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Toshiba MMY-MAP0724HT6UL Service Manual
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Toshiba MMY-MAP0724HT6UL Service Manual

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AIR CONDITIONER (MULTI TYPE)

SERVICE MANUAL

Outdoor Unit
<SUPER MODULAR MULTI SYSTEM-i>
Model name:
<Heat Pump Model>
MMY-MAP0724HT6UL
MMY-MAP0964HT6UL
MMY-MAP1144HT6UL
FILE No. A11-019
PRINTED IN JAPAN, Feb, 2012, TDOC

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Summary of Contents for Toshiba MMY-MAP0724HT6UL

  • Page 1: Service Manual

    FILE No. A11-019 AIR CONDITIONER (MULTI TYPE) SERVICE MANUAL 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: Table Of Contents

    Contents Generic Denomination: Air Conditioner ........4 New Refrigerant (R410A).
  • Page 3 7-2-7. Error/operation output ..........56 7-2-8.
  • Page 4 9-5. Diagnosis procedure for each check code ........132 9-6.

  • Page 5: Generic Denomination: Air Conditioner

    Generic Denomination: Air Conditioner Definition of Qualified Installer or Qualified Service Person The air conditioner must be installed, maintained, repaired and removed by a qualified installer or qualified service person. When any of these jobs is to be done, ask a qualified installer or qualified service person to do them for you. Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and ‘safety’...

  • Page 6: Warning Indications On The Air Conditioner Unit

    Warning Indications on the Air Conditioner Unit [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positions If removing the label during parts replace, stick it as the original. Warning indication Description WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing.

  • Page 7: Precautions For Safety

    Precautions for Safety The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker for both the indoor and outdoor units to the OFF position.
  • Page 8 WARNING Before starting to repair the air conditioner, read carefully through the Service Manual, and repair the air conditioner by following its instructions. Only qualified service person (*1) is allowed to repair the air conditioner. Repair of the air conditioner by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.
  • Page 9 If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical control box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, put a sign in place so that no-one will approach the Do not bring a work location before proceeding with the work.
  • Page 10 When the refrigerant gas leaks, find up the leaked position and repair it surely. If the leaked position cannot be found up and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. The poisonous gas generates when gas touches to fire such as fan heater, stove or cocking stove though the refrigerant gas itself is innocuous.
  • Page 11 Only a qualified installer (*1) or qualified service person (*1) is allowed to install the air conditioner. If the air conditioner is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result. Before starting to install the air conditioner, read carefully through the Installation Manual, and follow its instructions to install the air conditioner.

  • Page 12: Carrying In The Outdoor Unit

    Carrying in the Outdoor Unit CAUTION Handle the outdoor unit carefully, observing the following items. • To use a forklift or other machinery for loading / unloading in transportation, insert the prongs of the forklift into the rectangular holes for handling as shown below. •...
  • Page 13 Weight centre and weight ◆ Weight centre of an outdoor unit Unit: in (mm) Anchor bolt position Anchor bolt position 36.2” (920) 27.6” (700) Model type Weight (lb (kg)) (in (mm)) (in (mm)) (in (mm)) MAP0724HT6UL 21.3” (540) 15.8” (400) 24.4”...

  • Page 14: Adding Refrigerant

    Adding refrigerant After finishing vacuuming, exchange the vacuum pump with a refrigerant canister and start additional charging of refrigerant. Calculation of additional refrigerant charge amount Additional refrigerant charge Adjustment amount of Additional refrigerant charge Actual length of liquid × (lb) amount per liquid pipe 1ft refrigerant amount...

  • Page 15: New Refrigerant (R410A)

    New Refrigerant (R410A) This air conditioner adopts a new HFC type refrigerant (R410A) which does not deplete the ozone layer. 1. Safety Caution Concerned to New Refrigerant The pressure of R410A is high 1.6 times of that of the former refrigerant (R22). Accompanied with change of refrigerant, the refrigerating oil has been also changed.
  • Page 16 4. Tools (1) Required Tools for R410A Mixing of different types of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types. 1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) 2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22) 3) Tools commonly used for R410A and for conventional refrigerant (R22) The table below shows the tools exclusive for R410A and their interchangeability.

  • Page 17: Specifications

    Specifications (System with Non ducted indoor units) 460 V / 3 Ph / 60 Hz (Heat pump model) TOSHIBA Carrier VRF Air conditioner Outdoor unit model name MMY- MAP0724HT6UL MAP0964HT6UL MAP1144HT6UL Cooling Capacity (*1) kBtu/h Heating Capacity (*1) kBtu/h Power supply...
  • Page 18 460 V / 3 Ph / 60 Hz (Heat pump model) TOSHIBA Carrier VRF Air conditioner Outdoor unit set model name MMY- AP1444HT6UL AP1684HT6UL AP1924HT6UL AP2284HT6UL Outdoor unit model name MMY-MAP 0724HT6UL 0724HT6UL 0964HT6UL 0724HT6UL 0964HT6UL 0964HT6UL 1144HT6UL 1144HT6UL Cooling Capacity...

  • Page 19: Wiring Diagrams

    Wiring Diagrams 2-1. Outdoor unit Models: MMY-MAP0724HT6UL...
  • Page 20 Models: MMY-MAP0964HT6UL and MAP1144HT6UL...

  • Page 21: Parts Rating

    Parts Rating 3-1. Outdoor unit Name Model Specification 1 Compressor DA421A3FB-29M1 Output: 2.3 kW×2 1 Compressor DA421A3FB-29M1 Output: 2.1 kW×3 1 Compressor DA421A3FB-29M1 Output: 2.1 kW×3 2 4-way valve coil AC208-230 V 60 Hz 3 Pulse motor valve coil HAM-BD28TF-2 DC12 V 2-way valve coil AC208-230 V 60 Hz...

  • Page 22: Outdoor Inverter

    3-2. Outdoor inverter Name Model Specification 1 Power supply terminal block HP-T3015-31-3P-L3S AC600 V / 100 A, 3 P 4 Relay terminal block for reactor JXO-6B AC300 V / 20 A, 6 P 5 Communication terminal block JXO-B2H AC30 V (or no more than DC42 V) / 1 A, 6 P 6 Reactor (For comp.) CH-79 5.8 mH / 16 A...

  • Page 23: Parts Layout In Outdoor Unit

    3-3. Parts layout in outdoor unit Model: MMY-MAP0724HT6UL...
  • Page 24 Model: MMY-MAP0964HT6UL, MAP1144HT6UL...

  • Page 25: Parts Layout In Inverter Assembly

    3-4. Parts layout in inverter assembly Outdoor Unit (6ton) Model: MMY-MAP0724HT6UL Inverter P.C. board for fan Interface P.C. board [FAN IPDU] [Outdoor control P.C. board] (MCC-1610) (MCC-1606) Noise Filter P.C. board (MCC-1625) Power supply terminal block Relay connector for central control...
  • Page 26 Outdoor Unit (8, 10ton) Model: MMY-MAP0964HT6UL, MAP1144HT6UL Inverter P.C. board for fan Interface P.C. board [FAN IPDU] [Outdoor control P.C. board] (MCC-1610) (MCC-1606) Noise Filter P.C. board (MCC-1625) Power supply terminal block Relay connector for central control Communication terminal block Thermistor Magnet Contactor Inverter P.C.

  • Page 27: Outdoor (Inverter) Print Circuit Board

    3-5. Outdoor (inverter) print circuit board 3-5-1. Interface P.C. board (MCC-1606) Sensor input PMV2 PMV1 output PMV4 output output Option input/output High pressure SW UART communication 7-segment LED PD sensor Jumper select PS sensor For inter-unit cable between indoor and outdoor units For inter-unit cable between outdoor...

  • Page 28: Inverter P.c. Board For Compressor (Mcc-1595) A3-Ipdu

    3-5-2. Inverter P.C. board for compressor (MCC-1595) A3-IPDU Power supply Power supply input L3 input L2 CN03 CN02 Power supply input L1 CN01 Reactor connecting terminal CN09 Reactor connecting terminal CN10 Compressor output U-phase CN201 Compressor output V-phase CN202 Compressor output W-phase CN203 SW800 For inverter address setting...

