Mitsubishi Electric PUHY-HP72, PUHY-HP192, PUHY-HP120TNU-A, PUHY-HP240TSNU-A, PUHY-HP96, PUHY-HP240TYSNU-A, PUHY-HP120TYNU-A, PUHY-HP144 Service Manual
Specifications and Main Features
Frequently Asked Questions
User Manual
Safety Precautions
Please read the following safety precautions carefully before installing the unit to ensure safety.
Indicates a risk of death or serious injury.
Indicates a risk of serious injury or structural damage.
Make sure that this manual is passed on to the end user to retain for future reference.
Retain this manual for future reference. When the unit is reinstalled or repaired, have this manual available to those who pro-
vide these services. Make sure that this manual is passed on to any future users.
All electric work must be performed by qualified personnel.
Air tightness test must be performed by qualified personnel.
[1] General Precautions
General Precautions
Do not use refrigerant other than the type indicated in the manuals provided with the
unit and on the nameplate. Doing so may
cause the unit or pipes to burst, or result in
explosion or fire during use, during repair,
or at the time of disposal of the unit. It may
also be in violation of applicable laws. MITSUBISHI ELECTRIC CORPORATION cannot
be held responsible for malfunctions or accidents resulting from the use of the wrong
type of refrigerant.
Do not install the unit in a place where large
amounts of oil, steam, organic solvents, or
corrosive gases, such as sulfuric gas, are
present or where acidic/alkaline solutions
or sprays containing sulfur are used frequently. These substances can compromise the performance of the unit or cause
certain components of the unit to corrode,
which can result in refrigerant leakage, water leakage, injury, electric shock, malfunctions, smoke, or fire.
Do not try to defeat the safety fe atures of the
unit or make unauthorized setting changes.
Forcing the unit to operate the unit by defeating the safety features of the devices
such as the pressure switch or the temperature switch, making unauthorized changes
to the switch settings, or using accessories
other than the ones recommended by Mitsubishi Electric may result in smoke, fire, or
explosion.
To reduce the risk of shorting, current leakage, electric shock, malfunctions, smoke, or
fire, do not splash water on electric parts.
To reduce the risk of electric shock, malfunctions, smoke or fire, do not operate the
switches/buttons or touch other electrical
parts with wet hands.
To reduce the risk of pipe burst and explosion, do not allow gas refrigerant and refrigerant oil to be trapped in the refrigerant
circuit.
To reduce the risk of burns or frost bi tes, do
not touch the refrigerant pipes or refrigerant
circuit components with bare hand s during
and immediately after operation.
To reduce the risk of burns, do not touch
any electrical parts with bare hands during
or immediately after stopping operation.
To reduce the risk of injury from falling
tools, keep children away while installing,
inspecting, or repairing the unit.
Keep the space well ventilated. Refrigerant
can displace air and cause oxygen starvation. If leaked refrigerant comes in contact
with a heat source, toxic gas may be generated.
i
Always replace a fuse with one with the correct current rating. The use of improperly
rated fuses or a substitution of fuses with
steel or copper wire may result in bursting,
fire or explosion.
To reduce the risk of electric shock, smoke,
and fire due to infiltration of dust and water,
properly install all required covers and panels on the terminal box and control box.
To reduce the risk of injury from units falling
or falling over, periodically check the installation base for damage.
Consult an authorized agency for the proper
disposal of the unit. Refrigerant oil and refrigerant that may be left in the unit pose a
risk of fire, explosion, or environmental pollution.
To reduce the risk of being caught in rotating parts, electric shock, and burns, do not
operate the unit without all required panels
and guards being installed.
To reduce the risk of injury, do not sit,
stand, or place objects on the unit.
To reduce the risk of water leakage and malfunctions, do not turn off the power immediately after stopping operation. Leave the
unit turned on for at least 5 minutes before
turning off the power.
Do not install the unit over things that are
vulnerable to water damage from condensation dripping.
To reduce the risk of injury, electric shock,
and malfunctions, do not touch or allow cables to come in contact with the edges of
components.
To reduce the risk of injury, do not touch the
heat exchanger fins or sharp edges of components with bare hands.
[2] Transportation and Installation
Always wear protective gears when touching electrical components on the unit. Several minutes after the power is switched off,
residual voltage may still cause electric
shock.
To reduce the risk of electric shock and
burns, always wear protective gear when
working on units.
To reduce the risk of injury, do not insert fingers or foreign objects into air inlet/outlet
grills. If the unit is left on a damaged base, it
may fall and cause injury.
To reduce the risk of injury, always wear
protective gear when working on units.
