TOSHIBA TCBLD2UK Output Control Board Instruction Manual

Instruction Manual for TOSHIBA models including: TCBLD2UK, LPR-272D010, AW17861, TCBLD2UK Output Control Board, TCBLD2UK, Output Control Board, Control Board, Board

20141205 IM Refrigerant Monitoring TCUK-RMv1 2014

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ENGLISH

File Info : application/pdf, 34 Pages, 5.06MB

TBC-LD2UK TC-UK v3 2017 EN

Installation Manual

Model name:
TCBLD2UK

R410A
LEAK DETECTION, ISOLATION & PUMP BACK MODULE

TBC-LD2UK

LPR-272D010 A18025

ENGLISH

AW17861 AW17867

Please read this Installation Manual carefully before installing the Leak Detection, Isolation & Pump Back Module. · This Manual describes the installation method of the TCB-LD2UK (LD2) Controller, Isolation
Valves and Pressure Relief Valve (PRV). · You must also refer to the Installation and Owner's Manual attached to the Toshiba outdoor unit. · Please follow the manual(s) for your Air Handling Unit (AHU - local supply). · Carrier Solutions UK Ltd does not take any responsibility on the local design. · This product is exclusively designed to be connected to a Toshiba VRF "e-series" outdoor unit.
Do not use the LD2 Controller for any other application. · Do not modify or alter the LD2 Controller. Do not try to fix the controller if there is a malfunction

This appliance is for commercial use only and should not be accessible to the general public. This appliance is not intended for use by person (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

Contents

Precautions for Safety..................................................................................................... 5

Installation of New Refrigerant Air Conditioner ............................................................ 8

Selection of Installation Place ........................................................................................ 9

Refrigerant Piping............................................................................................................ 9

Electric Wiring................................................................................................................ 13

Overview: Leak Detection, Isolation & Pump Back Module ....................................... 14

Supplied Parts................................................................................................................ 15

Installation...................................................................................................................... 16

Electrical Work ............................................................................................................... 23

Applicable Controls ....................................................................................................... 27

Test Run ......................................................................................................................... 28

Reset ............................................................................................................................... 29

Trouble Shooting ........................................................................................................... 30

Declaration of Conformity ............................................................................................. 31

Service Parts .................................................................................................................. 32

This symbol mark is for EU countries only. This symbol mark is according to the directive 2002/96/EC
Article 10 Information for users and Annex IV. This product is designed and manufactured with high quality materials and components which can be recycled and reused. This symbol means that electrical and electronic equipment, at the end-of-life, should be disposed of separately from your household waste. Please dispose of this equipment at your local community waste collection / recycling centre. In the European Union there are separate collection systems for used electrical and electronic product.

Thank you for purchasing Toshiba air conditioning products. This Installation Manual describes the installation method of the outdoor unit. For installation of indoor units, follow the Installation Manual supplied with the indoor unit. Moreover, as this installation manual includes the important articles concerning the "Machinery" Directive (Directive 2006/42/ EC), please read through the manual and make sure you understand it. After installation, give this Installation Manual, the Owner's Manual and the Installation Manual supplied with the indoor unit to the customer and tell the customer to keep them safe. Prepare an exclusive power source for indoor units, independent to that for outdoor units. Y-shaped branching joints or a branching header (separately purchased) are required for connecting pipes between indoor and outdoor units. Choose either of them considering the system capacity concerning piping. For installing branching pipes, refer to the installation manual of the Y-shaped branching unit or branching header (separately purchased). Outdoor connecting branching joints are required for connecting between outdoor units.
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. A qualified installer or qualified service person is an agent who has the qualifications and knowledge described in the table below.

Agent Qualified installer
Qualified service person

Qualifications and knowledge which the agent must have
The qualified installer is a person who installs, maintains, relocates and removes the air conditioners made by Carrier Corporation. He or she has been trained to install, maintain, relocate and remove the air conditioners made by Carrier Corporation or, alternatively, he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations.
The qualified installer who is allowed to do the electrical work involved in installation, relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
The qualified installer who is allowed to do the refrigerant handling and piping work involved in installation, relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
The qualified installer who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
The qualified service person is a person who installs, repairs, maintains, relocates and removes the air conditioners made by Toshiba Carrier Corporation. He or she has been trained to install, repair, maintain, relocate and remove the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such operations by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to these operations.
The qualified service person who is allowed to do the electrical work involved in installation, repair, relocation and removal has the qualifications pertaining to this electrical work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to electrical work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
The qualified service person who is allowed to do the refrigerant handling and piping work involved in installation, repair, relocation and removal has the qualifications pertaining to this refrigerant handling and piping work as stipulated by the local laws and regulations, and he or she is a person who has been trained in matters relating to refrigerant handling and piping work on the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
The qualified service person who is allowed to work at heights has been trained in matters relating to working at heights with the air conditioners made by Toshiba Carrier Corporation or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.

Definition of Protective Gear When the air conditioner is to be transported, installed, maintained, repaired or removed, wear protective gloves and `safety' work clothing. In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below. Failure to wear the proper protective gear is dangerous because you will be more susceptible to injury, burns, electric shocks and other injuries.

Work undertaken
All types of work
Electrical-related work Work done at heights (50 cm or more) Transportation of heavy objects Repair of outdoor unit

Protective gear worn Protective gloves `Safety' working clothing Gloves to provide protection for electricians and from heat Insulating shoes Clothing to provide protection from electric shock
Helmets for use in industry
Shoes with additional protective toe cap
Gloves to provide protection for electricians and from heat

Warning Indications on the Air Conditioner Unit

Warning indication

Description
WARNING ELECTRICAL SHOCK HAZARD Disconnect all remote electric power supplies before servicing.

WARNING Moving parts. Do not operate unit with grille removed. Stop the unit before the servicing.

CAUTION High temperature parts. You might get burned when removing this panel.

CAUTION Do not touch the aluminium fins of the unit. Doing so may result in injury.

CAUTION BURST HAZARD Open the service valves before the operation; otherwise there might be the burst.

CAUTION Do not climb onto the fan guard. Doing so may result in injury.

