Mitsubishi CMB-P104, P96TGMU-A, PQRY-P72, CMB-P108, P1016NU-GA Service Handbook
...
AIR CONDITIONERS CITY MULTI
Models
PQHY-P72, P96TGMU-A
PQRY-P72, P96TGMU-A
CMB-P104, P105, P106, P108, P1010, P1013, P1016NU-G
CMB-P108, P1010, P1013, P1016NU-GA
CMB-P104, P108NU-GB
Service Handbook
Safety Precautions
Before installing the unit, thoroughly read the following safety precautions.
Observe these safety precautions for your safety.
WARNING
This symbol is intended to alert the user to the presence of important instructions that must be followed to avoid
the risk of serious injury or death.
CAUTION
This symbol is intended to alert the user to the presence of important instructions that must be followed to avoid
the risk of serious injury or damage to the unit.
After reading this manual, give it to the user to retain for future reference.
Keep this manual for easy reference. When the unit is moved or repaired, give this manual to those who provide these ser-
vices.
When the user changes, make sure that the new user receives this manual.
WARNING
Ask your dealer or a qualified technician to install the
unit.
Improper installation by the user may result in water leakage, electric shock, smoke, and/or fire.
Properly install the unit on a surface that can withstand
the weight of the unit.
Unit installed on an unstable surface may fall and cause injury.
Only use specified cables. Securely connect each cable so that the terminals do not carry the weight of the
cable.
Improperly connected or fixed cables may produce heat
and start a fire.
Take appropriate safety measures against strong
winds and earthquakes to prevent the unit from falling.
If the unit is not installed properly, the unit may fall and
cause serious injury to the person or damage to the unit.
Do not make any modifications or alterations to the
unit. Consult your dealer for repair.
Improper repair may result in water leakage, electric shock,
smoke, and/or fire.
In the event of a refrigerant leak, thoroughly ventilate
the room.
If refrigerant gas leaks and comes in contact with an open
flame, poisonous gases will be produced.
When installing the All-Fresh type units, take it into
consideration that the outside air may be discharged
directly into the room when the thermo is turned off.
Direct exposure to outdoor air may have an adverse effect
on health. It may also result in food spoilage.
Properly install the unit according to the instructions in
the installation manual.
Improper installation may result in water leakage, electric
shock, smoke, and/or fire.
Have all electrical work performed by an authorized
electrician according to the local regulations and instructions in this manual, and a dedicated circuit must
be used.
Insufficient capacity of the power supply circuit or improper
installation may result in malfunctions of the unit, electric
shock, smoke, and/or fire.
WARNING
Securely attach the terminal block cover (panel) to the
unit.
If the terminal block cover (panel) is not installed properly,
dust and/or water may infiltrate and pose a risk of electric
shock, smoke, and/or fire.
Only use the type of refrigerant that is indicated on the
unit when installing or reinstalling the unit.
Infiltration of any other type of refrigerant or air into the unit
may adversely affect the refrigerant cycle and may cause
the pipes to burst or explode.
When installing the unit in a small room, exercise caution and take measures against leaked refrigerant
reaching the limiting concentration.
Consult your dealer with any questions regarding limiting
concentrations and for precautionary measures before installing the unit. Leaked refrigerant gas exceeding the limiting concentration causes oxygen deficiency.
Consult your dealer or a specialist when moving or reinstalling the unit.
Improper installation may result in water leakage, electric
shock, and/or fire.
After completing the service work, check for a gas leak.
If leaked refrigerant is exposed to a heat source, such as a
fan heater, stove, or electric grill, poisonous gases may be
produced.
Do not try to defeat the safety features of the unit.
Forced operation of the pressure switch or the temperature
switch by defeating the safety features of these devices, or
the use of accessories other than the ones that are recommended by MITSUBISHI may result in smoke, fire, and/or
explosion.
Only use accessories recommended by MITSUBISHI.
Ask a qualified technician to install the unit. Improper installation by the user may result in water leakage, electric
shock, smoke, and/or fire.
Precautions for handling units for use with R410A
CAUTION
Do not use the existing refrigerant piping.
A large amount of chlorine that may be contained in the re-
sidual refrigerant and refrigerating machine oil in the existing piping may cause the refrigerating machine oil in the
new unit to deteriorate.
R410A is a high-pressure refrigerant and can cause the
existing pipes to burst.
Use refrigerant pipes made of phosphorus deoxidized
copper. Keep the inner and outer surfaces of the pipes
clean and free of such contaminants as sulfur, oxides,
dust, dirt, shaving particles, oil, and water.
These types of contaminants inside the refrigerant pipes
may cause the refrigerant oil to deteriorate.
Store the pipes to be installed indoors, and keep both
ends of the pipes sealed until immediately before brazing. (Keep elbows and other joints wrapped in plastic.)
Infiltration of dust, dirt, or water into the refrigerant system
may cause the refrigerating machine oil to deteriorate or
cause the unit to malfunction.
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
Infiltration of a large amount of mineral oil may cause the refrigerating machine oil to deteriorate.
Charge liquid refrigerant (as opposed to gaseous refrigerant) into the system.
If gaseous refrigerant is charged into the system, the composition of the refrigerant in the cylinder will change and
may result in performance loss.
Use a vacuum pump with a reverse-flow check valve.
If a vacuum pump that is not equipped with a reverse-flow
check valve is used, the vacuum pump oil may flow into the
refrigerant cycle and cause the refrigerating machine oil to
deteriorate.
Prepare tools for exclusive use with R410A. Do not use
the following tools if they have been used with the conventional refrigerant (gauge manifold, charging hose,
gas leak detector, reverse-flow check valve, refrigerant
charge base, vacuum gauge, and refrigerant recovery
equipment.).
If the refrigerant or the refrigerating machine oil left on
these tools are mixed in with R410A, it may cause the refrigerating machine oil to deteriorate.
