Page 1 FILE NO. A10-1421 Revision1: Oct. 2015 SERVICE MANUAL AIR-CONDITIONER (MULTI TYPE) Model name: MCY-MHP0305HT-C/0405HT-C/0505HT-C MCY-MHP0305HT/0405HT MCY-MHP0305HT-ID/0405HT-ID MCY-MHP0305HT-CF/0405HT-CF/0505HT-CF This service manual provides relevant explanations about new outdoor unit. Please refer to the following service manuals for each indoor units. Service contents Service parts <4-way Cassette Type>...
Page 2: Table Of Contents
Contents Precautions for safety ..........5 1 Product summary .
Page 3 8-4-2. Address setup and check procedure ........45 8-4-3.
Page 4 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.
Page 5 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 ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing.
Page 6: 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 7 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 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 8 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 9 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 10 Only a qualified installer or qualified service person 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 11 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 12 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 13: Product Summary
Product summary 1-1. Outdoor unit Corresponding HP Power supply Single phase MCY-MHP0305HT-C MCY-MHP0405HT-C MCY-MHP0505HT-C MCY-MHP0305HT-CF MCY-MHP0405HT-CF MCY-MHP0505HT-CF 220V 50Hz Single phase Model 220-240V (50Hz) MCY-MHP0305HT MCY-MHP0405HT name 220V (60Hz) Single phase MCY-MHP0305HT-ID MCY-MHP0405HT-ID 220-240V (50Hz) Cooling capacity (kW) * 11.2 13.5...
Page 14: Branching Joints And Headers
1-3. Branching joints and headers Model name Appearance i o j RBM-BY55E 1-4. PMV kit Model type Indoor unit capacity type Appearance 005 to 014 type 015 to 027 type...
Page 15: Construction Views
Construction views...
Page 16: Wiring Diagram
Wiring diagram...
Page 17: Parts Rating
Parts rating 4-1. Outdoor unit DA270A2T-21TD Output: 2.72kW 4-way valve coil STF-H01AJ1736A1 AC220-240Ｖ, 50/60Hz FQ-G593 AC220-240Ｖ, 50/60Hz SV2, SV4 valve coil l i o PQ-M10012-000230 DC12V AAG-M35YLTF-1 DC5V 0-3.73MPa Pressure sensor (For high pressure) AAG-L25YLTF-1 DC5V 0-0.98MPa Pressure sensor (For low pressure) High-pressure SW ACB-4UB32W OFF:3.73MPa ON:2.9MPa...
Page 18: Parts Layout In Outdoor Unit
4-3. Parts layout in outdoor unit...
Page 19: Parts Layout In Inverter Assembly
4-4. Parts layout in inverter assembly...
Page 20: Outdoor (Inverter) Print Circuit Board
4-5. Outdoor (inverter) print circuit board 4-5-1. Interface P.C. board (MCC-1639) Option input/output Jamper select CN508 CN510 CN513 CN511 CN509 CN512 SW 04,05,15 7-segment LED SW 06,07,09,10 SW 01,02,03 SW 11,12,13,14 PS sensor CN500 SW 16,17 PD sensor CN501 PMV 1 output CN300 Sensor input TL CN523 TS CN505 TE CN520 TD CN502 TO CN507...
Page 21: Inverter P.c. Board For Compressor (Mcc-1655) Ipdu
4-5-2. Inverter P.C. board for compressor (MCC-1655) IPDU Reactor connection connector (White) Power supply output CN01(Red) CN01(Red) Lead wire for ground Lead wire for ground P03(Gray) P03(Gray) Compressor output White Power supply connection lead wire P01(Black) P02(White) UART Fan motor output communication CN300(White) CN852(White)
Page 22: Refrigerant Piping Systematic Drawing
Refrigerant piping systematic drawing Outdoor unit Sensor (TO) Heat exchanger Sensor (TE) 4-Way valve Sensor (TS) Solenoid valve (SV4) Strainer Check joint Solenoid High pressure Check joint valve sensor (SV2) High pressure Low pressure Capillary sensor tube Strainer Muffler Sensor (TD) Accumulator Compressor Sensor (TL)
Page 23 Explanation of functional parts Functional part na (Hot gas bypass) (Connector CN311 : White) 1) Low pressure release function 2) High pressure release function 3) Gas balance function during stop time 4) Hot gas bypass into accumulator Solenoid valve (Start compensation valve of compressor) (Connector CN312: Red) 1) For gas balance start 2) High pressure release function...
Page 24: Control Outline
Control outline Outdoor unit Item Description of operation, numerical data, and other information Remarks 1. Pulse PMV1 control motor valve 1) During air conditioner operation, the pulse count of a PMV (pulse motor valve) is (PMV) controlled between 30 and 500. control 2) During cooling, the PMV opening is controlled on the basis of measurements provided by the TL temperature sensor and the Pd pressure sensor (under cool...