1 Precautions for safety
The manufacturer shall not assume any liability for the damage caused by not observing the description of this manual.
WARNING
General Before starting to install the air conditioner, read through the Installation Manual carefully, and follow its instructions to install the air
conditioner. Otherwise, falling down of the unit may occur, or the unit may cause noise, vibration or water leakage. Only a qualified installer (*1) or qualified service person (*1) is allowed to do installation work. If installation is carried out by an
unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result. If using separately sold products, make sure to use Toshiba specified products only. Using unspecified products may cause fire,
electric shock, water leak or other failure. Do not use any refrigerant different from the one specified for complement or replacement. Otherwise, abnormally high pressure may
be generated in the refrigeration cycle, which may result in a failure or explosion of the product or an injury to your body. Before opening the service panel of the outdoor unit, set the circuit breaker to the OFF position. Failure to set the circuit breaker to
the OFF position may result in electric shocks through contact with the interior parts. Only a qualified installer (*1) or qualified service person (*1) is allowed to remove the service panel of the outdoor unit and do the work required. Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breakers for both the indoor and outdoor units to the OFF position. Otherwise, electric shock may result. Place a "Work in progress" sign near the circuit breaker while the installation, maintenance, repair or removal work is being carried out. There is a danger of electric shocks if the circuit breaker is set to ON by mistake. Only a qualified installer (*1) or qualified service person (*1) is allowed to undertake work at heights using a stand of 50 cm or more or to remove the intake grille of the indoor unit to undertake work. Wear protective gloves and safety work clothing during installation, servicing and removal. Do not touch the aluminium fin of the outdoor unit. You may injure yourself if you do so. If the fin must be touched for some reason, first put on protective gloves and safety work clothing, and then proceed. Do not climb onto or place objects on top of the outdoor unit. You may fall or the objects may fall off of the outdoor unit and result in injury. When working at height, put a sign in place so that no-one will approach the work location before proceeding with the work. Parts or other objects may fall from above, possibly injuring a person below. Also, be sure that workers put on helmets. When cleaning the filter or other parts of the outdoor unit, set the circuit breaker to OFF without fail, and place a "Work in progress" sign near the circuit breaker before proceeding with the work. When working at heights, put a sign in place so that no-one will approach the work location, before proceeding with the work. Parts and other objects may fall from above, possibly injuring a person below. The refrigerant used by this air conditioner is the R410A. You shall ensure that the air conditioner is transported in stable condition. If you find any part of the product broken, contact your dealer. Do not disassemble, modify, repair or move the product yourself. Doing so may cause fire, electric shock, injury or water leaks. Ask a qualified installer or qualified service person to do any repairs or to move the product. Selection of installation location If you install the unit in a small room, take appropriate measures to prevent the refrigerant from exceeding the limit concentration even if it leaks. Consult the dealer from whom you purchased the air conditioner when you implement the measures. Accumulation of highly concentrated refrigerant may cause an oxygen deficiency accident. Do NOT use leak detection with HWM, DX and Multi-tenant Kit. It is not possible to connect leak detection sensors if CN80 connector on indoor unit is already in use. When installing leak detection onto 3-pipe system, it is not possible for the internal SSH control to operate in simultaneous mode. System cannot be set in Heating only mode (cooling made unavailable), via optional accessories or local system setup, as pump back control will not be able to operate correctly.
Do not install in a location where flammable gas may leaks are possible. If the gas should leak and accumulate around the unit, it may ignite and cause a fire.
When transporting the air conditioner, wear shoes with protective toe caps, protective gloves and other protective clothing. When transporting the air conditioner, do not take hold of the bands around the packing carton. You may injure yourself if the bands
should break. Install the indoor unit at least 2.5 m above the floor level since otherwise the users may injure themselves or receive electric shocks if
they poke their fingers or other objects into the indoor unit while the air conditioner is running. Do not place any combustion appliance in a place where it is directly exposed to the wind of air conditioner, otherwise it may cause
imperfect combustion. Places where the operation sound of the outdoor unit may cause a disturbance. (Especially at the boundary line with a neighbour,
install the air conditioner while considering the noise.) Installation Follow the instructions in the Installation Manual to install the air conditioner. Failure to follow these instructions may cause the
product to fall down or topple over or give rise to noise, vibration, water leakage or other failure. The designated bolts (M12) and nuts (M12) for securing the outdoor unit must be used when installing the unit. Install the outdoor unit property in a location that is durable enough to support the weight of the outdoor unit. Insufficient durability
may cause the outdoor unit to fall, which may result in injury. Install the unit in the prescribed manner for protection against strong wind and earthquake. Incorrect installation may result in the unit
falling down, or other accidents. Be sure to fix the screws back which have been removed for installation or other purposes.
5

Refrigerant Piping
Install the refrigerant pipe securely during the installation work before operating the air conditioner. If the compressor is operated with the valve open and without refrigerant pipe, the compressor sucks air and the refrigeration cycles is over pressurized, which may cause an injury.
Tighten the flare nut with a torque wrench in the specified manner. Excessive tighten of the flare nut may cause a crack in the flare nut after a long period, which may result in refrigerant leakage.
Ventilate the air if the refrigerant gas leaks during installation. If the leaked refrigerant gas comes into contact with fire, toxic gas may be produced.
After the installation work, confirm that refrigerant gas does not leak. If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may be generated.
When the air conditioner has been installed or relocated, follow the instructions in the Installation Manual and purge the air completely so that no gases other than the refrigerant will be mixed in the refrigerating cycle. Failure to purge the air completely may cause the air conditioner to malfunction.
Nitrogen gas must be used for the airtight test. The charge hose must be connected in such a way that it is not slack. If refrigerant gas has leaked during the installation work, ventilate the room immediately. If the leaked refrigerant gas comes in
contact with fire, noxious gas may be generated.
Electrical Wiring
Only a qualified installer (*1) or qualified service person (*1) is allowed to carry out the electrical work of the air conditioner. Under no circumstances must this work be done by an unqualified individual since failure to carry out the work properly may result in electric shocks and/or electrical leaks.
When connecting the electrical wires, repairing the electrical parts or undertaking other electrical jobs, wear gloves to provide protection for electricians and from heat, insulating shoes and clothing to provide protection from electric shocks. Failure to wear this protective gear may result in electric shocks.
When executing address setting, test run, or troubleshooting through the checking window on the electrical control box, put on insulated heat-proof gloves, insulated shoes and other clothing to provide protection from electric shock. Otherwise you may receive an electric shock.
Use wiring that meets the specifications in the Installation Manual and the stipulations in the local regulations and laws. Use of wiring which does not meet the specifications may give rise to electric shocks, electrical leakage, smoking and/or a fire.
Check that the product is properly earthed. (grounding work) Incomplete earthing may cause electric shock. Do not connect the earth wire to a gas pipe, water pipe, lightning conductor, or a telephone earth wire. After completing the repair or relocation work, check that the ground wires are connected properly. Install a circuit breaker that meets the specifications in the installation manual and the stipulations in the local regulations and laws. Install the circuit breaker where it can be easily accessed by the agent. When installing the circuit breaker outdoors, install one which is designed to be used outdoors. Under no circumstances must the power cable be extended. Connection trouble in the places where the cable is extended may give
rise to smoking and/or a fire. Electrical wiring work shall be conducted according to law and regulation in the community and installation manual. Failure to do so
may result in electrocution or short circuit. Do not supply power from the power terminal block equipped on the outdoor unit to another outdoor unit. Capacity overflow may
occur on the terminal block and may result in fire. When carrying out electric connection, use the wire specified in the Installation Manual and connect and fix the wires securely to
prevent them applying external force to the terminals. Improper connection or fixing may result in fire.
Test Run
Before operating the air conditioner after having completed the work, check that the electrical control box cover of the indoor unit and service panel of the outdoor unit are closed, and set the circuit breaker to the ON position. You may receive an electric shock if the power is turned on without first conducting these checks.
When you have noticed that some kind of trouble (such as when an error display has appeared, there is a smell of burning, abnormal sounds are heard, the air conditioner fails to cool or heat or water is leaking) has occurred in the air conditioner, do not touch the air conditioner yourself but set the circuit breaker to the OFF position, and contact a qualified service person. Take steps to ensure that the power will not be turned on (by marking "out of service" near the circuit breaker, for instance) until qualified service person arrives. Continuing to use the air conditioner in the trouble status may cause mechanical problems to escalate or result in electric shocks or other failure.
After the work has finished, be sure to use an insulation tester set (500 V Megger) to check the resistance is 2 M or more between the charge section and the non-charge metal section (Earth section). If the resistance value is low, a disaster such as a leak or electric shock is caused at user's side.
Upon completion of the installation work, check for refrigerant leaks and check the insulation resistance and water drainage. Then conduct a test run to check that the air conditioner is operating properly.
Explanations Given To User
Upon completion of the installation work, tell the user where the circuit breaker is located. If the user does not know where the circuit breaker is, he or she will not be able to turn it off in the event that trouble has occurred in the air conditioner.
If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person(*1) to have the repairs done. Do not set the circuit breaker to the ON position until the repairs are completed.
After the installation work, follow the Owner's Manual to explain to the customer how to use and maintain the unit.
6