Do not release refrigerant into the atmosphere. Collect and reuse the refrigerant, or
have it properly disposed of by an authorized agency. Refrigerant poses environmental hazards if released into the air.
Transportation and Installation
Lift the unit by placing the slings at designated locations. Support the outdoor unit
securely at four points to keep it from slipping and sliding. If the unit is not properly
supported, it may fall and cause personal
injury.
To reduce the risk of injury, do not carry the
product by the PP bands that are used on
some packages.
To reduce the risk of injury, products weighing 20 kg or more should be carried by two
or more people.
ii
[3] Installation
Installation
Do not install the unit where there is a risk
of leaking flammable gas.
If flammable gas accumulates around the
unit, it may ignite and cause a fire or explosion.
To reduce the risk of injury from coming in
contact with units, install units where they
are not accessible to people other than
maintenance personnel.
To reduce the risk of injury, properly dispose of the packing materials so that children will not play with them.
Properly dispose of the packing materials.
Plastic bags pose suffocation hazard to
children.
All drainage work should be performed by
the dealer or qualified personnel according
to the instructions detailed in the Installation Manual. Improper drainage work may
cause water leakage and resultant damage
to the furnishings.
Remove packing materials from the unit before operating the unit. Note that some accessories may be taped to the unit. Properly
install all accessories that are required. Failing to remove the packing materials or failing to install required accessories may
result in refrigerant leakage, oxygen deprivation, smoke, or fire.
Consult your dealer and take appropriate
measures to safeguard against refrigerant
leakage and resultant oxygen starvation. An
installation of a refrigerant gas detector is
recommended.
Any additional parts must be installed by
the dealer or qualified personnel. Only use
the parts specified by Mitsubishi Electric.
Installation by unauthorized personnel or
use of unauthorized parts or accessories
may result in water leakage, electric shock,
or fire.
Take appropriate safety measures against
wind gusts and earthquakes to prevent the
unit from toppling over and causing injury.
Do not install the unit over things that are
vulnerable to water damage. Provide an adequate collective drainage system for the
drain water from unit as necessary.
To reduce the risk of damage to the unit an d
resultant electric leak and electric shock,
keep small animals, snow, and rain water
from entering the unit by closing the gap in
the pipe and wire access holes.
[4] Piping Work
Piping Work
To reduce the risk of injury, including frost
bites, that may result from being blasted
with refrigerant, use caution when operating the refrigerant service valve. If refrigerant leaks out and comes in contact with an
open flame, toxic gases may be generated.
To reduce the risk of injury from units falling
or falling over, install the unit on a surface
that is strong enough to support its weight.
To reduce the risk of rain water or drain water from entering the room and damaging
the interior, drainage work must be performed by your dealer or qualified personnel according to the instructions detaile d in
the Installation Manual.
To reduce the risk of refrigerant catching
fire and causing burns, remove the refrigerant gas and the residual refrigerant oil in the
pipes before heating them.
iii
To reduce the risk of pipe damage, refrigerant leakage, and oxygen deprivation, use
pipes that meet the pipe thickness specifications, which vary by the type of refrigerant used, pipe diameter, and pipe material.
To reduce the risk of pipe burst or explosion, evacuate the refrigerant circuit using a
vacuum pump, and do not purge the system
with refrigerant.
To reduce the risk of explosion and de terioration of refrigerant oil caused by chloride,
do not use oxygen, flammable gas, or refrigerant that contains chloride as a pressurizing gas.
To prevent explosion, do not heat the unit
with refrigerant gas in the refrigerant circuit.
To reduce the risk of oxygen deprivation
and gas poisoning, check for gas leakage
and keep fire sources away.
Insulate pipe connections after completing
the air tightness test. Performing an air
tightness test with the pipe being insulated
may lead to failure to detect refrigerant leakage and cause oxygen deprivation.
To reduce the risk of pipe damage and resultant refrigerant leakage and oxygen deprivation, keep the field-installed pipes out
of contact with the edges of components.
To reduce the risk of pipe bursting and explosion due to abnormal pressure rise, do
not allow any substances other than R410A
(such as air) to enter the refrigerant circuit.
[5] Wiring Work
Wiring Work
To reduce the risk of wire breakage, overheating, smoke, and fire, keep undue force
from being applied to the wires.
To reduce the risk of wire breakage, overheating, smoke, or fire, properly secure the
cables in place and provide adequate slack
in the cables so as not to stress the terminals.
All electric work must be performed by a
qualified electrician according to the local
regulations, standards, and the instructions
detailed in the Installation Manual. Capacity
shortage to the power supply circuit or improper installation may result in malfunction, electric shock, smoke, or fire.