Infiltration of water may cause the refrigerating machine oil
to deteriorate.
Gas leak detectors for conventional refrigerants will not de-
tect an R410A leak because R410A is free of chlorine.
Do not use a charging cylinder.
If a charging cylinder is used, the composition of the refrigerant will change, and the unit may experience power loss.
Exercise special care when handling the tools for use
with R410A.
Infiltration of dust, dirt, or water into the refrigerant system
may cause the refrigerating machine oil to deteriorate.
Only use refrigerant R410A.
The use of other types of refrigerant that contain chlorine
(i.e. R22) may cause the refrigerating machine oil to deteriorate.
Before installing the unit
WARNING
Do not install the unit where a gas leak may occur.
If gaseous refrigerant leaks and piles up around the unit, it
may be ignited.
Do not use the unit to keep food items, animals, plants,
artifacts, or for other special purposes.
The unit is not designed to preserve food products.
Do not use the unit in an unusual environment.
Do not install the unit where a large amount of oil or steam
is present or where acidic or alkaline solutions or chemical
sprays are used frequently. Doing so may lead to a remarkable drop in performance, electric shock, malfunctions,
smoke, and/or fire.
The presence of organic solvents or corrosive gas (i.e. am-
monia, sulfur compounds, and acid) may cause gas leakage or water leakage.
When installing the unit in a hospital, take appropriate
measures to reduce noise interference.
High-frequency medical equipment may interfere with the
normal operation of the air conditioner or vice versa.
Do not install the unit on or over things that cannot get
wet.
When the humidity level exceeds 80% or if the drainage
system is clogged, the indoor unit may drip water. Drain water is also discharged from the outdoor unit. Install a centralized drainage system if necessary.
Before installing the unit (moving and reinstalling the unit) and performing electrical
work
WARNING
When installing or relocating the unit, make sure that
no substance other than the specified refrigerant
(R410A) enters the refrigerant circuit.
Any presence of foreign substance such as air can cause
abnormal pressure rise or explosion.
CAUTION
Properly ground the unit.
Do not connect the grounding wire to a gas pipe, water pipe,
lightning rod, or grounding wire from a telephone pole. Improper grounding may result in electric shock, smoke, fire,
and/or malfunction due to noise interference.
Do not put tension on the power supply wires.
If tension is put on the wires, they may break and result in
excessive heat, smoke, and/or fire.
Install an earth leakage breaker to avoid the risk of electric shock.
Failure to install an earth leakage breaker may result in
electric shock, smoke, and/or fire.
Use the kind of power supply wires that are specified in
the installation manual.
The use of wrong kind of power supply wires may result in
current leak, electric shock, and/or fire.
Use breakers and fuses (current breaker, remote switch
<switch + Type-B fuse>, moulded case circuit breaker)
with the proper current capacity.
The use of wrong capacity fuses, steel wires, or copper
wires may result in malfunctions, smoke, and/or fire.
Periodically check the installation base for damage.
If the unit is left on a damaged platform, it may fall and
cause injury.
Properly install the drain pipes according to the instructions in the installation manual. Keep them insulated to avoid dew condensation.
Improper plumbing work may result in water leakage and
damage to the furnishings.
Exercise caution when transporting products.
Products weighing more than 20 kg should not be carried
alone.
Do not carry the product by the PP bands that are used on
some products.
Do not touch the heat exchanger fins. They are sharp and
dangerous.
When lifting the unit with a crane, secure all four corners to
prevent the unit from falling.
Properly dispose of the packing materials.
Nails and wood pieces in the package may pose a risk of
injury.
Plastic bags may pose a risk of choking hazard to children.
Tear plastic bags into pieces before disposing of them.
Do not spray water on the air conditioner or immerse
the air conditioner in water.
Otherwise, electric shock and/or fire may result.
Before the test run
CAUTION
Turn on the unit at least 12 hours before the test run.
Keep the unit turned on throughout the season. If the unit is
turned off in the middle of a season, it may result in malfunctions.
To avoid the risk of electric shock or malfunction of the
unit, do not operate switches with wet hands.
Do not touch the refrigerant pipes with bare hands during and immediately after operation.
During or immediately after operation, certain parts of the
unit such as pipes and compressor may be either very cold
or hot, depending on the state of the refrigerant in the unit
at the time. To reduce the risk of frost bites and burns, do
not touch these parts with bare hands.
Do not operate the unit without panels and safety
guards.
Rotating, high-temperature, or high-voltage parts on the unit
pose a risk of burns and/or electric shock.
Do not turn off the power immediately after stopping
the operation.
Keep the unit on for at least five minutes before turning off
the power to prevent water leakage or malfunction.
Do not operate the unit without the air filter.
Dust particles may build up in the system and cause malfunctions.
