Mitsubishi MEE03K197 Installation Manual
For R407C Refrigerant
2004
Mineral Oil Recovery Work Manual
HEAD OFFICE: MITSUBISHI DENKI BLDG., 2-2-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
Issued in April 2004 MEE03K197
Printed in Japan
New publication effective April 2004
Specifications subject to change without notice.
This product is designed and intended for use in the residential, commer-
cial and light-industrial environment.
The product at hand is • Low Voltage Directive 73/23/EEC
based on the following • Electromagnetic Compatibility Directive 89/
EU regulations: 336/EEC
•Pressure Equipment Directive 97/23/EC
Please be sure to put the contact address/telephone number on
this manual before handing it to the customer.
Replace Multi Mineral Oil Recovery Work Manual PUHY-YREM-A
Cautions For REPLACE MULTI Installation Work
Flow of installation work in the field Items to be observed
•Please note that our Corporation is not liable to the reliability of existing piping,
wiring and power system for reuse (in relation with the gas leak of piping, partially
defective/disconnection of wiring, deteriorated insulation, characteristic faults due
to worn out system).
•For limitation on the refrigerant piping and applicable piping diameter, check the
existing piping for reuse in accordance with the specified check sheet by referring to product catalogs and this manuals for judgement to reuse.
•If vapor condensation was found in the past, check the thermal insulation.
•Any portion suffering condensation dripping, check the deterioration of the insulation, and repair the insulation materials if required.
•When the copper piping is seriously deteriorated, do not use parts with verdigris
or black spots.
•For reusing the existing control wiring between the outdoor unit, and remote controller, check the wire type , size or the like , based on the chec k sheet to judge the
possibility.
•Even when the above does not meet the item on the check sheet, existing wiring
may be reused depending on the number of connecting indoor units and piping
length. Ask us for details.
•For the power source system, employ the voltage and number of phase meeting
the outdoor unit, indoor unit and adopt the breaker capacity and wiring size based
on the power source wiring connection diagram.
•When the existing power source system (including the power source wiring) is
used, check the system for deterioration and damages.
•Check the refrigerating machine oil used in the existing system. (As is found at
the oil inspection), if the refrigerating machine oil used in the existing system is
mineral oil, use the ester oil sampling kit for inspection.
•When the length of piping for reuse is unknown, additional refrigerant charge is
to be calculated based on the quantity of recovered refrigerant. For this reason,
you are kindly requested to recover all refrigerant inside the existing outdoor/
indoor units and extended piping to check and record the quantity. (The standard of additional refrigerant is (Quantity of R22 recovered - Charged quantity of
existing outdoor unit + 3kg). Adjust the refrigerant quantity after mineral oil recovery operation.)
■ Outdoor unit
•Confirm the space around the outdoor unit.
(Verifying the installation space of the oil trap kit)
■ Turn the power source on, and confirm the normality of the system
•Check the remote controller or outdoor unit for error display.
•Run the indoor unit for fan operation after turning the remote controller on, and
check the air feeding and direction.
Do not run the compressor until finishing the mineral oil recovery operation.
■Mount the valves to the field piping (extended piping). (The ball valve is attached
to the outdoor unit.)
■Execute an airtight test to check the existing piping for deterioration or leaking.
■Calculate the quantity required by the extended piping, and charge the addi-
tional refrigerant. Make sure to enter the value in the additional refrigerant charge
column on the label of the outdoor unit.
■If the refrigerant charge is insufficient, enter the value also.
Without applying any operation, keep the ball v alves of the outdoor unit c losed
before mineral oil recovery operation.
It is necessary to charge refrigerant in a rated quantity and adjust the quantity.
Be sure to execute when the piping length is unknown.
For detail, consult the agent of your dealer.
Enter required items in the request form of REPLACE MULTI mineral oil recovery work.
During local installation work
Before local installation work
Confirming the possibility of existing
refrigerant piping for reuse
Confirming the possibility of existing
control wiring for reuse
Confirming the possibility of existing
power source system for reuse
Confirming the objective range for
replacing
Recovering the refrigerant of old system
Removing the outdoor/indoor units, remote controllers, etc.
Installing the outdoor/indoor units, remote
controllers, etc., and executing electrical
work
Setting the address, checking the system
Executing the piping work (mounting of
ball valve).
Air tightening and evacuating the existing
piping and charging refrigerant
Operating mineral oil recovery
Executing test run and adjustment (for
final verification of operation).
Safety Precautions
• Before installing the unit, make sure you read all the “Safety precautions”.
• The “Saf ety precautions” provide very important points regarding safety. Make sure you follow
them.
Symbols used in the text
Warning:
Describes precautions that should be observed to prevent danger of injury or death to the user.
Caution:
Describes precautions that should be observed to prevent damage to the unit.
Symbols used in the illustrations
: Indicates an action that must be avoided.
: Indicates that important instructions must be followed.
: Indicates a part which must be grounded.
: Beware of electric shock (This symbol is displayed on the
main unit label.) <Color: Yellow>
Warning:
Carefully read the labels affixed to the main unit.
Warning
Ask your dealer or specialized contractor for
installation.
•If your own installation w ork is improper, fire, electric
shock or water leakage may result.
Connect wiring using the specified cable and fasten it securely to prevent the external force of
the cable from being transferred to the terminal
connecting sections.
•Improper connection or fastening may cause heat
generation or fire.
Conduct specified installation work durable
against strong winds around buildings.
•Improper installation work can cause trouble i.e. the
unit toppling over.
Never attempt to repair the unit. For repair,
ask your dealer.
•Improper repair may result in water leakage, electric
shock or fire.
Do not touch the heat exchanger fins.
•Improper handling may cause cuts.
When refrigerant gas is leaked during work,
conduct ventilation.
•If refrigerant gas comes into contact with fire, it may
cause the generation of poisonous gases.
Please conduct correct installation work by
observing this Installation Manual.
•Improper installation work may result in water leakage, electric shock or fire.
Conduct all electrical work by a licensed engineer according to “Technical Standard relating to Electrical Facility,” “Wiring Regulation of Power Company,” and instructions in
this Manual, and always use an exclusive circuit.
•Insufficient power source capacity or improper installation may cause electric shock or fire.
When installing or moving the unit, do not
charge other than the specified refrigerant
(R407C) into the refrigeration cycle.
•Air if mixed generates abnormally high pressure inside the refrigeration cycle which may damage the
unit.
Do not reconstruct or reset the protection
devices.
•If the protection devices like the pressure switch or
thermal switch is forcibly operated by short circuiting, or parts other than that specified by Mitsubishi
Electric are used, fire or explosion may be caused.
Before Conducting Mineral Oil Recovery Operation
Caution
Turn the power source on 12 hours or mor e
before starting operation.
• Otherwise trouble may be caused. Do not turn the
power off during the operating season.
Do not operate the unit without the panels or
guard.
•Touching the rotating parts, high temperature parts
or high voltage may cause personal injury such as
burns or electric shock.
Do not operate switches with wet fingers.
•Electric shock may be caused.
Do not turn off the power source immediately
after stopping.
• Be sure to wait for 5 minutes or more. Otherwise
water leakage or troubles may be caused.
Do not touch the refrigerant piping during
operation or immediately after stopping with
bare hands.
• The refrigerant piping or the refrigerant circuit parts
of the compressor during operation or immediately
after stopping may have low or high temperature.
Touching with bare hands may cause a burn or frostbite.
Do not run the outdoor unit during a test run until
finishing the mineral oil recovery operation.
• The indoor unit fan will run.
Caution to Mineral Oil Recovery Operation
Warning
Caution
Be sufficiently careful to avoid the oil trap
kit, falling or toppling over.
• If this happens the oil trap kit may be damaged and
refrigerant piping may malfunction.