Relocation
Only a qualified installer (*1) or qualified service person (*1) is allowed to relocate the air conditioner. It is dangerous for the air conditioner to be relocated by an unqualified individual since a fire, electric shocks, injury, water leakage, noise and/or vibration may result.
When carrying out the pump-down work shut down the compressor before disconnecting the refrigerant pipe. Disconnecting the refrigerant pipe with the service valve left open and the compressor still operating will cause air or other gas to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly resulting in rupture, injury or other trouble.
Never recover the refrigerant into the outdoor unit. Be sure to use a refrigerant recovery machine to recover the refrigerant when moving or repairing. It is impossible to recover the refrigerant into the outdoor unit. Refrigerant recovery into the outdoor unit may result in serious accidents such as explosion of the unit, injury or other accidents.
(*1) Refer to the "Definition of Qualified Installer or Qualified Service Person."
CAUTION New refrigerant air conditioner installation
This air conditioner adopts the new HFC refrigerant (R410A) which does not destroy ozone layer. The characteristics of R410A refrigerant are; easy to absorb water, oxidizing membrane or oil, and its pressure is approx. 1.6 times
higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle. To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging port of the main unit and installation tools are changed from those for the conventional refrigerant. Accordingly the exclusive tools are required for the new refrigerant (R410A). For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust does not enter.
Disconnection of the appliance from mains power supply.
This appliance must be connected to the main power supply by means of a switch with a contact separation of at least 3 mm.
The installation fuse (all type can be used) must be used for the power supply line of this conditioner.
7

2 Installation of New Refrigerant Air Conditioner
This air conditioner adopts the new HFC refrigerant (R410A) which does not deplete the ozone layer. R410A refrigerant is vulnerable to impurities such as water, oxidizing membranes, or oils because the pressure of R410A refrigerant
is higher than that of the former refrigerant by approximately 1.6 times. As well as the adoption of the new refrigerant, the refrigerating oil has been also changed. Therefore, pay attention so that water,
dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle of the new refrigerant air conditioner during installation. To prevent mixing of refrigerant or refrigerating oil, the size of the charge port of the main unit or connecting section of the installation tool differs to that of an air conditioner for the former refrigerant. Accordingly, exclusive tools are required for the new refrigerant (R410A) as shown below. For connecting pipes, use new and clean piping materials so that water or dust does not enter.

Required Tools and Cautions on Handling
It is necessary to prepare the tools and parts for installation as described below. The tools and parts which will be newly prepared in the following items should be restricted to exclusive use.
Explanation of symbols : Newly prepared (It is necessary to use it exclusively with R410A, separately from those for R22 or R407C.) : Former tool is available.

Used Tools Gauge manifold Charging hose Charging cylinder Gas leak detector

Usage
Vacuuming, charging refrigerant and operation check
Charging refrigerant
Checking gas leak

Vacuum pump

Vacuum drying

Vacuum pump with counter flow Vacuum drying

Flare tool Bender Refrigerant recovery device

Flare processing of pipes
Bending processing of pipes
Recovering refrigerant

Torque wrench

Tightening flare nut

Pipe cutter

Cutting pipes

Refrigerant canister

Charging refrigerant

Welding machine / Nitrogen gas cylinder
Refrigerant charging balance

Welding of pipes Charging refrigerant

Proper Use of Tools / Parts Exclusive to R410A
Exclusive to R410A
Unusable (Use the Refrigerant charging balance.) Exclusive to R410A
Usable if a counter-flow preventive adapter is attached
R22 (Existing article) Usable by adjusting size
R22 (Existing article)
Exclusive to R410A Exclusive to Ø12.7 mm and Ø15.9 mm R22 (Existing article) Exclusive to R410A Enter the refrigerate name for identification R22 (Existing article)
R22 (Existing article)

3 Selection of Installation Place
Upon customer's approval, install the air conditioning apparatus in a place which satisfies the following conditions: Place where it can be installed correctly. Place which can reserve a sufficient service space for safe maintenance or checks. Place where there is no problem even if the drained water overflows. Avoid the following places: Salty places (seaside area) or places with much gas sulphide (hot spring area) (If selecting such a place, special maintenance is
required.) Places where oil (including machine oil), steam, oil smoke or corrosive gas is generated. Places where iron or other metal dust is present. If iron or other metal dust adheres to or collects on the interior of the air conditioner,
it may spontaneously combust and start a fire. Places where an organic solvent is used. Chemical plants with a cooling system using liquid carbon dioxide. Places where a device generating high frequency (inverter, non-utility generator, medical apparatus, or communication equipment) is
set. (Malfunction or abnormal control of the air conditioner, or interference to devices listed above may occur.) Places unable to bear the weight of the apparatus. Places with poor ventilation. Places where ambient temperature falls below -15°C for more than 72 hours running.
4 Refrigerant Piping
-FGAS Label
The air conditioning product contains fluorinated greenhouse gases covered by the Kyoto Protocol Chemical Name of Gas R410A Global Warming Potential (GWP) of Gas 1975
CAUTION
1. Stick the enclosed refrigerant label adjacent to the charging and/or recovering location. 2. Clearly write the charged refrigerant quantity on the refrigerant label using indelible ink. Then, place the included transparent
protective sheet over the label to prevent the writing from rubbing off. 3. Prevent emission of the contained fluorinated greenhouse gas. Ensure that the fluorinated greenhouse gas is never vented to the
atmosphere during installation, service or disposal. When any leakage of the contained fluorinated greenhouse gas is detected, the leak shall be stopped and repaired as soon as possible. 4. Only qualified service personnel are allowed to access and service this product. 5. Any handling of the fluorinated greenhouse gas in this product, such as when moving the product or recharging the gas, shall comply under (EC) Regulation No. 842/2006 on certain fluorinated greenhouse gases and any relevant local legislation. 6. Periodical inspections for refrigerant leaks may be required depending on European or local legislation. 7. Contact dealers, installers, etc., for any questions.
9

WARNING

If the refrigerant gas leaks during installation, ventilate the room. If the leaked refrigerant gas comes into contact with fire, noxious gas may be generated.
After installation, check that the refrigerant gas does not leak. If the refrigerant gas leaks into the room and comes into contact with fire such as a fan heater, stove, or kitchen range, noxious gas
may be generated.

REQUIREMENT For a brazing work of the refrigerant pipes, be sure to use nitrogen gas in order to prevent oxidation of the inside of the pipes;
otherwise clogging of the refrigerating cycle due to oxidized scale may occur. Use clean and new pipes for the refrigerant pipes and perform piping work so that water or dust does not contaminate the refrigerant. *Remove all flux after brazing. Be sure to use a double spanner to loosen or tighten the flare nut. If a single spanner is used, the required level of tightening cannot
be obtained. Tighten the flare nut with the specified torque. (If it is hard to loosen or tighten the flare nut of the balance pipe or packed valve of the liquid side with a double spanner, loosen or tighten the flare nut while holding the valve mounting plate with a spanner.)

Extruding margin of copper pipe with flare tools: A (Unit: mm)

Copper pipe outer dia.
9.5 12.7 15.9 19.1

+0 A -0.4 13.2 16.6 19.7 24.0

Connected section

External size

Internal size

Extruding margin of copper pipe with flare machining: B (Unit: mm)

Copper pipe outer dia.

