Mitsubishi MEE03K197 Installation Manual

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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

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?

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.

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

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

15.88

19.05

22.2

25.4

28.58

31.75

38.1

Liquid pipe

9.52

12.7

15.88

19.05

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

15.88

19.05

22.2

25.4

28.58

31.75

38.1

Liquid pipe

6.35

9.52

12.7

15.88

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

xx xx xxx

xxxxxxxx xxxxx

(within 25m) (within 15m)

P200 P250

❉

-4-

1. Remote controller line (MA remote controller)

(1) Length m

(2) Wire diameter mm

(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

(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

(2) Wire diameter mm

(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

(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

(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

-5-

YES

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

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?

❉

entralized

transmission line wire dia-

meter ≥ 1.25mm

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

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.

❉

Check transmission line.

Indoor-

outdoor transmission line

farthest length ≤ 200m?

❉1

Indoor-

outdoor transmission

line wire diameter

≥

125mm

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

Distance from power supply

unit to outdoor unit and sys-

tem controller

Wire diameter

200m or less 0.5mm

or more

130m or less 0.3mm

or more

-7-

0.5mm

0.75mm

0.3mm

1.25mm

100

150

200

0 5 10 15 20

100

150

200

0 5 10 15 20 25 32

0.75mm

0.5mm

0.3mm

1.25mm

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

25.4

28.58

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

5.3

-11-

1755

25 160

73 80

Knockout hole

Bottom piping hole

237

198

2✕2-14✕20

Oval hole

910

(15)880(bolt hole)

560(bolt hole)

215 (215)

990

840

16531

48 100

194

4080

7560

251100

234

149

Cross section X-X

Note1

Cross section Y-Y

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 view

Refrig. service

valve(gas)

Knockout hole

Left piping hole

Left side view

Knockout hole

1490

Knockout hole

<Front side hole for

the power supply>

813

590 55

(2) External dimensions

Models PUHY-P200, P250YREM-A Unit: mm

27 Knockout hole

<Left side hole for the

control wiring>

Refrig. service

valve (liquid)

12.7<flare>

40 Knockout hole

<Left side hole for

the power supply>

40 Knockout hole

<Bottom side hole for

the power supply>

27 Knockout hole

<Bottom side hole for

the control wiring>

Conn. pipe

200:

25.4 <brazed>

250:

28.58<brazed>

315:

31.75<brazed>

• 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)

40,

33,

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

1091

999

559

130

272

507577

336

845

75777

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

12.7 Flare connection

Refrigerant piping

(at outdoor unit)

Low pressure mm

28.58 Flange connection

Fitting side

High pressure mm

15.88 Flare connection

(at extended piping)

Low pressure mm

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>

28.58 <flange>

Refrigerant service valve <outdoor unit low pressure side>

19.05 <flare>

Terminal for PC connection <RS-232C>

Refrigerant service valve <outdoor unit high pressure side>

12.7 <flare>

Refrigerant service valve <outdoor unit high pressure side>

15.88 <flare>

Pressure gauge

Refrigerant service valve <oil recovery>

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

(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

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

12.7 (2 pcs.), each 1 pc. of φ19.05 and φ28.58

(

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.)

1.5mm2 or more Power supply cord parts of appliances for heat source shall not be lighter than polychloroprene sheathed flexible cord (design 245IEC57)

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 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)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

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-

3. Installation space and range of oil trap kit

The installation space required for the oil trap kit and for the piping network is as follows. The installation can be performed by using the front service space of the outdoor unit. In the case when the installation space of the oil trap kit can not be secured (due to obstacles), install it within the following restrictions on piping length. Arrange the installation so that the unit front is not exposed to seasonal winds (gusts).

(1) Restrictions

Item Allowable length Remarks

Piping length 5m or less

Height difference

Outdoor unit upper 5m or less

Outdoor unit lower 5m or less

Outdoor unit

Oil trap kit

The piping length added with piping length and height difference should be less than 5m.

In the case of P200 • 250YREM-A

Over 450

Over 990

Caution

When installing the oil trap kit on a slanted ground or at a place directly exposed to the seasonal wind (gust), ensure it will not be blown over.

• If the oil trap kit does fall over it will damage the solenoid valves disabling the ability to perform flushing operation. Refrigerant leak and personal injury may also occur.

-23-

4. Refrigerant piping work

4-1 Piping connection before flushing operation

(1) Piping connection to outdoor unit

Connect the outdoor unit and oil trap kit, pipe and wire by following the procedure. (1) Turn off the main power source of the outdoor unit. (2) Remove the service panel from the outdoor unit and oil trap kit, piping cover and the side panel (6

screws in total).

(3) Confirming the service valves of the outdoor unit, valves mounted to the extended piping and oil trap kit

are closed, and remove a piping cover. Mount the replace tank to the oil trap kit. (Use the Piping 1 and 2 provided to the oil trap kit to mount the replace tank.) ❉ Do not lose the Piping 1 and 2 of the oil trap kit, as it can be reused. When using the copper pipe for

general refrigerant piping, connection can be performed without using Piping 2 by using the valve of the replace tank.

Service valve

Replace tank

Service panel

In the case of P200 • 250YREM-A

Service valve (low pressure)

Service valve (high pressure)

Piping 1 (Accessory)

Piping 2 (Accessory)

Left side panel (upper)

Valve cover

-24-

(4)

(1)

(2) PAC-KP80FPP

(4) PAC-KP83FPP

Field piping

(1)

PAC-KP80FPP

(3)

PAC-KP82FPP

(2)

(4)

(3)

(1)

(3)

Connection method:

Remove short copper pipe and flare nut, select the flexible piping corresponding to the number in the drawing shown above from the following table, and connect to the port with same number.

No. Type Connection configuration

Quantity

P200, 250YREM-A

(1) PAC-KP80FPP

12.7 flare conn. – φ12.7 flare conn. 1

(2) PAC-KP80FPP

12.7 flare conn. – φ12.7 flare conn. 1

(3) PAC-KP82FPP Flange joint – φ19.05 flare conn. 1

(4) PAC-KP83FPP Flange joint – Flange joint

(4) Connect the flexible tube to the outdoor unit, valve mounted to the extended piping and oil trap kit (1) ~

(4). When general refrigerant piping copper pipe is used, select a suitable type by referring to the piping specification of flexible tube shown below. When the length of piping connected to the outdoor unit and oil trap kit exceeds 2m, use the general refrigerant piping copper pipe with the selected diameter for a portion of over 2m by referring to the following table.

