033 43A69016 43A69035 43A69018 43A69036 43A69037 43A60034 43A60035
Description Magnetic contactor - FC - 3 Transformer - TT01 MF - capacitor - 8F/450 V AC Capacitor - electrolytic 2200F/400 V Temperature sensor TS - blue Temperature sensor THO - green Temperature sensor TE - black Temperature sensor TD1 - white Temperature sensor TD2 - red Thermistor (PTC) Heatsink PC board (IPDU) MCC-1342 PC board (noise filter) MCC-1366 PC board (interface) MCC-1223 PC board (communication) MCC-1387 Terminal-6P Terminal-9P
Ref. Service part No. 118 43A34001 119 43A60016 120 43A55006 121 43A60020 122 43A60021 123 43A52006 124 125 126 127 128 129 130 131 132 133 134 43A60022 43A60023 43A60024 43A63002 43A63003 43A63004 43A63005 43A63006 43A60036 43A60037 43A60038
Description Relay Terminal block - 3P/60 A Reactor - CH - 25 - 2FK Fuse - 6 A Fuse - 20 A Magnetic contactor - FMCa 1S - 02 Fuse holder - 30 A Fuse - 3.15 A Fuse - 6.3 A Bushing Collar Supporter (PCB) Supporter assembly Supporter assembly Fuse - 20 A Fuse - 10 A Fuse-block
Ref. Service part No. 1 43107215 2 43146443 3 43046151 4 43046156 5 43046269 6 43046270 7 43847010 8 43146283 9 43146398 10 43146506 11 43A46011 12 43146505 13 43151231 14 43157252 78
Description Holder, sensor Solenoid coil 2-way valve Check valve Pulse modulating valve 2-way valve Capillary tube 2.0 diameter Check valve Valve body Solenoid coil Expansion valve 2-way valve Float switch Panel heater (RBM-Y1044F-PE)
Ref. Service part No. 15 43157253 16 43189026 17 43189027 18 43189028 19 20 21 22 23 43189029 43189031 43189032 43A47011 43A47012
Description Panel heater (RBM-Y1034F-PE) Insulator, liquid A Insulator, liquid B Insulator, header A (RBM-Y1044F-PE) Insulator, header A (RBM-Y1034F-PE) Insulator, header B (RBM-Y1044F-PE) Insulator, header B (RBM-Y1034F-PE) Capillary tube 0.8 diameter Capillary tube 1.0 diameter
Outdoor unit
109
PJ12
PJ13
102 109
LD4
PJ14
LD3
107 106
7-segment LED
Indoor units
LD2
LD1
109
PJ6
109
110
111
112
Ref. Service part No. 101 43158139 102 43169627 103 43150162 104 43150163 105 43150164 106 43150165
Description Transformer (FT69) PC board assembly (MCC-1222) Sensor (ThA) Sensor (ThB) Sensor (ThC) Sensor (ThD) (RBM-Y1044F-PE)
Ref. Service part No. 107 43150166 108 43151242 109 43A60001 110 43060776 111 43A60008 112 43A60007
Description Sensor (ThX) Micro-switch Terminal block 4P Terminal block 2P Fuse T1A Fuse holder 79
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MADE IN UK A90-0233
Revised October 2002