When using R410A tool

When using conventional tool

9.5 12.7 15.9 19.1

0 to 0.5

1.0 to 1.5

When using the conventional flare tool, to connect R410A pipes with flaring, make a margin approx. 0.5 mm longer than that of an R22 pipe so that the flare size matches the one specified. It is convenient to use a copper pipe gauge for size adjustment of the extruding margin. Half hard or hard materials may be cracked and may cause leakage of refrigerant when it is flared.
After flaring the connection, be sure the flared part is not damaged, deformed, uneven, or flattened, and that there are no cutting chips on it. Coupling size of brazed pipe

Standard outer dia. of connected copper pipe
6.35 9.52 12.70 15.88 19.05 22.22 28.58 34.92 38.10 41.28

Connected section

External size Internal size
Standard outer dia. (Allowable difference)

Min. depth of insertion

C 6.35 (±0.03)

(+0.04

6.45 -0.02)

9.52 (±0.03)

(+0.04

9.62 -0.02)

12.70 (±0.03)

(+0.04

12.81 -0.02)

15.88 (±0.03)

(+0.04

16.00 -0.02)

19.05 (±0.03)

(+0.03
19.19 -0.03)

11 10

22.22 (±0.03)

(+0.03
22.36 -0.03)

11 10

28.58 (±0.04)

(+0.06
28.75 -0.02)

13 12

34.90 (±0.04)

(+0.04
35.11 -0.04)

14 13

38.10 (±0.05)

(+0.08
38.31 -0.02)

15 14

41.28 (±0.05)

(+0.08
41.50 -0.02)

15 14

Oval value
0.06 or less 0.08 or less 0.10 or less 0.13 or less 0.15 or less 0.16 or less 0.20 or less 0.25 or less 0.27 or less 0.28 or less

Min. thickness of coupling
0.50 0.60 0.70 0.80 0.80 0.82 1.00 1.20 1.26 1.35

Warnings on Refrigerant Leakage
Check of Concentration Limit
The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its concentration will not exceed a set limit. The refrigerant R410A which is used in the air conditioner is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws to be imposed which protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its concentration should rise excessively. Suffocation from leakage of R410A is almost non-existent. With the recent increase in the number of high concentration buildings, however, the installation of multi air conditioner systems is on the increase because of the need for effective use of floor space, individual control, energy conservation by curtailing heat and carrying power etc. Most importantly, the multi air conditioner system is able to replenish a large amount of refrigerant compared with conventional individual air conditioners. If a single unit of the multi conditioner system is to be installed in a small room, select a suitable model and installation procedure so that if the refrigerant accidentally leaks out, its concentration does not reach the limit (and in the event of an emergency, measures can be made before injury can occur). 1. In a room where the concentration may exceed the limit, create an opening with adjacent rooms, or install mechanical ventilation
combined with a gas leak detection device. The concentration is calculated as detailed below. Total amount of refrigerant (kg)
Min. volume of the indoor unit installed room (m3) Concentration limit (kg/m3)
The concentration limit of R410A which is used in multi air conditioners is 0.3 kg/m3.
NOTE 1 If there are 2 or more refrigerating systems in a single refrigerating device, the amounts of refrigerant should be as charged in each independent device.
For the amount of charge in this example: The possible amount of leaked refrigerant gas in rooms A, B and C is 10 kg. The possible amount of leaked refrigerant gas in rooms D, E and F is 15 kg.
NOTE 2 The standards for minimum room volume are as follows. 1) No partition (shaded portion)
11

IMPORTANT
2. When there is an effective opening with the adjacent room for ventilation of leaking refrigerant gas (opening without a door, or an opening 0.15 % or larger than the respective floor spaces at the top or bottom of the door).
3. If an indoor unit is installed in each partitioned room and the refrigerant piping is interconnected, the smallest room of course becomes the object. But when a mechanical ventilation is installed interlocked with a gas leakage detector in the smallest room where the density limit is exceeded, the volume of the next smallest room becomes the object.
NOTE 3 The minimum indoor floor area compared with the amount of refrigerant is roughly as follows: (When the ceiling is 2.7 m high)
12
.

5 Electric wiring

WARNING
The appliance shall be installed in accordance with national wiring regulations. Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire.

CAUTION
Perform wiring of power supply complying with the rules and regulations of the local electric company. Refer to H07RN-F or 60245 IEC 66 regarding specifications of the power supply wire. Do not connect 380 V - 415 V power to the terminal blocks for control cables (U1, U2, U3, U4, U5, U6); otherwise, the unit may break
down. Be sure that electric wiring does not come into contact with high-temperature parts of piping; otherwise, the coating of cables may
melt and cause an accident. After connecting wires to the terminal block, take off the traps and fix the wires with cord clamps. Follow the same structure for both the control wiring and refrigerate piping. Do not conduct power to indoor units until vacuuming of the refrigerant pipes has finished. Refer to the installation manuals of indoor unit and flow selector unit for power wiring and communication wiring of indoor unit and
flow selector unit. Communication wiring and central control wiring use 2-core non-polarity wires. Use 2-core shield wires to prevent noise trouble. Connecting the closed end terminal of shield wire. (Connected to all connecting sections in each unit) Use 2-core non-polarity wire for remote controller. (A, B terminals) Use 2-core non-polarity wire for wiring of group control. (A, B
terminals)

Table-1 Communication wiring between indoor and outdoor units (L1, L2, L3), Central control wiring (L4)

Wiring

2-core, non-polarity

Type Size / Length

Shield wire 1.50mm2 (min. 1.25 mm2): Up to 1000m 2.50mm2 (min. 2.00 mm2): Up to 2000m (*1)

(*1): Total length of Communication wiring length for all refrigerant circuits (L1 + L2 + L3 + L4)

Table-2 Communication wiring between outdoor units (L5)

Wiring Type Size / Length

2-core, non-polarity
Shield wire 1.50mm2 (min.1.25 mm2 to 2.0 mm2) up to 100m (L5)

Table-3 Remote controller wiring (L6, L7)

Wire Size
Length

2-core, non-polarity 1.50mm2 (min. 0.5 mm2 to 2.0 mm2)
Up to 500m (L6 + L7) Up to 400m in case of wireless remote controller in group control. Up to 200m total length of communication wiring between indoor units L6

6 Overview: Leak Detection Isolation & Pump Back Module
The new Leak Detection Isolation & Pump Back Module enables automatic pump back of refrigerant from indoor side to outdoor, based on the detection of either an L30 fault code (activated via the external leak detection sensor TCB-LDS1 and TCB-LDS2) or via an internal CDU based refrigeration detection control algorithm that continually monitors key system parameters. Internal leak detection is completed via the continued monitoring of key system temperatures and pressures. When the software identifies that the refrigerant level within the system has dropped, a signal is sent from the CDU to the new LD2 control module activating a pump back operation (similar to that of test cool operation), returning refrigerant from the indoor side to the CDU. CDU isolation is achieved via dedicated isolation valves fitted to the main pipe work. On completion of the pump back a P15 fault code is displayed on both the 7 segment display on the CDU and the local / central remotes. External leak detection (TCB-LDS1 or TCB-LDS2 sensors): Please refer to Installation Manual.
Refrigerant Detection & Pump Back Example:-

CAUTION

To Disconnect the Appliance from Main Power Supply

This appliance must be connected to the main power supply by means of a switch with a constant separation of at least 3mm.

7 Supplied Parts

· VRF applications require the LD2 Controller plus appropriately sized isolation valves and a pressure release valve (PRV).
· The PRV and strainer is a kit the installer needs to assemble on site (including brazing).
· The Isolation Valves will require installation on site (including brazing). There are 7 different size models depending on system specification (see page 6).