Caution : Mount the connecting pipe (1) ~ (4) correctly without erroneous connection.

Erroneous connection does not allow recovery of mineral oil.

❉1 Service parts code R61 E91 494

Piping dia. Pipe thickness

(mm) (mm)

Piping length Remarks

(1)

12.7 0.9 2m

(2)

12.7 0.9 2m

(3)

19.05 1.0 2m Requires to mount short copper pipe (φ28.58–φ19.05)

(4)

28.58 1.2 2m Requires to mount flange ❉1

In the case of P200 • 250YREM-A

-25-

(

)

(

)

(

)

(

)

Valve rod

Stopper pin

Service port

Cap, Copper packing

Flare nut

Connection pipe (Accessory)

Packing (Accessory)

Valve rod Fully close at shipment, piping work, air tightening and evacuating work. Fully open after completing the above

works.

Cap, Copper packing

Remove the cap and operate the rod valve. Mount it at its original position after finishing work. (Clamping torque of valve rod cap : 25N

•m or more)

Stopper pin The valve rod does not rotate over 90˚.

Service port Use for the airtightness and evacuation inside existing piping in the field. Use two spanners to open/close. (Clamp-

ing torque : 14N

•m or more)

Flare nut Use two spanners to open/close with a clamping torque of 80N

•m. Coat refrigerating machine oil (ester oil, ether oil

or alkyl benzene (a little amount)) on the flare contacting surface.

Connection pipe Mount the packing (accessory) firmly to the valve flange to avoid gas leak. (Clamping torque : 23N

•m or more)

(Accessory) Coat refrigerating machine oil (ester oil, ether oil or alkyl benzene (a little amount)) on the flare contacting surface.

(2) Valve operation

• For piping connection and valve operation, follow the figure below. (The figure below shows the ball valve of the oil trap kit.)

• For the flange section of the piping (flexible tube), use new packing (provided only for 1 time use) and mount firmly to avoid gas leak. Coat refrigerating machine oil (ester oil, ether oil or alkyl benzene (a little amount)) on both sides of the packing.

• For opening/closing of flare nuts, use two spanners together. Coat refrigerating machine oil (ester oil, ether oil or alkyl benzene (a little amount)) on the flare contacting surface.

• After evacuation, make sure to fully open the handle. Operating with a valve closed generates abnor- mal pressure inside the refrigerant circuit, possibly damaging the compressor, 4-way valve etc. After completing work, tighten the service port and cap firmly, so as not to generate a gas leak.

Proper clamping torque by torque wrench

Copper pipe OD (mm) Clamping torque (N•m)

6.35 14 ~ 18

9.52 35 ~ 42

12.7 50 ~ 57.5

15.88 75 ~ 80

19.05 100 ~ 140

Standard of clamping angle

Pipe dia.

Clamping angle

6.35φ9.52 60˚ ~ 90˚

12.7φ15.88 30˚ ~ 60˚

19.05 20˚ ~ 35˚

Caution

Make sure to remove the connection pipe from the ball valve, and braze it outside the unit.

• Brazing it while mounted heats the ball valve which may cause machine trouble or gas leak. Also the wiring inside the unit may be burnt.

Caution

For the refrigerating machine oil to coat on the flare/flange connections, use ester oil, ether oil or alkylbenzene (a little amount).

• Mixing of mineral oil in a large quantity may cause a deterioration of refrigerating machine oil.

❉ When a torque wrench is not available, use the method below instead.

When tightening the flare nut with a spanner, the clamping torque may abruptly increases. Stop the tightening once at this moment, and rotate further for the angle shown in the above table.

(This figure shows the fully opened state.)

Ball valve Ball valve Ball valve Ball valve

Outdoor unit (1) Extended piping side (2) Extended piping side (3) Outdoor unit (4)

12.7

19.05

28.58

To outdoor unit To extended To extended piping To outdoor unit

piping

Part name Detail

15.88

-26-

LO HI

Lo knob Hi knob

(3) Airtightness and evacuation of flexible tube

(1) Airtight test

For the airtight test, pressurize the flexible tube from the service port on the end of it (at the oil trap kit side) while closing the refrigerant service valve (ball valve) of the oil trap kit, valve mounted to the extended piping and outdoor unit while opening the valve of the replace tank. After applying to 1 and

3 , apply to 2 and 4 . (The figure below shows the state of 1 and 3 .)

Make sure to pressurize all flexible tubes. (4 spots)

As the procedure of the airtight test gives the serious effect in deteriorating refrigerating machine oil, make sure to observe the items of restriction. In addition, as the composition of the non-azeotropic mixture of refrigerants R407C will change if there is a gas leak, therefore affecting the performance, so conduct the airtight test very carefully!

System analyzer

Nitrogen

gas

Oil

trap

kit

x Using combustible gas or air (oxygen) for the pres-

surizing gas can cause an explosion.

x Refrigerants not indicated on the equipment can not

be used.

x Charging from the cylinder under gas state changes

the composition of refrigerant inside the cylinder.

x Use parts like pressure gauge, charging hose, etc.

exclusive for R407C.

x The electric leak detector for R22 can not detect

R407C.

x The color rendering type (halide torch) can not be

used. (unable to detect)

Procedure of airtight test Restriction

1. For pressurizing with nitrogen gas

(1)

After pressurizing to the design pressure [ 1 , 2 : 2.98 MPa, 3 , 4 : 1.56MPa] with nitrogen gas, leave it for about 15 minutes. It is acceptable if no pressure drop is found. When the pressure drops, a test can be conducted using the foam method below to find the leaking spot.

(2) After pressurizing as above, spraying foaming agent

(Cuboflex) onto the spots where leaking is expected, such as the flare connections, brazed connections and flange connections, etc., and observe the generation of foaming visually.

(3) Wipe off the foaming agent after finishing the airtight

test.

