Toshiba HFC R407C User manual

Modular Multi System
Service Manual
Air Conditioner - Multi Split Type System
A90-0132
HFCR407C

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Contents
Introduction ......................................................................................................................... 5
Summary ............................................................................................................................. 8
Outline of MMS (Modular Multi System) ............................................................................ 10
Parts Specifications........................................................................................................... 12
Construction Views – Outdoor Units ................................................................................. 21
Construction Views – Indoor Units .................................................................................... 22
Wiring Diagrams ................................................................................................................ 31
Refrigerant Piping Systematic Drawings ........................................................................... 44
Combined Refrigerant Piping Systematic Drawings.......................................................... 49
Refrigerant Cycle Schematic – Indoor Units ..................................................................... 53
Outline of Control ..............................................................................................................54
Self Diagnostic Display Information................................................................................... 67
Control Circuit Configuration ............................................................................................. 71
Troubleshooting ................................................................................................................ 76
Back-up Operation .......................................................................................................... 122
Forced Function of Oil Level Detection ........................................................................... 126
Refrigerant Pipe Installation ............................................................................................ 127
Trial Operation ................................................................................................................ 132
Replacing the Compressor .............................................................................................. 145
Exploded Views and Service Parts ................................................................................. 156
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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.
These units comply with 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*.
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.
* 97/23/EC Pressure Equipment Directive information
Conformity assessment procedure: Module D1
Pressure equipment:
Compressor, category II, Module A1
Accumulator, category I
Liquid receiver, category II
High pressure switch, category II, Module A1
Notified body for inspection and quality assurance systems: BSI, Maylands Avenue, Hemel Hempstead, WP2 4SQ, UK.
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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 70°C.
Position of
fusible plug
System pressure measurement
To measure the system’s high and low pressures, connect a gauge manifold to the corresponding access port as indicated
below.
Low pressure
access port
High pressure
access port
Explanation of Toshiba serial number
A serial label is attached to all Toshiba air conditioning units. Located on the label is an 8-digit number, which represents the
month, year and batch number of the manufactured unit. A breakdown of the 8-digit number is defined below.
24480001
}
 
Year of
manufacture
2001 = 1
2002 = 2
2003 = 3
Site of
manufacture
8 = Plymouth
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.
Model batch serial number
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7
Introduction
Components
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1. Outdoor unit
Corresponding HP Inverter unit Fixed-speed unit
8 HP 10 HP 6 HP 8 HP 10 HP
Model name MM-A0224HT MM-A0280HT MM-A0160HX MM-A0224HX MM-A0280HX
Cooling capacity (kW) 22.4 28.0 16.0 22.4 28.0
Heating capacity (kW) 25.0 31.5 18.0 25.0 31.5
Corresponding HP Inverter unit Fixed-speed unit
8 HP 10 HP 6 HP 8 HP 10 HP
Model name MM-A0224CT MM-A0280CT MM-A0160CX MM-A0224CX MM-A0280CX
Cooling capacity (kW) 22.4 28.0 16.0 22.4 28.0
2. Outdoor units (combination of outdoor units)
Corresponding HP 8HP 10HP 14HP 16HP 18HP 20HP 22HP 24HP 26HP 28HP 30HP 32HP 34HP 36HP 38HP 40HP 42HP 44HP 46HP
Combined model
MM-A-HT/MM-A-CT 0224 0280 0384 0440 0504 0560 0608 0672 0728 0784 0840 0896 0952 1008 1064 1120 1176 1232 1288
Cooling capacity (kW) 22.4 28.0 38.4 44.8 50.4 56.0 60.8 67.2 72.8 78.4 84.0 89.6 95.2 100.8 106.4 112.0 117.6 123.2 128.8
Inverter unit 8HP 10HP 8HP 8HP 10HP 10HP 8HP 8HP 10HP 10HP 10HP 8HP 10HP 10HP 10HP 10HP 10HP 10HP 10HP
Combined Fixed-speed - - 6HP 8HP 8HP 10HP 8HP 8HP 8HP 10HP 10HP 8HP 8HP 10HP 10HP 10HP 8HP 10HP 10HP
outdoor units unit - -----6HP8HP8HP8HP10HP 8HP 8HP 8HP 10HP 10HP 8HP 8HP 10HP
-----------8HP8HP8HP8HP10HP 8HP 8HP 8HP
----------------8HP8HP8HP
No. of connectable
indoor units 13 16 16 18 18 20 22 24 26 28 30 32 34 36 38 40 40 40 40
Min. HP connected 4 57891011121314151617181920212223
Max. HP connected 10.8 13.5 18.9 21.6 24.3 27 29.7 32.4 35.1 37.8 40.5 43.2 45.9 48.6 51.3 54 56.7 59.4 62.1
3. Branching joints/headers
Model name Usage Appearance
Y-shape branching joint RBM-Y018-SK Indoor unit capacity code (*1): Total < 6.4
RBM-Y037-SK Indoor unit capacity code (*1): 6.4 = Total < 13.2 (*2)
RBM-Y071-SK Indoor unit capacity code (*1): 13.2 = Total < 25.2 (*2)
RBM-Y129-SK Indoor unit capacity code (*1): 25.2 = Total (*2)
4-branching header (*3) RBM-H4037-SK Indoor unit capacity code (*1): Total < 6.4 Max. 4
RBM-H4071-SK Indoor unit capacity code (*1): 6.4 = Total < 13.2 branches
8-branching header (*3) RBM-H8037-SK Indoor unit capacity code (*1): Total < 6.4 Max. 8
RBM-H8071-SK Indoor unit capacity code (*1): 6.4 = Total < 13.2 branches
T-shape branching joint 1 set of 3 types of T-shape joint pipes as described below.
(For connection of The required quantity is arranged and they are combined at the site.
outdoor unit) RBM-T129-SK
Connecting pipe Corresponding dia. (mm) Quantity
Balancing pipe 9.52 1
Piping at liquid side 12.7 to 22.2 1
Piping at gas side 22.2 to 54.1 1
(*1) Code is determined according to the capacity code of the Indoor units connected.
(*2) If the total capacity code value of Indoor units exceeds that of Outdoor units, apply the capacity code of Outdoor units.
(*3) When using a branch header, Indoor units with a maximum of 6.0 capacity code in total can be connected to each
branch.
NOTE: If the length of the gas pipe exceeds 30m from the 1st branching to an Indoor unit, increase the gas pipe size by
1 size, i.e. MM-U140 = Gas Ø22.2, Liquid Ø9.5