I Read Before Servicing
[1] Read Before Servicing............................................................................................................ 3
[2] Necessary Tools and Materials .............................................................................................. 4
[3] Piping Materials...................................................................................................................... 5
[4] Storage of Piping.................................................................................................................... 7
[5] Pipe Processing...................................................................................................................... 7
[6] Brazing ................................................................................................................................... 8
[7] Air Tightness Test................................................................................................................... 9
[8] Vacuum Drying (Evacuation)................................................................................................ 10
[9] Refrigerant Charging ............................................................................................................ 11
[10] Remedies to be taken in case of a Refrigerant Leak............................................................ 11
[11] Characteristics of the Conventional and the New Refrigerants ............................................ 12
[12] Notes on Refrigerating Machine Oil...................................................................................... 13
II Restrictions
[1] Types and Maximum allowable Length of Cables................................................................ 17
[2] Switch Settings and Address Settings.................................................................................. 18
[3] Sample System Connection ................................................................................................. 23
[4] An Example of a System to which an MA Remote Controller is connected ......................... 24
[5] An Example of a System to which an M-NET Remote Controller is connected ................... 46
[6] An Example of a System to which both MA Remote Controller and M-NET Remote
Controller are connected ......................................................................................................50
[7] Restrictions on Pipe Length.................................................................................................. 53
III Heat Source Unit / BC Controller Components
[1] Heat Source Unit Components and Refrigerant Circuit........................................................ 67
[2] Control Box of the Heat Source Unit .................................................................................... 69
[3] Heat Source Unit Circuit Board ............................................................................................ 70
[4] BC Controller (Under the panel)........................................................................................... 73
[5] Control Box of the BC Controller .......................................................................................... 75
[6] BC Controller Circuit Board .................................................................................................. 76
CONTENTS
IV Remote Controller
[1] Functions and Specifications of MA and ME Remote Controllers ........................................ 81
[2] Group Settings and Interlock Settings via the ME Remote Controller.................................. 82
[3] Interlock Settings via the MA Remote Controller.................................................................. 86
[4] Using the built-in Temperature Sensor on the Remote Controller........................................ 89
V Electrical Wiring Diagram
[1] Electrical Wiring Diagram of the Heat Source Unit............................................................... 93
[2] Electrical Wiring Diagram of the BC Controller..................................................................... 94
VI Refrigerant Circuit
[1] Refrigerant Circuit Diagram ................................................................................................ 105
[2] Principal Parts and Functions............................................................................................. 109
VII Control
[1] Functions and Factory Settings of the Dipswitches............................................................ 121
[2] Controlling the Heat Source Unit ........................................................................................ 129
[3] Controlling BC Controller.................................................................................................... 142
[4] Operation Flow Chart ......................................................................................................... 143
VIII Test Run Mode
[1] Items to be checked before a Test Run.............................................................................. 157
[2] Test Run Method................................................................................................................ 158
[3] Operating Characteristic and Refrigerant Amount.............................................................. 159
[4] Adjusting the Refrigerant Amount....................................................................................... 160
[5] Refrigerant Amount Adjust Mode ....................................................................................... 164
[6] The following symptoms are normal................................................................................... 168
[7] Standard Operation Data (Reference Data)....................................................................... 169
CONTENTS
IX Troubleshooting
[1] Check Code Lists................................................................................................................ 179
[2] Responding to Error Display on the Remote Controller...................................................... 182
[3] Investigation of Transmission Wave Shape/Noise ............................................................. 265
[4] Troubleshooting Principal Parts.......................................................................................... 268
[5] Refrigerant Leak ................................................................................................................. 298
[6] Servicing the BC controller ................................................................................................. 300
X LED Monitor Display on the Heat Source Unit Board
[1] How to Read the LED on the Service Monitor ....................................................................305
I Read Before Servicing
[1] Read Before Servicing....................................................................................................... 3
[2] Necessary Tools and Materials .........................................................................................4
[3] Piping Materials ................................................................................................................. 5
[4] Storage of Piping ............................................................................................................... 7
[5] Pipe Processing................................................................................................................. 7
[6] Brazing............................................................................................................................... 8
[7] Air Tightness Test.............................................................................................................. 9
[8] Vacuum Drying (Evacuation) ...........................................................................................10
[9] Refrigerant Charging ....................................................................................................... 11
[10] Remedies to be taken in case of a Refrigerant Leak....................................................... 11
[11] Characteristics of the Conventional and the New Refrigerants .......................................12
[12] Notes on Refrigerating Machine Oil................................................................................. 13
- 1 -
- 2 -
[ I Read Before Servicing ]
I Read Before Servicing
[1] Read Before Servicing
1. Check the type of refrigerant used in the system to be serviced.
Refrigerant Type CITY MULTI WY/WR2: R410A
2. Check the symptoms exhibited by the unit to be serviced.
Refer to this service handbook for symptoms relating to the refrigerant cycle.
3. Thoroughly read the safety precautions at the beginning of this manual.
4. Preparing necessary tools: Prepare a set of tools to be used exclusively with each type of refrigerant.
Refer to page 4 for information on the use of tools.
5. Verification of the connecting pipes: Verify the type of refrigerant used for the unit to be moved or replaced.
Use refrigerant pipes made of phosphorus deoxidized copper. Keep the inner and outer surfaces of the pipes clean and
free of such contaminants as sulfur, oxides, dust, dirt, shaving particles, oil, and water.
These types of contaminants inside the refrigerant pipes may cause the refrigerant oil to deteriorate.
6. If there is a leak of gaseous refrigerant and the remaining refrigerant is exposed to an open flame, a
poisonous gas hydrofluoric acid may form. Keep workplace well ventilated.
CAUTION
Install new pipes immediately after removing old ones to keep moisture out of the refrigerant circuit.
The use of refrigerant that contains chloride, such as R22, will cause the refrigerating machine oil to deteriorate.
- 3 -
[ I Read Before Servicing ]
[2] Necessary Tools and Materials
Prepare the following tools and materials necessary for installing and servicing the unit.
Tools for use with R410A (Adaptability of tools that are for use with R22)
1. To be used exclusively with R410A (not to be used if used with R22)
Tools/Materials Use Notes
Gauge Manifold Evacuation and refrigerant charging Higher than 5.09MPa[738psi] on the
high-pressure side
Charging Hose Evacuation and refrigerant charging
Refrigerant Recovery Cylinder Refrigerant recovery
Refrigerant Cylinder Refrigerant charging The refrigerant type is indicated. The
cylinder is pink.
Charging Port on the Refrigerant Cylinder Refrigerant charging The charge port diameter is larger than
that of the current port.
Flare Nut Connection of the unit with the pipes Use Type-2 Flare nuts.
2. Tools and materials that may be used with R410A with some restrictions
Tools/Materials Use Notes
Gas Leak Detector Gas leak detection The ones for use with HFC refrigerant
may be used.
Vacuum Pump Vacuum drying May be used if a check valve adapter is
attached.