2. For pressurizing with refrigerant gas and nitrogen gas

(1) Charge R407C under liquid state from the cylinder, and

pressurize it to about 0.2MPa by gas pressure. Then pressurize with nitrogen gas up to the design pressure [ 1 , 2 : 2.98MPa, 3 , 4 : 1.56MPa]. Avoid to continuous pressurization, pause during the process to confirm no pressure drop is found.

(2) By using an electric leak detector for R407C, check

gas leak at all spots likely to generate gas leak, such as the flare connections, brazed connections and flange connections.

(3) This may be used together with the foaming test.

Replace tank

-27-

Lo knob Hi knob

❉1. Use a scale with high accuracy (measurable up to 0.1kg). ❉2. Use a vacuum gauge equipped with reverse flow protector.

(Recommended vacuum gauge : ROBINAIR 14010 Thermistor Vacuum Gauge) Employ a vacuum pump that indicates 65Pa [abs] or less after operation for 5 minutes. Note: Use the parts such as a gauge manifold and charging hose only for specified refrigerant shown on

the equipment.

(2) Evacuation

For the evacuation of the flexible tube, evacuate the flexible tube from the service port on the end of it (at the oil trap kit side) while closing the refrigerant service valve (ball valve) of the oil trap kit, valve mounted to the extended piping and outdoor unit while opening the valve of the replace tank. After applying to 1 and

, apply to

and

. [The figure below shows the state of 1 and

.] Make sure to evacuate all flexible tubes. (4 tubes) After reaching the degree of vacuum at 650Pa [abs], evacuate further for 3 minutes or more. Then stop the vacuum pump and leave it for 3 minutes. Confirm that the degree of vacuum does not rise at this moment. (When the degree of vacuum increases by more than 130Pa, moisture has possibly been mixed. Pressurize dry nitrogen gas up to 0.05MPa, and evacuate again.) Last, open the ball valve of the oil trap kit and then those of the outdoor unit in that order. (The reverse order if applied may damage the compressor.) ❉ Never attempt to purge air by using refrigerant.

System analyzer

Oil

trap

kit

R407C cylinder

3-way joint

Val ve

Vacuum pump

Scale

❉1

Caution

Use a vacuum pump with reverse flow protector.

• Otherwise, the vacuum pump oil flows in reverse direction into the refrigerant circuit which may cause deterioration of the refrigerating machine oil of the equipment.

-28-

Field piping

Service port (for air tightening, evacuating)

4-2 Piping connection after flushing operation

(1) Piping connection with outdoor unit

To connect the piping kit (field work) with the outdoor unit, connect piping by following the procedure below. (1) After closing the service valve (ball valve) of the outdoor unit, valve mounted to the extended piping and

oil trap kit, remove the piping connecting the outdoor unit, valve mounted to the extended piping and oil trap kit.

(2) Connect the piping kit (field work) to the outdoor unit. In this case, use the parts (short copper pipe,

flare) provided with the outdoor unit.

(3) After air tightness

❉

and evacuating the inside of the piping kit, open the service valve inside the outdoor

unit. (in the order of the extended piping to the outdoor unit).

❉

(Conduct air tight test and evacuation from the service port of the service valve (ball valve) at the upper side of the outdoor unit. For the work procedure, refer to 4-1 (3) Air tightening/evacuating of flexible tube.)

Service port (for air tightening, evacuating)

In the case of P200 • 250YREM-A

Field piping

Piping kit (Field work)

-29-

M1M2

TBIA

TB3

N L

TB02

M1M2S

TB01

Switch

(Breakers for wiring

and current leakage)

L2 L1

Outdoor unit

Oil trap kit

L1 L2 L3

SWU3

SW1SW2SW3

SW4

L1 L2 L3 N

CNTYP1

CNRS3

CN20

CNX10

CNTR

CNFC1

CNVCC4

Main board

INV board

CNVCC3

CNS1

CNS2

CNFC2

CNPOW

CNFAN

T01

M1 M2 S

N L

(2) Connect the transmission line of the oil trap kit to the terminal block for outdoor unit transmission (TB3),

and the shielded earth line to the earth screw ( ). Connect the power source line of the oil trap kit to the terminal block for outdoor unit power source

(TB1A) (Refer to the figure above.) or to individual power source by using a power cord with plug.

5. Electrical wiring work

5-1 Wiring connection before flushing operation

(1) Wiring connection with outdoor unit

(1) Remove the control box cover of the outdoor unit. (The state within the control box cover is shown

below.)

In the case of P200 • 250YREM-A

A Power source terminal block (TB1) B Transmission line terminal block (TB3) C Centralized control terminal block (TB7) D Earth ( )

(3) Remove the screws (2 pcs.) of the terminal block cover

of the oil trap kit, connect the transmission line to the transmission line terminal block (TB02), the earth line to the earth screw ( ), and the power source line to the power source line terminal block (TB01). Connect the earth of shielded wire only to the outdoor unit, and apply insulation to the oil trap kit side. (The state in the terminal block cover is shown below.)

(4) Connect wiring to the oil trap kit through the square holes

(two spots at the center) on the left panel. In this case, be careful not to allow wirings to contact each other.

Wire thickness for power supply (mm )

Main cable Grand

1.5 1.5

1.25 or more

VCTF, VCTEK, CVV, CVS, VVR, VVF, VCT

or shielded wire CVVS/CPEVS

Notes: 1. Specific wiring requirements should adhere to the local wiring regulations of the region.

2. Power supply cords of parts of appliances for heat source use shall not be lighter than polychloroprene sheathed flexible cord (design 245 IEC57).

3. When the power source is supplied from the outdoor unit as shown in the figure above, the protection of the oil trap kit relies on the switch installed on the outdoor unit. Therefore, be sure to install the switch on the outdoor unit.

Power source line terminal block (TB01) A

PC connecting terminal (RS-232C) C

Transmission line terminal block (TB02) B

Transmission cables (mm2)

-30-

13 11

25 14

(2) Wiring connection with PC

(1) Connect RS-232C connecting cable (field supply) suitable for the

PC to the PC connecting terminal of the oil trap kit.

Connection with PC :

The oil trap kit is equipped with D-SUB25pin female connector (DTE) for the connection to the PC. Connect by using RS-232C cross cable (length : 15m or less) marketed.