Box Contents TCBLD2UK Controller

Required Accessories

* Customers will need to purchase three isolation valves for 3 pipe systems (MMY-MAP-6FT8P-E).
CAUTION
· Ensure that all Local, National and International regulations are satisfied. · Read this "PRECAUTIONS FOR SAFETY" carefully before installation. · The precautions described below include the important items regarding safety. Observe them without fail. · After the installation work, perform a trial operation to check for any problem. · Read this Manual to explain how to use and maintain the unit. · Turn off the main power supply switch (or breaker) before the unit maintenance. · Ask the customer to keep this installation owner's manual.
15

8 Installation
PRODUCT SPECIFICATION

LD2 Controller

Model Group Function

Model Name

Function Summary

TCB-LD2UK VRF (SMMSe / SHRMe / Mini SMMSe)
Leak Detection & Pump Back Control Module
Automatic Pump back of refrigerant from indoor side to outdoor, based on the detection of either a L30 fault code (activated via the external leak detection sensor - LDS1 and LDS2) or via an internal CDU based refrigeration detection control algorithm that continually monitors key system parameters.

Target Application

All VRF (SMMSe / SHRMe / Mini SMMSe) installations, where refrigerant concentration levels could exceed 0.44Kg/Cm2 (EN378), within an occupied space.

Height

400

Width

300

Depth

Weight

Switch/Indicator Protection *

Standard Rating

155 10
Hinged Perspex Cover 65

Low Ambient Protection Heater *

Audible Alarm

Yes

Audible Alarm Sound Level

Alarm Mute

Yes

Remote Indication Relay *

Visual Indicator (Neon)

Yes (Leak Detection - External and Internal)

Fault Code generated to Local Remote Controller

Yes (L30 or P15 depending on system setup and fault location)

Fault Code generated on CDU 7-Segment display

Yes (L30 or P15 depending on system setup)

Power Supply

1 Phase 230V 50Hz

Fused Supply

Number of Inputs

Number of Outputs

* Fitted accessory

Refrigerant Line Filter

Model Group

Model Name

Function

Refrigerant Pipe Connection (In/Out) Mesh Rating

Pressure Relief Valve - Strainer

Mueller Refrigeration Line Filters

Provides protection to the Pressure Relief Valve from

debris within the pipework

9.4

Stainless Steel 100 mesh

Pressure Regulating Valve

Model Group

Model Name

Function

Refrigerant Pipe Connection (In/Out) Setting Pressure Maximum Working Pressure

mm Mpa MPa

Pressure Relief Valve Saginomiya
Pressure Regulating Valve (Liquid to Suction Lines)
6.35 4.15 4.3

Refrigerant Isolation Valve

Model Name Model Series Refrigerant Pipe Connection (In/Out) A B C D Weight

Running Time (Open - Close)

Ambient Operation Limitations Ambient Humidity Limitations Power Consumption

Operating Voltage
Operation Frequency IP Rating Model Group Function

Series I

AW17861 AW17862 AW17863 AW17864 AW17865 AW17866 AW17867

12.7

15.9

19.0

22.2

28.6

34.9

41.3

102

107

116

128

136

94.23

150

1.00

1.08

1.09

1.10

1.41

2.51

3.15

Sec

90 @ 60 Hz 90 @ 60 Hz 90 @ 60 Hz 90 @ 60 Hz 125 @ 60 Hz 125 @ 60 Hz 125 @ 60 Hz 125 @ 50 Hz 125 @ 50 Hz 125 @ 50 Hz 125 @ 50 Hz 150 @ 50Hz 150 @ 50Hz 150 @ 50Hz

°C rh % VA

-32 to 55 95 2.3

-32 to 55 95 3

Vac

+20%, -15% +20%, -15% +20%, -15% +20%, -15%

24 ±20%

50/60

Cyclemaster Actuated Ball Valves

Isolation of Refridgerant Pipework (Gas & Liquid)

Series II

50/60 54

System Compatibility Tables
The leak Detection System (LD2) is designed to operate within all current Toshiba VRF systems (Mini SMMSe, SMMSe and SHRMe).

Mini SMMSe

Model Name TCBLD2UK
AW17861 AW17862 AW17863 AW17864 AW17865 AW17866 AW17867

Outdoor Unit Capacity Type (HP)

0404 (4)

0504 (5)

0604 (6)

* Smallest valve size available is ½" (12.7mm) make adjustment to pipework to fit.
SMMSe

Model Name
TCBLD2UK AW17861 AW17862 AW17863 AW17864 AW17865 AW17866 AW17867

8 to below 10
1 1
1

10 to below 12
1 1
1

Total Capacity codes of all outdoor units.

Equivalent to HP

12 to

14 to

22 to

24 to

below 14 below 22 below 24 below 26

26 to below 36
1

36 or more 1

1 1
1 1

SHRMe

Model Name
TCBLD2UK AW17861 AW17862 AW17863 AW17864 AW17865 AW17866 AW17867

8 to below 10
1 2
1

10 to below 12
1 2
1

Total Capacity codes of all outdoor units.

Equivalent to HP

12 to

14 to

22 to

24 to

below 14 below 22 below 24 below 26

26 to below 36
1

36 or more 1

2 2
1 1

TCBLD2UK Controller (LD2)
The LD2 controller must not be installed outside. To maintain waterproof integrity IP65 glands must be used through the gland plate (To avoid damage; when making holes for cable glands, please first remove the gland plate from the LD2 controller).
Weight: 10kg 19

Pressure Relief Valve (PRV) Assembly
The supplied components must be installed into the refrigerant pipework locally. When installing the PRV please take note of the following guidelines.
· The PRV has a diameter of 6.35mm and the Strainer has a diameter of 9.4mm, therefore a locally sourced reducer must be used for this assembly.
· The PRV must be installed in an upright position with the strainer fitted on the inlet side of the PRV (Shown below).
· The PRV must be installed between the CDU and Isolation valves. · The PRV body must be water cooled whilst brazing.
PRV Part Diagram

PRV (Water Cool when brazing)

Direction of Flow Inlet

Custom Local Pipework

Outlet

Strainer

Gas
PRV & Isolation Valve Pipe Schematic

Liquid

Gas
CDU
Liquid

PRV Strainer

M
Isolation Valves
M

PRV & Isolation Valve Full Schematic Example
PRV Assembly
NOTES 1. Carefully handle and prepare the PRV when fitting to prevent ingress of foreign matter such as dust or water. 2. Cautions when Brazing PRV
a) Whilst brazing, the PRV body must be water cooled to keep the component's temperature below 100°C. b) Whilst brazing, nitrogen gas must be flowed through the PRV valve and pipework to prevent internal
oxidization. c) Prevent cooling water from getting inside the PRV during brazing.
Isolation Valve Installation Summary
· The isolating valves are to be fitted in accordance with the instructions supplied with them. · Ensure the valves are located inside the building · Do not install within the protected refrigerant detection area. · Do not install inside an area that is noise sensitive. · Connect the isolation valve wiring to the dedicated terminals within the LD2 control panel, as detailed
within this installation manual. · Where indoor pipework diameter is smaller than the valve pipe diameter, a reducer should be used
(locally procured). WARNING
· DO NOT OPEN THE ACTUATOR. IF THE ACTUATOR IS INOPERATIVE, REPLACE THE UNIT. · Do not wire different types of actuators in parallel with these models. · Personal injury/loss of life may occur if a procedure is not performed as specified. · Equipment damage or loss of data may occur if the user does not follow a procedure as specified. · To avoid injury or loss of life, pay attention to any hazardous voltage when performing checks. IMPORTANT - Before commencing brazing of valve and pipe connection joints the valve must be in the "Open" position. Failure to manually open the valve may result in damage to internal components and malfunction in operation.
21

