Mitsubishi PCFY-P40VGM-E, PCFY-P63VGM-E, PCFY-P100VGM-E, PCFY-P125VGM-E Service Manual

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS

TECHNICAL & SERVICE MANUAL

July 2006

No. OC308

REVISED EDITION-A

Series PCFY

<Indoor unit> [Model name] [Service Ref.]

PCFY-P40VGM-E

PCFY-P63VGM-E

PCFY-P100VGM-E

PCFY-P125VGM-E

INDOOR UNIT

Ceiling Suspended

PCFY-P40VGM-E PCFY-P63VGM-E PCFY-P100VGM-E PCFY-P125VGM-E

R410A

CONTENTS

1. SAFETY PRECAUTION ······················2

2. PART NAMES AND FUNCTIONS ·······6

3. SPECIFICATIONS ·······························8

4. OUTLINES AND DIMENSIONS·········11

5. WIRING DIAGRAM····························15

REFRIGERANT SYSTEM DIAGRAM

7. TROUBLE SHOOTING······················17

8. DISASSEMBLY PROCEDURE··········24

9. PARTS LIST·······································28

10. RoHS PARTS LIST ···························35

11. OPTIONAL PARTS ··························42

R407C

Revision:

•

RoHS PARTS LIST

• Some descriptions have been modified.

• Please void OC308.

Note:

• This manual describes only service data of the indoor units.

• RoHS compliant products have <G> mark on the spec name plate.

• For servicing of RoHS compliant products, refer to the RoHS Parts List.

R22

is added.

··16

Do not use the existing refrigerant piping.

The old refrigerant and lubricant in the existing piping contains a large amount of chlorine which may cause the lubricant deterioration of the new unit.

Use “low residual oil piping”

If there is a large amount of residual oil (hydraulic oil, etc.) inside the piping and joints, deterioration of the lubricant will result.

Use ESTR , ETHER or HAB as the lubricant to coat flares and flange connection parts.

If large amount of mineral oil enter, that can cause deterioration of refrigerant oil etc.

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 a refrigerant other than R407C.

If another refrigerant (R22, etc.) is used, the chlorine in the refrigerant may cause the lubricant deterioration.

Use a vacuum pump with a reverse flow check valve.

The vacuum pump oil may flow back into the refrigerant cycle and cause the lubricant deterioration.

Store the piping to be used during installation indoors with keep both ends 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.

Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released.

Gravimeter

Unit

SAFETY PRECAUTION

CAUTIONS RELATED TO NEW REFRIGERANT

Cautions for units utilizing refrigerant R407C

[1] Cautions for service

·After recovering the all refrigerant in the unit, proceed to working.

·Do not release refrigerant in the air.

·After completing the repair service, recharge the cycle with the specified amount of liquid refrigerant.

[2] Refrigerant recharging

(1) Refrigerant recharging process

1Direct charging from the cylinder.

·R407C cylinder are available on the market has a syphon pipe.

·Leave the syphon pipe cylinder standing and recharge it. (By liquid refrigerant)

(2) Recharge in refrigerant leakage case

·After recovering the all refrigerant in the unit, proceed to working.

·Do not release the refrigerant in the air.

·After completing the repair service, recharge the cycle with the specified amount of liquid refrigerant.

[3] Service tools

Use the below service tools as exclusive tools for R407C refrigerant.

No. Tool name Specifications

1 Gauge manifold ·Only for R407C.

·Use the existing fitting SPECIFICATIONS. (UNF7/16)

·Use high-tension side pressure of 3.43MPa·G or over.

2 Charge hose ·Only for R407C.

·Use pressure performance of 5.10MPa·G or over.

3 Electronic scale 4 Gas leak detector ·Use the detector for R134a or R407C. 5 Adapter for reverse flow check. ·Attach on vacuum pump. 6 Refrigerant charge base. 7 Refrigerant cylinder. ·For R407C ·Top of cylinder (Brown)

·Cylinder with syphon

8 Refrigerant recovery equipment.

Cautions for units utilizing refrigerant R410A

Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before brazing. (Leave elbow joints, etc. in their packaging.)