  • Page 29: Inverter P.c. Board For Fan (Mcc-1610)

    3-5-3. Inverter P.C. board for fan (MCC-1610) UART communication between interface UART communication between A3-IPDU Fan motor output U-phase Fan motor output V-phase Fan motor output W-phase Reactor connecting terminal Power supply input Reactor connecting terminal...
  • Page 30 3-5-4. Noise Filter PC board (MCC-1625 -A, -B, -C) Power supply Power supply Power supply Power supply Power supply Power supply input L1 input L2 input L3 output to FAN output to I/F output to FAN CN31 CN32 CN33 CN23 CN22 CN24 MCC-1625-A...

  • Page 31: Refrigerant Piping Systematic Drawing

    Refrigerant Piping Systematic Drawing Model: MMY-MAP0724HT6UL Fan motor Right side Heat exchanger Left side Heat exchanger Reducer 4-way valve Check valve High-pressure sensor Low-pressure sensor Fusible plug Oil separator Fusible plug Check Check valve valve High-pressure High-pressure switch switch Liquid tank...
  • Page 32 Model: MMY-MAP0964HT6UL, MMY-MAP1144HT6UL Fan motor Right side Main heat exchanger Sub heat exchanger at right side Left side Main heat exchanger Check valve Sub heat exchanger at left side Check valve 4-way valve High-pressure sensor Low-pressure sensor Fusible plug Oil separator Fusible plug Accumulator...
  • Page 33 Explanation of Functional Parts Functional part name Functional outline (Connector CN321: White) SV3A 1) Supplies oil reserved in the oil header during ON time. (Connector CN321: White) SV3B 1) Returns oil supplied in the balance pipe to the compressor. (Connector CN321: White) SV3C 1) Pressurizes oil reserved in the oil header during ON time.

  • Page 34: Combined Refrigerant Piping System Schematic Diagrams

    Combined Refrigerant Piping System Schematic Diagrams 5-1. Normal operation (COOL mode / DEFROST mode) - high outside air temperature (roughly 68 °F (20 °C) or above) Follower unit (MMY-MAP0724HT6UL) Header unit (MMY-MAP0964HT6UL) 4-Way valve 4-Way valve Pressure sensor (high pressure)

  • Page 35: Normal Operation (Cool Mode) - Low Outside Air Temperature (Roughly Below 68 °F (20 °C))

    5-2. Normal operation (COOL mode) - low outside air temperature (roughly below 68 °F (20 °C)) Follower unit (MMY-MAP0724HT6UL) Header unit (MMY-MAP0964HT6UL) 4-Way valve 4-Way valve Pressure sensor (high pressure) Pressure sensor Pressure sensor (low pressure) (high pressure) Pressure sensor...

  • Page 36: Normal Operation (Heat Mode)

    5-3. Normal operation (HEAT mode) Follower unit (MMY-MAP0724HT6UL) Header unit (MMY-MAP0964HT6UL) 4-Way valve 4-Way valve Pressure sensor (high pressure) Pressure sensor Pressure sensor (low pressure) (high pressure) Pressure sensor (low pressure) Accumulator Liquid tank Accumulator Liquid tank Balance pipe Liquid pipe...

  • Page 37: Emergency Operation (Cooling Operation Under Header Outdoor Unit Backup Scenario)

    5-4. Emergency operation (cooling operation under header outdoor unit backup scenario) Leakage from PMV: Set Up as Temporary Header Liquid-side service valve Unit during Emergency = Full closure Operation Failure Follower unit (MMY-MAP0964HT6UL) Header unit (MMY-MAP0964HT6UL) 4-Way valve 4-Way valve Pressure sensor Pressure sensor (high pressure)

  • Page 38: Emergency Operation (Heating Operation Under Header Outdoor Unit Backup Scenario)

    5-5. Emergency operation (heating operation under header outdoor unit backup scenario) Leakage from PMV: Set Up as Temporary Liquid-side service valve Header Unit during = Full closure Emergency Operation Failure Follower unit (MMY-MAP0964HT6UL) Header unit (MMY-MAP0964HT6UL) 4-Way valve 4-Way valve Pressure sensor Pressure sensor (high pressure)

  • Page 39: Refrigerant Recovery From Failed Outdoor Unit

    5-6. Refrigerant recovery from failed outdoor unit (pump- down operation under follower outdoor unit backup scenario) Failure Follower unit (MMY-MAP0724HT6UL) Header unit (MMY-MAP0964HT6UL) 4-Way valve 4-Way valve Pressure sensor (high pressure) Liquid line bypass Pressure sensor (low pressure) Pressure sensor...

  • Page 40: Control Outline

    Control Outline Outdoor unit Item Description of operation, numerical data, and other information Remarks 1. Pulse 1. PMV1, 2 control (PMV1 and 2) • During heating, PMV control may be provided with PMV1 motor valve 1) During air conditioner operation, the pulse count of a PMV (pulse motor valve) is alone, operated at 45 pulses (PMV) controlled between 90 and 1000.
  • Page 41 Item Description of operation, numerical data, and other information Remarks 2. Outdoor 1. Cooling fan control fan control 1) Outdoor fan speed (mode) is controlled on the basis of measurements provided by the Pd pressure sensor. 2) For a specified period after the start of cooling operation, the header outdoor unit controls outdoor fan speed (mode) on the basis of measurements provided by the Pd pressure sensor.
  • Page 42 Item Description of operation, numerical data, and other information Remarks 4. Oil level 1) Judgment as to whether an optimum amount of oil is present in the compressor • Oil level detection takes place regardless of the detection cases is made on the basis of the temperature readings of sensors TK1 to TK5. number of compressors, control This control function is performed by the header unit and each follower unit...
  • Page 43 Item Description of operation, numerical data, and other information Remarks 5. Oil This control function is aimed at preventing compressors from running out of oil by equation evening out the oil supply to outdoor units, and is basically performed by opening/ control closing solenoid valves SV3A, SV3B, SV3C, SV3D, and SV3F.
  • Page 44 Item Description of operation, numerical data, and other information Remarks 7. Defrosting 1. Defrosting commencement conditions • Frost formation temperature is 29.3 °F (-1.5 °C). control • During heating operation, the cumulative duration of operation in which TE1 sensor • If the outdoor units are a temperature falls below frost formation temperature is measured, and when this (reverse combination of different...
  • Page 45 Item Description of operation, numerical data, and other information Remarks 8. Release 1. SV2 gas balance control valve control This control function is aimed at achieving gas balance by opening SV2 while compressors are turned off so as to reduce their startup load the next time they are turned on.
  • Page 46 Item Description of operation, numerical data, and other information Remarks 8. Release 4. SV41, 42, 43 low pressure release control valve control This control function is aimed at providing low pressure protection, and is individually performed by the header unit and each follower unit. (cont’d) The control takes place during defrost operation, heating startup pattern control operation, and cooling operation.
  • Page 47 Item Description of operation, numerical data, and other information Remarks 11. A3-IPDU IPDU controls inverter compressors by issuing commands relating to compressor control speeds, speed increases/decreases, and current release control values via the interface P.C. board. The main control functions of the IPDU P.C. board are described below. 1.
  • Page 48 <Schematic diagram for oil equation control> Unit Unit receiving oil transferring oil Header unit (MMY-MAP0964HT6UL) Follower unit (MMY-MAP0724HT6UL) 4-way valve 4-way valve High pressure sensor High pressure sensor Low pressure sensor Low pressure sensor...

  • Page 49: Applied Control And Functions

    Applied Control and Functions 7-1. Applied control for outdoor unit The outdoor fan high static pressure support and priority operation mode setting (cooling / heating / number of units / or priority indoor unit) functions are made available by setting relevant switches provided on the interface P.C. board of the outdoor unit.
  • Page 50 (2) Indoor unit setup method for priority indoor unit mode The setting can be changed only when the system is at rest. (Be sure to turn off the system prior to this operation.) Push the buttons simultaneously and hold for at least 4 seconds.

  • Page 51: Applied Control Of Outdoor Unit

    7-2. Applied control of outdoor unit Optional control P.C. boards provide access to a range of functions as listed below. Outdoor unit Control P.C. board to be used Outdoor unit interface P.C. board setting* for control Function Jumper to be P.C.

  • Page 52: Power Peak-Cut Control (Standard)

    7-2-1. Power peak-cut control (standard) Header outdoor unit L1: Display lamp suring power peak cut control Locally procured Optional PCB Outdoor unit Power interface PCB supply Display relay [OPERATION] Shield wire Shield wire Connection cable For SW1 and SW2, be sure to provide no- voltage contacts for each terminal.