• Falling down during flushing operation causes the
leak of refrigerant from the joint which is dangerous
if contacts it human body.
After flushing operation, check the residual pressure inside the oil trap kit with a pressure gauge.
If the residual pressure is exceeding 0.294MPa,
recover refrigerant inside the oil trap kit to reduce
the pressure to within 0.2 ~ 0.294MPa.
• Under high inner pressure, pressure rises during
storing, inducing a dangerous situation.
• Under low inner pressure, water content or foreign
matter enters during storing, causing corrosion to
the oil trap kit which may cause troubles.
Be careful not to expose the oil trap kit unit
(especially electrical parts) to rain water.
• The electrical parts if wet with rain water may cause
machine trouble.
• The electrical parts if wet with rain water may cause
electrical shock.
Conduct oil recovery from the oil recovery service valve outdoor or at a place with good ventilation. Use leather gloves when opening the oil recovery service valve and open it slowly.
• If done in a closed space, suffocation can be caused.
• Opening the oil recovery service valve fully and
quickly allows oil to splash, which is dangerous.
• As the oil recovered is of low temperature, frostbite
may be caused if it touches skin.
When the oil trap kit is transported while lying sideways, do not place any thing on the
sheet metal of the kit.
• Otherwise, the sheet metal or inner piping may be
deformed leading to breakage.
Before removing the oil trap kit after flushing operation, make sure to discharge and
process the oil recovered from the oil recovery service valve.
• If it is not discharged, the oil accumulated inside will
flow out during flushing operation hindering proper
recovery of mineral oil thus leading to machine
trouble.
For inspection, use the ester oil sampling kit
when the refrigerating machine oil used in the
existing unit is mineral oil.
(
Confirm the type of refrigerating machine oil used in the
existing unit by reading the name plate or the like.
)
• Proper checking can not be executed if not using the
kit meeting the refrigerating machine oil used by the
existing unit. This possibly causes machine trouble.
Precautions for Devices that Use R407C Refrigerant
Caution
Use refrigerant piping made of phosphorus
deoxidized copper and copper alloy seamless pipes and tubes. In addition, be sure
that the inner and outer surfaces of the pipes
are clean and free of hazardous sulphur, oxides, dust/dirt, shaving particles, moisture,
or any other contaminant.
•Contaminants on the inside of the refrigerant piping
may cause the refrigerating machine oil to deteriorate.
Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before brazing. (Store
elbows and other joints in a plastic bag.)
•If dust, dirt, or water enters the refrigerant cycle,
deterioration of the oil and compressor trouble may result.
Use ester oil, ether oil or alkylbenzene (small
amount) as the refrigerating machine oil to
coat flares and flange connections.
•The refrigerating machine oil will degrade if it is mixed
with a large amount of mineral oil.
Use liquid refrigerant to seal the system.
•If gas refrigerant is used to seal the system, the composition of the refrigerant in the cylinder will change
and performance may drop.
Do not use other refrigerant other than
R407C.
•Use of other refrigerants (R22 for example) may deteriorate refrigerating machine oil due to chlorine
generation.
Use a vacuum pump with reverse flow protection.
•Otherwise the vacuum pump oil will reversely flow
into the refrigerant circuit causing the possible deterioration of the refrigerating machine.
Do not use the following tools used for conventional refrigerant.
(Gauge manifold, Charging hose, Gas leak
detector, Reverse flow protector, Cap for refrigerant charge, Refrigerant recovery device)
•Mixing of conventional refrigerant /refrigerating machine oil may cause to deteriorate the refrigerating
machine oil.
•Mixing with water may cause deterioration of the refrigerating machine oil.
•As this refrigerant does not contain chloride, the gas
leak detector for conventional refrigerant gas can not
be used.
Do not use a charging cylinder.
•Use of a charging cylinder changes the composition
of refrigerant resulting in possible performance deterioration.
More careful management is required for the
tools than that for the conventional.
•Dust, trash or water content if mixed into the refrigerant circuit may cause to deteriorate the refrigerating machine oil.
Caution to Equipment Used for Replacing
Caution
Do not operate the valve before conducting
mineral oil recovery operation.
Operating valves before conducting mineral oil recovery operation may cause a deterioration in the performance of mineral oil recovery.
For mineral oil recovery operation, the system controller and MA remote controller may
be required to be remove sometimes.
•Improper handling can lead to an inability to perform
oil recovery operation.
• For removal, follow the instruction displayed on the
PC for mineral oil recovery.
• Mount the controllers again after finishing the oil recovery operation.
Observe a safe distance from the indoor unit
fan which runs during the mineral oil recovery operation.
Working in the surrounding of the indoor unit fan can
cause personal injury.
Record the quantity of refrigerant replenished.
(Enter into the column for replenished refrigerant
quantity on the label of the indoor unit.)
•Missing the description may deteriorate the performance of mineral oil recovery.
•Malfunction or poor cooling/heating may also be
caused.
During the mineral oil recovery operation, an
error display may be shown on the remote
controller or system controller.
•When an error display was shown during mineral oil
recovery operation, reset the error display after finishing the operation.
To conduct the refrigerant recovery/evacuation of the inside of exiting piping, choose
tools only used with R407C e.g. charging hose.
• Using a charging hose for R407C causes it to mix
the conventional refrigerating machine oil leading to
the deterioration of refrigerating machine oil.
Before Conducting Installation Work/Electrical Work
Caution
Do not install the unit at a place where combustible gas can possibly be generated.
•Leaked combustible gas if stagnated around the unit
may cause explosion.
Do not use the unit in a special atmosphere.
•Use in an atmosphere containing high levels of oil,
steam or sulfide gas may seriously degrades the performance or damage parts.
Do not install the unit on a material which is
not designed to be wet.
•If liquid drips from the oil trap kit, apply centralised
drainage work to the oil trap kit.
Apply grounding work securely.
• Do not connect the grounding line to gas pipe, city
water pipe, lightning rod or telephone grounding line.
Improper grounding may cause electric shock.
For the power source wiring, refrain from
giving tensile force to the wiring.
•Disconnection, heat generation or fire may be
caused.
Make sure to mount a leak breaker to the
power source.
•Otherwise electric shock may be caused.
Be sufficiently careful in transporting products.
•Do not transport a product with a weight exceeding
20kg by a single person.
•Some products are packed with PP band. Do not
use it as a means of transporting.
•During transport cuts may be caused by the fin surface of the heat exchanger , please refrain from touching it without gloves.
Do not use the same switch or the like for
plural outdoor units.
Otherwise, malfunction, heat generation or fire may
be caused.
When installing the unit in hospitals or communication equipment plants, prepare measures to prevent noise generation beforehand.
•The noise may cause the erroneous operation or
failure and may give negative eff ect to medial equipment or communication equipment to disturb medical treatment on human bodies or hinders image
broadcasting or generates noise.
Check possibility for the reuse of existing
refrigerant piping by observing this manual.
• The conventional refrigerating machine oil is con-
tained inside existing piping and some residual oil
deteriorates oil recovery performance which may
lead to the deterioration of refrigerating machine oil.
• The piping specification (diameter, length , height
difference) out of the use specified range may hinder
the mineral oil recovery performance, possibly leading to deterioration of refrigerating machine oil.
Do not use breakers or fuses other than that
with correct capacities.
•Use of a fuse with excessively large capacity or wire/
copper wire may cause troubles or fire.
For the power source wiring, use wire with
rated current capacity.
•Otherwise an electric leak, heat generation or fire
may be caused.
When using existing wiring (for power source
or transmission) or switches, check them for
disconnection and deterioration beforehand.
•Otherwise an electric leak, heat generation or fire
may be caused.
Dispose the packing materials properly.