Request:

In accordance with the type of the serial interface for the PC to be used, select the RS-232C cable for use. (The D-SUB connector of the oil trap kit is of 25 pins.)

(3) Address setting

Unscrew the screws (2 pcs.) of the control bo x at the oil tr ap kit, and set the address . The range of address setting for the oil trap kit is 00 ~ 99. Select the address that is not being used by the indoor units, outdoor units, remote controllers and PC.

5-2 Wiring connection after flushing operation

(1) Wiring connection with outdoor unit

(1) Remove all wiring (power source wiring, transmission wiring) connected to the oil trap kit i.e. the original

state before connecting the oil trap kit.

6. Connection work on rainy days

Please refrain from working on wiring and piping on rainy days. If the work is conducted, provide proper covering with vinyl sheet while paying attention to the items below.

(1) Prevent rain water from entering the piping. (2) Be careful not to expose the electrical parts of the outdoor unit and oil trap kit to rain fall. (3) Be careful not to touch the wiring with wet hands. Otherwise electric shock may be caused.

D-SUB 25pin female connector (DTE)

The standard for selecting RS-232C cable is given below. (For the connector with a special shape, consult the dealer of the PC.)

Connection with DOS/V PC

9-pin type of D-SUB25 connector

DOS/V PC

Oil trap kit

Caution

For the cable of D-SUB connector use, prepare the cross cable of 9 pin-25 pin. Otherwise abnormal communica-

tion may be caused.

Caution

Connect RS-232C cable while removing M-NET transmission line. Otherwise trouble may occur.

PC connecting terminal (RS-232C)

7. Flushing operation

(1) Installation method of S/W

Items to be prepared:

•REPLACE MULTI Setup Disk

•PC DOS-V machine (with CD ROM) WINDOWS95, 98, NT 4.0, 2000, ME or XP

Recommended conditions

CPU : 300MHz or more Memory : 64MByte or more HDD : 40MByte or more OS : WINDOWS 2000 or later

Installation method:

1. Set the [REPLACE MULTI Setup Disk] to the CD-ROM drive of the objective PC.

2. Execute the setup.exe of the CD-ROM drive and install by following the instruction displayed on the

screen.

Starting method of S/W for replacing:

1. Click the [START] button and click the [PROGRAM].

2. Click the [REPLACE MULTI] and start the S/W for replacing.

(2) Items to be confirmed before flushing operation

1. Set the address of the oil trap kit within a range of 00 ~ 99 not using the address being used by the

outdoor unit, indoor unit, remote controller and PC.

2. Set the communication port of the PC to “COM1.”

Change it to “COM1” if it is being set to other than “COM1.” Otherwise the flushing operation can not be executed.

3. (Only required at the existence of indoor units of under Ver30 or LOSSNAY with heating humidifier of

under Ver8.08 : Will be displayed on PC to remove ) Remove the system controller connected to the indoor/outdoor transmission line and MA remote controller grouped with different refrigerant systems. Reconnect them after flushing operation.

Request:

When flushing operation can not be executed normally, do not change the set time of the PC during the working of the S/W for replacing.

(3) Starting and finishing of flushing operation

Flushing operation procedure (1)

❉ The abbreviations used in this manual and on the PC screen display represent as follows;

Program version

Click the [REPLACE MIULTI] of the [PROGRAM] menu.

↓

Enter the self address Enter the address within 1 ~ 253 not using that being used by OC, OTK, IC and remote controllers. (The default value is set to 252.)

↓

Enter the OC address.

↓

Enter the OTK address 1. Do not enter the OTK address 2.

↓

Click [Connection information].

↓

Confirm the display of information connection monitored result. Click [YES] if it is correct.

Confirm the outdoor unit model name, self (MY) address : PC address, OC, OTK, IC addresses and connected numbers.

When it is not correct, click [NO] and check the connecting status of OC, IC, etc.

IC address input is not necessary.

OC : Outdoor unit OTK : Oil trap kit IC : Indoor unit RT : Replace tank

Ope Mode : Operation mode D. F. : Defrosting F. P. : Forcible powering Oil E. : Oil equalizing

Oil R. : Low frequency

oil recovery Ref. R. : Refrigerant recovery S. SH : Shell bottom SH

↓

Open and close all solenoid valves inside OTK, and check the operating sound of the solenoi d valves. (Opens/closes starting from SV1 in order)

↓

In checking the solenoid valve operating sound for existence, clicking [NO] opens/closes the solenoid valve for 2 times, while clicking [NO] for three times continually displays as shown left. Check the solenoid valves inside OTK in such case.

When the system controller is connected to the indoor/outdoor transmission line or MA remote controller is grouped with different refrigerant systems, shut off the outdoor unit power source and remove the system controller and MA remote controller. After removal, apply the power source and press the OK button. If the left display is not shown, it is not required to remove the system controller and MA remote controller.

↓

Click [Reference] and set the storage location and file name of the output file. (The default setting is the ¥program files ¥replacemulti¥ (date).csv.)

Clicking [Start] moves to the main screen.

↓

Be careful that the indoor unit fan operates during flushing operation. A v oid w orking on the internal part of the indoor unit during flushing.

↓

Clicking [Flushing mode] initiates flushing operation.

Below the [Flushing mode] button, the remaining time to complete the flushing operation and the estimated time required for re-flushing are displayed.

(As the remaining time only represents for the standard. It may change during the operation.)

Caution

(1) Operating sound may generate during the

flushing operation. This is caused by the switching operation of the solenoid vale not representing malfunction.

(2) Be careful that the piping (flexible tube) may

be heated to high temperature during flushing operation.

↓

Clicking [OTK/IC] displays the monitor display screen of OTK and IC.

↓

Clicking [Main monitor] returns to the main monitor screen display.

Standard of flushing operation time

The flushing operation time differs depending on the insufficient quantity of refrigerant, outdoor temperature and outdoor wind. In addition, the flushing time will be prolonged when the mean value of frequency, Fa v e , is lo wer than the target frequency. When the outdoor temperature drops below 20˚C or the mean value of the low pressure, LPsave, lowers below

0.46MPa, install the low temperature hood after checking the refrigerant quantity and the opening/closing status of the valves. Howev er, please note that the low pressure (63LS) may drop during 30 minutes after starting flushing operation caused by the initial status of refrigerant. Always take the operating condition into your account for proper operation. The standard of flushing operation with insufficient refrigerant is given by the table below.