Flare Tool Flare processing Flare processing dimensions for the pip-
ing in the system using the new refrigerant differ from those of R22. Refer to
page 6.
Refrigerant Recovery Equipment Refrigerant recovery May be used if compatible with R410A.
3. Tools and materials that are used with R22 that may also be used with R410A
Tools/Materials Use Notes
Vacuum Pump with a Check Valve Vacuum drying
Bender Bending pipes
Torque Wrench Tightening flare nuts Only the flare processing dimensions for
pipes that have a diameter of
ø12.70 (1/2") and ø15.88 (5/8") have
been changed.
Pipe Cutter Cutting pipes
Welder and Nitrogen Cylinder Welding pipes
Refrigerant Charging Meter Refrigerant charging
Vacuum Gauge Vacuum level check
4. Tools and materials that must not be used with R410A
Tools/Materials Use Notes
Charging Cylinder Refrigerant charging Prohibited to use
Tools for R410A must be handled with special care to keep moisture and dust from infiltrating the cycle.
- 4 -
[ I Read Before Servicing ]
[3] Piping Materials
Do not use the existing piping!
New Piping Existing Piping
NOOK
1. Copper pipe materials
O-material (Annealed) Soft copper pipes (annealed copper pipes). They can easily be bent with hands.
1/2H-material, H-material (Drawn) Hard copper pipes (straight pipes). They are stronger than the O-material (Annealed)
at the same radial thickness.
The distinction between O-materials (Annealed) and 1/2H-materials, H-materials (Drawn) is made based on the strength
of the pipes themselves.
O-materials (Annealed) can easily be bent with hands.
1/2H-materials, H-materials (Drawn) are considerably stronger than O-material (Annealed) at the same thickness.
2. Types of copper pipes
Maximum working pressure Refrigerant type
3.45 MPa[500psi] R22 etc.
4.30 MPa[624psi] R410A etc.
3. Piping materials/Radial thickness
Use refrigerant pipes made of phosphorus deoxidized copper.
The operation pressure of the units that use R410A is higher than that of the units that use R22.
Use pipes that have at least the radial thickness specified in the chart below.
Pipe size (mm[in]) Radial thickness (mm[in]) Type
ø6.35 [1/4"] 0.8t [0.0315]
ø9.52 [3/8"] 0.8t [0.0315]
ø12.7 [1/2"] 0.8t [0.0315]
ø15.88 [5/8"] 1.0t [0.0394]
ø19.05 [3/4"] 1.0t [0.0394]
ø22.2 [7/8"] 1.0t [0.0394]
ø28.58 [1-1/8"] 1.0t [0.0394]
The pipes in the system that uses the refrigerant currently on the market are made with O-material (Annealed), even if the
pipe diameter is less than ø19.05 (3/4"). For a system that uses R410A, use pipes that are made with 1/2H-material, Hmaterial (Drawn) unless the pipe diameter is at least ø19.05 (3/4") and the radial thickness is at least 1.2t.
The figures in the radial thickness column are based on the Japanese standards and provided only as a reference. Use
pipes that meet the local standards.
O-material (Annealed)
1/2H-material,
H-material (Drawn)
- 5 -
[ I Read Before Servicing ]
4. Thickness and refrigerant type indicated on the piping materials
Ask the pipe manufacturer for the symbols indicated on the piping material for new refrigerant.
5. Flare processing (O-material (Annealed) only)
The flare processing dimensions for the pipes that are used in the R410A system are larger than those in the R22 system.
Flare processing dimensions (mm[in])
Pipe size (mm[in])
ø6.35 [1/4"] 9.1 [0.358] 9.0 [0.354]
ø9.52 [3/8"] 13.2 [0.520] 13.0 [0.512]
ø12.7 [1/2"] 16.6 [0.654] 16.2 [0.638]
ø15.88 [5/8"] 19.7 [0.776] 19.4 [0.764]
ø19.05 [3/4"] 24.0 [0.945] 23.3 [0.917]
If a clutch-type flare tool is used to flare the pipes in the system using R410A, the length of the pipes must be between 1.0
and 1.5 mm. For margin adjustment, a copper pipe gauge is necessary.
A dimension (mm[in])
R410A R22
Dimension A
6. Flare nut
Type-2 flare nuts instead of type-1 are used to increase the strength. The size of some of the flare nuts have also been
changed.
Flare nut dimensions (mm[in])
Pipe size (mm[in])
ø6.35 [1/4"] 17.0 [0.669] 17.0 [0.669]
ø9.52 [3/8"] 22.0 [0.866] 22.0 [0.866]
ø12.7 [1/2"] 26.0 [1.024] 24.0 [0.945]
ø15.88 [5/8"] 29.0 [1.142] 27.0 [1.063]
ø19.05 [3/4"] 36.0 [1.417] 36.0 [1.417]
The figures in the radial thickness column are based on the Japanese standards and provided only as a reference. Use
pipes that meet the local standards.
B dimension (mm[in])
R410A R22
Dimension B
- 6 -
[4] Storage of Piping
OK
NO
OK
NO
1. Storage location
NO
OK
Store the pipes to be used indoors. (Warehouse at site or owner's warehouse)
If they are left outdoors, dust, dirt, or moisture may infiltrate and contaminate the pipe.
2. Sealing the pipe ends
[ I Read Before Servicing ]
OK
Both ends of the pipes should be sealed until just before brazing.
Keep elbow pipes and T-joints in plastic bags.
The new refrigerator oil is 10 times as hygroscopic as the conventional refrigerating machine oil (such as Suniso) and, if not
handled with care, could easily introduce moisture into the system. Keep moisture out of the pipes, for it will cause the oil
to deteriorate and cause a compressor failure.
[5] Pipe Processing
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
1. Notes
Use a minimum amount of oil.
Use only ester oil, ether oil, and alkylbenzene.