• As the packing materials are using metal products
or wooden pieces such as nails, nail wounds may
be caused if it is improperly treated. Please observe
caution to avoid this from occuring.
•Dispose the polyethylene bag for packing only after
tearing. Otherwise a suffocation accident may be
caused by children play with the disposed bag.
Be sure to mount the valve to the field piping
(extended piping).
After mineral oil recovery, the oil trap kit can not be
removed disabling air conditioning operation.
Provide thermal insulation to the valve on the
field piping (extended piping) properly.
•Insufficient thermal insulation generates condensation that may cause to deteriorate the performance.
• Provide thermal insulation (including lagging) after
recovering mineral oil.
I. Outline of Equipment .................................................................................................................... 10
1. Combination of units ...................................................................................................................... 10
2. Temperature range allowing mineral oil recovery operation .......................................................... 10
3. Items to be observed ..................................................................................................................... 10
II. Product Specification.................................................................................................................... 11
1. Outdoor unit ................................................................................................................................... 11
(1) Specification table
(2) External dimension
2. Oil trap kit ....................................................................................................................................... 13
(1) Specification table
(2) External dimension
III. Outline of Flushing Operation .......................................................................................................... 14
I. Parts Provided with Oil Trap Kit ................................................................................................. 17
1. Verifying the parts provided ........................................................................................................... 17
II. Carrying/Storing the Oil Trap Kit................................................................................................ 18
1. Transportation by vehicles ............................................................................................................. 18
2. Carrying-in/carrying-out ................................................................................................................. 18
3. Storing............................................................................................................................................ 18
III. Work Procedure of Mineral Oil Recovery Operation ............................................................ 19
1. Work flow ....................................................................................................................................... 19
2. Items to be checked before work ................................................................................................... 21
3. Installation space and range of oil trap kit...................................................................................... 23
(1) Restrictions
4. Refrigerant piping work .................................................................................................................. 24
4-1 Piping connection before flushing operation
4-2 Piping connection after flushing operation
5. Electrical wiring work ..................................................................................................................... 30
5-1 Wiring connection before flushing operation
5-2 Wiring connection after flushing operation
6. Connection work on rainy days ...................................................................................................... 31
7. Flushing operation ......................................................................................................................... 32
(1) Installation method of S/W
(2) Items to be confirmed before flushing operation
(3) Starting and finishing of flushing operation
(4) Mounting method of low outdoor temperature hood
IV.Work Procedure at Oil Inspection.............................................................................................. 45
1. Oil inspection after mineral oil recovery ......................................................................................... 45
(1) Oil sampling method
(2) Measuring method and judgement of refractive index
(3) Measures to be taken at oil inspection (No Good)
V. Mineral Oil Recovery Operation Data (Reference Data)........................................................... 53
1. Standard data (During flushing operation) .....................................................................................53
CONTENTS
System Design
Caution to REPLACE MULTI Installation Work
Safety Precautions
Installation / Operation Work
Simplified Judgment for Reuse of Existing Piping/Wiring
I. Judgment for Reuse of Existing Piping ..................................................................................... 2
1. Reusing CITY MULTI air conditioner system .................................................................................. 2
2. Reusing other makes or Mitsubishi other than CITY MULTI ........................................................... 2
II. Connection Range of Deformed Piping
..................................................................................... 4
III.
Judgment for Reuse of Existing Transmission Line Wiring................................................. 5
I. Construction of Oil Trap Kit......................................................................................................... 55
1. External appearance (with panel removed) ................................................................................... 55
2. Refrigerant circuit ........................................................................................................................... 56
3. Control box..................................................................................................................................... 57
II. Electrical Wiring Diagram ............................................................................................................ 58
III. Refrigerant Circuit Diagram ..............................................................................................59
1. Entire refrigerant circuit diagram at mineral oil recovery................................................................ 59
2. Refrigerant circuit diagram of oil trap kit ........................................................................................ 60
IV. Function List of Major Parts ........................................................................................................ 61
1. Outdoor unit ................................................................................................................................... 61
2. Oil trap kit ....................................................................................................................................... 62
3. Indoor unit ...................................................................................................................................... 63
V. Control of Mineral Oil Recovery Operation ............................................................................. 64
1. Initial control................................................................................................................................... 64
2. Control of solenoid valves.............................................................................................................. 64
3. Frequency control .......................................................................................................................... 65
4. Oil return control (Electronic expansion valve <SLEV> ) ............................................................... 66
5. Outdoor fan control ........................................................................................................................ 66
6. Sub-cooling coil control (Electronic expansion valve <LEV1>)...................................................... 66
7. Detecting circulation composition (CS circuit)................................................................................67
8. Distributed washing control and flow rate control (Indoor unit) ...................................................... 67
9. Indoor unit fan control .................................................................................................................... 67
VI. Operation Flow Chart.................................................................................................................... 68
1. Flushing operation ......................................................................................................................... 68
2. Flow chart of flushing operation ..................................................................................................... 69
VII. Troubleshooting ............................................................................................................................. 70
1. List of checking code ..................................................................................................................... 70
2. Self-diagnosis and countermeasure for malfunction and failure indicated by PC.......................... 72
3. Investigation of transmission wave shape/noise............................................................................ 87
4. Troubleshooting for major parts of outdoor unit and indoor unit .................................................... 97
5. Inverter......................................................................................................................................... 105
6. Control circuit ................................................................................................................................111
VIII. Monitor Display of Mineral Oil Recovery Operation by Outdoor Board LED.............. 112
1. How to view LED for service monitor ........................................................................................... 112
2. Synoptic table of the monitor display of mineral oil recovery operation by outdoor board LED ... 112
IX. Maintenance and Checking ....................................................................................................... 113
1. Maintenance and checking period ............................................................................................... 113
2. Maintenance and checking procedure for major parts for the oil trap kit ..................................... 114
3. Procedure for maintenance and checking of the portable refractometer ..................................... 118
4. Cautions when replacing the outdoor unit main board................................................................. 118
X. Information on Rating Plate....................................................................................................... 119
Service, Maintenance / Inspection
I. Judgment for Reuse of Existing Piping ..................................................................................... 2
1. Reusing CITY MULTI air conditioner system .................................................................................. 2
2. Reusing other makes or Mitsubishi other than CITY MULTI ........................................................... 2
II. Connection Range of Deformed Piping ..................................................................................... 4
III.
Judgment for Reuse of Existing Transmission Line Wiring ................................................. 5
Simplified Judgment for Reuse
of Existing Piping/Wiring
-1-
I. Judgment for Reuse of Existing Piping
Both the checking of gas leak inside existing piping and the verification of reliability relating to piping strength
belong to the scope of field work as same as in the past. Therefore, we are not liable to the quality of existing
piping.
Before starting the work, it is necessary to confirm that the existing piping in question owns the rated strength
(relating to the material, thickness, and corroded portions, if any).
Points to be observed for simplified judgment to reuse existing piping
1. Reusing CITY MULTI air conditioner system
The existing piping can basically be reused if no problem was found during your use in the past.
(Please check whether the trouble was caused by gas leak or it required frequent refrigerant replenishment.)
(1) Change to same capacity → Usable as it is
(2) Change to different capacity → Check whether the piping diameter, piping length, height difference, etc.
are within our operating range.
2. Reusing other makes or Mitsubishi other than CITY MULTI
(1) Check whether the packaged air conditioner used in the past was in operational trouble or not.
(Please check whether the trouble was caused by gas leak or it required frequent refrigerant replenish-
ment.)
(2) Confirm the type of refrigerating machine oil used by the existing facility.
SUNISO, MS, HAB, Barrel Freeze, Freol are acceptable. For other refrigerating machine oil than the
above, ask our factory in each case.