LPSave > 0.51[0.56] 0.51[0.56 ≥ LPSave > 0.41[0.46] 0.41[0.46] ≥ LPSave > 0.34

Target

frequency

PUHY-P200YREM-A

2 hours 3 hours 4 hours

65Hz

PUHY-P250YREM-A 78Hz Refrigerant charge

No insufficient Insufficient refrigerant Insufficient refrigerant

refrigerant –10% –30%

↓

After finishing flushing operation, refrigerant recovery operation will be executed. The remaining time of flushing operation is displayed below the [Refrigerant recovery] button. The recovery processing now is displayed for 18 minutes after starting refrigerant recovery operation, while the refrigerant recovered is finishing. ❉ The time required by the recovery processing

and the refrigerant recovered is shown individually.

❉ When the unit is stopped during the recovery

processing, it will be continued for 51 minutes.

↓

If the value of the low pressure (63LS) drops below 0.11MPa during recov ering refrigerant, the compressor stops with the display of [Stopping].

(Be careful, the outdoor fan rotates in full speed

even in stopping!) After stopping for 1 minute, the compressor restarts with the display of [Ref recovering].

↓

After finishing refrigerant recovery operation, the left screen appears. On this screen, close the ball valve of the outdoor unit and the valve mounted to the extended piping, click [OK].

↓

After confirming the closing of the ball valve of the outdoor unit and the valve mounted to the extended piping, click [YES].

↓

After opening the solenoid valve for several seconds, the left screen appears. On this screen, close the ball valve, and click [OK].

Flushing operation procedure (2)

↓

After turning the power source of OC and OTK off , recover mineral oil inside the oil trap kit and remove the piping (flexible tube) between the outdoor unit and oil trap kit. After connecting the piping kit (field work), execute evacuation. After evacuation, open the ball valve of the extended piping and OC that in order. Then remove the replace tank and confirming it

has no residual oil. After completing the above work, click [OK].

Caution Do not turn off the power source nor remove OTK before displaying the left screen.

Caution

(1) Before removing OTK, discharge the recov-

ered mineral oil through the mineral oil recovery service valve. Dispose the discharged oil in the field. (The oil pan should be prepared in the field.)

(2) The job site is desired to be outdoor or a place

with ventilating facility.

(3) To operate the oil recovery service valve, do it

slowly using leather gloves or the like.

(4) Recover mineral oil until the continuous dis-

charge of the liquid (recovered oil) from the oil recovery service valve stops. (The state of spraying or dripping is acceptable.)

(5) When removing the piping (flexible tube), note

that inside the piping contains gas refrigerant. Remove it after recovering the refrigerant.

(6) Confirm that the pressure inside the oil trap kit

is stable within 0.049 ~ 0.294MPa with a pressure gauge. When it is out of the above range, take countermeasures by confirming the inner pressure of the oil trap kit.

↓

Click [Finish], and turn the PC power source off. ❉To monitor the operation status, do not set to

[Finish].

↓

After that, remove the power source wiring between OC and OTK, and the connecting cable between OTK and PC. ❉To monitor the operation status, remov e only the

power source wiring between OC and OTK.

↓

Turn the power source of OC on, and confirm the operation.

•To start confirming the operation, use the test run

switch of the remote controller or OC.

Flushing operation procedure (3)

For Y series

Finishing of monitoring

To pause the work, click [Stop].

↓

At the display of the left message, click [YES].

OC stops the operation of the compressor.

Clicking [NO] allows OC to operate continually.

↓

Click [OK] and confirm the stopping of the compressor.

Emergency stopping method

The work can be paused or suspended during the flushing operation and refrigerant recovery operation.

↓

To restart the operation, click [Restart]. ([Refrigerant recovery] during refrigerant recovery operation) ([Restart] does not appear within about 3 minutes after stopping.) To suspend the operation, click [Finish].

Caution

At the restarting after pausing the work, the operation restarts from one step before that paused (about 5 minutes) after operating for initial processing (for about 15 minutes).

Display at erroneous input and detection of abnormality

At erroneous input or when abnormality is detected during operation, a message corresponding to the content of erroneous input or abnormality will be displayed. Conduct input and inspection work by following the message displayed on the screen.

Display example of erroneous input (Erroneous input of self address)

Display example of detecting abnormality (Detection of abnormal high pressure : [Error code 1302])

•Insufficient flow rate When an extremely insufficient flow rate is detected during flushing operation, the following message is displayed. Execute inspection and countermeasure by following the message displayed on the screen. As the low pressure (63LS) may drop depending on the initial refrigerant status for 30 minutes after start of flushing operation, please take proper measures while observing the operating condition.

Display of insufficient flow rate during backup control

• Backup control The backup control includes that for high pressure, discharge temperature (compressor shell temperature), radiator plate temperature (THHS), and secondary current (bus current), and the item presently backed up is shown in red color. The red color display continues until returning to normal control.

Clicking [Error history] displays the history of abnormality.

❉Displays the abnormality history both under

mineral oil recovery and normal operation.

❉During mineral oil recovering, the abnormality

history under normal operation is not displayed.

↓

Clicking [OK] returns to the main screen.

Clicking [Help] allows you to read the mineral oil recovery work manual in the form of PDF file.

Caution

To read PDF file, Acrobat Reader is required.

Display at operation status confirmation and abnormal history

The operating status of OC and IC while confirming their operation may be monitored. (Do not remove the transmission line of OTK after flushig operation and refrigerant recovery.) Note: Effective only to monitor the operating status by using PC.

Reading of mineral oil recovery work manual

(4) Mounting method of low outdoor temperature hood

Upon the request to install the low outdoor temperature hood displayed on the PC as shown below, mount the low outdoor temperature hood provided with the oil trap kit.