ISOLATION VALVE FITTING INSTRUCTIONS
1. To prevent damage to the valve assembly during installation, it is recommended that both the actuator (10) and the hub assembly (2-7) be removed prior to brazing. If this is not possible it is essential that the actuator and hub assembly be kept cool and isolated from the heat source, without the actuator getting wet.
2. To remove the actuator (10) from the hub assembly it is necessary to 1st loosen the adjustment lever (8) and then unscrew the two retaining Hex bolts (9) from the hub assembly (7). The actuator (10) can then be safely lifted and removed away from the hub (7).
3. The hub assembly (2-7) can then be removed from the valve body, by unscrewing the two retaining set screws (6) and then rotating the hub assembly in an anti-clockwise direction.
4. The ball valve (1) can then be brazed into the refrigeration pipework. Ensure the Schrader valve is removed (not fitted out of the box). It is recommended a wet rag is wrapped around the valve body, during brazing.
5. To refit Hub assembly and actuator reverse steps 1-4 above.
Additional Notes:
1. During the removal of the actuator (10), the shaft adapter inside the actuator may come loose. To refit align the shaft adapter with the Adjustment lever as shown in the picture. Ensure the raised tabs on the adapter are inserted last, as the act as the end stop
2. The Hub (7) needs not to be tightened all the way to the bottom of the valve body. Instead ensure orientation is correct and then secure with set screws (6) provided.
Isolation Valve Manual Override Procedure

ISOLATION VALVE ASSEMBLY

Shaft Adapter

Shaft Adapter Aligned with Adjustment Lever

To move the valve and lock the position with no power present: 1. Slide the red manual override knob toward the back of the actuator. 2. Make adjustments to the valve position 3. Slide the red manual override knob toward the front of the actuator.
Once power is restored, the actuator returns to automatic control. .

9 Electrical Work

WARNING
· Using the specified wires, ensure to connect the wires, and fix wires securely so that the external tension to the wires does not affect the connecting part of the terminals. Incomplete connection or fixation may cause a fire, etc.
· Be sure to connect earth wire (grounding work). Incomplete grounding causes an electric shock. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone wires.
· Appliance shall be installed in accordance with national wiring regulations. Capacity shortage of power circuit or incomplete installation may cause an electric shock or a fire.
CAUTION
· If incorrect / incomplete wiring is carried out, it will cause an electrical fire or smoke. · Be sure to install an earth leakage breaker that is not tripped by shock waves. If an earth leakage breaker is not
installed, an electric shock may be caused. · Do not damage or scratch the conductive core and inner insulator of power and inter-connecting wires when
stripping the insulation. · Use the power cord and inter-connecting wire of specified thickness, type and protective devices required
REQUIREMENT
· For power supply wiring, strictly conform to the Local Regulation for each country. · For wiring of power supply of the outdoor units, follow the Installation manual of each outdoor unit. · Perform the electric wiring so that it does not come in to contact with the high-temperature part of the pipe. The
cable insulation may melt in an accident · Be sure to remove the gland plate from the LD2 CONTROLLER when drilling gland holes. Use IP65 cable glands
when installing wires through the gland plate of the LD2 CONTROLLER. · Run the refrigerant piping and control wiring line in the same line. · Do not turn on the power of the LD2 CONTROLLER until vacuuming of the refrigerant pipes is complete.

Power Supply Wire and Interconnecting Wires Specifications

Power supply wire and interconnecting wires are procured locally. For the power supply specifications, see page 11 and follow the table. If the current carrying capacity of the cable is low then the cable may overheat. For specifications of the power capacity of the outdoor unit and the power supply wires, refer to the Installation manual attached to the outdoor unit.

Cable size must be calculated for site condition and correct glands fitted. All cables should be in conduit or armoured cables correctly glanded. This has to be done by the site installer.

LD2 CONTROLLER power supply

· For the power supply of the LD2 CONTROLLER, prepare the exclusive power supply separated from that of the outdoor
unit. · Power supply wire specification: Cable 3-Core 1.5mm2, in conformity with Design 60245 IEC 57.

Power supply wire

Power supply

220~240V ~ 50Hz

Power supply switch / Earth leakage breaker or power supply wirings / fuse rating for LD2 CONTROLLER should be selected by the accumulated total current values of the LD2 controller

Power supply wiring Recommended internal low voltage fuse (24VAC) Recommended internal high voltage fuse (230VAC)

Below 50m

1.5mm2 T500mA
T1A

Wire Specification Table

Wire Description Single Phase Power Cable
I1 I2 I4
Q1 Q2 Q3 Q4 EQ1 EQ4

Power Supply Cable

No. Cores

Max Length

50m

LD2 Input

2 (Screen)

200

2 (Screen)

200

2 (Non-screen)

100

LD2 Output

2 (Screen)

500

3 (Non-screen)

100

3 (Non-screen)

100

3 (Non-screen)

100

3 (Non-screen)

100

2 (Screen)

500

Summary of Inputs and Outputs

Key Description

I1 Input start signal from CN511_1 (Outdoor unit L30 detected)

I2 Input start signal from CN511_2 (Outdoor unit P15 detected)

I3 Pump back controller reset input

I4 External safety contact input

I5 Manual test input

I6 Audible alarm mute input

Q1 Global ON command to CN512_1 (Com & Cool)

Q2 Liquid and discharge isolation valves CLOSE

Q3 Liquid and discharge isolation valves OPEN

Q4 Suction isolation valve CLOSE

EQ1 Suction isolation valve OPEN

EQ2 L30 and / or P15 visual alarm

EQ3 L30 and / or P15 audible alarm

EQ4

Global OFF command to CN512_2 (Com & Heat)
24

Type DI DI DI DI DI DI DO DO DO DO DO DO DO DO

Ø 1.5 mm2
0.75mm2 0.75mm2 0.5 1.00 mm2
0.75mm2 0.5 1.00 mm2 0.5 1.00 mm2 0.5 1.00 mm2 0.5 1.00 mm2
0.75mm2
Terminal 1 & 2 3 & 4 No External Connection 5 & 6 No External Connection No External Connection 7 & 8 11 & 12 12 & 13 14 & 15 15 & 16 No External Connection No External Connection 9 & 10

TCB-LD2UK Electrical Connections

OOOO OO OOOOOOOOOOOOOOOOOOOO OOOO

24VAC
L

24VAC
N

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

L N

Terminal Label

Item

Description

24VAC L 24VAC N
1 & 2 3 & 4 5 & 6 7 & 8 9 & 10
11 12 13 14 15 16 17 ~ 18 19 ~ 20

Internal Power (x4)

No connection required - internal use only

Internal Power (x2)

No connection required - internal use only

Input CN511.1

Cable connection from Output 1 on PCB (TCB-PCIN4E Output 1)

Input CN511.2

Cable connection from Output 2 on PCB (TCB-PCIN4E Output 2)

External Safety Input Safety switch connection

Global ON

Input 512_1 Cable connection from option PCB (TCB-PCMO4E - COM & COOL)

Global OFF

Input 512_2 Cable connection from option PCB (TCB-PCMO4E - COM & HEAT)

Liquid & Discharge Isolation Valve Connection

Isolation valve CLOSE connection (Violet) Isolation valve COMMON connection (Red) Isolation valve OPEN connection (Orange)

Suction Isolation Valve Connection

Isolation valve CLOSE connection (Violet) Isolation valve COMMON connection (Red) Isolation valve OPEN connection (Orange)

Remote Indication

0 volt connection (used with other monitoring panels)

Spare Terminals

No connection required - No operation

L & N & (E) Power Supply

The LD2 CONTROLLER should be connected to the main power supply by means of a switch with a contact separation of at least 3mm.