(3) The branch types of T-fitting, Y-branch and header branching are acceptable.
The branch pipe applied with pressure loss (like the multi-distributor of SLIM) can not be used. Replace-
ment with new branch pipe is required in this case.
Estimate the branch configuration and piping size depending on the maker name, model name and con-
necting quantity of existing products.
(4) Confirm that the piping diameter, piping length, height difference, etc. are within our operating range.
Item, index of judgment for reusing of existing piping
Piping diameter, length
Type of refrigerating
machine oil
Air tightness
Distributor configuration
Thermal insulation
Piping system
Pipe thickness
None
Maker, type (model name), year of manufacturing
Operability of previous unit
Maker, type (model name), year of manufacturing
None
None
Refer to DATA BOOK
SUNISO, MS, HAB, Barrel Freeze, Freol
No pressure drop by leaving for one day after
pressurizing to 2.98Mpa
T-fitting, Y-fitting, Header branching
No peeling off of thermal insulation and caulking
Unit height difference should be within the standard
of typical unit
Pipe thickness equivalent to the standard of each
country
Items Judgment standard Indirect material for judgment
-2-
Start
In the piping planned for reuse,
are the outdoor and indoor
units connected?
Is the old unit Mitsubishi?
Do you wish to replace with our
Building Multi in the same capacity?
Do you know the piping
diameter/length?
Simplified judgment for reuse of existing piping (Flow)
Do you know the type of refrigerating
machine oil used by the old unit?
Is it SUNISO, MS, HAB,
Barrel Freeze or Freol?
Can you find the height
difference between outdoor and indoor
units, and between indoor units?
Is the height difference between
indoor and outdoor units less than
50m (40m when outdoor unit locates below
indoor unit), and that between indoor units
less than 15m maximum?
Do you know the piping
diameter/length?
Do the piping diameter and piping
length match our standard?
Do you know the configuration of
the branch piping?
Is the branch pipe of T, Y
or header branching?
Is a gas leak found?
Is there any branching pipe
not connected with indoor unit?
Is the thermal insulation of
piping peeling off ?
Is the rated strength
(material, thickness, corroded portion
if any) kept?
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
YES
Check it by
asking the maker.
Please check it.
Install new piping.
As the piping left alone
may allow the entry of
dust or the like, refrain
to reuse such piping.
Please investigate.
Please investigate
in the field.
Please investigate
in the field.
Change the branch pipe
with that specified by us.
Check the air tightness
in the field.
Is the air tightness of
the piping proper?
Isolate the branching pipe from
the refrigerant circuit during
mineral oil recovery work.
Use new piping. Existing piping can be used.
NO
NO
NO
NO
YES
YES
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
Do you know the maker,
type and model name?
Judge the possibility of
reuse by checking the configuration
while referring to the standard.
Was the old unit operated before
replacement without refrigerant leak?
Can you cut off the
branching pipe?
Provide proper thermal
insulation.
-3-
II. Connection Range of Deformed Piping
1. List of possibility to connect deformed piping (Chart)
(1) Outdoor – First branch [A section (Y series)]
Table-1
: Normal piping
: Usable (without performance deterioration)
● : Usable (with performance deterioration: Refer to DATA BOOK)
: Usable (with rule on refrigerant charge: Refer to the formula to judge refrigerant
charge on the next page.)
▲ : Usable (with limitation on piping length)
◆ : Possible for liquid piping of
φ
9.52
x : Not connectable
❉ : Limitation on mineral oil recovery work process
This list is presented just for your reference, even the item marked x may be acceptable occasionally depending on the specific field piping condition. Therefore, please
ask the factory individually in such case.
Gas pipe
φ
15.88
φ
19.05
φ
22.2
φ
25.4
φ
28.58
φ
31.75
φ
38.1
Liquid pipe
φ
9.52
φ
12.7
φ
15.88
φ
19.05
φ
22.2
(2) Branch – indoor [a ~ f sections]
Table-2 List of possibility to connect indoor unit/deformed piping
Formula to judge refrigerant charge:
For the case marked , it is necessary to take measures to reduce the piping length slightly, to raise the selecting model or reduce
the number of connected indoor units.
• Y series
M = 0.3 x L1 + 0.2 x L2 + 0.12 x L3 + 0.06 x L4 + 0.024 x L5 < 17.4
L1 : Piping length (m) of φ19.05mm
L2 : Piping length (m) of φ15.88mm
L3 : Piping length (m) of φ12.7mm
L4 : Piping length (m) of φ9.52mm
L5 : Piping length (m) of φ6.35mm
Gas pipeφ12.7
φ
15.88
φ
19.05
φ
22.2
φ
25.4
φ
28.58
φ
31.75
φ
38.1
Liquid pipe
φ
6.35
φ
9.52
φ
12.7
φ
15.88
φ
19.05
P20 P25 P32 P40 P50 P63 P71 P80 P100 P125 P140 P200 P250
xx xx xxx
xxx xx
xxxxx xx
xxxxxxx❉❉❉ x
xxxxxxxx x❉❉
xxxxxxxx xxx
xxxxxxxx xxxxx
xxxxxxxx xxxxx
xx xx xxx
xx
xxxxxxxx xxxxx
(within 25m) (within 15m)
P200 P250
x
x
x
x
x
❉
x
x
xx
xx
xx
x
x
-4-
1. Remote controller line (MA remote controller)
(1) Length m
(2) Wire diameter mm
2
(3) Number of wire (number of pole) Pole
(4) Type of wire (Shielded wire used/not used) Used / Not used
2. Remote controller line (M-NET remote controller)
(1) Length ❉1 m
(2) Wire diameter mm
2
(3) Number of wire (number of pole) Pole
(4) Type of wire (Shielded wire used/not used) Used / Not used
3. Remote controller line (System controller)
(1) Length ❉1 m
m
m
(2) Wire diameter mm
2
(3) Number of wire (number of pole) Pole
(4) Type of wire (Shielded wire used/not used) Used / Not used
(5)
System controller connection
Indoor / Centralized
Indoor system/centralized system
4. Indoor-outdoor transmission line
(1) Refrigerant system Single/Plural Single / Plural
(2) Transmission line farthest length
(3) Wire diameter mm
2
(4) Number of wire (Number of pole) Pole
(5) Type of wire (Shielded wire used/not used) Used / Not used
(6) Number of connected indoor units Unit
5. Centralized transmission line
(1) Transmission line farthest length
(2) Wire diameter mm
2
(3) Number of wire (Number of pole) Pole
(4) Type of wire (Shielded wire used/not used) Used / Not used
6. Availability of system diagram YES / NO
(Please try to obtain it much as possible.)
7. Existence of noise trouble on the unit before replacement YES / NO
(In case of YES, enter the trouble detail into the
column of remarks.) ❉2
8. Is the noise generation from high harmonics medical YES / NO
equipment estimated? (In case of YES, enter your
apprehensions in detail into the column of remarks.) ❉2
III.
Judgment for Reuse of Existing Transmission Line Wiring
To study on the reuse of existing transmission line, please refer to the flow shown later starting from the next
page.
For the reuse of existing transmission line, enter the necessary items into the check list, obtain the system
diagram and contact our dealer.
Check list for reuse of existing transmission line wiring
Checking item Result Remarks
❉1 Include the portion of the remote controller length (M-NET/System controller) exceeding 10m into the figure of the transmission line
length (Indoor-outdoor, centralized).
❉2 Regarding the judgment and countermeasure on noise, please contact our dealer.
❉1
❉1
-5-
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
ABS
ABS
ABS
ABS
Arrange the wire not
used as shown in Fig. A.
Arrange MA remote controller
line length below 200m.
Check MA remote
controller line
Number of wire (pole)
= 2 ?
Remote controller
line length
≤ 200m?