Page 25 Item Description of operation, numerical data, and other information Remarks 2. Outdoor 2. Heating fan control fan control 1) Outdoor fan speed (mode) is controlled on the basis of measurements provided by (continued) the TE temperature sensor. 2) If TE > 25 °C is continuously detected for 5 minutes, the operation may stop. 3) For a specified period after air conditioner startup and during defrosting, this control is disabled.
Page 26 Item Description of operation, numerical data, and other information Remarks 1. SV2 gas balance control 6. Release This control function is aimed at achieving gas balance by opening SV2 while valve control compressors are turned off so as to reduce their startup load the next time they are turned on.
Page 27 Item Description of operation, numerical data, and other information Remarks 7. Frequency High pressure release control release This function is to correct the operation command of the compressor and suppress the control rise of high pressure. 1) Control contents The operation frequency is decreased by 1 step when Pd pressure 3.4 MPa.
Page 28 Item Description of operation, numerical data, and other information Remarks 8. IPDU 2. Heat sink temperature detection control IPDU is provided with a TH sensor. control 1) This control performs the IGBT overheat protection by the detection of the TH (continued) sensor in Module IC200 for compressor driven in IPDU.
Page 29 <Other points to note> Cooling operation under low outside temperature conditions 1) If pressure falls to extremely low levels, indoor units may be shut down via freeze prevention control based on the indoor TC sensor. 2) If pressure falls to extremely low levels, frequency may be reduced via cooling capacity control. 3) When the discharge temperature sensor reading falls below 60 °C, the frequency may be increased above the level called for by the command received from the indoor unit.
Page 30: Applied Control For Outdoor Unit
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 31 (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 32: Applied Control Of Outdoor Unit
7-3. Applied control of outdoor unit 7-3-1. Optional P.C. board of outdoor unit installation Placing position Install the optional P.C. boards on top of the interface P.C. board in the outdoor unit. Be sure to turn off the power switch before installing. (1) Holes for installing supports are provided on the top of the interface P.C.
Page 33 Optional control P.C. boards provide access to a range of functions as listed below. Control P.C. board to be used Outdoor unit interface P.C. board setting* Jumper to be PCDM4E PCMO4E PCIN4E Connector No. DIP SW No. removed Power peak-cut control (Standard) –...
Page 34: Power Peak-Cut Control (Standard)
7-3-2. Power peak-cut control (standard) L1: Display lamp suring power peak cut control Outdoor unit Locally procured Optional PCB Power Display Outdoor unit supply interface PCB relay [OPERATION] Shield wire PJ17 CN513 SW07 [ON] [OFF] Bit 2 OFF Shield Connection cable wire For SW1 and SW2, be sure to provide no- voltage contacts for each terminal.
Page 35: Power Peak-Cut Control (Extended)
<SW07 Bit 2 OFF (two-step control)> Power peak-cut control is enabled as long as SW1, as shown on the wiring diagram, is ON (continuously). Jumper wire Input 0 % (forced stop) 60 % capacity (upper limit regulated) 100 % (normal operation) 100 % (normal operation) Note 1: Specifications of display relay contact •...
Page 36: Snowfall Fan Control
7-3-4. Snowfall fan control Outdoor unit Locally procured Connection Outdoor unit Optional PCB cable Snowfall sensor interface PCB COOL Shield HEAT 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...
Page 37: Night Operation (Sound Reduction) Control
7-3-6. Night operation (sound reduction) control Outdoor unit Locally procured Connection Outdoor unit Optional PCB cable interface PCB COOL HEAT Shield wire SW1: Night time signal switch Operation This function decreases noise at night or other times as necessary. Terminal Input signal Operation Night time control...
Page 38: Operation Mode Selection Control
7-3-7. Operation mode selection control Outdoor unit Locally procured Connection Outdoor unit Optional PCB cable interface PCB COOL HEAT Shield wire SW1: Cooling mode specified input switch SW2: Heating mode specified input switch NOTE SW1: COOL mode selection switch SW2: HEAT mode selection switch Input signal Operation Remarks...
Page 39: Error / Operation Output
7-3-8. Error / Operation output Locally procured Outdoor unit (See “NOTE”) Outdoor unit Optional PCB interface PCB OUTPUT1 SW16 OUTPUT2 OUTPUT3 Shield wire Operation In-operation output: An in-operation indication signal is output as long as at least one indoor unit is in operation in the line.