❉Although the standard is TH6 = 20˚C or less, the hood is required to be mounted to protect against

any outdoor wind or rain interfering with the flushing operation. In the case when the discharge pressure, 30 minutes after starting flushing operation is (63HS) < 20kg/cm

, or the mean value of low pressure, LPSave, is less than 0.46. As the low pressure (63LS) may drop depending on the initial refrigerant status for 30 minutes after start of flushing operation, please take a proper measure while observing the operating condition. In the case of TH6 > 43˚C, adjust the hood vertically for TH6 ≤ 43˚C. When the outdoor low temperature hood can not be mounted due to the centralized installation system, remove the spring for fastening.

(1) Installation condition : Mount hood at TH6 = 20˚C or less. (2) Mounting method : Place the hood to cover the outdoor unit from the top, fasten it by putting the spring

for fixing between the fin guard at the front and rear sides.

When it is left for a long time during the night, be careful not to loose the springs.

In the case of P200 • 250YREM-A

Fasten to fin guard

Fasten hood

Fasten to fin guard

IV. Work Procedure at Oil Inspection

1. Oil inspection after mineral oil recovery

List of oil inspection parts (for mineral oil)

Parts name Application Specification Remarks

(1) Ester oil sampling kit Oil sampling inside outdoor Vessel (1pc.), Bottle (2pcs. [1pc. charged with oil)]

unit Filler (2pcs.)

(2) Portable refractometer Measuring of oil refractive Recommended maker : K.K. Atago

index Product No. : N-3000E

(3) Oil pan (field supply) Oil recovery vessel

❉ (2) For the portable refractometer, read the instruction manual carefully before use, understand its function and operation fully.

Purchased Atago product your agent

Checking required parts

1. Operate outdoor unit.

2. Place oil pan and open for 1/2 seconds to collect oil from oil recovery service valve, and dispense the recovered oil.

3. 20 minutes after recovering oil of “2” mount the vessel (for sampling of oil to be measured) attached to ester oil sampling kit, and open it for 1/2 seconds to collect oil.

Evacuate the vessel (for sampling oil to be measured).

Caution:

(1) Laying the vessel horizontally for evacuation discharges oil together with

air. Evacuate while standing vertically.

(2) After reaching a vacuum degree of 650Pa, evacuate for about 15 sec-

onds or more and leave it for 15 seconds to confirm that the vacuum

degree does not rise. (3) Be careful error may be caused by insufficient evacuation. (4) Working below 20˚C, the desired vacuum degree can be attained sooner

if evacuating while heating the vessel with a dryer. (about 10 minutes)

Loosen the flare nut of the vessel (for sampling to be measured), open the bottle (for sampling oil to measure) cap, and pour the oil inside the vessel (for sampling oil to be measured).

Caution:

(1) Open/close the flare nut with two spanners. (2) Wipe off water content adhered to the vessel (for sampling oil to be mea-

sured) not allowing water enter into the bottle (for sampling oil to be mea-

sured).

Work flow Work content

Take the following items to site: ester oil sampling kit, portable refractometer and tools

Operating outdoor unit, collecting oil (for dispensing, sampling)

Evacuating vessel (sampling of oil for measurement)

Move the oil inside vessel (for sampling oil to be measured) to the bottle (for sampling oil to be measured)

Oil recovery service valve (BV5)

Vacuum pump

Accumulator

Bottle (for sampling oil to measure)

(1) Oil sampling method

Dealer of Atago products (As of December 2003)

Country Distributor TEL FAX

Belgium Analis 32-9-243-77-19 32-9-220-08-48

LEO KUEBLER 0721/22491+21090 0721/27903 Germany Kleinfeld Labortechnik GmbH 49-5108-9298-15 49-5108-9298-98 France Fisher Bioblock Scientific S.A. 33-3-88671414 33-3-88-675359 33-3-88671168- 33-3-8867-1125 Italy ANALYTICAL CONTROL S. P. A. 39-02-6122841 39-02-6127646 Netherland Luxembourg

GOFFIN MEYVIS 31-76-5-86000 31-76-5086086

Denmark Bie & Berntsen A-S 45 44 94 88 22 45 44 94 27 09 Ireland England

44-1525-372010 44-1525-853617

Greece P. BACACOS S. A. (ATHENS) 30-210-5232-631 30-210-5229-141 Spain GOMENSORO, S. A. 91-508-6586 91-508-6511 Portugal CONCESSUS, S. A. 351-21-387-2406 351-21-388-5950 Finland BERNER 358-9-134511 358-9-13451384 Austria VWR International GmbH 43-1-57600-323 43-1-57600-350 Sweden TAMRO MEDLAB AB 46-31-706-3000 46-31-706-3030

JENCONS SCIENTIFIC LTD

-45-

Open the cap of the oil charged bottle in the ester oil sampling kit, collect oil by using the filler provided, and drip one or two drops onto the prism surface of the portable refractometer.

Caution:

(1) Coat oil so that it spreads over the prism surface. (2) When air bubbles are found, refrigerant may possibly be present. Move the oil to be mea-

sured to the vessel and evacuate it again.

1. Direct the top end of the refractometer toward the direction of sun light, turn the ocular mirror to read the scale clearly while looking in the ocular mirror.

Caution:

(1) Measuring with direct solar radiation (sun light) may gen-

erate the coloring of the boundary line. Use soft lighting such as the reflecting light off a wall surface. Be careful, the sample oil loaded may drip while reading the scale.

(2) Grasping the refractometer with your whole hand during

measuring may give your body heat to the meter causing possible error.

(3) When the boundary line is vague despite ocular adjust-

ment, refrigerant may be dissolving. Move the oil to be measured to the vessel, and evacuate it again. Refrigerant can also be removed by opening/closing the light collecting plate (for about 20 times).

2. As the boundary line separating bright and dark sections horizontally appears in the visual field, read the scale on the boundary line. (Down to the 4th decimal point Example : 1.4530)

By using a soft tissue paper damped with water, wipe off the prism surface, light collecting plate and its surrounding, and further wipe off water content with a dry tissue paper.

Caution:

(1) As the prism is soft, be careful not to damage it during wiping. (2) As the contaminated prism surface may cause an error or make the boundary line vague,

always keep it clean by wiping.

Drip oil in the bottle inside the ester oil sampling kit into the portable refractometer.