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Summary
Operating conditions
• The units referred to within this manual conform with the protection requirements of Directives 89/336/EEC
Electromagnetic Compatibility and 73/23/EEC Low voltage.
• Operating conditions of the unit are as follows:
Outdoor temperature -5 ~ 43°C Cooling
-15 ~ 21°C Heating
Room temperature 18 ~ 32°C Cooling
15 ~ 29°C Heating
Room humidity <80% Cooling
Note 1: Cooling capacity is rated at the following temperature conditions:
Indoor air inlet temperature 27°C DB, 19°C WB.
Outdoor air inlet temperature 35°C DB.
Note 2: Heating capacity is rated at the following temperature conditions:
Indoor air inlet temperature 20°C DB.
Outdoor air inlet temperature 7°C DB, 6°C 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) 6.4 9.5 12.7 15.9 19.0 2.0 28.6 34.9 41.3 54.1
Nominal diameter (inch) 1/4 3/8 1/2 5/8 3/4 7/8 1-1/8 1-3/8 1-5/8 2-1/8
Note 8: Within this manual:
ODU = Outdoor Unit IDU = Indoor Unit
R/C = Remote Controller D.O.L. = Direct On-Line compressor
INV = Inverter ODU FIX = Fixed-speed ODU
DB = Dry Bulb WB = Wet Bulb
Mg-Sw = Magnetic Contactor IOL = Inner Overload Relay
OCR = Over Current Relay IGBT = Inverter Gate Bi-Polar Transistor
Note 9: MPaG ⇒kgf/cm2G conversion multiplier
1.0 MPaG = 10.2 kgf/cm2G
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2
Summary
Operating conditions
1. Model name
OUTDOOR
MM-A0280HT
A – Outdoor 0280 – 28 kW (10 HP) C - Cooling T – Inverter
0224 – 22.4 kW (8 HP H - Heating X – Fixed-speed
0160 – 16.0 kW (6 HP)
INDOOR
MM-TU056
B - Built-In Duct Type
C (CR) - Ceiling Type (IR Remote) 028 – 2.8 kW (1 HP)
K (KR) - High Wall Type (IR Remote) 042 – 4.2 kW (1.5 HP)
N - Chassis Type 056 – 5.6 kW (2 HP)
S (SR) - Low Wall Type (IR Remote) 080 – 8.0 kW (3 HP)
SB - Built-In Slim Duct Type 112 – 12.2 kW (4 HP)
TU - 2-way Cassette Type 140 – 14.0 kW (5 HP)
U - 4-way Cassette Type
Modular Multi
Modular Multi
2. Range of combined units
No. of combined units : 1 to 5 units
Capacity range : Equivalent to 38.4 kW type (14HP) to 128.8 kW (46HP)
3. Restriction for combination units
(1) The Inverter Unit should have the maximum capacity among all units in that combination.
(2) The 16.0 kW (6HP) fixed-speed unit is available only with the combination of 38.4 kW (14HP) and 60.8 kW
(22HP). (It cannot be used for any other combination.)
4. Mode priority
This Outdoor Unit is set to operate with the Heating mode taking precedence. This precedence can be switched
between Heat and Cool mode using the DIP switch 07 on the Outdoor Unit Interface PCB (MCC-1343-01) as follows:
Heat priority (factory set) Cool priority
ON
OFF
ON
OFF

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Outline of MMS (Modular Multi System)
• Branching
Combination of line and header branching is highly flexible. This allows for the
shortest design route possible, thereby saving on installation time and cost.
Line/header branching after header branching is only available with Toshiba’s
Multi Modular System.
Linebranching
Outdoor unit
Branching joint
Indoor unit
Headerbranching
Outdoor unit
Branching
header
Indoor unit
Line and header branching
Outdoor unit
Branching joint
Indoor unit
Line branching after header branching
Outdoor unit
Branching joint
Indoor unit
MMS
ONLY
Outdoor unit
Header
Header
Indoor unit
MMS
ONLY
1F
7F
8F
2F
3
Header
Header