Use ester oil, ether oil or alkylbenzene oil (small amount) as the refrigerant oil applied to flares and flange connections.

Charge refrigerant from liquid phase of gas cylinder.

If the refrigerant is charged from gas phase, composition change may occur in refrigerant and the efficiency will be lowered.

Do not use refrigerant other than R410A.

If other refrigerant (R22 etc.) is used, chlorine in refrigerant can cause deterioration of refrigerant oil etc.

Use a vacuum pump with a reverse flow check valve.

Vacuum pump oil may flow back into refrigerant cycle and that can cause deterioration of refrigerant oil etc.

Use the following tools specifically designed for use with R410A refrigerant.

The following tools are necessary to use R410A refrigerant.

Keep the tools with care.

If dirt, dust or moisture enter into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor.

Do not use a charging cylinder.

If a charging cylinder is used, the composition of refrigerant will change and the efficiency will be lowered.

Flare tool

Electronic refrigerant charging scale

Vacuum pump adaptor

Size adjustment gauge

Gauge manifold

Torque wrench

Gas leak detector

Charge hose

Tools for R410A

If dirt, dust or moisture enter into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor.

If large amount of mineral oil enter, that can cause deterioration of refrigerant oil etc.

Do not use the existing refrigerant piping.

The old refrigerant and lubricant in the existing piping contains a large amount of chlorine which may cause the lubricant deterioration of the new unit.

Use “low residual oil piping”

If there is a large amount of residual oil (hydraulic oil, etc.) inside the piping and joints, deterioration of the lubricant will result.

Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released.

[1] Cautions for service

Gravimeter

Unit

(1) Perform service after collecting the refrigerant left in unit completely. (2) Do not release refrigerant in the air. (3) After completing service, charge the cycle with specified amount of refrigerant. (4) When performing service, install a filter drier simultaneously.

Be sure to use a filter drier for new refrigerant.

[2] Additional refrigerant charge

When charging directly from cylinder

· Check that cylinder for R410A on the market is syphon type.

· Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.)

[3] Service tools

Use the below service tools as exclusive tools for R410A refrigerant.

No. Specifications

1 Gauge manifold ·Only for R410A

·Use the existing fitting

·Use high-tension side pressure of 5.3MPa·G or over.

2 Charge hose ·Only for R410A

·Use pressure performance of 5.09MPa·G or over.

3 Electronic scale 4 Gas leak detector ·Use the detector for R134a, R407C or R410A. 5 Adaptor for reverse flow check ·Attach on vacuum pump. 6 Refrigerant charge base 7 Refrigerant cylinder ·Only for R410A Top of cylinder (Pink)

8 Refrigerant recovery equipment

specifications

Cylinder with syphon

. (UNF1/2)

Air outlet

Intake grille

Air intake

Left/right guide vanes

Change the direction of airflow from the horizontal blower.

Long-life fillter

Removes dust and foreigh matter from air coming in through the grille (Recommended cleaning interval : Approx, every 2,500 operating hours)

Up/down guide vanes

Change the direction of airflow from the vartical blower.

PAR-21MAA

ON/OFF

FILTER

CHECK

OPERATION

CLEAR

TEST

TEMP.

BACK DAY

MONITOR/SET

CLOCK

ON/OFF

Set Temperature buttons

Down

Timer Menu button (Monitor/Set button)

Mode button (Return button)

Set Time buttons

Back

Ahead

Timer On/Off button (Set Day button)

Opening the door.

ON/OFF button

Fan Speed button

Filter button (<Enter> button)

Test Run button

Check button (Clear button)

Airflow Up/Down button

Louver button ( Operation button)

To preceding operation number.

Ventilation button (

Operation button)

To next operation number.

PART NAMES AND FUNCTIONS

● Indoor Unit

● Wired remote controller

On the controls are set, the same operation mode can be repeated by simply pressing the ON/OFF button.