To reduce the risk of electric shock, smoke,
or fire, install an inverter circuit breaker on
the power supply to each unit.
To keep the ceiling and floor from getting
wet due to condensation, properly insulate
the pipes.
Use properly rated breakers and fuses (inverter circuit breaker, local switch <switch +
fuse>, no-fuse breaker). The use of a breaker with a breaking capacity greater than the
specified capacity may cause electric
shock, malfunctions, smoke, or fire.
To reduce the risk of current leakage, overheating, smoke, or fire, use properly rated
cables with adequate current carrying capacity.
Proper grounding must be provided by a licensed electrician.
Do not connect the grounding wire to a gas
pipe, water pipe, lightning rod, or telephone
wire. Improper grounding may result in
electric shock, smoke, fire, or malfunction
due to electrical noise interference.
To reduce the risk of current leakage, wire
breakage, smoke, or fire, keep the wiring
out of contact with the refrigerant pipes and
other parts, especially sharp edges.
iv
[6] Relocation and Repairs
Relocation and Repairs
To reduce the risk of refrigerant leakage,
water leakage, injury, electric shock, and
fire, units should only be moved or repaired
by your dealer or qualified personnel.
To reduce the risk of wire shorting, electric
shock, malfunctions, or fire, keep circuit
boards dust free, and do not touch them
with your hands or tools.
[7] Additional Precautions
Additional Precautions
To avoid damage to the unit, use appropriate tools to install, inspect, or repair the
unit.
To reduce the risk or malfunction, turn on
the power at least 12 hours before starting
operation, and leave the power turned on
throughout the operating season.
Recover all refrigerant in the units, and dispose of it properly according t o any applicable laws and regulations.
Provide a maintenance access to allow for
the inspection of pipes above the ceiling or
the buried pipes.
Take appropriate measures against electrical noise interference when installing the air
conditioners in hospitals or facilities with
radio communication capabilities. Inverter,
high-frequency medical, or wireless communication equipment as well as power
generators may cause the air conditioning
system to malfunction. Air conditioning
system may also adversely affect the operation of these types of equipment by creating
electrical noise.
To reduce the risk of damage to the unit,
leave the valves on the unit closed until refrigerant charging is completed.
Place a wet towel on the refrigerant service
valve before brazing the pipes to keep its
temperature from rising above 120ºC and
damaging the surrounding equipment.
To reduce the risk of wire shorting, electric
leak, electric shock, smoke, or fire, do not
perform maintenance work in the rain.
To reduce the risk of injury, electric shock,
and fire, properly reinstall all removed components after completing repair work.
To reduce the risk of refrigerant and water
leakage, check the pipe supports and insulation for damage during inspection or repair, and replace or repair the ones that are
found to be deteriorated.
Direct the blazing torch flame away from the
adjacent cables and sheet metal to keep
them from being overheated and damaged.
Prepare tools for exclusive use with R410A.
Do not use the following tools if they have
been used with the conventional refrigerant
(R22): gauge manifold, charging hose, refrigerant leak detector, check valve, refrigerant charge spout, vacuum gauge, and
refrigerant recovery equipment. R410A
does not contain chloride, so leak detectors
for use with older types of refrigerants will
not detect an R410A leak. Infiltration of the
residual refrigerant, refrigerant oil, or water
on these tools may cause the refrigerant oil
in the new system to deter iorate o r damage
the compressor.
To reduce the risk of the vacuum pump oil
backflowing into the refrigerant cycle and
causing the refrigerant oil to deteriorate,
use a vacuum pump with a check valve.
Have a set of tools for exclusive use with
R410A. Consult your nearest Mitsubishi
Electric Dealer.
Keep dust, dirt, and water off charging hose
and flare tool. Infiltration of dust, dirt, or water into the refrigerant circuit may cause the
refrigerant oil to deteriorate or damage the
compressor.
v
Use refrigerant piping and couplings that
meet the applicable standards. For refrigerant pipes, use pipes made of phosphorus
deoxidized copper. Keep the inner and outer surfaces of pipes and couplings clean
and free of such contaminants as sulfur, oxides, dust, dirt, shaving particles, oil, and
moisture. Failure to follow these directions
may result in the deterioration of refrigerant
oil or compressor damage.
Store the piping materials indoors, and
keep both ends of the pipes sealed until immediately before brazing. Keep elbows and
other joints in plastic bags. Infiltration of
dust, dirt, or water into the refrigerant circuit may cause the refrigerant oil to deteriorate or damage the compressor.