NO
- 7 -
[ I Read Before Servicing ]
[6] Brazing
No changes have been made in the brazing procedures. Perform brazing with special care to keep foreign objects (such as
oxide scale, water, and dust) out of the refrigerant system.
Example: Inside the brazed connection
Use of oxidized solder for brazing Use of non-oxidized solder for brazing
1. Items to be strictly observed
Do not conduct refrigerant piping work outdoors if raining.
Use non-oxidized solder.
Use a brazing material (BCuP-3) that requires no flux when brazing between copper pipes or between a copper pipe and
copper coupling.
If installed refrigerant pipes are not immediately connected to the equipment, then braze and seal both ends.
2. Reasons
The new refrigerating machine oil is 10 times as hygroscopic as the conventional oil and is more likely to cause unit failure
if water infiltrates into the system.
Flux generally contains chloride. Residual flux in the refrigerant circuit will cause sludge to form.
3. Notes
Do not use commercially available antioxidants because they may cause the pipes to corrode or refrigerating machine oil
to deteriorate.
- 8 -
[ I Read Before Servicing ]
[7] Air Tightness Test
No changes have been made in the detection method. Note that a refrigerant leak detector for R22 will not detect an R410A
leak.
NO NO
Halide torch R22 leakage detector
1. Items to be strictly observed
Pressurize the equipment with nitrogen up to the design pressure (4.15MPa[601psi]), and then judge the equipment's air
tightness, taking temperature variations into account.
When using refrigerant instead of a leak detector to find the location of a leak, use R410A.
Refrigerant R410A must be charged in its liquid state (vs. gaseous state).
2. Reasons
Oxygen, if used for an air tightness test, poses a risk of explosion. (Only use nitrogen to check air tightness.)
Refrigerant R410A must be charged in its liquid state. If gaseous refrigerant in the cylinder is drawn out first, the compo-
sition of the remaining refrigerant in the cylinder will change and become unsuitable for use.
3. Notes
Procure a leak detector that is specifically designed to detect an HFC leak. A leak detector for R22 will not detect an
HFC(R410A) leak.
- 9 -
[ I Read Before Servicing ]
[8] Vacuum Drying (Evacuation)
(Photo1) 15010H (Photo2) 14010
Recommended vacuum gauge:
ROBINAIR 14010 Thermistor Vacuum Gauge
1. Vacuum pump with a reverse-flow check valve (Photo1)
To prevent the vacuum pump oil from flowing into the refrigerant circuit during power OFF or power failure, use a vacuum
pump with a reverse-flow check valve.
A reverse-flow check valve may also be added to the vacuum pump currently in use.
2. Standard of vacuum degree (Photos 2)
Use a vacuum pump that attains 0.5Torr(65Pa) or lower degree of vacuum after 5 minutes of operation, and connect it di-
rectly to the vacuum gauge. Use a pump well-maintained with an appropriate lubricant. A poorly maintained vacuum pump
may not be able to attain the desired degree of vacuum.
3. Required precision of vacuum gauge
Use a vacuum gauge that registers a vacuum degree of 5Torr(650Pa) and measures at intervals of 1Torr(130Pa). (A rec-
ommended vacuum gauge is shown in Photo2.)
Do not use a commonly used gauge manifold because it cannot register a vacuum degree of 5Torr(650Pa).
4. Evacuation time
After the degree of vacuum has reached 5Torr(650Pa), evacuate for an additional 1 hour. (A thorough vacuum drying re-
moves moisture in the pipes.)
Verify that the vacuum degree has not risen by more than 1Torr(130Pa) 1hour after evacuation. A rise by less than
1Torr(130Pa) is acceptable.
If the vacuum is lost by more than 1Torr(130Pa), conduct evacuation, following the instructions in section 6. Special vac-
uum drying.
5. Procedures for stopping vacuum pump
To prevent the reverse flow of vacuum pump oil, open the relief valve on the vacuum pump side, or draw in air by loosening
the charge hose, and then stop the operation.
The same procedures should be followed when stopping a vacuum pump with a reverse-flow check valve.
6. Special vacuum drying
When 5Torr(650Pa) or lower degree of vacuum cannot be attained after 3 hours of evacuation, it is likely that water has
penetrated the system or that there is a leak.
If water infiltrates the system, break the vacuum with nitrogen. Pressurize the system with nitrogen gas to
0.5kgf/cm
uum below 5Torr(650Pa) is attained or until the pressure stops rising.
Only use nitrogen gas for vacuum breaking. (The use of oxygen may result in an explosion.)
2
G(0.05MPa) and evacuate again. Repeat this cycle of pressurizing and evacuation either until the degree of vac-
- 10 -
[9] Refrigerant Charging
[ I Read Before Servicing ]
Cylinder with a siphon
Cylinder
Cylinder color R410A is pink. Refrigerant charging in the liquid state
Valve Valve
liquid
Cylinder without a siphon
Cylinder
liquid
1. Reasons
R410A is a pseudo-azeotropic HFC blend (boiling point R32=-52°C[-62°F], R125=-49°C[-52°F]) and can almost be han-
dled the same way as a single refrigerant, such as R22. To be safe, however, draw out the refrigerant from the cylinder
in the liquid phase. If the refrigerant in the gaseous phase is drawn out, the composition of the remaining refrigerant will
change and become unsuitable for use.
2. Notes
When using a cylinder with a siphon, refrigerant is charged in the liquid state without the need for turning it upside down.
Check the type of the cylinder on the label before use.
[10] Remedies to be taken in case of a Refrigerant Leak
If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced. Charge refrigerant in the
liquid state.)
Refer to "9. (5) Refrigerant leak".
- 11 -
[ I Read Before Servicing ]
[11] Characteristics of the Conventional and the New Refrigerants
1. Chemical property
As with R22, the new refrigerant (R410A) is low in toxicity and chemically stable nonflammable refrigerant.