To transmission
line checking
Arrange the wire not used
as shown in Fig. A.
Check system controller
remote controller line
Number of wire (pole)
= 2 ?
• Include a portion of wire length exceeding 10m into
the figure of the transmission line farthest length.
❉1
• Make the wire diameter and type as same as that of
transmission line.
To transmission
line checking
Check M-NET remote
controller line
Number of wire (pole)
= 2 ?
Remote controller
line length ≤10m?
To transmission
line checking
Arrange the wire not
used as shown in Fig. A.
• Include a portion of wire length exceeding 10m
into the figure of the indoor-outdoor transmis-
sion line length.
❉1
• Make the wire diameter and type the same as
that of the indoor-outdoor transmission line.
Power supply unit
(outdoor unit,
power supply
device, etc.) side
Fig. A Arrangement of wire not used
For the power supply unit (outdoor unit, power supply de-
vice, etc.) side, connect shielded wire to the terminal for
shielded wire, unshielded wire to the terminal for signal,
and open the other ends.
Insulate the opened ter
minals securely.
Shielded wire
Unshielded wire
-6-
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
NO
YES
NO
YES
YES
NO
Table A Usable wire diameter for centralized
system transmission line
❉1 Include a portion of remote controller (M-NET/System controller) wire length exceeding 10m into the figure of the transmission line
(indoor-outdoor / centralized systems) length.
❉2 Ask our dealer for the judgment and countermeasure on noise.
Arrange the indoor-outdoor
transmission line farthest
length less than 200m.
Confirming the number of indoor
units and the indoor-outdoor trans-
mission line farthest length, read the
usable wire diameter from the graph.
Arrange the wire not used
as shown in Table A.
Centralized
transmission line farthest
length ≤ 500m?
❉
1
C
entralized
transmission line wire dia-
meter ≥ 1.25mm
2
?
Shielded wire?
Connect the shielded wire to the
outdoor unit (power supply unit)
side for grounding.
The diameter of
the wire used is thicker than that read
from the B graph.
Replace the indoor-outdoor
transmission line by that with
a diameter over 1.25mm
2
.
Arrange the centralized
transmission line farthest length
less than 500m.
Confirming the centralized trans-
mission line farthest length, read
the usable wire diameter from
Table A.
When using other than shielded
wire, be careful for noise.
❉
2
Check transmission line.
Indoor-
outdoor transmission line
farthest length ≤ 200m?
❉1
Indoor-
outdoor transmission
line wire diameter
≥
125mm
2
?
Number of wire (pole)
= 2?
Single refrigerant
system?
Indoor-
outdoor transmission line
farthest length ≤ 120m?
❉1
Possible to reuse existing
transmission line
The wire
diameter of the used transmis-
sion line is thicker than that usable
in Table A?
Replace by the centralized
transmission line with a
diameter over 1.25mm
2
.
Distance from power supply
unit to outdoor unit and sys-
tem controller
Wire diameter
200m or less 0.5mm
2
or more
130m or less 0.3mm
2
or more
-7-
0.5mm
2
0.75mm
2
0.3mm
2
1.25mm
2
0
50
100
150
200
0 5 10 15 20
0
50
100
150
200
0 5 10 15 20 25 32
30
0.75mm
2
0.5mm
2
0.3mm
2
1.25mm
2
Fig. B Usable wire diameter
For connection with MA remote controller
Transmission line fa
rthest length (m)
Number of indoor unit
Transmission line farthest length (m)
Number of indoor unit
For connection with M-NET remote controller
-8-
I. Outline of Equipment .................................................................................................................... 10
1. Combination of units ...................................................................................................................... 10
2. Temperature range allowing mineral oil recovery operation .......................................................... 10
3. Items to be observed ..................................................................................................................... 10
II. Product Specification ....................................................................................................... 11
1. Outdoor unit ................................................................................................................................... 11
(1) Specification table .................................................................................................................... 11
(2) External dimension ................................................................................................................... 12
2. Oil trap kit ....................................................................................................................................... 13
(1) Specification table .................................................................................................................... 13
(2) External dimension ................................................................................................................... 13
III. Outline of Flushing Operation........................................................................................... 14
System Design
-9-
2. Temperature range allowing mineral oil recovery operation
Outdoor inlet dry bulb temperature –5 ~ 43˚C
3. Items to be observed
• Refrigerant flow sound, operating sound of solenoid valve switching
Caution Countermeasure
Install the unit at a place not affected by the
sound generated from the unit.
• RE: Effect of noise
Caution Countermeasure
During mineral oil recovery, flowing sound may be generated depending on the status of refrigerant. In addition, operating sound may be generated at the switching
of the solenoid valve.
(These symptoms do not represent abnormal states.)
As the air conditioner uses microcomputer, radiation noise
is emitted from the power source, transmission line and
unit body slightly. If the unit is installed near equipment
that amplify microscopic signals electrically (wireless microphone, medical equipment for example), these equipment may operate erroneously affected by the noise. Further installing the air conditioner near the equipment emitting strong noise (like electric discharge machine etc.)
may cause the malfunction of the air conditioner due to
the noise. In the case when such troubles are expected,
please take the countermeasure shown right.
The equipment which may likely be affected
by noise (receiver of wireless microphone or
antenna) are recommended to be install isolated from the transmission line, power source
line of the unit and the unit body.
The power source line of the equipment emitting strong noise and that of the air conditioner
should be separated, and the transmission
line, power source line and unit body should
be installed isolating each other as much as
possible.
I. Outline of Equipment
1. Combination of units
The connectable units to this product are shown below.
• Cool/heat selection Y System
Outdoor unit Total capacity of connected Quantity of connectable Connectable indoor unit
model name indoor unit model names indoor unit model name
PUHY-P200YREM-A 100 ~ 260 1-set ~ 13-set
PUHY-P250YREM-A 125 ~ 325 1-set ~ 16-set
P20 ~ P250
New refrigerant series indoor unit
and ventilation relating equipment
Note: The total capacity of connected indoor unit model name represents the summed up total of the numerical figure
portion of the indoor unit model names.
-10-
II. Product Specification
1. Outdoor unit
(1) Specification table
Y Series
Power source
Cooling capacity ❉1kW
Heating capacity kW
Power
Cooling kW
input
Heating kW
Cooling A
Current
Heating A
Refrigerant/Lubricant
Type x quantity
Compressor Motor output kW
Starting system
Crankcase heater W
Type x Quantity
Fan Airflow rate m3/min
Motor output kW
High pressure protection
Protection
Compressor
devices
Fan
Inverter
Refrigerant
Gas pipe mm
piping diameter
Liquid pipe mm
Noise level ❉2 dB(A)
External finish
High mm
External
Width mm
dimension
Depth
Net weight kg
Operating temperature range
Matters deserving special mention
Outdoor unit model name PUHY-P200YREM-A PUHY-P250YREM-A
Electrical
characteristic
3N~ 380/400/415V 50/60Hz
22.4 28.0
25.0 31.5
6.32 8.54
6.80 8.95
10.6/10.1/9.7 14.4/13.6/13.2
11.4/10.9/10.5 15.1/14.3/13.8
R407C/MEL32
Hermetic x 1
6.8
Inverter start
45 (240V) 45 (240V)
Propeller fan x 1
200 200
0.38 0.38
2.94MPa
Over current protection • over heat protection
Thermal switch
Over current protection • thermal protection
φ
25.4
φ
28.58
φ
12.7
φ
12.7
56 57
Pre-coated galvanized sheets
(MUNSELL 5Y 8/1 or similar)
1755 1755
990 990
840 840
239 239
A pipe of φ28.58 can be used for the gas pipe
Note : 1. Cooling/heating capacity indicates the maximum value at operation under the following condition.