Apply ester oil, ether oil, or a small amount
of alkyl benzene to flares and flanges. The
use and accidental infiltration of mineral oil
into the system may cause the refrigerant
oil to deteriorate or damage the compressor.
To reduce the risk of both the breaker on the
product side and the upstream breaker from
tripping and causing problems, split the
power supply system or provide protection
coordination between the earth leakage
breaker and no-fuse breaker.
Have a backup system, if failure of the unit
has a potential for causing significant problems or damages.
To reduce the risk of oxidized film from entering the refrigerant pipe and causing the
refrigerant oil to deteriorate or damaging
the compressor, braze pipes under nitrog en
purge.
Do not use the existing refrigerant piping. A
large amount of chloride that is contained in
the residual refrigerant and refrigerant oil in
the existing piping may cause the refrigerant oil in the new unit to deteriorate or damage the compressor.
Charge refrigerant in the liquid state. If refrigerant is charged in the gas phase, the
composition of the refrigerant in the cylinder will change, compromising the unit's
performance.
Do not use a charging cylinder. The use of a
charging cylinder will change the composition of the refrigerant, compromising the
unit's performance.
Charge the system with an appropriate
amount of refrigerant in the liquid phase.
Refer to the relevant sections in the manuals to calculate the appropriate amount of
refrigerant to be charged. Refrigerant overcharge or undercharge may resu lt in perf ormance drop or abnormal stop of operation.
To reduce the risk of power capacity shortage, always use a dedicated power supply
circuit.
vi
CONTENTS
Chapter 1Check Before Servicing
1-1Preparation for Piping Work..................................................................................................................1
1-2Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil.......................3
1-3Working with Refrigerant Piping.................................. ......................................................... ................7
1-4Precautions for Wiring.........................................................................................................................11
1-5Cautionary notes on installation environment and maintenance........................................ ............13
5-1Dipswitch Functions and Factory Settings..........................................................................................1
5-2Outdoor Unit Control ............................................... ............................ ..................................................9
Chapter 6Test Run
6-1Read before Test Run............................................................................................................................1
6-2Operation Characteristics and Refrigerant Charge ............................................................ ................2
6-3Evaluating and Adjusting Refrigerant Charge.....................................................................................2
6-4The Following Symptoms Are Normal .................................................................................................6
Chapter 7Troubleshooting Using Error Codes
7-1Error Code and Preliminary Error Code Lists .....................................................................................1
7-2Error Code Definitions and Solutions: Codes [0 - 999].......................................................................6
7-3Error Code Definitions and Solutions: Codes [1000 - 1999]...............................................................8
7-4Error Code Definitions and Solutions: Codes [2000 - 2999].............................................................12
7-5Error Code Definitions and Solutions: Codes [3000 - 3999].............................................................18
7-6Error Code Definitions and Solutions: Codes [4000 - 4999].............................................................21
7-7Error Code Definitions and Solutions: Codes [5000 - 5999].............................................................38
7-8Error Code Definitions and Solutions: Codes [6000 - 6999].............................................................45
7-9Error Code Definitions and Solutions: Codes [7000 - 7999].............................................................66
HWE18240_GB
CONTENTS
Chapter 8Troubleshooting Based on Observed Symptoms
8-10 Control Circuit......................................................................................................................................44
8-11 Measures for Refrigerant Leakage .....................................................................................................50
8-12 Parts Replacement Instructions .........................................................................................................52
8-13 Troubleshooting Problems Using the LED Status Indicators on the Outdoor Unit.......................79
9-2Operation Data Collection and Storage Functions .............................................................................4
9-3Software Rewrite Function on the USB................................................................................................8
9-4Maintenance LED Display and Troubleshooting...............................................................................10
Chapter 10LED Status Indicators on the Outdoor Unit Circuit Board
10-1 LED Status Indicators............................................................................................................................1
10-2 LED Status Indicators Table..................................................................................................................4
HWE18240_GB
Chapter 1Check Before Servicing
1-1Preparation for Piping Work ................................................................................................................ 1
1-1-1Read before Servicing ............................................................................................................................1
1-4Precautions for Wiring ............................................. ........................... ........................... .................... 11
1-5Cautionary notes on installation environment and maintenance .................................................. 13
HWE18240_GB
HWE18240_GB
[1-1 Preparation for Piping Work ]
1 Check Before Servicing
1-1Preparation for Piping Work
1-1-1Read before Servicing
1. Check the type of refrigerant used in the system to be serviced.
Refrigerant Type
Multi air conditioner for building application CITY MULTI: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.
For information about the correct use of tools, refer to the following page(s). [1-1-2 Tool Preparation]
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.