  • Page 53: Power Peak-Cut Control (Extended)

    <SW07 Bit 2 OFF (two-step control)> Power peak-cut control is enabled as long as SW1, as shown on the wiring diagram, is ON (continuously). SW07 Bit 1 Indicator relay Jumper wire Input Bit 1 OFF Bit 1 ON (L1) 0% (forced stop) 60% capacity (upper limit regulated) 100% (normal operation) 100% (normal operation)

  • Page 54: Snowfall Fan Control

    7-2-3. Snowfall fan control Header outdoor unit Locally procured Outdoor unit Optional PCB Connection interface PCB cable Snowfall senior Shield wire SW1: Snowfall detection switch (snowfall sensor) Operation An external snowfall signal turns on the outdoor unit fan. Terminal Input signal Operation Snowfall fan control (Turns on outdoor...

  • Page 55: Night Operation (Sound Reduction) Control

    7-2-5. Night operation (sound reduction) control Header outdoor unit Locally procured Outdoor unit Optional PCB Connection interface PCB cable Shield wire SW1: Night time signal switch Operation This function decreases noise at night or other times as necessary. Terminal Input signal Operation Night time control COOL...

  • Page 56: Operation Mode Selection Control

    7-2-6. Operation mode selection control Header outdoor unit Locally procured Outdoor unit Optional PCB Connection interface PCB cable Shield wire SW1: Cooling mode specified input switch SW2: Heating mode specified input switch NOTE SW1: COOL mode selection switch SW2: HEAT mode selection switch Input signal Operation Remarks...

  • Page 57: Error/Operation Output

    7-2-7. Error/operation output Locally procured Header outdoor unit (See “NOTE”) Outdoor unit Optional PCB interface PCB Shield wire Operation In-operation output: An in-operation indication signal is output as long as at least one indoor unit is in operation in the line. Error output: An error indication signal is output if an error occurs in at least one indoor/outdoor unit in the line.

  • Page 58: Compressor Operation Output

    7-2-8. Compressor operation output Locally procured Outdoor unit (See “NOTE”) Outdoor unit Optional PCB interface PCB Shield wire Operation When a compressor is in operation, a relay connected to the output terminal assigned to it is turned on (closed). When it is at rest, the relay is turned off (open). The output terminals are named OUTPUT1, OUTPUT2 and OUTPUT3 from left to right when facing the front of the outdoor unit, as shown in the diagram.

  • Page 59: Operating Rate Output

    7-2-9. Operating rate output Locally procured Header outdoor unit (See “NOTE”) Outdoor unit Optional PCB interface PCB MONITOR Shield wire Operation At the output terminals, a signal is present (relay closed) or absent (relay open) in various combinations according to the system operation factor, as shown in the diagram. The operation rate (FA) is the percentage ratio of the current output of the system to the maximum output (100%).

  • Page 60: Test Operation

    Test Operation 8-1. Procedure and summary of test operation A test operation is executed with the following procedure. When problems or an error occurs at any step, remove the causes of the problem or error referring to “9 Troubleshooting.” Checks before test operation Check basic items, mainly the installation work.

  • Page 61: Check Items Before Test Operation (Before Powering-On)

    8-2. Check items before test operation (before powering- Prior to the test operation, check the following items to verify there are no problems with the installation work. (1) In the case that a central control system is not connected: Follower unit (B) Header unit (A) Outdoor unit Indoor unit...
  • Page 62 (2) In the case that a central control system is connected (before address setup) Central remote control To other refrigerant line Other refrigerant line Header unit (A) Follower unit (B) Outdoor unit To indoor unit Indoor unit Remote Remote Remote control control control...
  • Page 63 Checklist 1 • Using Checklist 1, check that there are no problems with the installation work. Is the capacity of the Outdoor total capacity Header unit (A) Indoor unit circuit breaker (Earth Follower unit (B) leakage breaker) appropriate? Is the gauge of the Header unit (A) AWG Indoor unit AWG power cable correct?
  • Page 64 Checklist 2 Calculate the additional amount of refrigerant from the additional amount of refrigerant (A) by the pipe diameter on the liquid side, the pipe length to be connected, and the corrective amount of refrigerant (C) according to system horsepower. Actual length Additional refrigerant charge Adjustment amount of refrigerant...

  • Page 65: Check At Main Power-On

    8-3. Check at main power-on After turning on the main power of the indoor units and outdoor unit in the refrigerant line to conduct a test operation, check the following items in each outdoor and indoor unit. (After turning on the main power, be sure to check in order: indoor unit ➝ outdoor unit.) <Check on the outdoor unit>...

  • Page 66: Address Setup

    8-4. Address setup This product requires address setup before operation. Follow this procedure for address setup. 8-4-1. Precautions (1) Address setup is not performed simply by turning on the power supply. (2) For indoor units, address setup can be done either by manual address setup or by automatic address setup: Automatic address setup: Setup from SW15 on the interface PC board of the header unit Manual address setup: Setup from the wired remote control.

  • Page 67: Address Setup Procedure

    8-4-3. Address setup procedure Without central control or with central control of 1 refrigerant lines (Example 1) : use Address setting procedure 1 With central control of 2 refrigerant lines (Example 2) : use Address setting procedure 2 Example 1 Example 2 When a single refrigerant line is centrally When 2 or more refrigerant lines are centrally...
  • Page 68 (Example) Controlling 2 or more refrigerant lines as a group Outdoor Outdoor System wiring Indoor Indoor Indoor Indoor diagram (Group control) Remote control ◆ Address setting procedure 2 Set a system address for each system using SW 13 and 14 on the interface P.C. board on the header outdoor unit of each system.
  • Page 69 Be sure to disconnect the relay connectors between the [U1U2] and [U3U4] terminals on all the header outdoor units that will be connected to the central control. (Factory default: disconnected) INDOOR CENTRAL OUTDOOR UNIT CONTROL UNIT Turn on indoor units first, and then turn on outdoor units. About 1 minute after turning the power on, confirm that the 7-segment display on the interface P.C.
  • Page 70 Set the central control address. (For the setting of the central control address, refer to the installation manuals of the central control devices.) Header unit interface P.C. board 7-segment display SW30 * Header units are connected to the same central control, except the header unit with the smallest line address number.
  • Page 71 Switch setting (setting example when controlling 2 or more refrigerant lines centrally) Outdoor units (setting manually) *The items in bold font must be set manually. Outdoor unit’s interface Header unit Follower unit Header unit Follower unit Header unit Factory default P.C.
  • Page 72 Manual address setup from the remote control With indoor wiring work completed and outdoor wiring work not done—in cases where indoor unit addresses are decided in advance from the wired remote control, or in cases where addresses are change after address setup. (Wiring example for 2 refrigerant lines) Arrange one indoor unit and one remote control set to 1 by 1.
  • Page 73 NOTE (1) When setting the line address from the remote control, do not use addresses 29 and 30. Addresses 29 and 30 cannot be set up on the outdoor unit. If they are incorrectly used, the code “E04” (indoor/outdoor communication circuit error) is output. (2) When manual address setup has been done from a remote control, and central control over refrigerant lines is to be done, setup the header unit of each line as follows: •...
  • Page 74 To find an indoor unit’s position from its address ▼ When checking unit numbers controlled as a group Stop (Execute it while the units are stopped.) The indoor unit numbers in a group are indicated one after another. The fan and louvers of the indicated units are activated.
  • Page 75 Push and hold the TIME buttons at the same time for more than 4 seconds. At first, the line 1 and CODE No. (Address Change) are indicated on the LCD display. (Select an outdoor unit.) Push the (left side of the button) and buttons repeatedly to select a system address.
  • Page 76 Push the TIME buttons repeatedly to change the value indicated in the SET DATA section to that you want. Push the button. Push the button (left side of the button) repeatedly to select another indoor UNIT No. to change. Repeat steps to change the indoor unit addresses so as to make each of them unique.
  • Page 77 Push the button. • The address of one of the indoor units connected to the selected refrigerant line is indicated on the LCD display and the fan and louvers of the unit are activated. SET DATA At first, the current indoor unit address is displayed in (No system address is indicated.) Finish Press to finish...
  • Page 78 2) Turn on dip switch 2 of SW30 on the interface P.C. board of the header outdoor unit if the switch is OFF. (Leave it as it is if it has already been set to ON.) Central remote control Header Header Header Follower unit...
  • Page 79 In the case of an increase in address-undefined indoor units (extension, etc.) To set up the indoor address of a unit with an address that is undefined due to the extension of indoor units or replacement of PC board, etc., follow the methods below. Method 1 Set up an address individually from a wired remote control.