Page 40: 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.” Check basic items, mainly the installation work. Checks before test operation Be sure to enter the check results in 8-2．...
Page 41: Check Items Before Test Operation (Before Powering-On)
8-2. Check items before test operation (before powering-on) Prior to the test operation, check the following items to verify there are no problems with the installation work. Main check items for electric wiring The communication system differs from that of R22 or R407 refrigerant “Modular Multi system” air conditioners. Check wiring points again carefully.
Page 42 (2) In the case that a central control system is connected (before address setup) Central remote controller (1) (2) To other refrigerant line Other refrigerant line SW13 SW14 CN10 SW13 SW14 Outdoor unit CN10 CN02 SW30 CN02 SW30 To indoor unit Indoor unit Remote Remote...
Page 43 Checklist 1 Using Checklist 1, check that there are no problems with the installation work. Is the capacity of the circuit breaker Outdoor unit Indoor unit (Earth leakage breaker) appropriate? Is the gauge of the Outdoor unit Indoor unit power cable correct? n i l Central control system connection terminals (U3, U4) Is the power of indoor units supplied collectively?
Page 44 Checklist 2 Calculate the additional amount of refrigerant from the following: Additional refrigerant Corrective amount of Additional refrigerant Compensation by Real length of liquid charge amount per 1 m refrigerant depending charge amount at local outdoor HP pipe liquid pipe on the indoor units site (Table 3)
Page 45: 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 46: 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 P.C.
Page 47: Address Setup Procedure
8-4-3. Address setup procedure (Single refrigerant line): ress setting procedure 1 Central control of 2 or more refrigerant lines: go to Address setting procedure 2 When controlling a single refrigerant line When controlling 2 or more refrigerant lines (Example) centrally centrally Address setting procedure...
Page 48 (Example) Controlling 2 or more refrigerant lines as a group Outdoor Outdoor System wiring diagram Indoor Indoor Indoor Indoor (Group control) Remote controller Address setting procedure 2 Set a line address for each system using SW 13 and 14 on the interface P.C. board on the outdoor unit of each system.
Page 49 Be sure to disconnect the relay connectors CN10 which mounted interface P.C. board from CN02, on all the outdoor unit that will be connected to the central control. CN02 CN10 Communication terminal board Turn on indoor units first, and then turn on outdoor unit. About 1 minute after turning the power on, confirm that the 7-segment display on the interface U.
Page 50 Set the central control address. (For the setting of the central control address, refer to the installation manuals of the central control devices.) Outdoor unit interface P.C. board 7-segment display SW30 * Outdoor units are connected to the same central control, except the outdoor unit with the smallest line address number.
Page 51 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 Outdoor unit Outdoor unit Outdoor unit Factory default interface P.C. board SW13, 14 (Line (system) address) Dip switch 2 of SW30 (Terminator of indoor /...
Page 52 Manual address setting with the remote controller Procedure when setting indoor units’ addresses first under the condition that indoor wiring has been completed and outdoor wiring has not been started (manual setting using the remote controller) Wiring example of 2 refrigerant lines Refrigerant line 2 Refrigerant line 1 Outdoor...
Page 53 <Line (system) address> Push the TEMP. buttons repeatedly to set the CODE No. to Push the TIME buttons repeatedly to set a line address. (Match the address with the address on the interface P.C. board of the outdoor unit in the same refrigerant line.) Push button.
Page 54 Confirming the indoor unit addresses and the position of an indoor unit using the remote controller Confirming the numbers and positions of indoor units To see the indoor unit address of an indoor unit which you know the position of When the unit is individual (the indoor unit is paired with a wired remote controller one-to-one), or it is a group-controlled one.
Page 55 (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. Push and hold the buttons at the same time for more than 4 seconds. •...
Page 56 To select another line address Push the button to return to step • After returning to step , select another line address and check the indoor unit addresses of the line. Push the button to finish the procedure. Changing the indoor unit address using a remote controller To change an indoor unit address using a wired remote controller.