Note
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.
7. Specifications and system requirements may differ for products manufactured at different
times. Refer to the relevant chapters for specification details. Production periods can be found
from the serial number as follows.
8XP
1~9: Jan to Sept.
X~Z: Oct to Dec.
...
(Production month)
1 Check Before Servicing
HWE18240_GB
8: April 2018 to March 2019
(Production year)
chapter 1 - 1
[1-1 Preparation for Piping Work ]
1-1-2Tool Preparation
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 or R407C)
1. To be used exclusively with R410A (not to be used if used with R22 or R407C)
Tools/MaterialsUseNotes
Gauge ManifoldEvacuation and refrigerant chargingHigher than 5.09MPa[738psi] on the
Charging HoseEvacuation and refrigerant chargingThe hose diameter is larger than the
1 Check Before Servicing
Refrigerant Recovery CylinderRefrigerant recovery
Refrigerant CylinderRefrigerant chargingThe refrigerant type is indicated. The
Charging Port on the Refrigerant Cylinder Refrigerant chargingThe charge port diameter is larger
Flare NutConnection of the unit with the pipesUse Type-2 Flare nuts.
2. Tools and materials that may be used with R410A with some restrictions
high-pressure side
conventional model.
cylinder is pink.
than that of the current port.
Tools/MaterialsUseNotes
Gas Leak DetectorGas leak detectionThe ones for use with HFC refrigerant
Vacuum PumpVacuum dryingMay be used if a check valve adapter
Flare ToolFlare processingFlare processing dimensions for the
Refrigerant Recovery EquipmentRefrigerant recoveryMay be used if compatible with
may be used.
is attached.
piping in the system using the new refrigerant differ from those of R22. Refer to the following page(s). [1-2-1
Piping Materials]
R410A.
3. Tools and materials that are used with R22 or R407C that may also be used with R410A
Tools/MaterialsUseNotes
Vacuum Pump with a Check ValveVacuum drying
BenderBending pipes
Torque WrenchTightening flare nutsOnly the flare processing dimensions
for pipes that have a diameter of
ø12.7 (1/2") and ø15.88 (5/8") have
been changed.
4. Tools and materials that must not be used with R410A
Tools/MaterialsUseNotes
Charging CylinderRefrigerant chargingProhibited to use
Tools for R410A must be handled with special care to keep moisture and dust from infiltrating the cycle.
2 - chapter 1HWE18240_GB
[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2Handling and Characteristics of Piping Materials,
Refrigerant, and Refrigerant Oil
1-2-1Piping Materials
Do not use the existing piping!
1. Copper pipe materials
AnnealedSoft copper pipes (annealed copper pipes). They can easily be bent with hands.
DrawnHard copper pipes (straight pipes). They are stronger than the Annealed at the same
radial thickness.
The distinction between Annealed and Drawn is made based on the strength of the pipes themselves.
Annealed can easily be bent with hands.
Drawn are considerably stronger than Annealed at the same thickness.
2. Types of copper pipes
Maximum working pressureRefrigerant type
3.45 MPa [500psi]R22, R407C etc.
4.30 MPa [624psi]R410A etc.
1 Check Before Servicing
3. Piping materials/Radial thickness
Select piping materials that meet the requirements set forth in ASTM B280.
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 (R410A).
5. Flare processing
Select piping materials that meet the requirements set forth in ASTM.
6. Flare nut
Select piping materials that meet the requirements set forth in ASTM.
HWE18240_GB
chapter 1 - 3
[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2-2Storage of Piping Materials
1. Storage location
1 Check Before Servicing
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
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.
1-2-3Pipe Processing
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
When processing the severed ends of the pipes, keep the shaving dust out of the pipes to prevent malfunction of the refrigerant
circuit.
Use a minimum amount of oil.
Use only ester oil, ether oil, and alkylbenzene.
4 - chapter 1HWE18240_GB
[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2-4Characteristics of the New and Conventional 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 confined area.
New Refrigerant (HFC type)Conventional Refriger-
ant (HCFC type)
R410AR407CR22
R32/R125R32/R125/R134aR22
Composition (wt%)(50/50)(23/25/52)(100)
Type of RefrigerantPseudo-azeotropic
(25°C,MPa/77°F,psi) (gauge)
Saturated Steam Density
(25°C,kg/m
3
/77°F,psi)
64.042.544.4
FlammabilityNonflammableNonflammableNonflammable
Ozone Depletion Coefficient (ODP)
Global Warming Coefficient (GWP)
*1
*2
Refrigerant Charging MethodRefrigerant charging in
Replenishment of Refrigerant after a Refrigerant
000.055
208817741810
the liquid state
Refrigerant charging in
the liquid state
Refrigerant charging in
the gaseous state
AvailableAvailableAvailable
Leak
1 Check Before Servicing
*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.