  • Page 80: Check After Address Setup When Central Control System Is Connected

    8-4-4. Check after address setup when central control system is connected When the central control system is connected, check that the following setup has finished after address setup. Central remote control To other refrigerant line Line address = 1 Line address = 2 Other refrigerant line Header unit (A) Header unit (A)

  • Page 81: Troubleshooting In Test Operation

    8-5. Troubleshooting in test operation If there are phenomena such as the output of a check code or the remote control is not accepted when powered- on after wiring work or during address setup operation, the following causes are considered. 8-5-1.

  • Page 82: Operation From The Indoor Remote Control Is Not Accepted, And A Check Code Is Displayed On The 7-Segment Display Of The Interface Pc Board Of The Header Unit

    8-5-2. Operation from the indoor remote control is not accepted, and a check code is displayed on the 7-segment display of the interface PC board of the header unit. Header unit Indoor remote 7-segment Cause Countermeasures control status display Line addresses and indoor addresses of all the connected Set up addresses.

  • Page 83: In Checking The Number Of Connected Outdoor Units And Connected Indoor Units After Ad

    8-5-4. In checking the number of connected outdoor units and connected indoor units after address setup, a lower number of connected units is displayed. (There are outdoor/indoor units that do not operate in a test operation.) Status Cause Countermeasures Miswiring of communication lines between outdoor units After modification of wiring, set up the addresses again and The number of or an unconnected wire ( Fig.
  • Page 84 Miswiring example Remote Header unit Figure control 7-segment Miswiring example status display Header unit Header unit Fig. 1 E19-00 response Follower unit Header unit Fig. 2 E19-02 response Follower unit Header unit Follower unit Header unit Follower unit [Line 2] Header unit [Line 1] Fig.

  • Page 85: Test Operation Check

    8-6. Test operation check 8-6-1. Fan check START Check code appears Push the Start/Stop button on the remote control. When a check code has been displayed on the remote control, remove the cause of the error, referring to "Check code and check Check code position displayed on remote appears...

  • Page 86: Wired Remote Control

    8-6-2. Cooling/heating test operation check The cooling/heating test operation check can be performed on both the indoor remote control and the outdoor header unit interface PC board. (1) Test operation start/stop operation Test operation from the indoor remote control • Wired remote control: Refer to the items below in “Test operation” of the wired remote control. •...
  • Page 87 ▼ Wireless remote control (4-way Cassette type) ▼ Wireless remote control (Ceiling type) Procedure Operation content Procedure Operation content Turn off the air conditioner’s power. Turn on the air conditioner’s power. Remove the adjustment corner cap attached to the sensor section from the ceiling panel. For removing This operation is not accepted for 5 minutes when power has been turned on for the first time after installation, and method, follow the installation manual attached to the...
  • Page 88 (2) Test operation START Refer to "Test operation procedure" Test operation for one indoor unit of the indoor remote control. The operation does not start for approximately 3 minutes after Operation starts powering-on or stopping operation. Note: After powering-on, it may require up to 10 minutes to start the operation due to the initial communications of the system.
  • Page 89 Note 1: Criteria for the difference between suction and discharge temperatures (1) Cooling operation After operating for a minimum of 30 minutes in “COOL” mode, if the ΔT dry bulb temperature difference between suction and discharge air of the indoor unit is 46.4 °F (8 °C) or more, it is normal. (2) Heating operation After operating for a minimum of 30 minutes in “HEAT”...

  • Page 90: Service Support Function

    8-7. Service support function 8-7-1. Check function for connecting of refrigerant and control lines This function is provided to check misconnection of the refrigerant pipes and the control transmission line (Wiring over lines) between indoor unit and outdoor unit by using the switch on the interface P.C. board of the header unit. However, be sure to check the following items prior to executing this check function.
  • Page 91 (7-segment display) Operation start Press the push-switch SW04 on the interface P.C. board of the header unit for 2 seconds or more. The Cooling Operation operation starts. Check that 7-segment display [B] shows [ CC] for Heating cooling and [ HH] for heating. (7-segment display) Confirmation of check results (1) This check operation...

  • Page 92: Function To Start/Stop (On/Off) Indoor Unit From Outdoor Unit

    8-7-2. Function to start/stop (ON/OFF) indoor unit from outdoor unit The following functions of the indoor unit can start or stop by the switches on the interface P.C. board of the header unit. Function Outline Setup/Release 7-segment display Cooling test Changes the mode of all the [Setup] Section A...

  • Page 93: Operation Procedure

    (1) Cooling test operation function This function is provided to change collectively the mode of all the indoor units connected to the same system for the cooling test operation mode, by using switches on the interface board of the header unit. <Operation procedure>...
  • Page 94 (2) Heating test operation function This function is provided to change collectively the mode of all the indoor units connected to the same system for the heating test operation mode, by using switches on the interface board of the header unit. <Operation procedure>...
  • Page 95 (3) Batch start/stop (ON/OFF) function This function is provided to start/stop collectively all the indoor units connected to the same system by using switches on the interface board of the header unit. <Operation procedure> Be sure to turn on power at the indoor side Power ON before power-ON of outdoor unit.
  • Page 96 (4) Individual start/stop (ON/OFF) individual test operation function This function is provided to start/stop (ON/OFF) individually each indoor unit connected to the same system by using switches on the interface board of the header unit. Set SW01 [16] and set SW02, SW03 to indoor address No. (1 to 64) to be started (Refer to the following table*) - only the setup indoor unit starts operation.

  • Page 97: Error Clearing Function

    8-7-3. Error clearing function (1)Clearing from the wired remote control ▼ Error clearing in outdoor unit Error of the outdoor unit currently detected is cleared by the unit of one refrigerant circuit system to which the indoor units operated by the remote control is connected. (Error of the indoor unit is not cleared.) For clearing errors, the service monitor function of the remote control is used.
  • Page 98 (2)Clearing error by using switches on the interface board of the header unit Using the switches on the interface P.C. board of the header unit, this function is to clear the currently detected error for each refrigerant circuit system without resetting the power supply. Errors in both outdoor and indoor units are once cleared, and error detection is performed again.

  • Page 99: Remote Control Distinction Function

    8-7-4. Remote control distinction function This function is provided to distinguish the remote control connected to the indoor unit from the outdoor unit for a refrigerant circuit system by using switches on the interface P.C. board of the header unit. <Distinction procedure>...

  • Page 100: Pulse Motor Valve (Pmv) Forced Open/Close Function In Indoor Unit

    8-7-5. Pulse motor valve (PMV) forced open/close function in indoor unit This function is provided to open or close forcedly PMV for 2 minutes in all the indoor units by the switch operation on the interface P.C. board of the header unit. This function is also used to open PMV fully when turning off the power and executing an operation.

  • Page 101: Solenoid Valve Forced Open/Close Function In Outdoor Unit

    8-7-7. Solenoid valve forced open/close function in outdoor unit This function is provided to forcedly open each solenoid valve mounted in the outdoor unit by the switch operation on the interface P.C. board in the outdoor unit. Use this function to check there is no refrigerant clogging with ON/ OFF operation of the solenoid valve.

  • Page 102: Fan Operation Check In Outdoor Unit

    8-7-8. Fan operation check in outdoor unit This function is provided to check the fan operation of the outdoor unit by using switches on the interface P.C. board in the outdoor unit. The frequency of the fan speed can be controlled by setting of the switches. Use this function to check the operation or abnormal sound in the fan system.

  • Page 103: Abnormal Outdoor Unit Discrimination Method By Fan Operating Function

    8-7-9. Abnormal outdoor unit discrimination method by fan operating function This function is provided to forcedly operate the fan of the outdoor unit in which an error occurred or the fan of the normal outdoor unit by the switch operation on the interface P.C. board in the header unit. To specify which one of the follower units connected to the system was faulty, use this function for the system stop due to a follower unit fault (Check code [E28]).

  • Page 104: Manual Adjustment Function Of Outside Temperature (To) Sensor

    8-7-10. Manual adjustment function of outside temperature (TO) sensor This function is provided to fix TO sensor value manually by the switch operation on the interface P.C. board in the outdoor unit. When the unit stops abnormally due to TO sensor failure, etc, an emergent operation is available by setting up the value manually to position near the current outside temperature.
  • Page 105 <Service support function list> SW01 SW02 SW03 7-segment display [A] Function contents Refrigerant circuit and control communication line check function (Cooling [J . C] operation) Refrigerant circuit and control communication line check function (Heating [J . H] operation) [P . ] Indoor PMV forced full open function [A .