However, because the specific gravity of vapor refrigerant is greater than that of air, leaked refrigerant in a closed room will
accumulate at the bottom of the room and may cause hypoxia.
If exposed to an open flame, refrigerant will generate poisonous gases. Do not perform installation or service work in a con-
fined area.
New Refrigerant (HFC type) Conventional Refrigerant (HFC type)
R410A R22
R32/R125 R22
Composition (wt%) (50/50) (100)
Type of Refrigerant Pseudo-azeotropic Refrigerant Single Refrigerant
Chloride Not included Included
Safety Class A1/A1 A1
Molecular Weight 72.6 86.5
Boiling Point (°C/°F) -51.4/-60.5 -40.8/-41.4
Steam Pressure
(25°C,MPa/77°F,psi) (gauge)
Saturated Steam Density
(25°C,kg/m
3
/77°F,psi)
Flammability Nonflammable Nonflammable
Ozone Depletion Coefficient (ODP)
Global Warming Coefficient (GWP)
*1
*2
Refrigerant Charging Method Refrigerant charging in the liquid
Replenishment of Refrigerant after a Refrigerant Leak
1.557/226 0.94/136
64.0 44.4
0 0.055
1730 1700
Refrigerant charging in the gaseous
state
state
Available Available
*1 When CFC11 is used as a reference
*2 When CO
is used as a reference
2
2. Refrigerant composition
R410A is a pseudo-azeotropic HFC blend and can almost be handled the same way as a single refrigerant, such as R22.
To be safe, however, draw out the refrigerant from the cylinder in the liquid phase. If the refrigerant in the gaseous phase
is drawn out, the composition of the remaining refrigerant will change and become unsuitable for use.
If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced.
3. Pressure characteristics
The pressure in the system using R410A is 1.6 times as great as that in the system using R22.
Pressure (gauge)
Temperature (°C/°F)
-20/-4 0.30/44 0.14/20
0/32 0.70/102 0.40/58
20/68 1.34/194 0.81/117
40/104 2.31/335 1.44/209
60/140 3.73/541 2.33/338
65/149 4.17/605 2.60/377
R410A R22
MPa/psi MPa/psi
- 12 -
[ I Read Before Servicing ]
[12] Notes on Refrigerating Machine Oil
1. Refrigerating machine oil in the HFC refrigerant system
HFC type refrigerants use a refrigerating machine oil different from that used in the R22 system.
Note that the ester oil used in the system has properties that are different from commercially available ester oil.
Refrigerant Refrigerating machine oil
R22 Mineral oil
R410A Ester oil
2. Effects of contaminants
Refrigerating machine oil used in the HFC system must be handled with special care to keep contaminants out.
The table below shows the effect of contaminants in the refrigerating machine oil on the refrigeration cycle.
*1
3. The effects of contaminants in the refrigerating machine oil on the refrigeration cycle.
Cause Symptoms Effects on the refrigerant cycle
Water infiltration Frozen expansion valve
and capillary tubes
Sludge formation and ad-
Hydrolysis
Air infiltration Oxidization
Adhesion to expansion valve and capillary
tubes
Dust, dirt
Infiltration of
contaminants
Mineral oil
etc.
Infiltration of contaminants into the compressor
Sludge formation and adhesion Clogged expansion valve and capillary tubes
Oil degradation Burn-in on the orbiting scroll
hesion
Acid generation
Oxidization
Oil degradation
Clogged expansion valve and capillary tubes
Poor cooling performance
Compressor overheat
Motor insulation failure
Burnt motor
Coppering of the orbiting scroll
Lock
Burn-in on the orbiting scroll
Clogged expansion valve, capillary tubes, and
drier
Poor cooling performance
Compressor overheat
Burn-in on the orbiting scroll
Poor cooling performance
Compressor overheat
*1. Contaminants is defined as moisture, air, processing oil, dust/dirt, wrong types of refrigerant, and refrigerating machine oil.
- 13 -
- 14 -
II Restrictions
[1] Types and Maximum allowable Length of Cables ...........................................................17
[2] Switch Settings and Address Settings .............................................................................18
[3] Sample System Connection ............................................................................................23
[4] An Example of a System to which an MA Remote Controller is connected .................... 24
[5] An Example of a System to which an M-NET Remote Controller is connected .............. 46
[6] An Example of a System to which both MA Remote Controller and M-NET Remote
Controller are connected .................................................................................................50
[7] Restrictions on Pipe Length............................................................................................. 53
- 15 -
- 16 -
II Restrictions
[1] Types and Maximum allowable Length of Cables
1. Wiring work
(1) Notes
1) Have all electrical work performed by an authorized electrician according to the local regulations and instructions
in this manual.
2) Install the control cable at least 5cm[1-31/32"] away from the power supply cable to avoid noise interference. (Do
not put the control cable and power supply cable in the same conduit tube.)
3) Provide class-D grounding on the outdoor (heat source) unit.
4) Run the cable from the electric box of the indoor or outdoor (heat source) unit in such way that the box is accessible
for servicing.
5) Do not connect the terminal block for transmission line to supply voltage of 208V or 230V. Doing so will damage
the electronic components on the terminal block.
6) Use 2-core shielded cables as control cables. (Marked with OK in the figure below) Use a separate 2-core control
cable for each refrigerant system. Do not use a single multiple-core cable to connect indoor units that belong to
different refrigerant systems. The use of a multiple-core cable may result in signal transmission errors and malfunctions. (Marked with NO in the figure below)
[ II Restrictions ]
TB3
Heat source unit
TB7
2-core shielded cable
TB3
Heat source unit
TB7
Indoor unitIndoor unit
Multiple-core cable
Remote ControllerRemote Controller
NOOK
TB3
TB7
2-core shielded cable
TB3:Terminal block for transmission line connection TB7: Terminal block for transmission line for centralized control
(2) Control wiring
Different types of control wiring are used for different systems.