3. Pressure characteristics
The pressure in the system using R410A is 1.6 times as great as that in the system using R22.
[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2-5Refrigerant 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.
RefrigerantRefrigerating machine oil
R22 Mineral oil
R407CEster oil
R410A Ester oil
1 Check Before Servicing
This unit requires refrigerant oil that is compatible with low temperature refrigerant.
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.
CauseSymptomsEffects on the refrigerant cycle
Water infiltrationFrozen expansion valve
Hydrolysis
Air infiltrationOxidization
Adhesion to expansion valve and capillary
tubes
Dust, dirt
Infiltration of
contaminants
Mineral oil
etc.
Infiltration of contaminants into the compressor
Sludge formation and adhesionClogged expansio n valve and capillary tubes
Oil degradationBurn-in on the orbiting scroll
and capillary tubes
Sludge formation and adhesion
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
*1. Contaminants is defined as moisture, air, processing oil, dust/dirt, wrong types of refrigerant, and refrigerating machine oil.
6 - chapter 1HWE18240_GB
[1-3 Working with Refrigerant Piping ]
1-3Working with Refrigerant Piping
1-3-1Pipe 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 no inert gas during brazingUse of inert gas during brazing
1 Check Before Servicing
1. Items to be strictly observed
Do not conduct refrigerant piping work outdoors if raining.
Use inert gas during brazing.
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.
HWE18240_GB
chapter 1 - 7
[1-3 Working with Refrigerant Piping ]
1-3-2Air 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.
1 Check Before Servicing
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 tight-
ness, taking temperature variations into account.
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 composition
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.
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 (Photo 2)
Use a vacuum pump that attains 0.5Torr(65Pa) or lower degree of vacuum after 5 minutes of operation, and connect it directly
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 recommended 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 vacuum
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 pen-
etrated 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.)
7. Triple Evacuation
The method below can also be used to evacuate the system.
Evacuate the system to 4,000 microns from both service valves. System manifold gauges must not be used to measure vac-
uum. A micron gauge must be used at all times. Break the vacuum with Nitrogen (N2) into the discharge service valve to 0
PSIG.
Evacuate the system to 1,500 microns from the suction service valve. Break the vacuum with Nitrogen (N2) into the discharge
service valve to 0 PSIG.
Evacuate the system to 500 microns. System must hold the vacuum at 500 microns for a minimum of 1 hour.
Conduct a rise test for a minimum of 30 minutes
2
G(0.05MPa) and evacuate again. Repeat this cycle of pressurizing and evacuation either until the degree of vac-
1 Check Before Servicing
HWE18240_GB
chapter 1 - 9
[1-3 Working with Refrigerant Piping ]
1-3-4Refrigerant Charging
Cylinder with a siphon
1 Check Before Servicing
Cylinder color R410A is pink.Refrigerant charging in the liquid state
Cylinder
Cylinder without a siphon
Cylinder
ValveValve
liquid
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 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.
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.
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 the following page(s).[8-11 Measures for Refrigerant Leakage]
10 - chapter 1HWE18240_GB
[1-4 Precautions for Wiring ]
1-4Precautions for Wiring
Control boxes house high-voltage and high-temperature electrical parts.
They may still remain energized or hot after the power is turned off.
When opening or closing the front cover of the control box, keep out of contact with the internal parts.
Before inspecting the inside of the control box, turn off the power, leave the unit turned off for at least 10 minutes, and check
that the voltage across pins 1 and 5 of connector RYPN has dropped to 20 VDC or less.
It will take approximately 10 minutes until the voltage is discharged after power off.
Disconnect the relay connectors (RYFAN 1 and RYFAN 2) on the outdoor unit fan before performing maintenance work.
On (E)P72, disconnect RYFAN1 only.
Before connecting or disconnecting the connector, check that the outdoor unit fan is stopped and that the voltage across pins
1 and 5 of connector RYPN has dropped to 20 VDC or less.
If the outdoor unit fan is rotated by external forces such as strong winds, the main circuit capacitor can be charged and cause
an electric shock.
Refer to the wiring nameplate for details.
Reconnect the relay connectors (RYFAN 1 and RYFAN 2) after completion of maintenance work.
Before turning on the power, make sure the power-supply wire is properly connected. Also, perform a voltage check at the
power-supply terminal block. (Refer to item (5) in section [6-1 Read before Test Run])
When the power is on, the compressor is energized even while the compressor is stopped.