Page 57 To change all the indoor unit addresses using an arbitrary wired remote controller. (The method is available when the addresses have already been set automatically.) (When communication wirings of 2 or more refrigerant lines are interconnected for central control) NOTE You can change the addresses of indoor units in each refrigerant line using an arbitrary wired remote controller.
Page 58 Push the TIME buttons repeatedly to change the value of the indoor unit address in SET DATA. Change the value in SET DATA to that of a new address. Push the button to confirm the new address on SET DATA. Push the button (left side of the button) repeatedly to select another address to change.
Page 59 Turn on the indoor and outdoor units of the refrigerant line for which you want to initialize the addresses. About one minute after turning on the power, confirm that the 7-segment display on the outdoor unit indicates “U.1. - - -” and operate the interface P.C. board on the outdoor unit of the refrigerant line as follows.
Page 60 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 P.C. board, etc., follow the methods below. Method 1 Set up an address individually from a wired remote controller.
Page 61: 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 controller To other refrigerant line Outdoor unit Other refrigerant line Outdoor unit Outdoor unit SW13 SW14...
Page 62: 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 controller is not accepted when powered- on after wiring work or during address setup operation, the following causes are considered. 8-5-1.
Page 63: Operation From The Indoor Remote Controller Is Not Accepted, And A Check Code Is Displayed On The 7-Segment Display Of The Interface P.c. Board Of The Outdoor Unit
8-5-2. Operation from the indoor remote controller is not accepted, and a check code is displayed on the 7-segment display of the interface P.C. board of the outdoor unit. Outdoor Indoor remote unit 7- controller Cause Countermeasures segment status display Line addresses and indoor addresses of all the connected Set up addresses.
Page 64: Outdoor / Indoor Units That Do Not Operate In A Test Operation.)
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 indoor units After modification of wiring, set up the addresses again and...
Page 65: 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 controller. When a check code has been displayed on the remote controller, remove the cause of the error, referring to "Check code and check position displayed on Check code remote controller and outdoor unit."...
Page 66: Cooling / Heating Test Operation Check
8-6-2. Cooling / Heating test operation check The cooling / heating test operation check can be performed on both the indoor remote controller and the outdoor unit interface P.C. board. (1) Test operation start / stop operation Test operation from the indoor remote controller •...
Page 67 Wireless remote controller (4-way Cassette Wireless remote controller (Ceiling type and type) 1-way Cassette SH type) Procedure Operation content Procedure Operation content Start When Temporary button is pushed for 10 seconds or more, “Pi!” sound is heard and Push Temporary operation button. the operation changes to a forced cooling •...
Page 68 (2) Test operation START Refer to "Test operation procedure" Test operation for one indoor unit of the indoor remote controller. The operation does not start for approximately 3 minutes after Operation starts powering-on or stopping operation. Note: After powering-on, it may require up to 10 minutes to start the operation due to the initial communications of the system.
Page 69 Note 1: Criteria for the difference between suction and discharge temperatures (1) Cooling operation After operating for a minimum of 30 minutes in “COOL” mode, if the T dry bulb temperature difference between suction and discharge air of the indoor unit is 8 °C or more, it is normal. (2) Heating operation After operating for a minimum of 30 minutes in “HEAT”...
Page 70: 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 outdoor unit. However, be sure to check the following items prior to executing this check function.
Page 71 Operation start (7-segment display) Press the push-switch SW04 on the interface P.C. board of the outdoor unit for 2 seconds or more. The operation starts. Cooling Operation Check that 7-segment display [B] shows [CC] for Heating cooling and [ HH] for heating. Confirmation of check results (1) (7-segment display) This check operation...
Page 72: 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 outdoor unit. Cooling test Changes the mode of all the [Setup] Section A Section B...