● Operation buttons

● Display

For purposes of this explanation, all parts of the display are shown as lit. During actual operation, only the relevant items will be lit.

˚F˚C

ERROR CODE

AFTER

TIMER

TIME SUN MON TUE WED THU FRI SAT

ON OFF

Hr AFTER

FILTER

FUNCTION

ONLY1Hr.

WEEKLY

SIMPLE

AUTO OFF

Identifies the current operation

Shows the operating mode, etc. * Multilanguage display is sup-

ported.

“Centrally Controlled” indicator

Indicates that operation of the remote controller has been prohibited by a master controller.

“Timer Is Off” indicator

Indicates that the timer is off.

Temperature Setting

Shows the target temperature.

Day-of-Week

Shows the current day of the week.

Time/Timer Display

Shows the current time, unless the simple or Auto Off timer is set. If the simple or Auto Off timer is set, shows the time remaining.

“Sensor” indication

Displayed when the remote controller sensor is used.

“Locked” indicator

Indicates that remote controller buttons have been locked.

“Clean The Filter” indicator

Comes on when it is time to clean the filter.

Timer indicators

The indicator comes on if the corresponding timer is set.

Up/Down Air Direction indicator

The indicator shows the direction of the outcoming airflow.

“One Hour Only” indicator

Displayed if the airflow is set to weak and downward during COOL or DRY mode. (Operation varies according to model.) The indicator goes off after one hour, at which time the airflow direction also changes.

Room Temperature display

Shows the room temperature.

Louver display

Indicates the action of the swing louver. Does not appear if the louver is stationary.

(Power On indicator)

Indicates that the power is on.

Fan Speed indicator

Shows the selected fan speed.

Ventilation indicator

Appears when the unit is running in Ventilation mode.

Caution

● Only the Power on indicator lights when the unit is stopped and power supplied to the unit.

● If you press a button for a feature that is not installed at the indoor unit, the remote controller will display the “Not Available”

message. If you are using the remote controller to drive multiple indoor units, this message will appear only if he feature is not present at the parent unit.

● When power is turned ON for the first time, it is normal that “PLEASE WAIT” is displayed on the room temperature indication (For max. 2minutes). Please wait until this “PLEASE WAIT” indication disappear then start the operation.

Item

·Hz

kW kW kW kW

A A

— mm mm mm

—

k/min

—

[mm(in.) [mm(in.)

[mm

Cooling capacity

Power

Heat exchanger

Air filter

Fan ✕ No Air flow W

Pipe

dimensions

Unit drain pipe size Noise level W

Product weight

Exterior

(munsell symbol)

Fan motor

output

External

static pressure

Liquid

side

Gas side

Heating capacity

F a n

Dimensions

Height

Width Depth

Electric characteristic

Input

Cooling Heating Cooling Heating

Current

PCFY-P40VGM-E PCFY-P63VGM-E PCFY-P100VGM-E PCFY-P125VGM-E

Single phase 220-230-240V 50Hz / 220V 60Hz

4.5

5.0

0.10

0.46

7.1

8.0

0.13

0.60

11.2

12.5

0.16

0.73

14.0

16.0

0.24

1.10

1310

18 -16 -14 -12

0.07

15.88(5/8")

9.52(3/8")

39 -37 -34 -32

Unit : Munsell<0.70Y 8.59/0.97>

680

Cross fin (Aluminum plate fine and copper tube)

Sirocco fan ✕ 3

PP honey comb

I.D.26 (PVC pipe VP-20 connectable)

15.88(5/8") / 19.05(3/4")

9.52(3/8")

210 270

1310

25 -23 -20 -18

0.09

43 -41 -38 -36

1620

Sirocco fan ✕ 4

35 -32 -28 -26

0.15

44 -42 -39 -37

1000

Sirocco fan ✕ 2

12 -11 -10 -8

0.054

12.7(1/2")

6.35(1/4")

38 -36 -33 -29

SPECIFICATIONS

3-1. SPECIFICATIONS

Note 1. Rating conditions(JIS B 8615-1)

W Air flow and the noise level are indicated as High – Middium1 – Middium2 – Low.