It is energized to evaporate the liquid refrigerant that has accumulated in the compressor.
Before connecting wiring to TB7, check that the voltage has dropped below 20 VDC.
When a system controller is connected to the centralized control transmission cable to which power is supplied from the out-
door unit (power jumper on the outdoor unit is connected to CN40), be aware that power can be supplied to the centralized
control transmission and the system controller may detect an error and send an error notice if the outdoor unit fan is rotated
by external forces, such as strong winds, even when power to the outdoor unit is turned off.
When replacing the internal electrical components of the control box, tighten the screws to the recommended tightening
torque as specified below.
Recommended tightening torque for the internal electrical components of the control box
1 Check Before Servicing
ScrewRecommended tightening torque (N·m)
M30.69
M41.47
M52.55
M62.75
M86.20
1 When replacing semiconductor modules (e.g., INV board, fan board), apply heatsink silicone evenly to the semiconductor
module on the back of the circuit board. Next, tighten the screws holding the semiconductor module to one-third of the
specified torque, and then tighten the screws to the specified torque.
2 Deviating from the recommended tightening torque may cause damage to the unit or its parts.
Take the following steps to ensure that the screws are properly tightened.
1) Ensure that the spring washers are parallel to the terminal block.
Even if the tightening torque is observed, if the washers are not parallel to the terminal block, then the semiconductor module
is not installed properly.
Loose screws
Proper installation
Spring washers are parallel to
the terminal block
HWE18240_GB
chapter 1 - 11
[1-4 Precautions for Wiring ]
2) Check the wires are securely fastened to the screw terminals.
Screw the screws straight down so as not to damage the screw threads.
Hold the two round terminals back to back to ensure that the screw will screw down straight.
After tightening the screw, mark a line through the screw head, washer, and terminals with a permanent marker.
Example
Mark a line.
1 Check Before Servicing
Power supply terminal block, indoor-outdoor transmission line terminal block,
and centralized controller transmission line
Poor contact caused by loose screws may result in overheating and fire.
Continued use of the damaged circuit board may cause overheating and fire.
Daisy-chain
Power wires, transmission lines, centralized transmission lines
Place the round terminals back to back.
12 - chapter 1HWE18240_GB
[1-5 Cautionary notes on installation environment and maintenance ]
1-5Cautionary notes on installation environment and
maintenance
Salt-resistant unit is resistant to salt corrosion, but not salt-proof. Please note the following when
installing and maintaining outdoor units in marine atmosphere.
1) Install the salt-resistant unit out of direct exposure to sea breeze, and minimize the exposure to salt water mist.
2) Avoid installing a sun shade over the outdoor unit, so that rain will wash away salt deposits off the unit.
3) Install the unit horizontally to ensure proper water drainage from the base of the unit. Accumulation of water in the base of the
outdoor unit will significantly accelerate corrosion.
4) Periodically wash salt deposits off the unit, especially when the unit is installed in a coastal area.
5) Repair all noticeable scratches after installation and during maintenance.
6) Periodically check the unit, and apply anti-rust agent and replace corroded parts as necessary.
1 Check Before Servicing
HWE18240_GB
chapter 1 - 13
[1-5 Cautionary notes on installation environment and maintenance ]
1) "Maximum total capacity of connectable indoor units" refers to the sum of the numeric values in the indoor unit model names.
2) If the total capacity of the indoor units that are connected to a given outdoor unit exceeds the capacity of the outdoor unit, the
indoor units will not be able to perform at the rated capacity when they are operated simultaneously. Select a combination of
units so that the total capacity of the connected indoor units is at or below the capacity of the outdoor unit whenever possible.
Maximum
number of
connect-
able indoor
units
Types of connectable
indoor units
R410A series indoor units
2 Restrictions
HWE18240_GBchapter 2 - 1
[2-2 Types and Maximum Allowable Length of Cables ]
TB 3 TB 7 TB 3 TB
7
TB
3
TB 3 TB
7
TB
7
TB 3 TB
7
TB
3
TB
7
TB 3 TB 7 TB 3 TB
7
TB
3
TB 3 TB
7
TB
7
TB 3 TB
7
TB
3
TB
7
2-core shielded cable
2-core shielded cable
Indoor unit
Outdoor unit
TB3: Terminal block for indoor-outdoor transmission line TB7: Terminal block for centralized control
Remote Controller
Indoor unit
Outdoor unit
Remote Controller
multiple-core cable
2-2Types 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 external transmission cables 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 grounding for the outdoor unit as required.