❉1 Cooling Indoor : 27˚CDB/19˚CWB Outdoor : 35˚CDB
Heating Indoor : 20˚CDB Outdoor 7˚CDB/6˚CWB
Piping length : 7.5m
❉2 It is measured in anechoic room.
Indoor : 15˚CWB~24˚CWB
Outdoor : –5˚CDB~43˚CDB
(0˚CDB~43˚CDB with outdoor unit at lower position)
Indoor : 15˚CDB~27˚CDB
Outdoor : –15˚CWB~15.5˚CWB
mm
5.3
-11-
1755
25 160
73 80
Knockout hole
Bottom piping hole
<Bottom wiring hole>
237
198
2✕2-14✕20
Oval hole
910
(15)880(bolt hole)
15
560(bolt hole)
215 (215)
990
840
80
16531
79
70
48 100
194
4080
7560
251100
234
149
40
X
X
Cross section X-X
Note1
Y
Y
Cross section Y-Y
50
12 5
75778
121
Plane view
Air outlet
Rear view
Air
inlet
Air
inlet
Right side view
Knockout hole
Service panel
Knockout hole
Front piping hole
<Front wiring hole>
Front view
Refrig. service
valve(gas)
<flange>
Knockout hole
Left piping hole
Left side view
Knockout hole
1490
Knockout hole
<Front side hole for
the power supply>
78
99
813
590 55
(2) External dimensions
Models PUHY-P200, P250YREM-A Unit: mm
φ
27 Knockout hole
<Left side hole for the
control wiring>
Refrig. service
valve (liquid)
φ
12.7<flare>
φ
40 Knockout hole
<Left side hole for
the power supply>
φ
40 Knockout hole
<Bottom side hole for
the power supply>
φ
27 Knockout hole
<Bottom side hole for
the control wiring>
Conn. pipe
200:
φ
25.4 <brazed>
250:
φ
28.58<brazed>
315:
φ
31.75<brazed>
<Accessories>
• Refrigerant <gas> connecting pipe
............. 1 pc.
(The connecting pipe is fixed with the unit)
• Packing for connecting pipe
........................ 1 pc.
(Attached near ball valve)
• Wiring mounting board
................................
1 pc.
• Conduit mounting plate
(Painting the same color as the unit body)
φ
40,
φ
33,
φ
27 ....................................
Each 1 pc.
• Tapping screw 4 x 10 .................................
6 pcs
• Parts of mineral oil recovery
....................... 1 set
Note:
1. Please leave a space under the outdoor unit for
the piping. When you connect the piping from
the bottom.
(Please be careful not to close the hole of the
bottom plate by the basement.)
-12-
787
65
90
1091
999
559
92
130
272
507577
336
845
75777
A
N L
M1 M2 S
❉1 The packing is provided for 5 pcs. (mineral oil recovery for 1 time). Please purchase additional packing if required.
(Service parts code : R61 F14 514, Service model name code : P321009X01)
❉2 Service parts code : R61 M03 622, Service model name code : W650296G01
(2) External dimension
Notes: 1. For the connection and operation control of the oil
trap kit, you are kindly requested to obtain our approval.
2. Make the piping length between the oil trap kit and
the outdoor unit 5m or less. <The optional flexible
hose (2m) is prepared by Mitsubishi.>
2. Oil trap kit
(1) Specification table
Oil trap kit model name PAC-KP90VCLU
Power source ~N 220/230/240V 50Hz
Electrical
Power consumption kW 0.049
characteristic
Current A 0.20/0.21/0.22
External finish Galvanized steel sheets
Height mm
mm
mm
1091
External dimension Width 336
Depth 757
Ball valve side
High pressure mm
φ
12.7 Flare connection
Refrigerant piping
(at outdoor unit)
Low pressure mm
φ
28.58 Flange connection
Fitting side
High pressure mm
φ
15.88 Flare connection
(at extended piping)
Low pressure mm
φ
19.05 Flare connection
Net weight kg 76
Accessories
Packing ❉1, Hood for low OA ❉2
Pipe 1,Pipe 2, Saddle, Packing, Screw
Power source
terminal block cover
Refrigerant service
valve <outdoor unit
low pressure side>
φ
28.58 <flange>
Refrigerant service
valve <outdoor unit
low pressure side>
φ
19.05 <flare>
Terminal for PC
connection
<RS-232C>
Refrigerant service
valve <outdoor unit
high pressure side>
φ
12.7 <flare>
Refrigerant service
valve <outdoor unit
high pressure side>
φ
15.88 <flare>
Pressure gauge
Refrigerant service
valve <oil recovery>
φ
6.35 <flare>
Transmission terminal block Power source terminal block (TB01)
(TB02)
Details of A-section
Caster
<stopper side>
Piping
cover
Handle
Caster <swivel side>
with stopper
Valve
cover
-13-
0 20 40 60 80 100 120
III. Outline of Flushing Operation
Install the oil trap kit between the outdoor unit and extended piping. Operation of the outdoor unit is in cooling
mode, feeding the R407C charged in the system under a gas/liquid two-phase state from the oil trap kit heat
exchanger. By feeding the refrigerant in the gas/liquid two-phase state into the existing piping, the residual
mineral oil inside the existing extended piping can be recovered into the oil trap kit. Feeding oil fluidity solution
from upstream of the existing piping can maintain or even increase the fluidity of residual mineral oil, thus
allowing the mineral oil to flow through the indoor units.
The mineral oil used as the refrigerating machine oil of conventional refrigerant (R22) systems are oils mostly
incompatible with new refrigerant (R407C). By flowing R407C to piping attached with mineral oil, the mineral oil
is forced out and peeled off from the pipe wall by the shearing force applied between the mineral oil and
refrigerant liquid. Then it is carried out while floating on the surface of refrigerant liquid. If it is under gas/liquid
2-phase state at this moment, the liquid refrigerant will be accelerated by gas refrigerant flowing at high speed
in the center of the pipe. Thanks to this accelerated flow, the mineral oil inside piping can be collected quickly.
Outdoor unit Oil trap kit
4-way valve
Outdoor
heat exchanger
Oil
separator
Accumulator
Oil trap
Throttle
Oil
separator
Refrigerant heat
exchanger
Separates and recovers oil
with fluidity solution.
Outdoor unit
Indoor heat
exchanger
Indoor unit
throttle
Mineral oil
fluidity solution
Promotes flushing by lowing the
viscosity of the oil.
Flow of ester
Flow of mineral oil
Flow of refrigerant (hot gas)
Flow of refrigerant (low pressure gas)
Flow of refrigerant
(gas/liquid 2-phase refrigerant)
Principle of recovery by refrigerant under gas/liquid 2-phase state incompatible with mineral oil
(❉ mark portion above)
Piping center
Refrigerant gas
(R407C)
Floating layer of
mineral oil
Refrigerant liquid
(R407C)
Mineral oil attached
to wall surface
Pipe wall of refrigerant piping
Residual quantity
Flushing time (min)
Longest extended piping : 100m
Maximum extended length : 220m
(Liquid/gas going and returning for 440m)
Residual oil quantity in piping against flushing time
Replace tank
❉
-14-
Installation / Operation Work
I. Parts Provided with Oil Trap Kit ................................................................................................. 17
1. Verifying the parts provided ........................................................................................................... 17
II. Carrying/Storing the Oil Trap Kit................................................................................................ 18
1. Transportation by vehicles ............................................................................................................. 18
2. Carrying-in/carrying-out .................................................................................................................. 18
3. Storing ............................................................................................................................................ 18
III. Work Procedure of Mineral Oil Recovery Operation ............................................................ 19
1. Work flow ....................................................................................................................................... 19
2. Items to be checked before work ................................................................................................... 21
3. Installation space and range of oil trap kit ...................................................................................... 23
(1) Restrictions
4. Refrigerant piping work .................................................................................................................. 24
4-1 Piping connection before flushing operation
4-2 Piping connection after flushing operation
5. Electrical wiring work ..................................................................................................................... 30
5-1 Wiring connection before flushing operation
5-2 Wiring connection after flushing operation
6. Connection work on rainy days ...................................................................................................... 31
7. Flushing operation ......................................................................................................................... 32
(1) Installation method of S/W
(2) Items to be confirmed before flushing operation
(3) Starting and finishing of flushing operation
(4) Mounting method of low outdoor temperature hood
IV. Work Procedure at Oil Inspection .............................................................................................. 45
1. Oil inspection after mineral oil recovery ......................................................................................... 45
(1) Oil sampling method
(2) Measuring method and judgment of refractive index
(3) Measures to be taken at oil inspection (Failure to pass oil inspection test) (No Good)
V. Mineral Oil Recovery Operation Data (Reference Data) ........................................................... 53
1. Standard data (During flushing operation) .....................................................................................53
-15--16
-
I. Parts Provided with Oil Trap Kit
1. Verifying the parts provided
Please confirm that the following parts are provided with this oil trap kit.