  • Page 106: Monitor Function Of Remote Control Switch

    8-7-11. Monitor function of remote control switch When using a remote control with the model name RBC-AMT32UL, the following monitor functions can be used. Calling of display screen <Content> The sensor temperature or operation status of the remote control, indoor unit, or the outdoor unit can be known by calling up the service monitor mode from the remote control.
  • Page 107 CODE No. Data name Display format Unit Remote control display example Room temperature (During control) ×1 °C [0027]=27 °C Room temperature (Remote control) ×1 °C Indoor suction temperature (TA) ×1 °F Indoor coil temperature (TCJ) ×1 °F Indoor coil temperature (TC2) ×1 °F [0080]=80 °F...

  • Page 108: Troubleshooting

    Troubleshooting 9-1. Overview (1) Before engaging in troubleshooting (a) Applicable models All Super Module Multi (SMMS-i) models. (Indoor units: MMO-APOOO, Outdoor units: MMY-MAPOOO4HT6UL) (b) Tools and measuring devices required • Screwdrivers (Philips, flat head), spanners, long-nose pliers, nipper, pin to push reset switch, etc. •...

  • Page 109: Troubleshooting Method

    9-2. Troubleshooting method The remote controls (main remote control and central control remote control) and the interface P.C. board of an outdoor unit are provided with an LCD display (remote control) or a 7-segment display (outdoor interface P.C. board) to display operational status. Using this self-diagnosis feature, the fault site/faulty part may be identified in the event of a fault by following the method described below.
  • Page 110 (Error detected by main remote control) Check code Display of receiving unit Outdoor 7-segment display Indicator light block Typical fault site Description of error Main remote Operation Timer Ready controller Flash Sub-code No master remote control, faulty Signals cannot be received from indoor unit; –...
  • Page 111 IPDU: Intelligent Power Drive Unit (Inverter P.C. board) List of Check Codes (Outdoor Unit) : Lighting, : Flashing, : Goes off (Errors detected by SMMS-i outdoor interface - typical examples) ALT.: Flashing is alternately when there are two flashing LED SIM: Simultaneous flashing when there are two flashing LED Check code Display of receiving unit...
  • Page 112 Check code Display of receiving unit TCC-LINK Outdoor 7-segment display Indicator light block central control Typical fault site Description of error or wired Operation Timer Ready remote control Flash Sub-code display Outdoor suction Outdoor suction temperature sensor (TS1) has – temperature sensor (TS1) been open/short-circuited.
  • Page 113 Check code Display of receiving unit TCC-LINK Outdoor 7-segment display Indicator light block central control Typical fault site Description of error or wired Operation Timer Ready remote control Flash Sub-code display There are insufficient number of IPDUs (P.C. SIM Error in number of IPDUs boards) in inverter box.
  • Page 114 Check code Display of receiving unit TCC-LINK Outdoor 7-segment display Indicator light block central control Typical fault site Description of error or wired Operation Timer Ready remote control Flash Sub-code display 01: Compressor 1 Error in temperature Temperature sensor built into indoor IGBT (TH) 02: Compressor 2 sensor built into indoor has been open/short-circuited.

  • Page 115: Troubleshooting Based On Information Displayed On Remote Control

    9-3. Troubleshooting based on information displayed on remote control Using main remote control (RBC-AMT32UL) (1) Checking and testing When a fault occurs to an air conditioner, a check code and indoor unit No. are displayed on the display window of the remote control. Check codes are only displayed while the air conditioner is in operation.
  • Page 116 Using indoor unit indicators (receiving unit light block) (wireless type) To identify the check code, check the 7-segment display on the header unit. To check for check codes not displayed on the 7-segment display, consult the “List of Check Codes (Indoor Unit)” in “9-2. Troubleshooting method”.
  • Page 117 Light block Check code Cause of fault Heat exchanger temperature sensor (TCJ) error Operation Timer Ready Heat exchanger temperature sensor (TC2) error Indoor unit temperature sensor Heat exchanger temperature sensor (TC1) error errors Ambient temperature sensor (TA) error Alternate blinking Discharge temperature sensor (TF) error Discharge temperature sensor (TD1) error Operation Timer...
  • Page 118 Light block Check code Cause of fault Operation Timer Ready Outdoor EEPROM error Synchronized blinking Other (indications not involving check code) Light block Check code Cause of fault Operation Timer Ready – Test run in progress Synchronized blinking Operation Timer Ready Setting incompatibility –...

  • Page 119: Check Codes Displayed On Remote Control And Smms-I Outdoor Unit

    9-4. Check codes displayed on remote control and SMMS- i outdoor unit (7-segment display on I/F board) and locations to be checked For other types of outdoor units, refer to their own service manuals. Check code Location Outdoor 7-segment display Description System status Error detection condition(s)
  • Page 120 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Automatic All stop • Indoor automatic address setting • Perform automatic address Indoor-outdoor address starting is started while automatic setting again after disconnecting communication error...
  • Page 121 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Address of Dropping out of All stop Outdoor unit initially communicating • Backup setting is being used for outdoor unit outdoor unit normally fails to return signal for...
  • Page 122 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code TD2 sensor All stop Sensor resistance is infinity or zero • Check connection of TD2 sensor error (open/short circuit). connector.
  • Page 123 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Ps sensor error All stop Output voltage of Ps sensor is zero. • Check for connection error involving Ps sensor and Pd sensor connectors.
  • Page 124 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Activation of All stop Low-pressure Ps sensor detects • Check service valves to confirm low-pressure operating pressure lower than full opening protection 0.02MPa.
  • Page 125 Check code Location Outdoor 7-segment display Error detection Description System status Check items (locations) Wired condition(s) remote detection Check Sub-code control code 01: TK1 oil Oil level All stop No temperature change is • Check for disconnection of TK1 sensor. circuit error detection circuit detected by TK1 despite...
  • Page 126 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Indoor Duplicated Stop of There is more than one header unit • Check indoor addresses. unit indoor header corresponding in group.
  • Page 127 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Detected indoor Indoor External Stop of • Signal is present at external error When external device is address unit interlock of corresponding...
  • Page 128 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code 01: Compressor IPDU Heat sink All stop Temperature sensor built into • Check power supply voltage. 1 side overheating IGBT (TH) is overheated.
  • Page 129 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code Discharge All stop Discharge temperature (TD3) • Check outdoor service valves temperature exceeds 239 °F (115 °C). (gas side, liquid side) to confirm TD3 error full opening.
  • Page 130 Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection Check Sub-code control code 0∗: IGBT circuit IPDU Outdoor fan All stop (Sub code: 0∗) • Check fan motor. 1∗: Position IPDU error Fan IPDU over current protection •...

  • Page 131: Errors Detected By Tcc-Link Central Control Device

    Errors Detected by TCC-LINK Central Control Device Check code Location Outdoor 7-segment display Description System status Error detection condition(s) Check items (locations) Wired remote detection control Sub-code TCC-LINK TCC-LINK Continued Central control device is unable to • Check for defect in central control central control operation transmit signal.
  • Page 132 ▼ Points to Note When Servicing Compressor (1) When checking the outputs of inverters, remove the wiring from all the compressors. ▼ How to Check Inverter Output (1) Turn off the power supply. (2) Remove compressor leads from the IPDU P.C. board (A3-IPDU). (Be sure to remove all the leads.) (3) Turn on the power supply and start cooling or heating operation.

  • Page 133: Diagnosis Procedure For Each Check Code

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

  • Page 164: 7-Segment Display Function

    9-6. 7-segment display function 7-segment display on outdoor unit (interface P.C. board) The interface control P.C. board features a 7-segment LED display designed to check operational status. Display items can be changed by changing the combination of the number settings of rotary switches provided on the P.C. board (SW01, SW02 and SW03).
  • Page 165 (1)Display of System Information (Displayed on Header Outdoor Unit Only) SW01 SW02 SW03 Display detail Unused System capacity A […6]~[10]:6 to 20 ton B [ton] No. of outdoor units A […1]~[…2]:1 to 2 B […P] No. of indoor units connected / A […0.]~[48.]:0 to 48 (No.
  • Page 166 (2)Display of Outdoor Unit Information (Displayed on Each Outdoor Unit) SW01 SW02 SW03 Display detail Error data A Outdoor unit No.: [U1] to [U4] B Check code (only latest one displayed) If there is no check code, [– – –] is displayed. If there is sub-code, check code [∗...
  • Page 167 (3)Display of Outdoor Cycle Data (Displayed at Each Outdoor Unit) SW01 SW02 SW03 Display detail Pd pressure data Pd pressure (psi) is displayed in decimal format. ∗ ∗. ∗ P d. ∗ ∗. ∗ Ps pressure data Ps pressure (psi) is displayed in decimal format. P S.
  • Page 168 (4)Display of Outdoor Cycle Data (Displayed at Header Unit) * This method is used when displaying follower unit information on the 7-segment display of the header unit. SW01 SW02 SW03 Display detail A [U.∗], ∗: SW03 setting No. + 1 (Outdoor unit No. U2) Error data B Check code is displayed (latest one only).
  • Page 169 (5)Display of Indoor Unit Information (Displayed on Header Unit Only) SW01 SW02 SW03 Display detail Indoor BUS communication signal B Upon receiving signal: [… … 1], Other times: [… … …] receiving status Indoor check code B No check code: [– – –] Indoor capacity 0.6 to 4.5 B [ #.