TCB-LD2UK Diagram
26

AUDIBLE ALARM MUTE

P1 P2 I1 I2 I3 I4

I5 I6 I7 I8

SIEMENS LOGO 24RC

P1 P2 I1 I2 I3 I4

SIEMENS LOGO DM8 24R

EQ1

EQ3

EQ4

Input Functions
I1. Input start signal from CN51 1-1 (outdoor unit- L30 detected) I2. Input start signal from CN51 1-2 (outdoor unit- P15 detected) I3. Pump back controller reset input I4. External safety contact input I5. Manual test input I6. Audible alarm mute input

REFRIGERANT ALARM (RED)
AUDIBLE ALARM

Output Functions
Q1. Global ON command to CN512-1 (Com & Cool) Q2. Liquid and discharge isolation valves CLOSE Q3. Liquid and discharge isolation valves OPEN Q4. Suction isolation valve CLOSE EQ1. Suction isolation valve OPEN EQ2. L30 and/or P15 visual alarm EQ3. L30 and/or P15 audible alarm EQ4. Global OFF command to CN512-2 (Com & Heat)

LOW AMBIENT PROTECTION

THERMOSTAT

HEATER

MANUAL TEST

T500mA

RESET SWITCH

LL L LL L

NN NN N N

1 2 3 4 5 6 7 8 9 10

11 12 13

14 15 16

POWER

ON LED

(WHITE)

18
17 18 19 20

T1A

E L

N E

*Fitted accessory

CN511-1 CN511-2 EXTERNAL CN512

L30 SSH>35C SAFETY INPUT

DETECTED

CONTACT COM

ON TCC

COOL

CN512 INPUT COM
& HEAT

LIQUID & DISCHARGE
VALVE CLOSE OPEN

SUCTION VALVE
CLOSE OPEN

REMOTE INDICATION

10 Applicable Controls

· CDU requires configuration change to set system for Leak Detection Operation
· The following options can be set: Leak detection ON/OFF CDU operation SSH detection temperature
· See configuration set up below

System Configuration

SMMS-e / SHRM-e CDU I/F PCB

The CDU requires leak detection
(TCB-LD2UK) activation through set up
of control I/F PCB

Mini SMMS-e CDU I/F PCB

Option 1: External Leak Detection Activation (LDS1/2 Activation)

The software has been designed to maximise as far as possible the flexibility of the leak detection control. Depending on the setup chosen by the end user, the control can effectively be split into four (4) different setups (control methods). These are detailed within the table below

System Setup

Control Method

Outdoor PCB Configuration

Jumper 26

Switch 11 Bit 3

Cut

Off

Cut

Off

Cut

TCB-PCIN4E Connection Status
(CN511)
Connect
NOT Connect
Connect
NOT Connect

TCB-PCMO4E Connection Status
(CN512)
Connect
Connect
Connect
Connect

System Control Procedure

Control Method
1 2

Leak Detection Sensor Activation
Status (CN80)

CDU Operation Status

CDU 7 Segment Display

Activated

Pump Back Operation

P15

Activated

Normal Operation No Error Displayed

FCU Error Unit (CN80 Short Circuit) R/C On Display R/C Off Display

L30

R/C Off > On = L30

Other FCU Unit (CN80 Open) R/C On Display R/C Off Display

LD2 Controller Operation

Liq / Dis / Suc Valve Operation

Visual & Audible Alarms

P15

R/C Off > On = P15 Off (Open) > On (Close)

Off > On

L30

R/C Off > On = L30

Normal

No Display (Std)

No Action

Activated

System STOP

L30

R/C Off > On = L30

Ready

No Display (Std) Off (Open) > On (Close)

Off > On

Activated

System STOP

L30

R/C Off > On = L30

Ready

No Display (Std)

No Action

Option 2: Internal Leak Detection Activation (SSH Activation)

The internal leak detection software, based on the detection of Suction Superheat levels (SSH) provides the end user with four (4) options. These are detailed within the tables below

System Setup

Control Method
5 6

Outdoor PCB Configuration

Jumper 26

Switch 11 Bit 3

Cut

Off

Cut

Off

TCB-PCIN4E Connection Status
(CN511)
Connect
NOT Connect

TCB-PCMO4E Connection Status
(CN512)
Connect
Connect

Cut

Connect

NOT Connect

Connect

System Control Procedure

Control Method
5 6 7 8

Internal Detection Control Activated

CDU Operation Status

CDU 7 Segment Display

Activated Activated Activated Activated

Pump Back Operation
Normal Operation
Pump Back Operation
Normal Operation

P15 No Error Displayed
P15 No Error Displayed

FCU Units

R/C On Display

R/C Off Display

LD2 Controller Operation

Liq / Dis / Suc Valve Operation

Visual & Audible Alarms

P15

R/C Off > On = P15 Off (Open) > On (Close)

Off > On

Normal

No Display (Std)

No Action

P15

R/C Off > On = P15 Off (Open) > On (Close)

Off > On

Normal

No Display (Std)

No Action

SSH Set Up

· Suction Super Heat (SSH) detection value may be adjusted for your system. · This is adjusted using a combination of the following;
Rotary switches (SW01,SW02 & SW03) SW15 for interaction & setting SW04 & SW05 for temperature adjustment · Minimum & maximum settings are 20 & 99 respectively · See below for detailed operation
· System no operation (compressor OFF) · Set Rotary switches SW01 [2], SW02 [12] & SW03 [14] · 7-SEG shows [SH][ 35] (If J26 NOT cut, 7-SEG display is blank) * · SW15 push for over 15 sec (7-SEG blink) · SW04 push over 1 sec SSH +1K. SW04 push over 2sec SSH +5K · SW05 push over 1 sec SSH -1K. SW05 push over 2sec SSH -5K · SW15 push over 5 sec, SSH data set · Change rotary switch (SW01, SW02 & SW03) to position 0 to release SSH
setting.
CAUTION
· The SSH default control temperature is set to 35°C. Changes to this value may result in false or no operation of SSH detection.
11 Test Run
Preparation
· Before turning on the power supply, carry out the following procedure. 1) Using 500V-Megger, check that the resistance of 1M or more exists between the terminal block of the power supply and the earth (grounding). If resistance of less than 1M is detected, do not run the unit. 2) Check the service valve of the outdoor unit is fully opened.
· To protect the compressor at activation time, leave power-ON for 12 hours or more before operating. · Before starting a test run, be sure to set addresses following the installation manual supplied with the outdoor unit.
28