Refer to section "[4] An Example of a System to which an MA Remote Controller is connected - [6] An Example of a Sys-
tem to which both MA Remote Controller and M-NET Remote Controller are connected" before performing wiring work.
[Types and maximum allowable length of cables]
Control lines are categorized into 2 types: transmission line and remote controller line. Use the appropriate type of cables
and observe the maximum allowable length specified for a given system. If a given system has a long transmission line
or if a noise source is located near the unit, place the unit away from the noise source to reduce noise interference.
1) M-NET transmission line
Facility
type
Cable type
Maximum transmission
line distance between the
outdoor (heat source) unit
and the farthest indoor unit
Maximum transmission
line distance for centralized control and Indoor/
outdoor (heat source)
transmission line
(Maximum line distance
via outdoor (heat source)
unit)
Type Shielded cable CVVS, CPEVS, MVVS
Number of
cores
Cable size Larger than 1.25mm
500 m [1640ft] max.
*The maximum overall line length from the power supply unit on the transmission lines for
centralized control to each outdoor (heat source) unit or to the system controller is 200m
[656ft] max.
TB3
TB7
All facility types
2-core cable
2
[AWG16]
200 m [656ft] max.
- 17 -
[ II Restrictions ]
2) Remote controller wiring
Cable type
Maximum overall line
length
*1 MA remote controller refers to MA remote controller, MA deluxe remote controller, MA simple remote controller,
and wireless remote controller.
*2 M-NET remote controller refers to ME remote controller.
*3 The use of cables that are smaller than 0.75mm
*4 When connected to the terminal block on the Simple remote controller, use cables that meet the cable size specifications shown in the parenthesis.
Type
Number of
cores
Cable size
MA remote controller
VCTF, VCTFK, CVV, CVS,
*1
10m [32ft] or less
VVR, VVF, VCT
Shielded cable MVVS
2-core cable 2-core cable
0.3 to 1.25mm
[AWG22 to 16]
(0.75 to 1.25mm
0.3 to 1.25mm
[AWG22 to 16]
2 *3
[AWG18 to 14]
200 m [656ft] max. 10 m [32ft] max.
2
(AWG18) is recommended for easy handling.
M-NET remote controller
When the cable length exceeds 10m [32ft]
1) Follow the same specifi-
2 *3
2 ) *4
cations for M-NET
transmission lines.
The section of the cable that
exceeds 10m [32ft] must be
included in the maximum indoor-outdoor (heat source)
transmission line distance.
*2
[2] Switch Settings and Address Settings
1. Switch setting
The need for switch settings depends on the configuration of the system.
Refer to section "[4] An Example of a System to which an MA Remote Controller is connected - [6] An Example of a System
to which both MA Remote Controller and M-NET Remote Controller are connected" before performing wiring work.
Set the switches while the power is turned off.
If the switch settings are changed while the unit is being powered, those changes will not take effect, and the unit will not
function properly.
- 18 -
2. Address settings
(1) Address settings table
The need for address settings and the range of address setting depend on the configuration of the system.
[ II Restrictions ]
Unit or controller Address setting
Setting method Ad-
range
*1
Indoor
Main/sub unit 0, 01 to 50
unit
LOSSNAY , OA processing
unit
M-NET
remote
controller
Main remote
controller
Sub remote
controller
101 to 150 Add 100 to the smallest address of all the indoor units in
151 to 200
Assign the smallest address to the main indoor unit in the
group, and assign sequential address numbers to the rest of
the indoor units in the same group.
In an R2 system with a sub BC controller, make the settings
for the indoor units in the following order.
(i) Indoor unit to be connected to the main BC controller
(ii) Indoor unit to be connected to sub BC controller 1
(iii) Indoor unit to be connected to sub BC controller 2
Make the settings for the indoor units in the way that the formula "(i) < (ii) < (iii)" is true.
*5
Assign an arbitrary but unique address to each of these
units after assigning an address to all indoor units.
the same group.
*2
Add 150 to the smallest address of all the indoor units in
the same group.
MA remote controller No address settings required. (The main/sub setting must be made if 2 re-
mote controllers are connected to the system.)
Outdoor (heat source) unit 0, 51 to
100
*1,*3,*4
Assign an address that equals the sum of the smallest address of the indoor units in the same refrigerant system
and 50.
Auxiliary
unit
BC controller
(main)
0, 52 to 100
*3*4
Assign an address that equals the sum of the address of
the outdoor (heat source) unit in the same refrigerant system and 1.
BC controller
(sub)
Assign an address that equals the sum of the smallest address of the indoor units that are connected to the sub BC
controller and 50.
If a sub BC controller is connected, auto-startup function
will not be available.
System
controller
System remote
controller
ON/OFF remote
controller
Schedule timer
(compatible with
201 to 250 Assign an arbitrary but unique address within the range
listed on the left to each unit.
Assign an address that equals the sum of the smallest
group number of the group to be controlled and 200.
Assign an arbitrary but unique address within the range
listed on the left to each unit.
M-NET)
Central controller
G-50
0, 201 to 250 Assign an arbitrary but unique address within the range
listed on the left to each unit. The address must be set to
"0" to control the K-control unit.
LM adapter 201 to 250 Assign an arbitrary but unique address within the range
listed on the left to each unit.
dress
setting
00
00
101
Main
00
201
202
000
247
*1 No address settings are required for units in a system with one outdoor (heat source) unit (with some exceptions).
Address setting is required if a sub BC controller is connected.
*2 To set the M-NET remote controller address to "200", set it to "00".
*3 To set the outdoor (heat source) unit or auxiliary unit address to "100", set it to "50".
*4 If a given address overlaps any of the addresses that are assigned to other outdoor (heat source) units, use a dif-
ferent, unused address within the setting range (with some exceptions).
*5 Some indoor units have 2 or 3 controller boards that require address settings.