  • Page 170: Oil Level Judgment Display

    9-7. Oil level judgment display The current compressor oil level judgment results can be accessed by setting the switches provided on the interface P.C. board of an outdoor unit. Perform the checks in accordance with the procedure described below. Operation Procedure (1) Start the operation.

  • Page 171: Leakage/Clogging Of Refrigerating Cycle Circuit

    9-8. Leakage/clogging of refrigerating cycle circuit List of Check Codes Generated upon Occurrence of Leakage/Clogging in Outdoor Cycle or Oil Circuit Part (MMY-MAP0724HT6UL) Clogging Site of fault Unit generating Part Detected fault and check code Symptom (see next page) check code...
  • Page 172 Fan motor Right-side Heat exchanger Left-side Heat exchanger Reducer 4-way valve Check valve High-pressure sensor Low-pressure sensor Fusible Oil separator Fusible plug plug Check valve Check valve High-pressure High-pressure Accumulator Liquid tank Check valve Check valve Oil header Check valve Check valve Balance pipe Liquid-side...
  • Page 173 List of Check Codes Generated upon Occurrence of Leakage/Clogging in Outdoor Cycle or Oil Circuit Part (MMY-MAP0964HT6UL, MAP1144HT6UL) Clogging Site of fault Unit generating Part Detected fault and check code Symptom (see next page) check code Outdoor PMV1, 2, 4 Corresponding unit Activation of high-pressure protection Rise of pressure...
  • Page 174 Fan motor Right-side Main heat exchanger Right-side sub-heat exchanger Left-side Main Heat exchanger Check valve Left-side sub-heat exchanger Check valve 4-way valve High-pressure sensor Low- pressure sensor Fusible plug Oil separator Fusible plug Accumulator Liquid tank High- High- High-pressure pressure pressure SW Oil pipe Check valve...

  • Page 175: Sensor Characteristics

    9-9. Sensor characteristics Outdoor Unit ▼ Temperature sensor characteristics Outdoor TS1, TE1, TE2, TL and TO sensors Temperature Resistance [°F (°C)] [kΩ] Resistance [kΩ] (50 °F (10 °C) or below) Resistance [kΩ] (50 °F (10 °C) or above) Temperature [°F (°C)] Outdoor TD1,TD2,TD3,TK1,TK2,TK3,TK4 and TK5 sensors Temperature Resistance...
  • Page 176 Outdoor Unit ▼ Pressure sensor characteristics • Input / output wiring summary High pressure side (Pd) Low pressure side (Ps) Pin No. Input / output name Lead wire color Input / output name Lead wire color OUTPUT White — — —...
  • Page 177 Indoor TC1 sensor Temperature Resistance [°F (°C)] [kΩ] Resistance Resistance [kΩ] [kΩ] (55 °F (10 °C) (55 °F (10 °C) or or above) below) Temperature [°F (°C)] Indoor TC2 and TCJ sensors Temperature Resistance [°F (°C)] [kΩ] Resistance Resistance [kΩ] [kΩ] (55 °F (10 °C) or (55 °F (10 °C) or...

  • Page 178: Pressure Sensor Output Check

    9-10.Pressure sensor output check 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 Outdoor Unit ▼ Ps 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: Backup Operation (Emergency Operation)

    Backed-up outdoor unit Example Faulty Prohibited Note 4: With a two-outdoor unit system containing an MMY- Backed-up outdoor unit MAP0964HT6UL and a MMY-MAP0724HT6UL, do not Example Faulty preform outdoor unit backup operation to back up the MMY-MAP0964HT6UL. Prohibited It could lead to compressor failure due to the abnormal...

  • Page 181: Compressor Backup Operation Setting

    10-2.Compressor backup operation setting <Outline> If a fault occurs to one of the compressors installed in outdoor unit, follow the procedure described below to back up the faulty compressor by using the remaining, normal compressor(s). <Work Procedure> (1) Turn off the power supply to all the outdoor units connected to the system. (2) Set the DIP switches of SW06, provided on the interface P.C.

  • Page 182: Outdoor Unit Backup Operation Setting

    10-3.Outdoor unit backup operation setting <Outline> This product allows outdoor unit backup operation setting to be performed either at the header unit or a follower unit. If any of the fault modes specified below occurs to one of the outdoor units in a multi-outdoor unit system, proceed with outdoor unit backup operation.
  • Page 183 (6) Turn on the power supply to all the units connected to the system other than the failed follower unit. Determine what to do with the power supply to the failed follower unit in the following manner. <In case of fault in compressor, electrical part, I/F P.C. board, or IPDU P.C. board> Leave the power supply off.

  • Page 184: Header Outdoor Unit Backup Operation Setting (Failure Of Header Outdoor Unit)

    10-3-2. Header outdoor unit backup operation setting (failure of header outdoor unit) <Work procedure> (1) Turn off the power supply to all the units connected to the system at the source. [Setup of failed header outdoor unit] (2) Fully close the gas pipe service valve of the failed outdoor unit. (3) Leave the service valves of the liquid and balance pipes fully open (to prevent refrigerant stagnation in the failed outdoor unit).
  • Page 185 (8) Set Bits 1 and 2 of SW30 on the interface P.C. board same as that of the failed header unit (terminator resistance setting). Outdoor interface P.C. board of unit selected as new header unit Turn on Bit 2 of SW09. Set Bits 1 and 2 of SW30 identically to failed header unit.

  • Page 186: Cooling-Season Outdoor Unit Backup Operation Setting

    10-4.Cooling-season outdoor unit backup operation setting <Outline> Limited to summer and other situations where there is no need for heating operation, this function makes it possible to get backup operation up and running quickly without going through the normal setup procedure, regardless of which type of outdoor unit has failed, the header unit or a follower unit.

  • Page 187: Outdoor Unit Refrigerant Recovery Method

    Outdoor Unit Refrigerant Recovery Method 11-1.Refrigerant recovery from failed outdoor unit (pump- down) This product supports refrigerant pump-down, a function which allows refrigerant to be recovered from an outdoor unit in need of repair using a normal outdoor unit in a system featuring multiple outdoor units. 11-1-1.
  • Page 188 (5) [rd] [… FF] will be displayed on the 7-segment display, and pump-down operation will start. * To put the operation on hold midway, turn off the power supply to all the outdoor units, or press SW05 on the interface P.C. board. Header unit Failed outdoor unit Connect liquid pipe check joint and low...
  • Page 189 [Setup of failed outdoor unit] (12)When the low-pressure sensor output of the failed outdoor unit falls below 14.5 psi (0.10 MPa), fully close the balance pipe packed valve, and press SW05 on the interface P.C. board to finish the pump-down operation. (13)Turn off the power supply to all the outdoor units, and recover the residual refrigerant in the outdoor unit using a refrigerant recovery device.

  • Page 190: Refrigerant Recovery Procedure B (Case Of Outdoor Unit Backup Operation Setting)

    11-1-3. Refrigerant recovery procedure B (case of outdoor unit backup operation setting) <Outline> If outdoor unit backup operation setting is performed, use an alternative refrigerant recovery procedure as described below, provided that the power cannot be turned on for the failed outdoor unit. (Refrigerant will be recovered from the failed outdoor unit using the test cooling operation function.) Note 1: If cooling-season outdoor unit backup operation or outdoor unit backup operation is in progress with the power supply to the failed outdoor unit turned on, follow the procedure described in “11-1-2.
  • Page 191 [Setup of header unit] (8) While monitoring the low-pressure sensor output, adjust the pressure to around 17 psi (0.12 MPa) by slowly closing the gas pipe service valve. (9) Compare the manifold gauge pressure of the failed unit with the low-pressure sensor output of the header unit, and wait until the two pressure readings become almost identical.