Cooling : Indoor : D.B. 27°C W.B. 19°C Heating : Indoor : D.B. 20°C

outdoor : D.B. 35°C outdoor : D.B. 7°C W.B. 6°C

3-2. ELECTRICAL PARTS SPECIFICATIONS

Parts name

Model

Symbol

TH21

TH22

TH23

FUSE

LEV

TB2

TB5

TB15

Resistance 0:/15k", 10:/9.6k", 20:/6.3k", 25:/5.4k", 30:/4.3k", 40:/3.0k"

250V 6.3A

OFF 130: I5:

(L, N, ;) 330V 30A

(M1, M2, S) 250V 20A

(1, 2) 250V 10A

3µF ✕ 440V

Inner-thermostat

4µF ✕ 440V 4µF ✕ 440V 6µF ✕ 440VFan motor capacitor

Vane motor

Linear expansion valve

PCFY-P40VGM-E PCFY-P63VGM-E PCFY-P100VGM-E PCFY-P125VGM-E

Room temperature thermistor

Liquid pipe temperature thermistor

Gas pipe temperature thermistor

Fuse (Indoor controller board)

Fan motor (with inner-thermostat)

Power supply terminal block

Transmission terminal block

MA remote controller terminal block

DC12V Stepping

motor drive

[3.2 (0~2000pulse)

4-Pole Output 54W

D09B4P54MS

MP35EA

DC12V

MP42EA

DC12V

4-Pole Output 70W

D09C4P70MS

4-Pole Output 90W

D10B4P90MS

4-Pole Output 150W

D10B4P150MS

DC12V Stepping motor drive

[3.2 (0~2000pulse)

3-3. NOISE CRITERION CURVES

63 125 250 500 1000 2000 4000 8000

APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE

NC-60

NC-50

NC-40

NC-30

NC-20

NC-70

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar)

BAND CENTER FREQUENCIES, Hz

PCFY-P40VGM-E

NOTCH

Mi1 Mi2

SPL(dB)

33 30 27

LINE

63 125 250 500 1000 2000 4000 8000

APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE

NC-60

NC-50

NC-40

NC-30

NC-20

NC-70

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar)

BAND CENTER FREQUENCIES, Hz

PCFY-P63VGM-E

NOTCH

Mi1 Mi2

SPL(dB)

36 34 32

LINE

63 125 250 500 1000 2000 4000 8000

APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE

NC-60

NC-50

NC-40

NC-30

NC-20

NC-70

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar)

BAND CENTER FREQUENCIES, Hz

PCFY-P100VGM-E

NOTCH

Mi1 Mi2

SPL(dB)

37 35 33

LINE

63 125 250 500 1000 2000 4000 8000

APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE

NC-60

NC-50

NC-40

NC-30

NC-20

NC-70

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar)

BAND CENTER FREQUENCIES, Hz

PCFY-P125VGM-E

NOTCH

Mi1 Mi2

SPL(dB)

37 35 33

LINE

UNIT

About 1.4m

MICROPHONE

CEILING

OUTLINES AND DIMENSIONS4

Air intake

When electrical box

is pulled down

Electrical box

Air outlet

Electrical box

(Drainage)

(1/2F)gas

(1/4F)liquid

( FRONT VIEW )

Ceiling

56506

161 90

904

933 (Suspension bolt pitch)

157

210

226

241

201

182

180

680

254

150 18

70140

320 80

918

1000

983

6 ~ 7

928

525

42 179

161 32

175

131

352

171

138

263

INDOOR UNIT PCFY-P40VGM-E

refrigerant pipe will be only upper drain pipe arrangement.