Read the scale with the ocular mirror.

Remove oil adhered to the prism surface.

Apply the same operation to the bottle (for sampling oil to be measured).

(2) Measuring method and judgment of refractive index

Work flow Work content

Judgement [A difference of the refractive index between the oil charged bottle and the bottle (for sampling to be measured)]

+0.0015 or less

+0.0015 exceeded

Acceptable as it is. Execute flushing operation again.

Air bubble

Prism

Compressor

Oil recovery service valve (BV5)

In the case of P200 • 250YREM-A

Leave the bottle charged with oil inside the ester oil sampling kit and the bottle (for sampling oil to be measured) for 50 minutes to allow the oil to moved under the same environment as the outdoor or indoor. Locate the refractometer in the same environment.

Caution:

Although the bottles may be located either outdoor or indoor, leave them in the same place where the refractive index explained later is measured.

Adjusting temperature of bottle charged with oil in the ester oil sampling kit and the bottle to which oil is moved (for sampling oil to be measured)

Work flow Work content

1.46

1.45

-46-

Method of re-flushing operation

Depending on the difference of refractive index of the oil charged bottle (for sampling oil to be measured) with a refractometer, conduct cooling/heating operation and re-flushing operation (“NG mode” program for reflushing) for the rated frequencies as shown below. (Repeat the operation of (A)~(D) as follows.)

Difference of refractive index

Frequency of re-flushing operation

Operation method

0.0015 ~ 0.0025 1 time

0.0025 ~ 0.0040 2 times

0.0040 ~ 0.0070 3 times

0.0070 ~ 0.0115 4 times

Sectional name of portable refractometer

❉ For the portable refractometer, please read the in-

struction manual to understand the sectional function and control method fully before actual use.

(3) Measures to be taken at oil inspection (Failure to pass oil inspection test) (No Good)

Parts list

(1) Ester oil for Replenishment of ester Mounted to ball valve at

REPLACE MULTI oil (2L) to outdoor unit both ends

(2) A complete set of parts Execution of flushing Refer to III. Mineral oil

for mineral oil recovery operation recovery operation method. operation

(3) Valve (field supply) For evacuation –

(4) Charging hose Connection with outdoor –

(field supply) unit

(5) Gauge manifold Checking of oil flow –

(field supply)

Parts name Application Specification Remarks

• Service parts

• Requires the quantity below for re-flushing

operation of 1 time P200, 250YREM-A : 1 pc.

• Not required for the re-flushing operation of less than 2 times

Replenish and recover (1) ester oil for REPLACE MULTI while conducting cooling/heating operation.

Replenish and recover (1) ester oil for REPLACE MULTI while conducting re-flushing operation.

Scale correcting screw

Light collecting plate

Prism

-47-

Carrying in ester oil for REPLACE MULTI and tools

Mounting the ester oil sampling kit for REPLACE MULTI (A)

Replenishment/recovery of ester oil under cooling/heating modes

Work flow Work content

Checking the required parts

1. Unscrew 6 screws on the outdoor unit front panel, and remove the front panel.

2. Connect the ball valve (2) at the lower part of the ester oil kit to the oil recovery service valve B, and the upper ball valve (1) to the service check joint (high pressure) A.

Caution:

When connecting the service check joint, firstly connect the valve (field supply) to mount the charging hose.

To A

Lower ball valve (2)

Upper ball valve (1)

Service panel

Ester oil for REPLACE MULTI

To B

In the case of P200 • 250YREM-A

-48-

(1)

(2)

(3)

(4)

Evacuate the charging hose before and after the ester oil kit for REPLACE MULTI (by mounting the valve).

Caution:

(1) Evacuating with the ester oil kit for REPLACE MULTI (1) (2) laid horizontally discharges the

oil together with refrigerant. Stand it vertically for evacuation.

(2) After reaching a vacuum degree of

650Pa, evacuate for 5 seconds more, and stop the vacuum pump. Then leave it for 5 seconds and confirm the vacuum degree does not rise.

1. After evacuation, close the valve (4) before the vacuum pump and the high/low pressure valve of the gauge manifold.

2. Open the valves (1) (2) of the ester oil kit for REPLACE MULTI, the valve (3) connected to the service check joint, and the oil recovery service valve B (4 in total), and add oil by operating all indoor units for cooling or heating. (For P200

• 250YREM-A per 1 time : 1 pc., additional oil charge) (open valves in the order of

valve (3) connected to the service check joint, valve (1) to the REPLACE MULTI ester oil kit upper part, and valve (2) to the REPLACE MULTI ester oil kit lower part and the oil recovery service valve B.) The additional charge takes about 20 minutes per piece.

1. After completing all oil replenishment, close valve (3) connected to the service check joint.

2. After closing valve (3) connected to the high pressure service check joint A, change the connecting point from A (high pressure) to C low pressure service check joint. At this moment, place the vessel of the REPLACE MULTI ester oil kit on a scale.

3. Open valve (3) connected to the service check joint, and recover oil for 2kg.

4. After recovering oil, close the oil recovery service valve B, ball valve (2) of the REPLAC E MULTI ester oil kit, and valve (3) connected to the service check joint. (3 in total)

5. Open valve (4) before the vacuum pump and the high/low pressure valve of the gauge manifold, recover the refrigerant inside the REPLACE MULTI ester oil kit.

6. After recovering refrigerant, close the ball valve (1) of the REPLACE MULTI ester oil kit, valve (4) before the vacuum pump and the high/low pressure valve of the gauge manifold, and remove the REPLACE MULTI ester oil kit. ❉ Confirm that the oil quantity recovered inside the REPLACE MULTI ester oil kit is correct.

After completing oil replenishing and recovering work, check the cooled (heated) air supply and compressor operating status.

Evacuating the inside of charging hose (B)

Executing additional oil charging by opening valves (1)(2) (C)

Changing the connecting position of valve (3) (A→C), Executing oil recovery (D)

Confirming the operation (compressor starting)

Work flow Work content

Vacuum pump

3-way joint

Valve (3)

Gauge manifold

Valve (4)

Oil recovery service valve B

-49-

Carrying in ester oil for REPLACE MULTI and tools

Installing the oil trap kit, branch piping kit and PC

Air tightening and evacuating the inside of piping (flexible tube)

Mounting the ester oil sampling kit for REPLACE MULTI (A)

Replenishment/recovery of ester oil under re-flushing operation

Work flow Work content

Checking the required parts

1. Turn on the power source of the outdoor unit.

2. Remove the piping kit mounted between the outdoor unit and the valve on the extended

piping.