(1) The address to be assigned to the No.1 controller board (by the power supply terminal block) must be 1 smaller
than that to the No.2 controller board.
(2) No. 2 controller board address must be equal to the sum of the No. 1 controller board address and 1, and the
No.3 controller board address must equal to the No. 1 controller address and 2.
- 19 -
[ II Restrictions ]
(2) Power supply switch connector connection on the outdoor (heat source) unit
(Factory setting: The male power supply switch connector is connected to CN41.)
System configuration
System with one
outdoor (heat
source) unit
System with multiple outdoor (heat
source) units
Connection to the
system controller
Power supply unit for
transmission lines
Group operation of
units in a system with
multiple outdoor (heat
source) units
_ _ _ Leave CN41 as it is
Not connected _ Not grouped
Grouped Disconnect the male con-
With connection to
Not required Grouped/not grouped
the indoor unit system
With connection to
the centralized control system
Not required
(Powered from the
outdoor (heat source)
*1
Grouped/not grouped
unit)
Required Grouped/not grouped Leave CN41 as it is
Power supply switch connector connection
(Factory setting)
nector from the female
power supply switch connector (CN41) and connect it to the female power
supply switch connector
(CN40) on only one of the
outdoor (heat source)
*2
units.
*Connect the S (shielded)
terminal on the terminal
block (TB7) on the outdoor (heat source) unit
whose CN41 was replaced with CN40 to the
ground terminal ( ) on
the electric box.
(Factory setting)
*1 The need for a power supply unit for transmission lines depends on the system configuration.
*2 When connecting a system controller to the transmission line for centralized control or performing a group operation
of units in different refrigerant systems, the replacement of male power supply switch connector (CN41) must be
performed only on one of the outdoor (heat source) units in the system.
(3) Settings for the centralized control switch for the outdoor (heat source) unit (Factory setting: SW2-1 are set to OFF.)
System configuration Centralized control switch settings (SW2-1)
Connection to the system controller Not connected Leave it to OFF. (Factory setting)
Connection to the system controller Connected
*1
ON
*1. When only the LM adapter is connected, leave SW2-1 to OFF (as it is).
(4) Indoor unit port switch setting (R2 or WR2 series (factory setting: "0" ))
Make the setting for the port switch that corresponds to the connected BC (main/sub) controllers.
When more than two ports are used, make the setting on the port with a smaller port number.
The total capacity and the number of connectable indoor units per port is 54 and below, and 3 respectively.
(5) Selecting the position of temperature detection for the indoor unit (Factory setting: SW1-1 set to "OFF".)
1) To use the built-in sensor on the remote controller, set the SW1-1 to ON.
Some models of remote controllers are not equipped with a built-in temperature sensor.
Use the built-in temperature sensor on the indoor unit instead.
When using the built-in sensor on the remote controller, install the remote controller where room temperature can be
detected.
(Note) Factory setting for SW1-1 on the indoor unit of the All-Fresh Models is ON.
2) When an optional temperature sensor is used, set SW1-1 to OFF, and set SW3-8 to ON.
When using an optional temperature sensor, install it where room temperature can be detected.
- 20 -
[ II Restrictions ]
(6) Various start-stop controls (Indoor unit settings)
Each indoor unit (or group of indoor units) can be controlled individually by setting SW 1-9 and 1-10.
Function
Power ON/OFF by the plug
*2*3*4
Operation of the indoor unit when the operation is
resumed after the unit was stopped
Indoor unit will go into operation regardless of its oper-
Setting (SW1)
910
OFF ON
ation status before power off (power failure). (In approx. 5 minutes)
Automatic restoration after power failure Indoor unit will go into operation if it was in operation
ON OFF
when the power was turned off (or cut off due to power
failure). (In approx. 5 minutes)
Indoor unit will remain stopped regardless of its opera-
OFF OFF
tion status before power off (power failure).
*1. Requires that the dipswitch settings for all the units in the group be made.
*2. Not applicable to units with a built-in drain pump or humidifier.
*3. Models with a built-in drain pump cannot be turned on/off by the plug individually. All the units in the same refrigerant
circuits will be turned on or off by the plug.
*4. Do not cut off power to the outdoor (heat source) unit. Cutting off the power supply to the outdoor (heat source) unit
will cut off the power supply to the crankcase heater and may cause the compressor to malfunction when the unit is
put back into operation.
*1
(7) Miscellaneous settings
Cooling-only setting for the indoor unit: Cooling only model (Factory setting: SW3-1 "OFF.")
When using indoor unit as a cooling-only unit, set SW3-1 to ON.
(8) Various types of control using input-output signal connector on the outdoor (heat source) unit (various connection op-
tions)
Terminal
Type Usage Function
to be
used
Input Prohibiting cooling/heating operation (thermo OFF) by an external input to
the outdoor (heat source) unit.
Compressor
ON/OFF (level)
CN3D
*It can be used as the DEMAND control device for each system.
Performs a low level noise operation of the outdoor (heat source) unit by
an external input to the outdoor (heat source) unit.
(The unit can perform a NIGHT MODE operation under the following con-
NIGHT MODE or
STEP DEMAND
*1
(level)
ditions: Outdoor air temperature below 30°C during cooling operation/Outdoor air temperature above 3°C during heating operation.)
Forces the outdoor (heat source) unit to perform a fan operation by receiving signals from the snow sensor.
Output How to extract signals from the outdoor (heat source) unit
*It can be used as an operation status display device.
*It can be used for an interlock operation with external devices.
Snow sensor signal
input (level)
Operation status of
the compressor
Error status
CN3S
CN51
*1. NIGHT MODE is valid when Dip SW4-7 on the outdoor (heat source) unit are set to OFF. When Dip SW4-7 are set
to ON, STEP DEMAND control is possible, using different configurations of NIGHT MODE input and compressor ON/
OFF input settings.
- 21 -
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