  • Page 192: How To Operate System While Failed Outdoor Unit Being Repaired

    11-2.How to operate system while failed outdoor unit being repaired <Outline> After refrigerant is recovered from the failed outdoor unit through a pump-down operation, the overall amount of refrigerant held by the system becomes excessive, and this makes it impossible to operate the remaining outdoor units even though they are not faulty.

  • Page 193: Work Procedure After Repair

    11-3.Work procedure after repair When vacuuming in the repaired outdoor unit, follow the procedure described below. <Work procedure> (1) Fully open PMV1 and 2 and PMV4 (MMY-MAP0964HT6UL and MAP1144HT6UL only) in accordance with the table below. Note: PMV full-opening operation via short-circuiting of the CN30 pins is automatically undone after 2 minutes, causing the valves to fully close.

  • Page 194: Replacing Compressors

    Replacing Compressors 12-1.Compressor replacement procedure (outline) START WARNING In situations such as indoor unit relocation and repairs, Is the outdoor unit the only one in the system? it is not possible to recover all the refrigerant held by the system in the outdoor units. It could cause a serious accident, such as blow out or Manually open PMV1, 2 Recover refrigerant...

  • Page 195: Replacement Of Compressors

    12-2.Replacement of compressors <Checking color of oil in faulty compressor> • Lay the faulty compressor down, draw a small amount of oil via the oil equalization pipe, and check its color against color samples. • Determine the number of compressors to be replaced according to the color checking result. ASTM grade: Below 4 ➝...
  • Page 196 [When replacing normal as well as faulty compressor] - applicable to MMY- MAP0724HT6UL <Dismantling normal compressor> • Dismantle the normal compressor in the same way as the faulty compressor. WARNING When detaching a pipe by heating with a burner a welded joint, take care as any oil left in the piping may burn in a momentary flash of fire when the weld filler metal melts.
  • Page 197 [When replacing normal as well as faulty compressors] - applicable to MMY- MAP0964HT6UL and MAP1144HT6UL <Dismantling normal compressors> • Dismantle the normal compressors in the same way as the faulty compressor. WARNING When detaching a pipe by heating with a burner a welded joint, take care as any oil left in the piping may burn in a momentary flash of fire when the weld filler metal melts.
  • Page 198 (5) Disconnect the connector of PMV4 from the I/F P.C. board (6) Turn off the power switch of the outdoor unit. Note: Steps (4) and (5) are not required for MMY-MAP0724HT6UL. <Refrigerant charging> • Inject the same amount of refrigerant as the recovered residual refrigerant via the charging port of the liquid-side...

  • Page 199: Check Procedure To Search Cause Of Compressor Oil Shortage

    12-3.Check procedure to search cause of compressor oil shortage Are the balance pipes of all outdoor units connected to the Open the balance pipe valves fully. same refrigerant line fully open? Are there Correct the miswiring or connection. any miswiring or incorrect connection of TK1, TK2, TK3, TK4 and TK5 sensor in the unit that has replaced compressor?
  • Page 200 <MMY-MAP0964HT6UL and MAP1144HT6UL> Check items and procedures to follow when checking oil circuit with compressor(s) disconnected Check item Location Procedure 1) With PMV1, 2 and 4 fully closed, apply pressure to the check joint of liquid pipe with nitrogen, and check the pressure at the check joint of discharge pipe.
  • Page 201 <MMY-MAP0964HT6UL> Check items and procedures to follow when checking oil circuit with compressor(s) disconnected Check item Location Procedure 1) With PMV1 and 2 fully closed, apply pressure to the check joint of liquid pipe with nitrogen, and check the pressure at the check joint of discharge pipe. Leakage of outdoor PMV If the pressure at the check joint of discharge pipe increases, there is a leak from PMV1 or 2 (A) and check valve Leakage of check valve in...

  • Page 202: Outdoor Unit Parts Replacement Methods

    Outdoor Unit Parts Replacement Methods No. Part to be replaced Work procedure Remarks Cabinet Discharge cabinet Screws (4 corners) WARNING Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment 1) Stop the air conditioner operation, and turn Discharge cabinet off the circuit breaker.
  • Page 203 No. Part to be replaced Work procedure Remarks Cabinet 8) Remove the hook of the protective plate 8) Remove the hook (continued) (side) from the hole of the middle partition of the protective plate plate. (side) from the hole of (2 locations) the middle partition plate (2 locations)
  • Page 204 No. Part to be replaced Work procedure Remarks Propeller fan 2) Screws (4 corners) Fan motor WARNING Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment Discharge cabinet side cover 1) Stop the air conditioner operation, and turn off the circuit breaker.
  • Page 205 No. Part to be replaced Work procedure Remarks Propeller fan 10)Disconnect the faston connectors for the Fan motor fan motor leads (3 pieces) from the Fan 11) Screw (4 locations) IPDU, and pull the leads up and out. (continued) 11)Remove the fan motor. (M6 ×...
  • Page 206 No. Part to be replaced Work procedure Remarks Propeller fan 4) Remove the clamp filter from the fan motor 4) Clamp filter Fan motor with trouble, then attach the clamp filter to the substitution in the same way as before (continued) replacement.
  • Page 207 No. Part to be replaced Work procedure Remarks Heat exchanger 2) Moter base 3) Discharge cabinet anchor plate WARNING Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. Before the work, be sure to recover the refrigerant of outdoor unit into cylinders or another unit connected to the same system.
  • Page 208 No. Part to be replaced Work procedure Remarks Inverter assembly 4) Screw (with arrow mark) WARNING Removable design Wear a pair of gloves. Otherwise, you will risk an injury involving 4) Screw a replacement part or some other object. (with arrow mark) 4) Connector 1.
  • Page 209 No. Part to be replaced Work procedure Remarks Inverter assembly 2. Attachment Before pushing lower part in, pull (continued) Carry out installation by following the leads out through hole. ➝ dismantling procedure in reverse (8) 1)). Before pushing the lower part in, pull the reactor leads out.
  • Page 210 No. Part to be replaced Work procedure Remarks Inverter assembly Transformer relay board Interface board (control board) - Replacing circuit WARNING boards and electrical FAN IPDU board Noise filter board components Wear gloves. Failure to wear gloves creates the risk of personal injury by part replacement and other objects.
  • Page 211 No. Part to be replaced Work procedure Remarks Inverter assembly • 1210W chassis - Replacing circuit WARNING 3) Screw Claw (Slide to the right.) boards and electrical components Wear gloves. (Continued) Failure to wear gloves creates the risk of personal injury by part replacement and (5) Reactor other objects.
  • Page 212 No. Part to be replaced Work procedure Remarks 2-way valve coils Back Pressure sensors locations 072 type Liquid tank Transformer Oil separator Accumulator PD sensor Compressor 1 Compressor 2 PS sensor Inverter assembly Front 096 type Back 114 type Liquid tank Transformer Oil separator Accumulator...
  • Page 213 No. Part to be replaced Work procedure Remarks Temperature sensors Product Front View - locations and identification colors TD1 sensor (yellow) TD2 sensor (red) 072 type Accumulator Compressor 1 Compressor 2 Product Rear View TS1 sensor (gray) TK4 sensor (white) TK1 sensor (black) - One closer to you Transformer...
  • Page 214 No. Part to be replaced Work procedure Remarks Temperature sensors Product Front View - locations and TD1 sensor (yellow) TD2 sensor (red) TD3 sensor (black) identification colors (continued) 096 type 114 type Accumulator Compressor 1 Compressor 2 Compressor 3 Product Rear View TK4 sensor (white) TS1 sensor (gray) TK3 sensor (yellow)
  • Page 215 No. Part to be replaced Work procedure Remarks Pipe fixing rubber This model uses (split rubber rings and) stainless steel bands as a measure to improve reliability by - detachment/ anchoring vibrating system pipes. attachment <Locations where stainless steel fixing bands are used: 5> 072 type Suction pipe <=>...
  • Page 216 No. Part to be replaced Work procedure Remarks Pipe fixing rubber - detachment/ WARNING attachment (common) Wear a pair of gloves. Otherwise, you will risk an injury involving a replacement part or some other object. 1. Detachment 1) Hold the pipe fixing rubber in such a manner that your fingers and thumb are in Squeeze rubber to create small gap.
  • Page 217 No. Part to be replaced Work procedure Remarks 4-way valve - detachment/ WARNING attachment 072 type Wear a pair of gloves. 4) Brazed point Otherwise, you will risk an injury involving a replacement part or some other object. Before starting the work, be sure to recover the refrigerant of outdoor unit by removing it with a refrigerant recovery device.
  • Page 218 No. Part to be replaced Work procedure Remarks 4-way valve - detachment/ WARNING attachment 4) Brazed point (continued) Wear a pair of gloves. 096 type Otherwise, you will risk an injury involving 114 type a replacement part or some other object. Before starting the work, be sure to recover the refrigerant of outdoor unit by removing it with a refrigerant recovery device.
  • Page 219 No. Part to be replaced Work procedure Remarks Transformer Screw tightening locations WARNING for housing • Wear gloves. 2) M5 screws Failure to wear gloves creates the risk of personal injury by part replacement and other objects. • Do not attempt to modify the transformer. 1.
  • Page 220 No. Part to be replaced Work procedure Remarks Transformer 10)Remove the transformer housing back Screw tightening locations for transformer housing back screws and then remove the housing. (M4 x 0.2' (6mm), 4 pcs) Right side Left side Transformer housing 10) Screws Back 11)Remove the screws that secure the base Screw tightening locations for transformer re-assembly...