Page 73 (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 outdoor unit. <Operation procedure>...
Page 74 (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 outdoor unit. <Operation procedure>...
Page 75 (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 outdoor unit. <Operation procedure> Be sure to turn on the power at indoor Power ON side before power-ON of outdoor unit.
Page 76 (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 outdoor unit. Set SW01 [16] and set SW02, SW03 to indoor address No.
Page 77: Error Clearing Function
8-7-3. Error clearing function (1)Clearing from the main remote controller ▼ Error clearing in outdoor unit Error of the outdoor unit currently detected is cleared by the unit of one refrigerant circuit system to which the indoor units operated by the remote controller is connected. (Error of the indoor unit is not cleared.) For clearing errors, the service monitor function of the remote controller is used.
Page 78 (2)Clearing error by using switches on the interface board of the outdoor unit Using the switches on the interface P.C. board of the outdoor 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 79: Remote Controller Distinction Function
8-7-4. Remote controller distinction function This function is provided to distinguish the remote controller connected to the indoor unit from the outdoor unit for a refrigerant circuit system by using switches on the interface P.C. board of the outdoor unit. <Distinction procedure>...
Page 80: 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 outdoor unit. This function is also used to open PMV fully when turning off the power and executing an operation.
Page 81: 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 82: 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 83: Manual Adjustment Function Of Outside Temperature (To) Sensor
8-7-9. 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 84 <Service support function list> SW01 SW02 SW03 7-segment di Refrigerant circuit and control communication line check function (Cooling [J . C] operation) Refrigerant circuit and control communication line check function (Heating operation) l l u l l o n i l e l l v i t .
Page 85: Monitor Function Of Remote Controller Switch
8-7-10. Monitor function of remote controller switch When using a remote controller with the model name RBC-AMT32E, the following monitor functions can be used. Calling of display screen <Content> The sensor temperature or operation status of the remote controller, indoor unit, or the outdoor unit can be known by calling up the service monitor mode from the remote controller.
Page 86: Troubleshooting
Troubleshooting 9-1. Overview (1) Before engaging in troubleshooting (a) Applicable models Indoor units: MMO-APOOO, Outdoor units: MCY-MHPOOO5 (b) Tools and measuring devices required Screwdrivers (Philips, flat head), spanners, long-nose pliers, nipper, pin to push reset switch, etc. Multimeter, thermometer, pressure gauge, etc. (c) Things to check prior to troubleshooting (behaviors listed below are normal) A compressor would not start Could it just be the 3-minute delay period (3 minutes after compressor...
Page 87: Troubleshooting Method
9-2. Troubleshooting method The remote controllers (main remote controller and central control remote controller) and the interface P.C. board of an outdoor unit are provided with an LCD display (remote controller) or a 7-segment display (outdoor interface P.C. board) to display operational status. Using this self-diagnosis feature, the fault site / faulty part may be identified in the event of a fault by following the method described below.
Page 88 (Error detected by main remote controller) Check code Display of receiving unit Outdoor 7-segment display Indicator light block Main Typical fault site Description of error remote Operation Timer Ready Sub-code controller Flash No master remote controller, faulty Signals cannot be received from indoor unit; master –...
Page 89 List of Check Codes (Outdoor Unit) IPDU: Intelligent Power Drive Unit (Inverter P.C. board) : Lighting, : Flashing, : Goes off (Errors detected by 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 Outdoor 7-segment display...
Page 90 Check code Display of receiving unit Outdoor 7-segment display Indicator light block TCC-LINK Typical fault site Description of error central control or main remote Operation Timer Ready Sub-code Flash controller display Outdoor EEPROM is faulty (alarm and shutdown – for outdoor unit and continued operation for follower unit).