Name (1) Hood (for low OA) (2) Packing
Appearance
Storing position Provided at the control Provided at the control
box bottom box bottom
Quantity 1 pc. 5 pcs.
Name (3) Piping 1 (4) Piping 2
Appearance
Storing position Provided inside Provided inside
piping cover piping cover
Quantity 1pc. 1pc.
Name (5) Rubber mount (6) Saddle (7) Screw
Appearance
Storing position
Provided at the control Provided at the control Provided at the control
box bottom box bottom box bottom
Quantity 1pc. 1pc. 4pcs.
Inner diameter Outer diameter
φ
23
φ
35
(1) Service parts code : R61 M03 622, Service model name code : W650296G01
(2) The packing is provided for 5 pcs. (mineral oil recovery for 1 time). Please purchase additional
packing if required. (Service parts code : R61 F14 514, Service model name code : P321009X01)
-17-
II. Carrying/Storing the Oil Trap Kit
1. Transportation by vehicles
For the transportation by vehicles, ensure that sufficient care has been paid to the withstanding force of the product. However, please observe the items below and pay careful
attention to prevent the product from falling down or being damaged.
(1) When carrying the product while being laid down, locate the name plate on the up-
side.
Do not place any goods on the sheet metal surface.
Reason : The letters on the name plate can not be read. The inner piping may be
deformed leading to damage.
(2) Do not locate the piping cover downward.
Reason : The service valve is damaged causing possible gas leak.
(3) Carrying the product while locating the caster downward causes unstable condition
leading to falling down due to the vibration during transportation. Provide a measure
to prevent falling down.
2. Carrying-in / carrying-out
The product is mounted with the parts for transportation, including one handle, knobs (at 5 places) and casters (at swivel
side and stopper side). For the carrying-in and -out of the product, locate it horizontally (with the name plate at the upper
side) or vertically and pay careful attention to prevent it from falling or dropping due to obstacles. Refrain from locating the
piping cover facing downward. (If dropped, the service valve may be damaged.)
3. Storing
When storing the product, observe the items below.
(1) Store in a cool and dark place avoiding direct exposure to solar radiation. (Storing temperature less than 60˚C)
(2) Store the oil trap kit fixed with the stopper locating the caster in the downward facing position.
(3) Store the oil trap kit, flexible tube and branch piping kit mounted with the cap previously provided. (to prevent the entry
of dirt, dust and water)
(4) Store the oil trap kit, flexible tube with their original packing.
Do not lose the packing materials as they are to be used for storing.
Oil trap kit : Applied corrugated cardboard to upper part, wooden frames to lower part and fixed with PP band.
Flexible tube : Packed with corrugated cardboard
Piping cover
Knob
❉Unscrewing the screws
(at 4 spots) allows using
the handle.
Handle
Caster with stopper (swivel side)
Knob
Name plate
For the unit with a handle instead
of knobs, the handle can be dismantled by removing the upper/
lower panels and M8 bolts (2 pcs.)
fixing the handle. Do not operate
the unit with the upper/lower panels removed.
Knob
Knob
Caster (stopper side)
Surface with
name plate
Fixing material
-18-
Check the necessary parts (P20) & check the work preparation (P21).
1. Turn the outdoor unit power source off.
2. Mount the replace tank to the oil trap kit..
3. Connect the outdoor unit, valve mounted to the extended piping and oil trap kit with piping
(flexible tube).
4. Conduct airtight test and evacuation the piping (flexible tube) between the outdoor unit,
valve mounted to the extended piping and oil trap kit.
5. Open the ball valve. (in the order of oil trap kit (1)~(4), extended piping, outdoor unit (1) and
(4).)
6. For the oil trap kit, apply from L
1 and N of outdoor unit supply or a separate 220~240V
supply power source of the outdoor unit and the transmission line from the outdoor unit TB3.
7. Connect the oil trap kit and PC.
8. The system controller and MA remote controller may be required to be remove.
For detail, refer to 1~5 : Piping connection, 6
•7 Piping connection.
❉ When conducting mineral recovery work the next day, close all service valves of the out-
door unit, valve mounted to the extended piping and oil trap kit to finish the work, and open
all service valves immediately before starting flushing operation. (Otherwise mineral recovery time is extended due to prolonged start-up time, or the oil traped inside the kit is overflown hindering the normal mineral oil recovery.)
1. Apply power source to the outdoor unit, and confirm the completion of the start-up.
2. Check the operating sound caused by the ON/OFF of the solenoid valves.
3. Through the PC operation, drive the outdoor unit compressor to recover mineral oil inside the
extended piping. The recovery time requires for 1.5 ~ 3 hours. (Outdoor temperature below
20˚C, the low outdoor air hood should be fitted to the outdoor unit.)
However under low outdoor temperature, flushing operation may be required again due to
insufficient refrigerant.
❉ When the frequency or low pressure drops less than the rated value due to insufficient
refrigerant and the such like, the time required for the mineral oil recovery may exceed 3
hours. For detail, refer to P36.
4. Prevent the outdoor unit and oil trap kit from being exposed to rain directly.
5. Close the service valves of the outdoor unit and the valve mounted to the extended piping (4
positions).
6. Close the service valves of the oil trap kit (at 4 spots).
7. Turn off the power source of the outdoor unit once.
8. After flushing operation, recover mineral oil by opening the oil recovery service valve.
❉ The mineral oil recovered by flushing operation should be extracted each time from the oil
trap kit. During the work, observe that the pressure is staying within 0.049 ~ 0.294MPa.
1. Remove piping (flexible tube) and wiring between the outdoor unit, remove valves mounted
to the extended piping and oil trap kit.
2. Remove the oil trap kit.
3. After reconnecting the piping kit (field work) to the outdoor unit, execute evacuation.
4. Open the ball valve (in the order of extended piping, outdoor unit (1)
and (4).)
5. Mount the system controllers and MA remote controller previously removed.
❉ After removing the oil trap kit, confirm the inner pressure with a pressure gauge.
❉ Do not store the oil trap kit at a place exposed directly to solar radiation, but store in a cool
and dark place.
After recovering oil, conduct ordinary air conditioning operation, and check the cooled air (heated
air) and the operating condition of the compressor.
❉ The test run and adjustment work are not included. Execute them separately if
required.
This belongs to the field work category. Execute it after flushing.
1. For the inspection of oil, use suitable kit for the refrigerating machine oil used by the existing
unit. (Mineral oil : Ester collection kit)
2. When the recovery of mineral oil is insufficient, ester oil, etc. should be added.
❉ Note: Only in rare cases.