  • Page 221: C. Board Exchange Procedures

    Product code 431 6V 450 Interface P.C. board MCC-1606 ASM-PCB (I/F) 431 6V 451 Inverter P.C. board for MCC-1595 ASM-PCB (A3IPDU) MMY-MAP0724HT6UL Compressor MMY-MAP0964HT6UL MMY-MAP1144HT6UL 431 6V 452 Inverter P.C. board for fan MCC-1610 ASM-PCB (FANIPDU) 431 6V 453 Noise filter P.C. board...

  • Page 222: Interface Board Replacement Procedure

    Description Applicable model P.C. board type code Product code 431 6V 450 Interface P.C. Board MMY-MAP0724HT6UL MCC-1606 ASM-PCB (I/F) MMY-MAP0964HT6UL MMY-MAP1144HT6UL This Interface board is commonly installed in different models before shipment. When the board assembly is to be replaced, check the displayed inspection contents below and replace the board in accordance with the model, following the below procedure.

  • Page 223: Inverter P.c. Board For Compressor Replacement Procedure

    ) by pinching the top of the spacers by round-nose pliers or cutting the top of the spacers by nippers. Pinch this part by Compressor IPDU round-nose pliers White wire Ex. MMY-MAP0724HT6UL Spacer for removing the PCB. (B) DB01 (-) Black wire Fixation screw Spacer...
  • Page 224 (7) Set the dip switch (SW800) setting of the service board to match the switch setting from the original PCB. - Set the dip switch (SW800) depending on the position of the IPDU within the electrical control box, as shown in the following diagram. MMY-MAP0724HT6UL MMY-MAP0964HT6UL MMY-MAP1144HT6UL...

  • Page 225: Fan Ipdu P.c. Board (Mcc-1610) Replacement Procedure

    Description Applicable model P.C. board type code Product code 431 6V 452 Inverter P.C. board for MMY-MAP0724HT6UL MCC-1610 ASM-PCB (FANIPDU) MMY-MAP0964HT6UL MMY-MAP1144HT6UL Replacement steps: (1) Turn off the power supply of the outdoor unit and allow at least one minute for the capacitor to discharge.

  • Page 226: Noise Filter P.c. Board (Mcc-1625 A, B, C) Replacement Procedure

    Description Applicable model P.C. board type code Product code 431 6V 497 Noise filter P.C. board MMY-MAP0724HT6UL MCC-1625-A, B, C ASM-PCB (N/F) MMY-MAP0964HT6UL MMY-MAP1144HT6UL <1. Preparation (model selection)> All P.C. boards of this type leave the factory with default settings that are common to all applicable models. When replacing a P.C.
  • Page 227 (3) Disconnect all the connectors and fast-on terminals used to connect wiring to the noise filter P.C. board. • The line filter ( ) and its leads, both connected to the screw-on terminals ( ) of the noise filter P.C. board (A) will be removed in step 6.
  • Page 228 (7) Install the service P.C. boards (A), (B) and (C) in the outdoor unit controller. (Make sure that they are firmly secured to the card edge spacers ( (8) Securely connect the service P.C. boards to the chassis using the earthing screws ( ), ( ) removed in step 4.

  • Page 229: Exploded Diagram / Parts Price List

    Exploded Diagram / Parts Price List SMMS-i OUTDOOR UNIT MMY-MAP0724HT6UL...
  • Page 230 MMY-MAP0724HT6UL...
  • Page 231 REFRIGERATION CIRCUIT DIAGRAM (MMY-MAP0724HT6UL) MOTOR FAN CONDENSER RIGHT SIDE CONDENSER LEFT SIDE REDUCER VALVE 4WAY PULSE MOTOR VALVE 2 PULSE MOTOR VALVE 1 LOW PRESSURE HIGH PRESSURE SENSOR SENSOR PLUG SEPARATOR FUSIBLE HIGH PRESSURE TANK LIQUID SWITCH ACCUMULATOR COMPRESSOR 2...
  • Page 232 SMMS-i OUTDOOR UNIT MMY-MAP0964HT6UL, MMY-MAP1144HT6UL...
  • Page 233 MMY-MAP0964HT6UL, MMY-MAP1144HT6UL...
  • Page 234 REFRIGERATION CIRCUIT DIAGRAM (MMY-MAP0964HT6UL, MMY-MAP1144HT6UL) MOTOR FAN PULSE MOTOR CONDENSER VALVE 1 RIGHT SIDE PULSE MOTOR VALVE 2 CONDENSER LEFT SIDE PULSE MOTOR VALVE 4 VALVE 4WAY HIGH PRESSURE SENSOR LOW PRESSURE SENSOR SEPARATOR HIGH PRESSURE SWITCH PLUG FUSIBLE ACCUMULATOR HIGH PRESSURE SWITCH TANK LIQUID...
  • Page 235 VALVE, CHECKED 43146676 JOINT, CHECK 43149317 RUBBER, SUPPORTER, PIPE 43149338 RUBBER, SUPPORTER, PIPE 43149318 RUBBER, SUPPORTER, PIPE 43149319 RUBBER, SUPPORTER, PIPE 43149339 RUBBER, SUPPORTER, PIPE 43149358 RUBBER, SOPPORTER, PIPE 43149320 RUBBER, SUPPORTER, PIPE 43149321 RUBBER, SUPPORTER, PIPE 4311M671 MARK, TOSHIBA CARRIER...
  • Page 236 MMY-MAP Ref. No. Part No. Description 0724HT6UL 0964HT6UL 1144HT6UL 43163063 HOLDER, SENSOR, TO 4310A016 CABINET, SIDE, UP 43149391 SENSOR ASSY, HIGH PRESSURE 43149392 SENSOR ASSY, LOW PRESSURE 43100481 CABINET ASSY, SIDE, LEFT 43100482 CABINET ASSY, SIDE, RIGHT 43100483 CABINET ASSY, FRONT, DOWN 43100484 CABINET ASSY, BACK, DOWN 43100485...
  • Page 237 SMMS-i INV SERVICE PARTS LIST MMY-MAP0724HT6UL...
  • Page 238 SMMS-i INV SERVICE PARTS LIST MMY-MAP0964HT6UL, MMY-MAP1144HT6UL...
  • Page 239 MMY-MAP Ref. No. Part No. Description 0724HT6UL 0964HT6UL 1144HT6UL 43050425 SENSOR ASSY, SERVICE 43F63248 SUPPORTER, ASSY 43150315 SENSOR,TD (F6) 43160623 TERMINAL BLOCK, 3P, 100A 43158228 REACTOR 43160621 TERMINAL, 6P 43152520 CONTACTOR, MAGNETIC 43160583 TERMINAL, 6P 43F69524 SUPPORT, SPACER 43182011 SPACER (EDGE) 4316V497 PC BOARD ASSY, NOISE FILTER, MCC-1625 4316V450...
  • Page 240 WARNINGS ON REFRIGERANT LEAKAGE Check of Concentration Limit Important The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas NOTE 2 : leaking out, its concentration will not exceed a set limit. The standards for minimum room volume are as The refrigerant R410A which is used in the air conditioner is follows.
  • Page 241 Copyright © 2011 TOSHIBA CARRIER CORPORATION, ALL Rights Reserved.

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