Page 91 (Errors detected by IPDU featuring in outdoor unit - typical examples) Check code Display of receiving unit Outdoor 7-segment display TCC-LINK Indicator light block central control Typical fault site Description of error or main remote Operation Timer Ready Sub-code controller Flash display Error in temperature...
Page 92: Troubleshooting Based On Information Displayed On Remote Controller
9-3. Troubleshooting based on information displayed on remote controller Using main remote controller (RBC-AMT32E) (1) Checking and testing When a fault occurs to an air conditioner, a check code and indoor unit No. are displayed on the display window of the remote controller. Check codes are only displayed while the air conditioner is in operation.
Page 93 Using TCC-LINK central control remote controller (TCB-SC642TLE2) (1) Checking and testing Display of Unit No. Display of check code When a fault occurs to an air conditioner, a check code and indoor unit No. are displayed on the display window of the remote controller. Check codes are only displayed while the air Alternate blinking conditioner is in operation.
Page 94 Using indoor unit indicators (receiving unit light block) (wireless type) To identify the check code, check the 7-segment display on the outdoor 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 95 Discharge temperature sensor (TD) error Operation Timer Ready Heat exchanger temperature sensor (TE) error Liquid temperature sensor (TL) error Outdoor unit temperature sensor errors Outside air temperature sensor (TO) error Alternate blinking Suction temperature sensor (TS) error Heat sink sensor (TH) error Wiring error in heat exchanger sensor (TE) and liquid temperature sensor (TL) Outdoor unit temperature sensor wiring / installation error Wiring error in outdoor high pressure sensor (Pd) and low pressure sensor (Ps)
Page 96: Check Codes Displayed On Remote Controller And Outdoor Unit (7-Segment Display On I/F Board) And Locations To Be Checked
9-4. Check codes displayed on remote controller and 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 Error detection Description System status Check items (locations)
Page 97 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Remote Duplicated Stop of In two remote controller Check remote controller controller master remote corresponding configuration (including settings. controller unit wireless), both controllers are...
Page 98 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Indoor Indoor TCJ Stop of Sensor resistance is infinity • Check connection of TCJ unit sensor error corresponding or zero (open / short circuit).
Page 99 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code IPDU TH sensor error All stop Sensor resistance is zero Defect in IGBT built-in (short circuit). temperature sensor –...
Page 100 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code IPDU Current All stop Current flow of at least Check current detection detection circuit specified magnitude is circuit wiring. –...
Page 101 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Indoor Connection of Stop of There is at least one stand- Check indoor addresses. unit group control corresponding alone indoor unit to which –...
Page 102 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code...
Page 103 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code Inverter DC All stop Inverter DC voltage is too Check for defect in outdoor voltage (Vdc) high (overvoltage) or too P.C.
Page 104 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code 01: TS All stop Protective shutdown due to Check for insufficiency in condition leakdetection sustained suction refrigerant quantity. (TS condition) temperature at or above Check outdoor service...
Page 105 Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) remote detection Check Sub-code controller code 0 : IGBT circuit IPDU Outdoor fan All stop (Sub code: 0 ) Check fan motor. 1 : Position IPDU error Fan IPDU over current Check for defect in...
Page 106 Errors detected by TCC-LINK central control device Check code Location Error detection Outdoor 7-segment display Description System status Check items (locations) Main condition(s) detection remote Sub-code controller TCC-LINK TCC-LINK Continued Central control device is • Check for defect in central central control operation unable to transmit signal.
Page 107 Points to Note When Servicing Compressor (1) When checking the outputs of inverters, remove the wiring from the compressors. How to Check Inverter Output (1) Turn off the power supply. (2) Remove compressor leads from the IPDU P.C. board. (Be sure to remove all the leads.) (3) Turn on the power supply and start cooling or heating operation.