3. Connect the outdoor unit and oil trap kit with piping (flexible tube).

4. Apply airtight test and evacuation to the piping (flexible tube) between the outdoor unit, valve

mounted to the extended piping and oil trap kit.

5. Open the ball valves. [in the order of the oil trap kit (1)~(4), extended piping, and outdoor unit

(1), (4).]

6. For the oil trap kit, apply from L1 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. Remove the system controller if connected to the indoor system.

For detail, refer to 1~5 : Piping work and 6, 7 : Wiring connection.

1. Unscrew 6 screws on the outdoor unit front panel, and remove the front panel.

2. Connect the ball valve (2) at the lower part of the ester oil kit to the oil recovery service valve

B, and the upper ball valve (1) to the service check joint (high pressure) A.

Caution:

When connecting the service check joint, firstly connect the valve (field supply) to mount the charging hose.

To A

Lower ball valve (2)

Upper ball valve (1)

Ester oil for REPLACE MULTI

To B

In the case of P200 • 250YREM-A

Service panel

-50-

(1)

(2)

(3)

(4)

Evacuate the charging hose before and after the ester oil kit for REPLACE MULTI (by mounting the valve) by opening valve (4) before the vacuum pump and the high/low pressure valve of gauge manifold.

Caution:

A Evacuating with the ester oil kit for REPLACE MULTI (1) (2) laid horizontally discharges the

oil together with refrigerant. Stand it vertically for evacuation.

B After reaching a vacuum degree of

650Pa, evacuate for 5 seconds more, and stop the vacuum pump. Then leave it for 5 seconds and confirm the vacuum degree does not rise.

1. After evacuation, close valve (4) before the vacuum pump and the high/low pressure valve of

the gauge manifold.

2. Open the valves (1) (2) of the ester oil kit for REPLACE MULTI, valve (3) connected to the

service check joint, and the oil recovery service valve B (4 in total), add oil, operate for recovery. (per 1 time : 1 pc.) (open valves in the order of valve (3) connected to the service check joint, valve (1) at the REPLACE MULTI ester oil kit upper part, and valve (2) at the REPLACE MULTI ester oil kit lower part, and oil recovery service valve B.) The additional charge takes about 20 minutes per piece. The recovery time takes about 24 hours.

1. At about 20 minutes after starting flushing operation, close the ball valves (1) (2) of the RE-

PLACE M MULTI ester oil kit, valve (3) connected to the service check joint and oil recovery service valve B (4 in total). (close valves in the order of the valve (3) connected to the service check joint, the REPLACE MULTI ester oil kit upper part ball valve (1) and lower part ball valve) (2).

Remove the oil trap kit and REPLACE MULTI ester oil kit.

Reconnecting piping kit provided with outdoor unit, and conducting evacuation

Confirming the operation (compressor starting)

1. After flushing operation, close the service valves of the outdoor unit, and valve mounted to

the extended piping. (4 in total)

2. Close the service valves of the oil trap kit. (4 in total)

3. Turn off the power source of the outdoor unit once.

4. After flushing operation, recover oil by opening the oil recovery service valve.

(Confirm that about 2 litters of oil is recovered.) ❉ The mineral oil recovered by flushing operation should be extracted for each time, and

confirm that the pressure counts within 0.049~0.294MPa to proceed the work.

1. Remove the piping (Flexible tube) between the outdoor unit, valve mounted to the extended

piping and oil trap kit.

2. Remove the oil trap kit.

3. Remove the REPLACE MULTI ester oil kit. (Recover refrigerant inside the REPLACE MULTI

ester oil kit.)

4. After reconnecting the piping kit (field work) to the outdoor unit, conduct evacuation.

5. Open the ball valve of the outdoor unit, and valve mounted to the extended pipe. [in the order

of the extended piping to the outdoor unit (1) and (4)] ❉ After removing the REPLACE MULTI ester oil kit, confirm that ester oil does not flow out

from the lower ball valve.

❉ After removing the oil trap kit, check the inner pressure. ❉ Store the kit at a place not exposed to direct solar radiation (sun light) in a cool and dark

place.

After recovering mineral oil, check the cooled (heated) air supply and compressor operating status by conducting normal air conditioning.

Evacuating the inside of charging hose (B)

Executing flushing again by opening valves (1)(2) (C)

Recovering oil inside the oil trap kit (D)

Work flow Work content

Vacuum pump

3-way joint

Valve (3)

Gauge manifold

Valve (4)

Oil recovery service valve B

-51-

Conducting reflushing operation to improve mineral oil recovery conducts reflushing operation providing the PC screen below. Clicking [NG mode] initiates reflushing operation.

-52-

Ambient temp.

Indoor

˚C

Outdoor

Connected unit

Set

Indoor unit Operating unit

Model name –

Main piping

Piping Branch piping m

Total piping length

Refrigerant charge kg

Outdoor

Current A

unit

Voltage V

LEV

Indoor unit

opening

SC (LEV1) Pulse

Oil return (SLEV)

Pressure

High pressure (after O/S)

MPa

/Low pressure (before MA)

Discharge (TH1)

Heat exchanger outlet (TH5)

Outdoor

Low press. 2-phase temp. (TH2) ˚C

unit

SC heat exchanger outlet (TH7)

Bypass outlet (TH8)

Composition detected value (α OC)

V. Mineral Oil Recovery Operation Data (Reference Data)

1. Standard data (During flushing operation)

Outdoor unit model name

PUHY-P200YREM-A PUHY-P250YREM-A

Items

Conditions

(Dry bulb temp. /wet bulb temp.)

Sectional temperature

27/19

35/–

80/56x4/22 56x6/22

30/1

220

26.3 28.3

29.7 35.1

200

2000

2.35/0.48

3.4

0.23

-53-

Service, Maintenance / Inspection

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