How to Execute a Test Run
Turn on power to the Indoor Unit(s), CDU(s) and LD2 controller, using this order of operation. All units will initialise on power ON. The LD2 initialises for a duration of 2 minutes and the isolation valves are forced open during the process.
Insert the key into the MANUAL test switch on the front of the LD2 controller Turn the key switch clockwise and hold until the alarm activates. The switch has an auto return facility and on release the key the switch will return to the standby position. Observe the actions below to ensure test run is successful.
· Visual and Audible alarms will sound and system will enter pump back mode. · During Manual test operation the following may be observed:
CDU operation (compressor ON) Liquid & Discharge valves close Suction valve close System stop and check codes displayed · On completion of Manual test operation the LD2 can be reset using the RESET button mounted inside the controller.
· The buzzer may be silenced during the test run and normal operation by using the following procedures; Press Buzzer Mute button 1 second Buzzer 2hrs Off then constant operation Press Buzzer Mute button 5 seconds Buzzer OFF
N.B. System cannot be RESET until the test operation has been completed.
CAUTION
· Do not use the forced test run for cases other than a system test because it applies excessive load to the devices.
12 Reset
This procedure must not be completed until an engineer with the relevant qualifications has inspected, repaired and verified the system integrity.
Preparation
· The LD2 controller cannot be reset when the CDU(s) and/or the Indoor Unit(s) have error codes in relation to leak detection protocols; the result is continuous operation of the LD2 controller and alarms.
· Before pressing the reset button mounted on the inside of the controller ensure the following has been completed; 1) Power supply to CDU(s) must be power OFF. 2) Power supply to Indoor Unit(s) must be power OFF.
How to Execute Reset
· Open the TCB-LD2UK controller panel door · Press and hold the Reset button 1 second · The TCB-LD2UK controller now starts the reset process as follows;
Liquid, discharge & suction valves open Audio & visual alarms active · On completion of reset operation, the LD2 controllers audio & visual alarms will silence · Power OFF LD2 Controller · Power ON Indoor Unit(s) · Power ON CDU(s) · Power ON LD2 controller · The air conditioner is now ready to be operated
CAUTION
· Do not use the reset function if the system has not been investigated by an engineer with the relevant qualifications to inspect the air conditioner
29

13 Trouble Shooting
Using a Wired Remote Controller

Confirmation and Check
When a trouble occurred in the air conditioner, the check code and the indoor unit No. appear on the display part of the remote controller. The check code is only displayed during the operation. If the display disappears, operate the air conditioner according to the following "Confirmation of error history" for confirmation.
Confirmation of Error History
When a trouble occurred on the air conditioner, the trouble can be confirmed with the following procedure. (The trouble history is stored up to 4 troubles.) The history can be confirmed from both operating status and stop status.

Check code

Indoor unit No. in which an error occurred

Procedure 1
When pushing and buttons at the same time for 4 seconds or more, the following display appears. If [ service check] is displayed, the mode enters in the trouble history mode. · [01: Order of trouble history] is displayed in CODE No. window. · [Check code] is displayed in CHECK window. · [Indoor unit address in which an error occurred] is displayed in Unit No.

Procedure 2

Every pushing of "TEMP."

button used to set temperature, the trouble history stored in memory is displayed in

order.

The numbers in CODE No. indicate CODE No. [01] ( latest ) [04] (oldest).

REQUIREMENT

Do not push button because all of trouble history will be deleted.

Procedure 3
After confirmation, push

button to return to the usual display.

Common Check Codes Relating to Leak Detection

Check Code

Description

L30

External Interlock of Indoor Unit refrigerant leak detected at indoor unit on activation of LDS1 or LDS2 sensors.

P15

Gas Leak Detection refrigerant leak detected at CDU when SSH is 35°C for 15 minutes or over.

LD2 Visual Fault Sequences
The LED visual alarm (FCU/CDU) on the front panel of the LD2 controller will activate in different sequences to indicate a specific fault on the connected system. The specific faults and corresponding LED sequences are listed below.

Fault L30 (Indoor) External Safety Manual Test P15 (CDU) Power Failure

LED Sequence Continuous Light Continuous Light Continuous Light Flashing Light (1s ON, 1s OFF) Flashing Light (10s ON, 10s OFF)

14 Declaration of Conformity

DECLARATION OF CONFORMITY

Directives: Manufacturer:

2002/95/EC: Restriction of the use of certain hazardous substances (RoHS) 2014/35/EU: Low Voltage Directive 2004/108/EC: Electromagnetic compatibility
Carrier Solutions UK Ltd.

Address: Apparatus:

Porsham Close Belliver Industrial Estate Plymouth PL6 7DB
TCB-LD2UK Air conditioning Control Accessory

Standards to which conformity is declared: EN 60529: 1992
EN 61439-1: 2011 EN 61439-2: 2011 EN 61000-6-2: 2005 EN 61000-6-4: 2007

Note:

This declaration becomes invalid if technical or operational modifications are introduced without the manufacturers consent.

Signed:
Position: Date of Issue: Place Issued:

Engineering Director, Carrier Solutions UK Ltd. 17th November 2016
United Kingdom

TOSHIBA
Carrier Solutions UK Ltd

Carrier Solutions UK Ltd Porsham Close Belliver Industrial Estate Plymouth, UK PL6 7DB
T: +44 (0) 1752 753200 F: +44 (0) 1752 753222
31

15 Service Parts
TCB-LD2UK Controller

04
08 05

Location No. 01 02 03 04 05 06 07 08 09
A ccessory Fitted 01 02 03 04

Part No. 43AOAK01 43AOAK02 43AOAK03 43AOAK04 43AOAK06 43AOAK07 43AOAK08 43AOAK09 43AOAK10
Part No. R BC LAHLD2 R BC LATLD2 R BC R IC LD2 R BC HPC LD2

Description

Qty

Green LED 240V

(Power ON)

Buzzer Element 24V AC/DC

Push Button 1NO (Black)

(Buzzer Mute)

2 Position Spring Return Key Switch (Manual Test)

Red LED 24V AC/DC

(Alarm ON)

Siemens 24RCo Logic Module

Siemens DM8 24R Expansion Module

Siemens Transformer

Push Button 1NO (Green)

(Reset)

Description

Qty

Low Ambient Protection Heater

Low Ambient Thermostat

Remote Indication Relay

Hinged Perspex C over to Protect S witch/Indicators

PRV, Strainer & Valves
101 102

103 104

Location No. 101 102 103
104

Part No.

Description

Qty

43APJ010

Pressure Relief Valve (PRV)

43APJ025

Strainer

43APJ08A

Valve Actuator (AW17861 1/2" / 12.7mm)

43APJ08B

Valve Actuator (AW17862 5/8" / 15.9mm)

43APJ08C

Valve Actuator (AW17863 3/4" / 19.0mm)

43APJ08D

Valve Actuator (AW17864 7/8" / 22.2mm)

43APJ08E

Valve Actuator (AW17865 1 1/8" / 28.6mm)

43APJ09A

Valve Actuator (AW17866 1 3/8" / 34.9mm)

43APJ09B

Valve Actuator (AW 17867 1 5/8" / 41.3mm)

43APJ861

Ball Valve (AW17861 1/2" / 12.7mm)

43APJ862

Ball Valve (AW17862 5/8" / 15.9mm)

43APJ863

Ball Valve (AW17863 3/4" / 19.0mm)

43APJ864

Ball Valve (AW17864 7/8" / 22.2mm)

43APJ865

Ball Valve (AW17865 1 1/8" / 28.6mm)

43APJ866

Ball Valve (AW17866 1 3/8" / 34.9mm)

43APJ867

Ball Valve (AW17867 1 5/8" / 41.3mm)

Fault code diagnosis apps now available For
Apple iPhone & Android

24 Hour Technical Helpline: 0330 236 8630 option 5 Fault & DN Code Apps: Android & iPhone Web Page
toshiba-calc.co.uk/fault-codes/ technical.enquiries@toshiba-ac.com

Technical Department

AIR CONDITIONING A division of Carrier Solutions UK Ltd Parkfield House, Manchester Old Road, Middleton, Manchester, M24 4DY
www.toshiba-aircon.co.uk

UK Headquarters Toshiba Air Conditioning United Technologies House,
Guildford Road, Leatherhead, Surrey KT22 9UT
marketing.uk@toshiba-ac.com

Plymouth Carrier Solutions UK Ltd
Porsham Close, Belliver Industrial Estate,
Plymouth, Devon
PL6 7DB
toshiba.salesdesk.uk@toshiba-ac.com

References

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