Page 108: Diagnosis Procedure For Each Check Code
9-5. Diagnosis procedure for each check code...
Page 131: 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 132 (1)Display of system information (displayed on outdoor unit) Refrigerant name Display refrigerant name Refrigerant R410A System capacity A [3]~[5] : 3 to 5 HP [HP] Total capacity of indoor units A [i. No. of indoor units connected / A […0.]~[10.]:0 to 10 (No. of units connected) No.
Page 133 (2)Display of outdoor unit information (displayed on outdoor unit) B Check code (only latest one displayed) If there is no check code, [– – –] is displayed. If there is sub-code, check code [ ] and sub-code [– ] are displayed alternately, for 3 seconds and 1 second, respectively.
Page 134 (3)Display of outdoor cycle data (displayed on outdoor unit) Pd pressure data Pd pressure (MPaG) is displayed in decimal format. (MPaG: Approx. 10 times magnitude of kg/cm P d. Ps pressure data Ps pressure (MPaG) is displayed in decimal format. P S.
Page 135 (4)Display of indoor unit information (displayed on outdoor unit) Indoor BUS communication signal B Upon receiving signal: [… … 1], Other times: [… … …] receiving status Indoor check code B No check code: [– – –] Indoor HP capacity 0.6 to 6.0 HP : […0.6] to […6.0] Indoor request command B [ #.
Page 136: Sensor Characteristics
9-7. Sensor characteristics Outdoor Unit Temperature sensor characteristics Outdoor TS, TE, TL and TO sensors Temperature [°C] Resistance [k ] 101.7 76.3 57.7 44.0 33.8 Resistance 26.1 [k ] 20.4 (10 °C or below) Resistance [k ] 16.0 (10 °C or above) 12.6 10.0 33.8k...
Page 137 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 138 Indoor TC1 sensor Temperature [°C] Resistance [k ] Resistance Resistance [k ] [k ] (10 °C or below) (10 °C or above) Temperature [°C] Indoor TC2 and TCJ sensors Temperature [°C] Resistance [k ] Resistance Resistance [k ] [k ] (10 °C or below) (10 °C or above) Temperature [°C]...
Page 139: Pressure Sensor Output Check
9-8. Pressure sensor output check Outdoor Unit Pd sensor characteristics 0 to 3.73 MPa (0.5 to 4.3 V output for 0 to 3.73 MPa) Voltage readings across pins 1 and 3 of CN501 on I/F P.C. board (with negative-side probe of multimeter placed on pin 3) VOLT VOLT...
Page 140 Outdoor Unit Ps sensor characteristics 0 to 0.98 MPa (0.5 to 3.5 V output for 0 to 0.98 MPa) Voltage readings across pins 2 and 3 of CN500 on I/F P.C. board (with negative-side probe of multimeter placed on pin 3) VOLT VOLT VOLT...
Page 141: Outdoor Unit Parts Replacement Methods
Outdoor unit parts replacement methods Common WARNING Do not detach the inverter for 5 minutes after turning off the breaker as doing so may cause electric shocks. Front panel CAUTION Wear gloves when working on it. Failure to observe this precaution may cause injury due to components, etc.
Page 142 No. Component Procedure Remarks Discharge 1. Detachment cabinet 1) Perform Step 1 of 1. 2) Remove the screws of the discharge cabinet top of the heat exchanger plate. (M4×10, 1 ) ( Fig. 2-1 ) Heat exchanger Discharge screw (1 posi on) cabinet on plate ( Fig.
Page 143 Side panel 1. Detachment Side panel 1) Perform Step 1 of 1. 2) Remove the screws of the Side panel top of the heat exchanger plate. ( Fig. 3-1 ) (M4×10, 3 ) 3) Remove the screws of the Side panel and inverter assembly.
Page 144 Remarks Interface (I/F) WARNING P.C. board Interface P.C. board Do not detach the inverter for 5 minutes after turning off the breaker as doing so may cause Banding band electric shocks. (1 position) 1. Detachment 1) Perform Step 1 of 1 and step 1) of 3. 2) Remove the lead wire clamps (2 positions) fixing Lead wire the sensor lead.
Page 145 Interface (I/F) WARNING P.C. board Interface Do not detach the inverter for 5 minutes after P.C.board turning off the breaker as doing so may cause electric shocks. 1) Perform Step 1 of 1 and Step 4) of 1 of 4. 2) Remove the support hooks (8 positions) fixing the board to remove the interface P.C.board.
Page 146 IPDU WARNING P.C. board Do not detach the inverter for 5 minutes after IPDU turning off the breaker as doing so may cause P.C board electric shocks. ) Perform Step Step and Step of 4. Screws ) Remove the screws for inverter cover (A) and ( positions inverter fixing plate 3) Remove the connector connected from the interface...
Page 147 Reactor WARNING replacement Do not detach the inverter for 5 minutes after turning off the breaker as doing so may cause Reactor (2 positions) electric shocks. 1) Perform Step 1 of 1, Step 3) of 1 of 3. 2) Remove the connector from the reactor. (2 positions) 3) Remove the screws on the reactor.