III. Work Procedure of Mineral Oil Recovery Operation
1. Work flow
For P200 • P250YREM-A
Work flow Items to be verified
Carry in the oil trap kit (1 set),
replace tank, PC and tools.
Install the oil trap kit, replace
tank and PC.
Perform air tightness test
Evacuate the piping (Flexible tube)
Apply flushing inside of the exiting
piping.
Recover mineral oil inside the
oil trap kit.
Remove the oil trap kit.
Connect the piping kit processed
there, and evacuate inside of the
piping kit.
Confirm operation
(compressor starting).
Execute test run & adjustment.
Inspect oil one month after
operation.
-19-
Built-in solenoid valve, pressure sensor,
pressure gauge, service valve
φ
12.7 (2 pcs.), each 1 pc. of φ19.05 and φ28.58
(
φ
19.05 is for short copper pipe [requires φ28.58
–φ19.05 connection])
5 pcs. (outdoor unit 2 pcs. valve mounted to the extended piping 2 pcs., oil trap kit 1 pc.)
[provided inside oil trap kit]
Equipment:
DOS-V machine (suitable for PC-98NX or later)
CD ROM equipped
CPU : 300MHz or larger (recommended)
Memory : 64Mbyte or larger (recommended)
HDD : 40Mbyte or larger (recommended)
O/S : Windows95, 98, NT 4.0, 2000, ME, XP
Exclusive S/W for Replace
(Caution : Install on PC before mineral oil recovery.)
RS-232C cross cable (within 15m)
Oil trap kit connector specification : D-SUB25 Pin type
female connector (DTE)
(Caution: Select RS-232 cable depending on the type
of the serial interface of PC.)
φ
1.5mm2 or more
Power supply cord parts of appliances for heat source
shall not be lighter than polychloroprene sheathed
flexible cord (design 245IEC57)
φ
1.25mm2 or more
2-core cable (VCTF, VCTEK, CVV, CVS, VVR, VVF,
VCT or shielded wire CVVS/CPEVS)
Vessel with more than 2L capacity is required.
Refrigerant piping/wiring system diagrams are
required for each system
Vessel (1 pc.), bottles (2 pcs. 1 pc. with oil charged)
Mineral oil fluidity solution
Mineral Oil Recovery Operation
Parts List
Parts name Application Specification (quantity) Remarks
(1) Oil trap kit
(PAC-KP90VCLU)
(2) Flexible tube
(PAC-KP80FPP,
PAC-KP-82FPP,
PAC-KP83FPP)
(3) Packing
(4) PC (Field supply)
(5) Software
(6) Connecting cable
(field supply)
(7) Power source wiring
(field supply)
(8) Control wiring
(field supply)
(9) Oil pan (field supply)
(10) Refrigerant piping,
Wiring system diagram
(11) Ester oil check kit
(PAC-KP95ECK)
(Use when the refrigerating machine oil used
by conventional system
is the mineral oil.)
(12) Replace tank
(PAC-KP01RTK)
Mineral oil recovery
device
Piping connection between
oil trap kit and outdoor unit
and the valve mounted to the
extended piping
Connection between (2) flange
and outdoor unit
Mineral oil recovery
operation control
Mineral oil recovery
operation software
RS-232C connection of
oil trap kit and PC
Connection to oil trap kit
(Jumper from outdoor unit)
Mineral oil recovery vessel
Verification of connection with
system controller, others
To judge proper oil recovery
at oil inspection about one
month after flushing operation
executed
To lower the viscosity of
residual mineral oil
1 set
1 set
1 set for
1 outdoor unit
-20-
1) Check whether outdoor unit is being powered.
2) Check the insulation resistance
between power source terminal
and ground for over 1.0MΩ.
1) Confirm the ball valve of outdoor
unit is fully closed.
2) Confirm the ball valve of oil trap
kit is fully closed.
1) Check whether system controller
is connected to indoor/outdoor
transmission line.
2) The system controller that turns
the power source off when turning
the outdoor unit power source off
is connected to the indoor system.
(Power supply from outdoor unit)
3) Check MA remote controller for
grouping with different refrigerant
circuits.
1) Check whether the reading of
pressure gauge inside oil trap kit
is lower than 0.049 ~ 0.294MPa.
1) Open the oil recovery service
valve and check whether the liquid (recovered oil) flows out continually under liquid state.
2. Items to be checked before work
Check method Content of checking Countermeasure
(1) Confirming the power-
ing of outdoor unit
(2) Confirming the closed
ball valve of outdoor
unit, oil trap kit, and
the valve mounted to
the extended piping
(3) Confirming the con-
nection of the system
controller to transmission terminal block
Confirming MA remote
controller
(4) Confirming the inner
pressure of oil trap kit
(5) Confirming the oil
recovery of oil trap kit
1) LED display inside
outdoor unit control box
2) Confirming the powering time
1) Confirming the closed
ball valve of outdoor
unit and the valve
mounted to the extended piping
2) Confirming the closed
ball valve of oil trap kit
1) Confirming by observing refrigerant system
diagram
2) Confirming the field
connection
1) Confirming with pressure gauge
1) Confirming the operation of oil recovery
service valve
1) Power the outdoor unit for over 12
hours.
2) Power until the insulation resistance
between the power source terminal block and ground reaches
1.0MΩ or more.
1) Full opening of ball valve
• Check the valve operation by field
piping work.
• Refrigerant charge after flushing
operation.
2) Full closing of ball valve
• Confirmation of residual pressure
inside oil trap kit (by using a pressure gauge) →At no residual pressure, evacuate after confirming
airtightness inside oil trap kit and
charge refrigerant by 0.5kg.
1) 2) 3) Remove the system controller connected to the indoor/outdoor
transmission line and MA remote
controller grouped with different refrigerants. Reconnect them after
flushing operation. (Only required
when indoor unit under Ver30 or
LOSSNAY with heating humidifier
under Ver8.08 is existing. : Removal is indicated on the PC
screen. )
Refer to the countermeasure by confirming the oil trap kit inner pressure
shown on the next page.
1) Recover liquid (recovered oil) with
an oil pan and the like.
-21-
Countermeasure by Confirming Inner Pressure of Oil Trap Kit
(1) In the case of 0.049MPa or less
A leak exists, it must be located and repaired. After repairing the leakage inside the oil trap kit, confirm
successful airtightness test and evacuation. After evacuation, charge refrigerant 0.5kg.
(2) In the case of 0.294MPa or more
Confirm the outdoor temperature sensor (TH6) of the outdoor unit.
Reference to chart below.
1) Located at lower right side of line
Although this does not indicate abnormality, but causes increase in the inner pressure during storage
leading to possible danger. Recover refrigerant to lower the pressure until it reaches less than 0.294MPa.
For the method of refrigerant recovery, refer to [IX. 2. 2-3 Refrigerant recovery method].
2) Located at upper left side of line
This indicates the existence of liquid refrigerant. Liquid seal may be formed at storage. Recover refrigerant to lower the pressure until it reaches less than 0.294MPa same as above. For the method of
refrigerant recovery, refer to [IX. 2. 2-3 Refrigerant recovery method]. At recovery, measure the recovered quantity. If it exceeds 0.5kg, charge the excess quantity additionally when confirming operation.
In addition, check the operation of the solenoid valves. If they are faulty, replace the solenoid valves,
confirm airtightness and execute evacuation. After evacuation, charge refrigerant 0.5kg.
Saturated pressure against outdoor inlet dry bulb temperature (Gas)
Pressure (MPa)
Outdoor inlet dry bulb temperature TH6 (˚C)
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
1.6
-5 0 5 10 15 20 25 30 35 40
Abnormal (Possibility of liquid sealing)
Normal
-22-
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