4) Run the cable from the electric box of the indoor or outdoor unit in such way that the box is accessible for servicing.
5) Do not connect power supply wiring to the terminal block for transmission cable. Doing so will damage the electronic components on the terminal block.
6) Use 2-core shielded cables as transmission cables.
Do not use a single multiple-core cable to connect indoor units that belong to different refrigerant systems. Doing so may result
in signal transmission errors and malfunctions..
2 Restrictions
7) When extending the transmission cable, be sure to extend the shield wire.
(2) Control wiring
Different types of control wiring are used for different systems. Before performing wiring work, refer to the following page(s).
[2-7 Example System with an MA Remote Controller]
[2-8 Example System with an ME Remote Controller]
[2-9 Example System with an MA and an ME Remote Controller]
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
TypeShielded cable CVVS, CPEVS, MVVS
Number of
cores
Cable sizeLarger than 1.25mm
1000 m [3280ft] (500 m [1640ft]) max.
supply unit on the transmission lines for centralized control to each outdoor unit or to the
system controller is 200m [656ft] max.
*1 If a given system includes one or more unit or remote controller that does not support
the maximum allowable cable distance of 1,000 m [3280 ft], the maximum allowable cable distance in the system will be 500 m [1640 ft]. Refer to the latest catalog for information on which units and remote controllers support the maximum allowable cable
distance of 1,000 m [3280 ft].
Cable type
Maximum transmission
line distance between the
outdoor unit and the farthest indoor unit
Maximum transmission
line distance for centralized control and Indoor/
outdoor transmission line
(Maximum line distance
via outdoor unit)
All facility types
2-core cable
2
[AWG16]
200 m [656ft] max.
*1
*The maximum overall line length from the power
2 -chapter 2HWE18240_GB
[2-3 Switch Settings ]
2) Remote controller wiring
TypeVCTF, VCTFK, CVV, CVS, VVR, VVF, VCT Shielded cables CVVS, CPEVS, and MVVS
Number of
Cable type
cores
Cable size
Maximum overall line
length
*1 MA remote controller refers to MA remote controller (PAR-20MAU, PAR-21MAAU, PAR-30MAAU), MA simple re-
mote controller, and wireless remote controller.
*2 ME remote controller refers to ME remote controller, Compact ME remote controller, and LOSSNAY remote control-
ler.
*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 specifi-
cations shown in the parenthesis.
*5 When connecting PAR-30MAAU or MA Simple remote controller, use sheathed cables with a minimum thickness of
0.3 mm
2
.
MA remote controller
*1
2-core cable2-core cable
0.3 to 1.25mm
[AWG22 to 16]
2 *3 *5
0.3 to 1.25mm
[AWG22 to 16]
(0.75 to 1.25mm
The section of the cable that exceeds 10m
200 m [656ft] max.
[32ft] must be included in the maximum indoor-outdoor transmission line distance.
2
(AWG18) is recommended for easy handling.
ME remote controller
2 *3
2 ) *4
[AWG18 to 16]
*2
2 Restrictions
2-3Switch Settings
1. Switch setting
The necessary switch settings depend on system configuration. Before performing wiring work, refer to the following page(s).
[2-7 Example System with an MA Remote Controller]
[2-8 Example System with an ME Remote Controller]
[2-9 Example System with an MA and an ME Remote Controller]
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.
Units on which to set the switchesSymbolUnits to which the power must be shut off
*3
CITY MULTI indoor unitMain/sub unitICOutdoor units
LOSSNAY, OA processing unit
*1
LCOutdoor units
ATWWater Hex UnitAUOutdoor units and Water Hex Unit
Air handling kitICOutdoor units
unit
ME remote controllerMain/sub remote
RCOutdoor units
controller
MA remote controller
*4
Main/sub remote
MAIndoor units
controller
CITY MULTI outdoor unit
*2
OC,OS1,OS2Outdoor units
*1. Applicable when LOSSNAY units are connected to the indoor-outdoor transmission line.
*2. The outdoor units in the same refrigerant circuit are automatically designated as OC, OS1, and OS2 in the order of
capacity from large to small (if two or more units have the same capacity, in the order of address from small to large).
*3. Turn off the power to all the outdoor units in the same refrigerant circuit.
*4. When setting the switch SW4 of the control board, set it with the outdoor unit power on. Refer to the following page(s).
[5-1-1 Outdoor Unit Switch Functions and Factory Settings]
and Indoor units
*3
and LOSSNAY
*3
or field supplied air handling
*3
*3 *5
HWE18240_GBchapter 2 - 3
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