NOTES:

1. Use M10 or W3/8 screws for anchor bolt.

2. Please be sure when installing the drain-up machine (option parts).

Unit : mm

1 Drainage pipe connection (26mm I.D.) 5 Refrigerant-pipe connection (liquid pipe side/flared connection)

2 Drainage pipe connection (for the left arrangement) 6 Knock out hole for upper drain pipe arrangement

3 Knock out hole for left drain-piping arrangement 7 Knock out hole for left drain pipe arrangement

4 Refrigerant-pipe connection (gas pipe side/flared connection) 8 Knock out hole for wiring arrangement

(Drainage)

(5/8F)gas

(3/8F)liquid

Air intake

Air outlet

Electrical box

When electrical box

is pulled down

Ceiling

( FRONT VIEW )

Electrical box

506 56

90161

1240 (Suspension bolt pitch)

157

1228

1310

1214

1290

210

226

241

201

182

180

680

254

150 18

70140

320 80

6 ~ 7

1235

416525

42 179

161 32

175

131

171

138

263

PCFY-P63VGM-E

Unit : mm

refrigerant pipe will be only upper drain pipe arrangement.

NOTES:

1. Use M10 or W3/8 screws for anchor bolt.

2. Please be sure when installing the drain-up machine (option parts).

1 Drainage pipe connection (26mm I.D.) 5 Refrigerant-pipe connection (liquid pipe side/flared connection)

2 Drainage pipe connection (for the left arrangement) 6 Knock out hole for upper drain pipe arrangement

3 Knock out hole for left drain-piping arrangement 7 Knock out hole for left drain pipe arrangement

4 Refrigerant-pipe connection (gas pipe side/flared connection) 8 Knock out hole for wiring arrangement

(3/8F)liquid

(5/8F or 3/4F)gas

(Drainage)

Air intake

Air outlet

1240 (Suspension bolt pitch)

Electrical box

When electrical box

is pulled down

( FRONT VIEW )

Ceiling

Electrical box

506

90161

229

217

70140

18150

80320

1214

1310

81 96

207

270

680

254

1228

182

198

245

140

525

6 ~ 7

160 93

239

1235

687

263

171

138

192

236 1

PCFY-P100VGM-E

Unit : mm

refrigerant pipe will be only upper drain pipe arrangement.

NOTES:

1. Use M10 or W3/8 screws for anchor bolt.

2. Please be sure when installing the drain-up machine (option parts).

1 Drainage pipe connection (26mm I.D.) 5 Refrigerant-pipe connection (liquid pipe side/flared connection)

2 Drainage pipe connection (for the left arrangement) 6 Knock out hole for upper drain pipe arrangement

3 Knock out hole for left drain-piping arrangement 7 Knock out hole for left drain pipe arrangement

4 Refrigerant-pipe connection (gas pipe side/flared connection) 8 Knock out hole for wiring arrangement

Air intake

Air outlet

Electrical box

When electrical box

is pulled down

( FRONT VIEW )

Ceiling

Electrical box

(Drainage)

(5/8F or 3/4F)gas

(3/8F)liquid

506

90161

229

217

1545

1547 (Suspension bolt pitch)

1524

1620

1535

198

270

81 96

207

182

245

680

254

150 18

140 70

320

525 687

263

171

138

140

6 ~ 7

160 93

239

192

236

PCFY-P125VGM-E

Unit : mm

refrigerant pipe will be only upper drain pipe arrangement.

NOTES:

1. Use M10 or W3/8 screws for anchor bolt.

2. Please be sure when installing the drain-up machine (option parts).

1 Drainage pipe connection (26mm I.D.) 5 Refrigerant-pipe connection (liquid pipe side/flared connection)

2 Drainage pipe connection (for the left arrangement) 6 Knock out hole for upper drain pipe arrangement

3 Knock out hole for left drain-piping arrangement 7 Knock out hole for left drain pipe arrangement

4 Refrigerant-pipe connection (gas pipe side/flared connection) 8 Knock out hole for wiring arrangement

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