Page 148 Compressor 1. Removing the malfunctioning compressor Valve fixing plate replacement 1) Collect the refrigerant gas with the recovery. ( Fig. 9-1 ) 2) Perform Step 1 of 1, Step 1 of 3, Step 1 of 4, Step 2 of 4. Screws (4 positions) 3) Remove the screws the packed valve and ball valve from the valve fixing plate.
Page 149 Compressor 1. Installation of compressor installation 1) Install the compressor in the reverse procedure of removal. -insulation CAUTION mat (outside-1) Adjustment The tightening torque of the hexagonal bolt to position tion pipe 2. Vacuuming -insulation Discharge 1) Connect the vacuum pump to the valve charge mat (inside) pipe ports on the liquid and gas pipes.
Page 150 Fan guard 1. Detachment Screws (2 positions) 1) Perform Step 1 of 1, Step 1 of 2. Discharge cabinet CAUTION Fan guard For scratch protection, work on a carton box, cloth, or the like. 2) Remove the screws the discharge cabinet and fan guard knob.
Page 151 Component Procedure Remarks Heat 1. Detachment 4-way valve connection pipe exchanger 1) Collect the refrigerant gas with the recovery equipment. Remove with assembly a burner 2) Perform Step 1 of 1, Step 1 of 2, Step 1 of 3, Step 1 of 4, Header Step 2 of 4, Step 5) of 1 of 9.
Page 152 No. Component Procedure Remarks Detachment Handle 1) Perform Step 1) to 3) of 1 of 1. (Front Cushioning panel) 2) Remove the cushioning without tearing it. ( Fig. 14-1 ) 3) Use a flathead screwdriver or something to press on the 3 clamp hooks on the handle.
Page 153: C. Board Exchange Procedures
Please return to us P.C.board with the replacement record table attached,After P.C.board replaced. 1. Applicable models MCY-MHP0305HT MCY-MHP0405HT MCY-MHP0305HT-C MCY-MHP0405HT-C MCY-MHP0505HT-C MCY-MHP0305HT-ID MCY-MHP0405HT-ID MCY-MHP0305HT-CF...
Page 154 (5) Cut the jumper wires of the service P.C. board as indicated in the table below. These settings are different from the settings for the jumpers on the P.C. board (malfunctioning board) prior to its replacement. If the model setting is not selected, inspection code “L10” will be displayed, and the outdoor unit operation will remain stopped.
Page 155: Ipdu P.c. Board Replacement Procedure (Mcc-1655)
11-2.IPDU P.C. board replacement procedure (MCC-1655: 43H69024) 1. Applicable models MCY-MHP0305HT MCY-MHP0405HT MCY-MHP0305HT-C MCY-MHP0405HT-C MCY-MHP0505HT-C MCY-MHP0305HT-ID MCY-MHP0405HT-ID MCY-MHP0305HT-CF MCY-MHP0405HT-CF MCY-MHP0505HT-CF 2. Shipped parts list Please make sure that before you do the work, the following parts are shipped all. Parts name Quantity P.C.board Replacement Procedure Manual (English and Chinese each 1page A4 paper double side print.)
Page 156 card spacer Single-touch spacer screws M3×20 P.C.board Heatsink Push this in the direction of the IPDU P.C.board First remove the arrow to unlock and remove the (43H69024) Screws , and then P.C.board assembly remove the P.C. board assembly. Screw (M4×8) Used to secure the earth lead wire Screw tightening torque: 1.2 ±0.1 N m cord clamp...
Page 157: Exploded Diagram / Parts List
Exploded diagram / parts list MCY-MHP0305HT-C/0405HT-C/0505HT-C MCY-MHP0305HT/0405HT MCY-MHP0305HT-ID/0405HT-ID MCY-MHP0305HT-CF/0405HT-CF/0505HT-CF...
Page 158 43H19004 GUARD, FAN 43H19013 PLATE, STAY 43H07004 GUARD, FIN, SIDE 43H11010 INSULATOR, SOUND, INNER 43H11011 INSULATOR, SOUND, OUTER, LARGE 43H11012 INSULATOR, SOUND, OUTER, SMALL 43H11005 INSULATOR, SOUND, UP 43H07005 HANDLE 43H15002 MARK, TOSHIBA 43H88014 OWNER'S MANUAL, MCY-MHP0405HT-C 43H88015 OWNER'S MANUAL, MCY-MHP0405HT...
Page 159 Inverter assembly...
Page 160 Q'ty/Set MCY-MHP 0305HT 0305HT-C,CF 0305HT-ID Ref.No Part No. Description 0405HT 0405HT-C,CF 0405HT-ID 0505HT-C,CF 43H69023 PC BOARD ASSY, INTERFACE, MCC-1639 43H69024 PC BOARD ASSY, IPDU, MCC-1655 43H50001 HOLDER SENSOR TO) 43H50026 HOLDER,SENSOR(TE)
Page 161 FILE NO. SVM-13011 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 follows.
Page 162 Toshiba Carrier Air Conditioning (China) Co., Ltd. Building 1, No.60, 21st Avenue, Baiyang Street, Hangzhou Economic and Technological Development Area, China Revision record First issue Model Name: MCY-MHP0505HT-C Oct. 2015...

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Toshiba MCY-MHP0305HT-C Service Manual

Precautions for Safety

1 Product Summary

2 Construction Views

3 Wiring Diagram

4 Parts Rating

5 Refrigerant Piping Systematic Drawing

6 Control Outline

7 Applied Control for Outdoor Unit

8 Test Operation

9 Troubleshooting

10 Outdoor Unit Parts Replacement Methods

11 C. Board Exchange Procedures

12 Exploded Diagram / Parts List

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